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Precision Engine Controls Corporation ACT2000 Operation Manual

Precision engine control all-electric actuator model act2000 operation manual
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ACT2000
Operations
Manual
ACT2000
All-Electric Actuator
SD-6008-03

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Summary of Contents for Precision Engine Controls Corporation ACT2000

  • Page 1 ACT2000 Operations Manual ACT2000 All-Electric Actuator SD-6008-03...
  • Page 3 It is recommended that the user read this manual in its entirety. Operating the ACT2000 All-Electric Actuator in accordance with instructions herein ensures long term and reliable operation. If additional information is required, please contact:...
  • Page 4 ACT2000...

  • Page 5: Table Of Contents

    2.3 Basic Operation and State Description ... 2-6 2.4 Health Monitoring ... 2-8 2.5 FAULT Alarm... 2-9 2.6 OVERTEMP Alarm ...2-10 2.7 Automatic Shutdown ...2-10 2.8 ACT2000 Set-Up Parameters ...2-11 INSTALLATION ... 3-1 3.1 Inspection... 3-1 3.2 Environmental Considerations... 3-1 3.3 Mechanical Installation... 3-1 3.4 Electrical Installation...
  • Page 6 Table 3-1: Power Harness Recommended Wire Size...3-5 Table 3-2: Digital Harness Recommended Wire Size ...3-6 Table 3-3: ACT2000 Power Harness Wire List...3-7 Table 3-4: ACT2000 Digital Harness Wire List ...3-9 Table 3-5: Power Supply Requirements...3-10 Table 4-1: ACT2000 Initial Installation Troubleshooting Chart...4-2 Table 4-2: ACT2000 In-Service Troubleshooting Chart ...4-3...

  • Page 7: Introduction

    1.2 Mounting Provisions The ACT2000 can be pin or flange mounted. Figure 1-1 shows a pin-mounted actuator. Figure 1-2 shows a flange-mounted actuator. Other configurations can be provided. Please consult Precision Engine Controls Corporation.

  • Page 8: Main Housing Assembly

    The main housing contains rigid mechanical stops to prevent extension rod travel beyond the design specification. Rigid Stop Main Bearings Motor Rotor Motor Stator Motor Cover Figure 1-3 ACT2000 Cut-Away View Extension Shaft Rod End Bearing Motor Control Electronics Anti Rotation Guide Linear Drive Resolver Assembly...

  • Page 9: Brushless Dc Motor Assembly

    1.4 Brushless DC Motor Assembly A brushless DC motor powers the ACT2000 linear drive mechanism. The DC motor contains a stator and rotor. See Figure 1-3 Motor Stator The motor stator is attached to the main housing by a pre-loaded wave spring and screws.

  • Page 10: Linear Drive Mechanism

    This arrangement prevents actuator axial loads from passing through the resolver rotor and motor rotor. 1.8 Power and Digital Harness A four-wire electrical harness with two (2) meter free leads provides the ACT2000 electrical power inputs. The four-wire harness allows for redundant electrical inputs.

  • Page 11: Identification Plate

    ACT2000 1.9 Identification Plate A product identification plate is attached to the actuator housing assembly. Figure 1-4 shows a typical identification plate. The identification plate lists model designation, product part number, revision and unit serial number. Hazardous area operation, certification and electrical wiring interface information is also provided.
  • Page 12 ACT2000 NTENTIONALLY LANK...

  • Page 13: Functional Description And Operation

    Electric Actuator. 2.1 System Description The ACT2000 is a closed loop servo system containing motor control electronics (MCE) and a brushless DC motor driven ball screw actuator. The actuator closes its own control loop on an internally generated position feedback. Thus, the actuator continuously modulates its position and provides precise positioning.

  • Page 14: Driver Assy

    WHITE/ORANGE FAULT RTN BLACK OVERTEMP ALARM WHITE/BLACK OVERTEMP RTN WHT/ORN/BLU SERIAL TX OUT WHT/ORN/YEL SERIAL RX IN WHT/ORN/GRN SERIAL RTN Figure 2-1: ACT2000 Electronics System Block Diagram DRIVER ASSY REVERSE POLARITY PROTECTION POWER ELECTRONICS POWER INTERFACE INPUT TERMINATION 4-20mA OUTPUT...

  • Page 15: Figure 2-2: Typical Power Connection

    2.2.1 Power The ACT2000 operates on nominal 120 VDC, user-provided input voltage via the four-wire power harness. Refer to Figure 2-2 for typical connection. Refer to section 6 for specification values. Primary power wires. • +120 VDC is connected to the RED wire.

  • Page 16: Figure 2-4: Typical Analog Input Connection

    ACT2000 Run Command The RUN command is a user provided discrete input to the ACT2000 which allows the actuator to track position demand. The +24 VDC signal shall be provided on the VIOLET wire. The signal return shall be provided on the WHITE/VIOLET wire.

  • Page 17: Figure 2-6: Typical Fault Alarm Connection

    The Serial RX In wire is WHITE/ORANGE/YELLOW. • The Serial Tx Out wire is WHITE/ORANGE/BLUE. • The Serial Rtn wire is WHITE/ORANGE/GREEN. The RS232C type interface is used to communicate with the ACT2000 using ActWiz software. ACTUATOR DISCRETE OUTPUT FAULT ALARM [ORN]...

  • Page 18: Basic Operation And State Description

    ACT2000 2.3 Basic Operation and State Description The basic operation of the ACT2000 is described in the following sections. The Power-Up mode section covers the Power Up/Reset and the Set-Up states. The Run Mode section covers the Home/Dead Band, Holding Motor Current and the Run states.
  • Page 19 ActWiz software. Ensure there is no load on the extension rod when communicating with the actuator. Once the ACT2000 has completed the power-up operations, it will wait for a RUN command. The actuator will not move or hold load until a RUN command is received.

  • Page 20: Health Monitoring

    STOP position. Run State The RUN state is the ACT2000 normal operating mode. See Figure 2-7. In the RUN state, the actuator tracks position demand and will apply up to the maximum force to reach the demand position.

  • Page 21: Fault Alarm

    MCE outputs a separate OVERTEMP alarm. The actuator firmware also captures the fault data in the EEPROM. If any of these faults have occurred, the user should shut down the ACT2000 to investigate the failure cause If the ACT2000 is operational, a fault file can be uploaded using ActWiz software via the RS232 interface.

  • Page 22: Overtemp Alarm

    75 VDC for more than 10 seconds. This FAULT clears when the 120 VDC supply voltage returns. 2.6 OVERTEMP Alarm The OVERTEMP alarm is a discrete output from the ACT2000. The OVERTEMP circuit is CLOSED in the normal operating condition. During normal operation, the ACT2000 monitors the electronics and motor winding temperatures.

  • Page 23: Act2000 Set-Up Parameters

    Maximum Homing Velocity This parameter sets the maximum velocity used to find the HOME position. Maximum Homing Force This parameter sets the maximum force the ACT2000 will use to find the HOME position. Maximum Holding Force This parameter sets the maximum force at the HOME position while the position demand is <...
  • Page 24 Velocity Loop PID Constants Proportional Integral Derivative Maximum Velocity Maximum Force Maximum Homing Velocity Maximum Homing Force Maximum Holding Force Table 2-1 Typical ACT2000 Setup Parameters 2-12 Factory Setting Per Drawing Stand Alone Analog Retract 5.9 inches 0.1 inches Linear...

  • Page 25: Installation

    3.2 Environmental Considerations The ACT2000 will operate satisfactorily with ambient air temperature of -40 °C (-40 °F) to +93 °C (+200 °F). The ACT2000 is designed as an explosion-proof assembly. The ACT2000 enclosure is Canadian Standards Association (CSA) Type 3.

  • Page 26: Figure 3-1: Act2000-590P Envelope

    ACT2000 Figure 3-1: ACT2000-590P Envelope...

  • Page 27: Figure 3-2: Act2000-200F Envelope

    ACT2000 Figure 3-2: ACT2000-200F Envelope...

  • Page 28: Electrical Installation

    Wiring must be in accordance will local authorities jurisdiction. 3.4.1 Wiring Specifications and Requirements This section describes the recommended power and control harness wiring to the ACT2000. Please consult the factory if there are any questions. See Table 3-5 for DC power supply requirements.

  • Page 29: Table 3-1: Power Harness Recommended Wire Size

    European standards. Power Harness Recommended Wiring Under normal operation and load, the ACT2000 requires less than one (1) amp input current. Under transient operation (under load) the ACT2000 may require up to (20) amps of current.

  • Page 30: Table 3-2: Digital Harness Recommended Wire Size

    ACT2000 Note: For proper operation of the actuator, the voltage between the control inputs and the negative terminal of the power supply should be below 200 VDC. The discrete inputs and outputs are 24 VDC and are electrically isolated up to 500 VAC.

  • Page 31: Table 3-3: Act2000 Power Harness Wire List

    Note: Serial connection limited to 50 ft for local interface only with laptop PC. 3.4.2 Wire Lists This section will provide ACT2000 wire hook-up information. Power Harness Electrical Hook-Up Table 3-3 shows the factory wiring for the ACT2000 power harness. Wire Color WHITE/RED GREEN WHITE/GREEN...

  • Page 32: Power Supply

    Over Temp Alarm Shield Gnd Shield Gnd Serial RX in Serial TX out Serial RTN Shield Gnd ENGINE CONTROLLER Figure 3-3: ACT2000 Wiring Diagram ACT2000 PWR (RED) PWR [AUX] (WHT/RED) PWR RTN (GRN) PWR RTN [AUX] (WHT/GRN) Shield No Connection DEMAND (BRN)

  • Page 33: Table 3-4: Act2000 Digital Harness Wire List

    Table 3-4 shows the factory wiring and reference signals for the ACT2000 signal harness. Note: The serial wiring is segregated from the other wires. Wire Color Function WHITE/ORANGE/YELLOW Serial/RX In WHITE/ORANGE/BLUE Serial/TX Out WHITE/ORANGE/GREEN Serial Return BLACK OVER TEMP Alarm...

  • Page 34: Table 3-5 Power Supply Requirements

    ACT2000 Power Supply Requirements A battery power system is recommended, Table 3-5 lists the power supply requirements. Voltage: Max Ripple: Max Current: Typical Continuous Current: Typical Transient Current: *Output Capacitance: The output capacitance applies for non-battery power systems and assumes full stroke step changes in actuator position at rated load.

  • Page 35: Troubleshooting

    The information contained in this section is intended to aid maintenance technicians in troubleshooting and isolating causes of malfunctions in the ACT2000. Most electrical fault isolation of the actuator can be accomplished by using an external oscilloscope and digital voltmeter (DVM).

  • Page 36: Table 4-1 Act2000 Initial Installation Troubleshooting Chart

    Table 4-1 ACT2000 Initial Installation Troubleshooting Chart Symptom Probable Causes Actuator Inoperative - FAULT Power Wires not connected alarm No or low 120 VDC power Actuator Inoperative - No RUN or position command NO FAULT alarm Actuator moves toward Intermittent RUN command...

  • Page 37: Table 4-2 Act2000 In-Service Troubleshooting Chart

    If an open circuit is detected, send actuator to Precision Engine Controls Corporation for test and repair. WARNING: Shock Hazard – Remove all power to actuator prior to continuity check Table 4-3 ACT2000 Electrical Hook-Up Continuity Troubleshooting Chart Function Actuator Wire Colors DEMAND...
  • Page 38 ACT2000 NTENTIONALLY LANK...

  • Page 39: Decommissioning And Disposal

    5 DECOMMISSIONING AND DISPOSAL This section contains recommended ACT2000 decommissioning and disposal practices. It is for permanent removal or replacement of the installed product, with no intentions of rework, overhaul, or to be used as spares. For removal follow proper lockout /tagout procedures and verify no live electrical circuits: Disconnect power harness to ACT2000.
  • Page 40 ACT2000 NTENTIONALLY LANK...

  • Page 41: Act2000 General Specifications

    6 ACT2000 GENERAL SPECIFICATIONS Power Input RUN and RESET Command Input FAULT and OVERTEMP Output Analog Command Input Position and Motor Current Feedback Analog Maximum Common Mode Voltage Temperature Limits Maximum Velocity Maximum Continuous Force Maximum Peak Force Maximum Stroke...
  • Page 42 ACT2000 NTENTIONALLY LANK...

  • Page 43: Glossary

    A user-provided computer that executes commands to the ACT2000 and accepts analog and discrete feedback. Position Demand A 4mA to 20mA signal that commands the ACT2000 to move to a certain position. The signal is scaled with SPAN. Position Demand Feedback A 4mA to 20mA signal that communicates the actual ACT2000 position to the controller.
  • Page 44 ACT2000 NTENTIONALLY LANK...
  • Page 45 ACT2000...

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