Hamilton Sundstrand Company Automobile Electronics ACT2000 User Manual

ACT2000  
Operations  
Manual  
ACT2000  
All-Electric Actuator  
SD-6008-03  
Download from Www.Somanuals.com. All Manuals Search And Download.  
This manual provides installation, maintenance, and operating instructions for the  
ACT2000 All-Electric Actuator.  
Every attempt has been made to provide sufficient information in this  
manual for the proper operation and preventive maintenance of the  
actuator. 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:  
Marketing Department  
Precision Engine Controls Corporation  
11661 Sorrento Valley Road  
San Diego, California 92121  
(858) 792-3217 (800) 200-4404  
fax: (858) 792-3200  
© 2000 PRECISION ENGINE CONTROLS CORPORATION. ALL RIGHTS RESERVED  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
II  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Table of Contents  
Table of Contents ........................................................................................................................................i  
1
INTRODUCTION............................................................................................................................. 1-1  
1.1 Application ....................................................................................................................................1-1  
1.2 Mounting Provisions.....................................................................................................................1-1  
1.3 Main Housing Assembly..............................................................................................................1-2  
1.4 Brushless DC Motor Assembly....................................................................................................1-3  
1.5 Motor Control Electronics.............................................................................................................1-3  
1.6 Resolver Assembly ......................................................................................................................1-3  
1.7 Linear Drive Mechanism..............................................................................................................1-4  
1.8 Power and Digital Harness ..........................................................................................................1-4  
1.9 Identification Plate ........................................................................................................................1-5  
FUNCTIONAL DESCRIPTION AND OPERATION....................................................................... 2-1  
2.1 System Description ......................................................................................................................2-1  
2.2 Electronic Description ..................................................................................................................2-1  
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.....................................................................................................................3-4  
TROUBLESHOOTING.................................................................................................................... 4-1  
DECOMMISSIONING AND DISPOSAL ........................................................................................ 5-1  
ACT2000 GENERAL SPECIFICATIONS....................................................................................... 6-1  
GLOSSARY..................................................................................................................................... 7-1  
2
3
4
5
6
7
I
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
List of Figures  
Figure 1-1: ACT2000 Pin Mounted....................................................................................1-1  
Figure 1-2: ACT2000 Flange Mounted..............................................................................1-1  
Figure 1-3: ACT2000 Cut-Away View ...............................................................................1-2  
Figure 1-4: Typical Identification Plate...............................................................................1-5  
Figure 2-2: Typical Power Connection ..............................................................................2-3  
Figure 2-3: Typical Discrete Command Connection.........................................................2-3  
Figure 2-4: Typical Analog Input Connection....................................................................2-4  
Figure 2-5: Typical Analog Output Connection.................................................................2-4  
Figure 2-6: Typical Fault Alarm Connection......................................................................2-5  
Figure 2-7: ACT2000 State Machine.................................................................................2-7  
Figure 3-1: ACT2000-590P Envelope ...............................................................................3-2  
Figure 3-2: ACT2000-200F Envelope ...............................................................................3-3  
Figure 3-3: ACT2000 Wiring Diagram...............................................................................3-8  
List of Tables  
Table 2-1: ACT2000 Setup Parameters..........................................................................2-12  
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  
Table 4-3: ACT2000 Electrical Hook-Up Continuity Troubleshooting Chart.….…...4-3  
II  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
1 INTRODUCTION  
This publication covers operation, installation and maintenance instructions for  
the ACT2000 Actuators manufactured by Precision Engine Controls Corporation.  
1.1 Application  
The ACT2000 All-Electric Actuator is designed to meet general industrial motion  
control requirements for high temperature hazardous locations. Typical  
applications include gas turbine guide vane and valve motion control.  
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.  
Figure 1-1 ACT2000-590P Pin Mounted  
Figure 1-2 ACT2000-200F Flange Mounted  
The pin-mounted ACT2000 configuration includes a stainless steel machined  
clevis. The clevis is fully rotational to allow variable angular indexing as required  
for installation. The extension rod provides a female thread for user supplied end  
attachments. A spherical rod end bearing attachment is preferred.  
The ACT2000 contains a brushless direct current (DC) motor-driven linear  
actuator with on-board digital motor control electronics. The primary actuator  
components are described in the balance of this section.  
1-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
1.3 Main Housing Assembly  
The main housing assembly contains a main housing, motor cover, extension rod  
bearing, and associated seals. See Figure 1-3. The main housing assembly is the  
primary structural system component and supports all the bearings, motor control  
electronics, motor cover, and mountings, which forms the explosion-proof  
containment.  
In order to provide main bearing thermal dimensional stability, the housing is fitted  
with a stainless steel liner. The liner is permanently installed into the aluminum  
main housing. A retaining ring is included for redundant retention.  
The main housing contains rigid mechanical stops to prevent extension rod  
travel beyond the design specification.  
Extension Shaft  
Rod End Bearing  
Motor Control  
Electronics  
Rigid Stop  
Anti Rotation Guide  
Linear Drive  
Resolver Assembly  
Main  
Bearings  
Main Housing Assembly  
Motor Rotor  
Brushless DC  
Motor Assembly  
Motor Stator  
Motor End Bearing  
Motor Cover  
Mounting Clevis  
Figure 1-3 ACT2000 Cut-Away View  
1-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
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. Thermistors are embedded in the stator windings to monitor winding  
temperatures. The motor electrical power and thermistor wires pass from the  
motor through a conduit into the electronics housing.  
Motor Rotor  
The motor rotor is locked to the ball screw shaft via a straight key. The motor rotor  
contains powerful magnets that align with the energized stator windings thereby  
creating torque and shaft rotation.  
1.5 Motor Control Electronics  
The motor control electronics (MCE) are contained within the main housing  
electronics enclosure. The MCE includes harnesses, heat sink, digital and driver  
component assemblies (CA).  
The MCE electronics communicate with the user’s controller through analog and  
serial interfaces. The MCE controls the brushless DC motor, to position the  
actuator based on position feedback from the resolver.  
Note: The digital board analog and discrete interfaces are electrically  
isolated. The MCE serial interface is NOT electrically isolated.  
1.6 Resolver Assembly  
A Brushless, non-contacting resolver is the primary ACT2000 feedback sensor.  
A sinusoidal feedback signal is provided from the resolver to the motor control  
electronics. A sinusoidal signal from the MCE provides the resolver excitation.  
The resolver includes a stator and rotor. See Figure 1-3  
Resolver Stator  
The resolver stator is clamped to the main housing between the main bearing  
retaining nut and resolver retainer. The resolver stator angular position relative to  
the rotor is adjustable. Electrical wires from the resolver are reeled in the resolver  
adapter to allow rotation. The resolver wires, along with the motor and thermistor  
leads, are routed through a conduit into the electronics housing.  
Resolver Rotor  
The resolver rotor is mounted by a key to a ball screw shaft. As the rotor rotates,  
the stator transformer output signal provides shaft rotation information to the  
MCE.  
1-3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
1.7 Linear Drive Mechanism  
The Linear Drive Mechanism converts the rotary motion of the Motor Assembly to  
linear actuator motion. The core of the mechanical drive system is the linear ball  
screw drive containing a screw shaft, ball bearing fitted nut, extension rod and  
main duplex thrust bearings.  
Screw Shaft  
The thrust bearings, motor rotor, motor end bearing, and resolver rotor are  
mounted directly to the screw shaft. A ball bearing track is machined into the  
screw shaft.  
Ball Nut  
As the screw shaft rotates, the ball nut translates in an axial direction depending  
on shaft rotation.  
Extension Rod and Bearings  
The extension rod is threaded on the ball nut. As the ball nut translates, the  
extension rod moves in and out of the ACT2000 main housing.  
The extension rod support bearing is provided for lateral support. Thrust and  
radial loads are transferred from the extension rod through the ball nut to the main  
preloaded duplex thrust bearings. The thrust bearings transfer the loads to the  
main housing by the main bearing and shaft retaining nuts.  
A motor end bearing is provided for additional shaft radial stability. The resolver  
rotor, motor rotor, motor bearing, and spacers are stacked on the ball screw shaft  
and retained by a single nut. 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.  
A seventeen-wire electrical harness with ninety (90) inch free leads provides  
ACT2000 signal interface. Contained within this seventeen-wire harness are  
discrete commands, analog commands, feedback, and serial interface wires.  
1-4  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
Figure 1-4: Typical Identification Plate  
1-5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
INTENTIONALLY BLANK  
1-6  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
2 FUNCTIONAL DESCRIPTION AND OPERATION  
This section describes system functions employed in the ACT2000  
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.  
The ACT2000 requires only 120VDC power, 4-20 mA position demand, and  
discrete RUN command to achieve basic operational capability. The ACT2000  
provides position and motor current feedback via integral 4-20 mA circuits. Once  
120VDC power and RUN command are supplied, the actuator will track position  
demand.  
2.2 Electronic Description  
The ACT2000 electric actuator incorporates digital motor control electronics. The  
electronic system block diagram is shown in Figure 2-1. Contained within the  
motor control electronics (MCE) are digital and driver CA. The digital and driver  
component assemblies contain analog to digital converters, digital signal  
processor (DSP), application specific integrated circuit (ASIC) and power  
supplies.  
Digital CA  
The digital CA interfaces with a user-provided control system that is typically a  
programmable logic controller (PLC). The digital CA accepts analog position and  
discrete RUN and RESET commands from the control system. The digital CA  
provides analog position and motor current feedback to the control system. In  
addition, the digital CA provides discrete FAULT and OVERTEMP alarms to the  
control system.  
The digital CA receives position feedback from the resolver and current feedback  
from the driver CA. The digital CA can provide speed, temperature, voltage and  
other relevant information through the serial interface using ActWiz software.  
Contact Precision Engine Controls for ActWiz software.  
Note: The digital board analog and discrete interfaces are electrically  
isolated. The RS232C serial interface is NOT electrically isolated.  
Driver CA  
The driver CA interfaces with the user’s power supply; typically a 120 VDC  
battery. The driver CA controls current to the brushless DC motor and provides  
precise voltage and current inputs to the digital CA.  
2-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
DRIVER ASSY  
120V  
ACTUATOR  
POWER  
RED  
REVERSE  
POLARITY  
PROTECTION  
WHITE/RED  
+
GREEN  
WHITE/GREEN  
POWER  
ELECTRONICS  
BRUSHLESS  
DC MOTOR  
(80 - 160 VDC)  
-
POWER  
INTERFACE  
BROWN  
DEMAND  
INPUT  
TERMINATION  
WHITE/BROWN  
DEMAND RTN  
YELLOW  
POSITION  
WHITE/YELLOW  
BLUE  
RESOLVER  
POSITION RTN  
4-20mA  
OUTPUT  
MTR CURRENT  
WHITE/BLUE  
CONTROL  
MTR CURRENT RTN  
ELECTRONICS  
OPTICAL  
ISOLATION  
VIOLET  
RUN  
BALL SCREW  
AND  
WHITE/VIOLET  
GRAY  
RUN RTN  
RESET  
SHAFT  
WHITE/GRAY  
ORANGE  
RESET RTN  
FAULT ALARM  
WHITE/ORANGE  
BLACK  
FAULT RTN  
OVERTEMP ALARM  
WHITE/BLACK  
OVERTEMP RTN  
WHT/ORN/BLU  
WHT/ORN/YEL  
WHT/ORN/GRN  
SERIAL TX OUT  
SERIAL RX IN  
SERIAL RTN  
RS-232 DRIVER  
CONTROL  
INTERFACE  
DIGITAL ASSY  
ACTUATOR  
Figure 2-1: ACT2000 Electronics System Block Diagram  
2-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
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.  
The 120 VDC return wire is GREEN.  
Redundant power wires:  
+120 VDC is connected to the WHITE/RED wire.  
120 VDC return wire is WHITE/GREEN.  
ACTUATOR 120V INPUT  
BATTERY/POWER SUPPLY  
PWR  
[RED]  
PWR AUX [WHT/RED]  
120VDC  
REVERSE VOLTAGE PROTECTION  
FUSE  
PWR RTN AUX [WHT/GRN]  
PWR RTN  
[GRN]  
Figure 2-2: Typical Power Connection  
WARNING:  
Shock Hazard – Both the 120 VDC power and auxiliary wires should be  
connected. If only the primary power wires are connected, the 120 VDC  
auxiliary power wires are electrically “hot” and must be insulated on the  
ends.  
Note: If a 120 VDC power supply is used, it must have at least 50,000 uF  
internal capacitance. See Power Supply Requirements (Table 3-5).  
2.2.2 Discrete Commands  
The ACT2000 accepts two discrete, two-wire external commands: RUN and  
RESET. The commands are 24 VDC ON (High) and 0 VDC OFF (Low). Refer to  
Figure 2-3 for typical connection. Refer to Section 6 for specification values.  
CONTROLLER DISCRETE OUTPUT  
ACTUATOR DISCRETE INPUT  
RUN  
[VIO]  
RESET  
[GRY]  
24Vdc  
RUN RTN  
RESET RTN  
[WHT/VIO]  
[WHT/GRY]  
CONTROLLER DISCRETE OUTPUT  
ACTUATOR DISCRETE INPUT  
RUN  
RESET  
[VIO]  
[GRY]  
RUN RTN  
RESET RTN  
[WHT/VIO]  
[WHT/GRY]  
Figure 2-3: Typical Discrete Command Connection  
2-3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
Reset Command  
The RESET command is a user provided discrete input to the ACT2000, which  
causes the actuator to go through the initial homing sequence and reset all  
internal position indicators. RUN and position demand inputs are ignored during  
the RESET command. The +24VDC signal shall be provided on the GRAY wire.  
The signal return shall be provided on the WHITE/GRAY wire.  
2.2.3 Analog Inputs/Outputs  
The ACT2000 receives analog position demand from an external, user-provided  
controller and provides analog actuator position and motor current feedback.  
Refer to Figures 2-4 and 2-5 for typical connection. Refer to Section 6 for load  
specification values.  
ACTUATOR 4-20mA INPUT  
CONTROLLER 4-20mA OUTPUT  
DEMAND [BRN]  
+
-
+
-
200  
DEMAND RTN [WHT/BRN]  
Figure 2-4: Typical Analog Input Connection  
CONTROLLER 4-20mA INPUT  
ACTUATOR 4-20mA OUTPUT  
POSITION  
MTR CURRENT  
[YEL]  
[BLU]  
+
-
+
500  
-
POSITION RTN  
[WHT/YEL]  
[WHT/BLU]  
MTR CURRENT RTN  
Figure 2-5: Typical Analog Output Connection  
Position Demand  
The position demand is a 4-20mA user provided analog input that causes the  
actuator to a command position. The position demand shall be provided on the  
BROWN wire. The position demand return shall be provided on the  
WHITE/BROWN wire. The position demand internal impedance is 200 ohms. The  
position demand requires a sourcing current.  
Position Feedback  
The ACT2000 provides actuator analog position feedback to the user. This  
internally generated feedback signal is proportional to the actual position.  
The actuator position feedback is provided on the YELLOW wire. The actuator  
position feedback return is provided on the WHITE/YELLOW wire. The expected  
external impedance is 250 ohms. The maximum external impedance is 500  
ohms. Typically, the position feedback will be within + 0.1 mA of the position  
demand.  
2-4  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Motor Current Feedback  
The ACT2000 provides motor current feedback to the user. This internally  
generated feedback signal is proportional to actuator load. 4mA represents no  
load on the actuator.  
The motor current feedback is provided on the BLUE wire. The motor current  
feedback return is provided on the WHITE/BLUE wire. The expected external  
impedance is 250 ohms. The maximum external impedance is 500 Ohms.  
2.2.4 Fault Alarms  
The discrete alarm outputs are opto-isolated electronic switches that are normally  
closed. The user controller provides 24 VDC with current limiting resistor, to  
complete the circuit. If a FAULT or OVERTEMP alarm has occurred, the switch  
opens thereby communicating an alarm to the user’s controller. Refer to Figure 2-  
6 for typical connection. Refer to Section 6 for load specification values.  
CONTROLLER DISCRETE INPUT  
ACTUATOR DISCRETE OUTPUT  
FAULT ALARM  
OVERTEMP ALARM  
[ORN]  
[BLK]  
FAULT RTN  
OVERTEMP RTN  
[WHT/ORN]  
[WHT/BLK]  
ACTUATOR DISCRETE OUTPUT  
CONTROLLER DISCRETE INPUT  
FAULT RTN  
OVERTEMP RTN  
[WHT/ORN]  
[WHT/BLK]  
FAULT ALARM  
OVERTEMP ALARM  
[ORN]  
[BLK]  
Figure 2-6: Typical Fault Alarm Connection  
The FAULT alarm is provided on the ORANGE wire. The FAULT alarm return is  
provided on the WHITE/ORANGE wire.  
The OVERTEMP alarm is provided on the BLACK wire. The OVERTEMP alarm  
return is provided on the WHITE/BLACK wire.  
WARNING:  
Property Damage – Connection of 24 VDC power across the actuator  
discrete output will cause electrical failure of the output. Series resistance  
should be added to the 24 VDC output from the controller to limit the  
current to 25mA max.  
2.2.5 RS232 Communications  
RS232 serial communications is achieved with user-provided connection to the  
Serial Rx In, Serial Tx Out and Serial Rtn wires.  
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.  
2-5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
POWER  
UP/RESET  
SETUP  
COMMAND  
SETUP  
COMPLETE  
RUN  
COMMAND  
RESET  
COMMAND  
SET-UP  
RESET  
COMMAND  
RESET  
COMMAND  
HOME  
DEADBAND  
POSITION DEMAND  
<4.1 mA AND  
ACTUATOR POSITION  
FEED BACK  
<4.2 mA  
MOTOR CURRENT>MAX  
HOMING FORCE AND  
ACTUATOR VELOCITY <  
0.05 IN/SEC  
RUN  
HOLDING  
MOTOR  
POSITION  
DEMAND  
>4.1 mA  
CURRENT  
Figure 2-7: ACT2000 State Machine  
2.3.1 Power-Up Modes  
When 120 VDC is applied to the ACT2000, the on-board DC converter supplies  
power to the driver and digital boards. The ACT2000 will operate with voltages  
ranging from 80 VDC to 160 VDC.  
Power-Up/Reset State  
Once the digital signal processor (DSP) receives required voltage, it starts the  
firmware program and enters the POWER-UP/RESET state. See Figure 2-7. The  
program checks electronics health, clears system registers and retrieves set-up  
parameters from the electrically erasable programmable read only memory  
(EEPROM).  
Once the program is complete with the health check, it waits for either the RUN,  
RESET or SET-UP command.  
If the ACT2000 receives a SET-UP command from the ActWiz software  
(through the RS232 interface), firmware program will transition to the SET-UP  
state.  
2-6  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
If the ACT2000 receives a discrete RUN command, the firmware program will  
transition to the HOME DEAD BAND state.  
If the ACT2000 receives a discrete RESET command, the firmware program  
will continuously reset. The actuator will not function and will remain in the  
power-up/reset state.  
WARNING:  
Property Damage Hazard – Always remove RUN command during Set-Up  
state. If a RUN command is given during program download, the actuator  
will not respond until download is complete.  
Set-Up State  
The ACT2000 communicates with the user in this state. See Figure 2-7. Contact  
Precision Engine Controls for a copy of ActWiz software in order to communicate  
with the ACT2000.  
In this state, a set-up file can be uploaded or downloaded. A Fault file can also be  
uploaded using the ActWiz software. Please see ActWiz software manual for  
more information.  
The ACT2000 can only enter this state via POWER-UP/RESET. The ACT2000  
enters this state via a SET-UP command received via the RS232 interface.  
The actuator will leave this state after a file has been uploaded or downloaded.  
The ACT2000 will not hold position while in this state.  
WARNING:  
Property Damage Hazard – The ACT2000 will not hold position when  
communicating with 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.  
2.3.2 Run Modes  
Upon receipt of RUN command, the ACT2000 firmware program will transition to  
one of the run modes listed below.  
Note: As a safety feature, the ACT2000 will not move without a RUN  
command.  
Home/Dead Band State  
The HOME/DEAD BAND state is used to find HOME position after a  
POWER-UP/RESET. See Figure 2-7. The firmware program will transition to  
HOME/DEADBAND upon receipt of RUN command.  
While in the HOME/DEAD BAND state, the actuator moves at constant  
velocity (homing velocity) and direction (extend or retract) until a mechanical  
stop is found.  
Note: If RUN command is removed, the actuator will not function.  
2-7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
When the mechanical stop is found (actuator velocity less 0.05 inches per  
second), the MCE will apply the maximum homing force. Once the maximum  
homing force is applied, the firmware program will transition to the HOLDING  
MOTOR CURRENT state.  
Holding Motor Current State  
In the HOLDING MOTOR CURRENT state, the MCE applies a constant  
HOLDING FORCE, as long as, the position demand is > 2mA and < 4.1mA.  
See Figure 2-7. This feature allows the HOME position to thermally expand or  
contract without damaging the ACT2000.  
If the actuator firmware program entered the HOME/DEAD BAND state from  
POWER-UP/RESET, the firmware program will immediately define the current  
actuator position as HOME (zero).  
The actuator firmware program will also enter this state from RUN if the  
position demand is < 4.1mA and position feedback is < 4.2mA.  
Note: If RUN command is removed or position demand 2 mA, the  
actuator will go to the 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.  
The actuator firmware program enters this state from the HOLDING MOTOR  
CURRENT state if the position demand is 4.1mA. The actuator firmware  
program will remain in this state as long as the demand is greater than  
4.1mA.  
Note: If RUN command is removed or position demand 2 mA, the  
actuator will go to the STOP position.  
Stop Position  
The STOP position is a user defined, fail-safe position. The STOP position is a  
set-up parameter stored in the EEPROM. The STOP position may be anywhere  
between HOME (zero position) and maximum span.  
The STOP position is not a state per se. However, while in the STOP position the  
ACT2000 firmware program will track and hold the position defined in the Set-Up  
parameters.  
The actuator will move to the STOP position if RUN command is removed during  
any of the running modes or position demand is 2 mA (signal loss).  
2.4 Health Monitoring  
The firmware program continuously monitors system health while the ACT2000 is  
powered.  
2-8  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
If any of the health parameters are out of the normal operating range, the MCE  
outputs a discrete FAULT alarm to the user’s controller. The actuator firmware  
also captures the fault data in the EEPROM.  
If the motor or electronics temperature is above the normal operation range, the  
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. The fault file will provide fault information and possible  
cause.  
2.5 FAULT Alarm  
The FAULT alarm is a discrete output from the ACT2000. The FAULT circuit is  
CLOSED in the normal operating condition.  
During normal operation, the ACT2000 monitors system health. If the ACT2000  
detects a fault, the FAULT circuit OPENS and fault records in the fault file. The  
user-provided controller should detect the OPEN circuit.  
Should a FAULT occur, the user should shut down to troubleshoot the failure.  
Removing 120 VDC power shuts down the ACT2000. Toggling the RESET  
command will clear the FAULT alarm, but it does NOT clear the fault file.  
The following faults are recorded:  
Driver over-current  
The maximum MCE current output limit is 25 amps. If the MCE is outputting its  
maximum current for ten (10) seconds, the MCE signals a FAULT.  
Should MCE maximum current drop below the maximum current, the FAULT  
signal is cleared.  
Tracking error  
The ACT2000 position should continuously track demand. Should the position  
versus demand vary more than one motor revolution (0.20 inches) for more  
than ten (10) seconds, the MCE signals a FAULT.  
Should the position return to within one motor revolution, the FAULT signal is  
cleared.  
Watchdog expired  
The MCE watchdog timer continuously monitors the firmware program. Should  
the MCE firmware program stop functioning, or attempt to access an illegal  
address, the MCE signals a FAULT.  
This FAULT does not clear without RESET command.  
Resolver to Digital Converter (RDC) failure  
The MCE contains a resolver to digital converter chip (RDC) that provides  
position feedback information to the DSP. The RDC chip has on-board health  
monitoring.  
Should the RDC detect an internal tracking error, a signal is sent to the MCE.  
Upon receipt, the MCE signals a FAULT.  
2-9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
This FAULT does not clear without RESET command.  
Unregulated Voltage Low  
The MCE signals a FAULT if the reference voltage drops below minimum for  
ten (10) seconds.  
Should the voltage return to acceptable level, the FAULT signal is cleared.  
+/- 14V High/Low  
The MCE signals a FAULT if the internal ±14 VDC power supplies exceed  
operating limits. This FAULT does not clear without RESET command.  
Input voltage High/Low  
The MCE signals a FAULT if the 120 VDC supply exceeds 180 VDC or drops  
below 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. If ACT2000 detects the motor or electronics temperature  
above the maximum allowable, the OVERTEMP circuit is opened. The user-  
provided controller should detect the open circuit.  
An OVERTEMP Alarm will be indicated if the motor winding temperature is 130°C  
or higher for ten (10) seconds or the electronics temperature is 110°C or higher  
for ten (10) seconds.  
Should an OVERTEMP alarm occur, the user should shut down the actuator.  
Removing 120 VDC power shuts down the ACT2000. Toggling the RESET  
command will clear the FAULT alarm, but it does NOT clear the fault file.  
Note: The ACT2000 outputs an OVERTEMP alarm 5°C before the shut  
down threshold.  
2.7 Automatic Shutdown  
The ACT2000 has a self-protective shutdown feature.  
If any two motor winding temperatures exceed 135 °C for one (1) minute, the  
ACT2000 will shut down.  
If the electronics temperature exceeds 115 °C for one (1) minute, the  
ACT2000 will shut down.  
Note: Actuator position feedback and motor current will be set to 0 mA  
when the actuator shuts down.  
WARNING:  
Property Damage and Injury Hazard – If the motor windings exceed 135° C  
or the electronics exceed 115° C, the MCE will shut down power to the  
motor and electronics thereby allowing the actuator to move with load.  
Touching actuator may result in serious burn injury  
2-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
2.8 ACT2000 Set-Up Parameters  
The ACT2000 employs several variables to define its functionality. These  
variables are called set-up parameters. These parameters are downloaded  
through the RS232 interface to the ACT2000 using ActWiz software. See ActWiz  
Software Manual for further details.  
The user can define set up any of the following parameters:  
Home (Extend or Retract)  
This parameter controls the direction the ACT2000 will move, extend or retract, to  
find the mechanical stop (HOME).  
Span  
This parameter sets the maximum stroke length. The span is measured from the  
HOME position.  
Stop Position  
This parameter sets the signal loss position. The signal loss position is measured  
from the HOME position.  
Maximum Velocity  
This parameter sets the maximum velocity.  
Maximum Force  
This parameter sets the maximum force output.  
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 < 4.1mA.  
2-11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Table 2-1 lists the set-up parameters and factory default settings.  
Parameter  
Factory Setting  
Part Number  
Per Drawing  
Actuator Type  
Stand Alone  
Analog  
Command Source  
Home  
Retract  
5.9 inches  
0.1 inches  
Linear  
Span  
Stop Position  
Interpolation Table  
Position Loop Constant  
Current Loop PID Constants  
Proportional  
20  
2.0  
200  
0
Integral  
Derivative  
Velocity Loop PID Constants  
Proportional  
40  
Integral  
10,000  
0
Derivative  
Maximum Velocity  
Maximum Force  
Maximum Homing Velocity  
Maximum Homing Force  
Maximum Holding Force  
6 in/s  
1000 lbf  
0.5 in/s  
500 lbf  
500 lbf  
Table 2-1 Typical ACT2000 Setup Parameters  
2-12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
3 INSTALLATION  
The purpose of this section is to aid personnel in the installation, placement, and  
environmental considerations to be observed for the ACT2000 and associated  
equipment.  
3.1 Inspection  
The ACT2000 should be inspected immediately after unpacking. Check for  
damage, paying particular attention to the external lead wires.  
Note: Retain the actuator’s original shipping container. In the event of  
future transportation requirements, this container will minimize  
damage during shipment.  
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.  
WARNING: Property Damage – Solvent/water may enter the electronics  
area during a high-pressure wash.  
3.3 Mechanical Installation  
This section describes proper ACT2000 installation. Care should be exercised to  
ensure compliance with the factory recommendations.  
3.3.1 Space Requirements  
Figure 3-1 shows external dimensions and mounting provisions for the ACT2000-  
590P. Figure 3-2 shows the external dimensions and mounting provisions for the  
ACT2000-200F. The user should ensure additional swing clearance as required.  
3.3.2 Mounting Considerations  
The ACT2000 can be directly mounted to a gas turbine engine using brackets  
provided by the engine manufacturer. The ACT2000 can be mounted in any  
orientation (UP, DOWN, SIDEWAYS).  
The ACT2000 may provide a clevis, or other method, for installing the motor end.  
High strength bolts (0.375 diameter) are recommended to secure the actuator to  
a user-provided mount bracket.  
WARNING:  
Lifting Hazard – Do not attempt to hand lift actuator. Use appropriate lifting  
equipment.  
3-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Figure 3-1: ACT2000-590P Envelope  
3-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Figure 3-2: ACT2000-200F Envelope  
3-3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Note: The clevis can be rotated to any orientation to support installation.  
To rotate, loosen the four retaining screws and rotate to desired  
angle. Screw pattern can be indexed ± 45 degrees to provide  
additional adjustment. Torque the four retaining screws to  
117-138 in-lbs.  
WARNING:  
Explosion Hazard – Do not remove the clevis. Removing the clevis violates  
the warranty.  
The extension rod has a 0.375-24 UNF-3B female thread for user-provided  
hardware. The user may provide a standard 0.375-24-3B rod end  
(recommended) or other appropriate mounting hardware. The extension rod has  
wrench flats to counteract mounting hardware installation torque.  
WARNING:  
Property Damage Hazard – Always use the extension rod wrench flats  
when installing mounting hardware. Failure to use the wrench flats may  
damage or break the internal anti-rotation guide.  
3.3.3 Extension Rod Movement  
With 120 VDC power removed, the ACT2000 extension rod is free to move.  
Approximately 60 to 100 lbf is required to extend or retract the extension rod. A  
rod guide is provided internally to prevent extension rod rotation.  
WARNING:  
Property Damage Hazard – Do not attempt to rotate the extension rod. This  
may damage the internal anti-rotation guide and void the warranty.  
3.4 Electrical Installation  
The ACT2000 is suitable for use in hazardous locations. See nameplate  
for certifications. Care should be taken to ensure compliance with the factory  
recommendations. 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.  
3-4  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
WARNING:  
94/9/EC (ATEX) Compliance – Special Conditions for Safe Use:  
Two special factory-sealed unions are mounted on the equipment to ensure  
the electrical connection to the network and to provide the feedback signal  
to the user.  
The installation of these devices and the final connections to the conduit  
shall comply with the requirements of the 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.  
The recommended wiring is a two-conductor shielded cable containing twisted-  
pair wires with individual shields. Use a wire size large enough to accommodate  
the installation and provide a maximum one (1) ohm loop resistance. See Table  
3-1 (below) for recommended wire sizes.  
Distance to User Power  
Up to 500 ft  
Wire Size (Minimum)  
AWG 10 stranded  
Consult Factory  
Over 500 ft  
Table 3-1: Power Harness Recommended Wire Size  
WARNING:  
Shock Hazard – Both the 120 VDC power and auxiliary wires should be  
connected. If only the primary power wires are connected, the 120 VDC  
auxiliary power wires are electrically “hot” and must be insulated on the  
ends.  
Note: Use a separate conduit for the power wiring. This will prevent noise  
pickup and transmission from ancillary equipment, which could  
cause instability in the actuator.  
Signal Harness Recommended Wiring  
The signal harness contains both analog and digital inputs and outputs. The  
analog inputs and outputs are 4mA to 20mA and are electrically isolated up to  
500 VAC from the enclosure, 120VDC power, digital I/O, and serial interface. The  
analog interfaces are not isolated from each other.  
3-5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
The recommended wiring is a fourteen-conductor shielded cable containing  
twisted-pair wires with individual shields. Use a wire size large enough to  
accommodate the installation and provide a maximum fifty (50) ohm loop  
resistance. See Table 3-2 for recommended wire sizes.  
Distance to User Controller Wire Size (Minimum)  
Up to 1000 ft  
Over 1000 ft  
AWG 18 stranded  
Consult Factory  
Table 3-2: Digital Harness Recommended Wire Size  
Note: Use a separate conduit for the signal wiring. This will prevent noise  
pickup and transmission from ancillary equipment, which could  
cause instability in the actuator.  
Shielded Wiring  
All shielded cable must be a twisted conductor pair with either a foil or braided  
shield. All signal lines should be shielded to prevent picking up stray signals.  
Connect shields per Figure 3-3 (page 3-8). Wire exposed beyond the shield  
should be as short as possible.  
WARNING:  
Property Damage Hazard – This actuator is 89/339/EEC EMC Directive  
compliant (CE mark) using watertight, flexible conduit (plastic over steel)  
and Belden 8719 shielded, twisted pair audio, broadcast and  
instrumentation cable. Use of other conduit or wire invalidates EMC  
Directive compliance.  
Property Damage Hazard – Do Not connect 24VDC power without current  
limiting (25 mA) across digital or analog outputs.  
Serial Wiring  
The serial inputs are not electrically isolated. Isolation must be provided when  
connecting to a computer.  
3-6  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
WARNING:  
Property Damage Hazard – Serial inputs are not electrically isolated. Failure  
to properly isolate the user serial interface could result in actuator or  
computer damage. Use separate conduits for power and signal wiring.  
Close proximity to power lines may cause signal interference.  
Shock Hazard – The serial inputs are not electrically isolated. If the 120 VDC  
power input is floating (not grounded), the serial input connections may  
have up to 120 VDC present.  
Property Damage Hazard – DO NOT connect 24VDC power to any of the  
serial interface connections.  
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  
RED  
Function  
AWG  
14  
Power  
WHITE/RED  
GREEN  
Power (AUX)  
Power Return  
Power Return (AUX)  
14  
14  
WHITE/GREEN  
14  
Table 3-3: ACT2000 Power Harness Wire List  
3-7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Power Harness Electrical Hook-Up  
POWER SUPPLY  
ACT2000  
PWR (RED)  
+120VDC  
PWR [AUX] (WHT/RED)  
PWR RTN (GRN)  
PWR RTN [AUX] (WHT/GRN)  
Shield No Connection  
-120VDC Return  
Power Gnd Shield  
Digital Harness Electrical Hook-Up  
DEMAND (BRN)  
DEMAND RTN (WHT/BRN)  
Shield No Connection  
Demand  
Return  
Shield Gnd  
Run  
Return  
Shield Gnd  
RUN (VIO)  
RUN RTN (WHT/VIO)  
Shield No Connection  
RESET (GRY)  
RESET RTN (WHT/GRY)  
Shield No Connection  
Reset  
Return  
Shield Gnd  
MTR CURRENT (BLU)  
MTR CURRENT RTN(WHT/BLU)  
Shield No Connection  
Motor Current  
Motor Current RTN  
Shield Gnd  
Position  
Position RTN  
Shield Gnd  
POSITION (YEL)  
POSITION RTN(WHT/YEL)  
Shield No Connection  
FAULT ALARM (ORN)  
FAULT RTN (WHT ORN)  
Shield No Connection  
Fault Alarm  
Fault Alarm  
Shield Gnd  
OVERTEMP ALARM (BLK)  
OVERTEMP RTN (WHT/BLK)  
Shield No Connection  
Over Temp Alarm  
Over Temp Alarm  
Shield Gnd  
Shield No Connection  
Shield Gnd  
SERIAL TX OUT (WHT/ORN/BLU)  
SERIAL RX IN (WHT/ORN/YEL)  
SERIAL RTN (WHT/ORN/GRN)  
Shield No Connection  
Serial RX in  
Serial TX out  
Serial RTN  
Shield Gnd  
ENGINE CONTROLLER  
ACT2000  
Figure 3-3: ACT2000 Wiring Diagram  
3-8  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
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  
AWG  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
20  
Signals  
± 12 V  
± 12 V  
0 V  
WHITE/ORANGE/YELLOW Serial/RX In  
WHITE/ORANGE/BLUE  
WHITE/ORANGE/GREEN  
BLACK  
Serial/TX Out  
Serial Return  
OVER TEMP Alarm  
OVER TEMP Alarm Return  
FAULT Alarm  
0 / 24 V  
0 V  
WHITE/BLACK  
ORANGE  
0 / 24 V  
0 V  
WHITE/ORANGE  
VIOLET  
FAULT Alarm Return  
RUN Command  
0 / 24 V  
0 V  
WHITE/VIOLET  
GRAY  
RUN Command Return  
RESET Command  
RESET Command Return  
Position Demand  
0 / 24 V  
0 V  
WHITE/GRAY  
BROWN  
4 – 20mA  
0 V  
WHITE/BROWN  
YELLOW  
Position Demand Return  
Position Feedback  
Position Feedback RTN  
Motor Current  
4 – 20mA  
0 V  
WHITE/YELLOW  
BLUE  
4 – 20mA  
0 V  
WHITE/BLUE  
Motor Current RTN  
Note: The serial Return is connected to the 120 V input return.  
Table 3-4: ACT2000 Digital Harness Wire List  
3-9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Power Supply Requirements  
A battery power system is recommended, Table 3-5 lists the power supply  
requirements.  
Voltage:  
120VDC nominal  
80VDC minimum  
160VDC maximum  
4 VAC RMS or 12VAC p-p  
20 AMPS  
Max Ripple:  
Max Current:  
Typical Continuous Current: <1 AMP  
Typical Transient Current:  
+20 A <60ms  
+10A <600 ms  
-5A <100 ms  
*Output Capacitance:  
50,000 uF  
*The output capacitance applies for non-battery power systems and assumes full stroke step changes in actuator  
position at rated load.  
Table 3-5 Power Supply Requirements  
3-10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
4 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).  
The ACT2000 is comprised of highly reliable components and should not develop  
service problems under normal operating conditions. However, over a period of  
time and service, failures may develop. Personnel responsible for fault analysis  
should be thoroughly acquainted with physical and electrical configurations,  
Theory of Operation (Section 2), and Installation (Section 3).  
Resolve problems noted during operation or maintenance as soon as possible.  
The causes of many problems can be traced through the information contained in  
the block diagrams shown in Section 2.  
WARNING:  
Property Damage Hazard – Continuing to operate the actuator in a  
malfunctioning condition is hazardous to personnel and can cause  
property damage.  
Table 4-1 lists some common failures that can occur upon initial actuator  
installation. Table 4-2 lists some common failures that can occur after initial  
installation.  
In addition, the ACT2000 has some on-board troubleshooting capability. The  
ActWiz software has a fault file that can be uploaded to pinpoint a failure cause.  
See ActWiz Software Manual for more details.  
If, after following the troubleshooting procedures, the user is unable to find the  
cause of the problem and repair it, contact the factory for assistance. See Section  
8 for return information.  
4-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Table 4-1 ACT2000 Initial Installation Troubleshooting Chart  
Symptom  
Probable Causes  
Corrective Action  
Actuator Inoperative - FAULT Power Wires not connected  
alarm  
Ensure RED and GREEN wires correctly connected to  
Actuator  
No or low 120 VDC power  
Ensure 120 VDC Primary System Power at Actuator  
Actuator Inoperative -  
NO FAULT alarm  
No RUN or position command  
Ensure VIOLET and WHITE/VIOLET wires correctly  
connected to Actuator  
Ensure 24 VDC RUN and position command at  
Actuator  
Actuator moves toward  
HOME then stops  
Intermittent RUN command  
Ensure consistent 24 VDC RUN and position command  
Ensure position command at actuator  
Homing Force Too Low  
No position demand  
Actuator moves toward  
HOME intermittently  
Intermittent RESET command  
No position demand signal  
No position demand signal  
Varying position demand signal  
Ensure GRAY and WHITE/GRAY wires correctly  
connected to Actuator  
Ensure consistent 24 VDC RESET command  
Actuator finds HOME then  
moves to STOP position  
Ensure BROWN and WHITE/BROWN wires correctly  
connected to Actuator  
Ensure position demand > 2.0 mA at Actuator  
Actuator does not track  
position demand  
Ensure BROWN and WHITE/BROWN wires correctly  
connected to Actuator  
Ensure position demand > 4.1 mA at Actuator  
Actuator does not hold  
consistent position-oscillates  
or dithers  
Ensure stable position demand at the actuator  
No position feedback  
Position feedback wires not  
connected  
Ensure YELLOW and WHITE/YELLOW wires correctly  
connected  
No or low 120 VDC power  
Actuator auto shut down  
Ensure 120VDC at Actuator  
Upload Fault File- check for electronics or motor  
windings over temperature faults.  
Check for jammed extension rod  
No motor current feedback  
Motor current wires not  
connected  
Ensure BLUE and WHITE/BLUE wires correctly  
connected  
No or low 120 VDC power  
Actuator Operative- FAULT  
alarm active  
Open circuit  
Ensure ORANGE and WHITE/ORANGE wires  
correctly connected to Actuator  
Internal FAULT  
Open circuit  
Upload Fault File to identify source of fault  
Actuator Operative- OVER  
TEMP alarm active  
Ensure BLACK and WHITE/BLACK wires correctly  
connected to Actuator  
Electronics or Motor winding  
temperature out of range  
Reduce External ambient temperature  
Check for jammed extension rod  
RS232 Interface Inoperative Incorrect wiring  
Ensure WHITE/ORANGE/YELLOW,  
WHITE/ORANGE/BLUE, WHITE/ORANGE/GREEN  
wires correctly connected to Actuator and laptop PC.  
Ensure 120 VDC Primary System Power at Actuator  
Check laptop/PC com port  
No or low 120 VDC power  
COM1 not connected  
4-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
Table 4-2 ACT2000 In-Service Troubleshooting Chart  
Symptom  
Probable Causes  
Corrective Action  
FAULT alarm  
Various  
Upload Fault File to identify source of fault  
OVER TEMP alarm  
Ambient temperature limit  
exceeded  
Allow actuator to cool and re-start  
Reduce ambient temperature  
Electronics or Motor winding  
temperature out of range  
Check for jammed extension rod  
FAULT and OVERTEMP  
alarm  
No 120VDC Power  
DSP Failure  
Ensure 120 VDC at actuator  
Contact factory  
For troubleshooting purposes use Table 4-3 to verify the actuator electrical continuity integrity.  
Disconnect the actuator power and digital harness connectors and use a digital multimeter (DMM)  
to check the resistance values between the wires indicated on the table. 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  
DEMAND  
RUN  
Actuator Wire Colors  
BRN and WHT/BRN  
VIO and WHT/VIO  
Resistance Value  
225Ω  
4.7KΩ  
RESET  
POWER  
GRY and WHT/GRY  
RED and WHT/RED  
4.7KΩ  
High Impedance, but not  
open circuit.  
MOTOR CURRENT  
POSITION  
BLU and WHT/BLU  
YEL and WHT/YEL  
ORN and WHT/ORN  
BLK and WHT/BLK  
High Impedance  
High Impedance  
High Impedance  
High Impedance  
FAULT ALARM  
OVERTEMP  
4-3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
INTENTIONALLY BLANK  
4-4  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
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:  
1.  
2.  
Disconnect power harness to ACT2000.  
Disconnect signal harness to ACT2000  
Note: Follow local environmental codes in regards to disposal of electronic  
components, specifically all electrolytic capacitors.  
5-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
INTENTIONALLY BLANK  
5-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
6 ACT2000 GENERAL SPECIFICATIONS  
Nominal Voltage: 120 VDC  
Minimum Voltage: 80 VDC  
Maximum Voltage: 160 VDC  
Maximum Current: 20A  
Power Input  
Typical Transient Current: +20A < 60ms; +10A < 600ms; -5A < 100ms  
Typical Continuous Current: < 1A  
ON Voltage: 12 to 32 VDC; +24 VDC Nominal  
ON Current: 6.5 mA Nominal @ 24 VDC  
OFF Voltage: 3.5 VDC Maximum  
RUN and RESET Command Input  
FAULT and OVERTEMP Output  
OFF Current: 0.75 mA Maximum  
OFF Voltage: 32 VDC Maximum  
OFF Leakage Current: 150 µA Maximum  
ON Current: 25 mA Maximum  
ON Voltage Drop: 1.5 VDC Maximum @ 25 mA  
Current: 4 to 20 mA; 25 mA Maximum  
Voltage: 5 VDC Maximum  
Analog Command Input  
Internal Impedance: 200 Ω  
Current: 4 to 20 mA  
Position and Motor Current Feedback Analog  
External Load Resistance: 500 Maximum  
Maximum Common Mode Voltage  
Temperature Limits  
±200 VDC User I/O to 120 VDC Return (less serial interface)  
Operating Ambient: -40° C (-40° F) to +93° C (+200° F)  
Operating Fuel: -40° C (-40° F) to +125° C (+257° F)  
Storage: -40° C (-40° F) to +125° C (+257° F)  
Maximum Velocity  
Maximum Continuous Force  
Maximum Peak Force  
Maximum Stroke  
10 in/sec  
500 lbf (100% Duty Cycle)  
1000 lbf (100% Duty Cycle)  
5.9 in (Configuration Dependent)  
± 1% Full Stroke  
Accuracy  
Environmental Rating  
CSA Type 3, European IP65  
EMC  
Vibration  
EN 50081-2 and EN50082-2 for DC powered industrial equipment  
Mil-Std-810E, Category 4 (5 – 2000 Hz)  
30,000 Hours  
Mean Time Before Unscheduled Removal  
Life Cycles  
32,000 Minimum  
Electrical Connection  
Power Harness: (4) AWG 14, 90 in, ¾ NPT Conduit (EP)  
Digital Harness: (17) AWG 20, 90 in, ¾ NPT Conduit (EP)  
North American Certifications  
CSA Class I, Div 1, Group B, C, D; T4  
EEx d, IIB+H2; T4  
European Directive Compliance (CE Mark  
94/9/EC Potentially Explosive Atmospheres (ATEX)  
98/37/EC Machinery Directive  
89/336/EEC Electromagnetic Compatibility Directive (EMC)  
Materials  
Housings  
6061-T6 Anodized Aluminum  
Zinc Plated Steel  
Conduit Union  
Extension Rod  
Clevis  
17-4 PH CRES  
17-4 PH CRES  
Rod End Bearing  
Seals  
Aluminum Bronze  
Nitrile, RTV and Teflon  
6.0 in x 16.0 in  
Dimensions  
Approx. Dry Weight  
Pin Mounted 35 lbs. Max  
Flange Mounted 50 lbs. Max  
6-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
INTENTIONALLY BLANK  
6-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
7 GLOSSARY  
Term  
Definition  
RUN Command  
A discrete 24 VDC signal that enables the ACT2000 extension rod to  
move.  
RESET Command  
Controller  
A discrete 24 VDC signal that causes the ACT2000 internal program  
(firmware) to jump to the beginning.  
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  
Motor Current Feedback  
FAULT alarm  
A 4mA to 20mA signal that communicates the actual ACT2000  
position to the controller.  
A 4mA to 20mA signal that is proportional to the ACT2000 motor  
current. The signal is scaled with Max. Force.  
A discrete signal from the ACT2000 that communicates an internal  
failure. The controller will see an open circuit when a FAULT alarm is  
active.  
OVERTEMP alarm  
HOME  
A discrete signal from the ACT2000 that communicates an internal  
over temperature; electronics or motor. The controller will see an  
open circuit when OVERTEMP alarm is active.  
A mechanical rigid stop at which the ACT2000 calculates position  
from. HOME is found at start-up during Homing sequence. The  
ACT2000 defines HOME when the motor current exceeds the  
HOMING FORCE and velocity is zero. HOME is defined as 4mA  
position demand.  
Homing sequence  
SPAN  
When the ACT2000 extends or retracts to find a rigid mechanical  
stop.  
Maximum distance from HOME. SPAN is defined as 20mA position  
demand.  
STOP position  
A user-defined position between HOME and SPAN that the ACT2000  
travels to upon loss of RUN or position demand signal.  
Maximum Velocity  
A user defined maximum velocity in inches per second.  
Maximum Homing Force  
A user defined maximum homing force output setting. The motor  
control electronics uses this setting to determine the maximum motor  
current in the Homing sequence.  
Maximum Holding Force  
A user defined maximum force while in the Holding Motor Current  
state.  
7-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
INTENTIONALLY BLANK  
7-2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ACT2000  
7-1  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Graco Car Seat PD247308A User Manual
Grizzly Nail Gun H2911 User Manual
Honeywell Cell Phone 60s QS User Manual
Hotpoint Dishwasher LFZ 338 A HA IX User Manual
HP Hewlett Packard Laptop 2000 410us User Manual
HP Hewlett Packard PDAs Smartphones hx2000 Series User Manual
HP Hewlett Packard Work Light HP11857D User Manual
Husqvarna Saw 3120K User Manual
Husqvarna Snow Blower 1330SB XLSB User Manual
IKEA Washer IWM60 User Manual