Installation & Operation Manual - promationei.com...cabinet wiring to correct phasing errors. Field wiring and devices by others Remote Mounted MCC Wiring Diagram for P Series FM14_P23

P2-233N4-X-TS-RMCC-P with RMCC23-233P-QCP2-383N4-X-TS-RMCC-P with RMCC23-383P-QCP2-443N4-X-TS-RMCC-P with RMCC23-443P-QCP2-483N4-X-TS-RMCC-P with RMCC23-483P-QCP3-233N4-X-TS-RMCC-P with RMCC23-233P-QCP3-383N4-X-TS-RMCC-P with RMCC23-383P-QCP3-443N4-X-TS-RMCC-P with RMCC23-443P-QCP3-483N4-X-TS-RMCC-P with RMCC23-483P-QC

Installation & Operation Manual

This IOM is for the following ProMation Engineering Products:

This Manual covers 3 Phase Actuators shipped with a Motor Control Center, either direct or remote mounted. This information is valid for 50 Hz and 60Hz units.

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MCC

Field Manual

P2/3-MCC SeriesProportional with Torque Switch

3 Phase Quarter-Turn

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Page 1 of 23 P4/5/6-MCC-TS Premium Proportional Series

Actuators with integral motor control centers are shipped fully assembled and pre-wired for ease in installation.

Actuators are also available with separate motor control centers for use in remote control applications such as high ceiling mounted actuators with eye-level motor controls and chain wheel systems.

Table of ContentsPg 2 . . . . . . . . . . . . . . . . . . Product SpecificationsPg 3 . . . . . . . . . . . . . . . . . . Shipping and HandlingPg 3 . . . . . . . . . . . . . . . . . . Product Mounting and SetupPgs 4-5 . . . . . . . . . . . . . . . Wiring Diagram for P Series Remote Mounted MCCPgs 6-7 . . . . . . . . . . . . . . . Component IdentificationPg 8 . . . . . . . . . . . . . . . . . . Diagram of ControllerPg 9 . . . . . . . . . . . . . . . . . . Controller: Initial StartupPg 9 . . . . . . . . . . . . . . . . . . Power UpPg 9 . . . . . . . . . . . . . . . . . . Controller: Change INput/OUTput signal typePg 10 . . . . . . . . . . . . . . . . . Controller: Adjusting the actuator CW positionPg 11 . . . . . . . . . . . . . . . . . Cams: Adjusting the actuator CW positionPg 12 . . . . . . . . . . . . . . . . . Controller: Adjusting the actuator CCW positionPg 13 . . . . . . . . . . . . . . . . . Cams: Adjusting the actuator CCW positionPg 14 . . . . . . . . . . . . . . . . . Controller: Change Loss of Signal Response SettingPg 15 . . . . . . . . . . . . . . . . . Controller: Auto-Calibration ProcedurePg 16 . . . . . . . . . . . . . . . . . Cams: Adjusting the actuator Auxiliary SwitchesPgs 16-18 . . . . . . . . . . . . . Mechanical DataPg 19 . . . . . . . . . . . . . . . . . Phase Monitor CalibrationPg 20 . . . . . . . . . . . . . . . . . Troubleshooting Procedures for Phase monitorPgs 21-23 . . . . . . . . . . . . . Commissioning

Actuator Specifications P2 P3Torque “lb/Nm 800”lbs/90Nm 1335“lbs/150NmSupply Voltage 230/3/60 380/3/60 440/3/60 480/3/60 230/3/60 380/3/60 440/3/60 480/3/60Max Inrush Current 1.4A 0.7A 0.9A 0.9A 1.4A 0.7A 0.9A 0.9ARunning Current 0.8A 0.4A 0.4A 0.4A 0.8A 0.4A 0.4A 0.4AMotor PolyphaseRuntime (90°@60Hz/vdc) 15 sec 22 secRuntime (90°@50Hz) 17 sec 26 secDuty Cycle ManagedMotor Starts 1200 per hourWeight 26lbs/12kg (add 12lbs/5.5kg for MCC)Mechanical Connections ISO5211 F07 8pt 22mm

Electrical Entry (2) 3/4” NPT Remote MountField punched/drilled into MCC cabinet for Direct Mount

Electrical Terminations All applications have Field connections of 12-16ga and 10-14ga inside Motor Control Center.

Environmental Rating NEMA 4, 4X (Actuator), MCC is NEMA 4 standard or optionally 4X SS or FBG

Manual Override 5” HandwheelControl On/Off/Jog ProportionalActuator Case material Aluminum Alloy, Powder coated

Motor Protection 230°F/110°C Thermal F* Class*Totally Enclosed Non-Ventilated Motors

Ambient Temperature Operating Range

-22°F to +125°F -30°C to +52°C

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Product Specifications

IntroductionThis document provides necessary information for set-up, calibration, testing and use of the P Series quarter-turn electric actuators stated on the cover page. Each unit is shipped from the factory with initial calibration of mechanical stops, cams and switches completed for 0-90 degree operation. However, these are general settings and serve as a starting point for proper calibration of the actuator in its real-world application.

SafetySafety is a basic factor any time you maintain and operate mechanical equipment. Appropriate handling methods and proper use of tools and clothes can help prevent serious accidents -- accidents which can cause injuries to you or a fellow worker. This manual was created to enable a trained user to install, adjust and troubleshoot your ProMation actuator.

Only competent and trained personnel should install, maintain and operate ProMation Actuators. Any work related to this actuator must be carried out in accordance with this manual and related codes and regulations. Local workplace health and safety rules should always be followed.

Duty cycle Duty cycle is the percent of time that an actuator spends running as a fraction of the total time. Duty Cycle is directly related to heat; excessively repositioning an actuator typically results in motor overheating which can cause permanent damage and/or reduced service life.

Duty cycle can be calculated as follows: (example P13 series actuator running 3 seconds ON and 30 seconds OFF)Runtime = 3s, Total time = 3s + 30s = 33s, therefore this duty cycle would be 9% (3/33) Additionally, ProMation P series actuators are designed for a maximum of 1500 starts per hour (one start every 2.4 seconds maximum).

50°F10°C

75°F24°C

100°F38°C

125°F52°C

150°F65°C

25%

50%

75%

100%

On/Off/Jog

Proportional

Ambient Temperature

Duty cycle graph

These units are equipped with internal torque switches which protect the gear train, motor and controlled equipment from damage when high torque conditions exist. These protective devices are NOT adjustable. More information on this techology is found throughout this manual.WARNING! It is extremely important to not connect or disconnect the Mencom Cables (yellow cables) when power is present in the Motor Control Center (MCC).

“1” = CCW“0” = CWREFERENCE DIMPLE

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Shipping and Handling1. The P series actuator with the direct mount MCC system is shipped complete in a

single carton. For the remote mount MCC units, the P series actuator and the stand-alone MCC are shipped in two separate cartons. Included with both options is a complete field manual, detailing installation, wiring, comissioning and troubleshooting information.

2. WARNING! It is extremely important to not connect or disconnect the Mencom Cables (yellow cables) when power is present in the Motor Control Center (MCC).

3. Direct mount units are shipped with the actuator in the FULLY CW (REF DIMPLE AT “0”) position. Remote mount units are shipped with the actuator in the MID STROKE position (between “0” and “1”) to facilitate phase / interconnect wiring errors.

4. NOTE, THIS ACTUATOR MUST HAVE WATER TIGHT EMT FITTINGS, WITH CONDUIT DRAINAGE INSTALLED AND POWER SUPPLIED TO UNIT TO KEEP THE HEATER WARM AT THE TIME OF INSTALLATION.

5. Storage: This unit should NOT be stored outside unless it is powered up and has proper conduit terminations. When NOT powered up, it should be stored in a clean, dry environment at all times.

6. This actuator has been factory calibrated to operate between 0° and 90°. Most quarter-turn products will not require recalibration of these settings. If any travel adjustment is necessary, please refer to pages 10-16 for instructions.

7. The actuator CANNOT operate with a rotation greater than 95°.Product Mounting and Setup1. This actuator assembly contains a phase monitor which must be calibrated once the MCC is wired and permanently

connected to 3 phase wiring feeds. If the monitor is not properly calibrated, nuisance trips may be common. Please refer to pages 19-20 in this document for information.

2. Fit the actuator to the intended valve or damper recipient.• Be sure to note the position of the actuator as well as the intended valve or damper recipient for the actuator.• Using the proper linkage components and/or hardware, mount the actuator to the controlled device.• Check the 0-90 degree operation of the actuator using the handwheel. You should be able to freely rotate the

handwheel and position the actuator from fully CW to fully CCW without requiring undue force. • If binding occurs, remove the actuator from the controlled device and identify the reason for the binding.

3. Position the actuator again at the fully CW position (MCC Direct mount) or the MID POINT position (MCC Remote mount). All mounting hardware should be tight and secure BEFORE power is applied.

4. Make the electrical connections as shown on page 4 of this manual. • Three phase power is applied to terminals A, B & C. • The interface control circuits are all found on terminals 5 - 12 in the MCC cabinet. • Terminals 7-9 on switch card in actuator are an aux switch for the CW position (adjustable), and terminals 10-12 on

switch card in actuator are an aux switch for the CCW position (adjustable). • Auxiliary switches are rated 10A @ 250vac MAX. Terminals 7-12 on the switch card in the actuator are dry type

Form C. • Terminals 5 ~ 12 accept 12-16AWG solid/stranded wire.• Terminals A ~ C accept 10-14AWG solid/stranded wire (see Main Power Block Connection instructions on page

7 of this manual).• The switches located on the front of the MCC cabinet do NOT function as service disconnects.• The Phase Monitor MUST be calibrated BEFORE putting the actuator into service. (see Phase monitor calibration

instructions on page 19.• Do NOT wire multiple actuators together to use a common control. Only ONE MCC per control point. • The drain wire on the signal cables must be grounded at ONE END ONLY! (Preferably at the supply end).

5. Do NOT apply power at this time. 6. Torque Switch UnitsThese units are equipped with internal torque switches which protect the gear train, motor, and controlled equipment from damage when high torque conditions exist. These protective devices are NOT adjustable. More information on this tech-nology is found throughout this manual.

NOTICE:This unit has been tested and calibrated at the factory for proper phasing. Do NOT make changes to the internal cabinet wiring to correct phasing errors.

Field wiring and devices by others

Remote Mounted MCC

Wiring Diagram for P SeriesWiring Diagram for P Series

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Proportional Control(380v/3/60)

Torque Switch UnitsThese units are equipped with torque switches which provide mechanical overload protection for both the actuated device and the geartrain. These are factory set and are not adjustable without proper equipment. Torque switches are set to limit actuator torque to approximately 105% of the actuator rated output. The wiring diagram shows the wiring connections between the control board, the torque switches and the motor. The upper torque switch controls loading in the CW direction while the lower switch controls loading in the CCW direction.

Wire sizing Data is provided in the Wire Sizing Data table to assist in the selection of the proper wire size for ProMation P series actuators using various wire sizes over distance. Please make sure to reference the correct voltage and do not exceed the indicated length of the wire run for each model.

MAX distance between Actuator and Supply (feet)

Actuator P2 P3Voltage 230/3/60 380/3/60 440/3/60 480/3/60 230/3/60 380/3/60 440/3/60 480/3/60

1.4A 0.7A 0.9A 0.9A 1.4A 0.7A 0.9A 0.9A

18 1082 2165 3367 3673 1082 2165 3367 367316 1701 3401 5291 5772 1701 3401 5291 577214 2747 5495 8547 9324 2747 5495 8547 932412 4202 8403 13072 14260 4202 8403 13072 1426010 7143 14286 22222 24242 7143 14286 22222 242428 10661 21322 33167 36183 10661 21322 33167 36183

WireGage

Amps

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Wiring Diagram for P SeriesProportional Control

(380v/3/60)

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Component IdentificationMCC Controls - Front Panel

Installation Notes• These actuators are designed to be used in either a horizontal or upright position. Do NOT mount the assembly with

the actuator top below a horizontal position. • When installing conduit, use proper techniques for entry into the motor control cabinet. Use drip loops to prevent

conduit condensate from entering the actuator or the motor control cabinet.• Mechanical travel stops are factory calibrated for 90 degree operation. These stops are NOT designed to adjust

mechanical rotation by more than +/- 3 degrees, they are for positioning the handwheel only. • Use proper equipment to protect the NEMA 4 integrity of the enclosure.• The internal heater is to be used in ALL applications. • Do NOT install the actuator outdoors or in humid environments unless it is powered up and the heater is functioning. • Use proper wire size to prevent actuator failure (see chart on page 4 for proper wire sizing).

ON when actuator is fully CW

ON when actuator is RUNNING

ON when actuator is fully CCW

Access Latch(quarter-turn)

Positioning control switch when MCC is in LOCAL mode

ON when POWER is present AND

Mode switch is not “OFF”

Mode Switch(selects between LOCAL and

REMOTE operation)

WARNING!The Mode switch does NOT function as a service disconnect!

Power is still present inside this enclosure when the mode switch is OFF.

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Component IdentificationMCC Controls - Inside cabinet

Main3 PhasePower Block

Connections

Field Connection terminals

Phase Monitor

15 terminal DOOR connector

Actuator interconnect

terminals

Actuator MOTOR

connections

RUN indicator dropping

resistors (2)

120v control transformer

ReversingMotor

Starters

Phase monitor factory instructions

(in phase monitor box)

Main 3 Phase Power Block Connection Instructions (Use 10-14AWG)

18mm

ProportionalSignal Cable attached on

back of board

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The proportional control card has been calibrated and tested at the factory to operate between 0 degrees and 90 degrees operating range. There is normally no need for any adjustments at this point in the installation. Changes from the factory set cam settings and controller settings can be very difficult to reverse.

The default settings in the controller are as follows:• Input/Output Signal: 4-20mA (unless otherwise specified at time of Factory order)• Signal Response: Direct Acting (max signal = CCW)• Loss of Signal: Fail in Position• Controller version: 1.15

The Fault Status indicator will blink once per second under normal operating conditions. It will blink approximately three times per second if a fault has occurred. A fault status indication will not return to normal unless the fault has been cleared or the board has been powered down.

Under normal operation, the 4 digit display will show percentage of CCW position...i.e. 25 = 25% CCW, or roughly 22 degrees CCW.

Diagram of ControllerProportional Control

Thermal Sensor Ribbon Cable

Thermal Sensor Connector

Joystick

Signal Connections

Voltage Select

Fault Status (red LED)

5A Fuse

Switch Card Connector Potentiometer

Connector

4 Digit Display

Driving CCW (green LED) Driving CCW

(red LED)

pu

L

pu

R

Joystick

Signal Connection

4 digit display

5A Fuse

Driving Open

Driving Closed

Fault Status

Voltage Sel


Potentiometer Connector

GRN

RED

RED

Switch Card Connector

pu

L

pu

R

Joystick

Signal Connection

4 digit display

5A Fuse

Driving Open

Driving Closed

Fault Status

Voltage Sel


Potentiometer Connector

GRN

RED

RED

Switch Card Connector

Joystick Functionality

Voltage Select Settings

8825

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Press the joystick LEFT twice... Display reads:

Press the joystick DOWN twice... Display reads:

Press the joystick RIGHT once... Display reads:

Press the joystick RIGHT again... Display reads:Press the joystick UP or DOWNto toggle the display to availableselections...

When the correct INPUT signal isdisplayed, press the joystick IN... Display reads:


Press the joystick UP twice... Display reads:

Press the joystick RIGHT once... DOWN twice, then RIGHT once, the display will now show % of CCW position (0.0 = CLOSED)

process in and out

4-20 (mA) (default)

0-10 (vdc)

1-5 (vdc)

2-10 (vdc)

done

SET process signals

00 to 100

SET process signals

realtime

U

realtime

U

Controller: Change INput/OUTput signal typeFollow these instructions to change the input/output signal range or type:

(Assumes actuator is powered up, running and is at the default display showing position).

Power Up (baseline of normal functionality):1. Apply power to the actuator and wait 20

seconds for the controller to power up, self-test, and stabilize.

2. Immediately on power up the fault status light will begin blinking at a rate of once per second throughout operation

3. The 4 digit display will begin sequencing through the self-test messaging.

4. Because there are only 4 display characters the text will scroll or crawl across the display.

5. At this point the actuator is functioning properly.

6. Note: Autocalibrating AFTER any controller modifications wipes out those modifications and the controller starts from it’s new zero point.

Controller: Initial StartupThese instructions illustrate the initial power up sequence for power up, initial data displays, and position display so the user has a baseline for proper startup sequencing.

(Assumes actuator is properly mounted and wired as directed elsewhere in this manual).

Display reads: How the display behaves Notes

example display

Power off

Initial power on display test of all led elements

Software version (in this example: Version 1.15)

Actuator - Voltage (in this example: P13 Actuator - 120 volt)

Rotation display showing 0.0% CCW

(Blank display before power up)

(Static display for about 1 second)

(Text ‘crawls’ left to right. Displays twice.)

(Text ‘crawls’ left to right. Displays twice.)

(Static display, stays on.)

%%%%

8.8.8.8

UEr 1.15

P13-120

%%0.0

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Controller: Adjusting the actuator CW positionFollow these instructions to adjust the CW position controlled by the 105 Proportional Controller (standard operation).Proceed to the next page to adjust the CW position controlled by the travel cam.

(Assumes actuator is powered up, running and is at the default display, showing position).

Notice! Performing an Auto Calibration after this procedure will ERASE this custom stop set point and will return to the factory default setting. For this reason, you CANNOT run an Auto Calibration procedure at any time after this setting has been changed.


Press the joystick DOWN three times... Display reads:


Press the joystick DOWN once... Display reads:

Press the joystick RIGHT once... Display reads:(actual position in steps)

Press joystick UP and HOLD to drive further CCW or press DOWN and HOLD to drive further CLOSED. The adjusted CLOSED position MUST be between 50 and 1000 steps.

When the correct CLOSED position is established,press the joystick IN... Display reads:


Press the joystick UP three times Display reads:

Press the joystick RIGHT once... DOWN twice, then RIGHT once, the display will now show %of CCW position (0.0 = Fully CW)

SET Travel

Auto Set

Full Closed

done

SET travel

00 to 100

00 to 4096

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Loosen Mechanical Stop1. BEFORE power is applied, use a 17mm wrench (or channel locks) and a

5mm hex key to loosen the RIGHT SIDE mechanical stop. This is the CW stop limit adjustment. Turn the stop screw 5-6 turns CCW to allow electrical cam stop adjustment without running into the mechanical stop screw.

2. Use the manual hand wheel to position the actuator to your required CW position. This must be within +/- 3 degrees of the factory setting.

Adjust Cam 1 3. The lower cam is Cam 1, the CW end-of-travel adjustment. Once the actuator

is at its required CW position, with POWER OFF, use a 2.5mm hex key to free up the cam set screw. Once it is free, rotate the hex key to the RIGHT 10-15 degrees to reset the switch roller arm. Then snug the set screw up against the camshaft (CW) until slight pressure is felt. Then SLOWLY rotate the hex key pushing the cam to the LEFT until you hear the “click” on the bottom switch indicating that correct adjustment has been achieved. Tighten the set screw.

4. Apply power to the actuator and drive CCW at least 15-20 degrees. Then drive the actuator CW until the cam stops the electrical travel. Check to be sure this is the correct CW position you require. Repeat step 3 if further adjustment is needed.

Tighten Mechanical Stop5. While holding the 17mm wrench (or channel locks) on the RIGHT SIDE jam

nut to prevent the jam nut from locking, turn the 5mm hex key CW until the end of the stop screw bottoms out against the internal stop boss. Then turn the hex key ONE FULL TURN CCW before locking that adjustment with the jam nut. This procedure assures that the actuator reaches its end of travel electrically before there is any interference from the mechanical stop.

6. This completes the CW position calibration.

CW Mechanical Stop

CW Mechanical Stop

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Cams: Adjusting the actuator CW positionSerious Damage to the actuator will result if the motor is allowed to drive the gear train into the mechanical stop!! Remove power from this device BEFORE making any travel adjustments.This actuator has been factory calibrated to operate between 0° and 90°. Most quarter-turn products will not require recalibration of these settings.

Notice! After completing this step, you must initiate a recalibration routine (see AutoCalibration Procedures) in order for the changes to take effect in the controller.

Potentiometer Gear EngagementDuring the setting of the CW stop position, make sure that the potentiometer pinion gear and the camshaft sector gear do not drive past the point of engagement. If the sector gear does not have at least 2 full teeth contacting the potentiometer pinion gear, contact your distributor for mechanical recalibration instructions.

The mechanical stop screw limits handwheel operation ONLY and is NOT to be used as an electrical travel limiting device.

COM

NONC

CLOSEDLIMIT

SWITCH

LESSCLOSED

FURTHERCLOSED

COM

NONC

OPENLIMIT

SWITCH

LESSOPEN

FURTHEROPEN

COM

NONC

CW LIMIT SWITCH

LESSCW

FURTHERCW

COM

NONC

CCW LIMIT SWITCH

LESSCCW

FURTHERCCW

Cam 1

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Controller: Adjusting the actuator CCW position

Follow these instructions to adjust the CCW position controlled by the 105 Proportional Controller (standard operation).Proceed to the next page to adjust the CCW position controlled by the travel cam.

(Assumes actuator is powered up, running and is at the default display, showing position).

Notice! Performing an Auto Calibration after this procedure will ERASE this custom stop set point and will return to the factory default setting. For this reason, you CANNOT run an Auto Calibration procedure at any time after this setting has been changed.





Press the joystick RIGHT once... Display reads:(actual position in steps)

Press joystick UP and HOLD to drive further CCW or press DOWN and HOLD to drive further CW. The adjusted CCW position MUST be between 2500 and 4000 steps.

When the correct CCW position is established,press the joystick IN... Display reads:




SET Travel

Auto Set

Full open

done

SET travel

00 to 100

00 to 4096

realtiOe

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Loosen Mechanical Stop

1. BEFORE power is applied, use a 17mm wrench (or channel locks) and a 5mm hex key to loosen the LEFT SIDE mechanical stop. This is the CCW stop limit adjustment. Turn the stop screw 5-6 turns CCW to allow electrical cam stop adjustment without running into the mechanical stop screw.

2. Use the manual hand wheel to position the actuator to your required CCW position. This must be within +/- 3 degrees of the factory setting.

Adjust Cam 2

3. The second cam is Cam 2, the CCW end-of-travel adjustment. Once the actuator is at its required CCW position, with POWER OFF, use a 2.5mm hex key to free up the cam set screw. Once it is free, rotate the hex key to the LEFT 10-15 degrees to reset the switch roller arm. Then snug the set screw up against the camshaft (CW) until slight pressure is felt. Then SLOWLY rotate the hex key pushing the cam to the RIGHT until you hear the “click” on the second switch indicating that correct adjustment has been achieved. Tighten the set screw.

4. Apply power to the actuator and drive CW at least 15-20 degrees. Then drive the actuator CCW until the cam stops the electrical travel. Check to be sure this is the correct CCW position you require. Repeat step 3 if further adjustment is needed.

Tighten Mechanical Stop5. While holding the 17mm wrench (or channel locks) on the LEFT SIDE

jam nut to prevent the jam nut from locking, turn the 5mm hex key CW until the end of the stop screw bottoms out against the internal stop boss. Then turn the hex key ONE FULL TURN CCW before locking that adjustment with the jam nut. This procedure assures that the actuator reaches its end of travel electrically before there is any interference from the mechanical stop.

6. This completes the CCW position calibration.

CCW Mechanical Stop

CCW Mechanical Stop

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Cams: Adjusting the actuator CCW position

Notice! After completing this step, you must initiate a recalibration routine (see Auto-Calibration Procedures) in order for the changes to take effect in the controller.

The mechanical stop screw limits handwheel operation ONLY and is NOT to be used as an electrical travel limiting device.

Serious Damage to the actuator will result if the motor is allowed to drive the gear train into the mechanical stop!! Remove power from this device BEFORE making any travel adjustments.This actuator has been factory calibrated to operate between 0° and 90°. Most quarter-turn products will not require recalibration of these settings.

COM

NONC

CLOSEDLIMIT

SWITCH

LESSCLOSED

FURTHERCLOSED

COM

NONC

OPENLIMIT

SWITCH

LESSOPEN

FURTHEROPEN

COM

NONC

CW LIMIT SWITCH

LESSCW

FURTHERCW

COM

NONC

CCW LIMIT SWITCH

LESSCCW

FURTHERCCW

Cam 2

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Press the joystick DOWN once... Display reads:

Press the Joystick RIGHT once... Display reads:

Press the Joystick DOWN once... Display reads:

Press the Joystick RIGHT once... Display reads:

Press the joystick UP or DOWN to select Display reads:

{The display shows percentage of full CCW. i.e. 100.0 = full CCW. 50.0 = 50% CCW, 0.0 = Full CW. -0.1 = Fail in position (no move)}

After selection is displayed, press the joystick IN...

Display reads:

Press the joystick LEFT three times... Display reads:

Press the joystick UP twice... Display reads:


SET Process

in and out

INput Fault

done

SET Process

00 to 100

Fault Level

Fault Position

-0 .1

-0 .1 to 100 . 0

realtime

U

realtime

U

Controller: Change Loss of Signal Response Setting(Assumes actuator is powered up, running and is at the default display, showing position).

Notice: Any changes, settings or new calibration points are lost if a factory “Reset” is performed on the controller. Contact the factory for details.

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Controller: Auto-Calibration Procedure(Assumes actuator is powered up, running and is at the default display, showing position).

Notice: Any changes, settings or new calibration points are lost if a factory “Reset” is performed on the controller. Contact the factory for details.





Press the joystick IN. The display will show calibration routines AC1 through AC10, moving the actuator to different positions and recording data at each step. When the auto calibration routine is complete, the actuator will be in the fully CW position, and the display will read:




SET Travel

Auto Set

Push to run

done

SET travel

00 to 100

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Cams: Adjusting the actuator Auxiliary SwitchesAdjust Cam 31. The THIRD cam is Cam 3, the CW auxiliary switch adjustment.

Drive the actuator to its CW position. Then use a 2.5mm hex key to free up the cam set screw. Once it is free, rotate the hex key to the RIGHT 10-15 degrees to reset the switch roller arm. Then snug the set screw up against the camshaft (CW) until slight pressure is felt. Then SLOWLY rotate the hex key and cam to the LEFT until you hear the “click” on the third switch. Continue to rotate the cam between 3 and 5 degrees to the LEFT to make sure the auxiliary cam switch changes state before the actuator reaches its end of travel electrically. Tighten the cam set screw.

Adjust Cam 41. The FOURTH cam is Cam 4, the CCW auxiliary switch adjustment.

Drive the actuator to its CCW position. Then use a 2.5mm hex key to free up the cam set screw. Once it is free, rotate the hex key to the LEFT 10-15 degrees to reset the switch roller arm. Then snug the set screw up against the camshaft (CW) until slight pressure is felt. Then SLOWLY rotate the hex key to the RIGHT until you hear the “click” on the fourth switch. Continue to rotate the cam between 3 and 5 degrees to the RIGHT to make sure the auxiliary cam switch changes state before the actuator reaches its end of travel electrically. Tighten the cam set screw.

Cam 3

Cam 4

Mechanical Data

1

1

2

2

A A

B B

Drawn By

Finish

Promation Engineering Inc.16138 Flight Path Drive

Brooksville, Fl 34604Phone: 352-544-8436Fax: 352-544-8439

This Document is the property of ProMation Engineering,Inc. Distribution of this document without the written

consent of the owner is Strictly forbidden. Failure to comply will incur a liability for Damages.

Checked By4/15/2014

P2~P3 TS Dim Data Rev.

C

NO SCALE Sheet Number: 1

Material

ProMation Engineering, Inc.KHL

KHL

4/25/2013

P2_3 TS F07 8P22 DimData.idw

Created:

Last Checked:

Part No.

Dwg. Name

Dimensional Data for P2~P3 TS Actuators

Engineering Change NoticeChange Date Description Name

11.08.2013 New Document KHL

11.12.2013 Added rounded edges on Drive Coupling Data KHL

04.15.2014 Added tolerance on drive coupling data KHL

REVA

B

C

D

E

F

Dimensional Tolerances (Unless Otherwise Noted):X ± 2.5mm [X.X ± .1]

X.X ± .3mm [X.XX ± .01"]X.XX ± .13mm [X.XXX ± .005"]

ALL TOLERANCE FEATURES IN mm

Drive Coupling Fabrication Data

22.00 - .13.00+ mm

0.866 - 0.0050.000+ in

22.00 - .13.00+ mm

0.866 - 0.0050.000+ in

30.00 mm1.181 in

357 mm14.0 in

262 mm10.3 in

212 mm8.3 in

180 mm7.1 in

123 mm4.8 in

90 mm3.5 in

287 mm11.3 in

Add 257mm

[10.1"] to allowfor coverremoval

125 mm4.9 in

87 mm3.4 in

(2) 3/4" NPTEMT Entry

70 mm2.8 in(4) M8x1.25

20mm0.8"

22 mm0.9 in

F07 ISO Flange

30.00 mm1.181 in

P2/3-TS Series Dimensional Data

Depth Height

Width

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Mechanical Data

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Mechanical Data

Switch sequencing data is provided in the table below to show the change-of-state points during the rotation of the actuator from CCW to CW and back again. Switches for terminals 3 thru 6 are set at the factory and should NOT be changed. The INCLUDED auxiliary switches SW3 & SW4 are for terminals 7 thru 12 and those set points may be modified if need be. When so optioned, SW5 & SW6 auxiliary switches are initially set to function the same as auxiliary switches SW3 & SW4.

Switch Logic Map and Switch/Cam Arrangement

P Series Exploded View (P13-120N4 unit is shown)

Easily distinguishable yellow/red position

indicator

Worm Drive

Heavy Duty Drive Motor

Easily accessible switch & cam stacks

Modular ControlCards

Clutchless Override

Handwheel

Aluminum CastingNEMA 4X Protection

Aluminum CastingNEMA 4X Protection

Epicyclic Gearing

NEMA 4XCover Seal

Term

inal

ID#

12

11

10

9

8

7

-5° 0°CW CCW

85°5° 90° 95°

SW3 CCW AUX(Factory Set - Adj)

SW4 CW AUX(Factory Set - Adj)}

}Closed Common

Open Common

}Used by Controller

Open

Not Closed

Closed

Not Open

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Phase Monitor Calibration

At the heart of the ProMation Engineering Motor Control Center (MCC) is the Phase monitor relay. Unlike other three-phase industrial actuators, the ProMation Phase monitor utilizes a microprocessor-based design to provide protection against phase loss, phase reversal, phase unbalance, undervoltage and overvoltage as well as unbalanced voltages or single phasing regardless of any regenerative voltages.

The relay is energized when the phase sequence and all voltages are correct. Any one of five fault conditions will de-energize the relay. As standard, re-energization is automatic upon correction of the fault condition. The Phase monitor not only protects the motor, but the process as well. Phase disruption can cause the motor to run in an unintended direction.

A multi-color LED indicates normal condition and also provides specific fault indication to simplify troubleshooting. The Phase monitor offers a variety of user-adjustable settings. The percent phase unbalance is adjustable from 2-10%, and also has a “Disable” setting for those applications where poor voltage conditions could cause nuisance tripping. The undervoltage drop-out can be set at 80-95% of operating voltage (overvoltage setting is fixed at 110% of nominal). The adjustable time delay drop-out on undervoltage (0.1-20 seconds) eliminates nuisance tripping caused by momentary voltage fluctuations. There is also an adjustable time delay (1-300 seconds) on both power up and restart after a fault has been cleared.

Automatic Phase Protection

Phase Loss:Unit trips on loss of any Phase A, B or C.

Phase Reversal:Unit trips if rotation (sequence) of the three phases is anything other than A-B-C.

Undervoltage:Adjustable from 80-95% of nominal voltage. Unit trips when the average of all three lines is less than the adjusted set point for a period longer than the adjustable time delay drop-out.

Overvoltage:Fixed at 110% of nominal voltage. Unit trips when the average of all three lines is greater than the fixed set point for a period longer than the time delay drop-out.

Phase Unbalance:Adjustable from 2 - 10% unbalance. Unit trips when any one of the three lines deviates from the average of all three lines by more than the adjusted set point. There is also a “Disable” setting adjustment that will turn off the Phase Unbalance Protection if nuisance tripping is a problem.

Output Contacts:SPDT: 10A @ 240V AC/30V DC, 1/2HP @ 240V AC

Life:Mechanical: 10,000,000 operationsFull Load: 100,000 operations

Response Times:Power Up & Restart After Fault: 1 - 300 seconds adjustableDrop-out Due to Fault:

• Phase Loss & Reversal 100ms fixed• Phase Unbalance 2 seconds fixed• Undervoltage 0.1 - 20 seconds adjustable• Overvoltage Fixed Time Based on Inverse

Time Curve

Hysteresis: 2 - 3%

Load (Burden): Less than 3VA

Temperature: -28o to 65oC (-20o to 150oF)

Mounting: Uses an 8 pin octal socket.

Fault Conditions Specifications

● Universal voltage range of 208-480V provides the flexibility to cover a variety of applications with one unit

● Protects against phase loss, phase reversal, phase unbalance, undervoltage and overvoltage

● Variety of user-selectable and adjustable settings for the ultimate in three-phase protection

● Automatic or Manual Reset ● Multi-Color LED indicates

normal condition and defines fault to simplify troubleshooting

● Compact plug-in case utilizing industry-standard 8 pin octal socket

● 10A SPDT output contacts

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Factory Settings at time of delivery are as follows:

Undervoltage: 89%

Time Delay Undervoltage: 3 sec

Time Delay Restart: 3 sec

Phase Unbalance: 4%

Nominal Voltage: 230-480v

Status LED

Troubleshooting Procedures for Phase monitor

Condition Status Check

Phase monitor shows a solid GREEN LED Normal Operating Mode

This is the required operating mode. The phase monitor must show SOLID GREEN in order to proceed further

Phase monitor shows a flashing GREEN LED Power Up Restart Delay

This is the required delay after power is applied to the Phase monitor

Phase monitor shows a solid RED LED Phase Reversal (change any two phase connections inside the MCC on MAIN terminals A, B and C)

Phase monitor shows a RED LED flashing repeatedly 1 time

Phase Loss or Unbalance (incoming power problem)

Phase monitor shows a RED LED flashing repeatedly 2 times Undervoltage (incoming power problem)

Phase monitor shows a RED LED flashing repeatedly 3 times Overvoltage (incoming power problem)

Torque Switch cams shown in the NORMAL operating position (No high torque situations)

High Torque Cam (bottom) for CCW

Output Drive Rotation

High Torque Cam (top) for CW Output

Drive RotationHigh Torque Switch (top) for CW Output

Drive Rotation

High Torque Switch (bottom) for CCW


WARNING! Do NOT adjust the torque switch cam settings. This will VOID the

warranty.

Commissioning230/3 ~ 480/3 P Series actuators with MCC

After completing all mounting and wiring procedures and main power is available, it is now possible to commission the motor control station.

After three phase power is applied, the phase monitor will prove whether phases are properly sequenced and balanced. This will be indicated by the solid green LED on the face of the white phase monitor located inside the MCC. If the green LED is NOT present after power up, refer to the phase monitor troubleshooting section on page 20.

Pages 6 & 7 provide an overview of the features and components of the MCC.There are two switches and four indicators located on the door of the MCC:

The MODE switch selects the LOCAL or REMOTE operating mode. In LOCAL mode, the POSITIONING switch on the front of the MCC door controls the movement of the actuator between fully CCW, fully CW or stop anywhere in between. In REMOTE mode, a field controller provides the positioning of the actuator, wired to terminals 9 & 10 inside the MCC. In REMOTE mode, the positioning switch has no effect on the positioning of the actuator.

Test Procedure:

1. Turn the MODE switch to “Off” if not already done.2. Utilize the handwheel to rotate the actuator and damper, valve or other connected device through its full travel from full

CW to full CCW and back again to check for any possible interference. • Do NOT utilize any mechanical advantage devices to rotate the handwheel (pipes, wrenches, extension bars, etc.).

3. Manually position the actuator to its mid-stroke position.4. Turn the MODE switch to LOCAL.

• The BLUE “POWER” LED will turn on.• Measure 120 vac on terminals Hot (1) & Neu (2) on the switch card.• Measure 120 vac on the two heater terminals on the switch card.

5. Turn the POSITIONING switch to OPEN. • Measure terminals 2 (Neu) and 6 (Run CCW) for 120 vac. • The YELLOW “RUN” LED will turn ON and the actuator will drive to the fully CCW position.• The GREEN “OPEN” LED will turn on after the end of travel is reached, and the “RUN” indicator will turn OFF.

6. This unit incorporates a torque overload protection system. In NORMAL operating mode, the torque switch drive cam is in this position:

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Torque Switch cams shown with the lower cam in a TRIPPED position (high torque in the

CCW Output Drive Direction)




Drive Rotation



High Torque Switch (top) for CW Output

Drive RotationWARNING! Do NOT adjust the torque switch cam settings. This will VOID the

warranty.

Torque Switch cams shown with the upper cam in a TRIPPED position (high torque in

the CW Output Drive Direction)




Drive Rotation



High Torque Switch (top) for CW Output

Drive RotationWARNING! Do NOT adjust the torque switch cam settings. This will VOID the

warranty.

Commissioning (continued)

8. Turn the POSITIONING switch to CLOSE.• Measure terminals 2 (Neu) and 4 (Run CW) for 120 vac.• The YELLOW “RUN” LED will turn ON and the actuator will drive to the fully CW position. • The RED “CLOSED” LED will turn on after the end of travel is reached, and the “RUN” indicator will turn off.

9. Rotate the manual override handwheel in a CW direction to continue to drive the output drive in a CW direction until the drive system reaches the end of its MECHANICAL travel either by coming into contact with the mechanical stop screw OR it reaches the end of the valve (or damper) travel. This is indicative of an increasing force required to rotate the handwheel. At this point the torque switch cam shaft starts to rotate in a CCW direction. As you continue to rotate the handwheel in the CW direction the torque switch cam shaft will continue to rotate in the CCW direction until the UPPER cam trips the UPPER high torque switch. At this point, stop rotating the handwheel as you’ve simulated reaching the electrical drive limit of the actuator under excessively high torque situations in the CW output drive direction.

7. Rotate the manual override handwheel in a CCW direction to continue to drive the output drive in a CCW direction until the drive system reaches the end of its MECHANICAL travel either by coming into contact with the mechanical stop screw OR it reaches the end of the valve (or damper) travel. This is indicative of an increasing force required to rotate the handwheel. At this point the torque switch cam shaft starts to rotate in a CW direction. As you continue to rotate the handwheel in the CCW direction the torque switch cam shaft will continue to rotate in the CW direction until the LOWER cam trips the LOWER high torque switch. At this point, stop rotating the handwheel as you’ve simulated reaching the electrical drive limit of the actuator under excessively high torque situations in the CCW output drive direction.

10. At any point in the mid travel, the POSITIONING switch can be turned to the STOP position, whereupon the “RUN” indicator will turn OFF and the actuator will stop movement.

11. While in the LOCAL MODE, the field controller commands are ignored.12. Turn the MODE switch to REMOTE. The BLUE “POWER” LED will turn on.

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Commissioning (continued)

13. Command the field controller to generate an OPEN signal. The YELLOW “RUN” LED will turn ON and the actuator will drive to the fully CCW position. The GREEN “OPEN” LED will turn on after the end of travel is reached, and the “RUN” indicator will turn off.

14. Command the field controller to generate a CLOSE signal. The YELLOW “RUN” LED will turn ON and the actuator will drive to the fully CW position. The RED “CLOSED” LED will turn on after the end of travel is reached, and the “RUN” indicator will turn off.

15. At any point, the field controller can provide a signal between the full OPEN and full CLOSE signals. The actuator will move to this relative position, whereupon the “RUN” indicator will turn OFF and the actuator will stop movement.

16. While in the REMOTE MODE, the POSITIONING switch on the front of the MCC is ignored.17. Turn the MODE switch to “OFF”, and the BLUE “POWER” LED will turn off. In this mode, all commands from the

POSITIONING switch and the field controller are ignored. Power is removed from the CONTROL circuit of the actuator, and all LED indicators are turned OFF.

WARNING! THIS DOES NOT SERVE AS A SERVICE DISCONNECT! 3 PHASE MAIN POWER IS STILL PRESENT INSIDE THE MCC!

18. Motor Control Center and Actuator are now commissioned and operational.

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Industrial ApplicationsProMation Engineering actuators have been installed to operate process controls such as butterfly valves, ball valves, high performance valves, plug valves, gate valves and dampers, in a broad range of demanding industrial applications.

Power Generation

Water Processes Mining Oil and Gas Agriculture Chemicals

16138 Flight Path Drive Brooksville, FL 34604

Phone (352) 544-8436 Fax (352) 544-8439email: sales@promationei .com

Use your smart phone barcode scanner app here.

Full Documentation We offer complete wiring diagrams, field installation manuals and set up documentation for all our products, both in printed and digital form. We regularly host customized educational webinars for our customers.

RapidQuoteMost quotes and estimates are generated within hours of the request.

ProMation Engineering Services ProMation Engineering can provide design and technical services for OEM’s, projects with customized requirements and specialized operations.

Complete SupportProMation Engineering is committed to providing superior customer support compared to our larger competitors. Contact us today.

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