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9. Troubleshooting - Troubleshooting Procedures

98

10260S HercuLine® Actuator Installation, Operation and Maintenance Manual

Revision 5

7/07

Troubleshooting Procedures

Overview

Follow the procedure or flow chart to test for and determine actuator component operation. When using
the flow charts for troubleshooting, you may be instructed to go to another flow chart in order to identify
the faulty component. Instruction for replacing actuator components can be found either in Section 7,
Maintenance or in the kit with the replacement components.

Equipment needed

You will need the following equipment in order to troubleshoot the symptoms listed in the tables that
follow:

DC Milliammeter – mA dc

Calibration source – Volt, mA, etc.

Digital Voltmeter

Safety precautions

Exercise appropriate safety precautions when troubleshooting the actuator operation.

WARNING

While the unit is powered, a potentially lethal shock hazard exists inside the case. Do not open
the case while the unit is powered. Do not access the terminals while the unit is powered.

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Summary of Contents for HercuLine 10260S

Page 1: ...Honeywell Field Solutions 10260S HercuLine Smart Actuator Installation Operation and Maintenance Manual Doc No 62 86 25 08 Revision 5 Date 7 07 ...

Page 2: ...ility of the product in the application CE Conformity This product conforms with the protection requirements of the following European Council Directive 89 336 EEC the EMC directive and 73 23 EEC the Low Voltage Directive Conformance of this product with any other CE Mark Directive s shall not be assumed Attention The emission limits of EN 50081 2 are designed to provide reasonable protection agai...

Page 3: ...al Communications User Manual 51 52 25 66 Modbus RTU Serial Communications User Manual Communication Interface for Smart Actuator 51 52 25 103 HercuLink User Manual 62 86 25 11 Installation and Operation Manual Hart Communications 62 86 25 12 Contacts World Wide Web The following lists Honeywell s World Wide Web sites that will be of interest to our customers Honeywell Organization WWW Address URL...

Page 4: ...ser of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc may be accessible Failure to comply with these instructions could result in death or serious injury ATTENTION Electrostatic Discharge ESD hazards Observe precautions for handling electrostatic sensitive devices Protective Earth PE terminal Provided for connection of the protective earth green or...

Page 5: ...ion Overview 13 Before Starting 14 Installation Considerations 14 Actuator Mounting 14 Outline Dimension Drawings 14 Mechanical Installation 17 Linkage Set up 17 Electrical Installation 22 4 Set Up and Calibration Procedures 28 Overview 28 Local Display and Keypad 28 Set Up Tips 30 Set Up Groups 30 Set Up Procedure 32 Input Set Up Group 34 Equal Percentage Valve Characteristic 37 Quick Opening Val...

Page 6: ...8 Setting Auxiliary Switches actuators mfd pre 1 1 03 70 Setting Auxiliary Switches actuators mfd after 1 1 03 73 5 Start Up Operation 74 Power Up Diagnostics 74 Operations Checklist 74 Operating the Local Display at High Temperatures 75 Operating Displays 75 Motor Stall 75 Non Contact Sensor Operation 76 Remote Setpoint Operation 76 Regions of Motor Travel 77 6 Control Applications 78 Split Range...

Page 7: ...ntents Revision 5 10260S HercuLine Actuator Installation Operation and Maintenance Manual vii 7 07 Introduction 97 Troubleshooting Procedures 98 Appendix A 10260S Configuration Record Sheet 105 Index 109 ...

Page 8: ...Table 15 Digital Input Set Up Group Parameters 46 Table 16 Display Set Up Group Parameters 46 Table 17 Lock Set Up Group Parameters 47 Table 18 Read Status Set Up Group Parameters 49 Table 19 Drive Set Up Group Parameters 50 Table 20 Maintenance Set Up Group Parameters 53 Table 21 CAL POSOUT Group Parameters 55 Table 22 Auto Manual Switch Functions 56 Table 23 Input Calibration Procedure 60 Table ...

Page 9: ...h 56 Figure 17 Calibration Wiring Connections except slidewire emulation 58 Figure 18 Calibration Wiring Connections slidewire emulation 59 Figure 19 Location of NCS Assembly 66 Figure 20 Location of Auxiliary Switches 71 Figure 21 End of Travel Limit Switch Settings 72 Figure 22 Auxiliary Switch Settings 72 Figure 23 Terminal Block Connections for Modbus Communications 77 Figure 24 Regions of Mot...

Page 10: ......

Page 11: ...withstood without damage to the gear train End of travel limit switches are provided as standard equipment to prevent damage to the valve or damper and are backed up by mechanical stops Honeywell electric actuators provide instantaneous response to a demand signal eliminating system non linearity due to dead time Additionally since the actuator is electric the costs associated with providing and m...

Page 12: ...or potentiometer position sensing The non contact position sensor replaces the slidewire and wiper assembly for position sensing Once calibrated the non contacting position sensor requires no maintenance The non contact position sensing assembly consists of a position sensor and a bracket as shown in Figure 2 The position sensor spoiler is connected directly to the output shaft reflecting true sha...

Page 13: ...tion assembly consists of a non contact position sensor and a bracket as shown in Figure 2 The position sensor is identical to that described previously in the non contact position sensing feature A potentiometric voltage from the controller is supplied to the slidewire emulation circuit This voltage is ratiometrically conditioned with respect to the output shaft position from 0 to 100 and is avai...

Page 14: ...lay PWA Electromechanical relay circuit assemblies are available as an option The 10260S actuator can be equipped with up to two relay boards each containing two SPDT relay output circuits for a total of four Relay contacts can be programmed set up to indicate various operating conditions within the actuator such as position range limits deviation from input high or low temperature limits or input...

Page 15: ... the local keypad and display Customer Connections The 10260S features dedicated wiring terminals for ease of installation See Figure 13 for specific details Warranty Period The 10260S actuator warranty is effective for 18 months from the date of shipment unless otherwise noted See full warranty statement for details Honeywell Linkage Kits Honeywell turnbuckle and pipe linkage kits are available a...

Page 16: ...1 Introduction Honeywell Linkage Kits 6 10260S HercuLine Actuator Installation Operation and Maintenance Manual Revision 5 7 07 ...

Page 17: ...ncondensing over the full operating temperature range Scale 0 to 100 corresponding to full crank arm travel Crank Arm Adjustable radii 1 7 16 to a maximum of 5 Position adjustable through 360 rotation Optional 12 crank arm adjustable 0 12 radii Output Shaft 1 diameter 1 1 2 long is standard on 10261S 10262S 10264S 10266S 10267S and 10268S 1 diameter 2 long is standard on 10263S 10265S and 10269S o...

Page 18: ...uto Manual Switch Allows local manual and automatic operation of the actuator Optional Feature Limit Switches Standard Two SPDT end of travel limits Auxiliary Switches Optional SPDT switches rated 10 A at 125 Vac 5 A at 250 Vac Relays Optional Up to 4 SPDT switches rated 5 A at 125 Vac 2 5 A at 250 Vac Installation Category Overvoltage Category Category II Energy consuming equipment supplied from ...

Page 19: ...rature Coefficient Less than 0 030 of span per degree C for 0 C to 50 C Less than 0 05 of span per degree C for 30 C to 75 C Zero Suppression 90 of span Input Filters Selectable spike and low pass filters Solid State Motor Control Two triac switches for clockwise or counterclockwise motor operation Fail safe Operation If input signal exceeds configured input range Selectable and adjustable Feedbac...

Page 20: ...ons Display Operating Temperature 30 C to 50 C 20 F to 122 F Automatically shuts off when operating temperature exceeds 50 C Storage Temperature 40 C to 93 C 40 F to 200 F Keypad Keys Six single pushbutton keys allow access to all status displays and set up group parameters See 4 Set Up and Calibration Procedures page 28 for detailed information on display and keypad functions Specifications Commu...

Page 21: ...300 400 60 72 10265S TABLE I POWER SUPPLY SINGLE PHASE 120 VAC 60 Hz Single Phase 120 VAC 60Hz Motor 1 120 VAC 50 Hz Single Phase 120 VAC 50Hz Motor 2 220 240 VAC 60 Hz Single Phase 220 240 VAC 60Hz Motor 3 220 240 VAC 50 Hz Single Phase 220 240 VAC 50Hz Motor 4 TABLE II ANALOG INPUT OUTPUT SIGNALS Input 4 20 mA 0 20mA 1 5 Vdc 0 5 Vdc 1 10 Vdc 0 10Vdc 0 _ _ Output No Analog Position Output _ 00 4 ...

Page 22: ...CE _ 2 _ Tagging None _ _ 0 Linen Note 2 _ _ 1 Stainless Steel Note 2 _ _ 2 TABLE VIII FACTORY OPTIONS Special Manuals No Special Options US Manual Standard 0 _ Other None _ 0 Certificate of Conformance _ 2 ACCESSORIES Handheld Configuator HercuLink TM Palm Software Note 3 Battery powered 232 485 converter w cable HART Turk Cable for Handheld Connection Rod Adapters 5 8 Inch 083338 7 16 Inch 08333...

Page 23: ...al control element Use HAL software application to aid in mechanical installation Make all electrical connections for actuator according to local and national electrical codes Power up actuator Enter verify and adjust set up parameters for proper operation Adjust control arm linkage for accurate operation of final control element This section provides you with mechanical and electrical installatio...

Page 24: ...re as large as the foot mounting holes The following precautions should be taken when selecting an installation site Shield the actuator from rain or snow unless the NEMA 4 option was selected Allocate sufficient clearance around the actuator for the removal of all covers to permit inspection of internal parts and to provide access to the handwheel Use auxiliary shielding to protect the actuator f...

Page 25: ...ITION 2 PROVIDE ADEQUATE CLEARANCE AT ALL ACCESS COVERS FOR SERVICING AND ADJUSTMENTS 3 WIRING DIAGRAM IS LOCATED ON THE INSIDE OF THE TERMINAL BOARD COVER 5 16 24 UNF 2B x 500 12 7 DP TYP 4 TAPPED HOLES EACH SIDE ACCESS COVER TO TERMINAL BOARD TAPPED HOLE FOR 3 4 CONDUIT ACCESS COVER HANDWHEEL REF MOTOR REF TAPPED HOLE FOR 1 CONDUIT FULL CRANK TRAVEL 90 ACCESS COVER TO SPUR GEARING HANDWHEEL MOTO...

Page 26: ...EARANCE AT ALL ACCESS COVERS FOR SEVICING AND ADJUSTMENTS 3 WIRING DIAGRAM IS LOCATED ON THE INSIDE OF THE TERMINAL BOARD ACCESS COVER TAPPED HOLE FOR 3 4 CONDUIT ACCESS COVER TO TERMINAL BOARD ACCESS COVER 5 16 24 UNF 2B x 500 12 7 DP TYP 4 TAPPED HOLES EACH SIDE HANDWHEEL REF TAPPED HOLE FOR 1 CONDUIT MOTOR REF HANDWHEEL FULL CRANK TRAVEL 90 ACCESS COVER TO SPUR GEARING 1 2 20UNF 2B X 1 239 31 4...

Page 27: ...software application HAL The software can be ordered as P N 51197910 001 Constant Torque Linkage A constant torque linkage is employed when it is desired to provide a linear torque profile throughout the full range of final control element travel In this situation the actuator and driven crank arms will be set up proportionally with respect to each other Figure 5 shows a general linkage setup to a...

Page 28: ...ll be set up to provide a higher torque for seating or unseating the final control element Figure 7 shows a general linkage setup to achieve a non linear torque profile and Figure 8 shows the resultant profile Note that this linkage can be characterized in many different ways by varying start angles and rotation requirements of both the Actuator Crank Arm and the Driven Arm Vertical Centerline 5 V...

Page 29: ...ads Customer supplied nut and bolt 12 to 24 inches a n23201 1 2 Figure 9 Turnbuckle Linkage Kit Pipe Linkage Kits See Section 8 for available Kit numbers Pipe linkage kits are available from Honeywell and can be used for linkage lengths from 24 to 120 inches 60 to 305 cm The kits include the mechanical pipe couplings load rod end left hand thread connecting rods and locking nuts See Figure 10 Pipe...

Page 30: ...adjustable 1 7 16 to 5 radius and there is an optional 12 inch crank arm that is adjustable from 0 to 12 Part Number 154007 The 10260S Actuator crank arm uses a standard inch rod end to compliment the turnbuckle and pipe linkage kits See Figure 11 For applications that use a link rod a link rod adapter is available as an option in the Model Selection Guide 1 2 Rod End Crank Arm Figure 11 Standard ...

Page 31: ... Scale Option The projecting scale option is available for customers whose actuators are direct coupled so that it would be impossible to read the standard scale on the actuator The projecting scale is attached to the side of the actuator enclosure and is readable from a distance See Figure 12 Figure 12 Projecting Scale Option Exploded View ...

Page 32: ...nt carrying conductors connected to the actuator Turn off power before working on conductors Failure to observe this precaution may result in serious personal injury Actuator Connections WARNING The ground terminal must be connected to a reliable earth ground WARNING While the unit is powered a potentially lethal shock hazard exists inside the case Do not open the case while the unit is powered Do...

Page 33: ...3 Installation Electrical Installation Revision 5 10260S HercuLine Actuator Installation Operation and Maintenance Manual 23 7 07 ...

Page 34: ...OT IN AUTO 4 20 INPUT 28 29 Analog signal input from controller 4 20 OUTPUT 30 31 Analog signal output from actuator FEEDBACK 32 Feedback signal used in conjuction with 4 20 OUTPUT voltage when using Slidewire Emulation MODBUS COMMUNICATION 33 34 35 SHIELD Connection for RS485 Modbus loop wires HART COMMUNICATION 28 29 HART communication is for 4 20 mA input only DIGITAL INPUT 36 COM 37 INP Custom...

Page 35: ...ctuator Installation Operation and Maintenance Manual 25 7 07 Connection Terminal Numbers and LABEL See Figure 13 Descriptions SW5 RELAY3 22 NC 23 COM 24 NO Auxiliary switch 5 or Relay 3 connections SW6 RELAY4 25 NC 26 COM 27 NO Auxiliary switch 6 or Relay 4 connections ...

Page 36: ... 6 NC SW1 7 5 SW2 NC 3 4 N L USE COPPER CONDUCTORS ONLY INSTRUMENT AT INPUT OF CUSTOMER S RESISTOR TO BE MOUNTED CLOSED WHEN NOT IN AUTO REMOVE RESISTOR FOR VOLTAGE INPUT Figure 13 Actuator Terminal Connections 1 Before running actuator remotely with a PDA HercuLink first disconnect any master Modbus device at terminals shown master Modbus wires not shown 2 Ensure good connection to remaining Modb...

Page 37: ...9 on the actuator terminal block connections Observing polarity connect the signal input wires to terminals 28 and 29 of the terminal block See Figure 13 0 1 5 Vdc and 0 to 10 Vdc Input Signals For voltage signal input remove the resistor from terminals 28 and 29 on the actuator terminal block Observing polarity connect the signal input wires to terminals 28 and 29 of the terminal block Output Sig...

Page 38: ... keypad interface and calibration procedures Local Display and Keypad The alphanumeric display and keys on the keypad are the local operator interface for control monitoring and configuration of the 10260S actuator The display consists of a four character upper display and a six character lower display Six LEDs of various colors indicate actuator operating status Directly below the display are six...

Page 39: ...on between input value and actuator position POS Position Shows current actuator position Increases the configuration values shown on the display Also shown as In manual mode and POSition display selected pressing this key will drive actuator motor in direction of increasing signal input Decreases the configuration values shown on the display Also shown as In manual mode and POSition display selec...

Page 40: ... fast using the or key When in any set up group hold the FUNCTION key in to scroll through the function prompts within that group Changing values quickly When changing the value of a parameter you can adjust a more significant digit in the upper display by holding in one key or key and pressing the other or key at the same time The adjustment will move one digit to the left Press the key again and...

Page 41: ...e 14 SET DIGINP Select the parameters for external digital input states Table 15 SET DISPLA Select and set parameters for the local display Table 16 CAL INPUT Calibrate input zero and span values Calibration Procedure Table 23 CAL MOTOR Calibrate zero and span values for motor operation Calibration Procedure Table 24 CAL CURENT Calibrate actuator output Calibration Procedure Table 25 SET LOCK Set ...

Page 42: ...first set up group you see when you press SET UP 2 Select any Set Up Group SET UP Successive presses of the SET UP key will display the other set up group titles as listed in Table 6 You can also use the or keys to scroll through the set up groups in both directions Stop at the set up group title that describes the group of parameters you want to configure Then proceed to the next step 3 Select a ...

Page 43: ...rying to make an unacceptable entry or the value on the display is at its range limit The display may also show KEYERR Key error 6 Enter Value or Selection FUNCTION or SET UP This key selects another function prompt This key selects another set up group NOTE Pressing either key will cause the previously selected value or selection to be entered into memory 7 Exit Set Up mode DISPLAY Exits set up m...

Page 44: ...20 mA 0 to 20 mA 1 to 5 Volts dc 0 to 5 Volts dc 0 to 10 Volts dc Remote Setpoint via communications NOTE Changing the Input Actuation Type will restore the actuator calibration to its factory values INP HI 10 0 to 100 INPUT HIGH RANGE VALUE in is displayed INP LO 0 0 to 90 0 INPUT LOW RANGE VALUE in is displayed NOTE You must set Input Low range to a value that is at least 10 less than Input High...

Page 45: ...when the input exceeds its high end range value by 3 Last Position Actuator motor remains at last position Up Actuator motor moves to full scale value Down Actuator motor moves to zero value User selected value Actuator motor moves to a customer defined value Allows setting of failsafehi input value FsFVALH 0 to 100 default 100 FAILSAFEHI INPUT VALUE FailsafeHI Type USER only Selects the motor pos...

Page 46: ...ion of the input signal Custom Characterizer Selecting custom allows you to create a twentieth order characterization of input value x and associated shaft position y Characterization can be of equal percentage valve quick opening valve or user defined See CUSTOM prompt below CUSTOM EQUL default QUIK USER Equal percentage Sets the characterization as explained in Equal Percentage Valve Characteris...

Page 47: ... as presented in the graph The Xn VAL is the input value as a percentage of range and Yn VAL is the characterized output actuator shaft position as a percentage of range Table 9 Equal Percentage Valve Characteristic Table Order Xn VAL of Range Yn Val of Range Equal Percentage Valve Characterization 0 0 0 1 5 0 8 2 10 2 1 3 15 3 2 4 20 4 9 5 25 6 5 6 30 8 4 7 35 10 7 8 40 13 2 9 45 15 7 10 50 18 7 ...

Page 48: ...aracteristic as presented in the graph The Xn VAL is the input value as a percentage of range and Yn VAL is the characterized output actuator shaft position as a percentage of range Table 10 Quick Opening Valve Characteristic Table Order Xn VAL of Range Yn Val of Range Quick Opening Valve Characteristic 0 0 0 1 5 10 2 10 20 3 15 30 4 20 40 5 25 50 6 30 60 7 35 70 8 40 77 9 45 82 10 50 86 11 55 88 ...

Page 49: ...ame as PosR for upper limit Lower Limit Travel Same as PosR for lower limit Temperature High High temperature limit exceeded Temperature Low Low temperature limit exceeded Starts Motor starts limit exceeded Allows setting of multiplier value Stalled Motor position does not follow input Manual Actuator is set to manual mode Power Up Test Failure Failure of any power up diagnostic Failsafe Alarm Fai...

Page 50: ...r position has exceeded the lower limit of travel Same as Position Range Relay value parameter defines limits and units are in degrees of rotation or percent of span Temperature High The high temperature limit of the actuator has been exceeded Range is 30 to 75 C Relay value parameter defines temperature limits and units are in either degrees C or degrees F Temperature units are defined in the UNI...

Page 51: ... the motor travels above 80 the second trip point R12VAL is set so the relay energizes when the motor travels below 20 Set Up Group Parameter Value SET RELAY1 RTYP11 PosR R11VAL 80 0 R11HL HI RTYP12 PosR R12VAL 20 0 R12HL LO RLY1HY 0 0 The figure below shows the resulting action 100 0 18 Closed 20 80 RELAY 1 Normally Open Closed Open Motor Position 17 18 17 Relay Type Deviation Setting up a relay ...

Page 52: ...the motor position exceeds the upper limit trip point and can be set up as follows Note that relay hysteresis parameter RLY1HY value is set to 10 which is 10 of range This means that when the relay is energized due to the motor position exceeding the upper limit value the relay will not de energize until the motor moves to 10 below the trip point Set Up Group Parameter Value SET RELAY2 RTYP21 ULim...

Page 53: ...ut signal range of the actuator you must perform an output calibration See Calibrating Output page 62 When selecting the output range of the actuator the 4 20 mA selection is factory calibrated therefore no calibration is necessary If you change the CUROUT selection you must perform an output calibration so that the values at the actuator output terminals agree with the CUROUT selection Additional...

Page 54: ...ation and Maintenance Manual Revision 5 7 07 Lower Display Prompt Upper Display Selections Parameter Definition CUROUT Note If output type from model selection guide is Slidewire Emulation SW E Slidewire Emulation CUROUT Note If output type from model selection guide is None NONE No current output configured ...

Page 55: ...r the parameters listed below HART Selects HART as the Communications Protocol ADDRES 1 to 99 DEVICE ADDRESS Selects device address when used in a Modbus communications loop Select an address that is unique to other devices on the communications link BAUD 2400 4800 9600 19 2k BAUD RATE Selects the speed of data transfer All equipment on the link must be set to match the host setting XmtDLY NONE 10...

Page 56: ...n Value EndPos 0 100 in percent END POSITION VALUE DIGINP USER only Selects the motor position you want the actuator to go to when digital input signal present contact closure Display Set Up Group Table 16 lists the parameters and selections availible for the SET DISPLA group Table 16 Display Set Up Group Parameters Lower Display Prompt Upper Display Selections or Range of Setting Parameter Defini...

Page 57: ...n be selected to provide security access to calibration information set up parameters and supervisory functions Password can be a number from 0 to 4095 A password is required in order to change the lock parameter See Set Change Password below LOCK NONE default CAL CONF FULL LOCK OUT FEATURE Selects lockout security for calibration and supervisory functions and set up groups None No lockout of any ...

Page 58: ...The upper display will show 0 zero Use the or keys to increment the number to the correct password The default password can also be used See NOTE below 4 Press the FUNCTION key so that the lower display reads LOCK 5 Use the or keys so that display reads NONE and LOCK If the LOCK parameter is not set to NONE a password must be entered to change the parameter 6 Press the FUNCTION key until the lower...

Page 59: ...oubleshooting section RAMTST PASS FAIL RAM TEST DIAGNOSTIC Read Only Shows status of RAM test diagnostic Pass Test passed no errors Fail Test failed see Troubleshooting section SEETST PASS FAIL SERIAL EEPROM TEST DIAGNOSTIC Read Only Shows status of serial electrically eraseable PROM test diagnostic Pass Test passed no errors Fail Test failed see Troubleshooting section CFGTST PASS FAIL CONFIGURAT...

Page 60: ...ll range of travel SPEED 90 50hz 12s 24s 48s 72s 24s 48s 72s 48s 72s STROKE SPEED Read Only The speed is the number of seconds it takes for the actuator shaft to move its full range of travel POWER 1206 1205 2206 2205 POWER INPUT VOLTAGE AND FREQUENCY Read Only Selects the power input voltage and line frequency of the actuator 1206 120Volts 60Hz 1205 120Volts 50Hz 2206 220Volts 60Hz 2205 220Volts ...

Page 61: ...y or ddmmyy DATE OF LAST FACTORY CALIBRATION Factory set only Displays date of last factory calibration REPTYP NONE 01 02 03 04 05 06 07 08 09 10 11 12 13 REPAIR TYPE Factory set only Displays a repair code to identify the type of repair service previously performed None Future Non contact Sensor Main CPU PWA repair Motor service Power Distribution PWA service Switch repair Relay service Gear serv...

Page 62: ...int will be flashing at the leftmost digit for approximately three seconds Then the decimal point shifts to the right and flashes for three seconds before shifting again to the right This pattern repeats continuously 4 Set the digit to the left of the flashing decimal point Use the or keys to scroll through the character set of 0 through 9 and the letters A through Z Scroll through until the desir...

Page 63: ...perature since it was last reset TEMPLO nnnn F LOW TEMPERATURE LIMIT Displays the low temperature limit of the internal actuator temperature since it was last reset hh mm ss ACST ACCUMULATED STALL TIME Displays the accumulated stall time of the actuator motor since it was last reset STARTS nnnn ACCUMULATED MOTOR STARTS Displays the accumulated motor starts since it was last reset RLnCNT n 1 2 3 or...

Page 64: ...lbration value to its factory calibration Input Restores input calibration to the factory calibration Motor Restores motor calibration to the factory calibration Output Restores actuator output calibration to the factory calibration For 4 20 mA output only all other CUROUT selections require output calibration All Restores input motor and output calibration to the factory calibrations Position Sen...

Page 65: ...ameter Definition CALPOS n nnn POSITION SENSOR OUTPUT Read Only Displays the output voltage of the position sensor PWA To access the display Press Result SETUP until you see Upper Display CAL Lower Display POSOUT FUNCTION Upper Display DIS Lower Display CALPOS or key Upper Display BEGN Lower Display CALPOS FUNCTION Upper Display n nnn Sensor output in volts Lower Display POSOUT Auto Manual Drive S...

Page 66: ...7 MANUAL OFF CW CCW OFF A U T O AUTO MANUAL DRIVE Figure 16 Auto Manual Switch Table 22 Auto Manual Switch Functions Switch Setting Motor Drive Control AUTO Actuator moves according to signal input and set up configuration CCW Actuator moves to the fully counterclockwise position CW Actuator moves to the fully clockwise position OFF Actuator is idle ...

Page 67: ...ay to step through the calibration group functions ATTENTION Input calibraton and output calibrations are performed at the factory and may not be necessary Normally you may only need to perform Calibrate Motor Only qualified personnel should perform calibration Equipment Needed The table below lists the equipment you will need to calibrate the 10260S input and output circuits Procedure Equipment N...

Page 68: ...l source to the input terminals of the actuator as shown in Figure 17 or Figure 18 2 Place signal source output to low end of input signal and switch power on 3 Skip this step for slidewire emulation Connect a 250 ohm resistor across the Output terminals of the actuator and connect the DVM leads to the terminals Input 28 29 Output 30 31 250 ohm resistor needed for current signal source Calibrated ...

Page 69: ... Installation Operation and Maintenance Manual 59 7 07 Actuator Input 28 29 Output 30 31 32 Calibrated Signal Source Digital Voltmeter FB Terminal Block Power Supply 1 18 VDC 250 ohm resistor needed for current signal source Figure 18 Calibration Wiring Connections slidewire emulation ...

Page 70: ...hout completing the steps of the procedure To exit calibation mode press DISPLAY or SETUP keys Table 23 Input Calibration Procedure Step Operation Press Result 1 Enter Calibration Mode SETUP until you see Upper Display CAL Lower Display INPUT FUNCTION Upper Display DIS Lower Display CAL IN or key Upper Display BEGN Lower Display CAL IN 2 Calibrate Zero 0 FUNCTION Upper Display APLY Lower Display I...

Page 71: ...isplay CALMTR 2 Calibrate Zero 0 FUNCTION Upper Display APLY Lower Display MTR LO Use the Handwheeel or AUTO MANUAL switch to manually drive the actuator motor to its low position Wait 5 seconds then go to step 3 3 Calibrate Span 100 FUNCTION Upper Display APLY Lower Display MTR HI Use the Handwheeel or AUTO MANUAL switch to manually drive the actuator motor to its high position Wait 5 seconds the...

Page 72: ...ator output signal This procedure provides the steps to calibrate the actuator for a 0 4 to 20mA output If you are using another output type change the procedure accordingly Please note that the actuator output is factory calibrated for only the 4 20 mA output selection Any other output selection will require you to perform an output calibration ATTENTION For an output calibration to be saved you ...

Page 73: ... display will show a value of approximately 1981 4 FUNCTION Calibration for zero and span output values are now stored Output calibration is complete Slidewire Emulation The 10260S Actuator comes already calibrated from the factory If it becomes necessary to do a calibration in the field adjust the output using the procedure in Table 26 Refer to Figure 18 for a diagram to connect a signal source t...

Page 74: ...tion Sensor ATTENTION The Position Sensor is factory calibrated to a full span 90 degree rotation Under normal operation the position sensor does not require calibration NOTE Before you perform a calibration of the position sensor it is recommended that you first verify the voltage output from the sensor PWA See Position Sensor Operation in section 5 for the procedure Position sensor calibration m...

Page 75: ... key until the dispaly reads DIS CALPOS Press the or keys until the lower display reads BEGN CALPOS Press FUNCTION key The upper display now shows the output of the non contact sensor PWA in Volts 7 Loosen the allen screw in the hub of the NCS spoiler just enough to be able to rotate the spoiler See Figure 19 8 Adjust the NCS spoiler so that the voltage in the local display is 2 500 or 0 020 volts...

Page 76: ...ould be almost horizontal when properly positioned NCS PWA Figure 19 Location of NCS Assembly Table 28 Load NCS Factory Calibration Step Action 1 Reapply AC power to the actuator 2 Press SET UP key to access the MAINT set up group Press the FUNCTION key until the display reads LD CAL Press the or keys until the display reads POS 3 Perform the Calibrate Motor procedure exactly as in Table 24 Motor ...

Page 77: ...e the switch to go from NC to NO and turn off the power to the motor when the switch activates Switch activation may be detected by the clicking sound or with a continuity tester connected to the terminals Both the NC and NO contact states are available to the customer at the terminals see Figure 13 page 26 Rotate the actuator shaft using the manual handwheel or the auto manual switch to the 100 p...

Page 78: ...dge of the cams or your finger rotate the cams until the switches are set see Figure 20 Rotate the actuator shaft using the manual handwheel or the auto manual switch to the 0 position this is the 0 for CCW operation using the left hand scale or 100 for CW operation using the right hand scale If the actuator is installed on a damper or valve also make sure that this position is synchronized with t...

Page 79: ...urn off the power to the motor when the switch activates Both the NC and NO contact states are available to the customer at the terminals see Figure 13 page 26 If optional auxiliary switches were ordered these switches may also be set at this time See page 73 for details of setting auxiliary switches 3 No additional adjustments are required 4 Double check limit switch actuation by first manually d...

Page 80: ...ate the cams until the switches are set See Figure 20 The auxiliary switches should be set so switches 3 and 5 operate in synchronism with switch 1 i e both activating when the drive is going in the same direction and set switches 4 and 6 to operate in synchronism with switch 2 For Switches 3 and 5 Rotate the actuator shaft using the manual handwheel or the auto manual switch to the desired low sc...

Page 81: ...mpletely flatten the spring washer 5 Double check limit switch actuation by first manually driving the actuator to each end of travel and hearing the switch click or by detecting it with a continuity tester Secondly drive the actuator to both ends of travel using the auto manual switch or by providing minimum and full input signal and make sure the switches activate CAM 1 REF SWIT CH 1 SWIT CH 3 S...

Page 82: ...SW 2 End of travel limit switch settings Clockwise and counterclockwise rotation is the direction of the output shaft when facing the end of the shaft As shown clockwise rotation of the output shaft activates SW 1 at 0 on left hand pointer scale and CCW rotation activates SW 2 at 100 on left hand pointer scale Terminal numbers are next to circles see Figure 13 page 26 Figure 21 End of Travel Limit...

Page 83: ...r arm should go from being in an up not depressed state to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position This will cause the switch to go from NC to NO when the switch activates Switch activation may be detected by the clicking sound or with a continuity tester connected to the terminals Both the NC and NO contact states are availabl...

Page 84: ...raseable PROM SEETST Verification that valid parameter values are in the actuator configuration CFGTST Verification of valid calibration values CALTST Test of the local display and LED indicators all display segments and LED indicators light simultaneously The local display shows the status of the diagnostics as they are completed during power up TEST DONE is shown on the display when diagnostics ...

Page 85: ...00 OP 0 5 Output Upper Display Shows input value Lower Display Shows output value 100 0 DE 99 9 Deviation Upper Display Shows input value Lower Display Shows value of deviation of sensor from input 0 6 POS Position Upper Display Shows value of position sensor Lower Display prompt NOTE Position display will show negative values if appropriate NOTE When the AUTO MANUAL key is pressed placing the act...

Page 86: ...ve the motor to zero position Repeat Step 2 The display should read 1 600 or 0 060 Volts 5 Press DISPLAY key and then drive the motor to 100 position Repeat Step 2 The display should read 3 400 or 0 060 Volts 6 If the NCS needs adjustment refer to the Calibrate Non Contact Sensor procedure in Table 27 in Section 4 Remote Setpoint Operation The 10260S actuator can be set up to receive a digital inp...

Page 87: ...cumulated on the total number of motor starts as well as the total number of motor starts that occur in each region of travel The statistics can be accessed in the maintenance set up group The counts can also be reset to zero if desired or saved manually to memory See Maintenance Set Up Group for more information The regions of travel are set for full span motor travel 90 rotation If the actuator ...

Page 88: ... actuator to operate as part of a split valve configuration Table 30 Split Range Set Up Procedure Step Action To Set Actuator span to operate from 4 to 12 mA input 1 Enter Set Up mode by pressing SET UP key 2 Select SET INPUT group 3 Press FUNCTION key until INP HI on lower display is selected 4 Set INP HI value to 50 0 5 Press FUNCTION key to select INP LO and set value to 0 0 6 Press DISPLAY key...

Page 89: ...will revert to one of its failsafe states Signal failure is not a problem since the available failsafe settings allow you to set the actuator position on signal loss Basic Flow Control When the process variable signal is below set point the controller increases current 4 mA to 20 mA to the actuator input and opens the valve Controller set point governs valve position to obtain desired flow rate PV...

Page 90: ...otor positions receive the same signal as 1 motor positioned valves 2 and 3 will deliver the same amount of fuel This is true when the span and zero adjustment are all set the same as in curve 2 of the graph Other relationships between units exist if the span adjustment 3 for ratio or if the zero adjustment is changed 1 for bias Proportional with Bias Ratio Position mA PV SP 4 to 20 mA Controller ...

Page 91: ...ms 1 to 5 VDC Preferred Wiring Note Controller must be capable of sourcing the impedance NOTE If using HART communications for this application HART must be configured for Multi drop operation Hot 10260S Series Actuator 1 Neutral Ground 120 240 VAC 250 Ohms 1 to 5 VDC Current Output Controller 4 to 20 mA Hot 10260S Series Actuator 2 Neutral Ground 120 240 VAC Hot 10260S Series Actuator 3 Neutral G...

Page 92: ...it valve operation using two actualtors Hot 10260S Series Actuator 1 Neutral Ground 120 240 VAC 250 Ohms 1 to 5 VDC Current Output Controller 4 to 20 mA Hot 10260S Series Actuator 2 Neutral Ground 120 240 VAC 250 Ohms 1 to 5 VDC Preferred Wiring Note Controller must be capable of sourcing the impedance NOTE If using HART communications for this application HART must be configured for Multi drop op...

Page 93: ...6 Control Applications Master Slave Arrangement Revision 5 10260S HercuLine Actuator Installation Operation and Maintenance Manual 83 7 07 ...

Page 94: ......

Page 95: ...ommends that during major shutdown periods the spur gears should be inspected and lubricated Follow the steps in Table 31 to access the spur gear compartment and lubricate the gears if necessary WARNING Disconnect power before opening the actuator case to inspect the actuator gears A potentially dangerous pinch hazard exists inside the case if the unit is opened while powered Table 31 Spur Gear Lu...

Page 96: ...asic Maintenance 86 10260S HercuLine Actuator Installation Operation and Maintenance Manual Revision 5 7 07 Side Cover Side Cover Gasket Spur Gears Final Spur Gear Idler Gear Motor Pinion Figure 30 Spur Gear Location ...

Page 97: ...hal shock hazard exists inside the case if the unit is opened while powered Table 32 Motor Drive Fuse Replacment Procedure Step Action 1 Remove AC power from actuator 2 Remove the seven screws and the extended cover of the actuator case See Figure 31 3 Lay assembly down on a flat surface and remove old gasket 4 Locate the two fuses on the power distribution PWA See Figure 32 Carefully remove and r...

Page 98: ...3 Relay PWA Replacement Procedure Step Action 1 Remove AC power from actuator 2 Remove the seven screws and the extended cover of the actuator case See Figure 31 3 Lay assembly down on a flat surface and remove old gasket 4 Disconnect the wire connector from the relay PWA 5 Carefully remove the relay PWA Turn the locking tabs of the card guides away to unlock the PWA and slide it out from the card...

Page 99: ...u with a complete list of all the spare parts that may be needed for the 10260S Series Actuators and optional equipment Each kit contains replacement parts accessories and instructions for component replacement The numbers in Figure 33 identify the location of various actuator replacement components and are keyed to parts kits listed in this section 1 2 3 4 5 6 7 8 9 Figure 33 10260S Actuator Comp...

Page 100: ...art Description Motor Capacitor Motor 11uf 60 Hz Capacitor Motor 13uf 50 Hz Gasket Set 10260S Kit Instruction Kit 51205551 503 Motor 1026 7 8 9 120 V 50 60 Kit Part Description Motor Capacitor Motor 14uf Gasket Set 10260S Kit Instruction Kit 51205551 504 Motor 1026 1 2 4 6 7 8 9 240 V 50 60 Kit Part Description Motor Capacitor Motor Capacitor Motor Gasket Set 10260S Kit Instruction Kit 51205551 50...

Page 101: ...otor 10265 240 V 50 60 Kit Part Description Motor Capacitor Motor Capacitor Motor Gasket Set 10260S Kit Instruction c Idler Gear Kits Kit 51205552 501 Idler Gear 1026 1 2 4 6 7 Fiber 2 Kit Part Description Idler Gear Assy Fiber Gasket Set 10260S Kit Instruction Kit 51205552 502 Idler Gear 1026 8 9 Steel 2 Kit Part Description Idler Gear Assy Steel Gasket Set 10260S Kit Instruction Kit 51205552 503...

Page 102: ...n Non Contact Sensor PWA NCS Set Up Gage Screws 4 40 X 5 16 Gasket Set 10260S NCS Wire Assy Kit Instruction Replacement PWAs e Kit 51450802 501 Relay PWA Part Description Relay PWA Gasket Set 10260S Kit Instruction f Kit 51500163 501 Main CPU PWA Assembly Part Description Assembly Drawing Screws 6 32 X Main CPU PWA Card Guide Assy Card Guide Middle Screws 6 32 X 3 8 Screw Tap 6 32 X 3 8 Gasket Set...

Page 103: ...late Keypad Display Lens Display Overlay Transformer Screws 4 40 X 3 8 Screws 6 32 X 3 8 Sleeve Keypad Gasket Kit Instruction Kit 51500324 501 Display Upgrade Kit Complete Display and Cover Assembly h Kit 51500166 501 Power Distribution PWA Part Description Power Distribution PWA Gasket Set 10260S Kit Instruction Relay Upgrade Kit Kit 51450802 502 Relay PWA Upgrade Kit Part Description Relay PWA R...

Page 104: ...ies Kit Instruction Auto Manual Switch Kit Kit 51500581 501 Auto Manual Switch Kit Part Description Auto Manual Switch Wire Assy 10260S Auto Manual Label Knob Shrink Tubing Gasket Set 10260S Kit Instruction MOV Assembly Kits Kit 51500671 503 MOV Assembly Kit 130 Vac Part Description MOV Assembly 130 Vac Gasket Set 10260S Kit Instruction Kit 51500671 504 MOV Assembly Kit 275 Vac Part Description MO...

Page 105: ...Support Bracket Switches Switch Insulator Screw 4 40 X 75 Lockwasher 4 Washer N 4 Screw 4 40 X 1 25 Screw 4 40 X 1 75 Cable Assy Switch Gasket Set 10260S Kit Instruction k Cam Kits Kit 51205553 501 Cam Assembly Kit Part Description Bushing Cam Screw Soc Set 10 32 X Locking Nut Washer Toothed Washer Cam Spacer Cam Cam Kit Instruction Accessories Part Number 5 Crankarm Kit 51309967 501 12 Crankarm K...

Page 106: ...erall linkage length inches 150 to 300 lb ft 200 to 410 Nm Min Max Kit Number Min Max Pipe Size Kit Number 12 16 083381 24 28 1 083384 16 20 083382 24 84 1 083385 20 24 083383 24 120 2 083386 Turnbuckle Kit Rod end nut and bolt are supplied with the actuator 1 2 20 right hand threads 20 left hand threads Customer supplied nut and bolt 12 to 24 inches 1 2 Pipe Kit Rod end nut and bolt are supplied ...

Page 107: ... of failure that can be identified by noting the faulty actuator operation Table 34 Observable Symptoms of Failure Symptom Procedure No Actuator current output Replace CPU Assembly No Actuator slidewire output Replace CPU Assembly Local display does not light See Figure 34 Actuator fails one or more power up diagnostics See Figure 35 Actuator motor does not drive in response to input signal Perfor...

Page 108: ...or replacing actuator components can be found either in Section 7 Maintenance or in the kit with the replacement components Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow DC Milliammeter mA dc Calibration source Volt mA etc Digital Voltmeter Safety precautions Exercise appropriate safety precautions when troubleshooting...

Page 109: ... Do all diagnostics pass RAMTST PASS SEETST PASS CALTST PASS CFGTST PASS Replace display assembly Does motor reposition itself Yes Yes No No All LEDs and display segments light No E B Replace display assembly A Move handwheel on actuator 2 or 3 turns Cycle power to actuator Does display light up No Yes Observe self test Yes E Figure 34 Test for Actuator Operation ...

Page 110: ...e CPU assembly Cycle power to actuator If CFGTST fails again replace CPU assembly Replace CPU Assembly Observe self test Cycle power to actuator Does display light up RAMTST PASS SEETST PASS CALTST PASS Do all LEDs and display segments light up CFGTST PASS Check actuator configuration setup reconfigure if necessary Check actuator calibration recalibrate if necessary E B Yes No A Yes No No Yes Yes ...

Page 111: ...eshooting Procedures Revision 5 10260S HercuLine Actuator Installation Operation and Maintenance Manual 101 7 07 Test Non Contact Sensor PWA See Non Contact Sensor Operation in Section 5 for procedure in testing NCS PWA output ...

Page 112: ...elow Remove extended cover of actuator Are fuses good Replace fuses with same type and rating Yes D Check Fuses F1 and F2 on the power distribution PWA No Yes No Replace Power Distribution PWA Figure 36 Test Power Distribution PWA Power Distribution PWA Test Points Connector Test Points Pins Voltage J2 Pin 1 to pin 7 5 V J3 Pins 1 2 to pins 3 4 8 Pins 3 4 to pin 7 5 V 9 V J1 Pins 5 6 to pins 7 8 P...

Page 113: ...h Possible trouble spots a Auto Manual switch b Power Supply PWA See D c Limit switches d Motor e R C networks f etc Others Does motor drive in the CW direction Turn switch to Manual CW setting Turn switch to Manual CCW setting Does motor drive in the CCW direction E Yes No Yes No OK MANUAL OFF CW CCW OFF A U T O AUTO MANUAL DRIVE Figure 37 Test AUTO MANUAL Switch ...

Page 114: ...lock See Relay replacement in Maintenance Section 7 Set AUTO MANUAL switch to MAN Press SET UP button on keypad to enter Set up mode Does Relay operate Yes No OK Place ohmmeter across associated relay contacts at Actuator terminal block See below Figure 38 Test Relay Function Relay Associated Contacts at Terminal Block RELAY1 16 NC 17 COM 18 NO RELAY2 19 NC 20 COM 21 NO RELAY3 22 NC 23 COM 24 NO R...

Page 115: ... VAL X5 VAL X6 VAL X7 VAL X8 VAL X9 VAL X10VAL X11VAL X12VAL X13VAL X14VAL X15VAL X16VAL X17VAL X18VAL X19VAL X20VAL Y0 VAL Y1 VAL Y2 VAL __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ _______________...

Page 116: ...Relay Type R11VAL Relay Value R11 HL Relay High Low R11SCALE Relay Scale RTYP12 Relay Type R12VAL Relay Value R12 HL Relay High Low R12SCALE Relay ScaleRLY1HY Relay Hysteresis __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ NONE 0 LO X1 NONE 0 LO X1 0 RTYP21 Relay Type R21VAL Relay Value R21 HL ...

Page 117: ...___________ MODBUS 119 2K20MS FP B SET DIGINP DIGINP Digital Input State Endpos End Position Value __________________ __________________ UP 0 SET DISPLA DECMAL Decimal Point Location EUNITS Units Display UNITS Display Units __________________ __________________ __________________ 8888 Pcnt ENG SET LOCK LOCKID Password Lock LOCK Lock Out MAENAB Local Mode Change Enable __________________ __________...

Page 118: ...umulated Motor Starts for regions of motor travel y 0 through 9 TOTDEG Accumulated total degrees traveled DATSAV Forced Manual Maintenance Data Save __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only ...

Page 119: ...n 22 End of travel limit switch See Limit Switches Exiting Set Up mode 30 Failsafe 35 Failsafe Input Value 35 36 Feedback 9 Field Reversible Actuator Rotation 5 Fuses 8 Replacement 87 Gear Train 4 7 HAL Software 5 96 Hysteresis 39 Input Calibration 60 Input Characterization 36 Input Filters 34 Input High Range 34 Input Low Range 34 Input Set Up Group 34 Inputs 9 34 Installation Considerations 14 K...

Page 120: ...ore Factory Calibration Values 54 Scrolling through Set Up Groups 30 Self test Diagnostics 49 74 100 Set Up Groups Communications 45 Current out 43 Digital input 46 Display 46 Drive 50 Input 34 Maintenance 53 Read status 49 Relays 39 Short Stroke Motor calibration 61 Slidewire Emulation 3 9 27 Smart Electronics 4 Display and Keypad PWA 4 Enhanced electronics PWA 4 Power supply PWA 4 Relay PWA 4 Sp...

Page 121: ......

Page 122: ...Honeywell Field Solutions Honeywell Inc 512 Virginia Drive Fort Washington PA 19034 ...

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