Hamilton Sundstrand Company ACT2000 manual

ACT2000 Oper a tions Manual ACT2000 All-Electric Actuator SD-6008-03[...]

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This manual provides installation , maint enance, and operating instructio ns for the ACT2000 All-Electric Actuator. Every attempt has been made to provide sufficient information in this manual for the proper operation and preventive maintenance of t he actuator. It is recommended tha t the user read this manual in its entirety. Operating the ACT20[...]

ACT2000 II[...]

ACT2000 T able of Content s Table of Contents .............................................................................................................. .......................... i 1 INTRODUCTIO N ................................................................................................................... .......... 1-1 1.1 Application .[...]

ACT2000 List of Figures Figure 1-1: ACT20 00 Pin Mount ed ....................................................................................1-1 Figure 1-2: ACT2000 Flange Mounted ..............................................................................1-1 Figure 1-3: ACT2000 Cut-Away View .....................................................[...]

ACT2000 1 INTRODUCTION This publication covers operation, inst allation and m aintenance instructions for the ACT2000 Actuators manufactu red by Precision Engine Controls Corpo ration. 1.1 Application The ACT2000 All-Electric Actuator is d esigned to meet general industria l motion control requirements for high tempera ture hazardous location s. Ty[...]

ACT2000 1.3 Main Housing Assembly The main housing assem bly contains a main housing, motor cover, extension rod bearing, and associated seals. See Figure 1-3. The main housing assembly is the primary structural system component a nd supports all the b earings, motor control electronics, motor cover, and mountin gs, which forms the explo sion-proof[...]

ACT2000 1.4 Brushless DC Motor Assembl y A brushless DC motor powers the ACT2000 linear drive mechanism. Th e DC motor contains a stator and roto r. See Figure 1-3 Motor Stator The motor stator is attach ed to the main housing by a pre-load ed wave spring and screws. Thermistors are embedded in the stator winding s to monitor winding temperatures. [...]

ACT2000 1.7 Linear Drive Mechanism The Linear Drive Mechanism converts the rot ary motion of the Motor Assembly to linear actuator motion. T he core of the mechanica l drive system is the linea r ball screw drive containing a screw shaft, ball bearing fitted nut, exte nsion rod and main duplex thrust bearings. Screw Shaft The thrust bearings, mot o[...]

ACT2000 1.9 Identification Plate A product identificatio n plate is attached to the actuator housing assembly. Figure 1-4 shows a typical identif ication plate. The identification plate lists model de signation, product part number, revision and unit serial number. Hazardous area operation, ce rtification and electrical wiring interf ace informatio[...]

ACT2000 I NTENTIONALLY B LANK 1-6[...]

ACT2000 2-1 2 FUNCTIONAL DESCRIPTION AND OPERA TION This section describes system fu nctions employed in the ACT2000 Electric Actuator. 2.1 System Description The ACT2000 is a closed loop servo system containing motor control electr onics (MCE) and a brushless DC motor driven ball scr ew actuator. The actuator closes its own control loop on an inte[...]

ACT2000 ACTUATOR DRIVER ASSY CONTROL INTERFACE MTR CURRENT MTR CURRENT RTN POWER INTERFACE REVERSE POLARITY PROTECTION 120V ACTUATOR POWER (80 - 160 VDC) RED GREEN + - INPUT TERMINATION 4-20mA OUTPUT BROWN DEMAND DEMAND RTN BLACK VIOLET GRAY ORANGE RUN RUN RTN RESET RESET RTN FAULT ALARM FAULT RTN OVERTEMP ALARM OVERTEMP RTN BRUSHLESS DC MOTOR RESO[...]

ACT2000 2.2.1 Power The ACT2000 operates on nominal 12 0 VDC, user-provided input voltag e via the four-wire power harness. Refer to Figure 2-2 for typical connection. Refer to section 6 for specif ication values. Primary power wires. • +120 VDC is connected to the RED wire. • The 120 VDC return wire is GREEN. Redundant power wires: • +120 VD[...]

ACT2000 Run Command The RUN command is a user provided discrete input to the ACT2000 which allows the actuator to track po siti on demand. The + 24 VDC signal shall be provided on the VIOLET wire. The sig nal return shall be pr ovided on the WHITE/VIOLET wire. Reset Command The RESET command is a user provided discr ete input to the ACT2000, which [...]

ACT2000 Motor Current Feedback The ACT2000 provides motor curren t feedback to t he user. This internally generated feedback signal is pr oportional to actua tor load. 4mA represents no load on the actuator. The motor current feedback is provid ed on the BLUE wire. The motor cu rrent feedback return is provided on the W HITE/BLUE wire. The expected[...]

ACT2000 2.3 Basic Operation and S t ate Description The basic operation of the ACT2000 is described in the following sect ions. The Power-Up mode section covers the P ower Up/Reset and the Set-Up states. The Run Mode section covers the Home/Dead Band, Holding Motor Current and the Run states. SET-UP POWER UP/RESET HOME DEADBAND RUN HOLDING MOTOR CU[...]

ACT2000 • If the ACT2000 receives a discre te RUN command, the firmware program will transition to the HOME DEAD BAND state. • If the ACT2000 receives a discrete R ESET command, the firmware progr am will continuously re set. The actuator will not function and will re main in the power-up/reset state. WARNING: Property Damage Hazard – Al ways[...]

ACT2000 When the mechanical stop is found (actuator velocity less 0. 05 inches per second), the MCE will apply the maximum homing force. Once the maximum homing force is applied, the firmware program will transition to the HOLDING MOTOR CURRENT state. Holding Motor Current State In the HOLDING MOTOR CURRENT state, the MCE applies a constant HOLDING[...]

ACT2000 2-9 If any of the health param eters are out of the normal operating range, the MCE outputs a discrete FAULT alarm to the user’s contro ller. The actuator firmware also captures the fau lt data in the EEPROM. If the motor or electronics temperature is above the normal operation range, t he MCE outputs a separate OVERTEMP alarm. The actuat[...]

ACT2000 This FAULT does not cl ear without RESET command. Unregulated Voltage Lo w The MCE signals a FAULT if the reference voltage drops b elow minimum f or ten (10) seconds. Should the voltage re turn to acceptabl e level, the FAULT signal is cleared. +/- 14V High/Low The MCE signals a FAULT if the internal ± 14 VDC power supplie s exceed operat[...]

ACT2000 2-11 2.8 ACT2000 Set-Up Parameters The ACT2000 employs several variables to define its functiona lity. These variables are called set -up parameters. These par ameters are downloaded through the RS232 interf ace to the ACT2000 u sing ActWiz soft ware. See ActWiz Software Manual for further deta ils. The user can define set up any of the fol[...]

ACT2000 2-12 Table 2-1 lists the set-up parameters and factory d efault settings. Parameter Factory Setting Part Number Per Drawing Actuator Type Stand Alone Command So urce Analog Home Retract Span 5.9 inches Stop Position 0.1 inches Interpolation Table Linear Position Loop Constant 20 Current Loop PID Constants Proportional 2.0 Integral 200 Deriv[...]

ACT2000 3 INST ALLA TION The purpose of this sectio n is to aid personnel in the installation, pla cement, and environmental considerations to be ob served for the ACT2000 and asso ciated equipment. 3.1 Inspection The ACT2000 should be inspe cted immediately after unpacking. Check for damage, paying particular atten tion to the external lead wire s[...]

ACT2000 3-2 Figure 3-1: ACT2000-590P Envelop e[...]

ACT2000 3-3 Figure 3-2: ACT2000-200F Envelo pe[...]

ACT2000 Note: The cl evis can be rotate d to any orientati on to support i nstallation. To rotate, loosen the four retaining s crews and rotate to desired angle. Screw p attern can be i ndexed ± 45 degre es to provid e additional adjustment . Torque the four retaining screws to 117-138 in-lbs. WARNING: Explosion Hazard – Do not remove the clevis[...]

ACT2000 WARNING: 94/9/EC (ATEX) Compliance – Special Condi tions for Safe Use: Two special factory -sealed unions are mounted on the equipment to en sure the electrical connection to the network and to provide the feedback signal to the user. The installation of t hese devices and the f inal connections to the conduit shall comply with the re qui[...]

ACT2000 Note: For proper operation of the actuator, the voltage betwee n the control inputs and the negative te rminal of the power supply should be below 200 VDC. The discrete inputs and output s are 24 VDC and are ele ctrically isolated up to 500 VAC. The recommended wiring is a fourteen -conductor shielded cab le containing twisted-pair wires wi[...]

ACT2000 WARNING: Property Damage Hazard – Serial inputs are not electric ally isolated. Fai lure to properly isolate the user serial interface could result in actuator or computer damage. Use separate co nduits for power and signal wiring. Close proximity to power lines may cause signal interferen ce. Shock Hazard – The serial in puts are not e[...]

ACT2000 Power Harness Electrical Hook-Up POWER SUPPLY ACT2000 Digital Harness Electrical Hook-Up PWR (RED) PWR [AUX] (WHT/RED) PWR RTN (GRN) PWR RTN [AUX] (WHT/G RN) Shield No Connection DEMAND (BR N) DEMAND RTN (WHT/BRN ) Shield No Connection RUN (VIO) RUN RTN (WHT/VIO) Shield No Connection RESET (GRY) RESET RTN (WHT/GRY) Shield No Connection MTR [...]

ACT2000 Table 3-4 shows the fa ctory wiring and refer ence signals for the ACT2000 signal harness. Note: The serial wiring is segregated from the ot her wires. Wire Color Function AWG Signals WHITE/ORANGE/YELLOW Serial/RX In 20 ± 12 V WHITE/ORANGE/BLUE Serial/TX Out 20 ± 12 V WHITE/ORANGE/GREEN Serial Return 20 0 V BLACK OVER TEMP Alarm 20 0 / 24[...]

ACT2000 Power Supply Requirem ents A battery power system is recommended, Table 3 -5 lists the power supply requirements. Voltage: 120VDC nominal 80VDC minimum 160VDC maximum Max Ripple: 4 VAC RMS or 12VAC p-p Max Current: 20 AMPS Typical Continuous Cu rrent: <1 AMP Typical Transi ent Current: +20 A <60ms +10A <600 ms -5A <100 ms *Outpu[...]

ACT2000 4 TROUBLESHOOTING The information contained in this se ction is intende d to aid maintenance technicians in troublesho oting and isolating cause s of malfunctions in th e ACT2000. Most electrical fault isolation of the actuat or can be accomplished by using an external oscilloscope and digital voltmeter (DVM). The ACT2000 is comprised of hi[...]

ACT2000 Table 4-1 ACT20 00 Initial Installati on Troublesho oting Chart Symptom Prob able Causes Corrective Actio n Actuator Inoperative - FAULT alarm Power Wires not connected No or low 120 VDC power Ensure RED and GREEN wires correctly connected to Actuator Ensure 120 VDC Primary System Power at Actuator Actuator Inoperative - NO FAULT alarm No R[...]

ACT2000 Table 4-2 ACT20 00 In-Service Trou bleshooting Chart Symptom Prob able Causes Corrective Actio n FAULT alarm Various Upload F ault Fi le to ident ify source of f ault OVER TEMP alarm Ambient temperature limit exceeded Electronics or Mo tor winding temperatur e out of r ange Allow actuator to cool and re-start Reduce a mbient temp erature Ch[...]

ACT2000 I NTENTIONALLY B LANK 4-4[...]

ACT2000 5 DECOMMISSIONING AND DISPOSAL This section contains recommended ACT2000 decommissioning and disposal practices. It is fo r permanent removal or replacement of the in stalled product, with no intentions of rework, overhaul , or to be used as spares. For removal follow proper lockout /t agout procedures and verify no live electrical circuits[...]

ACT2000 I NTENTIONALLY B LANK 5-2[...]

ACT2000 6 ACT2000 GENERAL SPECIFICA TIONS Power Input Nominal Voltage: 120 VDC Minimum Voltage: 80 VDC Maximum Voltage: 160 VDC Maximum Current: 20A Typical Transient Current: +20A < 60ms; +10A < 600 ms; -5A < 100ms Typical Continuous Current: < 1A RUN and RESET Command Input ON Voltage: 12 to 32 VDC; +24 VDC Nominal ON Current: 6.5 mA [...]

ACT2000 I NTENTIONALLY B LANK 6-2[...]

ACT2000 7 GLOSSAR Y Term Definition RUN Command A discrete 24 VDC sign al that enables the ACT 2000 extension rod t o move. RESET Command A discrete 24 VD C signal that causes the ACT2000 internal program (firmware) to jump to the be ginning. Controller A user-provided computer t hat executes comm ands to the ACT200 0 and accepts anal og and discre[...]

ACT2000 I NTENTIONALLY B LANK 7-2[...]

ACT2000 7-1[...]