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

2000 to the manual e769983d-d341-4cc7-be9d-af66c897824b

2015-01-23

: Honeywell Honeywell-Herculine-2000-Users-Manual-261088 honeywell-herculine-2000-users-manual-261088 honeywell pdf

Open the PDF directly: View PDF .
Page Count: 128 [warning: Documents this large are best viewed by clicking the View PDF Link!]

Honeywell Field Solutions

HercuLine® 2000 Series Actuator

Installation, Operation and

Maintenance Manual

Doc. No.: 62-86-25-10

Revision: 7

Date: 7/08

ii HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Notices and Trademarks

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.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual iii

7/08

About This Document

Abstract

This manual describes the installation, set up, operation, maintenance, and troubleshooting of the

HercuLine 2000 series actuators.

References

The following list 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

Organization Phone Number

United States and Canada Honeywell 1-800-423-9883 Tech. Support

1-800-525-7439 Service

iv HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Symbol Definitions

The following table lists those symbols that may be used in this document to denote certain conditions.

Symbol Definition

This DANGER symbol indicates an imminently hazardous 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.

Contents

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual v

7/08

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

Contents

vi HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Lock Set Up Group .....................................................................................................53

Read Status Set Up Group.........................................................................................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

Contents

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual vii

7/08

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

Contents

viii HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Figures

Figure 1 HercuLine® 2000 Series Actuator 2

Figure 2 HercuLine® 2002 Actuator Internal View 3

Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators 14

Figure 4 Constant Torque Linkage 15

Figure 5 Variable Torque Linkage 16

Figure 6 Standard crank arm 16

Figure 7 Crank arm with optional ball joint and push rod 16

Figure 8 HercuLine® 2000 connections 18

Figure 9 HercuLine® 2001/2002 connections 19

Figure 10 HercuLine® 2003 connections 20

Figure 11 CE wiring part 1 21

Figure 12 CE Wiring part 2 22

Figure 13 Burner Control/Flame Safety Wiring 23

Figure 14 Series 90 connections 24

Figure 15 T775 Controller connections 25

Figure 16 Flow Diagram 27

Figure 17 Interconnection Diagram 27

Figure 18 Proportional Flow Using Multiple Actuators 28

Figure 19 Multiple Actuator Interconnection Diagrams 29

Figure 20 Interconnection Diagrams 30

Figure 21 HercuLine® 2000 Display and Keypad 31

Figure 22 Relay connectors 46

Figure 23 Regions of Motor Travel 62

Figure 24 Auto - Manual Switch 64

Figure 25 Calibration Wiring Connections (non-slidewire emulation) 66

Figure 26 Calibration Wiring Connections (slidewire emulation) 67

Figure 27 Jumper Location on CPU PWA 68

Figure 28 Location of NCS Assembly 75

Figure 29 Location of potentiometer position sensor 77

Figure 30 End of Travel Limit Switch Settings 78

Figure 31 Location of End-of-Travel Limit and Auxiliary Switches 80

Figure 32 Auxiliary Switch Settings 81

Figure 33 Terminal Block Connections for Modbus Communications 86

Figure 34 Spur Gear Location 88

Figure 35 Power Distribution PWA and Relay PWA Locations 89

Figure 36 Motor Drive Circuit Fuses 90

Figure 37 Replacement Kits 6, 7, 8, 11, 12, 14 91

Figure 38 Replacement Kit 10 92

Figure 39 Replacement Kits 1, 2, 3, 4, 5, 9, 15, 16, 19 93

Figure 40 Replacement Kit 13 94

Figure 41 Replacement Kits 17, 18 95

Figure 42 Test for Actuator Operation 107

Figure 43 Power Up Diagnostics 108

Figure 44 Test Power Distribution PWA 109

Figure 45 Test AUTO - MANUAL Switch 110

Figure 46 Test Relay Function 111

Introduction

Product Description

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 1

7/08

Introduction

Product Description

Honeywell’s HercuLine® 2000 series actuators are available in four versions: HercuLine® 2000,

HercuLine® 2001, HercuLine® 2002, 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

Introduction

Product Description

2 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Display and

keypad

Shaft and

position indicator

Handwheel

Auto/manual

switch

Conduit

entry

Figure 1 HercuLine® 2000 Series Actuator

Introduction

Product Description

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 3

7/08

TB3

Connector

for customer

input and

output

connection

on CPU

PWA

Display

Keypad

PWA

Wiring

Label

Non-contact

sensor

External

auto-manual

switch

TB1

customer

power

connection

Relay PWAs

Cams and

limit

switches

Mechanical Stops

TB3

Connector

for customer

input and

output

connection

on CPU

PWA

Display

Keypad

PWA

Wiring

Label

Non-contact

sensor

External

auto-manual

switch

TB1

customer

power

connection

Relay PWAs

Cams and

limit

switches

Mechanical Stops

Figure 2 HercuLine® 2002 Actuator Internal View

Introduction

Product Description

4 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Specifications

Technical and Operating Specifications

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 5

7/08

Specifications

This section provides you with the technical specifications and the model selection guide for the

HercuLine® 2000 Series Actuators.

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, self-

locking/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 set-

up.

Lubrication Texaco Starplex 2 EP Grease

Output Torque/Full

Travel Stroking Time

Torque lb-in (N

50 / (6.0)

100 / (11.5)

200 / (22.5)

400 / (45.0)

50 Hz (90°/150°)

4.5 / 7.5

9 / 15

18 / 30

36 / 60

54 / 90

60 Hz (90°/150°)

4 / 6

7 / 12

15 / 25

30 / 50

45 / 75

Specifications

Technical and Operating Specifications

6 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Electrical

Mains Supply 100-130 Vac single phase, 50 Hz or 60 Hz

200-240 Vac single phase, 50 Hz or 60 Hz

Motor Instant start/stop, non-coasting, 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

Clamp Bolt 88 lb-in (10 N-m)

Electrical and Performance Specifications

HercuLine® 2002 HercuLine® 2001 HercuLine® 2000/2003

Input Signals Analog:

• 0/4 to 20 mA (With CPU

PWA jumper in current

position)

• 0/1 to 5 Vdc

• 0 to 10 Vdc

Digital:

• Modbus RTU (RS485)

Analog:

• 0/4 to 20 mA (With CPU

PWA jumper in current

position)

• 0/1 to 5 Vdc

• 0 to 10 Vdc

• Series 90 control

Digital:

• Modbus RTU (RS485)

120 vac drive open/120 vac

drive close

240 vac drive open/240 vac

drive close

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

Load Requirement (4-20) Current Out — 0 to 1000 ohms NA

Input Impedance 0/4 to 20 mA

0/1 to 5 Vdc

0-10 vdc

250 ohms

10 K ohms

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)

Specifications

Technical and Operating Specifications

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 7

7/08

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™ NA

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 1000 ohm film potentiometer Dual 1000 ohm film

potentiometers

(not on 2003)

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

Hysteresis Less than 0.4 % of full scale NA

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

Repeatability 0.2 % of 90° span NA

Repositions

(minimum @ 90 or 150

degree stroke)

Table 1 option –050-

Table 1 option –100-

Table 1 option –200-

Table 1 option –400-

Table 1 option –600-

160

290

450

700

900

120

250

400

500

Voltage/ Supply

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

Temperature

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

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

Zero Suppression 90 % of span. NA

Input Filters Selectable spike and low pass filters. NA

Solid State Motor

Control Two triac switches for clockwise or anti-clockwise motor operation.

Transient voltage protection provided. NA

Failsafe operation If input signal exceeds configured input range. Selectable and

adjustable. NA

Direction of Rotation Field programmable Wire swap

Duty Cycle Continuous

Specifications

Technical and Operating Specifications

8 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

HercuLine® 2002 HercuLine® 2001 HercuLine® 2000/2003

Programmable

Functions Selectable and configurable operating parameters: NA

• Input range

• 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

Display Design Multi-segment LED displays that provides up to ten alphanumeric characters. Display

arrangement consists of two rows:

1st row (Upper display) – four characters

2nd 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.

Specifications

Technical and Operating Specifications

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 9

7/08

Specifications – 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.

Specifications

Model Selection Guide

10 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Model Selection Guide

Instructions

Select the desired key number. The arrow to the right marks the selection available.

Make the desired selections from Tables I thru VIII using the column below the arrow.

A dot ( ) denotes unrestricted availability.

Key Number V VI VII VIII IX

- - - - - _ _ - _ _ _ _ _ _ - _ -_-_ _

KEY NUMBER - Motor Selection Availability

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)

50 / (6.0) 7.5 sec 6 sec

100 / (11.5

)

15 sec 12 sec

200 / 22.5) 30 sec 25 sec

400 / (45.0

)

60 sec 50 sec

400 / (45.0) 90 sec 75 sec

TABLE II - ROTATION

Travel 90 degrees

150 degrees

360 degrees

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

TABLE IV - ANALOG INPUT/OUTPUT SIGNALS

Input 3 Wire Drive up/down 0 _ _

0/4-20 mA, 0/1-5 Vdc, 0-10 Vdc 2 _ _

0/4-20 mA, 0/1-5 Vdc, 0-10 Vdc 3 _ _

0 to 135 ohm input (Series 90 control) 4 _ _ a

Contact Input for 2003 6 _ _

Output None _ 00

(Note 1) Dual 1000 Ohm (1000 ohms over 150 degrees) _ 15 b

(Note 1) Dual 1000 Ohm (1000 ohms over 90 degrees) _ 19 c

Slidewire Emulation _ 60

Slidewire Emulation _ 65

0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc) _ 80

0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc) _ 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

4 Programmable Relay Outputs

_ 3

_ 4

2 _

4 _

_ 0

_ 2

246

245

360

0 _

090

150

126

125

100

200

400

600

2001

2002

2003

050

IVII

_ _ _

III

_ _ _ _ _ _

Selection

2000

_ _ __ _ _ _

50Hz 60Hz

continued

Specifications

Model Selection Guide

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 11

7/08

2002 2003

TABLE VI - OPTIONS Selection

Local keypad/ No local display interface supplied (Note 2) 0_ _ _ _ _

display Integrally mounted local display/keypad interface 1_ _ _ _ _

Local Auto/ No auto/manual switch _ 0_ _ _ _

manual switch Auto/manual switch with "Out of Auto Contact" _ 1_ _ _ _

Auto/manual switch with "Out of Auto Contact" _ 2_ _ _ _

Handwheel No Handwheel _ _ 0_ _ _

Handwheel _ _ 1_ _ _

Certificates None _ _ _ 0 _ _

Certificate of Conformance _ _ _ 1_ _

Approvals UL Type 4/IP66, CSA (Note 4) _ _ _ _ 0_

CE _ _ _ _ 1_

Shipped Rotation Counter clockwise shaft rotation on increasing signal _ _ _ _ _0

Clockwise shaft rotation on increasing signal _ _ _ _ _1

TABLE VII - COMMUNICATIONS/PROTOCOL

None No communications option board or protocol 0

Modbus RTU RS485 RS-485 Modbus compliant - standard with EEU 1

HART 5 HART Communications Protocol 2

TABLE VIII - MANUALS

Standard English 0

TABLE IX - FACTORY OPTIONS

Factory Options None

Restrictions

aIV _ 00 IV _ 60, _ 80

II II

ACCESSORIES

Mounting Hardware 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

Linkage Assembly 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.

HART Turk Cable for Handheld Connection 51452352-501

Handheld Config. HercuLink

Palm Software

(Note 3) Battery powered 232/485 converter with cable

Remote Mount Remote 4-20 mA requires 135 ohm fdbk, 120V 50/60Hz

Control 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

Notes: 1. 135 ohm available by parallelling 1K potentiometer with 158 Ohm resistor (supplied).

2. HercuLinkTM software (pn 51452354-509), RS232/485 converter (pn 51452354-510),

customer supplied PalmTM 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.

51452354-506

51452354-507

51452354-503

51452354-511

51452354-504

51452354-505

51452354-501

51452354-502

2000 2001

Available Only With

Table Selection

Not Available With

150

090

R7195A1056

R7195B1021

R7195A1064

51452354-508

R7195A1031

51452354-510

51452354-509

Restriction

Letter

150

090

Table Selection

Installation

Installation Overview

12 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Installation

Installation Overview

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

• Select a suitable 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.

Installation

Before Starting

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 13

7/08

Before Starting

Unpacking

If there are visible signs of damage to the shipping container, notify the carrier and Honeywell immediately.

If there is no visible damage, 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.

Installation

Actuator Mounting

14 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

CLEARANCE FOR TOP REMOVAL:

101,6

4.0

289

11.379

25.4

1.00

CLEARANCE FOR TOP REMOVAL:

101,6

4.0

289

11.379

25.4

1.00

inches

Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators

Installation

Mechanical Installation

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 15

7/08

Mechanical Installation

Linkage Set-up

Many applications require the use of a linkage assembly and often the final control element does not have a

linear torque 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

45° 45°

Vertical

Centerline

45° 45°

Start Stop Close Open

Drive Unit

Crank Arm

Damper

Crank Arm

Linkage

Horizontal Offset

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.

Installation

Mechanical Installation

16 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Vertical

Centerline

5°

Vertical

Centerline

45° 45°

Close Open

Actuator

Crank Arm

Damper

Crank Arm

Linkage

Horizontal Offset

a/n 23200

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

Installation

Electrical Installation

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 17

7/08

Electrical Installation

General Wiring Recommendations

Only qualified personnel should perform wiring.

Wiring must conform to national and local electrical codes.

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

14 Earth ground wire to common power supply.

18 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.

Installation

Electrical Installation

18 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

HercuLine® 2000 Terminal Connections

Table 3 Terminal Connections: HercuLine® 2000

Connection Terminal Numbers

and LABEL

See Figure 8

Descriptions

Hot 1

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

switch is present.

Neutral 2 Neutral wire for 120/240VAC mains supply

Auto/Manual Switch

Contact

Switch contact to indicate setting of actuator AUTO/MANUAL

switch.

Switch is closed when actuator is “NOT-IN-AUTO”

CW from Controller 5 CW motor drive

CCW from Controller 6 CCW motor drive

Potentiometer #1 7

Clockwise-End

Slider

Counterclockwise-End

Potentiometer #2 10

Clockwise-End

Slider

Counterclockwise-End

Protective Ground Ground wire connection for mains supply

158 ohm 158 ohm Install resistors to convert 1000 ohm

potentiometer to 135 ohms

REQUIRED ONLY IF AUTO/MANUAL

SWITCH IS PRESENT

158 ohm 158 ohm Install resistors to convert 1000 ohm

potentiometer to 135 ohms

REQUIRED ONLY IF AUTO/MANUAL

SWITCH IS PRESENT

Figure 8 HercuLine® 2000 connections

Installation

Electrical Installation

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 19

7/08

HercuLine® 2001/2002 with Auto/Manual Terminal Connections

Table 4 Terminal Connections: HercuLine® 2001/2002 with auto/manual

Connection Terminal Numbers

and LABEL

See Figure 9

Descriptions

TB1

Hot 1 Hot wire for 120/240VAC mains supply

Neutral 2 Neutral wire for 120/240VAC mains supply

Protective Ground 3 Ground wire connection for mains supply

Auto/Manual Switch

Contact

Switch contact to indicate setting of actuator AUTO/MANUAL

switch.

Switch is closed when actuator is “NOT-IN-AUTO”

TB3

4 to 20mA Output* 1 (+)

2 (-)

Analog signal output

Feedback 3 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

Auxiliary

Connector

Brown

Black

Blue

Black Wire Not Used

HART connection using

external Turck connector

HART

Communications

Connection

Auxiliary

Connector

Brown

Black

Blue

Black Wire Not Used

HART connection using

external Turck connector

Auxiliary

Connector

Brown

Black

Blue

Black Wire Not Used

HART connection using

external Turck connector

HART

Communications

Connection

Figure 9 HercuLine® 2001/2002 connections

Installation

Electrical Installation

20 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

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

Wiring

Figure 10 HercuLine® 2003 connections

Operation

The 2003 actuator is uni-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.

Installation

Electrical Installation

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 21

7/08

Power Connections

Depending on which power supply selection is ordered for your actuator, wire the power input (MAINS

POWER) as described in the previous tables 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

1 Remove AC power to actuator.

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

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

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

5 Install the appropriate MOV assembly as shown in Figure 11.

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

7 • Current input and output (slidewire emulation) connection

• Communications and digital input connection

TB1-2

TB1-1

Ground

screw

Communications

and digital input

Current input

and output

(slidewire

emulation)

Figure 11 CE wiring part 1

Installation

Electrical Installation

22 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Step Action

8 • AC power connection

• Auxiliary switches connection

• Relay contact connection

Relays 3 and 4

Relays 1 and 2

Aux switches

1 and 2

(SW3 and SW4)

Aux switches 3

and 4

(SW5 and SW6)

AC power

connection

Figure 12 CE Wiring part 2

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

10 Reapply AC power to the actuator.

11 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.

Burner Control/Flame Safety

Electrical Installation

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 23

7/08

Output Signal Connections

0/4-20 mA, 0/1-5 Vdc Feedback Signal Connections

ATTENTION

Shielded and grounded cables are recommended.

Actuator output 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.

+–

1 2 3 4 5 6 7 8 9 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

11 22 33 44 55 66 77 88 99 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

11 22 33

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

Typical Flame

Safety Module

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

1 2 3 4 5 6 7 8 9 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

11 22 33 44 55 66 77 88 99 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

11 22 33

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

Typical Flame

Safety Module

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

1 2 3 4 5 6 7 8 9 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

11 22 33 44 55 66 77 88 99 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

11 22 33

+–

1 2 3 4 5 6 7 8 9 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

11 22 33 44 55 66 77 88 99 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

11 22 33

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

Typical Flame

Safety Module

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

1 2 3 4 5 6 7 8 9 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

11 22 33 44 55 66 77 88 99 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

Typical Flame

Safety Module

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

1 2 3 4 5 6 7 8 9 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

11 22 33 44 55 66 77 88 99 10

HercuLine TB3

Add Jumper

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

+–

11 22 33

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

Typical Flame

Safety Module

To TB3 #10

To TB3 #5

•

Modulate

High Fire

Common

Low Filter

Figure 13 Burner Control/Flame Safety Wiring

Burner Control/Flame Safety

Series 90 Control – HercuLine® 2001 model only

24 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Series 90 Control – HercuLine® 2001 model only

Series 90 Controls are commonly used in building environmental systems and 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

4-20mA output

4-20mA input

White

Red

Blue

TB3

Figure 14 Series 90 connections

Considerations

1. 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.

2. 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.

Burner Control/Flame Safety

Series 90 Control – HercuLine® 2001 model only

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 25

7/08

GND to

HercuLine2001 (2)

uto

Man

I out from

HercuLine2001

+ Signal to

HercuLine2001

T775 B 3

T775 W 1

T775 R 2

Figure 15 T775 Controller connections

3. 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.

Burner Control/Flame Safety

Split Range

26 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Split Range

The HercuLine® 2001/2002 actuators can be set up to operate within a narrow input range (for example,

4 to 12mA input) in certain applications. The 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.

1 Enter Set Up mode by pressing SET UP key

2 Select SET INPUT group

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

4 Set INP HI value to 50.0

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

6 Press DISPLAY key to exit Set Up mode.

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

1 Enter Set Up mode by pressing SET UP key

2 Select SET INPUT group

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

4 Set INP HI value to 100.0

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

6 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.

Burner Control/Flame Safety

Master/Slave Arrangement

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 27

7/08

Basic Flow Control

When the process variable signal is below set point, the controller increases current (4 to 20mA) to the

actuator input and opens the valve. Controller set point governs valve position to obtain desired flow

rate.

SP 4 to 20 mA

Controller

Positioner & Actuator

Linkage

Position

Valve

Orifice Plate

FIC MP

Figure 16 Flow Diagram

Hot

Actuator

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Current Output Controller

4 to 20 mA

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.

Jumper W2

= Current

See Figure

27 for jumper

location

Burner Control/Flame Safety

Master/Slave Arrangement

28 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Proportional

with Bias

Ratio

Position

SP 4 to 20 mA

Controller

Positioner & Actuator

Linkage Valve

Orifice Plate

FIC

Linkage

Valve

Figure 18 Proportional Flow Using Multiple Actuators

Hot

10260S Series Actuator #1

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Current Output Controller

4 to 20 mA

Hot

10260S Series Actuator #2

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Hot

10260S Series Actuator #3

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Preferred

Wiring

Note: Controller must

be capable of sourcing

the impedance.

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

Actuator #1

Actuator #2

Actuator #3

Jumper W2

= Current

Jumper W2

= Current

Jumper W2

= Current

See Figure

27 for jumper

location

Burner Control/Flame Safety

Master/Slave Arrangement

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 29

7/08

Hot

10260S Series Actuator #1

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Current Output Controller

4 to 20 mA

Hot

10260S Series Actuator #2

Neutral

Ground

120/240

VAC

Hot

10260S Series Actuator #3

Neutral

Ground

120/240

VAC

Alternate

Wiring

Figure 19 Multiple Actuator Interconnection Diagrams

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

Actuator #1

Actuator #2

Actuator #3

Jumper W2

= Current

Jumper W2

= Voltage

Jumper W2

= Voltage

See Figure

27 for jumper

location

Burner Control/Flame Safety

Master/Slave Arrangement

30 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Split Valve Configuration

A common heat or cool type process requires two valves. In this case the controller has only one output.

The two motor 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.

Hot

10260S Series Actuator #1

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Current Output Controller

4 to 20 mA

Hot

10260S Series Actuator #2

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Preferred

Wiring

Note: Controller must

be capable of sourcing

the impedance.

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

Hot

10260S Series Actuator #1

Neutral

Ground

120/240

VAC

250 Ohms

1 to 5 VDC

Current Output Controller

4 to 20 mA

Hot

10260S Series Actuator #2

Neutral

Ground

120/240

VAC

Alternate

Wiring

Figure 20 Interconnection Diagrams

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

Actuator #1

Actuator #2

Actuator #1

Actuator #2

Jumper W2

= Current

Jumper W2

= Current

Jumper W2

= Current

Jumper W2

= Voltage

See Figure

27 for jumper

location

See Figure

27 for jumper

location

Set Up and Calibration Procedures

Overview

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 31

7/08

Set Up and Calibration Procedures

Overview

Once you have installed the actuator, you can verify, set or change certain operating parameters. Set up is

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.

DISPLAY

MAN/AUTO

FUNCTIONSET UP

STALLED

ALARM

MANUAL

AUTO

Upper Display

(Four Characters)

Lower Display

(Six Characters)

Figure 21 HercuLine® 2000 Display and Keypad

Set Up and Calibration Procedures

Local Display and Keypad

32 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Table 6 Keypad Description

Key or

LED Indicator Function

SET UP Places the actuator in the set up group select mode. Sequentially displays 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.

Set Up and Calibration Procedures

Set Up Tips

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 33

7/08

Set Up Tips

Table 7 contains tips that will help you view, verify and enter the operating parameters more quickly. If

you cannot change the parameters, 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

through the set up groups twice as fast using the or key. When in

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

significant digit in the upper display by holding in one key or and

pressing the other or 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.

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.

Set Up and Calibration Procedures

Set Up Groups

34 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Set Up Groups

Pressing the SET UP key on the keypad provides access to the various set up groups and allows you to set

up operating parameters, (such as 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

SET

RELAYn

n = 1, 2, 3, or 4

Select relay functions. NOTE: Set Relay groups will

show on display only if relays are installed in the

actuator.

Table 13

SET

CUROUT

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

CAL

INPUT

Calibrate input zero and span values.

Calibration

Procedure,

Table 25

CAL

MOTOR

Calibrate zero and span values for motor operation.

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.

Calibration

Procedure,

Table 26

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

Set Up and Calibration Procedures

Set Up Groups

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 35

7/08

SET

MAINT

Display various operating statistics. Reset

accumulated operating statistics

Table 22

CAL

POSOUT Use the display as an indicator, (in this case a

voltmeter) so you can verify that the position sensor is

operating properly.

Table 23

Set Up and Calibration Procedures

Set Up Procedure

36 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Set Up Procedure

Each of the set up groups and their functions are either pre-configured at the factory or set to their default

values. Tables 8 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 Result

1 Enter Set Up Mode SET UP

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.

2 Select any Set Up

Group

SET UP Successive presses of the SET UP key will display the other set

up group titles as listed in Table 8Error! Reference source not

found..

You can also use the or keys to scroll through the set up

groups in both directions.

Stop at the set up group title that describes the group of

parameters you want to configure. Then proceed to the next

step.

3 Select a Function

Parameter

FUNCTION Upper Display

4-20 Shows the current value or selection for the

function prompt in the selected set up group.

IN TYP

Lower Display

Shows the first function prompt within the selected

set up group.

Example display shows Input group function prompt “IN TYP”

and the selection.

4 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.

Set Up and Calibration Procedures

Set Up Procedure

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 37

7/08

Step Operation Press Result

5 Change the Value

or Selection

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).

6 Enter Value or

Selection

FUNCTION

SET UP

This key selects another function prompt.

This key selects another set up group.

NOTE: Pressing either key will cause the previously selected

value or selection to be entered into memory.

7 Exit Set Up mode DISPLAY Exits set up 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.

Set Up and Calibration Procedures

Configuration Prompt Hierarchy

38 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Configuration Prompt Hierarchy

TEMP TEMPHI TEMPLO ACSTAL STARTS RL1CNT

RL2CNT RL3CNT RL4CNT REGN0 REGN9 TOTDEG

DATSAV PASSWD MANRST LD CAL LD CFG RESTRT

…

VERSON SPEED POWER ROTATE TAG MFGDAT

LREP LCAL REPTYP

CUROUT

COMM ADDRES BAUD XmtDLY DBLBYT

DIGINP EndPos

DECMAL EUNITS UNITS

LOCKID LOCK MAENAB

FAILSF RAMTST SEETST CFGTST CALTST

RTYPny Rny VAL Rny E* Rny HL RTYPny Rny VAL Rny E*

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

RELAYn

IN TYP INP HI INP LO FILTYP Direct Dband FSTYPH

CHAR CUSTOM X0 VAL X20 VAL

Y0 VAL

…

Y20 VAL

…

FsVALH

FSTYPL FsVALL

MAINT

DRVINF

STATUS

LOCK

DISPLA

DIGINP

COMM

INPUT

CUROUT

Setup Groups Function Prompts

TEMP TEMPHI TEMPLO ACSTAL STARTS RL1CNT

RL2CNT RL3CNT RL4CNT REGN0 REGN9 TOTDEG

DATSAV PASSWD MANRST LD CAL LD CFG RESTRT

…

TEMP TEMPHI TEMPLO ACSTAL STARTS RL1CNT

RL2CNT RL3CNT RL4CNT REGN0 REGN9 TOTDEG

DATSAV PASSWD MANRST LD CAL LD CFG RESTRT

…

VERSON SPEED POWER ROTATE TAG MFGDAT

LREP LCAL REPTYP

VERSON SPEED POWER ROTATE TAG MFGDAT

LREP LCAL REPTYP

CUROUT

COMM ADDRES BAUD XmtDLY DBLBYT

DIGINP EndPos

DECMAL EUNITS UNITS

LOCKID LOCK MAENAB

FAILSF RAMTST SEETST CFGTST CALTST

RTYPny Rny VAL Rny E* Rny HL RTYPny Rny VAL Rny E*

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

RELAYn

IN TYP INP HI INP LO FILTYP Direct Dband FSTYPH

CHAR CUSTOM X0 VAL X20 VAL

Y0 VAL

…

Y20 VAL

…

FsVALH

FSTYPL FsVALL

MAINT

DRVINF

STATUS

LOCK

DISPLA

DIGINP

COMM

INPUT

CUROUT

Setup Groups Function Prompts

Set Up and Calibration Procedures

Input Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 39

7/08

Input Set Up Group

Table 10 lists the parameters and selections available when the SET INPUT group is selected.

On the keypad and local display:

• 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 or keys to view selections or change range settings.

Table 10 Input Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink Prompt

IN TYP

Note: If input

type from model

selection guide

is:

0/4-20mA, 0/1-

5Vdc, 0-10Vdc

4-20

0-20

1-5V

0-5V

0-10

R_SP

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.

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

INPUT HIGH RANGE VALUE in % is displayed.

NOTE: When Input Type (R_SP or S_90) is selected, Input

Hi is not configurable.

INP LO 0.0 to 90.0

default = 0.0

INPUT LOW RANGE VALUE in % is displayed.

NOTE: When Input Type (R_SP or S_90) is selected, Input

Hi is not configurable.

Set Up and Calibration Procedures

Input Set Up Group

40 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink Prompt

FILTYP NONE

SPIK

S+LP

LPAS

default = LPAS

INPUT FILTER TYPE— Allows the selection of a software

digital input filter to smooth the input signal.

Spike— Selects spike filter to remove transients in the input

signal when actuator is installed in noisy environments.

Spike plus Low Pass— Selects spike and low pass filtering.

* Allows setting of lag time constant for low pass filter.

Low Pass— Selects low pass filter.

* Allows setting of lag time constant.

NOTE: When Input Type (R_SP or S_90) is selected, Input

Filter Type = NONE.

LPFILT * 0 to 50.00

(in seconds)

default = 0.5

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.

NOTE: When Input Type (R_SP or S_90) is selected, Low

Pass Filter Value is not configurable.

Direct CCW

default = CCW

ACTUATOR ROTATION—This selection determines the

direction of rotation of the actuator shaft.

Counterclockwise rotation

Clockwise rotation

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.

Dband 0.2 to 5.0

(in percent of

span)

default = 0.5

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.

FSFTYPH

LAST

DOWN

USER

default = UP

FAILSAFEHI TYPE—Selects the motor position you want

the actuator to go to when input signal is above the high end

range value.

NOTE: Failsafe condition occurs when the input exceeds its

high end range value by 3%,

Last Position—Actuator motor remains at last position.

Up—Actuator motor moves to full scale value.

Down—Actuator motor moves to zero value.

User selected value—Actuator motor moves to a customer-

defined value.

* Allows setting of failsafehi input value.

FsFVALH *

0 to 100%

default = 100

FAILSAFEHI INPUT VALUE—(FailsafeHI Type USER only)

Selects the motor position you want the actuator to go to

when input signal is above the high end range value.

Range is from 0 to 100%.

Set Up and Calibration Procedures

Input Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 41

7/08

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink Prompt

FSFTYPL

LAST

DOWN

USER

default = DOWN

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.

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 Position—Actuator motor remains at last position.

Up—Actuator motor moves to full scale value.

Down—Actuator motor moves to zero value.

User selected value—Actuator motor moves to a customer-

defined value.

* Allows setting of failsafelo input value.

FsFVALL *

0 to 100%

default = 0

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

default = LINR

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.

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

n = 1 - 20

0 to 100 % Input Value— as a percentage of input range. Defaults are

in increments of 5%.

Yn VAL

n = 1 - 20

0 to 100 % Shaft Position Value— as a percentage of position range.

Defaults are in increments of 5%.

Set Up and Calibration Procedures

Input Set Up Group

42 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

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

Order Xn VAL

% of

Range

Yn Val

% of

Range

Equal Percentage Valve Characterization

0 0 0

1 5 0.8

2 10 2.1

3 15 3.2

4 20 4.9

5 25 6.5

6 30 8.4

7 35 10.7

8 40 13.2

9 45 15.7

10 50 18.7

11 55 22.6

12 60 27.2

13 65 33.4

14 70 40

15 75 46

16 80 53.8

17 85 63.2

18 90 73.7

19 95 86.2

20 100 100

10 20 30 40 50 60 70 80 90 100

Xn VAL - Actual Input

100

Yn VAL - Characterized Output

Set Up and Calibration Procedures

Input Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 43

7/08

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

Order Xn VAL

% of

Range

Yn Val

% of

Range

Quick Opening Valve Characteristic

0 0 0

1 5 10

2 10 20

3 15 30

4 20 40

5 25 50

6 30 60

7 35 70

8 40 77

9 45 82

10 50 86

11 55 88

12 60 90

13 65 92

14 70 94

15 75 95

16 80 96

17 85 97.5

18 90 98.5

19 95 99.5

20 100 100

Xn VAL - Actual Input

10 20 30 40 50 60 70 80 90 100

100

Yn VAL - Characterized Output

Set Up and Calibration Procedures

Relays Set Up Group

44 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Relays Set Up Group

ATTENTION

The Relay set up group parameters are accessible only if relay PWAs are installed in the

actuator. HercuLine® 2001 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

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink® Prompt

RTYPny

n = 1, 2, 3, or 4

y = 1 or 2

NONE

InPR

PosR

DEV

ULim

LLim

T Hi

T Lo

STRT

STAL

MAN

PWRF

FsFA

PosF

DiGI

TDEG

default = InPR and

NONE

RELAY TYPE— Selects the relay number and the relay

activation type. See Table 14 Relay Type Descriptions.

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

Total Degrees— total degrees traveled. Allows setting of

multiplier value.

RnyE* X1

X10k

default = X1

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).

RnyVAL

n = 1, 2, 3, or 4

y = 1 or 2

0.0 to 100.0 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.

Rny HL

n = 1, 2, 3, or 4

y = 1 or 2

LO RELAY HIGH/LOW— Sets relay trip point to high or low

limit.

RLYnHY

n = 1, 2, 3, or 4 0.0 to 100.0

(in percent) 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.

Set Up and Calibration Procedures

Relays Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 45

7/08

Table 14 Relay Type Descriptions

When this Relay Type is

selected…

(RTYP)

The Relay can be set up to indicate …

Input Range The upper / lower 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.)

Temperature Low 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 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.

Set Up and Calibration Procedures

Relays Set Up Group

46 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Relay connector #1

Relay connector #2

Relay connector #3

Relay connector #4

Figure 22 Relay connectors

Relay Examples

Relay Type - Position Range

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 Parameter Value

SET RELAY1 RTYP11 PosR

R11VAL 80.0

R11HL HI

RTYP12 PosR

R12VAL 20.0

R12HL LO

RLY1HY 0.0

The figure below shows the resulting action.

100%

Closed

20% 80%

RELAY 1

Normally Open

Closed

Open

Motor

Position

Set Up and Calibration Procedures

Relays Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 47

7/08

Relay Type - Deviation

Setting up a relay to alarm (energize) when the motor position deviates 10% (+ or -) from the actuator

setpoint can be set up as follows.

Set Up Group Parameter Value

SET RELAY1 RTYP11 DEV

R11VAL 10.00

R11HL HI

RTYP12 DEV

R12VAL -10.00

R12HL LO

RLY1HY 0.0

The resulting action is shown below.

100%

Closed

-10%

RELAY n

Normally Open

Closed

Open

Motor

Position

Input

50%

+10%

Set Up and Calibration Procedures

Relays Set Up Group

48 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Relay Type – Upper Limit Travel with Hysteresis

Selecting relay type ULim will cause the relay to energize when the motor position exceeds the upper limit

trip point, and can be set up as follows. Note that relay hysteresis parameter (RLY1HY) value is set to 10,

which is 10% of range. This means that when the relay is energized, due to the motor position exceeding

the upper limit value, the relay will not de-energize until the motor moves to 10% below the trip point.

Set Up Group Parameter Value

SET RELAY2 RTYP21 ULim

R21VAL 70.0

R21HL HI

RTYP22 NONE

RLY2HY 10.0

100%

Closed

70%

RELAY n

Normally Open

Motor

Position

60%

100%

Closed

70%

RELAY n

Normally Open

Open

Motor

Position

60%H

Open

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 Parameter Value

SET RELAY1 RTYP11 STRT

R11 E* X10K

R11VAL 20

R11HL HI

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.

Set Up and Calibration Procedures

Current Out Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 49

7/08

Current Out Set Up Group

Table 15 lists the parameters and selections available for the SET CUROUT group.

Table 15 Current Out Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink Prompt

CUROUT

Note: If output

type from model

selection guide

is:

0/4-20mA, 0/1-

5Vdc

4 – 20

0 – 20

1 – 5V

0 – 5V

OUTPUT SIGNAL RANGE— Selects the signal output

range.

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

Note: If output

type from model

selection guide

is:

Slidewire

Emulation

SW E Slidewire Emulation

CUROUT

Note: If output

type from model

selection guide

is:

None

NONE No current output configured.

Set Up and Calibration Procedures

Communications Set Up Group

50 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Communications Set Up Group

Table 16 lists the parameters and selections available for the SET COMM group.

Table 16 Communications Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink Prompt

COMM

DIS

MODB

HART

COMMUNICATONS PARAMETERS— Disables or enables

parameter displays for Modbus communciations set up.

Disabled— Locks out access to communications displays

and parameters.

Modbus— Allows access to the communication displays

and settings for the parameters listed below.

HART – selects HART as the communications protocol

ADDRES 1 to 99

default = 1

DEVICE ADDRESS— Selects device address when used in

a Modbus communications loop. Select an address that is

unique to other devices on the communications link.

BAUD 2400

4800

9600

19.2k

default = 19.2k

BAUD RATE— Selects the speed of data transfer. All

equipment on the link must be set to match the host setting.

XmtDLY NONE

10ms

20ms

30ms

40ms

50ms

default = 20ms

RESPONSE DELAY— Selects the time delay (in

milliseconds) before a response to a query is transmitted.

DBLBYT

FP B

FPBB

FP L

FPLB

default = FP B

FLOATING POINT DATA FORMAT— Selects the format for

transferring floating point data.

Byte Order

Floating Point Big Endian format— 0 1 2 3

Floating Point Big Endian format

with byte-swapped— 1 0 3 2

Floating Point Little Endian format— 3 2 1 0

Floating Point Little Endian format

with byte-swapped— 2 3 0 1

Set Up and Calibration Procedures

Digital Input Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 51

7/08

Digital Input Set Up Group

Table 17 lists the parameters and selections availible for the SET DIGINP group.

Table 17 Digital Input Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink® Prompt

DIGINP

NONE

DOWN

USER

default = UP

Digital Input State— Selects the position of the actuator in

response to a digital input signal (contact closure).

None— No action by the actuator.

Up— Actuator motor moves to full scale value.

Down— Actuator motor moves to zero value.

User selected value— Actuator motor moves to a

customer-selected value.

* Allows setting of End Position Value.

EndPos 0 – 100

(in percent) END POSITION VALUE— (DIGINP USER only) Selects the

motor position you want the actuator to go to when digital

input signal present (contact closure).

Set Up and Calibration Procedures

Display Set Up Group

52 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Display Set Up Group

Table 18 lists the parameters and selections availible for the SET DISPLAY group.

Table 18 Display Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink® Prompt

DECMAL

8888

888.8

default = 8888

DECIMAL POINT LOCATION— This selection determines

where the decimal point appears in the display.

None

One Place

Note: Be sure the selection agrees with the value to be

displayed. If display value requires 4 whole digits, the

decimal will not show.

EUNITS

PCNT

DEG

default = PCNT

UNITS DISPLAY— Selects the units of the position display.

Percent— Shows actuator position as a percentage of span.

(0 to 100%)

Degrees— Shows the actuator position in degrees of

rotation. (0 to 150°) (90°)

UNITS

ENGL

default = ENGL

DISPLAY UNITS— Selects standard for unit values for the

local display.

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)

Set Up and Calibration Procedures

Lock Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 53

7/08

Lock Set Up Group

Table 19 lists the parameters and selections available for the SET LOCK group.

Table 19 Lock Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink® Prompt

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

NONE

CAL

CONF

FULL

default = NONE

LOCK OUT FEATURE— Selects lockout security for

calibration and supervisory functions, and set up groups.

None— No lockout of any calibration or set up groups. You

select and change set up group values, and perform field

calibration.

Calibration— Lockout for calibration groups SET CALINP,

SET CALMTR, SET CALOUT and CAL POSOUT only. You

can select and change set up group values.

Configuration— Lockout for calibration groups and set up

group configuration. You can only scroll through and view

set up group values.

Full— Lockout for calibration and all set up group values.

Only SET LOCK and READ STATUS groups are accessible.

MAENAB

DIS

ENAB

default = ENAB

Manual / Auto— Allows the ability to lockout mode changes

from the front panel.

Disabled— Disables the front panel auto / manual switch

functionality.

Enabled— Enables the front panel auto / manual switch

functionality.

Set Up and Calibration Procedures

Lock Set Up Group

54 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

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

1 Press SET UP key until the display reads SET LOCK.

2 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.

3 Press the FUNCTION key until the lower display reads LOCKID.

4 The upper display will show 0 (zero). Use the or keys to increment the number to the

correct password. See NOTE below on use of keys.

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.

5 Press the FUNCTION key, the lower display should read LOCK. The upper display should not

be flashing. If it is repeat steps 3 & 4.

6 Use the or 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 Press the FUNCTION key until the lower display reads LOCKID.

8 The upper display will show 0 (zero). Use the or keys to increment the number to the

new password. See NOTE below on use of keys.

9 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 or and pressing the other or 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.

Set Up and Calibration Procedures

Read Status Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 55

7/08

Read Status Set Up Group

Table 20 lists the parameters and selections available for the READ STATUS group.

Table 20 Read Status Set Up Group Parameters

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink® Prompt

FAILSF

YES

FAILSAFE— Read Only. Shows whether actuator in

failsafe.

No— Actuator not in failsafe.

Yes— Actuator in failsafe, see

Troubleshooting (page 105)

RAMTST

PASS

FAIL

RAM TEST DIAGNOSTIC— Read Only. Shows status of

RAM test diagnostic.

Pass— Test passed, no errors

Fail— Test failed, see see

Troubleshooting (page 105)

SEETST

PASS

FAIL

SERIAL EEPROM TEST DIAGNOSTIC— Read Only.

Shows status of serial electrically eraseable PROM test

diagnostic.

Pass— Test passed, no errors

Fail— Test failed, see

Troubleshooting (page 105)

CFGTST

PASS

FAIL

CONFIGURATION TEST DIAGNOSTIC— Read Only.

Shows status of Configuration test diagnostic.

Pass— Test passed, no errors

Fail— Test failed, see

Troubleshooting (page 105)

CALTST

PASS

FAIL

CALIBRATION TEST DIAGNOSTIC— Read Only. Shows

status of Calibration test diagnostic.

Pass— Test passed, no errors

Fail— Test failed, see

Troubleshooting (page 105)

Set Up and Calibration Procedures

Drive Set Up Group

56 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Drive Set Up Group

Table 21 lists the parameters and selections available for the SET DRVINF group.

Table 21 Drive Set Up Group Parameters

Actuator 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

(150° @ 60hz)

6 S

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.

SPEED

(90° @ 60hz)

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.

SPEED

(150° @ 50hz)

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.

SPEED

(90° @ 50hz)

4.5 S

9 S

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.

POWER

1206

1205

2206

2205

POWER INPUT VOLTAGE AND FREQUENCY— Read

Only. Selects the power input voltage and line frequency of

the actuator.

1206— 120Volts, 60Hz

1205— 120Volts, 50Hz

2206— 220Volts, 60Hz

2205— 220Volts, 50Hz

ROTATE

150

ROTATION— Indicates the factory calibrated degrees of

rotation.

90— Factory calibrated for 90 degrees of rotation.

150— Factory calibrated for 150 degrees of rotation.

TAG nnnnnn TAG NAME— Selects the tag name or identifier of the

actuator. Up to 6 alphanumeric characters. See “Set Tag

Name” on next page.

DMFG mmddyy *

ddmmyy

MANUFACTURING DATE— Read Only. Displays date

code of manufacture for actuator.

Set Up and Calibration Procedures

Drive Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 57

7/08

Actuator Lower

Display

Prompt

Selections or

Range of Setting Parameter Definition/PDA HercuLink® Prompt

LREP mmddyy *

ddmmyy

DATE OF LAST REPAIR— Factory set only. Displays date

of last repair.

LCAL mmddyy *

ddmmyy

DATE OF LAST FACTORY CALIBRATION— Factory set

only. Displays date of last factory calibration

REPTYP

NONE

REPAIR TYPE— Factory set only. Displays a repair code to

identify the type of repair service previously performed.

None

Future

Non-contact Sensor

Main CPU PWA repair

Motor service

Power Distribution PWA service

Switch repair

Relay service

Gear 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.

Set Up and Calibration Procedures

Drive Set Up Group

58 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Set Tag Name

The actuator tag name can be an alphanumeric name up to six characters. The tag name is set by using the

keys on the keypad and the local display. Follow the steps below to set the tag name.

Step Action

1 Press SET UP key until the display reads SET DRVINF.

2 Press the FUNCTION key until the upper display reads TAG.

3 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.

4 Set the digit to the left of the flashing decimal point. Use the or keys to scroll through

the character set of 0 through 9, the letters ‘a’ through ‘z’ and the letters ‘A’ through ‘Z’ . Scroll

through until the desired character is displayed.

5 Wait for the decimal point to shift to the right and then scroll through using the or keys

until the next character is displayed.

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

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

Set Up and Calibration Procedures

Maintenance Set Up Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 59

7/08

Maintenance Set Up Group

The Maintenance set up group consists of information about actuator operation accumulated through time.

This 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

Actuator Lower

Display

Prompt

Selections or

Range of Setting 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.

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

displayed value times 105 to get actual value. Range is 0 to

999,900,000.

RLnCNT

n = 1, 2, 3 or 4

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

displayed value times 105 to get actual value. Range is 0 to

999,900,000.

REGNn

n = 0 to 9

nnnn ACCUMULATED MOTOR STARTS— Displays the

accumulated motor starts in the 1st 10% of motor span since

it was last reset. See

Regions of Motor Travel (page 62). Multiply displayed value

times 105 to get actual value. Range is 0 to 999,900,000.

TOTDEG nnnn TOTAL DEGREES OF MOTOR TRAVEL— Displays the

total number of degrees of motor travel since it was last

reset. Multiply displayed value times 105 to get actual value.

Range is 0 to 999,900,000.

Set Up and Calibration Procedures

Maintenance Set Up Group

60 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Actuator Lower

Display

Prompt

Selections or

Range of Setting 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.

DATSAV

DIS

ENAB

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 4-

digit password is required to enable any of the functions

below.

NOTE: Password is set (or changed) from the Lock set up

group.

MANRST

NONE

STAL

STRT

REGNn

n = 0 to 9

TEMP

TDEG

RELn

n = 1, 2, 3 or 4

ALL

SYST

default = NONE

MAINTENANCE STATISTIC RESET— Allows reset of the

following maintenance statistics:

None— No reset of maintenance statisitics

Stall— Resets accumulated stall time to zero.

Motor Starts— Resets the accumulated motor start counter

to zero.

Motor Starts in the Region— Resets the selected motor

span region counter to zero.

Temperature Statistics— Resets the high / low

temperature limit statistics.

Total Degrees— Resets the total degrees of motor travel to

zero.

Relay Counts— Resets the selected accumulated relay

cycle counter to zero.

All— Resets all maintenance statistics to zero.

SYST— Enables the system restart function.

Set Up and Calibration Procedures

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 61

7/08

Actuator Lower

Display

Prompt

Selections or

Range of Setting 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.

LD CAL NONE

INP

MTR

COUT

ALL

POS

default = NONE

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.

Motor— Restores motor calibration to the factory calibration.

Output — Restores actuator output calibration to the factory

calibration for the current configured output type.

All — Restores input (for the type configured), motor and

output (for the type configured) calibration to the factory

calibration.

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”.

LD CFG DIS

ENAB

default = DIS

RESTORE DEFAULT FACTORY CONFIGURATION—

Allows you to restore the factory default configuration.

DIS — Restore disabled.

ENAB— Restore enabled.

RESTRT DIS

ENAB

default = DIS

SYSTEM RESTART— Allows you to force the system to

restart.

DIS — Restart disabled.

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.

Set Up and Calibration Procedures

Regions of Motor Travel

62 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Regions of Motor Travel

The full span of motor travel can be 90° or 150° rotation. The span is divided into 10 regions of motor

travel as 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.

Degrees of Rotation

Percent of Span

0o 30o 60o 90o

0% 20% 40% 60% 80% 100%

Region of Travel 0 1 2 3 4 5 6 7 8 9

rees of Rotation

Pe rc en t of S pa n

0o 30 o 60 o 150 o

0% 20% 4 0% 60% 8 0% 100%

Regio n of Trave l 0 1 2 3 4 5 6 7 8 9

Figure 23 Regions of Motor Travel

Set Up and Calibration Procedures

CAL POSOUT Group

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 63

7/08

CAL POSOUT Group

The CAL POSOUT group is used to verify that the position sensor is operating and adjusted properly. This

group allows the local 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 = CAL

Lower Display = POSOUT

FUNCTION Upper Display = DIS

Lower Display = CALPOS

or key

Upper Display = BEGN

Lower Display = CALPOS

FUNCTION

Upper Display = n.nnn (sensor output in volts)

Lower Display = POSOUT

Set Up and Calibration Procedures

Auto - Manual Drive Switch

64 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Auto - Manual Drive Switch

The Auto - Manual switch is located on the side of the actuator case below the handwheel. The switch

allows 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.

MANUAL

OFF CWCCW

OFF

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.

CW Actuator moves to the fully clockwise position.

OFF Actuator is idle.

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 65

7/08

Calibration

Calibration of the HercuLine® 2000 Series Actuator may consist of calibrating the motor circuit that

positions the actuator with 0/4-20mA 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 Equipment Needed

Input Calibration • 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.

Set Up and Calibration Procedures

Calibration

66 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Calibration Set up

Follow the steps below to set up the test equipment and actuator to verify calibration or perform calibration

procedures.

Step Action

1 Determine input type (current or voltage).

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

68 for jumper location.

3 Connect the copper leads from the signal source to the input terminals of the actuator as

shown in Figure 25.

4 Place signal source output at zero and switch power on.

5 Connect a 250 ohm resistor across the Output terminals of the actuator and connect the DVM

leads to the terminals.

Actuator

Input

5 4

Output

2 1

Calibrated

Signal

Source

Digital

Voltmeter

+ -

Terminal Block

Internal 250 ohm resistor

settable through

Jumper W2

Current

Voltage

250 ohm

resistor

(supplied)

Figure 25 Calibration Wiring Connections (non-slidewire emulation)

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 67

7/08

Actuator

Input

5 4

Output

2 1 3

Calibrated

Signal

Source

Digital

Voltmeter

+ -

Terminal Block

Power

Supply

1-18 VDC

+ -

Internal 250 ohm resistor

settable through

Jumper W2

Current

Voltage

Figure 26 Calibration Wiring Connections (slidewire emulation)

Set Up and Calibration Procedures

Calibration

68 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Jumper W2

Figure 27 Jumper Location on CPU PWA

Calibrate Input

The HercuLine® 2001/2002 actuator accepts a variety of signal inputs.

1. 0 to 20 mA, or 4 to 20 mA

2. 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.

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 69

7/08

Table 25 Input Calibration Procedure

Step Operation Press Result

1 Enter Calibration

Mode

SETUP

until you see

Upper Display = CAL

Lower Display = INPUT

FUNCTION Upper Display = DIS

Lower Display = CAL IN

or key

Upper Display = BEGN

Lower Display = CAL IN

2 Calibrate Zero (0%) FUNCTION Upper Display = APLY

Lower Display = INZERO

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

value.

• Wait 5 seconds, then go to step 3.

3 Calibrate Span

(100%)

FUNCTION Upper Display = APLY

Lower Display = INSPAN

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

range value.

• Wait 5 seconds, then go to step 4.

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.

Set Up and Calibration Procedures

Calibration

70 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Calibrate Motor

Use the procedure in Table 26 to calibrate the actuator motor for 0% and 100% input signal

ATTENTION

For a motor calibration to be saved, 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 Press Result

1 Enter Calibration

Mode

SETUP

until you see

Upper Display = CAL

Lower Display = MOTOR

FUNCTION Upper Display = DIS

Lower Display = CALMTR

or key Upper Display = BEGN

Lower Display = CALMTR

2 Calibrate Zero (0%) FUNCTION Upper Display = APLY

Lower Display = MTR LO

• Use the Handwheeel or AUTO/MANUAL switch to manually

drive the actuator motor to its low position.

• Wait 5 seconds, then go to step 3.

3 Calibrate Span

(100%)

FUNCTION Upper Display = APLY

Lower Display = MTR HI

• Use the Handwheeel or AUTO/MANUAL switch to manually

drive the actuator motor to its high position.

• Wait 5 seconds, then go to step 4.

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.

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 71

7/08

Calibrate Output

HercuLine® 2001/2002 actuator can be one of three output types:

1. 0 to 20 mA, or 4 to 20 mA output

2. 0 to 5 Volts, or 1 to 5 Volts with 250 ohm range resistor

3. 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 Press Result

1 Enter Calibration

Mode

SETUP

until you see

Upper Display = CAL

Lower Display = CUR OUT

FUNCTION Upper Display = DIS

Lower Display = CALOUT

or key Upper Display = BEGN

Lower Display = CALOUT

Set Up and Calibration Procedures

Calibration

72 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Step Operation Press Result

2 Calibrate Zero (0%) FUNCTION Upper Display = xxx

Lower Display = ZERO

• Read meter connected to actuator output.

or key • 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.

3 Calibrate Span

(100%)

FUNCTION Upper Display = xxxx

Lower Display = SPAN

• Read meter connected to actuator output.

or 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.

4 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.

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 73

7/08

Table 28 Slidewire Emulation Calibration Procedure

Step Operation Press Result

1 Enter Calibration

Mode

SETUP

until you see

Upper Display = CAL

Lower Display = OUTPUT

FUNCTION Upper Display = DIS

Lower Display = CALOUT

or key Upper Display = BEGN

Lower Display = CALOUT

2 Calibrate Zero (0%) FUNCTION Upper Display = xxx

Lower Display = ZERO

xxx = arbitrary number assigned by software

or key 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

3 Calibrate Span

(100%)

FUNCTION Upper Display = xxxx

Lower Display = SPAN

xxx = arbitrary number assigned by software

or key Adjust actuator output voltage using key until value on DVM

ceases to change, then press down key until value on DVM

moves down one digit

FUNCTION 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.

Set Up and Calibration Procedures

Calibration

74 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

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

Table 29 NCS Position Sensor Calibration Procedure

Step Action

1 Remove AC power to the actuator.

2 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.

3 Reapply AC power to the actuator.

4 Press SET UP key to access the INPUT set up group.

Press FUNCTION key until the lower display reads Direct.

Press the or 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.

5 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.

6 Press SET UP key until the display reads CAL POSOUT.

Press the FUNCTION key until the dispaly reads DIS CALPOS.

Press the or keys until the lower display reads BEGN CALPOS.

Press FUNCTION key.

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

7 Loosen the allen screw in the hub of the NCS spoiler just enough to be able to rotate the

spoiler. See Figure 28.

8 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.

9 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.

10 Press DISPLAY key to exit calibration mode.

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

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

13 Continue with calibration procedure in Table 31.

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 75

7/08

NCS Spoiler (shown at full

150 degree travel CCW)

NCS PWA

NCS set

screw

Relay PWA card

guides (relay

PWAs removed)

Figure 28 Location of NCS Assembly

Set Up and Calibration Procedures

Calibration

76 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Table 30 Potentiometer Position Sensor Calibration Procedure

Step Action

1 Remove AC power to the actuator.

2 Remove the six screws and the top cover from the actuator case. See Figure 2.

Lay extended cover assembly on a flat surface. Remove relay cards if present.

3 Reapply AC power to the actuator.

4 Press SET UP key to access the INPUT set up group.

Press FUNCTION key until the lower display reads Direct.

Press the or 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.

5 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.

6 Press SET UP key until the display reads CAL POSOUT.

Press the FUNCTION key until the dispaly reads DIS CALPOS.

Press the or keys until the lower display reads BEGN CALPOS.

Press FUNCTION key.

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

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

the shaft.

8 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.

9 Tighten set screw with an allen wrench.

10 Press DISPLAY key to exit calibration mode.

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

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

13 Continue with calibration procedure in Table 31.

Set Up and Calibration Procedures

Calibration

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 77

7/08

Potentiometer position sensor Mounting bracket

Figure 29 Location of potentiometer position sensor

Table 31 Load Position Sensor Factory Calibration

Step Action

1 Reapply AC power to the actuator.

2 Press SET UP key to access the MAINT set up group. Press the FUNCTION key until the

display reads LD CAL.

Press the or keys until the display reads POS.

3 Perform the Calibrate Motor procedure exactly as in Table 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.

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

the actuator motor.

Set Up and Calibration Procedures

Setting End-of-Travel Limit Switches

78 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Setting End-of-Travel Limit Switches

ATTENTION

Referring to Figure 31. The first two cams (starting from the front) are for the 0% 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.

100%

8 (SW1 COM) 9 (SW2 COM)

155

SW#1

SW#2

LEFT HAND

POINTER

SCALE

END OF TR

VEL LIMIT SWITCH S ETTINGS

(FACTORY SET AT 0% AND 100%)

Clockwise and counterclockwise rotation is the direction of the output shaft

when facing the end of the shaft. As shown, clockwise rotation of the output

shaft activates SW 1 (at 0% on 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.

Clockwise Rotation

Counterclockwise Rotation

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.

Clockwise and counterclockwise rotation is the direction of the output shaft when

facing the end of the shaft. As shown, full clockwise rotation of the output shaft

activates SW1 and CCW rotation activates SW2.

Set Up and Calibration Procedures

Setting End-of-Travel Limit Switches

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 79

7/08

Table 32 End-of-Travel Limit Switch Setting Procedure

Step Action

1 Remove AC power to the actuator.

2 Remove the six screws and the cover from the actuator case. See Figure 2. Lay cover

assembly on a flat surface.

3 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).

4 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.

Set Up and Calibration Procedures

Setting End-of-Travel Limit Switches

80 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

ATTENTION

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

Relay #1

Relay #2

Relay #3

Relay #4

Aux switch #1

Aux switch #2

Aux switch #3

ux switch #4

End of travel switch #1

(stops CW rotation)

End of travel switch #2

(stops CCW rotation)

Relay PWAs

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

Set Up and Calibration Procedures

Setting Auxiliary Switches

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 81

7/08

Setting Auxiliary Switches

ATTENTION

Referring to Figure 31. The first two cams (starting from the front) are for the 0% and

100% end of 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.

SW #3

SW #4

100%

20 (SW4 COM)

LEFT HAND

POINTER SCALE

SW #5

SW #6

23 (SW5 COM)

(SW 6 COM) 26

17 (SW3 COM)

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.

Set Up and Calibration Procedures

Setting Auxiliary Switches

82 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Table 33 Auxiliary Switch Setting Procedure

Step Action

1 Remove AC power to the actuator.

2 Remove the six screws and the cover from the actuator case. See Figure 2. Lay cover

assembly on a flat surface.

3 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.

4 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.

5 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.

6 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.

Start-Up/Operation

Introduction

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 83

7/08

Start-Up/Operation

Introduction

After the actuator is completely installed, wired, and the preliminary adjustments made, it is advisable to check

the operation of the 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.

Start-Up/Operation

Operating Displays

84 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Operating Displays

Pressing the DISPLAY key cycles the display through a number of operating parameters. Table 34 shows a

number of sample displays that can be shown during operation.

Table 34 Typical Operating Displays

Display Description

0.0

INP

Input— Upper Display = Shows input value

Lower Display = prompt

OP 0.5

Output— Upper Display = Shows input value

Lower Display = Shows output value

100.0

DE 99.9

Deviation— Upper Display = Shows input value

Lower Display = Shows value of deviation of

sensor from input.

0.6

POS

Position— Upper Display = Shows value of position sensor.

Lower Display = prompt

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

NOTE: When the AUTO/MANUAL key is pressed, placing the 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.”

Start-Up/Operation

Position Sensor Operation

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 85

7/08

Position Sensor Operation

On HercuLine® 2000 and HercuLine® 2001 the potentiometer position sensor is a sealed film pot that is directly

coupled to the 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

1 Drive the motor to 50% position.

2 Press SET UP key on the keyboard until the display reads CAL POSOUT.

Press FUNCTION key until the display reads DIS CALPOS.

Press the or keys until the display reads BEGN CALPOS.

Press the FUNCTION key.

Upper Display = n.nnn (Output voltage of the sensor)

Lower Display =

POSOUT

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

4 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.

5 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.

6 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.

Start-Up/Operation

Remote Setpoint Operation

86 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

867

COMMUNICATION

SHIELD

INP

COM

DIGITAL INPUT

Actuator

Terminal

Block

Figure 33 Terminal Block Connections for Modbus Communications

Maintenance

Introduction

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 87

7/08

Maintenance

Introduction

There is some basic maintenance that is recommended for the HercuLine® 2000 Series Actuators. The

electronic PWAs within the actuator require no 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 Action

1 Remove AC power from actuator.

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

3 Inspect the final spur gear, the idler gear and motor pinion for excessive wear and adequate

lubrication. See Figure 34.

4 If needed, use Texaco Starplex 2 EP grease, or equivalent and apply lubricant to assure that

the gears are adequately protected.

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

6 Restore actuator to service.

Maintenance

Basic Maintenance

88 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Bottom cover Gears

Motor pinion

gear

Final output

spur gear

Idler spur

gear

Figure 34 Spur Gear Location

Maintenance

Replacement Procedures

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 89

7/08

Replacement Procedures

Fuse Replacement

The motor drive circuit contains two fuses. They are located on the power distribution PWA. If it becomes

necessary to 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

1 Remove AC power from actuator.

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

3 Lay assembly down on a flat surface.

4 Remove connectors from CPU and power distribution PWA.

5 Remove power distribution PWA.

6 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).

7 Reinstall power distribution PWA.

8 Reconnect connectors to CPU and power distribution PWA.

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

Power

distribution

PWA

}Relay PWA#1

}Relay PWA#2

Relay connector #1

Relay connector #2

Relay connector #3

Relay connector #4

CPU

connections

Figure 35 Power Distribution PWA and Relay PWA Locations

Maintenance

Replacement Procedures

90 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Power Distribution PWA

Fuses for

Motor Drive

Circuit

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

1 Remove AC power from actuator.

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

3 Lay assembly down on a flat surface.

4 Disconnect the wire connector from the relay PWA.

5 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.

6 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.

7 Plug in wire connector to relay PWA.

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

Replacement/Upgrade/Accessory Kits

Replacement Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 91

7/08

Replacement/Upgrade/Accessory Kits

Replacement Kits

This section provides you with a complete list of all the spare parts that may be needed for the 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

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

Replacement/Upgrade/Accessory Kits

Replacement Kits

92 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Figure 38 Replacement Kit 10

Replacement/Upgrade/Accessory Kits

Replacement Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 93

7/08

4,5,9

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

Replacement/Upgrade/Accessory Kits

Replacement Kits

94 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Figure 40 Replacement Kit 13

Replacement/Upgrade/Accessory Kits

Replacement Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 95

7/08

17, 18

Figure 41 Replacement Kits 17, 18

Replacement/Upgrade/Accessory Kits

Replacement Kits

96 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

See Figure 37 through Figure 41 for drawings of replacement kit contents.

Table 38 Replacement kits

Qty/Unit Part Number Description Figure ID #

51450802-503 Relay Kit 1

2 Relay Pwa

4 Plug 03 Position

1 Top Cover Gasket

Qty/Unit Part Number Description Figure ID #

51451397-501 CPU Kit 2

1 HercuLine® CPU Bd Assembly

1 Plug, 10 Pos

1 Label Phonix Connector 1 To 10

1 Insulator

4 Pin, Snap Lock, .125 X .187 Lg

1 Top Cover Gasket

Qty/Unit Part Number Description Figure ID #

1 51452302-501 PROM Kit 2

Qty/Unit Part Number Description Figure ID #

51451424-501 Backplane Kit 3

1 HercuLine® Backplane Assy

1 Card Guide Assy

1 Card Guide

4 Split Washer

4 Machine Screw-Pan Head-Slotted

4 Screw,Trilob Philph #4-20x.38

1 Top Cover Gasket

Qty/Unit Part Number Description Figure ID #

51451656-505 1000 Ohm Potentiometer Kit 90 Degrees

(HercuLine® 2000) 4

1 Pot 1 K Double 90 Degree

2 #6-32 Hex Nut N

2 #6 Washer

2 #6 Lock Washer

2 Machine Screw-Pan Hd-Cross Rec

1 Top Cover Gasket

Kit Instruction# 62-86-33-38

Replacement/Upgrade/Accessory Kits

Replacement Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 97

7/08

Qty/Unit Part Number Description Figure ID #

51451656-506 1000 Ohm Potentiometer Kit 150 Degrees

(HercuLine® 2000) 5

1 Pot 1 K Double 150 Degree

2 #6-32 Hex Nut N

2 #6 Washer

2 #6 Lock Washer

2 Machine Screw-Pan Hd-Cross Rec

1 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) 6

1 PCB Assembly

4 Screws SEMS #4-40 x .310 lg

1 Gasket

1 Cable Assembly

1 RVI T-Z Setup Gage

1 Bracket Molding

1 Stainless Steel Pin

1 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) 9

1 Position Sensor SA2001

2 #6-32 Hex Nut N

2 #6 Washer

2 #6 Lock Washer

2 Machine Screw-Pan Hd-Cross Rec

1 Top Cover Gasket

Kit Instruction# 62-86-33-40

Qty/Unit Part Number Description Figure ID #

515000657-502 Rvit-Z Ncs Replacement Kit 19

1 Ncs, Rvit-Z Pwa 0-150

4 Machnl 4-40 X .31 Pnslstl

1 Top Cover Gasket

Replacement/Upgrade/Accessory Kits

Replacement Kits

98 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Qty/Unit Part Number Description Figure ID #

51452174-501 Crank Arm Kit 6

1 Crank Arm

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

1 Kllwss1/4sp

1 Nut Nmsndc 1/4-20

Qty/Unit Part Number Description Figure ID #

50011455-501 120vac/60HZ Motor Kit 7

1 Motor 120v,50/60 Hz,

1 Capacitor, 3 µfd 400Vac

1 Cable plus Resistor assembly, 600 Ohm

1 Resistor Bracket

4 Split Washer M5

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

4 Socket head cap screw-M5 x 12

1 Top Cover Gasket

Kit Instruction# 62-86-33-36

Qty/Unit Part Number Description Figure ID #

50011455-502 120vac/50HZ Motor Kit 7

1 Motor 120v,50/60 Hz,

1 Capacitor, 4.0 µfd 400Vac

1 Cable plus Resistor assembly, 400 Ohm

1 Resistor Bracket

4 Split Washer M5

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

4 Socket head cap screw-M5 x 12

1 Top Cover Gasket

Kit Instruction# 62-86-33-36

Qty/Unit Part Number Description Figure ID #

50011455-503 240VAC/50/60HZ Motor Kit 7

1 Motor 240v,50/60 Hz,

1 Capacitor, .75 Mfd 400Vac

1 Cable plus Resistor assembly, 1100 Ohm

1 Resistor Bracket

4 Split Washer M5

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

2 Butt Splice (SA2000)

4 Socket head cap screw-M5 x 12

1 Top Cover Gasket

Kit Instruction# 62-86-33-36

Replacement/Upgrade/Accessory Kits

Replacement Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 99

7/08

Qty/Unit Part Number Description Figure ID #

51452443-501

51452443-507

51452443-508

51452443-509

51452443-510

51452443-511

Spur Gear Kit

1 Spur Gear 24p, 18t

1 Spur Gear 24p, 36t

1 Spur Gear 24p, 72t

1 Gear Assembly

1 Spur Gear 24p, 36t

1 Bottom Cover Gasket

1 Intermediate Shaft all except 7.5 seconds

1 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 11

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

1 Switch and Mounting Plate assembly (6

Kit Instruction# 62-86-33-45

Qty/Unit Part Number Description Figure ID #

51452443-503 Gasket Set Kit 12

1 Bottom Cover Gasket

1 Shaft Seal

1 O-Ring 2.144 Id X 0.070 Buna N

1 Top Cover Gasket

1 O-Ring Buna N

1 Display Gasket

Replacement/Upgrade/Accessory Kits

Replacement Kits

100 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Qty/Unit Part Number Description Figure ID #

51452443-504 Display and Keypad Kit 13

1 Display Gasket

1 Overlay, Display

1 Lens, Display

1 Gasket,Adhesive Die Cut

1 Display Mtg Collar Machining

1 Keypad, 6 Position

1 Support Plate-Keypad

1 Display Pwa

9 Sems #4-40 X .310lg Pnphstl

4 Screw,Metric Panhd,Cross Rec

4 Split Washer

6 Sleeve, Keypad

1 Display/Keybd Cable

1 Top Cover Gasket

Qty/Unit Part Number Description Figure ID #

51452443-505 R/C Kit (Motor date codes prior to 8/5/2005) 14

1 Capacitor, 2.25 Mfd

1 Resistor, 200 Ohm,25w

1 Capacitor, .75 Mfd, 400vac

1 Resistor, 500 Ohm,25w

1 Top Cover Gasket

1 Bottom Cover Gasket

Kit Instruction 62-86-33-44

Replacement/Upgrade/Accessory Kits

Replacement Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 101

7/08

Qty/Unit Part Number Description Figure ID #

51452443-506 R/C Kit (Motor date codes after to 8/5/2005)

1 Capacitor, 4.0 Mfd 1

1 Cable plus Resistor, 400Ohm 1

1 Capacitor, 3 Mfd, 400vac 1

1 Cable plus Resistor, 600 Ohm 1

1 Capacitor, 0.75 Mfd, 400vac

1 Cable plus Resistor, 1100 Ohm

1 Top Cover Gasket 1

1 Bottom Cover Gasket 1

Kit Instruction 62-86-33-44

Qty/Unit Part Number Description Figure ID #

51500166-503 Power Distribution Pwa Kit 15

1 Power Dist Pwa

1 Insulator

2 Pin, Snap Lock, .125 X .187 Lg

1 Top Cover Gasket

Qty/Unit Part Number Description Figure ID #

51500457-502 Transformer Kit 16

1 Transformer

2 Split Washer

2 Machine Screw-Pan Hd-Cross Rec

1 Top Cover Gasket

Qty/Unit Part Number Description Figure ID #

51500581-503 Auto/Manual Switch (upgrade for SA2000) 17

1 Auto/Manual Label

1 Nut, Sealing 3/8-32 Thrd

1 Knob

1 A/M Switch/Wire Assy

1 Label, Customer Wiring,

1 Top Cover Gasket

Replacement/Upgrade/Accessory Kits

Upgrade Kits

102 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Qty/Unit Part Number Description Figure ID #

51500581-504 Auto/Manual Switch (upgrade for SA2001 & SA2002) 18

1 Auto/Manual Label

1 Nut, Sealing 3/8-32 Thrd

1 Knob

1 A/M Switch/Wire Assy

1 Label, Customer Wiring,

1 Top Cover Gasket

Upgrade Kits

Qty/Unit Part Number Description

51452444-502 Cover (with Display no Handwheel)

1 Display gasket

1 Overlay, display

1 Lens, display

1 Gasket,adhesive die cut

1 Display mtg collar machining

1 Keypad, 6 position

1 Support plate-keypad

1 Display PWA

1 Top cover w/display no hndwhl

9 Sems #4-40 x .310lg pnphstl

4 Screw,metric panhd,cross rec

4 Split washer

6 Sleeve, keypad

1 Display/keybd cable HercuLine 2001/2002

1 Top cover gasket

Replacement/Upgrade/Accessory Kits

Upgrade Kits

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 103

7/08

Qty/Unit Part Number Description

51452444-503 Cover with Display and Handwheel

1 Display gasket

1 Overlay, display

1 Lens, display

1 Gasket,adhesive die cut

1 Display mtg collar machining

1 Keypad, 6 position

1 Support plate-keypad

1 Display PWA

1 Top cover w/display & hndwheel

9 Sems #4-40 x .310lg pnphstl

4 Screw,metric panhd,cross rec

1 Hand wheel

1 O-ring buna n

4 Split washer

6 Sleeve, keypad

1 Display/keybd cable HercuLine® 2001/2002

1 Retaining ring

1 Shim

1 Top cover gasket

Qty/Unit Part Number Description

51452444-504 Blank Cover with Handwheel

Qty/Unit Part Number Description

51451656-510 1000 ohms 90 degrees upgrade kit

2 Machine screw-pan hd-cross rec

1 Knob

1 Bracket molding

1 Pot 1K double 90 degree

2 #6 lock washer

2 Machine screw-pan hd-cross rec

2 #6-32 hex nut N

1 Stainless steel pin

1 3/32x4-40 setscrew sshxsocupsb

2 Washer #6

2 Flat washer M4 (zinc)

2 Resistor 158 ohms 1% 1/2W

Kit Instruction# 62-86-33-39

Replacement/Upgrade/Accessory Kits

Accessory Kits

104 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Qty/Unit Part Number Description

51451656-511 1000 ohms 150 degrees upgrade kit

2 Machine screw-pan hd-cross rec

1 Knob

1 Bracket molding

1 Pot 1K double 150 degree

2 #6 lock washer

2 Machine screw-pan hd-cross rec

2 #6-32 hex nut N

1 Stainless steel pin

1 3/32x4-40 setscrew sshxsocupsb

2 Washer #6

2 Flat washer M4 (zinc)

2 Resistor 158 ohms 1% 1/2W

Kit Instruction# 62-86-33-39

Accessory Kits

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

Troubleshooting

Introduction

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 105

7/08

Troubleshooting

Introduction

Troubleshooting procedures can be followed when inaccurate or faulty actuator operation is detected. In

this section, troubleshooting 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

Troubleshooting

Troubleshooting Procedures

106 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Troubleshooting Procedures

Overview

Follow the procedure or flow chart to test for and determine actuator component operation. When using

the flow charts 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.

Troubleshooting

Troubleshooting Procedures

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 107

7/08

Test for Actuator Operation

Do all diagnostics pass?

RAMTST PASS

SEETST PASS

CALTST PASS

CFGTST PASS

Replace display

assembly

Does motor

reposition

itself?

Yes

All LEDs and

display segments

light?

Replace display

assembly

Move handwheel

on actuator 2 or

3 turns.

Cycle power

to actuator.

Does display

light up?

Yes

Observe self test.

Yes

Figure 42 Test for Actuator Operation

Troubleshooting

Troubleshooting Procedures

108 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Power Up Self Test Diagnostics

Replace display

assembly.

Cycle power to

actuator. If CALTST

fails again, replace

CPU assembly.

Cycle power to

actuator. If CFGTST

fails again, replace

CPU assembly.

Replace CPU

Assembly.

Observe self test.

Cycle power

to actuator.

Does display

light up?

RAMTST PASS?

SEETST PASS?

CALTST PASS?

Do all LEDs

and display

segments light

up?

CFGTST PASS?

Check actuator

configuration

(setup), reconfigure

if necessary.

Check actuator

calibration,

recalibrate

if necessary.

Yes No

Yes

Figure 43 Power Up Diagnostics

Test Non-Contact Sensor PWA

See page 85.

Troubleshooting

Troubleshooting Procedures

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 109

7/08

Test Power Distribution PWA

Replace CPU

assembly.

Is correct

voltage present

at test points?

See below.

Remove top

cover of actuator.

re fuses good?

Replace fuses with

same type and

rating

Yes

Check Fuses F1

and F2 on the

power distribution

PWA.

Yes

Replace Power

Distribution PW

Figure 44 Test Power Distribution PWA

Power Distribution PWA Test Points

Connector Test Points - Pins Voltage

J2 Pin 1 to pin 7 5 V

J3 Pins 1,2 to pins 3, 4, 8

Pins 3, 4 to pin 7

5 V

9 V

J1 Pins 5, 6 to pins 7, 8

Pins 1, 2 to pins 7, 8

24 V

28 V + or – 3V

Troubleshooting

Troubleshooting Procedures

110 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Test AUTO - MANUAL DRIVE Switch

Possible trouble spots

a. Auto/Manual switch

b. Power Supply PWA. (See D)

c. Limit switches

d. Motor

e. R/C networks

f. etc.,Others?

Does motor

drive in the CW

direction?

Turn switch to

Manual CW setting.

Turn switch to

Manual CCW

setting.

Does motor

drive in the CCW

direction?

Yes No

MANUAL

OFF CWCCW

OFF

AUTO - MANUAL DRIVE

Figure 45 Test AUTO - MANUAL Switch

Troubleshooting

Troubleshooting Procedures

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 111

7/08

Test Relay Function

Set suspect Relay

type to MAN.

Replace Relay PWA or

Wire harness from Relay

PWA to terminal block.

See Relay replacement

in Maintenance, Section 7.

Set AUTO -

MANUAL switch

to MAN.

Press SET UP

button on keypad

to enter Set up

mode.

Does Relay

operate?

Yes No

Place ohmmeter

across associated

relay contacts at

Actuator terminal

block. See below.

Figure 46 Test Relay Function

Relay Associated Contacts

RELAY1

COM

RELAY2

COM

RELAY3

COM

RELAY4

COM

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

112 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

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

Prompt

Parameter Setting Default

SET INPUT IN TYP - Input Actuation Type

INP HI – Input High Range Value

INP LO – Input Low Range Value

FILTYP – Input Filter Type

LPFILT – Low Pass Filter Time Constant *

Direct – Actuator Rotation

Dband – Input Deadband

FSTYPH – Failsafehi Type

FSVALH – Failsafehi Input Value

FSTYPL – Failsafelo Type

FSVALL – Failsafelo Input Value

CHAR – Input Characterization type

CUSTOM -- Custom characterization type

X0 VAL -- User configurable characterizer value

X1 VAL -- User configurable characterizer value

X2 VAL -- User configurable characterizer value

X3 VAL -- User configurable characterizer value

X4 VAL -- User configurable characterizer value

X5 VAL -- User configurable characterizer value

X6 VAL -- User configurable characterizer value

X7 VAL -- User configurable characterizer value

X8 VAL -- User configurable characterizer value

X9 VAL -- User configurable characterizer value

X10 VAL - User configurable characterizer value

X11 VAL - User configurable characterizer value

X12 VAL - User configurable characterizer value

X13 VAL - User configurable characterizer value

X14 VAL - User configurable characterizer value

X15 VAL - User configurable characterizer value

X16 VAL - User configurable characterizer value

X17 VAL - User configurable characterizer value

X18 VAL - User configurable characterizer value

__________________

See Note 1

100

0.0

LPAS

CCW

0.5

100

DOWN

LINR

EQUL

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 113

7/08

Set Up Group

Prompt

Parameter Setting Default

X19 VAL - User configurable characterizer value

X20 VAL - User configurable characterizer value

Y0 VAL -- User configurable characterizer value

Y1 VAL -- User configurable characterizer value

Y2 VAL -- User configurable characterizer value

Y3 VAL -- User configurable characterizer value

Y4 VAL -- User configurable characterizer value

Y5 VAL -- User configurable characterizer value

Y6 VAL -- User configurable characterizer value

Y7 VAL -- User configurable characterizer value

Y8 VAL -- User configurable characterizer value

Y9 VAL -- User configurable characterizer value

Y10 VAL - User configurable characterizer value

Y11 VAL - User configurable characterizer value

Y12 VAL - User configurable characterizer value

Y13 VAL - User configurable characterizer value

Y14 VAL - User configurable characterizer value

Y15 VAL - User configurable characterizer value

Y16 VAL - User configurable characterizer value

Y17 VAL - User configurable characterizer value

Y18 VAL - User configurable characterizer value

Y19 VAL - User configurable characterizer value

Y20 VAL - User configurable characterizer value

__________________

95.0

100.0

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

SET RELAY RTYP11 – Relay Type

R11VAL – Relay Value

R11 HL – Relay High/Low

R11SCALE– Relay Scale

RTYP12 – Relay Type

R12VAL – Relay Value

R12 HL – Relay High/Low

R12SCALE– Relay Scale

RLY1HY – Relay Hysteresis

__________________

NONE

RTYP21 – Relay Type

R21VAL – Relay Value

R21 HL – Relay High/Low

R21SCALE– Relay Scale

RTYP22 – Relay Type

R22VAL – Relay Value

R22HL– Relay High/Low

R22SCALE– Relay Scale

RLY2HY – Relay Hysteresis

__________________

NONE

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

114 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Set Up Group

Prompt

Parameter Setting Default

RTYP31 – Relay Type

R31VAL – Relay Value

R31 HL – Relay High/Low

R31SCALE– Relay Scale

RTYP32 – Relay Type

R32VAL – Relay Value

R32HL– Relay High/Low

R32SCALE– Relay Scale

RLY3HY – Relay Hysteresis

__________________

NONE

RTYP41 – Relay Type

R41VAL – Relay Value

R41 HL – Relay High/Low

R41SCALE– Relay Scale

RTYP42 – Relay Type

R42VAL – Relay Value

R42HL– Relay High/Low

R42SCALE– Relay Scale

RLY4HY – Relay Hysteresis

__________________

NONE

SET CUROUT CUROUT - Output Signal Range

__________________

See Note 1

SET COMM COMM – Communications Parameters

ADDRES – Device Address

BAUD – Baud Rate

XmtDLY – Response Delay

DBLBYT – Floating Point Data Format

__________________

MODBUS

19.2K

20MS

FP B

SET DIGINP DIGINP – Digital Input State

Endpos – End Position Value

__________________

SET DISPLA DECMAL – Decimal Point Location

EUNITS – Units Display

UNITS – Display Units

__________________

8888

Pcnt

ENG

SET LOCK LOCKID – Password Lock

MAENAB – Enabled

LOCK – Lock Out

__________________

ENAB

NONE

READ STATUS FAILSF – Failsafe

RAMTST – RAM Test Diagnostic

SEETST – Serial EEPROM Test Diagnostic

CFGTST – Configuration Test Diagnostic

CALTST – Calibration Test Diagnostic

__________________

Read Only

Appendix A - HercuLine® 2001/2002 Configuration Record Sheet

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 115

7/08

Set Up Group

Prompt

Parameter Setting Default

SET DRVINF VERSON – Firmware Version

SPEED – Stroke Speed

POWER – Power Input Voltage Line Frequency

TAG – Tag Name

MFGDAT – Manufacturing Date

LREP – Date of Last Repair

LCAL – Date of Last Field Calibration

REPTYP – Repair Type

__________________

Read Only

Factory Set

SET MAIN TEMP – Actuator Temperature

TEMPHI – High Temperature Limit

TEMPLO – Low Temperature Limit

ACST – Accumulated Stall Time

STARTS – Accumulated Motor Starts

RLnCNTS – Relay Cycle Counts

n = 1, 2, 3, or 4

REGNy – Accumulated Motor Starts for regions

of motor travel.

y = 0 through 9

__________________

Read Only

DATSAV – Forced maintenance data save

MANRST – Maintenance Statistic Reset

LDCAL – Restore Factory Calibration Type

LDCFG – Restore Factory Default Configuration

RESTRT – System Restart

__________________

DIS

NONE

DIS

CAL NCSOUT NCSOUT – Non-contact sensor circuit output _________________ Read Only

Note 1: Type is set from model number.

Index

116 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Index

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

Baud Rate, 9, 50

Burner Control/Flame Safety, 23

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

Deadband, 7, 40

Decimal Point Location, 52

Deviation, 45

Relay type, 47

Device Address, 50

Direction of Rotation, 7

Duty Cycle, 7

Electrical and Performance Specifications, 6

Electrical Installation, 17

Enclosure, 5

Enclosure Rating, 6

End of travel Limit Switches, 6

Exiting Set Up mode, 33

Failsafe, 40, 41

Failsafe Input Value, 40, 41

Failsafe operation, 7

Feedback, 6

Flame Safety Module wiring diagram, 23

Fuses

Replacement, 89

Gear Train, 5

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

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

Index

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 117

7/08

Inputs, 39

Installation, 12

Installation Considerations, 13

Isolation, 6

Keypad, 8, 31

Description, 32

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

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

Non-Contact Sensor, 87

Checking, 108

Operation, 85

Non-Contact Sensor Output Calibration, 72, 73

Operating Temperature, 7

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

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

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

Index

118 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7

7/08

Stall, 84

Start Up Checklist, 83

Storage Temperature, 5

Stroke Speed, 56

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

Equipment, 106

Voltage/ Supply Stability, 7

Weight, 5

Zero Suppression, 7

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 119

7/08

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

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

2000 to the manual e769983d-d341-4cc7-be9d-af66c897824b

Navigation menu

Versions of this User Manual:

Views

Navigation