MicroTorque Precision Electric Rotary Actuator. Instruction Manual

Transcription

1 MicroTorque Precision Electric Rotary Actuator Instruction Manual

2 MicroMod Automation, Inc. The Company MicroMod Automation & Controls is dedicated to improving customer efficiency by providing the most cost-effective, application-specific process solutions available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation. We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support. The quality, accuracy and performance of the Company's products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology. Use of Instructions Warning. An instruction that draws attention to the risk of injury or death. Note. Clarification of an instruction or additional information. Caution. An instruction that draws attention to the risk of the product, process or surroundings. i Information. Further reference for more detailed information or technical details. Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices. Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of MicroMod Automation & Controls, Inc. Licensing, Trademarks and Copyrights MOD 30 and MOD 30ML are trademarks of MicroMod Automation & Controls, Inc. MODBUS is a trademark of Modicon Inc. Health and Safety To ensure that our products are safe and without risk to health, the following points must be noted: The relevant sections of these instructions must be read carefully before proceeding. 1. Warning Labels on containers and packages must be observed. 2. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given or injury or death could result. 3. Normal safety procedures must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/or temperature. 4. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used. 5. When disposing of chemicals, ensure that no two chemicals are mixed. Safety advice concerning the use of the equipment described in this manual may be obtained from the Company address on the back cover, together with servicing and spares information.

3 1 INTRODUCTION PRODUCT OVERVIEW FEATURES SPECIFICATIONS MODEL NUMBER BREAKDOWN DIAGRAMS Motor Side View Control Side View Heater option Control Panel Dimensions MECHANICAL INSTALLATION GENERAL BRACKET AND COUPLING INSTALLATION WIRING POWER WIRING AND GROUNDING Wiring recommendations Procedure SIGNAL WIRING Control Wiring Auxiliary Limit Switch Wiring Option Board and Option Module Wiring SETUP & CALIBRATION DESCRIPTION OF CONTROL PANEL FACTORY SETTINGS SETUP (REQUIRED CALIBRATION) CHANGING FACTORY DEFAULTS Over Travel Limit Switches and Stroke Feedback Potentiometer Calibration Reversing Actuator Rotation Input Type Position on Loss of Command Signal (close) Auxiliary Limit switches OPTION SETUP Setting Aux Close and Aux Open Relay Outputs Output Calibration Feedback Potentiometer Output Calibration mA Slide Wire Input Calibration ADDITIONAL INSTALLATION INFORMATION Stall Detection Feature Electronic Brake Feature Duty Cycle Control Feature COMMUNICATIONS WIRING S1- MODBUS ADDRESS AND LT RESISTOR S2 BAUD RATE, MODE AND PARITY HOST DEVICE WIRING AND SETTINGS SUPPORTED MODBUS FUNCTIONS MODBUS REGISTERS MICROMOD XMODBUS OPC SERVER COMMUNICATION Set up the OPC Device and Tags...34

4 5.7.2 Edit Com Port Settings Read Register Settings TROUBLESHOOTING ACTUATOR OPERATION COMMUNICATIONS...39 APPENDIX A MICROMOD CONTROLLER WIRING CROSS REFERENCE...40

5 IMPORTANT NOTICE This instruction manual contains important information regarding the installation, operation and troubleshooting of MicroMod s MicroTorque Electric Actuator. Please read these instructions carefully and save for future reference.

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7 1 INTRODUCTION The MicroTorque is a high resolution actuator designed to provide superior process control through precise positioning of rotary final control elements. Typical applications include ball valves, butterfly valves, and dampers. This Instruction Manual provides information on installation and use of the MicroTorque. 1.1 Product Overview The MicroTorque actuator has a LED and 3 pushbutton controls for easy commissioning. Rotation, zero and span, open and close position, auxiliary open and close positions, loss of signal position, and signal type are all configurable using this interface. A variety of factory installed or field-interchangeable control boards and modules make the MicroTorque a versatile choice. Inputs include 0-10V, 0-5V, 1-5V, 4-20mA, and a resistance module for use with slide wires. Output options include 4-20mA, 0-10V, isolated 4-20mA, and a 4-20mA with three relay outputs. A 485 Modbus communication module allows the actuator to be integrated into a SCADA system allowing for performance analysis and preventative maintenance. The MicroTorque is engineered for precise positioning. Its high resolution of.2 degrees provides for 450 repositions through 90 degrees of travel. The actuator has precision of.1 degrees. This combination of precision and accuracy make the MicroTorque suited to a variety of processes such as air damper actuation, feedwater valves, Fuel gas valves, and Steam valves. The widely used F3, F5, and F7 ISO 5211 mounting pattern allows for the actuator to easily be mounted to most devices. Custom mounting brackets are also available on request; contact MicroMod Automation s customer support for more information. The MicroTorque s NEMA 4 enclosure and optional heater make it suited for use in most environments and temperatures. 1

8 1.2 Features Speed, accuracy, stroke - Modulating accuracy of 450 positions through 90 - Repeatability of.2 degrees - Precision of.1 degree - Cycle time of 16 seconds for 90 degrees - 90 degree Stroke field adjustable from 30 to 270 Superior control features - Adaptive control automatically adjusts for changes in load - Pulsed power control of motor control make tiny repositions possible - Electronic braking allows for precise positioning without overshoot Easy setup - Push button reversible clockwise/counterclockwise operation. - Push button setting of open, close, and auxiliary positions. - Push button setting of loss of command to open, close, or last position. - Push button setting of zero and span. - Push button setting of feedback signal zero and span. - Push button Auto/Manual mode and forward reverse arrow buttons. Inputs and Outputs and switches and electronically configured settings - Standard 4-20mA, 0-5V, 1-5V, 0-10V inputs and optional resistance input (slide wire) - Optional 4-20mA, 2-wire 4-20mA and 4-20mA with two relay outputs - Standard 1KΩ feedback pot with 6000 points of resolution - Programmable span & zero settings - Fault relay, aux open relay, and aux close relay optional - Two additional limit switches for open and close with both NO and NC contacts. - Open, Close, Aux Open, Aux Close, and Loss of signal position set electronically with.2 degrees of accuracy. Safety features - Two motor travel limit switches standard - Fault conditions including - Motor stall, Loss of command signal, Loss of feedback - Fault LED and Optional fault relay - Duty cycle protection prevents motor from over heating - User configurable position on loss of command Communications - optional 2-wire 485 Modbus RTU communications - Flag registers provide configuration information and fault information. - Read operating characteristics for use with diagnostics - Optional integration with operator panels and popular SCADA packages 2

9 1.3 Specifications Item Specification(s) Motor Operating Specifications Torque 400 in. lbs Stroke Factory set 90, field adjustable Stroke Time 16 seconds/90 Duty Cycle Continuous (100%) Starts per Hour 1800 Rotation Field Programmable Loss of Power Stays in place Loss of Command Field Programmable End of travel Limit switches Standard field adjustable Power Specifications Power supply 117VAC ±10%, 50/60 Hz Power consumption 70 VA (normal), 250VA (max) Motor Off-state Leakage Current < 15mA Maximum Load Current 60ºC Fuse 6.3A TR5 Time Delay (replaceable) Input Specification Standard Input Types Input Impedance Loss-of-Signal Threshhold Standard Position Feedback (to be used with option modules) Standard Limit switches Aux Open Aux Close Environmental Characteristics Enclosure Rating Operating Temperature With Heating Option Storage Temperature Relative Humidity 4-20mA, 0-5VDC, 1-5VDC, 1-10VDC 251Ω ±1% (4-20 ma Input) 20K ohms (1-5 VDC, 0-5 VDC, 0-10 VDC Input) < 0.75V or > 5.5V (1-5 VDC input) < 3mA or > 22mA (4-20mA input) 1KΩ precision potentiometer SPDT, rated at 15A SPDT, rated at 15A UL Type 4 (NEMA 4), IP66 0ºC to +60ºC (32ºF to 140ºF) -20ºC to +60ºC (-4ºF to 140ºF) -40 C to +85 C (-40 F to +185 F) 0 to 90 % (noncondensing) Physical Characteristics Lubrication Lubrico LM203 Cover Material PVC composite Base Material Diecast Zinc alloy Gear Train Material 1018 low carbon steel Bracket material Carbon steel or stainless steel Weight 8.2 lbs Dimensions see figure Mounting specifications Mounting Pattern Actuator Output ISO 5211 F3, F5, and F7 standard 14mm square (8 point star) 3

10 Option Module Specifications Item Specification(s) OTR-100 V/mA Feedback Transmitter / Relay Output Current Output Range 0 to 8VDC or 400Ω maximum Resolution mA Voltage Output Range 0 to 10mA maximum Resolution VDC Relay Outputs Switch Contact Type SPST Contact Rating (non-inductive) 24VDC / 125VAC OTX-100 V/mA Feedback Transmitter Current Output Range Resolution Voltage Output Range Resolution 0 to 8VDC or 400Ω maximum mA 0 to 10mA maximum VDC OTX-101 Isolated 2-Wire Feedback Transmitter Loop Power Requirements Minimum Voltage 5.5 VDC Maximum Voltage 30 VDC Maximum Reverse Voltage 40 VDC Maximum Power Dissipation 0.6 W Current Output Range 4 to 20mA (adjustable) Resolution mA Environmental Stability Zero 0.005% of zero per C maximum Span 0.025% of span per C maximum XMA mA Slide Wire Transmitter Power Requirements Minimum Voltage Maximum Voltage Maximum Reverse Voltage Maximum Power Dissipation Input Impedance Output Specifications Zero Output, 4.0 ma 6 VDC 28 VDC 40 VDC 0.56 W 100K ohms Full Scale Output, 20.0 ma Accuracy Zero 25 C Span 25 C Environmental Stability Zero Span input = 0 VDC (factory setting) / 0 to 0.01 VDC (adjustable) input = 0.2 VDC (factory setting) / 0.14 to 0.2 VDC (adjustable) 0.010% of zero per C maximum 0.015% of span per C maximum 4

11 Option Module Specifications (cont d) Item XMA-105 Feedback Potentiometer Transmitter Operating Voltage Operating Current (not including output current and feedback pot) Input Specifications Zero (output = 4.0mA) Span (output = 20.0mA) Zero-to-Span Differential Input Impedance Feedback Potentiometer (total resistance) OCM-101 Modbus Communication Module Bus Connection Type Protocol Selectable Address Selectable Line Terminating Resistor (RBA) Line Polarization Cable Characteristic Impedance Specification(s) 11 to 32 VDC 5 to 8 ma 0.2 to 5 VDC 0.62 to 10 VDC 0.42 VDC minimum 200K ohms 1K to 10K ohms ANSI TIA/EIA RS-485A (electrically isolated up to 1500 VRMS) Modbus (selectable RTU or ASCII mode) Logic "1": +VBA Logic "0": -VBA 0 to 255 (1 to 247 usable) 150 ohm Not required A value of 100 ohms or greater may be preferred, especially for 19.2K and higher baud rates. BAUD RTU mode character periods RATE t1.5 (usec) t3.5 (usec) ,719 4, K 859 2, K K Transmitter Output Differential Output Voltage (VBA) Output Short Circuit Current A to B A or B to COM Transmitter Input Input Impedance (RBA) Input Logic Threshold Voltage (VBA) Input Hysteresis 5V no load 1.5V 54 ohm load 95mA typical 113mA typical 96K ohms min (1/8 node) 30mV min, 200mV max 20mV typical 5

12 1.4 Model Number Breakdown BASE INSTRUMENT MicroTorque Quarter-Turn Electric Actuator MT A MT TORQUE 400 in/lb 400 POWER REQUIREMENTS 115V AC 50/60 Hz 1 OPTION BOARDS (see Note 1) None 0 Feedback transmitter 4-20mA 1 Isolated 2-wire Feedback Transmitter 4-20mA 2 Feedback transmitter 4-20mA with relay output (3) 3 RS-485 Modbus RTU Communications M OPTION MODULE (see Note 1) None 0 Feedback transmitter 4-20mA 1 Slide Wire Transmitter, 4-20mA loop powered (for use with 100 ohm to 10K ohm slide wires) 2 HEATING None 0 Heater and thermostat for anti-condensation and operation to -40º C H DESIGN LEVEL Design Level A Note 1: MicroTorque will accommodate one option board and one option module simultaneously. The 4-20mA Feedback transmitter is available as an option board and an option module to allow greater flexibility in combining options. The board and module perform the same function. 6

13 1.5 Diagrams Motor Side View Control Side View 7

14 1.5.3 Heater option Note: the heater option is factory-installed only and cannot be added in the field Control Panel 8

15 1.5.5 Dimensions 9

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17 2 MECHANICAL INSTALLATION 2.1 General Caution Read and follow all instructions carefully to avoid damage to equipment or personnel. The MicroTorque actuator is intended to be mounted, wired and commissioned by a qualified installer. It is the responsibility of the installer to verify that the output torque of the actuator is appropriate for the torque requirements of the valve and that the actuator duty cycle is appropriate for the intended application. 2.2 Bracket and Coupling Installation Due to the wide variety of valves and dampers it is not possible to give detailed mounting instructions that will apply to all cases. The mounting instructions below give mounting recommendations followed by examples that relate to one of the more common mounting configurations. It is the responsibility of the qualified installer to adapt the instructions to their particular installation and reference the documentation of the valve or damper manufacturer when doing so. 1. Place coupling on valve stem. 2. Use size 14 wrench on actuator end of coupling to move the valve/damper to the closed position. NOTE: often the valve is in the closed position when the flat side of the valve stem is perpendicular to the run of the pipe 3. Align bracket over valve mounting holes in a manner such that the interior of the bracket is easily accessible by wrench and the coupling can be adjusted with a wrench as well. Use hardware provided to fasten the bracket to the valve. 4. Verify that the valve appears to be in the closed position. When in the closed position the corners of the valve coupling should line up with the mounting holes in the bracket (refer to following diagram): 5. Determine desired alignment of the actuator. The preferred alignment is where the maintenance technician will have the conduit side of the actuator to their left with room to work, and the opposite side of the actuator to his right with room to work. Cam adjustment will occur on the left side of the actuator. Wiring and pushbutton operation will occur on the right (refer to following diagram): 11

18 NOTE: Six inches of clearance above the top of the actuator cover is needed to allow for removal of the cover. 6. Position the actuator in the desired orientation above the bracket so that the coupling is centered on the 8-point star on the bottom of the actuator as shown below. 7. When the valve is in the closed position the square coupling should line up with the 8 point star on the actuator. Insert the coupling into the 8 point star. 8. Once the coupling is secure in the 8 point star use hardware provided with the bracket to secure the actuator to the bracket. NOTE: If the bracket mounting holes have a rotational offset from the actuator mounting holes, it will be necessary to realign the valve. Remove the actuator and use the wrench to move the valve into a position where the coupling can be inserted into the actuator. Once the coupling is reinserted, attach the actuator to the bracket using the hardware provided. If the new position does not correspond to the valve closed position, the default position settings will be skewed from the desired positions. Additional calibration may be necessary. 9. Remove the four bolts securing the actuator cover to the base (see Step 5 diagram for bolt locations). Remove the cover from the actuator and proceed with wiring. 12

19 3 WIRING Caution: High voltages are present on the inside of the unit when power is applied. AC power should be disconnected and antistatic measures should be taken prior to any wiring of these units. Warning: The MicroTorque actuator is intended to be mounted, wired and commissioned by a qualified installer. 3.1 Power wiring and grounding Wiring recommendations The power wire size must be from 14 AWG (1.6 mm) to 18 AWG (1.0 mm) with a 600V, -20 C +105 C UL, CSA approved rating. All power wiring must be in compliance with the requirements of the National Electrical Code or Canadian Electrical Code. In any installation where the power source does not have one side of the line connected as a neutral conductor, both sides of the line must be overcurrent protected. The actuator does not contain a power disconnect switch. Install a disconnect switch or circuit breaker between the actuator and its power source. Choose an accessible location as near to the actuator as practical, and identify the switch or breaker as the disconnecting device for the actuator. It is recommended that the signal and power wiring be separated as much as possible. For this reason we recommend using a T conduit to separate the power and signal wiring after exiting the actuator and routing the power wiring towards the top of the actuator enclosure and the signal wiring closer to the base. NOTE: The unit exhibits a particular sensitivity at 137MHz. Installations suspected of having a strong exposure near the specified limit in the range of 132Mhz to 142Mhz can increase immunity by installing a clamp-on ferrite (250 ohms or more at 100MHz) around the I/O cable(s). A Steward 28A2029-0A2 ferrite or equivalent is recommended Procedure 1. Verify that power to actuator is shut off at disconnect. 2. Locate terminal block J2 and wire power cables as shown in below schematic. NOTE: If the optional heater was purchased, the wires from the heater will be connected to terminals J2-1 and J2-2. Insert power connections into these terminals as well making sure that a solid electrical connection is made to both wires. Caution: Do not restore power at this time. 13

20 3.2 Signal Wiring Control Wiring The signal wire size can be as small as 22 AWG (0.65 mm). All analog input wiring must be shielded twisted pairs. Shields must be connected to a good noise free ground at the controller side. When the unit is configured to use a 0-5V, 0-10V, 1-5V, or 4-20mA command, the command signal should be connected to the appropriate terminal on J2 note that the unused input pin must be left unconnected. Wire the appropriate input signal to terminal block J2. Configuration of the input type is done in the Section 4, Setup & Calibration; only the physical connection needs to be made at this point. NOTE: If the slidewire option module XMA-108 was purchased (position 8 of actuator model number is 2), refer to Section for information on how to wire the control input Auxiliary Limit Switch Wiring If auxiliary limit switches are being used refer to below diagram for wiring information. Each limit switch has a normally open and normally closed terminal. 14

21 3.2.3 Option Board and Option Module Wiring Actuators ordered with an option module or option board have the module or board already installed. All required wiring internal to the actuator has been done in the factory; the installer need only connect the field wiring OTX-100 V/mA Feedback Transmitter and OTR-100 V/mA Feedback Transmitter / Relay Output The OTX-100 and OTR-100 both provide an output signal that can be scaled to any range from 0 to 20mA (for the current output) or from 0 to 10V (for the voltage output). The OTR-100 also has three relay contact outputs that can be used to drive alarm devices or provide process limit switches. 15

22 OTX-101 Isolated 2-Wire Feedback Transmitter Option The electrically isolated 4-20mA output is loop-powered and therefore requires only 2 wires. An on-board LED indicates when loop power is present XMA mA Slide Wire Transmitter Option XMA-108 option allows the actuator to accept a slide wire input (with total resistance of 100 ohms to 10K ohms) as the Command Input signal. 16

23 XMA-105 Feedback Potentiometer Transmitter When a feedback potentiometer of 1K to 10K ohms is used, the XMA-105 option can be used to provide a 4-20mA signal that is proportional to the potentiometer value. Since the feedback potentiometer monitors the position of an actuator, the 4-20mA signal can be used by a remote instrument to monitor or display actuator position. A 1-5V signal can be obtained by connecting a 250 ohm load resistor between the "4-20" and "-" terminals. 17

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25 4 SETUP & CALIBRATION 4.1 Description of Control Panel This section describes the function of the indicators and buttons on the Control Panel, shown below. The instructions for the procedures associated with the indicators and buttons are described in the following sections. MODE - The MODE button is used to select the desired function of operation. When the MODE button is pressed, the unit will switch to the next function and the appropriate LED indicator will turn on to let the user know which function is selected. Except for the MANUAL/FB POT CAL mode, the associated mode indicator will be steady on; for some of the modes other indicators will flash to indicate specific settings associated with the mode. ADJUST UP ( ) and ADJUST DOWN ( ) - The adjust up and adjust down buttons are used to adjust the setting of any given function. When a function is selected by the MODE button, the adjust buttons will affect that function only. Note, that the AUTO mode does not have any adjustable settings, and therefore, the adjust up ( ) and adjust down ( ) buttons have no effect. AUTO The AUTO function is the normal mode of operation for the actuator; all the other functions are used to set up the unit. The green AUTO indicator will illuminate when the unit is in AUTO mode. MANUAL/FB POT CAL - The MANUAL/FB POT CAL function allows manual operation of the actuator by using the adjust buttons ( and ) without affecting any other actuator settings. When the button is pressed, the motor winding connected to J1-1 is turned on. while the button turns on the J1-3 winding. Whether the actuator moves toward the open or closed position depends on which motor winding is connected to J1-1 and J1-3. The POT CAL feature provides an indication of the feedback potentiometer's setting. When the MANUAL/POT CAL function is selected, the yellow Manual/Pot Cal indicator will turn on - it may flash or be on steady, depending on the actuator position. The indicator will be on steady whenever the feedback potentiometer is at midrange of its rotation. As the actuator moves, causing the feedback potentiometer to move away from midrange, the indicator will begin to flash, and the indicator will flash at a decreasingly slower rate as the actuator moves further away from midrange. CLOSE - In the CLOSE function, the adjust buttons are used to set the actuator to any desired position, and upon pressing the MODE button (to select the next function, OPEN), the unit retains the setting as the defined closed position. The yellow CLOSE indicator will be illuminated during this operation. OPEN - The OPEN function works the same way as the CLOSE function with the exception that the adjust buttons are used to set the desired open position. The yellow OPEN indicator will be illuminated during this operation. 19

26 AUX CLOSE OUTPUT - The AUX CLOSE OUTPUT function is used to set an optional output setting that is associated with the closed position (an appropriate relay option module is required to use this output. The adjust buttons are used to set the actuator to a desired position. Whenever the actuator position falls between the defined closed position and the Aux Close position, the green Aux Close Output indicator will flash. AUX OPEN OUTPUT - The AUX OPEN OUTPUT function is used to set an optional output setting that is associated with the open position - an appropriate relay option module is required to use this output. The adjust buttons are used to set the actuator to a desired position. Whenever the actuator position falls between the defined open position and the Aux Open position, the green Aux Open Output indicator will flash. COMMAND TYPE - The COMMAND TYPE function is used to configure the command signal input for either 4-20mA, 1-5V, 0-5V, 0-10V, or digital so as to match the type of command signal being used (refer to Section 4.3.4). Upon selecting the COMMAND TYPE function, the yellow Command Input indicator will turn on steady, while the indicator corresponding to the selected type will flash. The adjust buttons ( or ) are then used to select the desired input type. The selection will be saved when the MODE button is pressed, which will also advance the unit to the LOSS OF COMMAND function. LOSS OF COMMAND (1-5V, 4-20mA, or a Digital input type only) - If the actuator detects a loss of the command signal, the Fault indicator will flash. The LOSS OF COMMAND function is used to set the desired default position (see Section 4.3.5). The unit indicates the selected default setting by flashing the Open function indicator for the open default position, or it will flash the Close function indicator for the closed default position. When neither indicator is on, then the "last position" default is selected. AUX POSITION OUT CAL - Note that the AUX POSITION OUT CAL indicator also serves as a Fault indicator. When the indicator is on steady, the AUX POSITION OUT CAL function is selected. When the indicator flashes, a Fault condition has been detected (see FAULT INDICATOR for details). AUX POSITION OUT CAL function is used to calibrate an optional feedback transmitter output. An appropriate transmitter option module is required to use this feature. When the AUX POSITION OUT CAL function is first selected (by pressing the MODE button while in the LOSS OF COMMAND function), the CLOSE indicator will flashpressing the MODE button again will leave the unit in the AUX POSITION OUT CAL function except that the OPEN indicator will flash. FAULT INDICATOR - The actuator electronics detect various fault conditions that prohibit the unit from controlling the actuator. When any of these conditions are detected, the Fault indicator will flash, and the motor outputs are turned off until all fault conditions have been corrected. 20

27 4.2 Factory Settings The following table shows the factory default settings for the MicroTorque. The degree settings are based on the CLOSE position corresponding to 0 degrees, and the OPEN position corresponding to 90 degrees. The installer should note that the electronically set positions are accurate to ±0.5 degrees, and the limit switch positions are accurate to ±2.0 degrees. If the default settings do not match the desired settings for the particular installation refer to Section 4.4, Changing Factory Defaults. Parameter Over travel limit switch(close direction) Close Aux close limit switch Aux close (OTR-100 or OCM-100 only) Aux open limit switch Aux open (OTR-100 or OCM-100 only) Open Over travel limit switch(open direction) Input signal type Feedback signal type(if applicable) Rotation Actuator mode Actuator position Position on loss of command Setting -2 degrees 0 degrees 10 degrees 10 degrees 80 degrees 80 degrees 90 degrees 92 degrees 4-20mA 4-20mA Clockwise to close Manual Close Close 4.3 Setup (Required Calibration) The following calibration steps are generally required for any installation. If at any step the result is different from the expected result, refer to Section 4.2, Changing Factory Defaults. 1. Remove the actuator cover. 2. The yellow MANUAL LED should be illuminated. If it is not, press the MODE button until the MANUAL LED is illuminated. 3. Use the arrow buttons to move the actuator in the CLOSE direction (clockwise), making sure not to drive the actuator past the physical limits of the valve. Expected Result: The over travel limit switch disconnects power to the motor before damage to the valve occurs. 4. Use the arrow buttons to move the actuator in the OPEN direction (counter-clockwise) making sure not to drive the actuator past the physical limits of the valve. Expected Result: The over travel limit switch disconnects power to the motor before damage to the valve occurs. 5. Press mode button once to activate the close function. The CLOSE LED will illuminate, indicating the CLOSE function is active, and the actuator will move to the set close position. 6. Verify that this position matches the desired position. If not, use up and down arrows to move the desired position. NOTE: When the mode button is pressed in the next step the new CLOSE position will be set. 7. Press the MODE button once to activate the OPEN function. The OPEN LED will illuminate, indicating the OPEN function is active, and the actuator will move to the set open position. 8. Verify that this position matches the desired position. If not, use up and down arrows to move the desired position. 9. Press the MODE button to set the new position. 21

28 At this point the standard actuator is calibrated and functional. However if your desired configuration does not match the factory defaults additional calibration may be necessary. The Slidewire option and any options not factory-installed also require additional calibration. 4.4 Changing Factory Defaults This section provides instructions for option setup and additional calibration. Additional calibration should be done in the order listed in this section, skipping any steps that are not relevant to you particular installation Over Travel Limit Switches and Stroke 1. Locate the limit switch cam to be adjusted (refer to diagram below): 2. Press the MODE button until the MANUAL indicator is illuminated. Use the arrow buttons to rotate the actuator shaft so that the set screw on the cam is visible and is accessible with an Allen wrench. 3. Remove power from the actuator. Warning: Failure to remove power can result in electric shock 4. Loosen the set screw using an Allen wrench. 5. Restore power to the actuator. 6. Use the arrow button to move the actuator to the desired over travel position. NOTE: If adjusting the limit switch by more than 80 degrees the feedback potentiometer may have to be adjusted. 7. Remove power to the actuator. Warning: Failure to remove power can result in electric shock 8. Remove the wires from the limit switch, first making note of where they were connected. 9. Connect a multimeter to the common and NO terminals of the limit switch and set it to check for continuity. 10. If setting the limit switch for rotation in a clockwise direction follow Procedure A. If setting the limit switch for rotation in a counterclockwise direction follow Procedure B. Refer to the diagram below. Procedure A: Rotate the bottom cam counterclockwise until the back edge of the flat engages the lever of the limit switch and the circuit just registers continuity. Tighten the set screw. 22

29 Procedure B: Rotate the bottom cam clockwise until the front edge of the flat engages the lever of the limit switch and the circuit just registers continuity. Tighten the set screw. 11. Reconnect the limit switch wires in their original locations. 12. Restore power to the actuator and verify that limit switch set correctly. 13. Repeat procedure if necessary for the other limit switch Feedback Potentiometer Calibration Calibration of the Feedback Potentiometer should not normally be necessary. However if the installer adjusts the stroke to near 270 and only adjusts one cam, or if a field replacement of the potentiometer is required, it will need to be calibrated. 1. Place the actuator in manual mode by pressing the MODE button until the yellow MANUAL indicator is illuminated. 2. Use the arrow buttons to move the metal arrow to mid-position. 3. If the MANUAL LED is flashing, loosen the gear on the actuator shaft using the Allen wrench. 4. Rotate the gear until the LED is no longer flashing, indicating that the potentiometer is at its mid position. NOTE: The LED will flash faster as it gets closer to its mid position. 5. Once the LED is illuminated and steady (no longer flashing), tighten the set screw on the gear Reversing Actuator Rotation The default rotation direction is Clockwise to close. To reverse the direction: 1. Press the MODE button until the CLOSE LED illuminates. The actuator will move to the current CLOSE position. 2. Use the arrow button to move the actuator to the desired CLOSE position. 3. Press the MODE button to accept this as the new CLOSE position. The OPEN Led should now be illuminated. 4. Use the arrow button to move the actuator to the desired OPEN position. 5. Push the MODE button to accept the desired new OPEN position. 23

30 4.4.4 Input Type The default input type is 4-20mA. To change the input type: 1. Press the MODE button until the yellow COMMAND TYPE LED is illuminated. 2. Use the up and down arrows to select an input type. The LED next to the selected input type will flash. 3. Once the desired input is selected, press the MODE button. NOTE: If 0-5V or 0-10V are selected the Loss of Command failsafe setting is not functional Position on Loss of Command Signal (close) When the input type is 4-20mA, the MicroTorque provides the option of setting a failsafe position upon loss of the command signal. This function is not available if the selected input is 0-5V or 0-10V. 1. Press the MODE button until the red LOSS OF COMMAND LED is illuminated. 2. Use the arrow buttons to select OPEN (OPEN LED flashing), CLOSE (CLOSE LED flashing), or LAST (both LEDs flashing). 3. Press the MODE button once to accept the selected position Auxiliary Limit switches The limit switches and electronically set limits are factory calibrated to the default positions shown in Section 4.2. If alternate positions are desired follow below procedure. 1. Locate the limit switch cam to be adjusted (refer to diagram below). 2. Press the MODE button until the MANUAL LED is illuminated. 3. Use the arrow buttons to rotate the actuator shaft so that the set screw on the cam is visible and accessible with an Allen wrench. 4. Remove power from actuator. Warning: Failure to remove power can result in electric shock 5. Loosen the set screw using a 5/64 Allen wrench. 6. Restore power to the actuator. 7. Use the arrow button to move the actuator to the desired position. 24

31 8. Remove power from the actuator. Warning: Failure to remove power can result in electric shock 9. Locate the terminals corresponding to the limit switch to be calibrated. If any wires are connected to the side of the terminal opposite the potentiometer, disconnect the wires first making note of their location. Warning: Terminals may be wired to high voltage! Remove power at shutoff before disconnecting wires from terminals to avoid electric shock 10. Connect a multimeter to the common and NO terminals of the limit switch and set it to check for continuity. 11. If setting the limit switch for rotation in a clockwise direction, follow Procedure A. If setting the limit switch for rotation in a counterclockwise direction follow Procedure B. Refer to the diagram below. Procedure A: Rotate the bottom cam counterclockwise until the back edge of the flat engages the lever of the limit switch and the circuit just registers continuity. Tighten the set screw. Procedure B: Rotate the bottom cam clockwise until the front edge of the flat engages the lever of the limit switch and the circuit just registers continuity. Tighten the set screw. 12. Reconnect the wires that were removed in Step Restore power to the actuator. 14. Use the arrow buttons to verify that limit switch set correctly. 4.5 Option Setup Setting Aux Close and Aux Open Relay Outputs The electronic AUX CLOSE and AUX OPEN settings are based on the internal feedback potentiometer. They are accurate to within 0.1 degree. The following procedure applies to the OTR -100 Feedback Transmitter/Relay Output and OCM-101 Modbus options: 1. Push the MODE button until AUX Close or AUX open LED illuminates. 2. Use the arrow buttons to move the actuator to the desired AUX CLOSE or AUX OPEN position. 3. Press the MODE button to accept the new position. 25

32 4.5.2 Output Calibration This section applies to the OTR-100 Feedback Transmitter/Relay Output, OTX-100 Feedback Transmitter, OTX wire Feedback Transmitter 1. Press the mode button until AUX POSITION OUT LED remains illuminated (solid) while the CLOSE indicator is illuminated. 2. Use the arrow buttons to adjust the desired voltage/current output at the close position.(refer to wiring diagrams to determine where to measure voltage/current) 3. Press the mode button until AUX POSITION OUT indicator remains illuminated (solid) while the OPEN indicator is illuminated. 4. Use the arrow buttons to adjust the desired voltage/current output at the open position.(refer to wiring diagrams to determine where to measure voltage/current) Feedback Potentiometer Output Calibration The zero and span adjustments on the XMA-105 option module allow the user to scale the 4-20mA signal to correspond with the zero and span positions of the actuator. 1. Position the actuator to the zero position 2. Adjust the XMA-105 zero to achieve the desired output (usually 4 ma). 3. Position the actuator to the span position and adjust the XMA-105 span to achieve the desired output (usually 20 ma). 4. Repeat this process until the zero and span positions yield the desired output from the XMA-105 without further adjustment mA Slide Wire Input Calibration 1. Set the slide wire float to its high level position 2. Push and hold the CAL push button, and adjust the "ZERO" trimmer for a 4mA output. 3. Set the float to its low level position 4. Push and hold the CAL push button, and adjust the "SPAN" trimmer for a 20mA output. 5. After releasing the CAL push button, the XMA-108 will begin averaging the signal and will take approximately 60 seconds to achieve final position. 26

33 4.6 Additional Installation Information This section contains additional information regarding standard features that should be taken into account during installation and setup of the actuator Stall Detection Feature The Stall Detection feature (see FAULT INDICATOR) essentially performs a similar function as commonly used torque switches. The feature does not measure torque, but rather motion. The Stall Detection feature is useful for detecting when any of the motor wires become disconnected. However, limit switches employed in actuators essentially disconnect one of the motor windings. The unit will detect this as a motor stall. To avoid this condition, the limit switches must be set outside of the operating range set by the CLOSE and OPEN functions Electronic Brake Feature The Electronic Brake feature provides highly reliable and accurate braking of the motor, and it is a key element in achieving high resolution. The Electronic Brake feature provides the primary braking of the motor. The actuator's limit switches should be set outside of the operating range set by the CLOSE and OPEN functions. The Electronic Brake feature degrades in performance if a limit switch is engaged. Limit switches exhibit wide variations, and the actuator s electronics can position more precisely at closed and open than the limit switches. A limit switch serves better as a fail safe device to protect against electrical failures in the actuator Duty Cycle Control Feature The Duty Cycle Control feature accurately monitors the relative heating of the motor and automatically duty cycles the unit at a safe level when a process becomes unstable, or if a control loop is not properly set. While the thermal switch in the motor protects the motor from overheating, thermal switches can shutdown the actuator for ten minutes or more. Further, typical thermal switches do not activate until temperatures inside the actuator become too high for other components in the actuator. The Duty Cycle Control feature allows continuous operation of the motor until it detects an excess heat build up in the motor (usually well below the limit of the thermal switch). At that time, duty cycle operation is automatically enabled and continues until the motor cools enough to resume continuous operation. The duty cycle period is approximately 2 seconds with an on time that automatically varies depending on the heating of the motor. While this operation slows down the actuator's operation slightly, it does not impact the resolution performance of the actuator, and it prevents disruption of a process due to a thermal switch shutdown. 27

34 28

35 5 COMMUNICATIONS To connect to Modbus, the actuator requires an OCM-101 Modbus Option Module. The OCM-101 plugs into the actuator controller and provides the necessary connections for the bus. It also provides the means for configuring the module for various bus settings such as RTU/ASCII mode, Parity, baud rate, and node address. All actuator parameters can be monitored, or read, any time the actuator is powered and on line. Reading parameters does not interfere with the actuator s operation or settings. Some parameters can be changed, or written, via the bus; these are referred to as Read/Write Parameters. The actuator will prohibit writing of various parameters to protect against accidental interference with critical DHC functions or settings; these are referred to as Read Only Parameters. The actuator has a number of modes of operation. With the exception of the AUTO mode, all the modes are intended for either setup or trouble shooting tasks. In those cases, it usually means that a human operator has decided to control the actuator at the actuator site. To prevent confusion, or even a hazard, to the human operator, the actuator will ignore read/write parameters from the bus that run the actuator. The automation system can continue reading or writing such parameters, but the actuator will not act on those parameters until it is returned to the AUTO mode. 5.1 Wiring The OCM-101 module provides an isolated 2-wire RS-485 bus connection using the Modbus RTU protocol. The bus connections are electrically isolated and should not be connected to the actuator s signal ground. The COM terminal should be connected directly to earth ground, preferably only at one point for the entire bus; generally earth ground is connected at the master device. Shielded twisted pair should be used: Belden No. 3106A is recommended. 29

36 5.2 S1- Modbus Address and LT Resistor Setting S1-1 to the ON position connects the line terminating (LT) resistor between terminals A and B. It should only be turned on for units at each end of the bus. S1-2 to S1-9 set the Modbus node address. The switches represent the binary value of the desired address, where S1-2 is the most significant bit and S1-9 is the least significant bit. The ON position represents a logic "1", while the OFF position represents a logic "0". The factory default settings are: Modbus Address = 32 Terminating resistor = CONNECTED The standard Modbus protocol reserves address 0 (all switches OFF) for broadcast commands. Also, addresses 248 to 255 (switch settings to ) are reserved by the Modbus organization. Setting the switches to any of these addresses disables the OCM-101, which essentially removes the unit from the bus. If the address switches are changed while the bus is active, the OCM-101 will terminate any Modbus sequence in progress before accepting the new address. 5.3 S2 Baud Rate, Mode and Parity Switch S2 controls the baud rate, mode, and parity (refer to the diagram below). The factory default settings are: BAUD Rate = 19,200 Mode = RTU Parity = No Parity Setting the parity to NONE results in two stop bits. With MicroMod s MOD 30ML and MODCELL, setting parity to NONE results in 1 stop bit. The integrator should be aware of this difference and adjust the installation accordingly. The effect of the parity bit is shown in the following bus timing diagrams. The mode setting determines if the communication mode will be Modbus RTU or ASCII. This document addresses the more commonly used Modbus RTU protocol. For more information on ASCII mode contact MicroMod. 30

37 5.4 Host Device Wiring and Settings 5.5 Supported Modbus Functions The MicroTorque OCM-101 supports the Modbus functions listed below. If a function that is not supported is received, exception code $01 will be returned. NOTE: all the information in this section refers to the MicroTorque OCM-101 Modbus option module. FUNCTION $03 - Read Holding Registers Function $03 is used to read a number of contiguous registers in a Modbus slave unit, where each register has a specific 16 bit (2 bytes) address and contains a 16 bit value. Section 6.4 discusses holding registers in the OCM-101. Master Command Slave Function Code Starting register Number of registers Checksum Address address to be read Default = 32 3 $0000 to $ CRC bytes Slave Response Slave Function Code Number of bytes to Data bytes returned Checksum Address be returned Default = CRC bytes FUNCTION $06 Write Single Registers Function Code $06 is used to write to a register. Master Command Slave Function Code Register address Two Data Bytes Checksum Address Default = 32 6 $0000 to $0005 When writing to $000 the most significant byte must be 0 2 CRC bytes Slave Response Slave Function Code Register address Two Data Bytes Checksum Address Default = 32 6 $0000 to $ CRC bytes FUNCTION $08 Diagnostics Function $08 is used for diagnostics and control of Modbus slave devices. The MicroTorque functions as a Slave device. The function code uses SubFunctions to perform diagnostic operations. The OCM-101 supports a limited number of SubFunctions, as listed below. If an unsupported SubFunction is used, exception code $03 will be returned. $0000 Return Query Data two bytes of test data are sent out. The OCM-101 returns the two tybes to confirm that the data was received. $0001 Restart Communications Option This restarts the OCM-101 and exits Listen Only mode. $0004 Force Listen Only Mode Removes the actuator from the bus. The OCM-101 will continue monitoring the bus for SubFunction $0001, at which point it will resume normal operation. 31

38 Master Command Slave Function Code Two SubFunction Bytes Two Data Bytes Checksum Address Default = 32 8 $0000 No restrictions on bytes 2 CRC $0001 Most significant byte must be $00 or $FF, otherwise exception code $03 will be returned bytes $0004 Must be $0000, otherwise exception code $03 will be returned Slave Response Slave Function Code Two SubFunction Bytes Data bytes returned Checksum Address Default = 32 8 $0000 No restrictions on bytes 2 CRC $0001 bytes $0004 Modbus Error Response If the actuator cannot process a command it will generate an error message in the format shown below. Part of the message will be the exception code. The OCM-101 supports the exception codes listed below. $01 Function Function not supported $03 Data Data does not fit wit the function. Either the value or thenumber of bytes is wrong. 5.6 Modbus Registers The table below lists the information available on the MicroTorque Modbus registers. The information given is sufficient for typical monitoring applications. If additional information is required contact MicroMod technical support. When two parameters are listed in the Parameter column, the parameter listed first corresponds to the most significant bye of the register. Register Register Parameter Register and Flag Descriptions Number Address Aux Closed Position A 0 to value corresponding to 0% (closed) to 100% (open). This value is associated with the close limit alarm (bit 7 of Alarm Flags register 24) Bit 7 is set to 1 when Position register value is less than Aux Close Value. Bit 7 is set to 0 when Position register value is greater or equal to the Aux Close Value + 1% Aux Open Position A 0 to value corresponding to 0% (closed) to 100% (open). This value is associated with the close limit alarm (bit 6 of Alarm Flags register 24) Bit 6 is set to 1 when Position register value is less than Aux Open Value. Bit 6 is set to 0 when Position register value is greater or equal to the Aux Open Value + 1% 32

39 Register Register Parameter Register and Flag Descriptions Number Address Analog Command Input A 0 to value (0-100%) corresponding to the analog command input. Analog Input 0% 100% 4-20mA 4mA 20mA 1-5V 1V 5V 0-5V 0V 5V 0-10V 0V 10V Position A value (0% closed, 100% open) corresponding to the feedback potentiometer value Average % Duty Cycle A 0 to value (0-100%) that represents the average duty cycle over the past seconds Maximum Deviation A 0 to value (0-100%) that represents the difference between the desired position and the actual position A Hours of Operation (MSW) B Hours of Operation (LSW) C Cycles of Operation (MSW) D Cycles of Operation (LSW) E Configuration / Alarm Flags Configuration Flags Number of hours since manufacture that power has been applied to the unit. Cannot be reset. Number of cycles since manufacture that power has been applied to the unit. Cannot be reset. Bits 7, 6 not used Bits 5, 4 loss of command setting 00 last position 01 close 10 open Bits 3, 2, 1 Command Type 000 digital mA V V V Alarm Flags see register Alarm Flags Alarm Flags (can also be read from Register 15) 1 indicates alarm condition 0 indicates no alarm 7 Aux close limit (see register 2) 6 Aux open limit (see register 3) 5 Not supported 4 Not supported 3 Motor alarm (M2 stall) Bit is set when M2 winding is turned on an no motion is detected 2 Motor alarm (M1 stall) Bit is set when M1 winding is turned on an no motion is detected 1 Feedback Pot alarm Bit is set to 1 if pot is operated outside of range. Also detects open or short. 0 Loss of Command Set to 1 when command signal is lost. This 33

40 feature is not available for 0-5Vor 0-10V signals. 5.7 MicroMod XModbus OPC Server Communication This section describes how to communicate with the actuator using MicroMod s XModbus (Extended Modbus) OPC server Set up the OPC Device and Tags The OPC Server requires tags to be configured in order to read the registers from the actuator. 1. Launch the XModbus OPC Server 2. Select File New to create a new server file 3. Select Add New Modbus Device 4. NOTE: make sure not to select New XModbus Device. The actuator supports only standard Modbus. 5. In the popup window change the following parameters as necessary: 6. Port = from the pulldown menu select the serial port to which the actuator is connected 7. Address = enter the Modbus address of the actuator. Factory default is 32; if multiple actuators are on the bus this may have been changed during setup. 8. Read Consecutive Register = 1 9. Click on the device you created and select New Tag 10. In the popup window that appears, enter the register you want to read 11. In the List Box next to the register select Holding Register. NOTE: if you are unsure which register to select, 15 is a good choice for actuators that are not installed and 8 is a good choice for installed actuators. Add more tags as desired. Each tag corresponds to a register Edit Com Port Settings 1. Select Edit Com Ports 2. In the popup window that appears edit the following parameters as necessary: 3. Port = com port to which the actuator is connected 4. Enable = this box should be checked 5. Baud rate = baud rate of the actuator. Default is Parity = parity being used (default is None). 7. Flow = none, or hardware for serial gear and hardware for black box 8. Data bits = 8 RTU 9. Stop bits = 2 for no parity, and one for even parity (default is 2) 10. Click OK 34

41 5.7.3 Read Register Settings 1. Click View Monitor To the right of each tag, the value stored in the register should appear. If the value reads BAD, verify that the settings of the OPC server, actuator, and serial communication device are correct and that the serial communication cables are correctly connected. 35

42 6 TROUBLESHOOTING 6.1 Actuator Operation PROBLEM POSSIBLE CAUSES REMEDIES No response from unit (All lights are off.) No power Excessive voltage applied to unit Blown or missing fuse Check power source. Replace unit. Replace with appropriate fuse; see "Specifications" in Section 1.3. No response from unit, and no response from the adjust ( and ) or Mode buttons. (MANUAL / FB POT CAL light is illuminated Jumper wire on J7 terminal block is missing. Install jumper wire on J7 terminal block. solid.) Auto/Manual station is improperly wired. Check wiring on Auto/Manual station; see "Override Mode" in manual. Actuator rotates valve backwards. Actuator or valve is mounted incorrectly on coupling. Actuator needs to be reverse acting. No input signal connected when using 4-20mA, 1-5VDC, or Digital inputs. Remount actuator as necessary. Refer to "Close" and "Open" modes in manual. Connect input signal and refer to "Loss of Command" in manual. Actuator does not respond to input signal. (FAULT indicator constantly flashes.) Actuator does not respond to input signal. (FAULT indicator is off.) Input signal polarity reversed. Input signal wired to wrong terminal. Feedback potentiometer out of range. Feedback potentiometer or motor/ solenoids are improperly wired. Defective feedback potentiometer. Defective motor brake (holds motor) Defective motor (not turning) Motor turns, but actuator output shaft is not moving. Closed and open positions are set to the same position. Reverse input wires. Check input signal wiring; refer to "Power/Signal J2" in manual. Check wiring; refer to "Actuator J1" in manual. Refer to "Manual/FB Pot Cal" in manual. Replace feedback potentiometer. Repair or replace motor brake. Repair or replace motor. Repair or replace actuator. Set closed and open settings; refer to "Close" and "Open" modes in manual. 36

43 PROBLEM POSSIBLE CAUSES REMEDIES FAULT indicator flashes after actuator reaches the fully closed or open position. Closed or open limit switches set inside the operating range. Torque switches trip due to mechanical end stops set inside the operating range. Adjust limit switch cams; refer to "Close" and "Open" modes in manual. Adjust mechanical end stops; refer to "Close" and "Open" modes in manual. AUX CLOSE OUTPUT or AUX OPEN OUTPUT indicators flash. Actuator position is near closed or open. If an OTR-100 option module is installed, set Aux Close and Aux Open positions; refer to "Aux Close Output" and "Aux Open Output" modes in manual. If an OTR-100 option module is not installed, no remedy is required. Actuator operates erratically. (FAULT indicator flashes erratically.) Actuator hunts for position. Triac output failure (Motor buzzes and overheats.) AC ripple induced on the command input signal. Defective feedback potentiometer Loose feedback potentiometer or loose feedback potentiometer gears Sloppy gear tooth engagement No motor brake or brake slipping Unstable command input signal from PID control loop Exposure to water from conduit entrance Exposure to water from unsealed actuator housing Exposure to moisture from condensate Corrosion from exposure to salts or acids External power applied to motor connections at J1-1 or J1-3. Motor capacitor is defective, or has incorrect voltage rating. Lightning or power surge. Use equipment that isolates AC ripple from the command signal. Replace feedback potentiometer. Tighten feedback potentiometer and/or potentiometer gears. Adjust feedback potentiometer gears for tight engagement. Install or repair motor brake. Adjust PID parameters for stable command signal. Perform appropriate remedy, then replace unit: Install drip loop at conduit entrance. Inspect and/or replace actuator housing gasket; use actuator with proper sealing. Use heater and thermostat and/or desiccant packets. Use corrosion inhibitors and desiccant packets. Remove connector J1 prior to applying external power. Replace motor capacitor. Replace unit. 37

44 Fault Indicator The actuator electronics detect various fault conditions that prohibit them from controlling the actuator. When any of these conditions are detected, the Fault indicator will flash, and the motor outputs are turned off until all fault conditions have been corrected. If an appropriate relay option module is installed, the Fault relay output on the option module will also turn off. A communications option module can read the specific condition(s) causing the fault. Note that a fault condition DOES NOT disable the motor outputs when manually controlling the actuator with the the adjust buttons; while useful for troubleshooting, care should be exercised when operating the motor under a fault condition. The various fault conditions are described below: LOSS OF COMMAND - If the command signal is disconnected or out of range, the fault indicator will remain on until the signal is reconnected or back in range. FEEDBACK POT FAULT - A fault condition is detected whenever the feedback signal is out of range (that is, less than 5% of the potentiometer value or more than 95% of the potentiometer value), or when any of the potentiometer connections are broken. Normal operation resumes when the potentiometer is reconnected or back in range. MOTOR 1 STALL - A fault condition is detected when no actuator motion is detected while the Motor 1 output is turned on. The fault condition will disable the Motor 1 output only, and the fault is cleared when the electronics detect a motion greater than 1.5 in either direction. The fault can be cleared if 1) the command signal commands a Motor 2 operation, 2) manual operation with the adjust buttons results in a motion greater than 1.5, or 3) a mechanical manual override forces the 1.5 motion, provided the mechanical motion is monitored by the feedback pot. MOTOR 2 STALL - A fault is detected when no actuator motion is detected while the Motor 2 output is turned on. The fault can be cleared in the same manner as a Motor 1 Stall (see above). DOUBLE STALL - If the electronics detect no actuator motion in either direction, both motor outputs will be disabled. The command signal cannot clear this condition; only manual operation or a mechanical override can clear the fault. Alternatively, the unit can be powered off and then on to temporarily clear the fault; however, this practice should be avoided without permanently correcting the cause of such a fault. 38

45 6.2 Communications If the actuator is not communicating with the Modbus master device, verify that the settings of the OPC server, actuator, and serial communication device (converter) are correct. The table below refers to the Port Com Statistics dialog box in the XModbus OPC Server. To open this dialog: 1. Select Edit Com ports 2. In the list block, select the communication port you are using 3. Click the Statistics button to open the popup dialog box. PROBLEM POSSIBLE CAUSES REMEDIES No messages are being sent. No messages are being received. Messages are being received but value reads BAD Error messages are being registered Com port is being used by another program. Baud rate mismatch Problem with message format Problem with command format Check the Hardware Device Manager in the computer s control panel for any com ports being used by other programs. Close any other program that uses serial communications. It may be necessary to restart the computer. Make sure baud rate in the OPC server matches baud rate in the actuator. Check parity, flow, data bits, and stop bits in the OPC server, actuator, and serial converter. In the OPC Server, select Tools- Debug to open debug window and read error messages. 39