Honeywell Herculine 2000 Users Manual 62 86 25 10 HercuLine® Series Actuator Installation, Operation And Maintenance

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HercuLine® 2000 Series Actuator
Installation, Operation and
Maintenance Manual

Honeywell Field Solutions

Doc. No.:

62-86-25-10

Revision:

Date:

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
your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of
coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole
remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is believed to be accurate
and reliable as of this printing. However, we assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the
customer to determine the suitability 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 against harmful interference when
this equipment is operated in an industrial environment. Operation of this equipment in a residential area may cause
harmful interference. This equipment generates, uses, and can radiate radio frequency energy and may cause
interference to radio and television reception when the equipment is used closer than 30 m to the antenna(e). In
special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional
mitigating measures to further reduce the electromagnetic emissions of this equipment.

Honeywell Process Solutions
512 Virginia Drive
Fort Washington, PA 19034
®

HercuLink® and HercuLine are trademarks of Honeywell
Palm is a trademark of Palm Inc.
Other brand or product names are trademarks of their respective owners.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
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 identifies all documents that may be sources of reference for material discussed in this
publication.
Document Title

Doc ID

HercuLine 2000 Series Actuator Specification

61-86-03-14

HercuLine 2000 Series Actuator Model Selection Guide

62-86-16-21

Modbus RTU Serial Communications User Manual

51-52-25-66

Modbus® RTU Serial Communications User Manual
Configuration/Remote Calibration Interfaces for HercuLine Actuators

51-52-25-103

HercuLink™ User Manual

62-86-25-11

HART Communications Installation and Operations Manual

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)

Corporate

http://www.honeywell.com

Honeywell Process Solutions

http://www.honeywell.com/ps

Telephone
Contact us by telephone at the numbers listed below.
Organization
United States and Canada

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Honeywell

Phone Number
1-800-423-9883
1-800-525-7439

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Tech. Support
Service

iii

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 situation, which,
if not avoided, will result in death or serious injury.
This WARNING symbol indicates a potentially hazardous situation, which, if
not avoided, could result in death or serious injury.
This CAUTION symbol may be present on Control Product instrumentation
and literature. If present on a product, the user must consult the
appropriate part of the accompanying product literature for more
information.
This CAUTION symbol indicates a potentially hazardous situation, which, if
not avoided, may result in property damage.
WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user 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 green/yellow) supply system conductor.
Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.
Chassis Ground. Identifies a connection to the chassis or frame of the equipment
shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requirements.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Contents

Introduction ............................................................................................. 1
Product Description ......................................................................................................1

Specifications .......................................................................................... 5
Technical and Operating Specifications .......................................................................5
Model Selection Guide ...............................................................................................10

Installation ............................................................................................. 12
Installation Overview ..................................................................................................12
Mechanical Stops .......................................................................................................12
Before Starting............................................................................................................13
Actuator Mounting ......................................................................................................13
Mechanical Installation ...............................................................................................15
Electrical Installation...................................................................................................17

Burner Control/Flame Safety................................................................. 23
Series 90 Control – HercuLine® 2001 model only ......................................................24
Split Range .................................................................................................................26
Master/Slave Arrangement.........................................................................................26

Set Up and Calibration Procedures ....................................................... 31
Overview.....................................................................................................................31
Local Display and Keypad..........................................................................................31
Set Up Tips.................................................................................................................33
Set Up Groups............................................................................................................34
Set Up Procedure .......................................................................................................36
Configuration Prompt Hierarchy .................................................................................38
Input Set Up Group.....................................................................................................39
Relays Set Up Group..................................................................................................44
Current Out Set Up Group..........................................................................................49
Communications Set Up Group..................................................................................50
Digital Input Set Up Group .........................................................................................51
Display Set Up Group.................................................................................................52
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Contents

Lock Set Up Group .....................................................................................................53
Read Status Set Up Group.........................................................................................55
Drive Set Up Group ....................................................................................................56
Maintenance Set Up Group........................................................................................59
Regions of Motor Travel .............................................................................................62
CAL POSOUT Group .................................................................................................63
Auto - Manual Drive Switch ........................................................................................64
Calibration ..................................................................................................................65
Setting End-of-Travel Limit Switches .........................................................................78
Setting Auxiliary Switches ..........................................................................................81

Start-Up/Operation ................................................................................ 83
Introduction.................................................................................................................83
Power-up Diagnostics.................................................................................................83
Operations Checklist ..................................................................................................83
Operating Displays .....................................................................................................84
Motor Stall ..................................................................................................................84
Position Sensor Operation .........................................................................................85
Remote Setpoint Operation........................................................................................85

Maintenance.......................................................................................... 87
Introduction.................................................................................................................87
Basic Maintenance .....................................................................................................87
Replacement Procedures...........................................................................................89

Replacement/Upgrade/Accessory Kits .................................................. 91
Replacement Kits .......................................................................................................91
Upgrade Kits.............................................................................................................102
Accessory Kits ..........................................................................................................104

Troubleshooting .................................................................................. 105
Introduction...............................................................................................................105
Troubleshooting Procedures ....................................................................................106

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet...... 112
Index ................................................................................................... 116

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Contents

Tables
Table 1 Specifications - General.............................................................................................................................5
Table 2 Recommended Minimum Wire Size........................................................................................................17
Table 3 Terminal Connections: HercuLine® 2000...............................................................................................18
Table 4 Terminal Connections: HercuLine® 2001/2002 with auto/manual.........................................................19
Table 5 Split Range Set Up Procedure .................................................................................................................26
Table 6 Keypad Description .................................................................................................................................32
Table 7 Set Up Tips ..............................................................................................................................................33
Table 8 Set Up Groups .........................................................................................................................................34
Table 9 Set Up Procedure Using Display and Keypad .........................................................................................36
Table 10 Input Set Up Group Parameters .............................................................................................................39
Table 11 Equal Percentage Valve Characteristics ................................................................................................42
Table 12 Quick Opening Valve Characteristic .....................................................................................................43
Table 13 Relay Set Up Group Parameters ............................................................................................................44
Table 14 Relay Type Descriptions........................................................................................................................45
Table 15 Current Out Set Up Group Parameters ..................................................................................................49
Table 16 Communications Set Up Group Parameters ..........................................................................................50
Table 17 Digital Input Set Up Group Parameters.................................................................................................51
Table 18 Display Set Up Group Parameters .........................................................................................................52
Table 19 Lock Set Up Group Parameters .............................................................................................................53
Table 20 Read Status Set Up Group Parameters ..................................................................................................55
Table 21 Drive Set Up Group Parameters ............................................................................................................56
Table 22 Maintenance Set Up Group Parameters.................................................................................................59
Table 23 CAL POSOUT Group Parameters.........................................................................................................63
Table 24 Auto - Manual Switch Functions ...........................................................................................................64
Table 25 Input Calibration Procedure...................................................................................................................69
Table 26 Motor Calibration Procedure .................................................................................................................70
Table 27 Output Calibration Procedure ................................................................................................................71
Table 28 Slidewire Emulation Calibration Procedure ..........................................................................................73
Table 29 NCS Position Sensor Calibration Procedure.........................................................................................74
Table 30 Potentiometer Position Sensor Calibration Procedure ..........................................................................76
Table 31 Load Position Sensor Factory Calibration .............................................................................................77
Table 32 End-of-Travel Limit Switch Setting Procedure .....................................................................................79
Table 33 Auxiliary Switch Setting Procedure ......................................................................................................82
Table 34 Typical Operating Displays ...................................................................................................................84
Table 35 Spur Gear Lubrication Procedure ..........................................................................................................87
Table 36 Motor Drive Fuse Replacment Procedure .............................................................................................89
Table 37 Relay PWA Replacement Procedure .....................................................................................................90
Table 38 Replacement kits....................................................................................................................................96
Table 39 Observable Symptoms of Failure ........................................................................................................105

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vii

Contents

Figures
Figure 1 HercuLine® 2000 Series Actuator
Figure 2 HercuLine® 2002 Actuator Internal View
Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators
Figure 4 Constant Torque Linkage
Figure 5 Variable Torque Linkage
Figure 6 Standard crank arm
Figure 7 Crank arm with optional ball joint and push rod
Figure 8 HercuLine® 2000 connections
Figure 9 HercuLine® 2001/2002 connections
Figure 10 HercuLine® 2003 connections
Figure 11 CE wiring part 1
Figure 12 CE Wiring part 2
Figure 13 Burner Control/Flame Safety Wiring
Figure 14 Series 90 connections
Figure 15 T775 Controller connections
Figure 16 Flow Diagram
Figure 17 Interconnection Diagram
Figure 18 Proportional Flow Using Multiple Actuators
Figure 19 Multiple Actuator Interconnection Diagrams
Figure 20 Interconnection Diagrams
Figure 21 HercuLine® 2000 Display and Keypad
Figure 22 Relay connectors
Figure 23 Regions of Motor Travel
Figure 24 Auto - Manual Switch
Figure 25 Calibration Wiring Connections (non-slidewire emulation)
Figure 26 Calibration Wiring Connections (slidewire emulation)
Figure 27 Jumper Location on CPU PWA
Figure 28 Location of NCS Assembly
Figure 29 Location of potentiometer position sensor
Figure 30 End of Travel Limit Switch Settings
Figure 31 Location of End-of-Travel Limit and Auxiliary Switches
Figure 32 Auxiliary Switch Settings
Figure 33 Terminal Block Connections for Modbus Communications
Figure 34 Spur Gear Location
Figure 35 Power Distribution PWA and Relay PWA Locations
Figure 36 Motor Drive Circuit Fuses
Figure 37 Replacement Kits 6, 7, 8, 11, 12, 14
Figure 38 Replacement Kit 10
Figure 39 Replacement Kits 1, 2, 3, 4, 5, 9, 15, 16, 19
Figure 40 Replacement Kit 13
Figure 41 Replacement Kits 17, 18
Figure 42 Test for Actuator Operation
Figure 43 Power Up Diagnostics
Figure 44 Test Power Distribution PWA
Figure 45 Test AUTO - MANUAL Switch
Figure 46 Test Relay Function

viii

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Introduction
Product Description

Introduction
Product Description
Honeywell’s HercuLine® 2000 series actuators are available in four versions: HercuLine® 2000,
HercuLine® 2001, HercuLine® 2002, and HercuLine® 2003. All are low torque, precision electric rotary
actuators incorporating all of the high quality and reliable features of the traditional HercuLine series
actuators. These precision control and high reliability actuators ensure processes operate at maximum
efficiency, with minimal downtime, and lowest lifetime cost.
Honeywell's HercuLine® 2000 series actuators are precision engineered for exceptional reliability,
accurate positioning, and low maintenance (Figure 1). Designed for very precise positioning of dampers
and quarter turn valves the HercuLine® 2000 series actuators perform especially well in extremely
demanding environments requiring continuous-duty, high reliability, and low maintenance.
Model distinctions
HercuLine® 2000 series actuators are used in applications requiring on/off or power to open/close position
proportional with 135 or 1000 ohm feedback.
HercuLine® 2001 and 2002 are smart actuators used in applications requiring current proportional control
or digital control. They offer digital electronics providing for precision positioning control, easy set-up and
configuration, on board health monitoring, and network communications. Programming access is provided
through our HercuLink® Palm PDA software connected to the actuator via a 232/485 converter, via HART
communications or through the optional local keypad and display.
HercuLine® 2002 smart actuators offer features and functions similar to the HercuLine® 2001 and are
used for more severe service applications requiring features such as non-contact position sensing.
HercuLine® 2003 actuators are unidirectional/ 360 degree rotation, special purpose actuators.
The keypad and display are available on the HercuLine® 2001 and HercuLine® 2002 products at
additional charge.
HercuLink® Software
HercuLink® Computer software enables access to programming and communication functions available as
standard with the HercuLine® 2001 and 2002 actuators without the added expense of the keypad &
display HMI. Using a Palm™ PDA, laptop PC or desktop computer, HercuLink® software, and a
RS232/485 converter users may configure, calibrate, and access maintenance information locally or
remotely to the actuator.
Using HercuLink® software, the computer may be used as a master device over a Modbus network to
access information to/from the actuators and to control the device. Set-up configurations may also be
stored on the computer for download to other HercuLine® devices. Information may be stored on the users
PC in CSV format for use in preventative maintenance programs.
• Certified on Palm™ m125, m130, and m505.
• Compatible with Palm OS3.5 or higher.
• Compatible with Windows 2000 or XP operating systems
• Minimum system requirements:
• Windows 2000 (w/service pack 2), Windows NT (w/service pack 5), Windows ME, Windows XP
• 200 MHz Pentium with 64 Megs Ram

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Introduction
Product Description

Display and
keypad
Handwheel

Conduit
entry

Shaft and
position indicator
Auto/manual
switch

Figure 1 HercuLine® 2000 Series Actuator

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Introduction
Product Description

Display
Keypad
PWA

Wiring
Label

Mechanical Stops
TB3
Connector
for customer
input and
output
connection
on CPU
PWA

Cams and
limit
switches

TB1
customer
power
connection

Relay PWAs

Non-contact
sensor

External
auto-manual
switch

Figure 2 HercuLine® 2002 Actuator Internal View

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Introduction
Product Description

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Specifications
Technical and Operating Specifications

Specifications
This section provides you with the technical specifications and the model selection guide for the
HercuLine® 2000 Series Actuators.

Technical and Operating Specifications
Table 1 Specifications - General
Physical
Weight

2000: 25 lb. (11.36 kg)
2001,2002: 27 lbs. (12.27 kg)

Enclosure

Precision-machined die cast aluminum housing, finished in light gray powder coat
epoxy.

Gear Train

Alloy steel, high efficiency steel spur gear primary train. Precision ground, selflocking/self releasing worm gear final mesh.

Mechanical Stops

Factory set at 90° or 150° (+/-5°).
Attention: Do not adjust the mechanical Stops. Adjusting the stops will void
the warranty

Storage Temperature

–40 °C to +93 °C (–40 °C to +200 °F)

Relative Humidity

0 % to 99 % R.H. non-condensing over the full operating temperature range.

Scale

0 % to 100 % corresponding to full crank arm travel.

Crank Arm

Adjustable radii 1.0 in (25.4mm) to a maximum of 2.8 in (71.1mm). Position
adjustable through 360° rotation.

Output Shaft

0.625+/-.005 in (15.88 +/-.13mm) diameter

Rotation

90° or 150° degrees between 0 % and 100 % on scale, limited by mechanical stops.

Manual Handwheel

Provides a means of positioning the actuator in the event of a power failure or setup.

Lubrication

Texaco Starplex 2 EP Grease

Output Torque/Full
Travel Stroking Time

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Torque lb-in (N
M)
50 / (6.0)
100 / (11.5)
200 / (22.5)
400 / (45.0)
400 / (45.0)

50 Hz (90°/150°)
4.5 / 7.5
9 / 15
18 / 30
36 / 60
54 / 90

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

60 Hz (90°/150°)
4/6
7 / 12
15 / 25
30 / 50
45 / 75

Specifications
Technical and Operating Specifications

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, non-burnout, continuous duty, permanent
magnet, synchronous induction motor. Can be stalled up to 100 hours without
damage.

Motor Current

= No load = full load = locked rotor = 0.4 amp for 120Vac, 0.2 amp for 240 Vac

Loss of Power

Stays in place on loss of power

Local Auto/Manual Switch

Optional – Allows local and automatic operation of the actuator.

End of travel Limit
Switches

Standard – adjustable to limit actuator travel to less than 90 or 150 degrees
respectively

Auxiliary Switches/Relays

Optional – Up to 4 additional SPDT switches rated at (10 A at 125 Vac, 5 A at 250
Vac).
Certifications

Approvals

CSA/UL (Standard)
CE Compliant (optional)

Enclosure Rating

Type 4 (NEMA 4), IP66 (standard)
Torque Settings of Crank Arm Bolts
88 lb-in (10 N-m)

Clamp Bolt

Electrical and Performance Specifications
HercuLine® 2002
Input Signals

HercuLine® 2001

Analog:

• 0/4 to 20 mA (With CPU

PWA jumper in current
position)

• 0/1 to 5 Vdc

• 0 to 10 Vdc

Digital:

• Series 90 control

• Modbus RTU (RS485)

Digital:

HercuLine® 2000/2003
120 vac drive open/120 vac
drive close
240 vac drive open/240 vac
drive close

• Modbus RTU (RS485)

Isolation

Input signal, output signal and power are isolated from each other.

Load Requirement (4-20)

Current Out — 0 to 1000 ohms

Input Impedance

0/4 to 20 mA

250 ohms

0/1 to 5 Vdc

10 K ohms

0-10 vdc
Feedback

0 to 20 mA, 4 to 20 mA
0 to 5 Vdc & 1 to 5 Vdc with 250 ohm resistor, (0 to 16 Vdc with 800
ohm resistor)

Dual output 1000 ohms
over 90 degrees (135 ohms
with 158 resistor)
Dual output 1000 ohms
over 150 degrees (135
ohms with with 158 resistor)

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Specifications
Technical and Operating Specifications

HercuLine® 2002

HercuLine® 2001

HercuLine® 2000/2003

Feedback

Slidewire emulation - Provides
output voltage ratiometric to
shaft position and
potentiometric to supply voltage
(1 Vdc to 18 Vdc) without a
slidewire. Emulates a 100 ohm
to 1000 ohm slidewire. 10 mA
output maximum.

Communications

Modbus RTU or optional HART™

Operating Temperature

–40°C to +75 °C (–40°F to +170 °F)

-40°C to +85 °C (-40°F to
+185 °F)

Position sensing

Non-contact position sensor

Sensitivity

0.2 % to 5 % of 90° span, proportional to deadband

Hysteresis

Less than 0.4 % of full scale

Deadband

0.2 % to 5 % of 90° span, programmable. Shipped at 0.5 %

Repeatability

0.2 % of 90° span

1000 ohm film potentiometer

Dual 1000 ohm film
potentiometers
(not on 2003)

Repositions
(minimum @ 90 or 150
degree stroke)
Table 1 option –050Table 1 option –100Table 1 option –200Table 1 option –400Table 1 option –600-

160
290
450
700
900

120
250
400
400
400

500

Voltage/ Supply
Stability

0.25 % of span with +10/–15 % voltage change

Temperature
Coefficient

Less than ± 0.030 % of span per degree C for 0 °C to 50 °C

Zero Suppression

90 % of span.

Input Filters

Selectable spike and low pass filters.

Solid State Motor
Control

Two triac switches for clockwise or anti-clockwise motor operation.
Transient voltage protection provided.

Failsafe operation

If input signal exceeds configured input range. Selectable and
adjustable.

Direction of Rotation

Field programmable

Wire swap

Duty Cycle

Continuous

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Less than ± 0.05 % of span per degree C for –40 °C to 75 °C

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Specifications
Technical and Operating Specifications

HercuLine® 2002

HercuLine® 2001

Selectable and configurable operating parameters:

Programmable
Functions

HercuLine® 2000/2003
NA

• Input range
• Input filtering
• Input characterization
• Security
• Digital Input action
• Deadband
• Failsafe on loss of input signal
• Failsafe on loss of position sensor
• Direction of rotation
• Relay closure action
• Communication parameters
• Split range operation
• Output range
• Alarms

Specifications – Local Display and Keypad
Display
Multi-segment LED displays that provides up to ten alphanumeric characters. Display
arrangement consists of two rows:

Display Design

st
1 row (Upper display) – four characters
nd

row (Lower display) – six characters.

LED indicators

Six single LEDs provide actuator status and alarm indications.

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 Set Up and Calibration Procedures (page 31) for detailed information on display and keypad functions.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Specifications
Technical and Operating Specifications

Specifications – Communications
Communications
Communications
Option

RS 485 Serial Communication, Modbus RTU Protocol

Connection

Twisted pair cable with shield

Maximum loop length

600 meters (2000 feet)

Communication Mode

Half duplex

Baud Rate

300, 600, 1200, 2400, 4800, 9600, 19.2K

Required Specifications – PDA (customer provided)
PDA
Operating System

Palm OS version 3.5 or greater

RAM

At least 8 MB

Communications

Serial port with RS232 compatible levels to drive external converter
Note: As of this writing only Palm devices have this feature. Honeywell has qualified
the M105, M125, M130, and M505 devices with the HercuLink application.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Specifications
Model Selection Guide

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 thru VIII using the column below the arrow.
A dot ( ) denotes unrestricted availability.
Key Number
____
-

___

III

___

- __

- ______

KEY NUMBER - Motor Selection
Basic Motor Unit (no electronics)
Basic Motor Unit plus Digital Electronics
Enhanced Performance Motor Unit with Non-contact Position Sensing
Unidirectional Motor (M640D Replacement)
TABLE I - TORQUE & SPEED SELECTION (speed per 150 degree rotation)
Torque, lb-in/(N-M)
50Hz
60Hz
50 / (6.0)
7.5 sec
6 sec
100 / (11.5)
15 sec
12 sec
200 / 22.5)
30 sec
25 sec
60 sec
50 sec
400 / (45.0)
400 / (45.0)
90 sec
75 sec
TABLE II - ROTATION
Travel

90 degrees
150 degrees
360 degrees

VII

VIII

Selection
2000
2001
2002
2003

Availability

050
100
200
400
600
090
150
360

TABLE III - POWER SUPPLY
Single Phase
100 - 130 Vac, 60 Hz
100 - 130 Vac, 50 Hz
200 - 240 Vac, 60 Hz
200 - 240 Vac, 50 Hz

126
125
246
245

TABLE IV - ANALOG INPUT/OUTPUT SIGNALS
Input
3 Wire Drive up/down
0/4-20 mA, 0/1-5 Vdc, 0-10 Vdc
0/4-20 mA, 0/1-5 Vdc, 0-10 Vdc
0 to 135 ohm input (Series 90 control)
Contact Input for 2003
Output
None
(Note 1)
Dual 1000 Ohm (1000 ohms over 150 degrees)
(Note 1)
Dual 1000 Ohm (1000 ohms over 90 degrees)
Slidewire Emulation
Slidewire Emulation
0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc)
0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc)

0__
2__
3__
4__
6__
_ 00
_ 15
_ 19
_ 60
_ 65
_ 80
_ 85

TABLE V - SWITCH AND RELAY OUTPUTS (2 end-of-travel switches are standard)
Auxiliary Outputs
No Auxiliary Switches
2 Auxilliary Switches
4 Auxilliary Switches
Relay Outputs
No Relays
2 Programmable Relay Outputs
2 Programmable Relay Outputs
4 Programmable Relay Outputs

0_
2_
4_
_0
_2
_3
_4

b
c

continued

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Specifications
Model Selection Guide

2000 2001 2002 2003

TABLE VI - OPTIONS
Local keypad/
display
Local Auto/
manual switch
Handwheel

Certificates
Approvals
Shipped Rotation

No local display interface supplied
(Note 2)
Integrally mounted local display/keypad interface
No auto/manual switch
Auto/manual switch with "Out of Auto Contact"
Auto/manual switch with "Out of Auto Contact"
No Handwheel
Handwheel
None
Certificate of Conformance
UL Type 4/IP66, CSA
(Note 4)
CE
Counter clockwise shaft rotation on increasing signal
Clockwise shaft rotation on increasing signal

Selection
0_ _ _ _ _
1_ _ _ _ _
_ 0_ _ _ _
_ 1_ _ _ _
_ 2_ _ _ _
_ _ 0_ _ _
_ _ 1_ _ _
___0__
_ _ _ 1_ _
_ _ _ _ 0_
_ _ _ _ 1_
_ _ _ _ _0
_ _ _ _ _1

TABLE VII - COMMUNICATIONS/PROTOCOL
None
No communications option board or protocol
Modbus RTU RS485 RS-485 Modbus compliant - standard with EEU
HART 5
HART Communications Protocol

0
1
2

TABLE VIII - MANUALS
Standard
English

TABLE IX - FACTORY OPTIONS
Factory Options
None
Restrictions
Restriction
Letter
a
b
c
ACCESSORIES
Mounting Hardware

Linkage Assembly

HART
Handheld Config.
(Note 3)

Remote Mount
Control

Notes:

Revision 7
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Available Only With
Table
Selection
IV
_ 00
150
II
II

090

Not Available With
Table
Selection
IV
_ 60, _ 80
090
II
II

150

Mounting plate adapter for Barber Colman Series MP495
Mounting plate adapter for Landis & Staefa SQM53/56
Direct Couple Valve Hardware
North American Valve Retrofit Kit
Ball joint for 5/16" dia. Pushrod
Pushrod 12 in. (304,5 mm) long, 5/16 " dia.
Pushrod 18 in. (457,2 mm) long, 5/16 " dia.
Pushrod 24 in. 609,6 mm) long, 5/16 " dia.
Pushrod 48 in. (1219,2 mm) long, 5/16 " dia.
Turk Cable for Handheld Connection
TM
HercuLink Palm Software
Battery powered 232/485 converter with cable
Remote 4-20 mA requires 135 ohm fdbk, 120V 50/60Hz
Remote 4-20 mA requires 1000 ohm fdbk, 120V 50/60Hz
Remote 4-20 mA requires 135 ohm fdbk, 220V 50/60Hz
Remote 135 ohm input requires 135 ohm fdbk, 120V 50/60Hz

51452354-501
51452354-502
51452354-503
51452354-511
51452354-504
51452354-505
51452354-506
51452354-507
51452354-508
51452352-501
51452354-509
51452354-510
R7195A1031
R7195A1056
R7195A1064
R7195B1021

1. 135 ohm available by parallelling 1K potentiometer with 158 Ohm resistor (supplied).
TM
2. HercuLink software (pn 51452354-509), RS232/485 converter (pn 51452354-510),
TM
customer supplied Palm PDA running OS3.5 or higher and Palm serial cable are required
for the 2001 and 2002 actuators if no display is selected.
3. Requires PDA manufacturer's serial interface cable.
4. CSA approval is good for 75°C and a maximum relay load of 3.5 amps or 70°C with a
relay load of 5 amps.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Installation
Installation Overview

Installation
Installation Overview
The procedures to install the HercuLine® 2000 Series actuator and place it in service require that you:
•

Select a suitable location for installation. (See Installation Considerations below.)

•

Mount the actuator securely.

•

Install mechanical connections or linkage between control arm and final 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 installation information required to mount and connect
the HercuLine® 2000 Series Actuator to your specific application. Unpacking instructions, installation
consisderations, electrical and safety precautions also included in this section should be observed.

Mechanical Stops
Factory set at 90° or 150° (+/-5°).
See Figure 2 for location.

Attention: Do not adjust the mechanical stops. Adjusting the stops will void the warranty.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
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Installation
Before Starting

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, compare the contents with the packing list. Notify the carrier and Honeywell
immediately if there is equipment damage or shortage.
Please do not return goods without contacting Honeywell Applications Center in advance. The contact number
is 1-800-423-9883.
Installation Considerations
Mount the actuator in a location where it will be easily accessible for maintenance and for manual operation by
means of the handwheel. The exact location must be determined in accordance with the linkage used.
It is important that the actuator be mounted securely to a solid foundation commensurate with the maximum
torque developed. Use studs or bolts that are as large as the foot mounting holes.
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.

Actuator Mounting
Firmly bolt the actuator to a mounting surface that will not distort when subjected to the torque stresses
generated by the actuator. The output shaft of the actuator should be parallel to the output shaft of the driven
device. The output shaft crank arm is fully adjustable through 360°.
Mounting holes (bottom and side) and location of shaft/crank arm duplicate mounting for Honeywell
Actionators M640A, 740A, 940A for drop-in replacement. Optional adaptor plates available for replacing
Landis and Staefa SQM53/56 and Barber Coleman series MP495 models.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Installation
Actuator Mounting

CLEARANCE FOR TOP REMOVAL:
101,6
4.0

289
11.379

25.4
1.00

mm
inches

Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
7/08

Installation
Mechanical Installation

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 curve. The actuator linkage can be set up to achieve an optimal delivered torque distribution for
specific applications. To assist with linkage design, Honeywell offers a linkage analysis software application
(HAL). The software can be ordered as P/N 51197910-001.
Constant Torque Linkage (typical)
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 4 shows a general linkage setup to achieve a linear torque
profile.

Vertical
Centerline

Vertical
Centerline
45°
Start
Drive Unit
Crank Arm

45°

Linkage
Stop

45°

Close
Horizontal Offset

Open
Damper
Crank Arm
a/n 23199

Figure 4 Constant Torque Linkage

Variable Torque Linkage
A variable torque linkage is employed when it is desired to provide a non-linear torque profile throughout the
full range of final control element travel. In this general situation, the actuator and driven crank arms will be set
up to provide a higher torque for seating or unseating the final control element. Figure 5 shows a general
linkage setup to achieve a non-linear torque 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.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Installation
Mechanical Installation

Vertical
Centerline

Vertical
Centerline
45°

Actuator
Crank Arm

45°

Linkage
Close

5°

Horizontal Offset

a/n 23200

Open
Damper
Crank Arm

Figure 5 Variable Torque Linkage

Actuator Crank Arms
The HercuLine® 2000 Series Actuator comes standard with a crank arm with adjustable radius of 1.0 in
(25.4mm) to 2.80 in (71.12mm). See Figure 6.

Figure 6 Standard crank arm

Figure 7 Crank arm with optional ball joint and push rod

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Installation
Electrical Installation

Electrical Installation
General Wiring Recommendations
Only qualified personnel should perform wiring.
Wiring must conform to national and local electrical codes.

In general, copper wire used. Unless locally applicable codes dictate otherwise, the recommended minimum
wire sizes in Table 2 should be observed.
Table 2 Recommended Minimum Wire Size
AWG

Description

Earth ground wire to common power supply.

Earth ground wire to single actuator. 120/240 V ac line leads. +24 V and common
signal leads. Common signal leads, relays, and aux switches.

Safety Precautions
An external disconnect switch must be installed to break all current 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
ATTENTION

The ground terminal must be connected to a reliable earth ground.
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.

The actuator terminal connections for the field wiring are located behind the cover on the actuator case as
shown in Figure 2. Power and field wiring is brought into the actuator through two access holes located on the
side of the actuator case.
Use both openings: one for low level wiring (control signal) and the other for high
level wiring (120Vac).
Do not run both the High Level and Low Level wiring through the same
opening.

The screw terminals, locations, and descriptions for all customer connections are identified in the tables and
figures that follow.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Installation
Electrical Installation

HercuLine® 2000 Terminal Connections
Table 3 Terminal Connections: HercuLine® 2000
Connection

Descriptions

Terminal Numbers
and LABEL
See Figure 8

Hot

Hot wire for 120/240VAC mains supply. Use only if Auto/Manual
switch is present.

Neutral

Neutral wire for 120/240VAC mains supply

Auto/Manual Switch
Contact

3
4

Switch contact to indicate setting of actuator AUTO/MANUAL
switch.
Switch is closed when actuator is “NOT-IN-AUTO”

CW from Controller

CW motor drive

CCW from Controller

CCW motor drive

Potentiometer #1

7
8
9

Clockwise-End
Slider
Counterclockwise-End

Potentiometer #2

10
11
12

Clockwise-End
Slider
Counterclockwise-End

Protective Ground

Ground wire connection for mains supply

158 ohm

Install resistors to convert 1000 ohm
potentiometer to 135 ohms
1

1 REQUIRED ONLY IF AUTO/MANUAL
SWITCH IS PRESENT

Figure 8 HercuLine® 2000 connections

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Installation
Electrical Installation

HercuLine® 2001/2002 with Auto/Manual Terminal Connections
Table 4 Terminal Connections: HercuLine® 2001/2002 with auto/manual
Terminal Numbers
and LABEL

Connection

Descriptions

See Figure 9
TB1
Hot

Hot wire for 120/240VAC mains supply

Neutral

Neutral wire for 120/240VAC mains supply

Protective Ground

Ground wire connection for mains supply

Auto/Manual Switch
Contact

4
5

Switch contact to indicate setting of actuator AUTO/MANUAL
switch.
Switch is closed when actuator is “NOT-IN-AUTO”

6
TB3
4 to 20mA Output*

1 (+)
2 (-)

Analog signal output

Feedback

Feedback signal used in conjunction with 4 to 20mA OUTPUT
voltage when using Slidewire Emulation

4 to 20mA Input

4 (+)
5 (-)

Analog signal input

Modbus
Communication

6 (+)
7 (-)
8 Shield

Connection for RS485 Modbus loop wires

HART Communications

4 (+)
5 (-)

HART Communication is 4-20 mA only.

Digital Input

9 Com
10 Input

Customer’s contact closure

HART
Communications
Connection

HART connection using
external Turck connector
Auxiliary
Connector

Brown

Blue
Black

Black Wire Not Used

Figure 9 HercuLine® 2001/2002 connections

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Installation
Electrical Installation

HercuLine® 2003 Wiring Connections and Operation (Actionator 640D Replacement)
Wiring

Figure 10 HercuLine® 2003 connections
Operation
The 2003 actuator is uni-directional (it does not reverse rotation with a reversal in control action).
Figure 10 illustrates the internal wiring and the external connections.
The smaller insert of the figure describes the limit switch action for one complete cycle. When the two-position
controller detects a sufficient fall in temperature in a heating application, the switch portion between the “4” and
“5” terminals will close.
The motor then rotates for 180º or until the opening switch breaks (stops are adjustable, factory set at 180º), and
stops in full open position.
A subsequent rise in temperature causes the controller to close the switch between the “4” and “6” terminals
when the motor will start to rotate (in the same direction) for 180º or until the closing switch breaks.
The motor stops in the closed position and completes one cycle.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Installation
Electrical Installation

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 and figures. Wiring must conform to national and local electrical
codes.
CE Wiring
When wiring the actuator power input for CE approved units, you must also install a MOV and ferrite beads
supplied with the CE unit.
You need the following tools:
•

5mm hex key

•

small flat blade screwdriver

•

small needle nose pliers
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.
Step

Action

Remove AC power to actuator.

Loosen the 6 captive screws (use 5mm hex key) and remove the cover.

Locate the terminals TB1-1, TB1-2 and ground screw.

Loosen the screws at terminals TB1-1 and TB1-2. Remove screw used for ground.

Install the appropriate MOV assembly as shown in Figure 11.

All ferrites require 1 loop of wire per ferrite. Connect as shown in following steps.

• Current input and output (slidewire emulation) connection
• Communications and digital input connection

Ground
screw

Current input
and output
(slidewire
emulation)

TB1-2
TB1-1

Communications
and digital input

Figure 11 CE wiring part 1

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Installation
Electrical Installation

Step

Action
• AC power connection
• Auxiliary switches connection
• Relay contact connection

Aux switches
1 and 2
(SW3 and SW4)
Aux switches 3
and 4
(SW5 and SW6)

Relays 1 and 2
Relays 3 and 4
AC power
connection

Figure 12 CE Wiring part 2
9

Install new gasket and top cover. Secure top cover with 6 captive screws.

Reapply AC power to the actuator.

Actuator is ready for use.

Input Signal Connections
ATTENTION
Shielded and grounded cables are recommended.

0/4-20 mA Input Signals
For current signal input, ensure jumper W2 on the CPU PWA is in the “Current” position. See Figure 27 on
page 68. Observing polarity, connect the signal input wires TB3–4(+) and TB3–5(-) on CPU terminal board.
0/1-5 Vdc and 0 to 10 Vdc Input Signals
For voltage signal input, ensure jumper W2 on the CPU PWA is in the “Voltage” position. See Figure 27 on
page 68. Observing polarity, connect the signal input wires to terminals TB3–4(+) and TB3–5(-) of the terminal
block.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Burner Control/Flame Safety
Electrical Installation

Output Signal Connections
0/4-20 mA, 0/1-5 Vdc Feedback Signal Connections
ATTENTION
Shielded and grounded cables are recommended.

Actuator output is a 4 to 20 mA analog signal. If a voltage input is required for customer devices, a range
resistor is needed at the device input. Refer to (page 19) for more information.
Slidewire Emulator Connections
ATTENTION
Shielded and grounded cables are recommended.

If you ordered the Slidewire output option for your actuator, it is set at the factory to provide an output that
emulates 100 to 1000 ohm slidewires. Refer to (page 19) for more information.

Burner Control/Flame Safety
Introduction
Often, Gas Fired control applications use a Flame Safety System that drives the gas valve to full closed and full
open during the start-up sequencefor the burner. HercuLine® 2000 Series actuators have been designed to be
compatible with the Flame Safety Systems and to perform the required operations.
Configuration
In the Input Set Up Group (Page 39), configure the parameter FSTYPL to Down .
In the Digital Input Set Up group (Page 51), configure the parameter DIG INP to Up.
Wiring
Figure 13 Burner Control/Flame Safety Wiring shows a Typical Flame Safety Module wiring diagram.
HercuLine TB3
1 2
High Fire

•

Common

•

To TB3 #10
To TB3 #5

3 44

+ –

8 9 10

Add Jumper

Low Filter

Modulate

•

+ 4 to 20 Output from Controller
– 4 to 20 Output from Controller

Typical Flame
Safety Module

Figure 13 Burner Control/Flame Safety Wiring
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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Burner Control/Flame Safety
Series 90 Control – HercuLine® 2001 model only

Series 90 Control – HercuLine® 2001 model only
Series 90 Controls are commonly used in building environmental systems and flame safeguard systems to
provide modulating control. The control is affected by balancing a 135 ohm potentiometer. The HercuLine
2001 provides an emulation of this system as follows. The current output is used to excite the potentiometer in
the controller. To do this it is set permanently at 11 ma. This produces a 1.5 volt span. The wiper is then
connected to the HercuLine 2001 input, which is operating in voltage mode. The returns from both the input
and the output are tied together.
Series 90 terminals are typically color coded white, red and blue. Conventionally, red is the wiper and white
and blue are the two ends of the potentiometer. On a drop in temperature, the wiper moves toward the blue
terminal.
Connections

TB3

4-20mA output

4-20mA input

White

24+

Red

Blue

Figure 14 Series 90 connections
Considerations

This connection performs an emulation of a series 90 motor. If the controller being used is also an
emulation of a Series 90, the connections required may be different. Shown in Figure 15 are the
connections found necessary to connect a T775 controller through an S443A S90 Auto/Manual Control. If
the controller has the capability to provide a 4/20 or voltage output, it is easier to use that mode. It will
require only two wires and it will allow the independent use of the 4/20 output. If help is required, contact
Honeywell.

Due to variations in the definition of rotation directions, it may be necessary to reverse the action of the
actuator from CCW to CW or vice versa.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Burner Control/Flame Safety
Series 90 Control – HercuLine® 2001 model only

Auto

I out from
HercuLine2001

W
W

T775 B 3

+ Signal to
HercuLine2001

T775 W 1

R
R
Man

GND to
HercuLine2001 (2)
B

T775 R 2

Figure 15 T775 Controller connections
3.

Revision 7
7/08

In the T775 controller manual there are several examples of using resistances or potentiometers as high and
low limit controls. Because of the mode of emulation of Series 90, it is likely that these connections will
not work as intended. Instead, use the output or input limits which are programmable in the
HercuLine® 2001.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Burner Control/Flame Safety
Split Range

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 procedure in Table 5 describes how to set up an actuator
to operate as part of a split valve configuration.
Table 5 Split Range Set Up Procedure
Step

Action

To Set Actuator span to operate from 4 to 12 mA input.

Enter Set Up mode by pressing SET UP key

Select SET INPUT group

Press FUNCTION key until INP HI (on lower display) is selected.

Set INP HI value to 50.0

Press FUNCTION key to select INP LO and set value to 0.0

Press DISPLAY key to exit Set Up mode.

To Set Actuator span to operate from 12 to 20 mA input.

Enter Set Up mode by pressing SET UP key

Select SET INPUT group

Press FUNCTION key until INP HI (on lower display) is selected.

Set INP HI value to 100.0

Press FUNCTION key to select INP LO and set value to 50.0

Press DISPLAY key to exit Set Up mode.
ATTENTION
Be sure to review failsafe strategy for your process application.

Master/Slave Arrangement
Introduction
With the motor positioner, the controlling signal for the actuator is a 4 to 20mA from a current output
controller as shown in the flow diagram in Figure 16.
Unlike the position output controller, the current output controller must produce a continuous analog
signal or the actuator 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.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Burner Control/Flame Safety
Master/Slave Arrangement

Basic Flow Control
When the process variable signal is below set point, the controller increases current (4 to 20mA) to the
actuator input and opens the valve. Controller set point governs valve position to obtain desired flow
rate.

Orifice Plate
PV

Positioner & Actuator
Controller
SP

FIC

Valve

4 to 20 mA

Linkage

Position

Figure 16 Flow Diagram

Current Output Controller

Actuator
See Figure
27 for jumper
location

+
4 to 20 mA
-

Jumper W2
= Current

250 Ohms
1 to 5 VDC

Hot
Neutral
Ground

120/240
VAC

Figure 17 Interconnection Diagram
Proportional Flow using Multiple Actuators
Refer to flow diagram in Figure 18 and interconnection diagrams in Figure 19. The controller governs
flow rate in one burner. Only that flow is measured. Since #2 and #3 motor 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.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Burner Control/Flame Safety
Master/Slave Arrangement

Orifice Plate
PV

FT
Positioner & Actuator

Controller
SP

4 to 20 mA

FIC

MP
#1

Valve

Linkage

MP
#2

Linkage

Valve

Proportional
with Bias

MP
#3

Linkage

Valve

Ratio
Position

Figure 18 Proportional Flow Using Multiple Actuators

Current Output Controller

+
4 to 20 mA
Note: Controller must
be capable of sourcing
the impedance.

See Figure
27 for jumper
location

Actuator #1
10260S Series Actuator #1

Jumper W2
= Current
250 Ohms
1 to 5 VDC

Hot
Neutral
Ground

120/240
VAC

Actuator #2
10260S Series Actuator #2

Jumper W2
= Current
250 Ohms
1 to 5 VDC

Hot
Neutral 120/240
VAC
Ground

Actuator #3
10260S Series Actuator #3

Preferred
Wiring

Jumper W2
= Current
250 Ohms
1 to 5 VDC

Hot
Neutral
Ground

120/240
VAC

NOTE: If using HART® communications, for this application HART®must be configured for Multi-drop operation.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Burner Control/Flame Safety
Master/Slave Arrangement

Current Output Controller

10260S Actuator
Series Actuator
#1 #1

Jumper W2

+
4 to 20 mA
-

= Current
250
Ohms
1 to 5 VDC

Hot
Neutral
Ground

120/240
VAC

10260S Series Actuator #2

Actuator #2

See Figure
27 for jumper
location

Jumper W2
= Voltage

Hot
Neutral 120/240
VAC
Ground

10260S Series Actuator #3

Actuator #3

Alternate
Wiring

Jumper W2
= Voltage

Hot
Neutral 120/240
VAC
Ground

Figure 19 Multiple Actuator Interconnection Diagrams
NOTE: If using HART® communications, for this application HART® must be configured for Multi-drop operation.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Burner Control/Flame Safety
Master/Slave Arrangement

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 positioners are calibrated differently, one responds to 4 to 12mA and the other responds
to 12 to 20mA. At 12mA, both valves are closed; one opening below 12mA and the other above 12mA.
Refer to Figure 20 for an interconnection diagram for split valve operation using two actuators.

Current Output Controller

+
4 to 20 mA
-

10260S
Series #1
Actuator #1
Actuator

Jumper W2
= Current
250
Ohms
1 to 5 VDC

Hot
Neutral
Ground

Actuator
#2Actuator #2
10260S
Series

Note: Controller must
be capable of sourcing
the impedance.

Jumper W2
= Current

250 Ohms
1 to 5 VDC

Preferred
Wiring

120/240
VAC

See Figure
27 for jumper
location

Hot
Neutral 120/240
VAC
Ground

NOTE: If using HART® communications, for this application HART® must be configured for Multi-drop operation.

Current Output Controller

+
4 to 20 mA
-

Actuator
10260S
Series#1
Actuator #1

Jumper W2
= Current
250 Ohms
1 to 5 VDC

Hot
Neutral
Ground

120/240
VAC

Actuator
#2 Actuator #2
10260S
Series
See Figure
27 for jumper
location

Alternate
Wiring

Jumper W2
= Voltage

Hot
Neutral 120/240
VAC
Ground

Figure 20 Interconnection Diagrams
NOTE: If using HART® communications, for this application HART® must be configured for Multi-drop operation.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Overview

Set Up and Calibration Procedures
Overview
Once you have installed the actuator, you can verify, set or change certain operating parameters. Set up is
accomplished through use of the local display and keypad interface through your PDA with HercuLink®
software (see HercuLink® manual 62-86-25-11) or via the HART® communication option. Please keep in
mind that the unit is calibrated at the factory for your application and can be placed into service right out of
the box. Changing operating parameters may require recalibration of the actuator. This section details the
various operating parameters and functions of the actuator available using the local display and 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 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 keys that allow you to setup, monitor, and control the actuator locally, as well as call up various
operating parameters and configuration values on the display. Figure 21 shows the physical features of the
display and keypad. Table 6 summarizes the various functions you can perform using the keys as well as
descriptions of the status indicators.

STALLED
ALARM
MANUAL

Upper Display
(Four Characters)

AUTO

Lower Display
(Six Characters)

SET UP

FUNCTION

MAN/AUTO

DISPLAY

Figure 21 HercuLine® 2000 Display and Keypad

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Local Display and Keypad

Table 6 Keypad Description
Key or
LED Indicator

Function

SET UP

Places the actuator in the set up group select mode. Sequentially displays the set
up groups and allows the FUNCTION key to display function parameters within the
set up group.
See Set Up and Calibration Procedures (page 31)Error! Reference source not
found. for descriptions of the various options available in the set up groups.

FUNCTION

Used in conjunction with the SET UP key to select the individual functions of a
selected configuration set up group.
Used during field calibration procedure.

MAN/AUTO

Alternately selects:
MAN - Actuator is in Manual mode.
AUTO - Actuator is in Automatic mode.
NOTE: When in Manual mode the POS display is automatically selected so you
can use the up and down arrow keys to drive actuator motor manually.
NOTE: This button is disabled if MAENAB is set to DIS. See Table 19 (page 53).

DISPLAY

Pressing this key repeatedly cycles through the operating parameters that can be
shown on the lower display.
INP – Input. Shows the value of the actuator input.
OP – Output. Shows the value of the actuator output
DE – Deviation. Shows deviation between input value and actuator position.
POS – Position. Shows current actuator position.

INCREMENT

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.
DECREMENT

Decreases 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 decreasing signal input.
Indicates the movement of the actuator arm in the counterclockwise direction.
NOTE: Actuator rotation is the direction of the output shaft when facing the end of
the shaft and refers to the direction of rotation on increasing signal.

☼

Indicates the movement of the actuator arm in the clockwise direction.
NOTE: Actuator rotation is the direction of the output shaft when facing the end of
the shaft and refers to the direction of rotation on increasing signal.

☼

☼ STALLED

Indicates that the actuator has detected a motor stall condition.

☼ ALARM

Indicates a programmed alarm condition exists.

☼ MANUAL

Indicates actuator is in manual mode

☼ AUTO

Indicates actuator is in automatic mode.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Set Up Tips

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, check the status of the “SET LOCK” parameter. Also some parameters
require that you enter a security password before you access or change the parameter value.
Table 7 Set Up Tips
Function

Tip

Displaying Groups

Use the SET UP key to display and scroll through the set up groups. The
group titles are listed in the order that they appear on the actuator
display.

Displaying Functions

Use the FUNCTION key to display the individual function parameters
under each set up group. The prompts are listed in the order of their
appearance in each group. See Tables 8 through 19.

Scrolling

Pressing and holding the SET UP key will scroll through the set up
groups. However, when any set up group is displayed, you can scroll
key. When in
through the set up groups twice as fast using the or
any set up group, hold the FUNCTION key in to scroll through the
prompts within that group.

Changing values quickly

When changing the value of a parameter, you can adjust a more
or
significant digit in the upper display by holding in one key
pressing the other
or
at the same time.

and

• The adjustment will move one digit to the left.
• Press the key again and you will move one more digit to the left.

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Exiting Set Up mode

To exit Set Up mode, press the DISPLAY key.
This returns the display to the same state it was in immediately preceding
entry into the Set Up mode.

Timing out from
Set Up mode

If you are in Set Up (configuration) mode and do not press any keys for
thirty seconds, the actuator display will time out and revert to the mode
and display that was being used prior to entry into Set Up mode.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Set Up Groups

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 input types and alarms), calibrate the actuator’s inputs and outputs, set
communications, and check actuator status. Table 8 on the next page lists the set up groups that are
available by using the SET UP and FUNCTION keys on the keypad.
Table 8 Set Up Groups
Set Up Group Title

Pressing the FUNCTION Key Allows You to…

For Details, See

SET
INPUT

Select and set various parameters associated with the
input signal to the actuator.

Table 10

Select relay functions. NOTE: Set Relay groups will
show on display only if relays are installed in the
actuator.

Table 13

Select the output signal type of the actuator.

Table 15

SET
COMM

Select communication parameters for remote control of
actuator when connected to a SCADA system.

Table 16

SET
DIGINP

Select the parameters for external digital input states.

Table 17

SET
DISPLA

Select and set parameters for the local display.

Table 18

SET
RELAYn
n = 1, 2, 3, or 4
SET
CUROUT

CAL
INPUT
CAL
MOTOR

Calibrate input zero and span values.

Calibration
Procedure,
Table 25

Calibrate zero and span values for motor operation.

Calibration
Procedure,
Table 26

ATTENTION
When calibrating the motor to a short stroke range,
you must reset the end-of-travel limit switches. See
Setting End-of-Travel Limit Switches.

CAL
CURENT

Calibrate actuator output.

Calibration
Procedure,
Table 27

SET
LOCK

Set or change security password. Enable or disable
security access to set up parameters and calibration
set up.

Table 19

READ
STATUS

Display operating and alarm status. Display self-test
diagnostic results.

Table 20

SET
DRVINF

Display and/or set various parameters specific to the
actuator.

Table 21

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Set Up Groups

SET
MAINT
CAL
POSOUT

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Display various operating statistics. Reset
accumulated operating statistics

Table 22

Use the display as an indicator, (in this case a
voltmeter) so you can verify that the position sensor is
operating properly.

Table 23

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Set Up Procedure

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 through 19 list and describe the options available in each set up group. The following
procedure shows you the key press sequence to access any set up group or any associated Function
parameter. Make sure lock set up group “LOCK” function is set to “NONE” or “CAL.” Also some
parameters require that you enter a security password before you access or change the parameter.
You can use this procedure to access the set up groups and select all parameters.
Table 9 Set Up Procedure Using Display and Keypad
Step

Operation

Press

Enter Set Up Mode

SET UP

Result
Upper Display =

SET

Lets you know you are in the set up mode and a set up group
title is being displayed in the lower display.
Lower Display =

INPUT

This is the first set up group you see when you press SET UP.

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 8Error! Reference source not
found..
You can also use the or
groups in both directions.

keys to scroll through the set up

Stop at the set up group title that describes the group of
parameters you want to configure. Then proceed to the next
step.

Select a Function
Parameter

FUNCTION

Upper Display

4-20
Shows the current value or selection for the
function prompt in the selected set up group.
Lower Display
IN TYP

Shows the first function prompt within the selected

set up group.
Example display shows Input group function prompt “IN TYP”
and the selection.

Select other
function parameters

FUNCTION

Successive presses of the FUNCTION key will sequentially
display the other function prompts of the selected set up group.
Stop at the function prompt that you want to change, and then
proceed to the next step.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Set Up Procedure

Step

Operation

Change the Value
or Selection

Press

Result
These keys increase or decrease the value, or display the next
available selection for the selected function prompt.

See Table 7, Set Up Tips for instructions to increase or decrease
a value quickly.
Change the value or selection to meet your needs.
NOTE: If the display flashes, you are trying to make an
unacceptable entry, or the value on the display is at its range
limit. The display may also show “KEYERR” (Key error).

Enter Value or
Selection

FUNCTION

This key selects another function prompt.

or
SET UP

This key selects another set up group.
NOTE: Pressing either key will cause the previously selected
value or selection to be entered into memory.

Exit Set Up mode

DISPLAY

Exits set up mode and returns actuator to the same state it was
in immediately preceding entry into the set up mode. Any
changes you have made are stored in memory.
If you do not press any keys for 30 seconds, the display times
out and reverts to the mode and display shown prior to entering
the set up mode.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Configuration Prompt Hierarchy

Configuration Prompt Hierarchy
Setup Groups

Function Prompts
IN TYP INP HI

INPUT

FSTYPL

RELAYn

FsVALL

Y0 VAL

…

Y20 VAL

RTYPny

Rny VAL

Rny E*

Rny HL

RLYnHY

CUROUT

COMM

ADDRES

DIGINP

EndPos

DISPLA

DECMAL

LOCK

LOCKID

STATUS

FAILSF

RAMTST

VERSON

SPEED

MAINT

FILTYP

CHAR

CUROUT

DRVINF

INP LO

EUNITS
LOCK

LREP

LCAL

TEMP

TEMPHI

Direct

CUSTOM

Rny HL

Dband

FSTYPH

X0 VAL

RTYPny

…

FsVALH
X20 VAL

Rny VAL

Rny E*

n = 1,2,3 or 4 y = 1 or 2

BAUD

XmtDLY

DBLBYT

UNITS
MAENAB
SEETST

POWER

CFGTST

CALTST

ROTATE

TAG

ACSTAL

STARTS

MFGDAT

REPTYP
TEMPLO

RL2CNT

RL3CNT

RL4CNT

REGN0

DATSAV

PASSWD

MANRST

LD CAL

…
LD CFG

RL1CNT
REGN9

TOTDEG

RESTRT

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Input Set Up Group

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:
•

Press the SET UP key to enter the Input Set Up group.

•

Press the FUNCTION key to scroll through the prompts listed in the set up group.

•

Press the

keys to view selections or change range settings.
Table 10 Input Set Up Group Parameters

Actuator Lower
Display
Prompt

Selections or
Range of Setting

INPUT ACTUATION TYPE— This selection specifies the
signal type and range you are going to use for the actuator
input. Be sure that the values configured for the high and low
range, alarm setpoint, etc. are within the measuring range
for the selected signal range.

IN TYP
Note: If input
type from model
selection guide
is:
0/4-20mA, 0/15Vdc, 0-10Vdc

Parameter Definition/PDA HercuLink Prompt

4-20
0-20
1-5V
0-5V
0-10
R_SP

4 to 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.

IN TYP

S_90

Series 90 – 0 to 135 ohms.
Note: If input type from model selection guide is: Series 90
control

INP HI

10.0 to 100
default = 100

INP LO

0.0 to 90.0
default = 0.0

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INPUT HIGH RANGE VALUE in % is displayed.
NOTE: When Input Type (R_SP or S_90) is selected, Input
Hi is not configurable.
INPUT LOW RANGE VALUE in % is displayed.
NOTE: When Input Type (R_SP or S_90) is selected, Input
Hi is not configurable.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Input Set Up Group

Actuator Lower
Display
Prompt

Selections or
Range of Setting
NONE

INPUT FILTER TYPE— Allows the selection of a software
digital input filter to smooth the input signal.

SPIK

Spike— Selects spike filter to remove transients in the input
signal when actuator is installed in noisy environments.

S+LP

Spike plus Low Pass— Selects spike and low pass filtering.
* Allows setting of lag time constant for low pass filter.

LPAS

Low Pass— Selects low pass filter.
* Allows setting of lag time constant.

FILTYP

LPFILT *

Direct

Parameter Definition/PDA HercuLink Prompt

default = LPAS

NOTE: When Input Type (R_SP or S_90) is selected, Input
Filter Type = NONE.

0 to 50.00
(in seconds)

LAG TIME CONSTANT— (Filter Type S+LP or LPAS only)
Allows you to set the first order lag time constant of the low
pass filter when selected. Range is from 0 to 50 seconds.

default = 0.5

NOTE: When Input Type (R_SP or S_90) is selected, Low
Pass Filter Value is not configurable.

CCW
CW

ACTUATOR ROTATION—This selection determines the
direction of rotation of the actuator shaft.
Counterclockwise rotation
Clockwise rotation

default = CCW
Dband

0.2 to 5.0
(in percent of
span)

NOTE: Actuator rotation is the direction of the output shaft
when facing the end of the shaft and refers to the direction of
rotation on increasing signal.
INPUT DEADBAND— Specifies an adjustable gap that is the
difference between the setpoint value and the value at which
the motor energizes. Deadband is set in percent of full span.

default = 0.5
FAILSAFEHI TYPE—Selects the motor position you want
the actuator to go to when input signal is above the high end
range value.

FSFTYPH

NOTE: Failsafe condition occurs when the input exceeds its
high end range value by 3%,
LAST

Up—Actuator motor moves to full scale value.

DOWN

Down—Actuator motor moves to zero value.

USER

User selected value—Actuator motor moves to a customerdefined value.

default = UP
0 to 100%
FsFVALH *
default = 100

Last Position—Actuator motor remains at last position.

* Allows setting of failsafehi input value.
FAILSAFEHI INPUT VALUE—(FailsafeHI Type USER only)
Selects the motor position you want the actuator to go to
when input signal is above the high end range value.
Range is from 0 to 100%.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Input Set Up Group

Actuator Lower
Display
Prompt

Selections or
Range of Setting

Parameter Definition/PDA HercuLink Prompt

FAILSAFELO TYPE—Selects the motor position you want
the actuator to go to when input signal is below the low end
range value or on loss of input signal.

FSFTYPL

NOTE: Failsafe condition occurs when the input exceeds its
low end range value by 3%, or when the input signal goes to
zero. For input types 0 to 20mA, 0 to 5 V, and 0 to 10 V
there is no failsafe condition at the zero value.
LAST

Last Position—Actuator motor remains at last position.

Up—Actuator motor moves to full scale value.

DOWN

Down—Actuator motor moves to zero value.

USER

User selected value—Actuator motor moves to a customerdefined value.

default = DOWN
0 to 100%
FsFVALL *
default = 0

* Allows setting of failsafelo input value.
FAILSAFELO INPUT VALUE—(FailsafeLO Type USER
only) Selects the motor position you want the actuator to go
to when input signal is below the low end range value or on
loss of input.
Range is from 0 to 100%.

CHAR

LINR
SQRT
CUST

INPUT CHARACTERIZATION— Selects a characterization
type that causes the actuator to characterize a linear input
signal to represent a non-linear input.
Linear— Provides linear characterization of the input signal.
Square Root— Provides square root characterizations of
the input signal.

default = LINR

Custom— Custom characterization. Selecting custom
allows you to create a twentieth order characterization of
input value (x) and associated shaft position (y).
NOTE: Selecting CUST input characterization causes the
following prompt CUSTOM to be displayed.

CUSTOM

EQUL
QUIK
USER
default = EQUL

Equal percentage – Sets the characterization as explained
in Equal Percentage Valve Characteristic on page 42.
Values are read-only.
Quick opening - Sets the characterization as explained in
Quick Opening Valve Characteristic on page 43. Values are
read-only.
User-configurable – Lets you create your own
characterization using the following Xn VAL and Yn VAL
prompts.

Xn VAL

0 to 100 %

Input Value— as a percentage of input range. Defaults are
in increments of 5%.

0 to 100 %

Shaft Position Value— as a percentage of position range.
Defaults are in increments of 5%.

n = 1 - 20
Yn VAL
n = 1 - 20

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Input Set Up Group

Equal Percentage Valve Characteristic
Table 11 contains values that approximate an equal percentage valve characteristic in the actuator. When
the EQUL custom characterization type is selected, the values in Table 11 are automatically loaded into the
actuator configuration to produce the characteristic 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 11 Equal Percentage Valve Characteristics
Yn Val

% of
Range

0.8

2.1

3.2

4.9

6.5

8.4

10.7

13.2

15.7

18.7

22.6

27.2

33.4

53.8

63.2

73.7

86.2

100

Equal Percentage Valve Characterization

Yn VAL - Characterized Output

Xn VAL
Order

100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
10

100

Xn VAL - Actual Input

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Input Set Up Group

Quick Opening Valve Characteristic
Table 12 contains values that approximate the characteristic of a quick opening control valve. When the
QUIK custom characterization type is selected, the values in Table 12 are automatically loaded into the
actuator configuration to produce the characteristic 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 12 Quick Opening Valve Characteristic
Yn Val

% of
Range

97.5

98.5

99.5

100

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Quick Opening Valve Characteristic

Yn VAL - Characterized Output

Xn VAL
Order

100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
10

100

Xn VAL - Actual Input

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Relays Set Up Group

Relays Set Up Group
ATTENTION
The Relay set up group parameters are accessible only if relay PWAs are installed in the
®
actuator. HercuLine 2001 actuators can be equipped with one PWA –for a total of two SPDT
relays. Using the Relay set up groups you can program the installed relays to operate in
response to various operating conditions.

Table 13 lists the parameters and selections available when the SET RELAYn group is selected.
Table 13 Relay Set Up Group Parameters
Parameter Definition/PDA HercuLink® Prompt

Actuator Lower
Display
Prompt

Selections or
Range of Setting

RTYPny

NONE

RELAY TYPE— Selects the relay number and the relay
activation type. See Table 14 Relay Type Descriptions.

InPR
PosR

Input Range— Upper / lower limits of input signal exceeded
Position Range— Upper / lower limits of motor position
exceeded
Deviation— Deviation from input exceeded
Upper Limit Travel— Same 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— Failsafe condition detected
Position Sensor Signal Failure— position output out of valid
range
Digital Input— Digital input closure

n = 1, 2, 3, or 4
y = 1 or 2

DEV
ULim
LLim
T Hi
T Lo
STRT
STAL
MAN
PWRF
FsFA
PosF
DiGI
TDEG
default = InPR and
NONE
RnyE*

X1
X10k
default = X1

RnyVAL
n = 1, 2, 3, or 4
y = 1 or 2

0.0 to 100.0

Rny HL
n = 1, 2, 3, or 4
y = 1 or 2

HI
LO

RLYnHY
n = 1, 2, 3, or 4

0.0 to 100.0
(in percent)

Total Degrees— total degrees traveled. Allows setting of
multiplier value.
MULTIPLIER— (Relay Types STRT and TDEG only)
Selects the multiplier for the number limit of motor starts and
total degrees traveled before the relay is activated. Multiplier
specifies the value on display as times one (X1) or times ten
thousand (X10k).
RELAY VALUE— Sets numerical value of limit where relay
trips (energizes). Units are determined by the relay type
selection. See Table 14 Relay Type Descriptions for units.
RELAY HIGH/LOW— Sets relay trip point to high or low
limit.
RELAY HYSTERESIS— 0.0 to 100.0% of span or full output.
NOTE: Relay Hysteresis parameter is accessible only if
appropriate relay type is selected.

n is the relay number, y is the relay contact.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Relays Set Up Group

Table 14 Relay Type Descriptions
When this Relay Type is
selected…

The Relay can be set up to indicate …

(RTYP)
Input Range

The upper / lower limits of the input signal have been exceeded.
Relay value parameter defines range limits and units are in percent of full span.

Position Range

Upper / lower limits of motor position have been exceeded.
Relay value parameter defines range limits and units are in either percent of
span or degrees of rotation. See “Relay Examples “for setting range limits.

Deviation

Motor position has exceeded deviation limit from input. (Deviation is defined as:
setpoint – motor position = Deviation)
Relay value parameter defines limits and units are in percent of span.
See “Relay Examples” for setting deviation limit.

Upper Limit Travel

The motor position has exceeded the upper limit of travel.
(Same as Position Range.)
Relay value parameter defines limits and units are in degrees of rotation or
percent of span. See “Relay Examples” for setting upper limit with hysteresis.

Lower Limit Travel

The motor 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. Relay value
parameter defines temperature limits and units are in either degrees C or
degrees F.
(Temperature units are defined in the UNITS setting of the DISPLA set up
group.)
The low temperature limit of the actuator has been exceeded. Relay value
parameter defines temperature limits and units are in either degrees C or
degrees F.

Temperature Low

(Temperature units are defined in the UNITS setting of the DISPLA set up
group.)
Starts

The accumulated motor starts have exceeded the limit. Relay value parameter
defines the limit. See “Relay Examples” for setting motor starts limit. Range is
from 10 to 99,990,000.

Stall

The motor is in a stall condition.

Manual Mode

The actuator is in manual mode.

Power Up Test Failure

A failure of any one of the power up test diagnostics. See READ STATUS set up
group.

Failsafe

The actuator is in failsafe. (input signal loss or input signal out of valid range)

Position Sensor Failure

The potentiometer or non-contact sensor output is out of range or has failed.

Digital Input

The digital input closure.

Total Degrees

The total degrees traveled.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Relays Set Up Group

Relay connector #1
Relay connector #2
Relay connector #3
Relay connector #4

Figure 22 Relay connectors
Relay Examples
Relay Type - Position Range
Selecting PosR relay type, you can cause the relay to energize when the actuator motor travels below 20%
of range and above 80% of range. Note in the example below that Relay 1 is set up to provide two trip
points. The first trip point (R11VAL) causes the relay to energize when 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
SET RELAY1

Parameter

Value

RTYP11

PosR

R11VAL

80.0

R11HL

RTYP12

PosR

R12VAL

20.0

R12HL

RLY1HY

0.0

The figure below shows the resulting action.
Motor
Position

20%

80%

100%

17
Open

18
Closed

Closed

RELAY 1
Normally Open

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Relays Set Up Group

Relay Type - Deviation
Setting up a relay to alarm (energize) when the motor position deviates 10% (+ or -) from the actuator
setpoint can be set up as follows.
Set Up Group
SET RELAY1

Parameter

Value

RTYP11

DEV

R11VAL

10.00

R11HL

RTYP12

DEV

R12VAL

-10.00

R12HL

RLY1HY

0.0

The resulting action is shown below.
Motor
Position

Input
50%

0%
-10%

100%
+10%

Closed

Closed
Open
RELAY n
Normally Open

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Relays Set Up Group

Relay Type – Upper Limit Travel with Hysteresis
Selecting relay type ULim will cause the relay to energize when 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
SET RELAY2

Motor
Position

Parameter

Value

RTYP21

ULim

R21VAL

70.0

R21HL

RTYP22

NONE

RLY2HY

10.0

Open

RELAY n
Normally Open

Motor
Position

100%

60% H 70%

60%

Open

RELAY n
Normally Open

y
s
t
e
r
e
s
I
s

Closed

H
y
s
t
e
r
e
s
I
s

100%

70%

Closed

Relay Type – Motor Starts
Selecting relay type STRT will cause the relay to trip when the number of motor starts exceeds the selected
limit. The motor starts value is stored as one of the maintenance group statistics. This example sets the
motor starts limit at 200,000 for Relay 1.
Set Up Group

SET RELAY1

Parameter

Value

RTYP11

STRT

R11 E*

X10K

R11VAL

R11HL

RTYP12

NONE

The resulting action is that Relay 1 will trip when the number of accumulated motor starts in the
maintenance group exceeds 200,000.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Current Out Set Up Group

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 Parameters
Actuator Lower
Display
Prompt

Selections or
Range of Setting

Parameter Definition/PDA HercuLink Prompt

OUTPUT SIGNAL RANGE— Selects the signal output
range.

CUROUT
Note: If output
type from model
selection guide
is:
0/4-20mA, 0/15Vdc

4 – 20
0 – 20
1 – 5V
0 – 5V

4 to 20 mA
0 to 20 mA
1 to 5 Volts (250 ohm resistor required)
0 to 5 Volts (250 ohm resistor required)

CUROUT

SW E

Slidewire Emulation

NONE

No current output configured.

Note: If output
type from model
selection guide
is:
Slidewire
Emulation
CUROUT
Note: If output
type from model
selection guide
is:
None

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Communications Set Up Group

Communications Set Up Group
Table 16 lists the parameters and selections available for the SET COMM group.
Table 16 Communications Set Up Group Parameters
Actuator Lower
Display
Prompt

Selections or
Range of Setting

COMMUNICATONS PARAMETERS— Disables or enables
parameter displays for Modbus communciations set up.

COMM

ADDRES

DIS

Disabled— Locks out access to communications displays
and parameters.

MODB

Modbus— Allows access to the communication displays
and settings for the parameters listed below.

HART

HART – selects HART as the communications protocol

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.

default = 1
BAUD

Parameter Definition/PDA HercuLink Prompt

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.

default = 19.2k
XmtDLY

NONE
10ms
20ms
30ms
40ms
50ms

RESPONSE DELAY— Selects the time delay (in
milliseconds) before a response to a query is transmitted.

default = 20ms
FLOATING POINT DATA FORMAT— Selects the format for
transferring floating point data.

DBLBYT

Byte Order
FP B
FPBB
FP L
FPLB

default = FP B

Floating Point Big Endian format—
Floating Point Big Endian format
with byte-swapped—
Floating Point Little Endian format—
Floating Point Little Endian format
with byte-swapped—

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

0123
1032
3210
2301

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Set Up and Calibration Procedures
Digital Input Set Up Group

Digital Input Set Up Group
Table 17 lists the parameters and selections availible for the SET DIGINP group.
Table 17 Digital Input Set Up Group Parameters
Actuator Lower
Display
Prompt

Selections or
Range of Setting

Digital Input State— Selects the position of the actuator in
response to a digital input signal (contact closure).

DIGINP
NONE

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None— No action by the actuator.

Up— Actuator motor moves to full scale value.

DOWN

Down— Actuator motor moves to zero value.

USER

User selected value— Actuator motor moves to a
customer-selected value.
* Allows setting of End Position Value.

default = UP
EndPos

Parameter Definition/PDA HercuLink® Prompt

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).

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Display Set Up Group

Display Set Up Group
Table 18 lists the parameters and selections availible for the SET DISPLAY group.
Table 18 Display Set Up Group Parameters
Actuator Lower
Display
Prompt

Selections or
Range of Setting

DECIMAL POINT LOCATION— This selection determines
where the decimal point appears in the display.

DECMAL
8888

None

888.8

One Place

default = 8888

Note: Be sure the selection agrees with the value to be
displayed. If display value requires 4 whole digits, the
decimal will not show.
UNITS DISPLAY— Selects the units of the position display.

EUNITS
PCNT

Percent— Shows actuator position as a percentage of span.
(0 to 100%)

DEG

Degrees— Shows the actuator position in degrees of
rotation. (0 to 150°) (90°)

default = PCNT

DISPLAY UNITS— Selects standard for unit values for the
local display.

UNITS
SI
ENGL

default = ENGL

Parameter Definition/PDA HercuLink® Prompt

SI— Display will show unit values in international (metric)
units. (Temperature in degrees C, Date format: ddmmyy)
English— Display will show unit values in U.S. units.
(Temperature in degrees F, Date format: mmddyy)

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Lock Set Up Group

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 Lower
Display
Prompt

Selections or
Range of Setting

LOCKID

0 to 4095

default = 0

PASSWORD LOCK— 4-digit password can be selected to
provide security access to calibration information, set up
parameters and supervisory functions. Password can be a
number from 0 to 4095.
LOCK OUT FEATURE— Selects lockout security for
calibration and supervisory functions, and set up groups.

LOCK
NONE

None— No lockout of any calibration or set up groups. You
select and change set up group values, and perform field
calibration.

CAL

Calibration— Lockout for calibration groups SET CALINP,
SET CALMTR, SET CALOUT and CAL POSOUT only. You
can select and change set up group values.

CONF

Configuration— Lockout for calibration groups and set up
group configuration. You can only scroll through and view
set up group values.

FULL

Full— Lockout for calibration and all set up group values.
Only SET LOCK and READ STATUS groups are accessible.

default = NONE

Manual / Auto— Allows the ability to lockout mode changes
from the front panel.

MAENAB
DIS
ENAB

default = ENAB

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Parameter Definition/PDA HercuLink® Prompt

Disabled— Disables the front panel auto / manual switch
functionality.
Enabled— Enables the front panel auto / manual switch
functionality.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Lock Set Up Group

Set/Change Password
A password is required to disable the ability to readily change features of the actuator. Lock out of
calibration capability and other supervisory functions can be controlled by using a password. The
password can be any number from 0 to 4095. The password is set and/or changed by using the keys on the
kepad and the local display. Follow the steps below to change the password.
NOTE: The LOCK parameter must be set to NONE in order to change the password.
Step

Action

Press SET UP key until the display reads SET LOCK.

Press the FUNCTION key until the lower display reads LOCK.
If the prompt in the upper display is flashing, a password is required to change the LOCK type,
proceed to step 3.
If the upper display is not flashing and you want to change the LOCK type, proceed to step 5.
If the upper display is not flashing and you want to change the password proceed to step 3.

Press the FUNCTION key until the lower display reads LOCKID.

The upper display will show 0 (zero). Use the
or
correct password. See NOTE below on use of keys.

keys to increment the number to the

Note: If the password can not be recovered to allow user access, a universal password can be
obtained by calling the Honeywell Tactical Assistance center.

Press the FUNCTION key, the lower display should read LOCK. The upper display should not
be flashing. If it is repeat steps 3 & 4.

Use the

keys to change the LOCK type to the desired selection.

If your not changing the password proceed to step 9.
If your changing the password set the LOCK type to NONE and proceed to step 7.

7
8
9

Press the FUNCTION key until the lower display reads LOCKID.
The upper display will show 0 (zero). Use the or
new password. See NOTE below on use of keys.

keys to increment the number to the

Press FUNCTION key to view next parameter. Press DISPLAY to exit set up mode.
(LOCK type has now been changed or Password is now set to new value).

NOTE: When changing the value of the number, you can adjust a more significant digit in the upper
display by holding in one key

and pressing the other

at the same time.

The adjustment will move one digit to the left.
Press the key again and you will move one more digit to the left.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Read Status Set Up Group

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 Parameters
Actuator Lower
Display
Prompt

Selections or
Range of Setting

Parameter Definition/PDA HercuLink® Prompt

FAILSAFE— Read Only. Shows whether actuator in
failsafe.

FAILSF
NO

No— Actuator not in failsafe.

YES

Yes— Actuator in failsafe, see
Troubleshooting (page 105)
RAM TEST DIAGNOSTIC— Read Only. Shows status of
RAM test diagnostic.

RAMTST
PASS

Pass— Test passed, no errors

FAIL

Fail— Test failed, see see
Troubleshooting (page 105)
SERIAL EEPROM TEST DIAGNOSTIC— Read Only.
Shows status of serial electrically eraseable PROM test
diagnostic.

SEETST

PASS
FAIL

Pass— Test passed, no errors

Fail— Test failed, see
Troubleshooting (page 105)
CONFIGURATION TEST DIAGNOSTIC— Read Only.
Shows status of Configuration test diagnostic.

CFGTST
PASS

Pass— Test passed, no errors

FAIL

Fail— Test failed, see
Troubleshooting (page 105)
CALIBRATION TEST DIAGNOSTIC— Read Only. Shows
status of Calibration test diagnostic.

CALTST
PASS

Pass— Test passed, no errors

FAIL

Fail— Test failed, see
Troubleshooting (page 105)

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Drive Set Up Group

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 Lower
Display
Prompt

Selections or
Range of Setting

Parameter Definition/PDA HercuLink® Prompt

VERSON

nnnn

FIRMWARE VERSION— Read Only. Displays the firmware
version currently in use by the actuator’s CPU.

SPEED

6S
12 S
25 S
50 S
75 S

STROKE SPEED— Read Only. The speed is the number of
seconds it takes for the actuator shaft to move its full range
of travel.

3.2 S
7.2 S
15 S
30 S
45 S

STROKE SPEED— Read Only. The speed is the number of
seconds it takes for the actuator shaft to move its full range
of travel.

7.5 S
15 S
30 S
60 S
90 S

STROKE SPEED— Read Only. The speed is the number of
seconds it takes for the actuator shaft to move its full range
of travel.

4.5 S
9S
18 S
36 S
54 S

STROKE SPEED— Read Only. The speed is the number of
seconds it takes for the actuator shaft to move its full range
of travel.

(150° @ 60hz)

SPEED

(90° @ 60hz)

SPEED

(150° @ 50hz)

SPEED

(90° @ 50hz)

POWER INPUT VOLTAGE AND FREQUENCY— Read
Only. Selects the power input voltage and line frequency of
the actuator.

POWER

1206
1205
2206
2205

ROTATION— Indicates the factory calibrated degrees of
rotation.

ROTATE

1206— 120Volts, 60Hz
1205— 120Volts, 50Hz
2206— 220Volts, 60Hz
2205— 220Volts, 50Hz

90— Factory calibrated for 90 degrees of rotation.

150

150— Factory calibrated for 150 degrees of rotation.

TAG

nnnnnn

DMFG

mmddyy *
or
ddmmyy

TAG NAME— Selects the tag name or identifier of the
actuator. Up to 6 alphanumeric characters. See “Set Tag
Name” on next page.
MANUFACTURING DATE— Read Only. Displays date
code of manufacture for actuator.

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Set Up and Calibration Procedures
Drive Set Up Group

Actuator Lower
Display
Prompt

Selections or
Range of Setting

Parameter Definition/PDA HercuLink® Prompt

LREP

mmddyy *
or
ddmmyy

DATE OF LAST REPAIR— Factory set only. Displays date
of last repair.

LCAL

mmddyy *
or
ddmmyy

DATE OF LAST FACTORY CALIBRATION— Factory set
only. Displays date of last factory calibration
REPAIR TYPE— Factory set only. Displays a repair code to
identify the type of repair service previously performed.

REPTYP
NONE
01
02
03
04
05
06
07
08
09
10
11
12
13

None
Future
Non-contact Sensor
Main CPU PWA repair
Motor service
Power Distribution PWA service
Switch repair
Relay service
Gear service
Service to repair water damage
Service to repair damage caused by heat
Service to repair due to over-voltage damage
Actuator reconfigured
Warranty Repair

* NOTE: Date format is set by the UNITS parameter. See SET DISPLA set up group.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Drive Set Up Group

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 local display. Follow the steps below to set the tag name.

Step

Action

Press SET UP key until the display reads SET DRVINF.

Press the FUNCTION key until the upper display reads TAG.

The lower display contains six digits. A decimal point 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.

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, the letters ‘a’ through ‘z’ and the letters ‘A’ through ‘Z’ . Scroll
through until the desired character is displayed.

Wait for the decimal point to shift to the right and then scroll through using the
until the next character is displayed.

Repeat for each character of the tag until the complete tag name is displayed.

Press the FUNCTION key to go to the next parameter, or press DISPLAY to exit set up mode.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

keys

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Set Up and Calibration Procedures
Maintenance Set Up Group

Maintenance Set Up Group
The Maintenance set up group consists of information about actuator operation accumulated through time.
This information (or maintenance statistics) can be used to evaluate actuator operation and determine
predicted or scheduled maintenance periods. Table 22 lists the parameters and selections available for the
SET MAINTENANCE group.
Please note that maintenance statistics are written to the EEPROM every 8 hours. Therefore the statistics
are saved in the event of a power interruption.

Table 22 Maintenance Set Up Group Parameters
Parameter Definition/PDA HercuLink® Prompt

Actuator Lower
Display
Prompt

Selections or
Range of Setting

TEMP

nnnn F *

ACTUATOR TEMPERATURE— Read Only. Displays the
current internal temperature of the actuator.

TEMPHI

nnnn F *

HIGH TEMPERATURE LIMIT— Displays the high
temperature limit of the internal actuator temperature 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. Multiply
5
displayed value times 10 to get actual value. Range is 0 to
999,900,000.

RLnCNT

nnnn

RELAY CYCLE COUNTS— Displays the accumulated cycle
counts of a relay since it was last reset. One relay cycle is
when a relay is energized and deenergized. Multiply
5
displayed value times 10 to get actual value. Range is 0 to
999,900,000.

nnnn

ACCUMULATED MOTOR STARTS— Displays the
accumulated motor starts in the 1st 10% of motor span since
it was last reset. See

n = 1, 2, 3 or 4

REGNn

n = 0 to 9

PDA users: The prompts are organized differently on your PDA’s HercuLink
software. Grayed prompts are under Configuration, Maintenance. Non-grayed
prompts are under Maintenance.

Regions of Motor Travel (page 62). Multiply displayed value
5
times 10 to get actual value. Range is 0 to 999,900,000.
TOTDEG

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nnnn

TOTAL DEGREES OF MOTOR TRAVEL— Displays the
total number of degrees of motor travel since it was last
5
reset. Multiply displayed value times 10 to get actual value.
Range is 0 to 999,900,000.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Maintenance Set Up Group

Actuator Lower
Display
Prompt

Selections or
Range of Setting

DATSAV
DIS
ENAB

Parameter Definition/PDA HercuLink® Prompt
PDA users: The prompts are organized differently on your PDA’s HercuLink
software. Grayed prompts are under Configuration, Maintenance. Non-grayed
prompts are under Maintenance.

MAINTENANCE DATA FORCED SAVE— Allows you to
manually force a save of the current maintenance data
values.
DISABLE— Forced data save is disabled.
ENABLE— Forced data save is enabled.

PASSWRD

nnnn

PASSWORD— If a password has been activated, then a 4digit password is required to enable any of the functions
below.

NOTE: Password is set (or changed) from the Lock set up
group.
MAINTENANCE STATISTIC RESET— Allows reset of the
following maintenance statistics:

MANRST
NONE

None— No reset of maintenance statisitics

STAL

Stall— Resets accumulated stall time to zero.

STRT

Motor Starts— Resets the accumulated motor start counter
to zero.

REGNn
n = 0 to 9

Motor Starts in the Region— Resets the selected motor
span region counter to zero.

TEMP

Temperature Statistics— Resets the high / low
temperature limit statistics.

TDEG

Total Degrees— Resets the total degrees of motor travel to
zero.

RELn
n = 1, 2, 3 or 4
ALL
SYST

Relay Counts— Resets the selected accumulated relay
cycle counter to zero.
All— Resets all maintenance statistics to zero.
SYST— Enables the system restart function.

default = NONE

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Set Up and Calibration Procedures

Actuator Lower
Display
Prompt

Selections or
Range of Setting

LD CAL

NONE

Parameter Definition/PDA HercuLink® Prompt
®
PDA users: The prompts are organized differently on your PDA’s HercuLink
software. Grayed prompts are under Configuration, Maintenance. Non-grayed
prompts are under Maintenance.

INP
MTR

RESTORE CALIBRATION TYPE— Allows you to restore a
calbration value to its factory calibration.
Input — Restores input calibration to the factory calibration
for the current configured input type.

COUT

Motor— Restores motor calibration to the factory calibration.

ALL

Output — Restores actuator output calibration to the factory
calibration for the current configured output type.

POS

All — Restores input (for the type configured), motor and
output (for the type configured) calibration to the factory
calibration.

default = NONE
LD CFG

DIS
ENAB

POS — Allows a position sensor field calibration to be stored
as a factory calibration. This is to be used when a sensor is
replaced in the field. See “Calibrate POS Output”.
RESTORE DEFAULT FACTORY CONFIGURATION—
Allows you to restore the factory default configuration.
DIS — Restore disabled.

default = DIS
RESTRT

DIS
ENAB

ENAB— Restore enabled.
SYSTEM RESTART— Allows you to force the system to
restart.
DIS — Restart disabled.

default = DIS

ENAB— Restart enabled.

Note: The MANRST function must be set to SYST.
* Temperature units are displayed in degrees C or F, and are set by the UNITS parameter. See SET
DISPLA set up group.
† Note that the upper display contains the parameter name and the lower display contains the value.
This is to allow for the display of hours: minutes: seconds.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Regions of Motor Travel

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 shown in Figure 23 (regions are numbered 0 through 9). Maintenance statistics are accumulated
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. See the Maintenance Set Up Group for more information. The regions of travel are determined
by the full span motor travel (90° or 150° rotation). If the actuator is set up to operate in a smaller range,
for example between 40% and 80% of full span, the maintenance statistics will show motor starts only in
regions 4 through 7.
Percent of Span
0%
Region of Travel

20%

40%
2

0o
Degrees of Rotation

60%
4

80%

30o

100%
9

60o

90o

Pe rc en t of S pa n
0%
Regio n of Trave l

20%
0

4 0%
2

0o
De gr ee s of R ot at io n

30 o

60%
4

8 0%

60 o

100%
9

150 o

Figure 23 Regions of Motor Travel

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
CAL POSOUT Group

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 display to indicate the output voltage of the position sensor. This display is used
when verifying the POS sensor is operating and that it is properly calibrated. Table 23 shows the selections
available for the CAL POSOUT group.
Table 23 CAL POSOUT Group Parameters
Actuator Lower
Display
Prompt

Selections or
Range of Setting

Parameter Definition/PDA HercuLink Prompt

CALPOS

n.nnn

POSITION SENSOR OUTPUT— Read Only. Displays the
output voltage of the position sensor

To access the display…

Press

Result

SETUP
until you see

Upper Display =
Lower Display =

CAL
POSOUT

FUNCTION

Upper Display =
Lower Display =

DIS
CALPOS

Upper Display =
Lower Display =

BEGN
CALPOS

Upper Display =
Lower Display =

n.nnn (sensor output in volts)
POSOUT

key

FUNCTION

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Auto - Manual Drive Switch

Auto - Manual Drive Switch
The Auto - Manual switch is located on the side of the actuator case below the handwheel. The switch
allows manual mode control of the actuator motor for set up, calibration and troubleshooting.
Figure 24 shows an illustration of the Auto - Manual switch and Table 24 describes the switch settings.
The Auto - Manual Drive switch setting overrides all input signals (analog signal and remote setpoint) and
local display mode settings. When not in auto the manual LED will flash every second.

CCW

MANUAL
OFF

OFF
A
U
T
O

AUTO - MANUAL DRIVE
Figure 24 Auto - Manual Switch

Table 24 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.

Actuator moves to the fully clockwise position.

OFF

Actuator is idle.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Calibration

Calibration
Calibration of the HercuLine® 2000 Series Actuator may consist of calibrating the motor circuit that
positions the actuator with 0/4-20mA input signal, calibrating the potentiometer or non-contact sensor, and
calibrating the slidewire emulation output or the 0/4-20mA output signal. Typically, only a motor
calibration is required for installation.
Calibration is performed by connecting test equipment to the input terminals or output terminals and then
using the keypad and display to step through the calibration group functions.
ATTENTION

Input calibration 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.
High voltages exist inside the actuator case. Do not touch the powered wires inside.
Death or serious injury can occur.

Equipment Needed
The table below lists the equipment you will need to calibrate the HercuLine® 2000 input and output
circuits.
Procedure
Input Calibration

Equipment Needed
• A calibrated signal source which can provide current (4 to 20

mA) or voltage (0 to 10 V) with an accuracy of 0.02% or better.
• Two insulated copper leads for connecting the current source

to the actuator.
Output Calibration

• A digital voltmeter with an accuracy of 0.01% or better.
• A 250 ohm resistor 0.01% tolerance.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Calibration

Calibration Set up
Follow the steps below to set up the test equipment and actuator to verify calibration or perform calibration
procedures.
Step

Action

Determine input type (current or voltage).

Set jumper W2 on main CPU board according to type of signal source. See Figure 27 on page
68 for jumper location.

Connect the copper leads from the signal source to the input terminals of the actuator as
shown in Figure 25.

Place signal source output at zero and switch power on.

Connect a 250 ohm resistor across the Output terminals of the actuator and connect the DVM
leads to the terminals.

Actuator

Calibrated
Signal
Source +
-

Terminal Block
Input
5 4
- +

Output
2 1
- +

Digital
Voltmeter
+

Internal 250 ohm resistor
settable through
Jumper W2

250 ohm
resistor
(supplied)

Current
Voltage
Figure 25 Calibration Wiring Connections (non-slidewire emulation)

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Calibration

Actuator
Digital
Voltmeter
Calibrated
Signal
Source +
-

Terminal Block
Input
5 4
- +

Output
2 1 3
- + FB

Internal 250 ohm resistor
settable through
Jumper W2

Power
Supply
1-18 VDC
+

Current
Voltage

Figure 26 Calibration Wiring Connections (slidewire emulation)

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Calibration

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 to 20 mA

0 to 5 Volts,1 to 5 Volts, or 0 to 10 Volts

The input type is selected through the Input set up group using the local keypad.
Refer to Figure 25 for the wiring connections and follow the procedure in Table 25 to calibrate the input
circuit of the HercuLine® 2001/2002 actuator.
ATTENTION

For an input calibration to be saved, you must complete the procedure. The calibration will not
be saved if you exit without completing the steps of the procedure.
To exit calibation mode, press DISPLAY or SETUP keys.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Set Up and Calibration Procedures
Calibration

Table 25 Input Calibration Procedure
Step

Operation

Enter Calibration
Mode

Press

SETUP
until you see

Upper Display =
Lower Display =

CAL
INPUT

FUNCTION

Upper Display =
Lower Display =

DIS
CAL IN

Upper Display =
Lower Display =

BEGN
CAL IN

Upper Display =
Lower Display =

APLY
INZERO

Calibrate Zero (0%)

Result

key

FUNCTION

• Adjust the signal source to an output value equal to 0% range

value.
• Wait 5 seconds, then go to step 3.

Calibrate Span
(100%)

FUNCTION

Upper Display =
Lower Display =

APLY
INSPAN

• Adjust the signal source to an output value equal to 100%

range value.
• Wait 5 seconds, then go to step 4.

FUNCTION

Calibration for zero and span input values are now saved. Input
calibration is complete.
NOTE: The display will automatically go to the CAL MOTOR set
up display. See Table 26. You may also exit calibation mode by
pressing the DISPLAY or SETUP keys.
ATTENTION:
When calibrating the motor to a short stroke range, you must
reset the end-of-travel limit switches. See Setting End-of-Travel
Limit Switches.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Calibration

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, you must complete the procedure. The calibration will not
be saved if you exit without completing the steps of the procedure.

ATTENTION

When calibrating the motor to a short stroke range, you must reset the end-of-travel limit
switches. See Setting End-of-Travel Limit Switches.

Table 26 Motor Calibration Procedure
Step

Operation

Enter Calibration
Mode

Press

SETUP
until you see

Upper Display =
Lower Display =

CAL
MOTOR

FUNCTION

Upper Display =
Lower Display =

DIS
CALMTR

Upper Display =
Lower Display =

BEGN
CALMTR

Upper Display =
Lower Display =

APLY
MTR LO

Calibrate Zero (0%)

Result

key

FUNCTION

• 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.

Calibrate Span
(100%)

FUNCTION

Upper Display =
Lower Display =

APLY
MTR HI

• Use the Handwheeel or AUTO/MANUAL switch to manually

drive the actuator motor to its high position.
• Wait 5 seconds, then go to step 4.

FUNCTION

Calibration for zero and span motor positions are now saved.
Motor calibration is complete.
NOTE: The display will automatically go to the CAL CURENT
set up display. See Table 27. You may also exit calibation
mode by pressing the DISPLAY or SETUP keys.

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Set Up and Calibration Procedures
Calibration

Calibrate Output
HercuLine® 2001/2002 actuator can be one of three output types:
1.

0 to 20 mA, or 4 to 20 mA output

0 to 5 Volts, or 1 to 5 Volts with 250 ohm range resistor

Slidewire emulation.

The output signal range is selected through the Current Out set up group using the keypad and local
display.
0/4-20 mA Output
The HercuLine® 2001/2002 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 27. Refer to Figure 25 for a
diagram to connect a signal source to the actuator input and a DVM to measure actuator output signal.
This procedure provides the steps to calibrate the actuator for a 4 to 20mA output. If you are using another
output type, change the procedure accordingly.
ATTENTION

For an output calibration to be saved, you must complete the procedure. The calibration will
not be saved if you exit without completing the steps of the procedure.
To exit calibation mode, press DISPLAY or SETUP keys.

Table 27 Output Calibration Procedure
Step

Operation

Enter Calibration
Mode

Press

SETUP
until you see

Upper Display =
Lower Display =

CAL
CUR OUT

FUNCTION

Upper Display =
Lower Display =

DIS
CALOUT

Upper Display =
Lower Display =

BEGN
CALOUT

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Result

key

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Calibration

Step

Operation

Press

Result

Calibrate Zero (0%)

FUNCTION

Upper Display =
Lower Display =

xxx
ZERO

• Read meter connected to actuator output.

key

• Adjust actuator output to a value equal to 0% output as read

from the DVM.
NOTE: Typically for a 4 mA output, the display will show a value
of approximately 382. A lower limit value is imposed on the zero
output. If the value is 357 or lower, the actuator will not allow you
to calibrate the zero output. The value must be larger than 357
for a valid calibration.

Calibrate Span
(100%)

FUNCTION

Upper Display =
Lower Display =

xxxx
SPAN

• Read meter connected to actuator output.

key

• Adjust actuator output to a value equal to 100% output as read

from the DVM.
• NOTE: Typically for a 20 mA output, the display will show a

value of approximately 1887.
FUNCTION

Calibration for zero and span output values are now stored.
Output calibration is complete.

Slidewire Emulation
The HercuLine® 2001/2002 Actuator comes already calibrated from the factory. If it becomes necessary to
do a calibrationin the field, adjust the output using the procedure in Table 28. Refer to Figure 26 for a
diagram to connect a signal source to the actuator input and a DVM to measure actuator output signal.
ATTENTION

For a slidewire emulation output calibration to be saved, you must complete the procedure.
The calibration will not be saved if you exit without completing the steps of the procedure.
To exit calibration mode, press DISPLAY or SETUP keys.

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Set Up and Calibration Procedures
Calibration

Table 28 Slidewire Emulation Calibration Procedure
Step

Operation

Enter Calibration
Mode

Press

SETUP
until you see

Upper Display =
Lower Display =

CAL
OUTPUT

FUNCTION

Upper Display =
Lower Display =

DIS
CALOUT

Upper Display =
Lower Display =

BEGN
CALOUT

Upper Display =
Lower Display =

xxx
ZERO

Calibrate Zero (0%)

Result

key

FUNCTION

xxx = arbitrary number assigned by software
or

Calibrate Span
(100%)

key

FUNCTION

Adjust actuator output voltage using down key until value on
DVM ceases to change, then press up key until value on DVM
moves up one digit
Upper Display =
Lower Display =

xxxx
SPAN

xxx = arbitrary number assigned by software
or

key

FUNCTION

key until value on DVM
Adjust actuator output voltage using
down key until value on DVM
ceases to change, then press
moves down one digit
Calibration for zero and span output values are now stored.
Slidewire Emulation Output Calibration is complete. Read meter
connected to actuator output.

Calibrate Position Sensor
ATTENTION
The Position Sensor is factory calibrated. Under normal operation it does not require
calibration.

Sensor calibration may be necessary due to any of the following conditions:
•

The sensor output is incorrect,

•

The position sensor in the actuator has been replaced,

•

The position sensor adjustment has been disturbed.

When the position sensor has been replaced (or serviced), you should perform a calibration of the position
sensor circuit and then store it as the motor factory calibration. Please note that performing this procedure
will destroy any previously stored motor factory calibration values. Table 29 outlines the steps to perform a
calibration to the position sensor circuit.
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Set Up and Calibration Procedures
Calibration

While the unit is powered, a potentially lethal shock hazard exists inside the case.

Table 29 NCS Position Sensor Calibration Procedure
Step

Action

Remove AC power to the actuator.

Remove the six screws and the top cover from the actuator case. See Figure 2.
Lay extended cover assembly on a flat surface. Remove relay cards if present.

Reapply AC power to the actuator.

Press SET UP key to access the INPUT set up group.
Press FUNCTION key until the lower display reads Direct.
Press the

keys to set Actuator Rotation direction to CCW.

NOTE: Actuator direction must be set to CCW for this procedure. Direction can be changed
after calibration is complete.

Drive the actuator to the 50% position (this refers to the position on the actuator scale for CCW
rotation). This should be done manually with the handwheel or with the AUTO - MANUAL
switch.

Press SET UP key until the display reads CAL POSOUT.
Press the FUNCTION key until the dispaly reads DIS CALPOS.
Press the

keys until the lower display reads BEGN CALPOS.

Press FUNCTION key.
The upper display now shows the output of the position sensor in Volts.

Loosen the allen screw in the hub of the NCS spoiler just enough to be able to rotate the
spoiler. See Figure 28.

Adjust the NCS spoiler so that the voltage in the local display is 2.500 ± 0.010 volts dc. The
allen screw should be almost in a vertical position. The bottom edge of the spoiler should
almost be horizontal in relation to the NCS PWA. See Figure 28.

Tighten NCS spoiler set screw with an allen wrench, holding spoilers located on each side of
the NCS PWA in position.
IMPORTANT: Spoilers need to be held in position both rotationally and longitudinally along
the drive shaft extension. An air gap must be maintained between the surface of the PWA and
each spoiler. (Any plastic or paper insulating material may be used to create this gap while
positioning the spoilers). Make sure that neither spoiler is touching the sensor PWA when the
adjustment is complete.

Press DISPLAY key to exit calibration mode.

Remove AC power to the actuator. Reinstall relay cards If present.

Install a new gasket and replace extended cover. Secure to actuator with screws.

Continue with calibration procedure in Table 31.

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Set Up and Calibration Procedures
Calibration

NCS set
screw

NCS PWA

Relay PWA card
guides (relay
PWAs removed)

NCS Spoiler (shown at full
150 degree travel CCW)

Figure 28 Location of NCS Assembly

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Calibration

Table 30 Potentiometer Position Sensor Calibration Procedure
Step

Action

Remove AC power to the actuator.

Remove the six screws and the top cover from the actuator case. See Figure 2.
Lay extended cover assembly on a flat surface. Remove relay cards if present.

Reapply AC power to the actuator.

Press SET UP key to access the INPUT set up group.
Press FUNCTION key until the lower display reads Direct.
Press the

keys to set Actuator Rotation direction to CCW.

NOTE: Actuator direction must be set to CCW for this procedure. Direction can be changed
after calibration is complete.

Drive the actuator to the 50% position (this refers to the position on the actuator scale for CCW
rotation). This should be done manually with the handwheel or with the AUTO - MANUAL
switch.

Press SET UP key until the display reads CAL POSOUT.
Press the FUNCTION key until the dispaly reads DIS CALPOS.
Press the

keys until the lower display reads BEGN CALPOS.

Press FUNCTION key.
The upper display now shows the output of the position sensor in Volts.

Loosen the set screw at the end of the switch camshaft where the potentiometer connects to
the shaft.

Using pliers, adjust the white plastic knob on the back side of the potentiometer so the voltage
in the local display is 2.500 ± 0.010 volts dc.

Tighten set screw with an allen wrench.

Press DISPLAY key to exit calibration mode.

Remove AC power to the actuator. Reinstall relay cards If present.

Install a new gasket and replace extended cover. Secure to actuator with screws.

Continue with calibration procedure in Table 31.

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Set Up and Calibration Procedures
Calibration

Potentiometer position sensor

Mounting bracket

Figure 29 Location of potentiometer position sensor

Table 31 Load Position Sensor Factory Calibration
Step

Action

Reapply AC power to the actuator.

Press SET UP key to access the MAINT set up group. Press the FUNCTION key until the
display reads LD CAL.
Press the

keys until the display reads POS.

Perform the Calibrate Motor procedure exactly as in Table 26 Motor calibration must be
performed for the factory configured full span range (0-100%).
ATTENTION

When calibrating the motor to a short stroke range, you must reset the end-of-travel limit
switches. See Setting End-of-Travel Limit Switches.

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When motor calibration is complete, the calibration is now stored as the factory calibration of
the actuator motor.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Setting End-of-Travel Limit Switches

Setting End-of-Travel Limit Switches
ATTENTION
Referring to Figure 31. The first two cams (starting from the front) are for the 0% and
100% limit switches (Switch #1 and Switch #2) and should not need any adjustments as
they are factory set to stop the drive at 0% and 100%. See Figure 30 for limit switch
settings.

END OF TRAVEL LIMIT SWITCH S ETTINGS
(FACTORY SET A T 0% AND 100%)
LEFT HAND
POINTER
SCALE
14
SW#1

100%

0%
8 (SW1 COM)
NC

9 (SW2 COM)
7

Clockwise Rotation

5
SW#2

Counterclockwise Rotation
Clockwise
andcounterclockwise
counterclockwise rotation
thethe
direction
of the
shaft when
Clockwise
and
rotationis is
direction
of output
the output
shaft
facing
the end
theof
shaft.
shown,
clockwise
rotationrotation
of the output
shaft
when
facing
the of
end
the As
shaft.
As full
shown,
clockwise
of the
output
activates
SW1
and
CCW
rotation
activates
SW2.
shaft activates SW 1 (at 0% on the left hand pointer scale) and CCW rotation
activates SW 2 (at 100% on the left hand pointer scale). Terminal numbers
are next to the circles.

Figure 30 End of Travel Limit Switch Settings
REFERENCE

An unactuated switch will have its normally closed (NC) contacts closed and its normally open
(NO) contacts open.
An actuated switch will have its NC contacts become open and its NO contacts become
closed. Both NC and NO contacts are available at the terminal block. See Figure 8 (page 18)
and Figure 9 (page 19).
An unactuated switch has its roller arm in the up position when adjacent to the reduced
diameter portion of the cam.

If it becomes necessary to do adjust the limit switch cams in the field, use the procedure given in Table 32.
While the unit is powered, a potentially lethal shock hazard exists inside the case.

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Set Up and Calibration Procedures
Setting End-of-Travel Limit Switches

Table 32 End-of-Travel Limit Switch Setting Procedure
Step

Action

Remove AC power to the actuator.

Remove the six screws and the cover from the actuator case. See Figure 2. Lay cover
assembly on a flat surface.

Using a flat blade screwdriver in the slots at the edge of the cams, or your finger, rotate the
cams until the switches are set. (See Figure 31).
• 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 bottom scale or 100% for CW operation
using the top scale). If the actuator is installed on a damper or valve, also make sure that
this position is synchronized with the travel of the final control element.
• Rotate the #1 limit switch operating cam to activate at this position. The switch roller 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 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.
• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the

100% position (this is 100% for CCW operation using the bottom scale or 0% for CW
operation using the top scale). If the actuator is installed on a damper or valve, also make
sure that this position is synchronized with the travel of the final control element.
• Rotate the #2 limit switch operating cam to activate at this position. The switch roller 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 and turn off the power to the motor when the switch
activates.
• If optional auxiliary switches were ordered, these switches may also be set at this time. (See

Setting Auxiliary Switches (page 81).

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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 and turn off the motor.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Setting End-of-Travel Limit Switches

ATTENTION

Make sure you do not to set the switches too close to the hard stop.

Relay PWAs
Relay #1
Relay #2
Relay #3
Relay #4

Aux switch #1
Aux switch #2
Aux switch #3
Aux switch #4

End of travel switch #1
(stops CW rotation)
End of travel switch #2
(stops CCW rotation)

Figure 31 Location of End-of-Travel Limit and Auxiliary Switches

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Set Up and Calibration Procedures
Setting Auxiliary Switches

Setting Auxiliary Switches
ATTENTION
Referring to Figure 31. The first two cams (starting from the front) are for the 0% and
100% end of travel limit switches (Switches #1 and #2) and should not need any
adjustments as they are factory set to stop the actuator precisely at 0% and 100%. See
Setting End-of-Travel Limit Switches (page 78).

Additional switch settings should be set so that switch #3 operates in synchronism with switch
#1 (i.e., both activating when the actuator is going in the same direction) and switch #4 to
operates in synchronism with switch #2, etc. See Figure 32 for auxiliary switch settings.

LEFT HAND
POINTER SCALE

SW #3

17 (SW3 COM)
18
NO

25
SW #6

(SW 6 COM) 26
23 (SW5 COM)
NC

SW #4

SW #5

100%

20 (SW4 COM)
16

Figure 32 Auxiliary Switch Settings
If it becomes necessary to do adjust the auxillary switch cams in the field, use the procedure given in Table
33.
While the unit is powered, a potentially lethal shock hazard exists inside the case.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Set Up and Calibration Procedures
Setting Auxiliary Switches

Table 33 Auxiliary Switch Setting Procedure
Step

Action

Remove AC power to the actuator.

Remove the six screws and the cover from the actuator case. See Figure 2. Lay cover
assembly on a flat surface.

Using a flat blade screwdriver on the slots on edge of cams, or your fingers, rotate the cams
until the switches are set. (See Figure 31)
• 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. See Figure 32 for auxiliary
switch settings.

For Switches #3 and #5:
• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the

desired low scale position.
• Rotate the #3 switch operating cam to activate at this position. The switch roller 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 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.
• Repeat for Switch #5 if applicable.

For Switches #4 and #6:
• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the

desired up scale position.
• Rotate the #4 switch operating cam to activate at this position. The switch roller 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 and turn off the power to the motor when the switch activates.
• Repeat for Switch #6 if applicable.

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Start-Up/Operation
Introduction

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 actuator and controlled device before placing it in service. In other words, operate the
controlled device and check its direction of travel in response to an increase of the input signal and make sure it
is correct for the process. Actuators having the optional auto-manual switch must have the knob set in the
AUTO position.
This section provides a checklist that can be used to do a walk-through with the actuator before it is actually
used for control. Other features which may be helpful in understanding actuator operation are also provided.

Power-up Diagnostics
When power is applied to the actuator, the actuator electronics performs a diagnostic routine on various device
components. These tests include a:
•

RAM diagnostic (RAMTST),

•

Check of the electrically eraseable 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 are complete and actuator should be in AUTO mode. See Table 20 for
more information on the power up diagnostics.

Operations Checklist
To make sure that the actuator is properly installed and set up for your particular application, you should check
and verify the following:
•

Verify that the configuration is correct for your application by stepping through all set up groups and
checking the setting of all set up parameters.

•

Verify operation of end-of-travel limit switches.

•

Verify operation of auxiliary switches or relay function (if installed).

•

Check operation of AUTO - MANUAL DRIVE switch (if present), by setting the knob to the CW and CCW
- MANUAL positions. The output shaft should rotate in the direction indicated by the knob. The LED
indicator on the local display should also indicate the actuator is in manual mode.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Start-Up/Operation
Operating Displays

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 shown during operation.
Table 34 Typical Operating Displays
Display

Description
Input—

Upper Display = Shows input value
Lower Display = prompt

Output—

Upper Display = Shows input value
Lower Display = Shows output value

Deviation—

Upper Display = Shows input value
Lower Display = Shows value of deviation of
sensor from input.

Position—

Upper Display = Shows value of position sensor.
Lower Display = prompt

0.0
INP

00
OP 0.5

100.0
DE 99.9

0.6
POS

NOTE: Position display will show negative values, if appropriate.

NOTE: When the AUTO/MANUAL key is pressed, placing the actuator in manual mode, the local display
mode is forced to the Position display (POS). The Manual L.E.D. indicator should be lit. When the
AUTO/MANUAL key is pressed again, placing the actuator in auto mode, the local display mode is forced to
the Output display (OP). The Auto L.E.D. indicator should be lit. Set up parameters can still be accessed.

Motor Stall
The actuator is equipped with a low current motor that prevents against burnout if the motor becomes stalled. A
stall condition occurs when the motor position does not follow the input, or if the motor does not reach setpoint
within a given period of time.
When the stall condition occurs, a stall alarm is indicated. The actuator sets the STALLED LED indicator ON
and also any other alarms or relay contacts that are programmed to close whenever a stall condition is detected.
The motor drive for the indicated direction is shut off approximately 3 minutes after the stall alarm is indicated.
Also, the appropriate CW/CCW LED direction indicator is turned OFF.
The maintenance statistic for accumulated stall time gets updated during the stalled condition.
To reactivate the drive in the stalled direction, change the position of the drive to the opposite direction and set
at a point below where the stall originally occurred, then start the drive in the stalled direction.
Note: A stall condition is not detected if a limit end of travel limit switch is activated while the motor is moving
toward the setpoint, or if the motor position is within 0.5% of calibrated motor 0% and 100% end points.”

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Start-Up/Operation
Position Sensor Operation

Position Sensor Operation
On HercuLine® 2000 and HercuLine® 2001 the potentiometer position sensor is a sealed film pot that is directly
coupled to the output shaft. On HercuLine® 2002 the non-contact sensor (NCS) is inductively coupled to the
output shaft of the actuator so that the sensor detects shaft position. The sensor is adjusted at the factory and
under normal conditions and requires no adjustment. A simple check can verify that the sensor working
properly and that it is in adjustment. Verification of the output is performed by setting the drive motor to its
zero, midpoint and 100% positions and observing the output voltage of the sensor. The actuator has a feature
that the sensor output voltage can be read from the local display.

Step

Action

Drive the motor to 50% position.

Press SET UP key on the keyboard until the display reads CAL POSOUT.
Press FUNCTION key until the display reads DIS CALPOS.
Press the

keys until the display reads BEGN CALPOS.

Press the FUNCTION key.
Upper Display = n.nnn (Output voltage of the sensor)
Lower Display = POSOUT

The display should read 2.500 +/– 0.012 Volts for both 90° and 150° operation.

Press DISPLAY key and then drive the motor to zero position. Repeat Step 2.
The display should read 1.600 +/– 0.060 Volts for 90° operation; 1.000 +/- 0.060 volts for 150°
operation.

Press DISPLAY key and then drive the motor to 100% position. Repeat Step 2.
The display should read 3.400 +/– 0.060 Volts for 90° operation; 4.000 +/- 0.060 volts for 150°
operation.

If the sensor needs adjustment, refer to the “Calibrate Non-Contact Sensor” procedure in Table
29 (page 74).

Remote Setpoint Operation
The HercuLine® 2001/2002 actuator can be set up to receive a digital input from a remote source. The actuator
uses RS485 communications that supports digital Modbus RTU protocol. Press the SET UP key to select the
Input set up group. Change the Input Type to Remote Setpoint (R_SP). Make the necessary connections to
terminals 6, 7, 8 on the actuator terminal block. See Figure 33. Communicaton parameters should be set to the
same values as the host device. The actuator communication parameters are accessed in the Communications
Set Up group.
There are some restrictions to actuator operation when remote setpoint input is active. In order to provide a
bumpless transfer when switching from one input signal type to remote setpoint, the actuator will use the last
known analog input value as its setpoint when switching to remote setpoint input operation. No input filtering
is active on the input signal to the actuator.

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Start-Up/Operation
Remote Setpoint Operation

Actuator
Terminal
Block

SHIELD

COM M UNICATION

COM

INP

DIGITAL INPUT

Figure 33 Terminal Block Connections for Modbus Communications

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Maintenance
Introduction

Maintenance
Introduction
There is some basic maintenance that is recommended for the HercuLine® 2000 Series Actuators. The
electronic PWAs within the actuator require no maintenance or servicing under normal conditions.
If there is a problem, refer to information in this section or to Troubleshooting (page 105) .

Basic Maintenance
Position Sensor
Under normal conditions the position sensor does not require maintenance.
Main Gear Lubrication
Under normal operating conditions, the main worm gear should not require maintenance.
Spur Gear Lubrication
Honeywell recommends that during major shutdown periods the spur gears should be inspected and
lubricated. Follow the steps in Table 35 to access the spur gear compartment and lubricate the gears if
necessary.
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 open while
powered.

Table 35 Spur Gear Lubrication Procedure
Step

Revision 7
7/08

Action

Remove AC power from actuator.

Remove the six screws and the bottom cover of the actuator case. See Figure 34.

Inspect the final spur gear, the idler gear and motor pinion for excessive wear and adequate
lubrication. See Figure 34.

If needed, use Texaco Starplex 2 EP grease, or equivalent and apply lubricant to assure that
the gears are adequately protected.

Install a new gasket and replace side cover. Secure to actuator with screws.

Restore actuator to service.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Maintenance
Basic Maintenance

Bottom cover

Gears

Idler spur
gear

Final output
spur gear

Motor pinion
gear

Figure 34 Spur Gear Location

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Maintenance
Replacement Procedures

Replacement Procedures
Fuse Replacement
The motor drive circuit contains two fuses. They are located on the power distribution PWA. If it becomes
necessary to replace these fuses, follow the procedure in Table 36 and refer to Figure 36 for fuse location.
Disconnect power before opening the actuator case to replace the fuse(s). A
potentially lethal shock hazard exists inside the case if the unit is opened while
powered.

Table 36 Motor Drive Fuse Replacment Procedure
Step

Action

Remove AC power from actuator.

Remove the 6 screws and the extended cover of the actuator case. See Figure 35.

Lay assembly down on a flat surface.

Remove connectors from CPU and power distribution PWA.

Remove power distribution PWA.

Locate the two fuses on the power distribution PWA. See Figure 36. Carefully remove and
replace fuse(s) with Wickmann T1 type 6A 250V, or equivalent (not available from Honeywell).

Reinstall power distribution PWA.

Reconnect connectors to CPU and power distribution PWA.

Install a new gasket and replace extended cover. Secure to actuator with screws.

Relay connector #1
Relay connector #2
Relay connector #3
Relay connector #4

}Relay PWA#1
}Relay PWA#2

Power
distribution
PWA

CPU
connections

Figure 35 Power Distribution PWA and Relay PWA Locations

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Maintenance
Replacement Procedures

Fuses for
Motor Drive
Circuit
Power Distribution PWA

Figure 36 Motor Drive Circuit Fuses
Relay PWA Replacement
If a relay PWA needs to be replaced, follow the procedure in Table 37 to access and replace the PWA.
Disconnect power before opening the actuator case. A potentially lethal shock
hazard exists inside the case if the unit is opened while powered.

Table 37 Relay PWA Replacement Procedure
Step

Action

Remove AC power from actuator.

Remove the six screws and the cover of the actuator case. See Figure 35.

Lay assembly down on a flat surface.

Disconnect the wire connector from the relay PWA.

Carefully remove the relay PWA. Pry the locking tabs of the card guides away to unlock the
PWA and slide it out from the card guides.

Install the replacement relay PWA by sliding it into the card guides until it mates with the
backplane board. Locking tabs on the card guides will engage to secure the PWA in place.

Plug in wire connector to relay PWA.

Install a new gasket if needed and replace cover. Secure to actuator with screws.

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
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Replacement/Upgrade/Accessory Kits
Replacement Kits

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 HercuLine®
2000 Series Actuators and optional equipment.
To determine which kit you need, cross-reference Figure 37 through Figure 41 with Table 38 on page 96.
Each kit contains replacement parts accessories and instructions for component replacement.

6,7
,8

14
11

Figure 37 Replacement Kits 6, 7, 8, 11, 12, 14

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Replacement/Upgrade/Accessory Kits
Replacement Kits

Figure 38 Replacement Kit 10

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Replacement/Upgrade/Accessory Kits
Replacement Kits

1
15
19

4,5,9
2

16
3

Figure 39 Replacement Kits 1, 2, 3, 4, 5, 9, 15, 16, 19

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Replacement/Upgrade/Accessory Kits
Replacement Kits

Figure 40 Replacement Kit 13

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
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Replacement/Upgrade/Accessory Kits
Replacement Kits

17, 18

Figure 41 Replacement Kits 17, 18

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Replacement/Upgrade/Accessory Kits
Replacement Kits

See Figure 37 through Figure 41 for drawings of replacement kit contents.
Table 38 Replacement kits
Qty/Unit

Part Number

Description

Figure ID #

51450802-503

Relay Kit

Description

Figure ID #

CPU Kit

Relay Pwa

Plug 03 Position

Top Cover Gasket

Qty/Unit

Part Number
51451397-501

HercuLine CPU Bd Assembly

Plug, 10 Pos

Label Phonix Connector 1 To 10

Insulator

Pin, Snap Lock, .125 X .187 Lg

Top Cover Gasket

Qty/Unit

1
Qty/Unit

Part Number

Description

Figure ID #

51452302-501

PROM Kit

Part Number

Description

Figure ID #

Backplane Kit

51451424-501

HercuLine Backplane Assy
®

1
1

Card Guide Assy

Card Guide

Split Washer

Machine Screw-Pan Head-Slotted

Screw,Trilob Philph #4-20x.38

Top Cover Gasket

Qty/Unit

Part Number

Description

Figure ID #

51451656-505

1000 Ohm Potentiometer Kit 90 Degrees
(HercuLine® 2000)

Pot 1 K Double 90 Degree

#6-32 Hex Nut N

#6 Washer

#6 Lock Washer

Machine Screw-Pan Hd-Cross Rec

Top Cover Gasket
Kit Instruction# 62-86-33-38

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Replacement/Upgrade/Accessory Kits
Replacement Kits

Qty/Unit

Part Number

Description

Figure ID #

51451656-506

1000 Ohm Potentiometer Kit 150 Degrees
(HercuLine® 2000)

Pot 1 K Double 150 Degree

#6-32 Hex Nut N

#6 Washer

#6 Lock Washer

Machine Screw-Pan Hd-Cross Rec

Top Cover Gasket
Kit Instruction# 62-86-33-38

Qty/Unit

Part Number

Description

Figure ID #

50018180-501

Upgrade to Non Contact Position Sensor
(HercuLine® 2001)

PCB Assembly

Screws SEMS #4-40 x .310 lg

Gasket

Cable Assembly

RVI T-Z Setup Gage

Bracket Molding

Stainless Steel Pin

Set Screw 3/32 x 4-40
Kit Instruction# 62-86-33-46

Qty/Unit

Part Number

Description

Figure ID #

51452342-501

10K Ohm Potentiometer Kit (HercuLine® 2001)

Position Sensor

SA2001

#6-32 Hex Nut N

#6 Washer

#6 Lock Washer

Machine Screw-Pan Hd-Cross Rec

Top Cover Gasket
Kit Instruction# 62-86-33-40

Qty/Unit

Part Number
515000657-502

Description
Rvit-Z Ncs Replacement Kit

Ncs, Rvit-Z Pwa 0-150

Machnl

Top Cover Gasket

Revision 7
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Figure ID #

4-40 X .31 Pnslstl

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Replacement/Upgrade/Accessory Kits
Replacement Kits

Qty/Unit

Part Number

Description

Figure ID #

51452174-501

Crank Arm Kit

Crank Arm

Screw,Hex Hd,1 3/4 X 1/4-20

Kllwss1/4sp

Nut Nmsndc 1/4-20

Qty/Unit

Part Number

Description

Figure ID #

50011455-501

120vac/60HZ Motor Kit

Motor 120v,50/60 Hz,

Capacitor, 3 µfd 400Vac

Cable plus Resistor assembly, 600 Ohm

Resistor Bracket

Split Washer M5

M3 X 5mm lg screw w/ext tooth lock washer

Socket head cap screw-M5 x 12

Top Cover Gasket
Kit Instruction# 62-86-33-36

Qty/Unit

Part Number

Description

Figure ID #

50011455-502

120vac/50HZ Motor Kit

Motor 120v,50/60 Hz,

Capacitor, 4.0 µfd 400Vac

Cable plus Resistor assembly, 400 Ohm

Resistor Bracket

Split Washer M5

M3 X 5mm lg screw w/ext tooth lock washer

Socket head cap screw-M5 x 12

Top Cover Gasket
Kit Instruction# 62-86-33-36

Qty/Unit

Part Number

Description

Figure ID #

50011455-503

240VAC/50/60HZ Motor Kit

Motor 240v,50/60 Hz,

Capacitor, .75 Mfd 400Vac

Cable plus Resistor assembly, 1100 Ohm

Resistor Bracket

Split Washer M5

M3 X 5mm lg screw w/ext tooth lock washer

Butt Splice (SA2000)

Socket head cap screw-M5 x 12

Top Cover Gasket
Kit Instruction# 62-86-33-36

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Replacement/Upgrade/Accessory Kits
Replacement Kits

Qty/Unit

Part Number

Description

Figure ID #

Spur Gear Kit

51452443-501
51452443-507
51452443-508
51452443-509
51452443-510
51452443-511

Spur Gear 24p, 18t

Spur Gear 24p, 36t

Spur Gear 24p, 72t

Gear Assembly

Spur Gear 24p, 36t

Bottom Cover Gasket

Intermediate Shaft all except 7.5 seconds

Intermediate Shaft – 7.5 seconds
Kit Instructions# 62-86-33-35

Qty/Unit

Part Number

Description

Figure ID #

51452443-502

Auxiliary Switch Kit Replacement and Upgrade

Cam Assembly (4 Aux switches, 2 end of travel switches)

Switch and Mounting Plate assembly (6
Kit Instruction# 62-86-33-45

Qty/Unit

Part Number
51452443-503

Description

Figure ID #

Gasket Set Kit

Bottom Cover Gasket

Shaft Seal

O-Ring 2.144 Id X 0.070 Buna N

Top Cover Gasket

O-Ring Buna N

Display Gasket

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Replacement/Upgrade/Accessory Kits
Replacement Kits

Qty/Unit

Part Number

Description

Figure ID #

51452443-504

Display and Keypad Kit

Display Gasket

Overlay, Display

Lens, Display

Gasket,Adhesive Die Cut

Display Mtg Collar Machining

Keypad, 6 Position

Support Plate-Keypad

Display Pwa

Sems #4-40 X .310lg Pnphstl

Screw,Metric Panhd,Cross Rec

Split Washer

Sleeve, Keypad

Display/Keybd Cable

Top Cover Gasket

Qty/Unit

Part Number

Description

Figure ID #

51452443-505

R/C Kit (Motor date codes prior to 8/5/2005)

Capacitor, 2.25 Mfd

Resistor, 200 Ohm,25w

Capacitor, .75 Mfd, 400vac

Resistor, 500 Ohm,25w

Top Cover Gasket

Bottom Cover Gasket
Kit Instruction 62-86-33-44

100

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Replacement/Upgrade/Accessory Kits
Replacement Kits

Qty/Unit

Part Number

Description

51452443-506

R/C Kit (Motor date codes after to 8/5/2005)

Figure ID #

Capacitor, 4.0 Mfd

Cable plus Resistor, 400Ohm

Capacitor, 3 Mfd, 400vac

Cable plus Resistor, 600 Ohm

Capacitor, 0.75 Mfd, 400vac

Cable plus Resistor, 1100 Ohm

Top Cover Gasket

Bottom Cover Gasket

Kit Instruction 62-86-33-44
Qty/Unit

Part Number

Description

Figure ID #

51500166-503

Power Distribution Pwa Kit

Power Dist Pwa

Insulator

Pin, Snap Lock, .125 X .187 Lg

Top Cover Gasket

Qty/Unit

Part Number

Description

Figure ID #

51500457-502

Transformer Kit

Transformer

Split Washer

Machine Screw-Pan Hd-Cross Rec

Top Cover Gasket

Qty/Unit

Part Number
51500581-503

Description
Auto/Manual Switch (upgrade for SA2000)

Auto/Manual Label

Nut, Sealing 3/8-32 Thrd

Knob

A/M Switch/Wire Assy

Label, Customer Wiring,

Top Cover Gasket

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Figure ID #

101

Replacement/Upgrade/Accessory Kits
Upgrade Kits

Qty/Unit

Part Number
51500581-504

Description
Auto/Manual Switch (upgrade for SA2001 & SA2002)

Auto/Manual Label

Nut, Sealing 3/8-32 Thrd

Knob

A/M Switch/Wire Assy

Label, Customer Wiring,

Top Cover Gasket

Figure ID #

Upgrade Kits
Qty/Unit

Part Number

Description

51452444-502

Cover (with Display no Handwheel)

Display gasket

Overlay, display

Lens, display

Gasket,adhesive die cut

Display mtg collar machining

Keypad, 6 position

Support plate-keypad

Display PWA

Top cover w/display no hndwhl

Sems #4-40 x .310lg pnphstl

Screw,metric panhd,cross rec

Split washer

Sleeve, keypad

Display/keybd cable

Top cover gasket

102

HercuLine 2001/2002

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Replacement/Upgrade/Accessory Kits
Upgrade Kits

Qty/Unit

Part Number

Description

51452444-503

Cover with Display and Handwheel

Display gasket

Overlay, display

Lens, display

Gasket,adhesive die cut

Display mtg collar machining

Keypad, 6 position

Support plate-keypad

Display PWA

Top cover w/display & hndwheel

Sems #4-40 x .310lg pnphstl

Screw,metric panhd,cross rec

Hand wheel

O-ring buna n

Split washer

Sleeve, keypad

Display/keybd cable

Retaining ring

Shim

Top cover gasket

Qty/Unit

Part Number
51452444-504

Qty/Unit

HercuLine® 2001/2002

Description

Blank Cover with Handwheel

Part Number

Description

51451656-510

1000 ohms 90 degrees upgrade kit

Machine screw-pan hd-cross rec

Knob

Bracket molding

Pot 1K double 90 degree

#6 lock washer

Machine screw-pan hd-cross rec

#6-32 hex nut N

Stainless steel pin

3/32x4-40 setscrew sshxsocupsb

Washer #6

Flat washer M4 (zinc)

Resistor 158 ohms 1% 1/2W
Kit Instruction# 62-86-33-39

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103

Replacement/Upgrade/Accessory Kits
Accessory Kits

Qty/Unit

Part Number

Description

51451656-511

1000 ohms 150 degrees upgrade kit

Machine screw-pan hd-cross rec

Knob

Bracket molding

Pot 1K double 150 degree

#6 lock washer

Machine screw-pan hd-cross rec

#6-32 hex nut N

Stainless steel pin

3/32x4-40 setscrew sshxsocupsb

Washer #6

Flat washer M4 (zinc)

Resistor 158 ohms 1% 1/2W
Kit Instruction# 62-86-33-39

Accessory Kits

104

Part Number

Description

51197910-001

HAL Linkage Analysis software

51452354-509

HercuLink® software (PC/Palm)

51452354-510

Battery powered Palm/485 converter w/cables

51452174-501

Crank Arm - Standard

51452791-001

Crank Arm – 2003 Unit

51452352-501

Turk Cable for Communication Connection

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Troubleshooting
Introduction

Troubleshooting
Introduction
Troubleshooting procedures can be followed when inaccurate or faulty actuator operation is detected. In
this section, troubleshooting procedures consist of a few simple flow charts to test for proper function of
various actuator components. Component replacement is at the PWA or assembly level.
Table 39 indicates some of the observable symptoms of failure that can be identified by noting the faulty
actuator operation.

Table 39 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 42

Actuator fails one or more power up diagnostics.

See Figure 43

Actuator motor does not drive in response to input signal.

Perform input calibration.
See Figure 42

Actuator motor does not drive to proper position.

Perform motor calibration.

Actuator Motor is “Hunting”
(Motor does not drive to a position and stop.)

Process control loop is not tuned correctly.
Refer to the Instruction Manual for your
controller on how to tune a loop.
Increase the Deadband in the Actuator
and/or in the control loop.

Position sensor position is not correct.

See page 85.

Auto/Manual Switch does not operate correctly.

See Figure 45

Relay(s) does not operate.

See Figure 46

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

105

Troubleshooting
Troubleshooting Procedures

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 Maintenance
(page 87) 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.
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.

106

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Troubleshooting
Troubleshooting Procedures

Test for Actuator Operation
A

Cycle power
to actuator.

Yes

Does display
light up?

Move handwheel
on actuator 2 or
3 turns.

Observe self test.

Do all diagnostics pass?
RAMTST PASS
SEETST PASS
CALTST PASS
CFGTST PASS

Yes

All LEDs and
display segments
light?
Yes

Does motor
reposition
itself?

Yes
B

Replace display
assembly

Figure 42 Test for Actuator Operation

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HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

107

Troubleshooting
Troubleshooting Procedures

Power Up Self Test Diagnostics
B

Cycle power
to actuator.

Yes

Does display
light up?

A
Observe self test.

Yes

CALTST PASS?

RAMTST PASS?

SEETST PASS?

CFGTST PASS?

Check actuator
calibration,
recalibrate
if necessary.

Replace CPU
Assembly.

Check actuator
configuration
(setup), reconfigure
if necessary.

Cycle power to
actuator. If CFGTST
fails again, replace
CPU assembly.

Cycle power to
actuator. If CALTST
fails again, replace
CPU assembly.

Yes

Do all LEDs
and display
segments light
up?
Yes

Replace display
assembly.
E

Figure 43 Power Up Diagnostics

Test Non-Contact Sensor PWA
See page 85.
108

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Troubleshooting
Troubleshooting Procedures

Test Power Distribution PWA

Remove top
cover of actuator.

Check Fuses F1
and F2 on the
power distribution
PWA.

Yes

Are fuses good?

Replace fuses with
same type and
rating
Is correct
voltage present
at test points?
See below.

Yes

Replace Power
Distribution PWA.

Replace CPU
assembly.

Figure 44 Test Power Distribution PWA
Power Distribution PWA Test Points
Connector

Voltage

Pin 1 to pin 7

Pins 1,2 to pins 3, 4, 8

Pins 3, 4 to pin 7

Pins 5, 6 to pins 7, 8

24 V

Pins 1, 2 to pins 7, 8

28 V + or – 3V

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Test Points - Pins

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

109

Troubleshooting
Troubleshooting Procedures

Test AUTO - MANUAL DRIVE Switch
E

Turn switch to
Manual CCW
setting.

Yes

Does motor
drive in the CCW
direction?

Turn switch to
Manual CW setting.

Does motor
drive in the CW
direction?

Yes

CCW

MANUAL
OFF

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?

OFF
A
U
T
O

AUTO - MANUAL DRIVE

Figure 45 Test AUTO - MANUAL Switch

110

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Troubleshooting
Troubleshooting Procedures

Test Relay Function

Press SET UP
button on keypad
to enter Set up
mode.

Set suspect Relay
type to MAN.

Set AUTO MANUAL switch
to MAN.

Place ohmmeter
across associated
relay contacts at
Actuator terminal
block. See below.

Yes

Does Relay
operate?

Replace Relay PWA or
Wire harness from Relay
PWA to terminal block.
See Relay replacement
in Maintenance, Section 7.

Figure 46 Test Relay Function
Relay

Revision 7
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Associated Contacts

RELAY1

NC
COM
NO

RELAY2

NC
COM
NO

RELAY3

NC
COM
NO

RELAY4

NC
COM
NO

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

111

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

Appendix A - HercuLine® 2001/2002 Configuration Record
Sheet

Enter the value or selection for each set up parameter on this sheet so you will have a record of how your
actuator is configured.
Set Up Group

Parameter

Setting

Default

IN TYP - Input Actuation Type

__________________

See Note 1

INP HI – Input High Range Value

__________________

100

INP LO – Input Low Range Value

__________________

0.0

FILTYP – Input Filter Type

__________________

LPAS

LPFILT – Low Pass Filter Time Constant *

__________________

Direct – Actuator Rotation

__________________

CCW

Dband – Input Deadband

__________________

0.5

FSTYPH – Failsafehi Type

__________________

FSVALH – Failsafehi Input Value

__________________

100

FSTYPL – Failsafelo Type

__________________

DOWN

FSVALL – Failsafelo Input Value

__________________

CHAR – Input Characterization type

__________________

LINR

CUSTOM -- Custom characterization type

__________________

EQUL

X0 VAL -- User configurable characterizer value

__________________

0.0

X1 VAL -- User configurable characterizer value

__________________

5.0

X2 VAL -- User configurable characterizer value

__________________

10.0

X3 VAL -- User configurable characterizer value

__________________

15.0

X4 VAL -- User configurable characterizer value

__________________

20.0

X5 VAL -- User configurable characterizer value

__________________

25.0

X6 VAL -- User configurable characterizer value

__________________

30.0

X7 VAL -- User configurable characterizer value

__________________

35.0

X8 VAL -- User configurable characterizer value

__________________

40.0

X9 VAL -- User configurable characterizer value

__________________

45.0

X10 VAL - User configurable characterizer value

__________________

50.0

X11 VAL - User configurable characterizer value

__________________

55.0

X12 VAL - User configurable characterizer value

__________________

60.0

X13 VAL - User configurable characterizer value

__________________

65.0

X14 VAL - User configurable characterizer value

__________________

70.0

X15 VAL - User configurable characterizer value

__________________

75.0

X16 VAL - User configurable characterizer value

__________________

80.0

X17 VAL - User configurable characterizer value

__________________

85.0

X18 VAL - User configurable characterizer value

__________________

90.0

Prompt

SET INPUT

112

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

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Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

Set Up Group

Parameter

Setting

Default

X19 VAL - User configurable characterizer value

__________________

95.0

X20 VAL - User configurable characterizer value

__________________

100.0

Y0 VAL -- User configurable characterizer value

__________________

Y1 VAL -- User configurable characterizer value

__________________

0.8

Y2 VAL -- User configurable characterizer value

__________________

2.1

Y3 VAL -- User configurable characterizer value

__________________

3.2

Y4 VAL -- User configurable characterizer value

__________________

4.9

Y5 VAL -- User configurable characterizer value

__________________

6.5

Y6 VAL -- User configurable characterizer value

__________________

8.4

Y7 VAL -- User configurable characterizer value

__________________

10.7

Y8 VAL -- User configurable characterizer value

__________________

13.2

Y9 VAL -- User configurable characterizer value

__________________

15.7

Y10 VAL - User configurable characterizer value

__________________

18.7

Y11 VAL - User configurable characterizer value

__________________

22.6

Y12 VAL - User configurable characterizer value

__________________

27.2

Y13 VAL - User configurable characterizer value

__________________

33.4

Y14 VAL - User configurable characterizer value

__________________

Y15 VAL - User configurable characterizer value

__________________

Y16 VAL - User configurable characterizer value

__________________

53.8

Y17 VAL - User configurable characterizer value

__________________

63.2

Y18 VAL - User configurable characterizer value

__________________

73.7

Y19 VAL - User configurable characterizer value

__________________

86.2

Y20 VAL - User configurable characterizer value

__________________

100

RTYP11 – Relay Type

__________________

NONE

R11VAL – Relay Value

__________________

R11 HL – Relay High/Low

__________________

R11SCALE– Relay Scale

__________________

RTYP12 – Relay Type

__________________

NONE

R12VAL – Relay Value

__________________

R12 HL – Relay High/Low

__________________

R12SCALE– Relay Scale

__________________

Prompt

SET RELAY

Revision 7
7/08

RLY1HY – Relay Hysteresis

__________________

RTYP21 – Relay Type

__________________

NONE

R21VAL – Relay Value

__________________

R21 HL – Relay High/Low

__________________

R21SCALE– Relay Scale

__________________

RTYP22 – Relay Type

__________________

NONE

R22VAL – Relay Value

__________________

R22HL– Relay High/Low

__________________

R22SCALE– Relay Scale

__________________

RLY2HY – Relay Hysteresis

__________________

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

113

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

Set Up Group

Parameter

Setting

Default

Prompt

SET CUROUT
SET COMM

SET DIGINP
SET DISPLA

SET LOCK

READ STATUS

114

RTYP31 – Relay Type

__________________

NONE

R31VAL – Relay Value

__________________

R31 HL – Relay High/Low

__________________

R31SCALE– Relay Scale

__________________

RTYP32 – Relay Type

__________________

NONE

R32VAL – Relay Value

__________________

R32HL– Relay High/Low

__________________

R32SCALE– Relay Scale

__________________

RLY3HY – Relay Hysteresis

__________________

RTYP41 – Relay Type

__________________

NONE

R41VAL – Relay Value

__________________

R41 HL – Relay High/Low

__________________

R41SCALE– Relay Scale

__________________

RTYP42 – Relay Type

__________________

NONE

R42VAL – Relay Value

__________________

R42HL– Relay High/Low

__________________

R42SCALE– Relay Scale

__________________

RLY4HY – Relay Hysteresis

__________________

See Note 1

COMM – Communications Parameters

__________________

MODBUS

ADDRES – Device Address

__________________

BAUD – Baud Rate

__________________

19.2K

XmtDLY – Response Delay

__________________

20MS

DBLBYT – Floating Point Data Format

__________________

FP B

DIGINP – Digital Input State

__________________

Endpos – End Position Value

__________________

DECMAL – Decimal Point Location

__________________

8888

EUNITS – Units Display

__________________

Pcnt

UNITS – Display Units

__________________

ENG

LOCKID – Password Lock

__________________

MAENAB – Enabled

__________________

ENAB

LOCK – Lock Out

__________________

NONE

FAILSF – Failsafe

__________________

Read Only

RAMTST – RAM Test Diagnostic

__________________

Read Only

SEETST – Serial EEPROM Test Diagnostic

__________________

Read Only

CFGTST – Configuration Test Diagnostic

__________________

Read Only

CALTST – Calibration Test Diagnostic

__________________

Read Only

CUROUT - Output Signal Range

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
7/08

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

Set Up Group

Parameter

Setting

Default

__________________

Read Only

SPEED – Stroke Speed

__________________

Factory Set

POWER – Power Input Voltage Line Frequency

__________________

Factory Set

TAG – Tag Name

__________________

MFGDAT – Manufacturing Date

__________________

Factory Set

LREP – Date of Last Repair

__________________

Factory Set

LCAL – Date of Last Field Calibration

__________________

Factory Set

REPTYP – Repair Type

__________________

Factory Set

TEMP – Actuator Temperature

__________________

Read Only

TEMPHI – High Temperature Limit

__________________

Read Only

TEMPLO – Low Temperature Limit

__________________

Read Only

ACST – Accumulated Stall Time

__________________

Read Only

STARTS – Accumulated Motor Starts

__________________

Read Only

RLnCNTS – Relay Cycle Counts

__________________

Read Only

Prompt

SET DRVINF

SET MAIN

VERSON – Firmware Version

n = 1, 2, 3, or 4
REGNy – Accumulated Motor Starts for regions
of motor travel.

Read Only
__________________

Read Only

y = 0 through 9

CAL NCSOUT

DATSAV – Forced maintenance data save

__________________

DIS

MANRST – Maintenance Statistic Reset

__________________

NONE

LDCAL – Restore Factory Calibration Type

__________________

NONE

LDCFG – Restore Factory Default Configuration

__________________

DIS

RESTRT – System Restart

__________________

DIS

NCSOUT – Non-contact sensor circuit output

_________________

Read Only

Note 1: Type is set from model number.

Revision 7
7/08

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

115

Index

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
Temperature limits, 59
Total degrees of motor travel, 59
Applications
Basic flow control, 27
Proportional flow with multiple actuators, 27
Split range, 26, 30
Approvals, 6
Auto/Manual Switch
Testing, 110
Auto-Manual Switch, 64
Auxiliary Switches, 81
Setting, 81
Auxiliary Switches/Relays, 6

B
Baud Rate, 9, 50
Burner Control/Flame Safety, 23

E
Electrical and Performance Specifications, 6
Electrical Installation, 17
Enclosure, 5
Enclosure Rating, 6
End of travel Limit Switches, 6
Exiting Set Up mode, 33

F
Failsafe, 40, 41
Failsafe Input Value, 40, 41
Failsafe operation, 7
Feedback, 6
Flame Safety Module wiring diagram, 23
Fuses
Replacement, 89

C
Calibration, 65
Set up, 66
Calibration Values
Restore, 61
CE Wiring, 21
Change Password
LOCKID parameter, 54
Clamp Bolt, 6
Communications, 7, 9
Floating point data transfer, 50
Configuration Prompt Hierarchy, 38
Configuration Record Sheet, 112
Configuration Tips, 33
Connections
Output, 23
Slidewire emulation, 23
Crank Arm, 5
Crank Arms, 16
Customer Connections, 17
CW and CCW Direction. See Actuator Rotation

116

Deadband, 7, 40
Decimal Point Location, 52
Deviation, 45
Relay type, 47
Device Address, 50
Direction of Rotation, 7
Duty Cycle, 7

Gear Train, 5

H
Handwheel, 5
HercuLine 2000 Terminal Connections, 18
HercuLine 2001/2002 with Auto/Manual Terminal
Connections, 19
HerculLine 2003 Wiring Connections and Operation, 20
Hysteresis, 7, 44

I
Input Calibration, 68
Input Characterization, 41
Input Filters, 7, 40
Input High Range, 39
Input Impedance, 6
Input Low Range, 39
Input Set Up Group, 39
Input Signal Connections, 22
Input Signals, 6

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
7/08

Index

Inputs, 39
Installation, 12
Installation Considerations, 13
Isolation, 6

Keypad, 8, 31
Description, 32

L
LEDs on Local Display, 32
Limit Switches, 78
Setting, 78
Linkage Kits, 96
Linkage Set-up, 15
Constant torque, 15
Crank arms, 16
Variable torque, 15
Load Requirement, 6
Local Auto/Manual Switch, 6
Local Display, 8, 31
Description, 31
LEDs description, 32
Operating displays, 84
Set up, 52
LOCK parameter, 33, 36
Lubrication, 5
Main (Worm) gear, 87
Spur gear, 87

M
Main Gear Lubrication, 87
Mains Supply, 6
Mechanical Installation, 15
Mechanical Stops, 5
Modbus communications, 50, 85
Model distinctions, 1
Motor, 6
Motor Calibration, 70
Motor Current, 6
Motor Speed, 56
Motor Stall, 84
Motor Starts, 45
Relay type, 48
Mounting, 13

N
Non-Contact Sensor, 87
Checking, 108
Operation, 85
Non-Contact Sensor Output Calibration, 72, 73

O
Operating Temperature, 7
Revision 7
7/08

Output Calibration, 71
Output Shaft, 5
Output Torque, 5
Output Type, 49
Outputs, 49

Password, 60
(LOCKID), 53
Change, 54
PDA, 9
Position Range
Relay type, 46
Position sensing, 7
POSITION SENSOR OUTPUT, 63
Power Supply PWA
Checking, 109
Product Description, 1
Programmable Functions, 8
Pushbuttons
Description, 32

R
Regions of Motor Travel, 62
REGN parameter, 59
Relative Humidity, 5
Relay Function
Testing, 111
Relay PWA Replacement, 90
Relay Type, 44, 45
Remote Setpoint Operation, 85
Repeatability, 7
Restore Factory Calibration Values, 61
Rotation, 5

S
Scale, 5
Scrolling through Set Up Groups, 33
Self-test Diagnostics, 55, 83, 108
Sensitivity, 7
Set Up and Calibration Procedures, 31
Set Up Groups
Communications, 50
Current out, 49
Digital input, 51
Display, 52
Drive, 56
Input, 39
Lock, 53
Maintenance, 59
Read status, 55
Relays, 44
Slidewire Emulation, 23
Solid State Motor Control, 7
specifications, 5
Split Range, 26
Spur Gear Lubrication, 87

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

117

Index

Equipment, 106

Stall, 84
Start Up Checklist, 83
Storage Temperature, 5
Stroke Speed, 56

V
Voltage/ Supply Stability, 7

T
Tag Name, 58
TAG parameter, 56
Technical and Operating Specifications, 5
Temperature Coefficient, 7
Terminal Connections, 18, 19
Total Degrees of Motor Travel
TOTDEG parameter, 59
Troubleshooting, 105

118

W
Weight, 5

Z
Zero Suppression, 7

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

Revision 7
7/08

HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual

119

Honeywell Process Solutions
Industrial Measurement and Control
512 Virginia Drive
Fort Washington, PA 19034
62-86-25-10 0708

Printed in USA

http://hpsweb.honeywell.com

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Title                           : 62-86-25-10 HercuLine® 2000 Series Actuator Installation, Operation and Maintenance Manual
Creator                         : Honeywell Field Solutions
Description                     : Installation Instructions
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Issue                           : Installation, Operation and Maintenance Manual
Date                            : HercuLine™ 2000 Series Actuator
Approval                        : 1
Company                         : Honeywell
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Subject                         : Installation Instructions
Author                          : Honeywell Field Solutions

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