installation, operating & maintenance manual€¦ · · 2003-07-15a separate installation,...

Installation, Operating& Maintenance Manual

Series 75 Electric Actuators

A separate Installation, Operating & Maintenance Manualexists for the Dataflo C and P versions of this product

- contact Norbro for further details.

The Norcom product complies with thefollowing European directives and standards.

Directives

89/36/EEC Electromagnetic Compatibility

73/23/EEC Low Voltage Directive

92/59/EEC General Product Safety

Standards

EN 50014: 1992 General Requirements

EN 60529: 1992

EN 60529: 1989Ingress protection

Contents

Installation, Operating & Maintenance ManualDescription .......................................................................................................................................... 2

1. Specifications ..................................................................................................................................... 2

1.1 Environmental considerations .................................................................................................................. 21.2 Storing the actuator prior to use............................................................................................................... 2 1.3 Control integrity......................................................................................................................................... 2 1.4 Coding....................................................................................................................................................... 3 1.5 Manual overrides ...................................................................................................................................... 3

2. Installation .......................................................................................................................................................... 4

2.1 Mounting configurations .......................................................................................................................... 42.2 Mounting the actuator to the valve ........................................................................................................... 4 2.3 ‘E’ Series mounted valves......................................................................................................................... 4 2.4 ISO Top mounted valves........................................................................................................................... 52.5 Mounting the actuator to the valve (modulating) ...................................................................................... 52.6 Electrical installation and cam adjustment ............................................................................................... 6 2.7 Cam adjustment........................................................................................................................................ 82.8 Cover re-assembly .................................................................................................................................... 92.9 Size conversion......................................................................................................................................... 9

3. Maintenance and trouble shooting ............................................................................................................ 10

3.1 Electrical supply ..................................................................................................................................... 103.2 Electrical connections ............................................................................................................................. 10 3.3 Limit switches.......................................................................................................................................... 103.4 Capacitors............................................................................................................................................... 10 3.5 Motor....................................................................................................................................................... 10 3.6 Gear train................................................................................................................................................ 103.7 Valve ....................................................................................................................................................... 10

4. Feedback potentiometer option (single / dual) ....................................................................................... 11

4.1 General description ................................................................................................................................ 114.2 Assembly ................................................................................................................................................ 11 4.3 Size 10 - 23 actuator feedback potentiometer assembly (single / dual)................................................. 114.4 Size 25 & 30 actuator feedback potentiometer assembly (single / dual) ............................................... 12 4.5 Feedback potentiometer to actuator assembly....................................................................................... 13 4.6 Wiring...................................................................................................................................................... 134.7 Wiring to options..................................................................................................................................... 14 4.8 Feedback potentiometer adjustment ...................................................................................................... 144.9 Feedback potentiometer calibration (single)........................................................................................... 14 4.10 Feedback potentiometer calibration (dual) ............................................................................................. 15

5 Heater / thermostat option ........................................................................................................................... 16

5.1 Insallation ............................................................................................................................................... 165.2 Wiring...................................................................................................................................................... 17

6 Mechanical brake option ............................................................................................................................... 18

6.1 Mechanical brake assembly ................................................................................................................... 186.2 Assembling the bracket to the actuator .................................................................................................. 186.3 Wiring...................................................................................................................................................... 196.4 Testing..................................................................................................................................................... 19

7 Centre-off option sizes 10 -30 ..................................................................................................................... 20

7.1 Actuator rotation ..................................................................................................................................... 207.2 Installaton of the centre-off option .......................................................................................................... 217.3 Wiring of the centre-off option ................................................................................................................ 227.4 Setting the centre-off cams..................................................................................................................... 247.5 Operating the actuator ............................................................................................................................ 247.6 Customer DC switching and wiring......................................................................................................... 25

8 Extra limit switch option (M1 or M2) sizes 10 - 30 ................................................................................. 26

8.1 Installing extra limit switch(es)................................................................................................................ 268.2 Installing the cam(s)................................................................................................................................ 268.3 Wiring the switch(es) .............................................................................................................................. 26

9 Cycle length controller option (CLC) sizes 10 - 30 ................................................................................ 2810 Exploded view drawings .............................................................................................................................. 30

Series 75 sizes 10 - 23 ........................................................................................................................................ 30Series 75 sizes 25 - 30 ........................................................................................................................................ 32

Page

2

DESCRIPTIONThe distinctive yellow and black housing of Worcester Controls series 75 electric actuators are known throughout the world for their quality of build and low maintenance. The standard range of quarter turn actuators, utilising only threesizes of housing, can provide output torque from anywhere between 17.3 - 345 Nmvia a permanently lubricated gear train. The AC actuators use a capacitor start /run motor which are equipped with an integral thermal overload protection systemand automatic reset. All series 75 electric actuators have manual override facilities.

1. SPECIFICATIONS

1.1 ENVIRONMENTAL CONSIDERATIONS

The series 75 electric actuators are electro - mechanical devices and are subject tonormal wear. The life of the actuator is dependent on the application andenvironment in which it is used. If used in high temperature areas the duty cyclewill be affected (consult Worcester Controls for revised duty cycle and operatingtimes). It is highly recommended by Worcester Controls that for actuators which areto be mounted outdoors use a heater / thermostat in conjunction with a drain /breather kit. The operation of the actuator and the heat that is generated during thecycles from the electric motor(s) heats the air in the enclosure and expands. Whenthe actuator cools, the moisture in the air condenses and water droplets form onthe inside of the actuator cover. The more cycles the actuator completes the morewater that is formed in the enclosure. The heater / thermostat is used to keep thehousing at a constant temperature and the drain / breather to let any water escapethrough the lowest point in the actuator base if required.

1.2 STORING THE ACTUATOR PRIOR TO USE

Prior to use, the actuators should be stored in areas that do not exceed 85%relative humidity and which have a temperature range of between 4.5 - 48.5°C. Donot store in areas where acidic, alkali fumes or radiation is present or within 50 feetof any source of ozone.

The actuator enclosure has an internationaly recognised rating of IP 66. To upholdthe integrity of the enclosure a conduit that is equal to or better than IP66 must befitted.

The electrical conduit entry size is 1/2" NPT for actuator sizes 10-30 with exceptionof the size 23 which has a 3/4" NPT.

1.3 CONTROL INTEGRITY

For both the AC and DC standard electric actuators the actuator shaft will stoptravelling if the power supply to the motor(s) is interrupted in any way.

IOM Manual Series 75 Electric Actuators


3

1.4 CODING

The series 75 product coding is divided into field (A-M) as detailed below;

1.5 MANUAL OVERRIDES

This facility should only be used when the electrical supply to the actuator is turned'off' or when the actuator has failed after the electrical supply has been restored.If the actuator has been manually overridden the motor will drive until the clutch re-engages driving the valve to the end of travel.

Size 10-23: Pull the declutching knob up to expose the shaft flats. Using a correctly sized spanner on the flats rotate the actuator shaft to the desired position. To re-engage, return the actuator shaft to the original position of disengagement and remove the spanner. The knob will drop down covering the flats.

Size 25/30: Simply rotate the handwheel in either direction to achieve the desired position.

NOTE: The actuator should only be manually operated over the quadrant that thecams are adjusted for. Operating outside of this quadrant could possibly disrupt theworking of the actuator / valve assembly.

© Copyright Worcester Controls (UK) Ltd.

A B C D E F G H J K L M

1 2 3 4 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 19 20 21 22 23 24

Example:10 754W 240A

Size 10 series 75 electric actuator

60% Duty cycle

Gasket interface seal - waterproof

240 VAC motor voltage

FIELD DIGITS DESCRIPTIONA 1 & 2 Actuator sizeB 3 - 5 Actuator standard variantsC 6 & 7 Actuator seriesD 8 Duty cycleE 9 Enclosure optionF 10 & 11 Limit switch optionG 12 - 15 Motor voltageH 16 Cycle length control optionJ 17 DFC 17 Setpoint input signalK 18 & 19 I 75 & DFP 17 input signalL 20 DFC 17 Process input signalM 21 - 24 Special variants

4

2. INSTALLATION

2.1 MOUNTING CONFIGURATIONS

a) Standard mounting configuration (In-line).

This is where the actuator and valve are 'in-line' with each other so that the closed position of the actuator is also the closed position of the valve.

b) Alternative mounting configuration (cross line).

This is where the actuator is mounted 'across' the line of the valve. If space is limited and this is the only actuator / valve orientation that can be achieved then the standard working quadrant of the electric actuator should be changed. See ‘NOTE’ in section 2.7.1

2.2 MOUNTING THE ACTUATOR TO THE VALVE (non modulating)

NOTE: All mounting instructions are detailed for standard configuration only (in-line). For alternative mounting configuration rotate the bracket through 90° when assembling to the actuator base.

2.2.1 THROUGH BOLTED MOUNTED VALVES (non ISO mounting)

a) To attach the mounting bracket to the actuator base, orientate the mounting bracket so that the solid side of the bracket is parallel with the conduit entry.Loosely tighten the four screws and lock washers using a correctly sized tool. Prior to assembling the actuator to the valve, ensure that the valve stem and actuator output shaft are correctly orientated.

WARNING: Ball valves can trap pressurised media in the cavity. If the valve isinstalled in line and is or has been in operation, make sure there is NOpressure to or in the valve before removing any body bolts.

b) Close valve so that the stem flats are perpendicular to the line of flow.

c) Remove the wrench retaining nut, spring washer and wrench.

d) Remove the two upper body bolts and nuts or the four upper socket head cap screws from the valve.

e) Locate and centralise the coupling on the valve stem.

f) Lower the actuator and mounting bracket assembly over the coupling and engage the actuator output drive and position the solid sides of the bracket over the valve end connectors.

g) Secure the mounting bracket to the valve by using the new longer body bolts and nuts or the old socket head cap screws. Tighten the body fasteners as stated in the valve I.O.M.

2.3 'E' SERIES MOUNTED VALVES

a) To attach the mounting bracket to the actuator base, orientate the mounting bracket so that the solid side of the bracket is parallel with the conduit entry.Loosely tighten the four screws and lock washers using a correctly sized tool. Prior to assembling the actuator to the valve, ensure that the valve stem and actuator output shaft are correctly orientated.



5

b) Close valve so that the stem flats are perpendicular to the line of flow.

c) Remove the wrench by unscrewing the set screws.

d) Locate and centralise the coupling on the valve stem.

e) Lower the actuator and mounting bracket assembly over the coupling and engage the actuator output drive and position the solid sides of the bracket over the valve stem mounting platform.

f) Secure the mounting bracket to the valve by using the mounting bolts provided. Tighten the body fasteners as stated in the valve I.O.M.

2.4 ISO TOP MOUNTED VALVES

a) To attach the mounting bracket to the actuator base, orientate the mounting bracket so that the solid side of the bracket is perpendicular to the conduit entry. Loosely tighten the four screws and lock washers using a correctly sized tool. Prior to assembling the actuator to the valve, ensure that the valve stem and actuator output shaft are correctly orientated.

b) Close valve so that the stem flats or stem indication line is perpendicular to the line of flow.

c) For the larger sized valve remove the wrench retaining screw and wrench.For the smaller valves remove the wrench retaining nut, spring washer and wrench. For valves that use stop plates and stop pins that interfere with the ISO pattern on the valve mounting platform, follow the details below,i) Remove the split nut.ii) Remove the stop plate.iii) Remove the stop pin.iv) Fit the profiled washer.v) Fit the split nut and tighten to the torque as stated in the valve I.O.M.

d) Locate and centralise the coupling on the valve stem.

e) Lower the actuator and mounting bracket assembly over the coupling and engage the actuator output drive and position the bracket square on the valve mounting platform.

f) Secure the mounting bracket to the valve by using the screws and lock washers provided. Tighten the screws securely using a correctly sized tool.

2.5 MOUNTING THE ACTUATOR TO THE VALVE (modulating)

The mounting kit which is used in modulating and control assemblies has a special coupling which enables the backlash between the actuator output shaft to the coupling and from the coupling to the valve stem to be reduced / eliminatedby tightening the four set screws (two at either end ).

To eliminate the over heating of motors due to frequent start-ups when the actuators are being used in modulating / control processes, a minimum duty cycleof 60% actuators should be used.


6

2.6 ELECTRICAL INSTALLATION AND CAM ADJUSTMENT

WARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand adjustment. This must be carried out only by a qualified electrician.

Worcester Controls do not accept any responsibility for problems that may arise from incorrect installation of this product.

To gain access to the terminal inside the actuator, remove the cover as follows:

10-2375: Enclosures W, X and Z - unscrew the manual override knob retainingscrew and remove knob. Remove the two cover screws from the cover (the othersix screws are in a bag in the actuator) and lift cover from the actuator base.

25-3075 Z: Unscrew the indicator knob retaining screw and remove the indicatorknob from the shaft. Remove the cover screws and lift the cover from the actuatorbase.

2.6.1 EARTHING

Actuators 10-2375 W, X and Z have an earthing screw / clamp in the base of the actuator located by the conduit entry. For the larger sizes of actuator 25 and 30, earth the actuator by connecting the Earth wire, using correct techniques, to the screw located next to the letter 'G'.

The table below shows the size of actuator, voltage and fuse rating for overcurrent protection.

NOTE: The table shows the minimum rating to prevent the inrush current from blowing the fuse.

The table below indicates the amperage drawn for each size of actuator, duty cycle and voltage.

AC ACTUATORS

NOTE: The * next to the current value denotes the actuator stall current.


ACTUATOR SIZE VOLTAGE FUSE RATING10 to 23 120 VAC 5A

25 and 30 120 VAC 10A10 to 23 240 VAC 3A

25 and 30 240 VAC 5A10 to 23 12 VDC 10A10 to 23 24 VDC 5A

25 and 30 24 VDC 20A

SUFFIX DUTYVOLTAGE

ACTUATOR SIZECODE CYCLE 10 12 15 17 20 22 23 25 30

2 8%120

*1.60 *1.60 *1.60 *1.60 *3.00 *3.00 N/A N/A N/ABlank 20%

VAC*0.70 *0.70 *0.70 *0.70 *1.50 *1.50 N/A *3.35 *3.90

4 60% *0.40 *0.40 *0.40 *0.40 *0.75 *0.75 *0.70 *3.10 *3.10

2 8%240

*0.60 *0.60 *0.60 *0.60 *1.40 *1.40 N/A N/A N/ABlank 20%

VAC*0.40 *0.40 *0.40 *0.40 *0.90 *0.90 N/A *1.60 *1.70

4 60% *0.15 *0.15 *0.15 *0.15 *0.35 *0.35 *0.40 *1.50 *1.50


7

DC ACTUATORS

NOTE: The * next to the current value denotes the actuator stall current.

The following options will increase the locked rotor current on DC models only asshown below;

Mechanical Brake: 12 VDC - 0.8 A 24 VDC - 0.4 AHeater: 12 VDC - 1.3 A 24 VDC - 0.7 AMechanical Brake & Heater: 12 VDC - 2.0 A 24 VDC - 1.0 A

2.6.2 CYCLE TIME (in seconds)

When the electrical installation of the actuator is complete it is advisable to cycle the assembly to ensure that the actuator, valve and mounting kit are aligned and that the actuator is cycling in the correct quadrant.

See Page 8, AC and DC wiring diagrams, for recommended customer wiring circuit.Size 10 - 30 (VAC) 75: To cycle the actuator to the 'open' position wire the correct supply voltage to the terminals 1 and 3 (neutral to 1 and live to 3). If the actuator travels past or stops short of the open position then the cams require adjustment.

Size 10 - 23 (VDC) 75: To cycle the actuator to the 'open' position wire the correct supply voltage to the terminals 1 and 3 (negative to 1 and positive to 3). If the actuator travels past or stops short of the open position then the cams require adjustment.


SUFFIX DUTYVOLTAGE

ACTUATOR SIZECODE CYCLE 10 12 15 17 20 22 23 25 30

Blank 20% 12 *1.40 *1.20 N/A N/A *5.00 *4.20 N/A N/A N/A4 60% VDC 0.50 0.50 N/A N/A 1.60 1.50 2.00 N/A N/A

Blank 20% 24 *0.70 *0.60 N/A N/A *2.50 *3.00 N/A 5.50 3.904 60% VDC 0.25 0.25 N/A N/A 0.80 0.75 *1.00 3.10 3.10

SUFFIX ACTUATOR SIZECODE 10 12 15 17 20 22 23 25 30

2 3 5 3 5 3 5 N/A N/A N/ABlank 6 9 6 9 6 9 N/A 12 18

4 21 31 21 31 21 31 31 18 28

8


IMPORTANT: Each actuator should be electrically powered through its own individual switch to isolate the unused winding.Each AC motor has a “thermal protector” as shown by in the diagram.

See table on Page 6 for minimum fuse rating when overcurrent protection is usedIin motor power circuit.

2.7 CAM ADJUSTMENT

Turn off the electrical supply to the electric actuator and release the cam set screw(s).

Move the actuator manually (see Section 1.5) to the open position and adjust thecam so that the microswitch 'clicks' and then tighten the set screw. To re-check theopening position, cycle the actuator clockwise towards the closed position. This canbe done by either using the manual override or by moving the live wire to terminal4 for AC models. For DC models change the negative wire (1) to terminal four andthe positive wire (3) into terminal one and turn on the electrical supply. Cycle theactuator to the open position and repeat if the actuator is under or over rotating.WARNING: Do not bend the microswitch levers when adjusting the cams for the actuator travel limits.

2.7.1 After aligning the actuator, mounting kit and the valve, securely tighten the four actuator mounting screws using a correctly sized tool.

NOTE: If the actuator requires to be mounted in the 'cross line' mounting configuration then the operating quadrant should be moved 90° clockwise so that the closed position is now adjacent to the conduit entry and the open position is 90° counter clockwise from the conduit entry. Adjust the cams in the same way as Section 2.7. The quadrant indication label must also be moved to indicate the new operating quadrant.

AC Circuit DC Circuit


9© Copyright Worcester Controls (UK) Ltd.

2.8 COVER RE-ASSEMBLY

Replace the actuator cover ensuring that the interface gasket / seal is correctly installed. Fit and tighten all cover retaining screws securely.

For X and Z enclosure actuators tighten the cover retaining screws diagonally to atorque of 8 - 9 Nm.

To test the interface clearance, a standard feeler gauge of 0.04mm (0.0015")thickness should not be able to penetrate more than 3 mm between the base andthe cover.

Replace the actuator declutching / indicator knob and tighten the retaining screw.

2.9 SIZE CONVERSION

Each size of electric actuator 10, 15 and 20 contains an off-set motor module anda dual geared Bull gear. This allows each of the above sizes to be converted to anintermediate size, i.e. 10 - 12; 15 - 17 and 20 - 22.

The function of this conversion is to increase the working radius of the motormodule which results in an increase in output torque. Due to the increase in outputtorque and the working radius, the operating time of the actuator will reduce.

By converting the actuator the torque will increase to the mid point between thesizes 10 and 15, and 15-20.

To convert the electric actuator, disconnect all electrical supplies to the actuator.Loosen the cam set screws and rotate them so that the ramps are pointing towardsthe terminal strip.

AC Actuators: Disconnect the Yellow and Grey motor wires from the capacitiornoting the colour of the wires that they were disconnecting from. Remove all cableties at secure the motor wires to the motor module.

DC Actuators: Disconnect the Red motor wire from terminal number (1) and theBlack motor wire from the two crimped Blue wires.

Unscrew the four mounting screws which are located in the centre of the motormodule. Remove the motor module and rotate through 180° so that the ‘SLOW’,located by the motor module mounting holes, is pointing to the actuator outputshaft. Using the four motor module screws reassemble and tighten.

AC Actuators: Rewire the motor wires to the capacitor reversing the Yellow andGrey motor wires.

DC Actuators: Reverse the Red and Black motor wires so that the Red wire iscrimped to the two Blue wires and the Black wire is terminated in terminal number (1).

Secure all wires away from moving / rotating parts using the cable ties provided.

Reset cams. See Page 8 Section 2.7.

The size 23 electric actuator has only a single Bull gear and therefore only onetorque output.

Although the size 25 and 30 electric actuators share the same size of housing andgearing system, the only difference is the primary gear which is connected to thebottom of the motor. Conversions carried out on the size 25 / 30 by the end userare not recommended.

10


3. MAINTENANCE AND TROUBLE SHOOTING

The series 75 electric actuators require very little maintenance throughout its working life. Should the actuator fail to operate, the following points should be checked prior to contacting Worcester Controls for advice.

3.1 ELECTRICAL SUPPLY

Ensure that the series 75 electric actuator is supplied with the correct voltage.

3.2 ELECTRICAL CONNECTIONS

Ensure that all the electrical connections are good and conform to the correctwiring diagram.

3.3 LIMIT SWITCHES

If both of the limit switches are operated simultaneously the actuator will notoperate. Ensure that only one switch is operated at any one time. (Damage willoccur if both switches are opperated together)

3.4 CAPACITORS

The AC actuator operates with the use of a capacitor. If the capacitor is defectivethen the actuator will not start and / or run. Replace if necessary.

3.5 MOTOR

If one of the motor windings is open or short circuited, the actuator will not operate.If the motor temperature is to high the thermal overload protection will prevent themotor from operating. For this to reset, let the actuator motor cool down to roomtemperature before using the actuator again. If the actuator fails to operate afterapplying voltage to the actuator, replace entire motor module.

3.6 GEAR TRAIN

(Sizes 10-23) Remove the motor module by unscrewing the four screws located bythe actuator shaft. Spin the motor shaft by hand to rotate the module output gearpinion. If the output gear pinion fails to rotate replace entire motor module. Alsocheck the bull gear for damaged or missing teeth.

(Sizes 25 and 30) Remove the actuator from the valve and operate the handwheel.If the output drive protruding from the base of the actuator does not rotate then thegearing is damaged. Return the actuator to Worcester Controls for repair.

3.7 VALVE

With the actuator removed from the valve, operate the valve stem with a wrench to determine whether the valve torque has risen due to process conditions or damage


11

4 FEEDBACK POTENTIOMETER OPTION (SINGLE / DUAL)WARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand / or adjustment. This must be carried out only by a qualified electrician.

4.1 GENERAL DESCRIPTION

There are two types of feedback potentiometer; single and dual.

The function of either feedback potentiometer within the series 75 electric actuatoris to feedback the shaft position, either by resistive indication (remote) orinconjunction with other options such as AF-17 positioner or 4-75 position indicatoror both.

Remote indication is where the single feedback potentiometer wires are terminatedin terminal 10, 11 and 12. The end user would utilise the resistance feedback fromthe potentiometer to determine the position of the actuator shaft.

The feedback potentiometer could be used inconjunction with other options aswellas giving remote resistive indication. The dual feedback potentiometer would berequired as two separate feedbacks are used for two different operations; one forthe remote resistive indication and the other for the option selected.

NOTE: Each single feedback potentiometer can only be used for one operation.A dual feedback potentiometer must be used if two operation are required.

4.2 ASSEMBLY

Prior to assembling the feedback potentiometer assembly into the actuator, cyclethe actuator to check that the rotation reaches the fully open and fully closedposition.

If the actuator rotation requires adjustment, reset the appropriate cam(s).See Page 8 Section 2.7.

4.3 SIZE 10 - 23 ACTUATOR FEEDBACK POTENTIOMETER ASSEMBLY(single / dual)

To assemble the feedback potentiometer to the mounting bracket, remove the smallspur gear and locate the potentiometer shaft through the large hole so that thebody of the potentiometer is directly above the bracket mounting holes.See Page 12 Figure 1.

Rotate the potentiometer body so that the orientation pin locates into the small hole.

Place the lock washer followed by the nut onto the potentiometer housing andtighten.

NOTE: Do not over tighten as the plastic thread may strip.

Place the small spur gear onto the potentiometer shaft so that the plastic gear isflush with the end of the shaft. Do not tighten.

ITEM NO. DESCRIPTION1 Limit switches2 Motor module3 Motor module mounting screws4 Terminal strip5 Actuator shaft6 Potentiometer7 Potentiometer bracket8 Spur gear9 Spur gear set screw

12


4.4 SIZE 25 AND 30 ACTUATOR FEEDBACK POTENTIOMETER ASSEMBLY(single / dual)

To assemble the feedback potentiometer to the mounting bracket, remove the smallspur gear and locate the potentiometer shaft through the large hole so that thepotentiometer shaft is directly above the bracket mounting holes. See Figure 2 below.

Rotate the potentiometer body so that the orientation pin locates into the small hole.

Place the lock washer followed by the nut onto the potentiometer housing andtighten.

NOTE: Do not over tighten as the plastic thread may strip.

Place the small spur gear onto the potentiometer shaft so that the plastic gear isflush with the end of the shaft. Do not tighten.

ITEM NO. DESCRIPTION10 Potentiometer leads11 Potentiometer shaft12 Face gear13 Potentiometer bracket14 Mounting screw15 Motor support plate16 Snap rings (spacers - standard)17 Spacers and cam No. 3 M1 option

Cams No. 3, 4 M2 option

10-23 75 25 & 30 75

Fig. 1 Fig. 2



4.5 FEEDBACK POTENTIOMETER TO ACTUATOR ASSEMBLY

4.5.1 SIZES 10-23

Remove the two motor module mounting screws that are located furthest awayfrom the actuator shaft taking care not to damage any secured wires.

If required, remove the cable ties that secures the wires to gain access to thespecific mounting screws.

Line up the potentiometer shaft with the actuator shaft and secure the bracket withthe two motor module mounting screws. Secure all motor wires if they weredisturbed.

4.5.2 SIZES 25 AND 30

The potentiometer mounting holes can be found between the terminal strip and theactuator shaft. Position the potentiometer bracket, with the wires facing away fromthe actuator shaft, and align with the actuator shaft before securing with the twoscrews provided.

4.6 WIRING

All wiring to the actuator terminal strip should be made only to the mid point.

For potentiometer wires which require terminating in the actuator terminal strip, it isrecommended that the wires are run as per figures 1 and 2.

The dual potentiometer is two potentiometers sharing the same shaft which are joined in the middle by a metal clamp. The potentiometer which is closest to the shaft is pot ‘A’ and the furthest from the shaft is pot ‘B’.

SINGLE & DUAL FEEDBACK POTENTIOMETER SIZES 10 - 30

Customerconnections

Customerconnections

Gre

en

Wht

/Blk

Pur

ple

Gre

en

Wht

/Blk

Pur

ple

Single feedback POT ordual potentiometer

(Section B only)Alternativeplacement

INT

ER

NA

LE

XT

ER

NA

LTERMINAL STRIP WIRE COLOUR

10 Green11 White / black (or white only)12 Purple

14


4.7 WIRING TO OPTIONS

If the dual feedback potentiometer is used with an AF-17 positioner board then pot‘A’ is directly wired into TB1 (terminal block 1) located in the top right hand side ofthe circuit board.

In conjunction with the AF-17, pot ‘B’ could be required for remote resistiveindication and therefore the potentiometer wires require terminating in terminals 7,8 and 9 (AF-17 signal input wires already in 10 and 11).

If, however, the requirement is for a 4-20mA output from the AF-17 board, revision10 only, pot ‘B’ should be wired directly to TB2 located to the right of the actuatorshaft. To achieve the mA output from the circuit board, the two wire connector (redand black) should be fitted into the white connector found under the circuit board atthe front. If available terminate the two wires into terminals 8 and 9.

4.8 FEEDBACK POTENTIOMETER ADJUSTMENT

For all sizes of actuator and both types of potentiometer, place the large face gearover the actuator shaft leading with the gear teeth. Locate the appropriate numberof circlips, (one for 10-23 or two for 25/30) over the face gear seating the clipssquare on the small posts.

NOTE: The face gear was designed as a friction fit to the actuator shaft. Forpositive shaft position wipe all grease from actuator shaft prior to fitting the facegear.

Lower the face gear and adjust the small spur gear so that 1.5 to 2.0mm ofengagement is achieved. Secure the small spur gear by tightening the set screw.

4.9 FEEDBACK POTENTIOMETER CALIBRATION (single)

To calibrate the single feedback potentiometer the actuator must be in either thefully open or fully closed position.

With all electrical supplies to the actuator switched off and the actuator in the fullyclosed position, connect an Ohmmeter across the purple and white / black wires.Rotate the face gear, thus rotating the potentiometer shaft, until the Ohmmeterreads approximately 80 to 90 Ohms.

NOTE: If the actuator was in the fully open position the Ohmmeter should beconnected across the green and white / black wires.

Connect the electrical supply and cycle the actuator to the opposite position so thatthe resistance can be measured.

With the actuator now in the open position, switch off the electrical supply andmeasure the resistance of the feedback potentiometer across the purple and white/ black wires. If the actuator was cycled from the open position and is now in theclosed position, measure across the green and white / black wires.

In either case the Ohmmeter reading should be greater than 700 Ohms. If this isnot the case then cycle the actuator back to the original position and recheck theresistance, not forgetting to switch off the electrical supply first.



4.10 FEEDBACK POTENTIOMETER CALIBRATION (dual)

To calibrate the dual feedback potentiometer the actuator must be in either the fullyopen or fully closed position.

Before calibrating the whole feedback potentiometer, it is recommended that thetwo pots ‘A’ and ‘B’ should be checked against each other, as detailed below;

a) Using an Ohmmeter, measure across the purple and white / black wiresfrom pot ‘A’.

b) Measure the resistance across the same wires from pot ‘B’.

c) Potentiometer ‘B’ values should be no more than +/- 10% of potentiometer‘A’ values.

d) To adjust, release the clamp screw partially and rotate pot ‘B’ potentiometer body until the values are within tolerance.

With all electrical supplies to the actuator switched off and the actuator in the fullyclosed position, connect an Ohmmeter across the purple and white / black wires.Rotate the face gear, thus rotating the potentiometer shaft, until the Ohmmeterreads approximately 80 to 90 Ohms.

NOTE: If the actuator was in the fully open position then the Ohmmeter should beconnected across the green and white / black wires.

Connect the electrical supply and cycle the actuator to the opposite position so thatthe resistance can be measured.

With the actuator now in the open position, switch off the electrical supply andmeasure the resistance of the feedback potentiometer across the purple and white/ black wires. If the actuator was cycled from the open position and is now in theclosed position, measure across the green and white / black wires.

In either case the Ohmmeter reading should be greater than 700 Ohms. If this isnot the case then cycle the actuator back to the original position and recheck theresistance. See Page 14 Section 4.9, not forgetting to switch off the electricalsupply first.

IMPORTANT: The feedback potentiometer has now been calibrated for one 90°quadrant. If for any reason the actuator output shaft should rotate to another 90°quadrant or multiple 360° rotation then the potentiometer will no longer be incalibration and must be recalibrated.

To indicate that a potentiometer has been installed, fit the potentiometer cautionlabel to the outside of the actuator cover.

After the feedback potentiometer has been calibrated and the caution label afixedto the actuator cover, replace the cover and position / indicator knob.


16

5 HEATER / THERMOSTAT OPTIONWARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand adjustment. This must be carried out only by a qualified electrician.

IMPORTANT: When installing the heater / thermostat ensure that the voltage isidentical to that of the electric actuator supply.

5.1 INSTALLATION

5.1.1 SIZES 10 - 23

To install the heater / thermostat kit into the electric actuator remove the actuatorcover by removing the position / indicator knob and all the cover screws.

To gain access to the area where the heater is to be fitted it is recommended thatthe motor module should be removed (see Page 9 Section 2.9).

Using an appropriate clearner, remove all traces of oil, dirt and grease from thesurface where the heater is to be fitted. See Figure 3 opposite.

Remove the backing paper from the heater and locate onto the motor modulestarting at the depression in the middle. From the centre working outwards, pressfirmly taking care to apply the heater tightly on the curves of the motor module.Smooth the heater foil either side of the heater element.

NOTE: All wires terminated in the terminal strip should only be inserted to themid-point.

When multiple wires require terminating in terminal number 1, connect the shortwhite wire into terminal number 1 and crimp all other common wires together usingthe closed end splice provided.

Secure the thermostat to the actuator using the plastic clamp provided. Fit theclamp arround the thermostat and remove the screw located nearest the terminalstrip from the right hand microswitch. Placing the screw and nylon washer throughthe clamp, reasemble and tighten.

Ensure that all wiring is kept away from moving / rotating parts.

5.1.2 SIZES 25 & 30

To install the heater / thermostat kit into the electric actuator remove the actuatorcover by removing the position / indicator knob and all the cover screws.

Using an appropriate clearner, remove all traces of oil, dirt and grease from thesurface where the heater is to be fitted. See See Figure 4 opposite.

Remove the backing paper from the foil heater and locate onto the small radius ofthe gear train support housing located at the front left, when viewed from theterminal strip. Working outward from the centre, press firmly taking care to applythe heater tightly on the curves of the gear train support housing. Smooth theheater foil either side of the heater element.

NOTE: All wires terminated in the terminal strip should only be inserted to themid-point.


© Copyright Worcester Controls (UK) Ltd. 17

When multiple wires require terminating in terminal number 1, connect the shortwhite wire into terminal number 1 and connect all other common wires togetherusing the connector provided

Remove the socket head cap screw from the motor support plate. Fit the clamparound the thermostat and secure to the actuator using the plastic clamp provided.The screw is located on the front left hand side, nearest to terminal number 1.Placing the screw and nylon washer through the clamp reasemble and tighten.

Ensure that all wiring is kept away from moving / rotating parts.

5.2 WIRING

Connect one wire from the heater to terminal number 1. Crimp the remainingheater wire to either of the thermostat wire using the closed end splice. Wire theremaining thermostat wire to terminal number 2.

The thermostat contacts will close at 26.5°C and will open at 32.5°C.

NOTE: If the heater / thermostat is used with the electrical failsafe option ( F75 )then an AC heater kit must be used. If these two options are required then theheater should be wired into terminals 11 & 12 of the actuators terminal strip. Fromthe actuator terminal strip the wires should be terminated into 9 & 10 of the F75.

Heater

Heater

Geartrainsupport

Thermostat

Motorsupportplate

Thermostat

Fig. 3

10-23 75

Fig. 4

25/30 75


18

6 MECHANICAL BRAKE OPTIONWARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand adjustment. This must be carried out only by a qualified electrician.The mechanical brake coil voltage must be identical to the actuator voltage.

6.1 MECHANICAL BRAKE ASSEMBLY

To install the mechanical brake into the electric actuator (sizes 10 - 23) remove theactuator cover by removing the position / indicator knob and all the cover retainingscrews.

To assemble the mechanical brake to the actuator motor follow as detailed below;

a) Orientate the mechanical brake braket so that the two large posts are facingto the left.

b) Place the mechanical brake coil housing on the bracket so that the plunger is located between the two large posts and that the label is facing upwards.With the coil wires located between the two smaller posts and the coil housing lined up with the marks on the bracket, secure with the two screws and lockwashers.

6.2 ASSEMBLING THE BRACKET TO THE ACTUATOR

6.2.1 120 & 240 VAC ACTUATORS SIZES 10, 12, 15 & 17

The bracket is mounted to the actuator with the plunger facing away from theactuator shaft. Remove the appropriate motor mounting screws and assemble thebracket to the motor. Before securing, assemble the two support pillars over theopposing pre-drilled posts and secure by using the two screws provided.

6.2.2 SIZES 20, 22 & 23

These actuators have two motors. Assemble the mechanical brake with the plungerfacing away from the actuator shaft. Remove the four inner motor mounting screwsand reassemble and secure the mechanicl brake bracket.

6.2.3 12 & 24 VDC ACTUATORS

All sizes of 12 and 24 VDC actuators require the use of the four support pillars andscrews.

NOTE: The extended motor shafts for the 12 and 24 VDC motors are smaller indiameter than those of the 120 and 240 VAC. The small sleeves require insertinginto the center bore of the brake disc.

Mount the brake arm so that the middle hole locates on the appropriate large postand that the hole at the end of the arm locates on the pin which is secured in theplunger.

Using the larger of the two retaining clips, locate on the large post which is used topivot the brake arm and press down firmly leading with the depressed side. Ensurethat the retaining clip allows the mechanical brake arm to move freely once assembled.

Connect the open looped end of the spring to the remaining hole on the brake arm.Connect the closed loop to the small post on the same side of the braket and



secure by using the remaining small retaining clip. Leading with the depressed sideof the clip, press firmly but make sure that the clip does not interfere with thespring.

Place the brake disc on the extended motor shaft and secure by tightening the twoset screws.

Prior to wiring, check that the operation of the brake assembly. The brake armshould clear the brake disc when the plunger is fully retracted into the coil housing.

If the brake arm clears the brake disc then wire the mechanical brake follow theappropriate wiring diagram.

If, however the brake arm still touches the brake disc the loosen the two mountingscrews that hold the coil to the mounting braket and move the coil towards theactuator shaft and tighten.

6.3 WIRING

6.3.1 120 & 240 VAC ACTUATORS

Simply connect the two ¼” connector spades to the motor capacitor.

6.3.2 12 AND 24 VDC ACTUATORS

The wires from the 12/24 VDC mechanical brakes are to be connected to theexisting wiring. Either lead from the coil housing to be terminated in terminalnumber 1. The remaining wire from the coil housing should be connected to themotors black wire crimp located on the microswitch.

Using the cable tie provided, secure all leads away from moving / rotating parts.

6.4 TESTING

Cycle the actuator in both directions visually checking that the brake arm clears thebrake disc when the actuator is rotating and stops the actuator immediately whenthe electrical supply is removed.

After checking the operation of the mechanical brake replace the actuator coverand position / indicator knob.

Fig. 5


20

7 CENTRE-OFF OPTION SIZES 10 - 30WARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand adjustment. This must be carried out only by a qualified electrician.

IMPORTANT: Centre-off kits should not be installed into actuators which have extralimit switches already fitted. If required, contact Worcester Controls.

Remove the actuator position / indicator knob and unscrew the eight coverretaining screws. Carefully remove the cover and gasket.

7.1 ACTUATOR ROTATION

Prior to installing the centre-off kit into the actuator, it is important to check therotation of the standard electric actuator.

7.1.1 AC ACTUATORS

Cycle the actuator to the fully closed position (CW) by connecting the electricalsupply to terminals 1 and 4 (neutral in 1 and live in 4) if the actuator was receivedin the open position.

Cycle the actuator to the fully open position (CCW) by connecting the live wire toterminal 3.

If the actuator fails to stop or over travels in either direction, the cams requireadjustment. See Page 8 Section 2.7.

7.1.2 DC ACTUATORS

Cycle the actuator to the fully closed position (CW) by connecting the electricalsupply to terminals 1 and 4 (negative in 1 and positive in 4) if the actuator wasreceived in the open position.

Cycle the actuator to the fully open position (CCW) by connecting the negative wireto terminal 3 and the positive wire to terminal number 1.

If the actuator fails to stop or over travels in either direction, the cams requireadjustment. See Page 8 Section 2.7.

With the actuator in the fully open position (CCW), release cam number 1 (loweston the actuator shaft) by unscrewing the set screw.

Cycle the actuator as in 7.1, using correct instructions for the nature of supply(AC or DC), until the actuator rotates a full 180°. The indicator knob should now bepointing towards the conduit entry.

Rotate cam number 1 until the microswitch number 1 ‘clicks’ and retighten thecams set screw.

This position is now refered to as 0°, centre-off position as 90° (old closed position)and the fully open as 180°.

Cycle the actuator to the 180° position to check that the cams are the correctpositions.



NOTE: If a standard mounting kit (non modulating) is used between the actuatorand valve, either cam may be require adjustment to achieve correct valve porting.However, this is not the case if a modulating mounting kit is used.

Now the standard end of travel cams have been set, it must be remembered thatthe only common position between the standard actuator and the repositionedcams is the fully open position (CCW).

7.2 INSTALLATION OF THE CENTRE-OFF OPTION

All additional wiring should be made to the mid point of the terminal strip.

7.2.1 SIZES 10 - 23 ACTUATORS

To assemble the centre-off switches, unscrew the limit switch mounting screws.Orientate the centre-off switches so that the levers are directly above the existinglimit switch levers. Place the plastic spacers and insulators between the twoswitches and secure using the mounting screws. The centre-off switch above limitswitch number 1 is referred to as number 3 and the centre-off switch above limitswitch number 2 is referred to as number 4.

Prior to placing the centre-off cams on the actuator shaft, orientate the the number3 cam so that the curved ramp is positioned on the right hand side facing theterminal strip. Cam number 4 should be orientated so that the ramp is on the lefthand side and also facing the terminal strip. Place the following on the actuatorshaft. Cam spacer, followed by cam number 3, followed by another spacer andfinally cam number 4. When viewed from the the terminal strip with the actuatorshaft vertical cam number 1 is at the bottom and cam number 4 is at the top.See Figure 6 for switch identification.

7.2.2 SIZES 25 AND 30 ACTUATORS

To assemble the centre-off switches, unscrew the limit switch mounting screws.Orientate the centre-off switches so that the levers are directly above the existinglimit switch levers. Place the plastic spacers and insulators provided in the centre-off kit between the two switches. With the existing spacers located under thelimit switches, secure using the longer mounting screws provided. The centre-offswitch above limit switch number 1 is referred to as number 3 and the centre-offswitch above limit switch number 2 is referred to as number 4.

Prior to assembling the two cams onto the shaft, fit the slotted bushes into thecams to reduce the inside diameter. Place the following on the actuator shaft. Camspacer, followed by cam number 3, followed by another spacer and finally camnumber 4. When viewed from the the terminal strip with the actuator shaft verticalcam number 1 is at the bottom and cam number 4 is at the top. See Page 23Figure 6 for switch identification.


22

7.3 WIRING OF THE CENTRE-OFF OPTION

7.3.1 AC ACTUATORS

Use the Red wire from the centre-off kit and connect the smaller spade connectorto the N.O (normally open) terminal of switch number 4. Connect the largerconnector spade of the Red wire to the capacitor to which the Blue wire from theN.C (normally closed) terminal of switch number 1.

Using the Black wire from the centre-off kit, connect the smaller spade connector tothe N.O (normally open) terminal of switch number 3. Connect the larger connectorspade of the Red wire to the capacitor to which the Grey wire from the N.C(normally closed) terminal of switch number 2.

Using the Orange wire from the centre-off kit, conect to two spades to the commonterminals of switches 3 and 4. The stripped wire should be terminated in terminalnumber 7.

7.3.2 DC ACTUATORS

Figure 6 shows the wiring for sizes 10, 20 & 23. For intermediate sizes sush as 12,17 and 22 reverse the Red and Black motor wires.

Using the Red wire from the centre-off kit connect the connector spade to thecommon of switch number 4. Without removing the existing motor wire, terminatethe other end of the Red wire in terminal number 1.

The Orange wire from the centre-off kit has two connector spades. Crimped intoone of the spades is another length of wire of which the other end is stripped.Connect the two connector spades to the N.O (normally open) terminals ofswitches 3 and 4 and terminate the stripped end into terminal number 7.

Using the longer of the two Blue wires from the centre-off kit, connect theconnector spade to the N.C (normally closed) terminal of switch number 4 andterminate the stripped end of the wire into terminal number 9.

Using the Grey wire from the centre-off kit, connect the connector spade to the N.C(normally closed) terminal of switch number 3 and terminate the stripped end of thewire into treminal number 8.

Using the remaining Blue wire from the centre-off kit, connect the coonector spadeto the common terminal of switch number 3 and recrimp the stripped end with thetwo existing Blue wires from the N.C (normally closed) terminals from switches 1, 2and the motor wire.

Secure all wires away from moving / rotating parts.



1. Swich configuration is as follows (when viewedfrom the terminal strip side of the actuator).

2. Actuator shown at 0° position (fully CW)

3. Cam settings are as follows:

SWITCH 1 - Opens at 0° controls 1st divert position.

SWITCH 2 - Opens at 180° controls 2nd divert position.

SWITCH 3 - Opens at 89° controls centre-off positionfrom 1st divert position.

SWITCH 4 - Opens at 91° controls centre-off position from 2nd divert position.

NOTE: Switches 1 & 2 and cams 1 & 2 are standard.Switches 3 & 4 and cams 3 & 4 are centre-off type.

Use cam spacer if required to line up cam and switch.

180° Centre-off actuator

series 75 W, X & Z shown

View A

Standard 90° actuator

series 75 W, X & Z shown Typical view showing location ofcentre-off cams & limit switches

set in the centre-off position.

AC Circuit DC Circuit

Fig. 6


24

7.4 SETTING THE CENTRE-OFF CAMS

Prior to connecting the electrical supply, use the manual override (see Page 3Section 1.5) to position the actuator shaft in the mid position - 90° (old fully closed -CW).

In this position rotate cam number 3 clockwise so that the hooked lever of switchnumber 3 has opeated. Rotate the number 3 cam counter clockwise so that thehooked lever has just dropped off the curved ramp. Tighten the cam set screwwithout moving the cam.

Rotate cam number 4 counter clockwise so that the hooked lever of switch number4 has just matches the curve of the ramp. Tighten the cam set screw withoutmoving the cam.

To release the manual override, rotate the actuator shaft to the position where itwas disengaged.

7.5 OPERATING THE ACTUATOR

Connect the electrical supply as per the correct wiring diagram. See Page 23Figure 6 for both AC and DC wiring circuits.

To check the rotation of the actuator and valve assembly, cycle the actuator to boththe fully clockwise position (0°) and fully counter clockwise (180°). Check the valveporting in both positions.

All DC references are detailed in parentheses.

With the actuator in the 180° position - fully counter clockwise, apply electricalpower to terminals 1 and 7 ( positive to 7 and negative to 8) to cycle the actuatorclockwise to the centre-off position.

If the actuator is in the fully clockwise position 0°, then apply electrical power toterminals 1 and 7 ( positive to 7 and negative to 9) to cycle the actuator counterclockwise to the centre-off position.

NOTE: If the actuator shaft stops prior to or after the required position, then thecams 3 and/or 4 require adjustment. The centre-off switches must never beoperated at the same time. To achieve the centre-off position 90° accurately, thecentre-off cams must be set an equal amount either side of the centre-off position.Either centre-off switch must break contact before the other makes contact.

For a final operational check, supply electrical power to the following terminals;

1 and 4 ( positive to 1 and negative to 4)1 and 3 (negative to 1 and positive to 3)1 and 7 ( negative to 8 and positive to 7).

With the centre-off cams adjusted correctly the actuator should not hunt oroscillate. If either of these occur, then simple adjust the centre-off cams ensuringthat the switches break before they make.



7.6 CUSTOMER DC SWITCHING AND WIRING

Using a three pole three position rotary switch, wire as detailed below;

Connect pole 1 position 1 to pole 2 position 3 and terminate in terminal number 1.Connect pole 2 to common pole 3 and terminate in terminal number 8.Connect pole 1 position 3 to terminal number 4.Connect pole 2 position 1 to terminal number 3.Connect pole 2 position 2 to terminal number 7.Connect pole 3 position 2 to terminal number 9.Connect the positive supply to pole 2 common.Connect the negative supply to pole1 common.

NOTE: Pole 3 position 1 and 3 are not used.

To indicate the 0° position, lamps should be wired between terminals 5 and apositive supply.

To indicate the 180° position, lamps should be wired between terminals 6 and anegative supply.

The centre-off position has no indication as standard.

Check that all the wires are terminated correctly and that all the connector spadesare firmly in place.Secured all wires away from moving / rotating parts.

Reassemble the actuator cover and tighten the cover retaining screws diagonallyand evenly. Replace the actuator position / indicator knob and afix the newposition / indication label to the actuator cover.

26


8 EXTRA LIMIT SWITCH OPTION (M1 or M2). SIZES 10 - 30WARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand adjustment. This must be carried out only by a qualified electrician.

8.1 INSTALLING EXTRA LIMIT SWITCH(ES)

To install the extra limit switches, remove the position / indicator knob byunscrewing the retaining screw. Remove the actuator cover retaining screw andcarefully remove the cover.

One extra limit switch - M 1Two extra limit switches - M 2

All illustrations as shown opposite are for the M1 kit. For M2, repeat the instructionsfor the remaining switch.

When viewed from the terminal strip with the actuator shaft in the vertical position,the right hand side switch / cam (number 1) controls the closing position and theleft hand switch / cam (number 2) controls the opening position.

8.1.1 SIZES 10 - 23

Unscrew and remove the two mounting screws from switch number 1. Locate theextra limit switch (number 3) and insulator on the existing switch and replace thetwo mounting screws and tighten. For the M2 kit, repeat the above for theremaining switch.

8.1.2 SIZES 25 & 30

Unscrew and remove the two mounting screws from switch number 1. Locate theextra limit switch (number 3) on the existing switch and secure using the longerscrews provided. For the M2 kit, repeat the above for the remaining switch.

8.2 INSTALLING THE CAM(S)

Prior to placing the extra cam (number 3 - M1 kit) on the actuator shaft, orientate itso that the ramp is facing the right with the set screw facing the terminal strip. Forthe M2 kit, orientate cam number 4 so that the ramp is facing the left and the setscrew is facing the terminal strip.

With the actuator in the closed position and switch number 1 operated, rotate camnumber 3 in a clockwise direction until switch number 3 operates. Continuing in thesame direction, rotate the number 3 cam a further 1 to 3° and secure by tighteningthe cam set screw. For the M2 kit, rotate the actuator to the open position. Rotatethe number 4 cam in a counter clockwise direction until switch number 4 operates.Continuing in the same direction, rotate the number 4 cam a further 1 to 3° andsecure by tightening the cam set screw.

8.3 WIRING THE SWITCH(ES)

M1 common - terminal number 7.M1 normally closed - terminal number 8.M1 normally open -terminal number 9.M2 common - terminal number 10.M2 normally closed - terminal number 11.M2 normally open - terminal number 12.



Typical top view

Fig. 7

10 - 23 75 25 / 30 75

28


9 CYCLE LENGTH CONTROLLER (CLC) OPTION SIZES 10 - 30WARNING: Actuators which have either 120 or 240 VAC indicated on theproduct label use mains power. Switch off electric supply prior to installationand adjustment. This must be carried out only by a qualified electrician.Prior to installation, ensure that the cycle length controller has the samevoltage rating as the electric actuator.

The cycle length controller functions by interupting the electrical power supply, andtherefore creating pulses, to the electric actuator.

To install the cycle length controller, remove the position / indicator knob byunscrewing the retaining screw. To remove the actuator cover, unscrew the actuatorcover retaining screws and remove carefully.

When viewed from the the terminal strip with the actuator shaft vertical, the cyclelength controller should be mounted on the right hand limit switch with the twopotentiometers facing the conduit entry. Remove the screws from the right handlimit switch and assemble the cycle length controller with the plastic spacers inbetween.

Using the longer screws provided in the cycle length controller kit, tighten the cyclelength controller and switch assembly.

Wire the cycle length controller in the required configuration as shown below.See Figure 8.

The cycle length controller has two potentiometers. One is the ‘ON’ time and theother is the ‘OFF’ time. Adjust both potentiometer to the mid point.

The ‘ON’ potentiometer controls the length of the power supply pulse. By rotatingthe potentiometer fully counter clockwise (CCW) longer pulses will be created.Rotating the potentiometer fully clockwise (CW) shortens the power supply pulse.

The ‘OFF’ potentiometer controls the time between the power supply pulses. Byrotating the potentiometer fully counter clockwise (CCW) longer time delays will becreated. Rotating the potentiometer fully clockwise (CW) shortens the time betweenpulses.

To reduce the cycle time of the actuator, rotate the ‘ON’ potentiometer counterclockwise and the ‘OFF’ potentiometer in the clockwise direction.

To increase the cycle time of the actuator, rotate the ‘ON’ potentiometer clockwiseand the ‘OFF’ potentiometer in the counter clockwise direction.

Fig. 8


Notes:



30

10 EXPLODED VIEW DRAWINGS

SERIES 75 SIZES 10-23

NOTE: Series 75 W is shown.Series 75 general purpose,X end Z units have differentbases and covers.

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

1718

19

30

27

2

23

24

ll

4

14

11

1213

310

29

1

25

16

20

8

26

15

5

6

7

28

l21

22



Item No. Qty. Description Material/Finish1 1 Base Aluminium Casting2 1 Cover Aluminium Casting3 1 Base plate Zinc Casting4 1 Motor module Zinc Casting5 1 Output shaft Steel6 2 Gear drive pin Steel7 1 Bull gear Steel8 1 Capacitor washer (w/fibre if reqd.) Phenolic Encapsulated9 1 Capacitor bracket Steal

10 1 Terminal strip based material Polyethylene11 2 Limit switch encapsulated Phenolic12 2 Limit switch cam Zinc Casting13 1/Cam Cam sat screw Steel14 4 Limit switch screw Steel15 6 Base plate screw Steel16 8 Hex screw (W, X, Z) Stainless Steel16 4 Hex screw (GP) Steel17 1 Position indicator (W, X, Z) Molded Phenolic18 1 Indicator set screw (W, X, Z) Steel19 1 Seal (W, X, Z) Reinforced Rubber20 1 Gasket (W only) Neoprene20 1 Flange seal (Z only) Buna N21 1 Bearing Bronze22 1 Seal Reinforced Nitrile23 4 Screw Steel24 4 Lock washer Steel25 1 Conduit plug Polyethylene26 1 Capacitor tie Plastic27 1 Searing (W, X, Z) Bronze28 1 Roller bearing (size 23 only) Steal29 1 Seat ring, base plate Nylon30 1 ‘O’ ring (W, X, Z) Buna

31

32


SERIES 75 SIZES 25-30

l

l

l

l

l

l

ll

l

l

l

l

l

l

l

l

ll

l

ll

l

l

l

ll

l

ll

l

l

l

l

l

l

l

ll

ll

l

l l

l

l

l

l

l

l

l

l

l

l

l

l

32

33

17

34

4

l 41

37

35

36

45

31

30

3

26

25

9

7

43

18

14

20

21

242322

48

1

5

8

6

12

11

10

27

28

45

38

42

47

44

40

39

5149

50

29

46

2

44

19

15

13

16

17



Item No. Qty. Description Material/Finish1 1 Base Aluminium2 1 Cover Aluminium3 1 Gear train support Aluminium4 1 Motor5 1 Output gear Steel casting6 2 Planet gear Hardened steel7 1 Planetary gear Ductile iron8 1 Worm gear Steel9 1 Sensing shaft Steel

10 2 Pin, spring Steel11 2 Shaft Hardened steel12 2 Bushing Bronze13 2 Thrust washer Steel14 1 Pin, Spring Steel15 4 Belleville washer Steel16 1 Nut Steel17 2 Seal Rubber, steel18 1 Manual override shaft Steel19 1 Pin, cotter Steel20 1 Pin, spring Steel21 1 Handwheel, manual override Aluminium22 1 Thrust washer Steel23 1 Tru-arc ring Steel24 1 Seal Rubber, steel25 1 Sun gear Steel26 I Bushing Bronze27 4 Cap screw Steel28 4 ‘L’ washer Steel29 1 Capacitor washer (w/fibre if reqd.) Phenolic encapsulated30 1 Input gear Steel31 1 Nut Steel32 1 Cap screw Steel33 1 Position indicator Aluminium34 1 Bushing Bronze35 1 Motor support plate Aluminium36 1 Gear, pinion Steel37 2 Set screw Steel38 1 Terminal strip Polyethylene based material39 2 Limit switch cam Zinc casting40 1/Cam Set screw Steel41 1 Fan Plastic42 2 Limit switches Phenolic encapsulated43 1 ‘O’ ring Buna44 9 Cap screw Steel45 9 Lock washer Steel46 12 Cap screw Steel47 1 Sensing shaft retaining ring Steel48 1 ConduIt plug Polyethylene49 1 Capacitor bracket Steel50 1 Capacitor tie Plastic51 1 Capacitor bracket screw Steel

Invensys Flow Control (UK) Ltd.Burrell Road, Haywards Heath, West Sussex RH16 1TL, England An Invensys Company Telephone: +44 (0)1444 314400 Telefax: +44 (0)1444 314401Website: www.worcestercontrols.co.ukInformation given in this leaflet is made in good faith and based on specific testing but does not, however, constitute a guarantee.

Published and printed by Invensys Flow Control (UK) Ltd © Copyright Invensys Flow Control (UK) Ltd PB 41 Iss. 4/00

installation, operating & maintenance manual€¦ · · 2003-07-15a separate installation,...

Documents