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Hamilton Sundstrand Company Precision ACT2000 Series, User Manual

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Hamilton Sundstrand Company Precision ACT2000 Series User Manual Download Page 55

 

 

 

5  TROUBLESHOOTING 

This section provides troubleshooting information for the ACT2000. You 
can isolate most electrical faults 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, 
whoever is responsible for fault analysis should be thoroughly acquainted 
with physical and electrical configurations, Theory of Operation 
(Section 2), and Installation (Section 1). 

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 diagram shown in Section 2. 

CAUTION 

Continuing to operate the actuator in a malfunctioning condition is 
hazardous to personnel and can cause property damage. 

Tables 5-1 and 5-2 list common failures that can occur before or after 
actuator installation, respectively. 

In addition, the ACT2000 has on-board troubleshooting capability. The 
ActWiz software has a fault file that you can upload to pinpoint a failure 
cause. See the ActWiz Software Manual for more details. 

If, after following the troubleshooting procedures, you still can’t find the 
cause of the problem and repair it, contact the factory for assistance. 

 

CH. 4: TROUBLESHOOTING THE ACT2000

 

49

 

Summary of Contents for Precision ACT2000 Series

Page 1: ...User Manual ACT2000 All Electric Actuator SD 6008 Rev 6 October 2008 PRECISION ENGINE CONTROLS CORPORATION...

Page 2: ...his manual in its entirety to fully understand the system Operating the ACT2000 All Electric Actuator in accordance with instructions herein ensures long term and reliable operation If you need additi...

Page 3: ...tion 21 2 2 Electrical Description 21 2 3 Mechanical Description 25 2 4 Identification Plate 30 3 OPERATING THE ACT2000 33 3 1 Powering Up 33 3 2 Finding Home Position 33 3 3 Holding Motor Current Sta...

Page 4: ...on Plate 30 Figure 2 5 Typical Refurbishment Plate 31 Figure 3 1 ACT2000 Basic Operation Flow Chart 35 Figure 3 2 Actuator Position vs DEMAND Home as Mech Stop in Actuator 37 Figure 3 3 Dead Band of A...

Page 5: ...or P Ns 50026XX XXX or Any Remanufactured Part with Config 116 and above Configuration 116 and above Firmware version 3 00 and above Third generation isolated RS 232 Actuator P Ns 50026XX XXX or Any R...

Page 6: ...he ACT2000 it is necessary for the user to have a fundamental understanding of Electronics concepts such as voltage current and switches Mechanical motion control concepts such as inertia torque veloc...

Page 7: ...shipping container In the event of future transportation requirements this container will minimize any damage during shipment Recommended Installation Process Users must determine if it is best to co...

Page 8: ...rical noise is to Ensure that the ACT2000 is properly grounded as per Section 1 4 of this manual Environmental Considerations The ACT2000 operates satisfactorily with ambient air temperature of 40 C 4...

Page 9: ...er I O to 120 VDC Return less serial interface Performance All performance values are based on use with ACT2000 in default configuration Any changes to ACT2000 firmware settings to change stroke profi...

Page 10: ...x 16 7 in ACT2000 590P 6 0 in x 10 0 in x 12 9 in ACT2000 200F Weight 35 lbs ACT2000 590P 50 lbs ACT2000 200F 1 3 Mechanical Installation This section describes proper ACT2000 installation Ensure com...

Page 11: ...also be taken when rotating the clevis or indexing the screw pattern to avoid scratching the flame path or introducing particulates to the assembly Connecting the Flange ACT2000 200F only The ACT2000...

Page 12: ...creasing the rate of wear on the ACT2000 The extension rod has wrench flats to counteract mounting hardware installation torque WARNING Property Damage Hazard Always use the extension rod wrench flats...

Page 13: ...Figure 1 1 ACT2000 590P Dimensions INSTALLING THE ACT2000 7...

Page 14: ...8 ACT2000 USER GUIDE Figure 1 2 ACT2000 200F Dimensions...

Page 15: ...Figure 1 3 ACT2000 590P Pin Mounting Provisions INSTALLING THE ACT2000 9...

Page 16: ...10 ACT2000 USER GUIDE Figure 1 4 ACT2000 200F Flange Mounting Provisions...

Page 17: ...contact On the pin mounted version ACT2000 590P this threaded hole is located on the underside of the unit below the identification plate see Figure 1 3 On the flange mounted version ACT2000 200F this...

Page 18: ...T POWER SUPPLY 120 VDC FUSE 50 000 F Figure 1 6 Typical Power Connection With Power Supply Figure 1 7 Typical Power Connection With Battery WARNING Shock Hazard Connect both the 120 VDC power and auxi...

Page 19: ...Typical 20 Amps 1 Amp 20 A 60 ms 10 A 600 ms 5 A 100 ms Output Capacitance 50 000 F typical Table 1 2 Power Supply Requirements The output capacitance applies for non battery power systems and assumes...

Page 20: ...be performed at both the minimum and maximum expected operating voltages Also the output capacitance should be carefully positioned so that it is never disconnected from the ACT2000 power input durin...

Page 21: ...rial TX Out 20 WHITE ORANGE GREEN Serial RETURN 20 BLACK OVER TEMP Alarm 20 WHITE BLACK OVER TEMP Alarm RETURN 20 ORANGE FAULT Alarm 20 WHITE ORANGE FAULT Alarm RETURN 20 VIOLET RUN Command 20 WHITE V...

Page 22: ...No Connection Shield No Connection Shield No Connection Shield No Connection Shield No Connection Demand Demand RTN Run Position RTN Run RTN Reset Reset RTN Motor Current Motor Current RTN Position F...

Page 23: ...isolated up to 500 VAC from the enclosure 120 VDC power digital I O and serial interface The analog interfaces are not isolated from each other See Figure 1 10 for a typical analog output connection C...

Page 24: ...erial Communications Interface Signal levels for the serial communications input and output are per RS232 standards See Figure 1 13 for a typical RS232 serial interface connection See Table 1 5 for co...

Page 25: ...y have up to 120 VDC present Property Damage Hazard DO NOT connect 24 VDC power to any of the serial interface connections Note The pin designations shown in Table 1 5 are for the COM port on the comp...

Page 26: ...y in the actuator If conduit is not used signal wires should be at least 4 6 inches from any other wires Ensure that all shielded cables are twisted conductor pairs with either a foil or braided shiel...

Page 27: ...well as for the resolver and thermistor inputs from the actuator Note The MCE analog and discrete signal interfaces are electrically isolated The serial communication interface is optically isolated 2...

Page 28: ...D signal is correlated to the position of the actuator within its span The minimum Demand signal of 4 0 mA is correlated to the Home position The maximum Demand signal of 20 mA is correlated to the fu...

Page 29: ...Figure 2 1 ACT2000 Electronics System Block Diagram CH 2 UNDERSTANDING THE ACT2000 23...

Page 30: ...larm switch will open interrupting the circuit with the user s controller The default configuration for the OVERTEMP alarm is Motor OVERTEMP where the circuit will open if the temperature in two or mo...

Page 31: ...main bearing This liner is permanently installed into the aluminum main housing A retaining ring is included for redundant retention The main housing also contains rigid mechanical stops to prevent e...

Page 32: ...converts the rotary motion of the Motor Assembly to linear actuator motion The core of the mechanical drive system is the linear ball screw drive containing a screw shaft ball bearing fitted nut exte...

Page 33: ...ning nuts A motor end bearing is provided for additional radial shaft stability The resolver rotor motor rotor motor bearing and spacers are all stacked on the ball screw shaft and retained by a singl...

Page 34: ...28 ACT2000 USER GUIDE Figure 2 2 ACT2000 590P Cut Away View...

Page 35: ...Linear Drive Anti Rotation Guide Brushless DC Motor Assembly Main Housing Assembly Motor End Bearing Mounting Clevis Motor Cover Motor Stator Motor Rotor Main Bearings Rigid Stop Figure 2 3 ACT2000 20...

Page 36: ...unit serial number Hazardous area operation certification and electrical wiring interface information is also provided When a unit is refurbished by PECC a product refurbishment plate is also attached...

Page 37: ...Figure 2 5 Typical Refurbishment Plate CH 2 UNDERSTANDING THE ACT2000 31...

Page 38: ...32 ACT2000 USER GUIDE INTENTIONALLY BLANK...

Page 39: ...ase of power up the actuator will not respond until the download is complete and the Home position has been established 3 2 Finding Home Position When the status check and other steps in the Power Up...

Page 40: ...e Holding Motor Current state the actuator applies a constant Holding Force This feature allows the Home position to thermally expand or contract without damaging the ACT2000 This Holding Force is spe...

Page 41: ...Figure 3 1 ACT2000 Basic Operation Flow Chart CH 3 OPERATING THE ACT2000 35...

Page 42: ...r will only move for DEMAND signals 4 1 mA The DEMAND signal range between 4 0 mA and 4 1 mA is therefore considered a Dead Band See Figure 3 3 Once a DEMAND signal 4 1 mA is detected the actuator wil...

Page 43: ...may be necessary to reduce the Span value in the Set Up parameters to allow for the distance between the mechanical stop in the user s system and the mechanical stop in the actuator Interpolation of...

Page 44: ...38 ACT2000 USER GUIDE Figure 3 3 Dead Band of Actuator Position vs DEMAND Curve Figure 3 4 Actuator Position vs DEMAND Home as a Mech Stop in User s System...

Page 45: ...ng the RESET command will clear the FAULT alarm but it will NOT clear the fault file 3 7 Monitoring System Health The firmware program continuously monitors system health while the ACT2000 is powered...

Page 46: ...er the OVERTEMP alarm circuit opens See Table 3 2 for details about the default configuration of the OVERTEMP alarm See Table 3 4 for a list of Over Temp conditions represented by the OVERTEMP alarm i...

Page 47: ...s N A No Yes EEPROM Write N A N A Yes N A No Yes Table 3 1 Default Configuration For FAULT Alarm Fault Type Low Alarm High Alarm Fault Enable Persist Time Shut Down Output Driver Overcurrent N A 1000...

Page 48: ...watchdog timer timeout or illegal address attempt Fault RDC Failure 1 Sec Tests hardware for RDC failure sets Fault if RDC failure bit set Retract Extended Command N A Fault not used Unregulated Volt...

Page 49: ...e The ACT2000 has a self protective shutdown feature The ACT2000 will shutdown if Any two motor winding temperatures exceed 135 C for ten 10 seconds or more 130 C for 60 seconds The electronics temper...

Page 50: ...See the ActWiz Software Manual for further details Power Up Set Up State The ACT2000 is in Power Up Set Up state immediately after the ACT2000 has been powered up or reset This is after the system re...

Page 51: ...w Demand signal is interpolated between defined points Linear Position Loop Constant 20 Current Loop PID Constants Proportional 2 0 Integral 200 Derivative 0 Velocity Loop PID Constants Proportional 4...

Page 52: ...46 ACT2000 USER GUIDE INTENTIONALLY BLANK...

Page 53: ...ss actuator to valve alignment or actuator to load alignment any damage to housing or mounting hardware any damage to power and signal harnesses parts that are worn loose or shifted due to shock vibra...

Page 54: ...48 ACT2000 USER GUIDE INTENTIONALLY BLANK...

Page 55: ...as soon as possible The causes of many problems can be traced through the information contained in the block diagram shown in Section 2 CAUTION Continuing to operate the actuator in a malfunctioning...

Page 56: ...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 w...

Page 57: ...and digital harness connectors and use a digital multi meter DMM to check the resistance values between the wires indicated on the table If an open circuit is detected send the ACT2000 to Precision E...

Page 58: ...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 but it does NOT clear the fault file Note The...

Page 59: ...or a signal is sent to the MCE Upon receipt the MCE signals a fault This fault does not clear without RESET command Unregulated Voltage Low The MCE signals a fault if the reference voltage drops below...

Page 60: ...54 ACT2000 USER GUIDE INTENTIONALLY BLANK...

Page 61: ...erhaul or to be used as spares For removal follow proper lockout tagout procedures and verify no live electrical circuits Disconnect the 4 wires of the integral power harness to the ACT2000 Disconnect...

Page 62: ...56 ACT2000 USER GUIDE INTENTIONALLY BLANK...

Page 63: ...e ACT2000 that communicates an internal over temperature electronics or motor The user s controller will see an open circuit when the OVERTEMP alarm is active HOME A mechanical rigid stop from which t...

Page 64: ...INTENTIONALLY BLANK 58 ACT2000 USER GUIDE...

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