Honeywell HercuLine 10260S Installation, Operation And Maintenance Manual
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Honeywell HercuLine 10260S Installation, Operation And Maintenance Manual

Honeywell HercuLine 10260S Installation, Operation And Maintenance Manual

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10260S HercuLine
Smart Actuator
®
Installation, Operation and
Maintenance Manual
Doc. No.:
62-86-25-08
Revision:
5
Date:
7/07
Honeywell Field Solutions

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Summary of Contents for Honeywell HercuLine 10260S

  • Page 1 10260S HercuLine Smart Actuator ® Installation, Operation and Maintenance Manual Doc. No.: 62-86-25-08 Revision: Date: 7/07 Honeywell Field Solutions...
  • Page 2 However, we assume no responsibility for its use. While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application.
  • Page 3 HercuLink User Manual 62-86-25-11 Installation and Operation Manual Hart Communications 62-86-25-12 Contacts World Wide Web The following lists Honeywell’s World Wide Web sites that will be of interest to our customers. Honeywell Organization WWW Address (URL) Corporate http://www.honeywell.com Industrial Measurement and Control http://www.honeywell.com/imc...
  • Page 4 Symbol Definitions The following table lists those symbols used in this document to denote certain conditions. Symbol Definition This DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. This WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

  • Page 5: Table Of Contents

    Contents Contents....................v 1. Introduction ..................1 Product Description ......................1 Applications ........................1 Features ........................2 Honeywell Linkage Kits ....................5 HAL Software Application.......................5 2. Specifications ..................7 Technical and Operating Specifications ...............7 Model Selection Guide ....................11 3. Installation ..................13 Installation Overview ....................13 Before Starting......................14...
  • Page 6 7. Maintenance..................85 Basic Maintenance .....................85 Spur Gear Lubrication ......................85 Replacement Procedures...................87 8. Replacement/Recommended Spare Parts ........89 Linkage Parts/Kits.......................96 Honeywell Actuator Linkage Analysis Software (HAL)..........96 9. Troubleshooting................97 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual Revision 5 7/07...
  • Page 7 Contents Introduction.........................97 Troubleshooting Procedures ..................98 Appendix A - 10260S Configuration Record Sheet ......105 Index ....................109 Revision 5 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual 7/07...
  • Page 8 Contents Tables Table 1 Specifications - General..........................7 Table 2 Recommended Minimum Wire Size......................22 Table 3 Actuator Terminal Connections........................24 Table 4 Keypad Description ............................. 29 Table 5 Set Up Tips ..............................30 Table 6 Set Up Groups ............................. 31 Table 7 Set Up Procedure Using Display and Keypad .....................
  • Page 9 Figures Figure 1 10260S Smart Actuator ..........................2 Figure 2 10260S Internal View........................... 3 Figure 3 Outline and Dimensions of Herculine Models 10261S, -62S, -64S, -66S, -67S, -68S, and -69S Actuators15 Figure 4 Outline and Dimensions of Herculine Models 10263S and 10265S Actuators.......... 16 Figure 5 Constant Torque Linkage ...........................

  • Page 11: Introduction

    Applications Honeywell actuators have a long and respected history in the industrial actuator market. 10260S actuators are designed for precision modulation of final control devices such as dampers, vanes, fluid couplings, scoop tubes, fuel/air ratio valves, windbox dampers, and coal mill dampers, and quarter turn valves. The robustness of the design serves as the basis for long-term reliability and reduced operating costs.

  • Page 12: Features

    1. Introduction - Features Top Cover Local Display and Keypad Extended Cover Terminal Cover Crank Arm and (Access to customer connections) Rod End Handwheel Auto-Manual Switch Figure 1 10260S Smart Actuator Features Non-contact Position Sensing (NCS) with True Shaft Position Indication Non-contact position sensing eliminates maintenance problems and nuisance shutdowns that are common with slidewire or potentiometer position sensing.

  • Page 13: Figure 2 10260S Internal View

    1. Introduction - Features Slidewire Emulation A truly unique feature, slidewire emulation allows direct replacement of existing three-wire control actuators without requiring controller changes while gaining all of the advantages of the maintenance-free non-contact sensing. This is ideal for replacement of installed actuators that cause control problems due to slidewire wear.
  • Page 14 1. Introduction - Features 10260S Smart Electronics Enhanced Electronics Printed Wiring Assembly (Main PWA) An enhanced electronics printed wiring assembly (PWA) provides digital control to the 10260S actuator. The Main PWA is the central interface which features a microprocessor controlled CPU with associated flash PROM and RAM.

  • Page 15: Honeywell Linkage Kits

    (page 89) for available linkage parts and kits. HAL Software Application Honeywell has designed a linkage analysis program (HAL) that is used to design linkage set-up for your particular application. HAL is a Windows-based software program that aids you in selecting the correct size Honeywell actuator, determine the start angles, linkage length and crank length, and characterize torque profiles for dampers and valves.
  • Page 16 1. Introduction - Honeywell Linkage Kits 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual Revision 5 7/07...

  • Page 17: Specifications

    2. Specifications - Technical and Operating Specifications 2. Specifications This section provides you with the technical specifications and the model selection guide for the 10260S Series Smart Actuators. Technical and Operating Specifications Table 1 Specifications - General Physical Weight 45 lb. (20.5 kg) net Enclosure Precision-machined Aluminum alloy casting, finished in light gray powder coat epoxy.
  • Page 18 2. Specifications - Technical and Operating Specifications Electrical 120 Vac single phase, 50 or 60 Hz Mains Supply 240 Vac single phase, 50 or 60 Hz Motor Instant start/stop, non-coasting, non-burnout, continuous duty permanent magnet synchronous induction motor. Can be stalled up to 100 hours without damage. Motor Current = No load = full load = locked rotor Model No.
  • Page 19 2. Specifications - Technical and Operating Specifications Specifications - Actuator with Digital Electronics Electrical Input Signals Analog: 0/4 to 20 mA (With supplied shunt resistor for current range: 250 ohms ±0.1 % Part Number: 070756) 0/1 to 5 Vdc 0 to 10 Vdc Digital: Modbus RTU RS485 (Remote setpoint) Input...
  • Page 20 2. Specifications - Technical and Operating Specifications Specifications – Local Display and Keypad Display Display Design Multi-segment LED displays that provide up to ten alphanumeric characters. Display arrangement consists of two rows: row (Upper display) – four characters row (Lower display) – six characters. LED indicators Six single LEDs provide actuator status and alarm indications.

  • Page 21: Model Selection Guide

    2. Specifications - Model Selection Guide Model Selection Guide The following 10260 Smart Actuator models are covered in this manual. You can verify the model description of your actuator by comparing the model number stamped on the top cover identification plate with the following tables in this model selection guide.
  • Page 22 2. Specifications - Model Selection Guide TABLE VI - OPTIONS Shafts Standard 0 _ _ _ _ 5 Inch Extension 1 _ _ _ _ 3 Inch Extension 3 _ _ _ _ Projecting Scale None _ 0 _ _ _ 3/4 Inch Shaft Coupling _ 1 _ _ _ 3/4 Inch Shaft Coupling, CCW to Open...

  • Page 23: Installation

    3. Installation - Installation Overview 3. Installation Installation Overview The procedures to install the 10260S actuator and place it in service require that you: • Select a suitable location for installation. (See Installation Considerations below.) • Mount the actuator securely. •...

  • Page 24: Before Starting

    If there are visible signs of damage to the shipping container, notify the carrier and Honeywell immediately. If there is no visible damage, compare the contents with the packing list. Notify the carrier and Honeywell immediately if there is equipment damage or shortage.
  • Page 25 3. Installation - Actuator Mounting Figure 3 Outline and Dimensions of Herculine Models 10261S, -62S, -64S, -66S, -67S, -68S, and -69S Actuators Revision 5 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual 7/07...

  • Page 26: Figure 4 Outline And Dimensions Of Herculine Models 10263S And 10265S Actuators

    3. Installation - Actuator Mounting Figure 4 Outline and Dimensions of Herculine Models 10263S and 10265S Actuators 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual Revision 5 7/07...

  • Page 27: Mechanical Installation

    The 10260S Actuator linkage can be set up to achieve an optimal delivered torque distribution for specific applications. To assist with linkage design, Honeywell offers a linkage analysis software application (HAL). The software can be ordered as P/N 51197910-001.

  • Page 28: Figure 7 Variable Torque Linkage

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

  • Page 29: Figure 9 Turnbuckle Linkage Kit

    (See Section 8 for available Kit numbers) Pipe linkage kits are available from Honeywell and can be used for linkage lengths from 24 to 120 inches (60 to 305 cm). The kits include the mechanical pipe couplings, load rod end (left-hand thread), connecting rods and locking nuts.

  • Page 30: Figure 11 Standard 5-Inch Crank Arm

    3. Installation - Mechanical Installation Actuator Crank Arms The 10260S Smart Actuator comes standard with a 5-inch crank arm (adjustable 1 7/16” to 5” radius) and there is an optional 12-inch crank arm that is adjustable from 0 to 12”. Part Number 154007 The 10260S Actuator crank arm uses a standard ½...

  • Page 31: Figure 12 Projecting Scale Option Exploded View

    3. Installation - Mechanical Installation Projecting Scale Option The projecting scale option is available for customers whose actuators are direct coupled so that it would be impossible to read the standard scale on the actuator. The projecting scale is attached to the side of the actuator enclosure and is readable from a distance.

  • Page 32: Electrical Installation

    3. Installation - Electrical Installation Electrical Installation General Wiring Recommendations WARNING Only qualified personnel should perform wiring. Wiring must conform to national and local electrical codes. In general, stranded copper wire should be used. Unless locally applicable codes dictate otherwise, the recommended minimum wire sizes in Table 2 should be observed.
  • Page 33 3. Installation - Electrical Installation Revision 5 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual 7/07...

  • Page 34: Table 3 Actuator Terminal Connections

    3. Installation - Electrical Installation Table 3 Actuator Terminal Connections Terminal Numbers Connection Descriptions and LABEL Figure 13. Hot wire for 120/240 Vac mains supply NEUTRAL N - 3 Neutral wire for 120/240 Vac mains supply Ground Ground wire connection for mains supply AUTO/MANUAL 10 –...
  • Page 35 3. Installation - Electrical Installation Terminal Numbers Connection Descriptions and LABEL Figure 13. SW5/RELAY3 Auxiliary switch 5 or Relay 3 connections. SW6/RELAY4 Auxiliary switch 6 or Relay 4 connections. Revision 5 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual 7/07...

  • Page 36: Figure 13 Actuator Terminal Connections

    3. Installation - Electrical Installation 120V/240VAC 50/60 Hz NEUTRAL MAINS POW ER INTERNAL AUTO/MAN CONNECTIONS SW 3/RELAY1 SW ITCH CONTACT CLOSED W HE N "NOT -IN- AUTO " SW 4/RELAY 2 SW 5/RELAY 3 SW 6/RELAY 4 REMOVE R ESISTOR FOR VOL TAGE IN PUT IN P SHIELD...
  • Page 37 3. Installation - Electrical Installation Power Connections The AC power supply input option is a Table I selection in the model selection guide. Depending on which power supply selection is ordered for your actuator, wire the power input (MAINS POWER) as described in Table 3 and Figure 13.

  • Page 38: Set Up And Calibration Procedures

    4. Set Up and Calibration Procedures - Overview 4. Set Up and Calibration Procedures Overview Once you have installed the 10260S smart actuator, you can verify, set or change certain operating parameters. Set up is accomplished through use of the local display and keypad interface. Please keep in mind that the unit is calibrated at the factory for your application and can be placed into service right out of the box.

  • Page 39: Table 4 Keypad Description

    4. Set Up and Calibration Procedures - Local Display and Keypad Table 4 Keypad Description Key or Function LED Indicator SET UP Places the actuator in the set up group select mode. Sequentially displays set up groups and allows the FUNCTION key to display function parameters within the set up group.

  • Page 40: Set Up Tips

    4. Set Up and Calibration Procedures - Set Up Tips Set Up Tips Table 5 contains tips that will help you view, verify and enter the operating parameters more quickly. If you can not change the parameters, check the status of the “ SET LOCK” parameter. Also some parameters require that you enter a security password before you access or change the parameter value.

  • Page 41: Table 6 Set Up Groups

    4. Set Up and Calibration Procedures - Set Up Groups Table 6 Set Up Groups Set Up Group Title Pressing the FUNCTION Key Allows You to… For Details, See Select and set various parameters associated with the Table 8 INPUT input signal to the actuator.

  • Page 42: Set Up Procedure

    4. Set Up and Calibration Procedures - Set Up Procedure Set Up Procedure Each of the set up groups and their functions are either pre-configured at the factory or set to their default values. Tables 8 through 19 list and describe the options available in each set up group. The following procedure shows you the key press sequence to access any set up group or any associated Function parameter.
  • Page 43 4. Set Up and Calibration Procedures - Set Up Procedure Step Operation Press Result Change the Value These keys increase or decrease the value, or display the next or Selection available selection for the selected function prompt. See Table 5, Set Up Tips for instructions to increase or decrease a value quickly.

  • Page 44: Input Set Up Group

    4. Set Up and Calibration Procedures - Input Set Up Group Input Set Up Group Table 8 lists the parameters and selections available when the SET INPUT group is selected. On the keypad and local display: • Press the SET UP key to enter the Input Set Up group. •...
  • Page 45 4. Set Up and Calibration Procedures - Input Set Up Group Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting ACTUATOR ROTATION—This selection determines the Direct direction of rotation of the actuator shaft. Counterclockwise rotation [default] Clockwise rotation NOTE: Actuator rotation is the direction of the output shaft when facing the end of the shaft and refers to the direction of rotation on increasing signal.
  • Page 46 4. Set Up and Calibration Procedures - Input Set Up Group Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting 0 to 100% FAILSAFELO INPUT VALUE—(FailsafeLO Type USER FsFVALL * only) Selects the motor position you want the actuator to go to when input signal is below the low end range value or on default = 0 loss of input.

  • Page 47: Equal Percentage Valve Characteristic

    4. Set Up and Calibration Procedures - Input Set Up Group Equal Percentage Valve Characteristic Table 9 contains values that approximate an equal percentage valve characteristic in the actuator. When the EQUL custom characterization type is selected, the values in Table 9 are automatically loaded into the actuator configuration to produce the characteristic as presented in the graph.

  • Page 48: Quick Opening Valve Characteristic

    4. Set Up and Calibration Procedures - Input Set Up Group Quick Opening Valve Characteristic Table 10 contains values that approximate the characteristic of a quick opening control valve. When the QUIK custom characterization type is selected, the values in Table 10 are automatically loaded into the actuator configuration to produce the characteristic as presented in the graph.

  • Page 49: Relays Set Up Group

    4. Set Up and Calibration Procedures - Relays Set Up Group Relays Set Up Group ATTENTION The Relay set up group parameters are accessible only if relay PWAs are installed in the actuator. 10260S series actuators can be equipped with up to two relay PWAs –for a total of four SPDT relays.

  • Page 50: Table 12 Relay Type Descriptions

    4. Set Up and Calibration Procedures - Relays Set Up Group Table 12 Relay Type Descriptions When this Relay Type is selected… The Relay can be set up to indicate … (RTYP) The upper / lower limits of the input signal have been exceeded. Input Range Relay value parameter defines range limits and units are in percent of full span.

  • Page 51: Relay Examples

    4. Set Up and Calibration Procedures - Relays Set Up Group Relay Examples Relay Type - Position Range Selecting PosR relay type, you can cause the relay to energize when the actuator motor travels below 20% of range and above 80% of range. Note in the example below that Relay 1 is set up to provide two trip points.
  • Page 52 4. Set Up and Calibration Procedures - Relays Set Up Group Relay Type – Deviation, continued Input Motor 100% Position -10% +10% Closed Closed Open RELAY n Normally Open Relay Type – Upper Limit Travel with Hysteresis Selecting relay type ULim will cause the relay to energize when the motor position exceeds the upper limit trip point, and can be set up as follows.

  • Page 53: Current Out Set Up Group

    4. Set Up and Calibration Procedures - Current Out Set Up Group Relay Type – Motor Starts Selecting relay type STRT will cause the relay to trip when the number of motor starts exceeds the selected limit. The motor starts value is stored as one of the maintenance group statistics. This example sets the motor starts limit at 200,000 for Relay 1.
  • Page 54 4. Set Up and Calibration Procedures - Current Out Set Up Group Lower Display Upper Display Parameter Definition Prompt Selections CUROUT SW E Slidewire Emulation Note: If output type from model selection guide Slidewire Emulation CUROUT NONE No current output configured. Note: If output type from model selection guide...

  • Page 55: Communications Set Up Group

    4. Set Up and Calibration Procedures - Communications Set Up Group Communications Set Up Group Table 14 lists the parameters and selections available for the SET COMM group. Table 14 Communications Set Up Group Parameters Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting...

  • Page 56: Digital Input Set Up Group

    4. Set Up and Calibration Procedures - Digital Input Set Up Group Digital Input Set Up Group Table 15 lists the parameters and selections availible for the SET DIGINP group. Table 15 Digital Input Set Up Group Parameters Lower Display Upper Display Parameter Definition Prompt...

  • Page 57: Lock Set Up Group

    4. Set Up and Calibration Procedures - Lock Set Up Group Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting DISPLAY UNITS—Selects standard for unit values for the UNITS local display. SI—Display will show unit values in international (metric) units.

  • Page 58: Set/Change Password

    4. Set Up and Calibration Procedures - Lock Set Up Group Set/Change Password A password is required to enable and disable lockout features of the actuator. Lock out of calibration information and other supervisory functions are controlled using the password. The password can be any number from 0 to 4095.

  • Page 59: Read Status Set Up Group

    4. Set Up and Calibration Procedures - Read Status Set Up Group Read Status Set Up Group Table 18 lists the parameters and selections available for the READ STATUS group. Table 18 Read Status Set Up Group Parameters Lower Display Upper Display Parameter Definition Prompt...

  • Page 60: Drive Set Up Group

    4. Set Up and Calibration Procedures - Drive Set Up Group Drive Set Up Group Table 19 lists the parameters and selections available for the SET DRVINF group. Table 19 Drive Set Up Group Parameters Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting...
  • Page 61 4. Set Up and Calibration Procedures - Drive Set Up Group Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting mmddyy * MANUFACTURING DATE—Read Only. Displays datecode MFGDAT of manufacture for actuator. ddmmyy mmddyy * DATE OF LAST REPAIR—Factory set only. Displays date LREP of last repair.

  • Page 62: Set Tag Name

    4. Set Up and Calibration Procedures - Drive Set Up Group Set Tag Name The actuator tag name can be an alphanumeric name up to six characters. The tag name is set by using the keys on the keypad and the local display. Follow the steps below to set the tag name. Step Action Press SET UP key until the display reads SET DRVINF.

  • Page 63: Maintenance Set Up Group

    4. Set Up and Calibration Procedures - Maintenance Set Up Group Maintenance Set Up Group The Maintenance set up group consists of information about actuator operation accumulated through time. This information (or maintenance statistics) can be used to evaluate actuator operation and determine predicted or scheduled maintenance periods.
  • Page 64 4. Set Up and Calibration Procedures - Lower Display Upper Display Parameter Definition Prompt Selections or Range of Setting MANRST MAINTENANCE STATISTIC RESET—Allows reset of the following maintenance statistics: NONE None—No reset of maintenance statisitics STAL Stall—Resets accumulated stall time to zero. STRT Motor Starts—Resets accumulated motor start counts to zero.

  • Page 65: Cal Posout Group

    4. Set Up and Calibration Procedures - CAL POSOUT Group CAL POSOUT Group The CAL POSOUT group is used to verify that the position sensor is operating and adjusted properly. This group allows the local display to indicate the output voltage of the position sensor PWA. This display is used when verifying that the sensor is operating and that it is properly calibrated.

  • Page 66: Table 22 Auto - Manual Switch Functions

    4. Set Up and Calibration Procedures - Auto - Manual Drive Switch MANUAL AUTO - MANUAL DRIVE Figure 16 Auto - Manual Switch Table 22 Auto - Manual Switch Functions Switch Setting Motor Drive Control AUTO Actuator moves according to signal input and set up configuration. Actuator moves to the fully counterclockwise position.

  • Page 67: Calibration

    4. Set Up and Calibration Procedures - Calibration Calibration Calibration of the 10260S Series Actuator may consist of calibrating the position sensor, calibrating the motor circuit that positions the actuator with 0/4-20mA input signal, or calibrating the slidewire emulation output or the 0/4-20mA output signal. Calibration is performed by connecting test equipment to the input terminals or output terminals and then using the keypad and display to step through the calibration group functions.

  • Page 68: Figure 17 Calibration Wiring Connections (Except Slidewire Emulation)

    4. Set Up and Calibration Procedures - Calibration Calibration Set up Follow the steps below to set up the test equipment and actuator to verify calibration or perform calibration procedures. Step Action Connect the copper leads from the signal source to the input terminals of the actuator as shown in Figure 17 or Figure 18.

  • Page 69: Figure 18 Calibration Wiring Connections (Slidewire Emulation)

    4. Set Up and Calibration Procedures - Calibration Actuator Digital Voltmeter Calibrated Signal Terminal Block Source Input Output 28 29 30 31 32 Power Supply 1-18 VDC 250 ohm resistor needed for current signal source Figure 18 Calibration Wiring Connections (slidewire emulation) Revision 5 10260S HercuLine®...

  • Page 70: Table 23 Input Calibration Procedure

    4. Set Up and Calibration Procedures - Calibration Calibrate Input The 10260S actuator accepts a variety of signal inputs. 1. 0 mA to 20 mA, or 4 mA to 20 mA 2. 0 Volts to 5 Volts, 1 Volt to 5 Volts, or 0 Volts to 10 Volts The input type is selected through the Input set up group using the local keypad.

  • Page 71: Table 24 Motor Calibration Procedure

    4. Set Up and Calibration Procedures - Calibration Calibrate Motor Use the procedure in Table 24 to calibrate the actuator motor for 0 % and 100 % input signal ATTENTION For a motor calibration to be saved, you must complete the procedure. The calibration will not be saved if you exit without completing the steps of the procedure.

  • Page 72: Table 25 Output Calibration Procedure

    4. Set Up and Calibration Procedures - Calibration Calibrate Output 10260S actuator can be one of three output types: 1. 0 mA to 20 mA, or 4 mA to 20 mA output 2. 0 Volts to 5 Volts, or 1 Volt to 5 Volts with 250 ohm range resistor 3.

  • Page 73: Table 26 Slidewire Emulation Calibration Procedure

    4. Set Up and Calibration Procedures - Calibration Step Operation Press Result • Adjust actuator output to a value equal to 0% output as read cont’d from the DVM. NOTE: Typically for a 4 mA output, the display will show a value of approximately 381.
  • Page 74 4. Set Up and Calibration Procedures - Calibration Step Operation Press Result Calibrate Zero (0%) FUNCTION Upper Display = Lower Display = ZERO xxx = arbitrary number assigned by software Adjust actuator output voltage using down key until value on DVM ceases to change, then press up key until value on DVM moves up one digit Calibrate Span...

  • Page 75: Table 27 Non Contact Sensor Calibration Procedure

    4. Set Up and Calibration Procedures - Calibration Table 27 Non Contact Sensor Calibration Procedure Step Action Remove AC power to the actuator. Remove the seven screws and the extended cover from the actuator case. See Figure 2. Lay extended cover assembly on a flat surface. Reapply AC power to the actuator.

  • Page 76: Table 28 Load Ncs Factory Calibration

    4. Set Up and Calibration Procedures - Calibration Step Action Install a new gasket and replace extended cover. Secure to actuator with screws. Continue with calibration procedure in Table 28. NCS Spoiler Set Screw NCS Spoiler Allen Screw 0.05" Hex Bottom of NCS spoiler should be almost horizontal NCS PWA...

  • Page 77: Setting End-Of-Travel Limit Switches (Actuators Mfd. Pre-1/1/03)

    4. Set Up and Calibration Procedures - Setting End-of-Travel Limit Switches (actuators mfd. pre-1/1/03) Setting End-of-Travel Limit Switches (actuators mfd. pre-1/1/03) WARNING While the unit is powered, a potentially lethal shock hazard exists inside the case. ATTENTION The first two cams (starting from the back) are for the 0 % and 100 % limit switches and should not need any adjustments as they are factory set to stop the drive at 0 % and 100 %.

  • Page 78: Setting End-Of-Travel Limit Switches (Actuators Mfd. After 1/1/03)

    4. Set Up and Calibration Procedures - Setting End-of-Travel Limit Switches (actuators mfd. after 1/1/03) ATTENTION Make sure not to set the switch too close to the hard stop. REFERENCE An unactuated switch will have its normally closed (NC) contacts closed and its normally open (NO) contacts open.
  • Page 79 4. Set Up and Calibration Procedures - Setting End-of-Travel Limit Switches (actuators mfd. after 1/1/03) • Rotate the #2 limit switch operating cam to activate at this position. The switch roller arm should go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position.

  • Page 80: Setting Auxiliary Switches (Actuators Mfd. Pre-1/1/03)

    4. Set Up and Calibration Procedures - Setting Auxiliary Switches (actuators mfd. pre-1/1/03) Setting Auxiliary Switches (actuators mfd. pre-1/1/03) WARNING While the unit is powered, a potentially lethal shock hazard exists inside the case. ATTENTION The first two cams (starting from the back) are for the 0 % and 100 % end of travel limit switches and should not need any adjustments as they are factory set to stop the actuator at 0 % and 100 %.

  • Page 81: Figure 20 Location Of Auxiliary Switches

    4. Set Up and Calibration Procedures - Setting Auxiliary Switches (actuators mfd. pre-1/1/03) 4. Once the cams are set in the correct positions, turn the locking nut clockwise until snug tight (it does not have to be “hard” tight and does not have to completely flatten the spring washer). 5.

  • Page 82: Figure 21 End Of Travel Limit Switch Settings

    4. Set Up and Calibration Procedures - Setting Auxiliary Switches (actuators mfd. pre-1/1/03) End of travel limit switch settings 100% Left hand 8 (SW1 COM) 9 (SW2 COM) Pointer scale SW#1 SW#2 Clockwise and counterclockwise rotation is the direction of the output shaft when facing the end of the shaft.

  • Page 83: Setting Auxiliary Switches (Actuators Mfd. After 1/1/03)

    4. Set Up and Calibration Procedures - Setting Auxiliary Switches (actuators mfd. after 1/1/03) Setting Auxiliary Switches (actuators mfd. after 1/1/03) WARNING While the unit is powered, a potentially lethal shock hazard exists inside the case. ATTENTION The first two cams (starting from the back) are for the 0 % and 100 % end of travel limit switches and should not need any adjustments as they are factory set to stop the actuator at 0 % and 100%.

  • Page 84: Start-Up/Operation

    5. Start-Up/Operation - Power Up Diagnostics 5. Start-Up/Operation Introduction After the actuator is completely installed, wired, and the preliminary adjustments made, it is advisable to check the operation of the actuator and controlled device before placing it in service. In other words, operate the controlled device and check its direction of travel in response to an increase of the input signal and make sure it is correct for the process.

  • Page 85: Operating The Local Display At High Temperatures

    5. Start-Up/Operation - Operating the Local Display at High Temperatures Operating the Local Display at High Temperatures The temperature limits for the actuator local display are listed as -30 ° C to +50 ° C (-20 ° F to +122 ° F). The display is programmed to shut off automatically at operating temperatures above +50 °...

  • Page 86: Non-Contact Sensor Operation

    5. Start-Up/Operation - Non-Contact Sensor Operation Non-Contact Sensor Operation The non-contact sensor (NCS) is magnetically coupled to the output shaft of the actuator so that the sensor detects shaft position. The sensor is adjusted at the factory and under normal conditions, the NCS requires no adjustment.

  • Page 87: Regions Of Motor Travel

    5. Start-Up/Operation - Regions of Motor Travel Actuator Terminal Block SHIELD FEEDBACK COMMUNICATION DIGITAL INPUT Figure 23 Terminal Block Connections for Modbus Communications Regions of Motor Travel The full span of motor travel is 90 ° rotation. The span is divided into 10 regions of motor travel as shown in Figure 24 (regions are numbered 0 through 9).

  • Page 88: Control Applications

    6. Control Applications - Split Range 6. Control Applications Introduction The 10260S Smart Actuator can operate in a variety of control applications. Examples are given in this section for the actuator to operate in: • A basic flow control application •...

  • Page 89: Master/Slave Arrangement

    6. Control Applications - Master/Slave Arrangement Master/Slave Arrangement Introduction With the motor positioner, the controlling signal for the actuator is a 4 mA to 20 mA from a current output controller as shown in the flow diagram in Figure 25. Unlike the position output controller, the current output controller must produce a continuous analog signal or the actuator will revert to one of its failsafe states.

  • Page 90: Figure 27 Proportional Flow Using Multiple Actuators

    6. Control Applications - Master/Slave Arrangement Proportional Flow using Multiple Actuators Refer to flow diagram in Figure 27 and interconnection diagrams in Figure 28. The controller governs flow rate in one burner. Only that flow is measured. Since #2 and #3 motor positions receive the same signal as #1 motor positioned, valves #2 and #3 will deliver the same amount of fuel.

  • Page 91: Figure 28 Multiple Actuator Interconnection Diagrams

    6. Control Applications - Master/Slave Arrangement Current Output Controller 10260S Series Actuator #1 120/240 Neutral 250 Ohms 4 to 20 mA Ground 1 to 5 VDC Note: Controller must 10260S Series Actuator #2 be capable of sourcing the impedance. 120/240 Neutral 250 Ohms Ground...

  • Page 92: Figure 29 Interconnection Diagrams

    6. Control Applications - Master/Slave Arrangement Split Valve Configuration A common heat or cool type process requires two valves. In this case the controller has only one output. The two motor positioners are calibrated differently, one responds to 4 mA to 12 mA and the other responds to 12 mA to 20 mA.
  • Page 93 6. Control Applications - Master/Slave Arrangement Revision 5 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual 7/07...

  • Page 95: Maintenance

    Under normal operating conditions, the main worm gear should not require maintenance. Spur Gear Lubrication Honeywell recommends that during major shutdown periods the spur gears should be inspected and lubricated. Follow the steps in Table 31 to access the spur gear compartment and lubricate the gears if necessary.

  • Page 96: Figure 30 Spur Gear Location

    7. Maintenance - Basic Maintenance Spur Gears Side Cover Gasket Side Cover Final Spur Gear Idler Gear Motor Pinion Figure 30 Spur Gear Location 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual Revision 5 7/07...

  • Page 97: Replacement Procedures

    7. Maintenance - Replacement Procedures Replacement Procedures Fuse Replacement The motor drive circuit contains two fuses. They are located on the power distribution PWA. If it becomes necessary to replace these fuses, follow the procedure in Table 32 and refer to Figure 32 for fuse location. WARNING Disconnect power before opening the actuator case to replace the fuse(s).

  • Page 98: Table 33 Relay Pwa Replacement Procedure

    7. Maintenance - Replacement Procedures Fuses for Motor Drive Circuit Power Distribution PWA Figure 32 Motor Drive Circuit Fuses Relay PWA Replacement If a relay PWA needs to be replaced, follow the procedure in Table 33 to access and replace the PWA. WARNING Disconnect power before opening the actuator case.

  • Page 99: Replacement/Recommended Spare Parts

    8. Replacement/Recommended Spare Parts - 8. Replacement/Recommended Spare Parts Introduction This section provides you with a complete list of all the spare parts that may be needed for the 10260S Series Actuators and optional equipment. Each kit contains replacement parts accessories and instructions for component replacement.
  • Page 100 8. Replacement/Recommended Spare Parts - Motor Kits Kit #51205551-501 Motor 1026(1, 2, 4, 6) 120 V 50/60 Kit Part Description Motor Capacitor, Motor 7.5uf Gasket Set (10260S) Kit Instruction Kit #51205551-502 Motor 10263 120 V 50/60 Kit Part Description Motor Capacitor, Motor 11uf - 60 Hz Capacitor, Motor 13uf - 50 Hz Gasket Set (10260S)
  • Page 101 8. Replacement/Recommended Spare Parts - Kit #51205551-506 Motor 10265 120 V 50/60 Kit Part Description Motor Capacitor, Motor 11uf - 60 Hz Capacitor, Motor 13uf - 50 Hz Gasket Set (10260S) Kit Instruction Kit #51205551-507 Motor 10265 240 V 50/60 Kit Part Description Motor Capacitor, Motor...
  • Page 102 8. Replacement/Recommended Spare Parts - Non-Contact Sensor Kit Kit #51500523-501 Non-Contact Sensor (NCS) Replacement Part Description Non-Contact Sensor PWA NCS Set Up Gage Screws, #4-40 X 5/16” Gasket Set (10260S) NCS Wire Assy Kit Instruction Replacement PWAs Kit #51450802-501 Relay PWA Part Description Relay PWA Gasket Set (10260S)
  • Page 103 8. Replacement/Recommended Spare Parts - Kit #51451231-501 Display PWA Assembly Part Description Assembly Drawing Top Cover Cable Ties Display/keypad Cable Display PWA Keypad Support Plate, Keypad Display Lens Display Overlay Transformer Screws #4-40 X 3/8” Screws #6-32 X 3/8” Sleeve, Keypad Gasket Kit Instruction Kit# 51500324-501 Display Upgrade Kit...
  • Page 104 8. Replacement/Recommended Spare Parts - Kit Instruction Transformer Kit Kit #51500457-501 Transformer Kit Part Description Transformer Gasket Set (10260S) Cable Ties Kit Instruction Auto/Manual Switch Kit Kit #51500581-501 Auto/Manual Switch Kit Part Description Auto/Manual Switch/Wire Assy (10260S) Auto/Manual Label Knob Shrink Tubing Gasket Set (10260S) Kit Instruction...
  • Page 105 8. Replacement/Recommended Spare Parts - Limit/Auxiliary Switch Kits Kit #51205550-501 Switch Kit Part Description Switch Bracket Screws, #10-32 X ½” Lockwasher, #10 Washer (N) #10 Switch Support Bracket Switches Switch Insulator Screw, #4-40 X .75” Lockwasher, #4 Washer (N) #4 Screw, #4-40 X 1.25”...

  • Page 106: Linkage Parts/Kits

    1/2"-20 right-hand threads 1/2"-20 left-hand threads * cut to size with standard NPT both ends a/n 23202 Honeywell Actuator Linkage Analysis Software (HAL) Part Number: 51197910-001 Replacement Fuses Wickmann T1: 6A 250V 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual...

  • Page 107: Troubleshooting

    9. Troubleshooting - Introduction 9. Troubleshooting Introduction Troubleshooting procedures can be followed when inaccurate or faulty actuator operation is detected. In this section, troubleshooting procedures consist of a few simple flow charts to test for proper function of various actuator components. Component replacement is at the PWA or assembly level. Table 34 indicates some of the observable symptoms of failure that can be identified by noting the faulty actuator operation.

  • Page 108: Troubleshooting Procedures

    9. Troubleshooting - Troubleshooting Procedures Troubleshooting Procedures Overview Follow the procedure or flow chart to test for and determine actuator component operation. When using the flow charts for troubleshooting, you may be instructed to go to another flow chart in order to identify the faulty component.

  • Page 109: Figure 34 Test For Actuator Operation

    9. Troubleshooting - Troubleshooting Procedures Test for Actuator Operation Cycle power to actuator. Does display light up? Move handwheel Observe self test. on actuator 2 or 3 turns. Does motor reposition Do all diagnostics pass? itself? RAMTST PASS SEETST PASS CALTST PASS CFGTST PASS Replace display...

  • Page 110: Figure 35 Power Up Diagnostics

    9. Troubleshooting - Troubleshooting Procedures Power Up Self Test Diagnostics Cycle power to actuator. Does display light up? Observe self test. RAMTST PASS? Replace CPU SEETST PASS? Assembly. Check actuator Cycle power to configuration actuator. If CFGTST CFGTST PASS? (setup), reconfigure fails again, replace if necessary.
  • Page 111 9. Troubleshooting - Troubleshooting Procedures Test Non-Contact Sensor PWA See “Non-Contact Sensor Operation” in Section 5 for procedure in testing NCS PWA output. Revision 5 10260S HercuLine® Actuator Installation, Operation and Maintenance Manual 7/07...

  • Page 112: Figure 36 Test Power Distribution Pwa

    9. Troubleshooting - Troubleshooting Procedures Test Power Distribution PWA Remove extended cover of actuator. Check Fuses F1 and F2 on the power distribution PWA. Are fuses good? Replace fuses with same type and rating Is correct voltage present at test points? See below.

  • Page 113: Figure 37 Test Auto - Manual Switch

    9. Troubleshooting - Troubleshooting Procedures Test AUTO - MANUAL DRIVE Switch Turn switch to Manual CCW setting. Does motor drive in the CCW direction? Turn switch to Manual CW setting. Does motor drive in the CW direction? Possible trouble spots a.

  • Page 114: Figure 38 Test Relay Function

    9. Troubleshooting - Test Relay Function Press SET UP button on keypad to enter Set up mode. Set suspect Relay Set AUTO - type to MAN. MANUAL switch to MAN. Place ohmmeter across associated relay contacts at Does Relay Actuator terminal operate? block.

  • Page 115: Appendix A - 10260S Configuration Record Sheet

    Appendix A - 10260S Configuration Record Sheet - Appendix A - 10260S Configuration Record Sheet Enter the value or selection for each set up parameter on this sheet so you will have a record of how your actuator is configured. Set Up Group Parameter Setting...
  • Page 116 Appendix A - 10260S Configuration Record Sheet - Set Up Group Parameter Setting Default Prompt Y3 VAL -- __________________ Y4 VAL -- __________________ Y5 VAL -- __________________ Y6 VAL -- __________________ Y7 VAL -- __________________ 10.7 Y8 VAL -- __________________ 13.2 Y9 VAL -- __________________...
  • Page 117 Appendix A - 10260S Configuration Record Sheet - Set Up Group Parameter Setting Default Prompt R32VAL – Relay Value __________________ R32 HL – Relay High/Low __________________ R32SCALE– Relay Scale __________________ RLY3HY – Relay Hysteresis __________________ RTYP41 – Relay Type __________________ NONE R41VAL –...
  • Page 118 Appendix A - 10260S Configuration Record Sheet - Set Up Group Parameter Setting Default Prompt LCAL – Date of Last Field Calibration __________________ Factory Set REPTYP – Repair Type __________________ Factory Set TEMP – Actuator Temperature __________________ Read Only SET MAIN TEMPHI –...

  • Page 119: Index

    Index - Index Actuator Rotation............35, 56 HAL Software .............. 5, 96 Actuator Set Up ..............30 Hysteresis ................. 39 Set up groups..............30 Input Calibration .............. 60 Set up procedure............32 Input Characterization ............36 Actuator Statistics Input Filters ..............34 Accumulated motor starts..........53 Input High Range .............
  • Page 120 Index (LOCKID) ..............47 Drive ................50 Change .................48 Input................34 Position Range Maintenance..............53 Relay type..............41 Read status..............49 Power Supply PWA Relays ................39 Checking ..............102 Short Stroke Projecting Scale Option ............21 Motor calibration ............61 Pushbuttons Slidewire Emulation..........3, 9, 27 Description ..............29 Smart Electronics ...............
  • Page 122 Honeywell Field Solutions Honeywell Inc. 512 Virginia Drive Fort Washington, PA 19034...

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