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Limitorque Actuation Systems

Limitorque®

Modutronic 20 IIInstallation & Maintenance Manual

401-12000 Rev. B

Feb. 2003

Modutronic 20 II Installation & Maintenance Manual 401-12000 • Revision B • February 2003IV

Modutronic 20 II Installation & Maintenance Manual

©2003 Copyright Limitorque. All rights reserved. Printed in the United States of America.

DisclaimerNo part of this book shall be reproduced, stored in a retrieval system, or transmitted by anymeans, electronic, mechanical, photocopying, recording, or otherwise without writtenpermission from Limitorque. While every precaution has been taken in the preparation of thebook, the publisher assumes no responsibility for errors or omissions. Neither is any liabilityassumed for damages resulting from the use of the information contained herein.

This document is the proprietary information of Limitorque furnished for customer use ONLY.No other uses are authorized without written permission from Limitorque.

Limitorque reserves the right to make changes, without notice, to this document and theproducts it describes. Limitorque shall not be liable for technical or editorial errors or omissionsmade herein; nor for incidental or consequential damages resulting from the furnishing, perfor-mance, or use of this document.

The choice of system components is the responsibility of the buyer, and how they are usedcannot be the liability of Limitorque. However, Limitorque’s sales team and application engineersare always available to assist you in making your decision.

This manual contains information that is correct to the best of Limitorque’s knowledge. It isintended to be a guide and should not be considered as a sole source of technical instruction,replacing good technical judgment, since all possible situations cannot be anticipated. If there isany doubt as to the exact installation, configuration, and/or use, call Limitorque at (434) 528-4400. The latest revisions to this document are available online at http://www.limitorque.com

Flow Control Division


401-12000 • Revision B • February 2003 Modutronic 20 II Installation & Maintenance Manual V

Table of Contents

1 Introduction 1-11.1 Safety Information 1-11.2 Product Identification 1-21.3 Product Description 1-21.4 Product Features 1-21.5 Product Specifications 1-3

2 Operation 2-1

3 Definitions 3-1

4 Initial Checkout & Setup 4-14.1 Verify Correct Motor Rotation (Phasing) & OPEN/CLOSE

Pushbutton Operation 4-14.2 Verify Limit Switch & Torque Switch Settings 4-34.3 Adjusting the Actuator Feedback Potentiometer 4-34.4 Connecting the Modutronic 20 II to Customer Command Signal Leads 4-4

5 Modutronic 20 II Presets 5-1

6 Calibration Procedure 6-1

7 Troubleshooting 7-1

8 Wiring Diagram 8-1

9 Schematic 9-1



Modutronic 20 II Installation & Maintenance Manual 401-12000 • Revision B • February 2003VI

Figures

Figure 1.1 – Modutronic 20 II 1-2Figure 2.1 – LY with a Modutronic 20 II & Associated Actuator

Components 2-1Figure 3.1 – Calibration Positions 3-1Figure 4.1 – Standard Motor Rotation & Reverse Motor Rotation Wiring Diagrams

for Dual Voltage, Capacitor Start, Induction Run, and Single-Phase Low-Voltage Motors 4-2

Figure 4.2 – Standard Motor Rotation & Reverse Motor Rotation Wiring Diagrams for Dual Voltage, Capacitor Start, Induction Run, and Single-Phase High-Voltage Motors 4-2

Figure 4.3 – Potentiometer Calibration Components Shown on a LY Position Indicator 4-3

Figure 6.1 – Calibration Adjustments for the Modutronic 20 II 6-1Figure 6.2 – mA Calibrator Typically Connects to an Interconnect Board

Terminal Strip or Terminal Strips Located in the Rear of a Panel-Mounted Modutronic 20 II 6-2

Figure 6.3 – Modutronic 20 II Board Component Locations 6-2Figure 6.4 – FAIL TO Mode JP1 Jumper 6-5Figure 8.1 – Modutronic 20 II Typical 3-Phase Wiring Diagram 8-2, 8-3Figure 9.1 – Modutronic 20 II Schematic Diagram 9-2, 9-3

Tables

Table 4.1 – Modutronic 20 II Terminal Connections 4-4Table 5.1 – ON/OFF Potentiometer Turns for Desired Operating Time 5-1Table 6.1 – DIP Switch Setting Levels of Deadband Accuracy 6-3



401-12000 • Revision B • February 2003 Modutronic 20 II Installation & Maintenance Manual 1-1

1 Introduction

1.1 Safety Information

This Installation & Maintenance Manual was written for the user who is adding Modutronic 20 IIcapability to an existing actuator or who wants to adjust and/or troubleshoot a previouslyinstalled Modutronic 20 II Controller. These guidelines provide the information that is necessaryto correctly install, set up, calibrate, and troubleshoot the Modutronic 20 II Controller.

Your safety and satisfaction are very important to Limitorque. Please follow all instructionscarefully and pay special attention to safety.

The following methods will be used to emphasize text throughout this manual:

a WARNING: Refers to personal safety. This alerts the reader to potential danger or harm.Failure to follow the advice in warning notices could result in personal injury or death.

CAUTION: Directs attention to general precautions, which, if not followed, could result inpersonal injury and/or equipment damage.

NOTE: Highlights information critical to the understanding or use of these products.

Bold text highlights other important information that is critical to system components.

CAPITALIZED text stresses attention to the details of the procedure.

Underlined text emphasizes crucial words in sentences that could be misunderstood if the wordis not recognized.

The purpose of these emphasized blocks of text is to alert the reader to possible hazards asso-ciated with the equipment and the precautions that can be taken to reduce the risk of personalinjury and damage to the equipment.

Read and become familiar with the material in these guidelines before attempting installation,operation, or maintenance of the equipment. Failure to observe precautions could result inserious bodily injury, damage to the equipment, or operational difficulty.

a WARNING: Read this Installation & Maintenance Manual carefully and completely beforeattempting to install or operate the Modutronic 20 II. Be aware of electrical hazards wheninstalling or performing maintenance on the Modutronic.



Modutronic 20 II Installation & Maintenance Manual 401-12000 • Revision B • February 20031-2

1.2 Product Identification

Figure 1.1 – Modutronic 20 II

1.3 Product Description

The Modutronic 20 IITM is a solid state-integrated circuit-based controller. It is used to operateelectric valve actuators in wastewater, petrochemical, and other industry applications requiringaccurate modulation positioning. The standard input consists of a 4-20 mA signal generated by aprocess controller; the resulting output is used to accurately and repeatably position a valveactuator through conventional or solid state switching of either single or three-phase AC power.

1.4 Product Features

• Accuracy and repeatability of positioning within 1% of full-scale for actuator stroke times > 30seconds.

• Solid state circuitry for longer life and reliable service.• 4-20 mA command signal.• Can be used to control single or three-phase systems.• Jumper selectable Lock-in-Last or Fail-Closed configurations if command signal is lost.• Five parameters available for adjustment allows actuator/application match.• Adjustable ON and OFF motor control timers.• LED indicators display signal, power, and control status to simplify calibration and monitor

performance.

LIMITO RQUE

CO RPORATIO N

LYNCHBURG, VA USA

MODUTRONIC20

MODEL II

CLOSE

OPENCLOSE

SPANGAIN

POWER ON

INPUT ACTIVE

ON TIME

OFF TIME

Zero, Span,Gain CalibrationPotentiometers

61-825-0713-1

SALES/SERVICE

804-528-4400

StatusIndicator Lights

On-Time/Off-TimeCalibrationPotentiometers

Cover

Open/CloseIndicatorLights

WiringHarness

1 2 3 4 5 6 7 8 9 10




1.5 Product Specifications

Modutronic 20 II SpecificationsPower Requirements Derived from actuator supply

Board power 18 VAC or 24 VDC (±10%).3VAControl Signal 4-20 mA Accuracy Within ±1% (>30 second stroke)Loss of Command Fail-to-last-positionSignal Selections Fail-to-minimum-signal-positionTemperature -40°C to +85°C (operating)Maximum Starts Solid state reverser–600/hourPer Hour Electromagnetic contactor–100/hourMaximum direct Motor current–4.5 A Inrush, 3 A Holdingoutput loadingDimensions Mod 20–1.5"H x 3.25"W x 4"L

Separate enclosure11.7"H x 12.75"W x 17.4"L

Deadband Adjustable between 1% and 10%Resolution 1%Linearity 1%Humidity To 95% (non-condensing)




This page is intentionally blank.




2 Operation

The Modutronic 20 II receives an input signal, normally 4-20 mA, from the external processcontroller. This signal is compared (within the Mod 20 II circuitry) to the present position of theactuator as indicated by the signal from the Feedback Potentiometer attached to the gear train ofthe actuator. The comparison of these two signals generates an error signal that dictates thedirection and distance the actuator needs to be driven.

Upon generation of the error signal, the appropriate output triac is enabled and 115-volt controlpower is directed to the output contactor (this may be an electro-mechanical contactor or a solidstate reverser depending upon the application).

As the actuator drives toward the set-point, it enters a region surrounding the set-point where thecontrol function within the Mod 20 II changes from a continuous power application to a pulsingmode (proportional band). The Mod 20 II continuously compares the valve’s actual position to thedesired set-point through its circuitry; motor pulsing is continued until the actuator is accuratelypositioned at the set-point. The point in the valve travel at which the pulsing mode is enabled andspacing/duration of the pulses are all user adjustable on the Mod 20 II.

Figure 2.1 – LY with a Modutronic 20 II & Associated Actuator Components

Motor

FeedbackPot(X2)

Control Transformer

4-20 mA out

InterconnectBoard

Gearing tovalve stem

Conventionalcontactor or

soild statereverser

Single orThree-Phase

Power

Input4-20mA

L1

L3L2

Actuator Body

MDPI

MotorCompartment

ControlCompartment

R-1Converter(Optional)

Mod 20 II34 Feed- Motor18 back ControlVAC IN IN/OUT1 2 3 4 5 6 7 8 9 1 0




3 Definitions

Figure 3.1 – Calibration Positions

Command Signal Input signal provided by user to assign the desired valve position.Deadband Adjusts the maximum allowable error signal. (Difference between the PositionCommand Signal and Position Feedback Potentiometer Signal). Selectable on the Mod 20 II DIPSwitch. See Table 6.1 for DIP Switch setting chart.Proportional Band (Pulsing Window) controls the point on the scale of valve travel that themotor begins the pulsing mode. (Increasing GAIN decreases the window width). • Adjusting the GAIN Potentiometer fully CW (increasing GAIN/decreasing pulsing window),

sets the GAIN to its maximum setting causing the motor to run continuously up to the Set-Point before power is turned off from the motor.

• Adjusting the GAIN Potentiometer CCW (decreasing GAIN/increasing pulsing window),causes the Mod 20 II to begin to “pulse” the motor on and off as it approaches the Set-Point.

On Time Adjusts the time that the electro-mechanical contactors or Solid State Reversers areengaged while in the pulsing window.Off Time Adjusts the time that the electro-mechanical contactors or Solid State Reversers orSolid State Reversers are disengaged while in the pulsing window.Set-Point Desired stopping position for Mod 20 II; determined by the Command Signal.Span Calibrates the Mod 20 II to align the Maximum Command Signal (normally 20 mA) withthe Position Feedback Potentiometer at the open position.Zero Calibrates the Mod 20 II to align the Minimum Command Signal (normally 4 mA) with thePosition Feedback Potentiometer at the close position.

Span

Valve Travel

(Zero/Minimum

Command Signal)

Valve Travel

Deadband

Proportional Band(Pulsing Window )

Set Point

(MaximumCommand Signal)




4 Initial Checkout & Setup

4.1 Verify Correct Motor Rotation (Phasing) & OPEN/CLOSEPushbutton Operation

It is very important to check for correct motor rotation to insure that serious damage to the valveor other equipment does not occur. If the actuator motor rotates in the wrong direction, over-torque damage could occur to the equipment.

Prior to being shipped from the factory, each actuator is inspected to verify proper operation ofthe Torque and Position Limit Switch and to ensure that they function correctly (i.e. closes whenthe CLOSE pushbutton is depressed, opens with the OPEN pushbutton, etc.). These inspections aremade with a properly phased power source connected as described in the actuator manual.

CAUTION: To ensure proper operation and to prevent your actuator or other actuatedequipment from damage, verify that your unit is properly connected to its power source.

NOTE: Your application may vary from the following standard wiring configurations for three-phase, single-phase, and DC motors. Refer to your actuator wiring diagram for user-specificwiring configuration.

Three-Phase Motor1. Using the Handwheel, move the valve to a midtravel position (midtravel position allows elec-

trical operation in the valve “safe” area and keeps the OPEN and CLOSED Limit Switches fromtripping while testing motor direction).

2. Test motor direction by momentarily pressing the OPEN pushbutton:a. If the actuator moves toward CLOSED, immediately turn all power OFF and reverse the

motor leads T1 and T3.NOTE: Refer to your actuator wiring diagram for user-specific wiring configuration.

b. If the actuator moves toward OPEN, the motor is wired properly for the application.

Single-Phase Motor1. Using the Handwheel, move the valve to a midtravel position (midtravel position allows elec-

trical operation in the valve “safe” area and keeps the OPEN and CLOSED limit switches fromtripping while testing motor direction).

2. Test motor direction by momentarily pressing the OPEN pushbutton:a. If the actuator moves toward CLOSED, immediately turn power OFF and proceed with the

following instructions that match your application.1. Permanent Split Capacitor single phase motors can be connected for opposite rotation

by interchanging the leads T1 and T2 coming from the motor to the terminal strip.




2. Single voltage, capacitor start, induction run, single phase motors interchange leadsT2 and T3 coming from the motor to the terminal strip.

3. Dual voltage, capacitor start, induction run, single phase motors can be connected foropposite rotation but the connection depends on whether the motor is operated on lowvoltage or operated on high voltage.• Low voltage motors are connected for opposite rotation as shown in the changes

between the Standard Rotation configuration and the Reverse Rotation configuration inFigure 4.1. This is accomplished by interchanging the two leads T1 and T3 comingfrom the motor with the two leads T6 and T8 also coming from the motor. No otherchanges are necessary.

Figure 4.1 – Standard Motor Rotation & Reverse Motor Rotation Wiring Diagrams for DualVoltage, Capacitor Start, Induction Run, and Single-Phase Low-Voltage Motors

• High voltage motors are connected for opposite rotation as shown in the changesbetween the Standard Rotation configuration and the Reverse Rotation configuration inFigure 4.2. This is accomplished by interchanging two set of leads. First, interchangethe leads T1 and T8 coming from the motor. Second, interchange leads T3 and T6 atthe starting relays R1 and R2. No other changes are necessary.

Figure 4.2 – Standard Motor Rotation & Reverse Motor Rotation Wiring Diagrams for DualVoltage, Capacitor Start, Induction Run, and Single-Phase High-Voltage Motors

b) Test Motor direction again by momentarily pressing the OPEN pushbutton. If the actuator moves toward OPEN, the motor is wired properly for the application. If not, checkthe wiring diagram for proper wiring.

Standard RotationWiring

T6

T3

L1

L2

4 C5R2 T7

O

C

R1

R2Cap

1

21

2

O

C

R1 T54 5 O

T6 T9

T10

T3

T1

T4T8

T2

Reverse RotationWiring

T6

T3

L1

L2

4 C5R2 T7

O

C

R1

R2Cap

1

21

2

O

C

R1 T54 5 O

T8 T4

T2

T6

T8

T9

T1

T10

Standard RotationWiring

T6

L1

L2

4 C5R2 T7

O

C

R1

R2Cap1

21

2

O

C

R1T5

4 5 O

T8 T10

T3

T4

T4

T1 T2 T3

T4

T6 T9

T4

Reverse RotationWiring

T6

L1

L2

4 C5R2 T7

O

C

R1

R2Cap1

21

2

O

C

R1T5

4 5 O

T1 T2

T3

T9

T4

T8 T10 T6

T4

T3 T4

T4

T3T6




4.2 Verify Limit Switch & Torque Switch Settings

Set the OPEN and CLOSE Limit Switch and the Torque Switch according to the instructions inthe specific Actuator instruction manual.

4.3 Adjusting the Actuator Feedback Potentiometer

a WARNING: Hazardous Voltage. Turn power OFF before calibrating the FeedbackPotentiometer.

1. Shut off all power to the actuator.2. Using the Handwheel, position the actuator to mid-travel (valve at the 50% position).3. Disconnect the Potentiometer Wiring Harness from where it is plugged in or

connected to a Terminal Strip.4. Using an Ohm Meter verify that the Potentiometer is in mid-travel position. The resistance

from each End Connection to the Center Connection should be half of the full resistance of thePotentiometer. Example: 1000 ohm Potentiometer should read approximately 500 ohms fromone of the End Connections to the Center Connection.

Figure 4.3 – Potentiometer Calibration Components Shown on a LY Position Indicator

5. If the reading is not correct, proceed to Step 6. If the reading is correct proceed to Step 7.6. a. Loosen the small Set Screw that retains the Potentiometer Drive Spur Gear to the

Potentiometer Shaft.b. Remove the Spur Gear to allow manual rotation of the Potentiometer Shaft.c. Rotate the Potentiometer Shaft until the correct readings are obtained as described in

Step 4.d. Reposition the Spur Gear to re-engage with the Gear Train.e. Proceed to Step 7.

7. Disconnect the Ohm Meter and re-connect the Potentiometer wiring to original connection.

PotentiometerShaft

Spur Gear

Setscrew

EndConnection

CenterConnection

Ohm Meterto Pot Leads

PotentiometerDrive Gear

50 1000PERCENT OPEN

Limitorque




4.4 Connecting the Mod 20 II to Customer Command Signal Leads

a WARNING: Hazardous Voltage. Turn power OFF before removing the actuator cover andconnecting the command signal.

If the Mod 20 II was factory installed, the only connection required is the user input commandsignal leads (normally 4-20mA). These connections should be made at the terminal strip inaccordance with the wiring diagram enclosed with the actuator. NOTE: if the unit does not have Limitorque supplied pushbuttons, refer to your wiring diagram toinstall a customer supplied pushbutton station.

If retrofitting or adding a Mod 20 II to an existing actuator, use the following connections tableand your wiring diagram for wire lead designations.

Table 4.1 – Modutronic 20 II Terminal ConnectionsL120 Non-Compact

Mod 20 II Integral P.C. BoardTerminals Description (61-825-0337-3)P1-1 18 Volt AC 18 Volt AC See NoteP1-2 18 Volt AC Power Source See NoteP1-3 Negative 4-20 mA signal TB1-5 -4-20 mAP1-4 Positive 4-20 mA signal TB1-4 +4-20 mAP1-5 Potentiometer TB1-8P1-6 Potentiometer (wiper) TB1-9P1-7 Potentiometer TB1-10P1-8 115 Volt AC (output common) TB2-5P1-9 Close Contactor Output TB2-6P1-10 Open Contactor Output TB2-7Note: To Terminal Strip or Control Power Transformer with 18-Volt tap.

}}




5 Mod 20 II Presets

a WARNING: Hazardous Voltage. Turn power OFF before removing the actuator cover andconnecting your command signal.

1. Shut off all power to the actuator to avoid equipment damage or personal injury.2. Rotate the GAIN Potentiometer fully CCW , then 15 turns CW to reach the midpoint of

the Potentiometer. (See Figure 6.3 for Potentiometer locations).Note: Each 30-turn Potentiometer will faintly ‘click’ when rotated to either the maximum or mini-mum position.3. Rotate the ZERO Potentiometer fully CCW , then 15 turns CW to reach the midpoint

of the Potentiometer. 4. Rotate the SPAN Potentiometer fully CCW , then 15 turns CW to reach the midpoint

of the Potentiometer.5. The following initial adjustments to the ON TIME and OFF TIME Potentiometers should be

made to establish the proper pulsing sequence and duration for both electro-mechanical andsolid state contactors.a. Electro-mechanical contactor

1. Rotate ON TIME and OFF TIME Potentiometers fully CCW , then 15 turns CW to the midpoint of the Potentiometer.

2. Rotate both the ON TIME and OFF TIME Potentiometers the number of times indicated inthe Table 5.1 to obtain the desired operating time.

Table 5.1 – ON/OFF Potentiometer Turns for Desired Operating TimeOperationTime On Time Off Time<60 seconds 11 turns CW 30 turns CW60-120 seconds 13 turns CW 30 turns CW120 or > seconds 17 turns CW 25 turns CW

b. Solid state reversers1. Rotate ON TIME and OFF TIME Potentiometers fully CCW .2. Rotate ON TIME Potentiometer 6 turns CW .3. Rotate OFF TIME Potentiometer 8 turns CW .4. This will provide a .04 second ON pulse and a .5 second OFF pulse.

NOTE: a. Rotating the ON TIME Potentiometer CW will increase the ON time.b. Rotating the OFF TIME Potentiometer CW will increase the OFF time.c. Adjusting one control (ON or OFF TIME Potentiometer) will affect the

adjustment of the other control (ON or OFF Time Potentiometer).NOTE: a. Electro-mechanical Starters should not exceed 100 total starts per hour.

b. Solid State Reversers should not exceed 600 total starts per hour.




6 Calibration Procedure

a WARNING: Hazardous Voltage in Control Compartment. Exercise caution while calibratingthe Mod 20 II with the Actuator Control Compartment open and power ON.

The purpose of performing the calibration procedure is to achieve the maximum accuracyobtainable for each particular actuator application while providing stable operation. The actuatorgear ratio and many other factors determine the optimum calibration settings.

Four DIP Switches mounted on the Mod 20 II, as well as the ZERO, SPAN, GAIN, ON TIME,and OFF TIME potentiometers, are used to obtain the proper settings for your application. Thisprocedure will proceed from the most accurate settings to the least accurate settings until unitstability is achieved.

Figure 6.1 – Calibration Adjustments for the Modutronic 20 II

1. Turn all power to the actuator OFF.2. Verify that the procedures for the Initial Checkout & Setup (pages 4-1 through 4-4) and Mod

20 II Presets (page 5-1) have been properly completed.3. To simulate a command signal, connect the mA Calibrator to the Command Input Leads on

the Mod 20 II. These terminations are typically connected to the actuator Interconnect Boardor if the Mod 20 II is panel mounted, on the Rear Terminal Strip of the panel mount. In eithercase, these leads are labeled on your wiring diagram and will lead to connections 3 (P1-3[-])and 4 (P1-4[+]) on the Mod 20 II.

LIMITORQUE

CORPORATION

LYNCHBURG, VA USA

MODUTRONIC20

MODEL II

CLOSE

OPENCLOSE

SPANGAIN

POWER ON

INPUT ACTIVE

ON TI ME

OFF TIME

DIP Switch




Figure 6.2 – mA Calibrator Typically Connects (suggest Altek Model 334, www.altekcalibrators.com)to an Interconnect Board Terminal Strip or Terminal Strips Located in the Rear of aPanel-Mounted Mod 20 II

4. Set the Mod 20 II DIP Switch #3 to the ON position and DIP switch #s 1, 2, and 4 to the OFFposition. This will set the error margin (DEADBAND) to 1% accuracy.

Figure 6.3 – Modutronic 20 II Board Component Locations

16.00

INPUT OUTPUT

mA CALIBRATOR

OUTPUTmA

mA

24v

IN

OFF

OFF

POWERON

Interconnect Board

1 2 3 4 5 6 7 8 9 10 11 12

15 16 17 18 19 20 21 22 23 24

OR

0%

ADJUST

100%

FINECOARSE

Zero

Span

Gain

PowerOn

InputActiveLEDONTime

OFFTime

DIPSwitch

CLOSELED

OPENLED




Table 6.1 – DIP Switch Setting Levels of Deadband AccuracyDip Switch Number

Deadband Percentage 1 2 3 4± .5% Off Off Off On± 1% Off Off On Off± 1.5% Off Off On On± 2.5% Off On Off Off± 3.0% Off On Off On± 3.5% Off On On Off± 4.0% Off On On On± 6.0% On Off Off Off± 6.5% On Off Off On± 7.0% On Off On Off± 7.5% On Off On On± 8.5% On On Off Off± 9.0% On On Off Off± 9.5% On On On Off± 10.0% On On On On

a WARNING: Hazardous Voltage in Control Compartment. Exercise caution while calibratingthe Mod 20 II with the Actuator Control Compartment open and power ON.

5. Set the mA Calibrator for the minimum signal level (normally 4 mA). The INPUT ACTIVE LEDon the Mod 20 II should be illuminated. If not, reverse the polarity of the mA calibratorconnections.

6. If the Actuator is equipped with an AUTO/MANUAL or LOCAL/REMOTE selector switch, turnthe selector to the AUTO or REMOTE position.

7. Apply power to the Actuator and the Mod 20 II. The POWER ON LED on the Mod 20 II shouldbe illuminated.

8. The Actuator may run in either direction and then stop; a. If the unit stops, proceed to Step 9. b. If the unit hunts back and forth, decrease the DEADBAND accuracy by changing the DIP

Switch setting (refer to Table 6.1). Continue to Step 9.c. If the unit runs all the way to one end of travel and stops, the Potentiometer Leads are prob-

ably wired backwards; reverse the Feedback Potentiometer’s polarity by reversing the endleads at the Terminal Strip or on the Interconnect Board (if your application uses theCompact Integral Interconnect Board, the Plug-in Harness from the Pot to the InterconnectBoard can be rotated 180˚ to reverse the polarity).

9. Adjust the ZERO point. This step calibrates the minimum or zero set-point to correspond tothe end-of-travel of the Actuator and of the Feedback Potentiometer. Rotate the ZERO controlslowly in the CW direction. This will cause the Actuator to be driven slowly towards theminimum control position (normally CLOSED). Continue rotating the ZERO control CWuntil the minimum (CLOSED) Position Limit Switch trips and the motor stops. The CLOSELED should illuminate each time the Motor operates.




10. Adjust the control SPAN. This step calibrates the total SPAN of the control function and setsthe maximum setting to correspond to the end-of-travel of the Actuator and of the FeedbackPotentiometer.a. Set the mA Calibrator to the maximum command signal (normally 20 mA).b. The unit may:

1. Run toward the maximum position and stop short of the Position Limit Switch trippoint, or

2. Remain in position.c. Rotate the SPAN Potentiometer slowly CW . This will cause the Actuator to move

slowly toward the maximum (normally OPEN) position. Continue rotating the SPAN controlCW until the maximum (OPEN) Position Limit Switch trips and the motor stops. TheOPEN LED should illuminate each time the Motor operates.

11. After initially setting the ZERO and SPAN setting, use the mA Calibrator to set the CommandSignal back to the minimum setting (usually 4 mA); allow the actuator to run until it stops.Now fine-tune the ZERO setting for the position where the Limit Switch just trips.

12. Use the mA Calibrator to set the Command Signal back to the maximum setting (usually 20mA); allow the actuator to run until it stops. Now fine-tune the SPAN setting for the positionwhere the Limit Switch just trips.

NOTE: If hunting continues during calibration procedure, it may be necessary to temporarilydecrease the GAIN setting or increase the DEADBAND setting to get the ZERO and SPAN settingscalibrated.13. Adjust the ON TIME (optional). This step adjusts the period of time the Motor is energized in

the pulsing mode when it is approaching the final set-point position.NOTE: The ON TIME must be adjusted prior to adjusting the OFF TIME. Adjusting the ON TIMEafter adjusting the OFF TIME will require repeating the OFF TIME adjustment.

The duration of the ON TIME pulse to the Contactor/Solid State Reverser is increased byrotating the ON TIME Potentiometer CW .14. Adjust the OFF TIME (optional). This step adjusts the period of time the Motor is de-

energized in the pulsing mode when it is approaching the final set-point position. This canalso be described as the interval between ON TIME pulses. The duration of the OFF TIMEpulse to the Contactor/Solid State Reverser is increased by rotating the OFF TIMEPotentiometer CW .

15. Adjust the GAIN. This step calibrates the width of the pulsing window around the set-point.This control works in conjunction with the four DIP Switches located on the Mod 20 II circuitboard to determine the final accuracy of the unit in regard to set point position. The wider thepulsing window, the greater distance from the set-point the unit enters the pulsing mode. Itis desirable to minimize the pulsing window without causing the Actuator to hunt (oscillateuncontrollably around the set-point).a. For the initial calibration, ensure that DIP Switch 3 is ON and Dip Switches #s 1, 2, and 4

are OFF. This will provide 1% DEADBAND.NOTE: If no DIP Switch is set to the ON position, the actuator will not operate.b. Make sure the GAIN Pot is at the midpoint, then rotate the GAIN Potentiometer

one turn CW .




c. Start with the mA Calibrator at 4 mA, then make a 5 mA change in the output of the mACalibrator to provide a significant change of position; now watch the action of the actuator.1. If the actuator hunts upon reaching the new set-point, reduce the GAIN control by

turning in the CCW direction until the hunting stops and proceed to Step e.2. If the unit continues to hunt after the GAIN control adjustment, proceed to Step d.

d. Rotate the GAIN control fully CCW and then 15 turns CW ; adjust the DEAD-BAND to a less accurate setting and repeat the GAIN setting procedure starting withStep a. For example, if DIP Switch 3 is ON and DIP Switches 1, 2, and 4 are OFF theDEADBAND setting is at 1% accuracy; change the DIP Switch setting to 1-1/2% accuracy and repeat the procedures 13a through 13e until the correct DIP Switch andGAIN control eliminates actuator hunting. See Table 6.1 for DIP Switch setting levels of deadband accuracy.

e. Rotate the GAIN control an extra 1/2 turn CCW to eliminate the possibility of futureactuator hunting.

16. Set desired FAIL TO mode. See Figure 6.4. a. If LOCK-IN-LAST-POSITION is desired when loss of input signal occurs, install a jumper

at JP1 to connect Pin 1 and 2.b. If FAIL-TO-4mA-POSITION is desired when loss of input signal occurs, install a jumper

at JP1 to connect Pin 2 and 3.NOTE: Be sure to use one of the two jumper selections discussed above; FAIL-TO operation willbe forfeited if JP1 is not used.

Figure 6.4 – FAIL TO Mode JP1 Jumper

17. Your Mod 20 II should now be properly calibrated.

Lock-In-Last Fail-to-4 mA-PositionJP1

1 2 3JP1

1 2 3




7 Troubleshooting

Symptom Possible Cause Corrective ActionUnit will not operate 1. No power to unit 1a. Verify Power Supply iselectrically in AUTO or electrically correct and presentMANUAL at actuator.

1b. Verify Power Leads are connected in accordance with the applicable wiring diagram.1c. Inspect for Blown Fuse, tripped Circuit Breaker, or OPEN Disconnect Switch.

2. Wiring problems 2a. (LYs with internal Mod 20 II board) Check push-on terminal between the Integral PC Board and the Micro Switches. Check for bad Micro Switches on SW Station.

3. Starter Wires loose 3a. Check all the connections on the Reversing Starter.

4. Thermal overloads have 4a. Measure continuity in the tripped circuit. If you have an open

circuit, wait for the motor to cool, then try to operate actuator. You may need to reduce the number of starts per hour.

Unit will not operate 1. No power to Mod 20 II 1a. Verify incoming 18 VAC electrically in AUTO between terminals P1-1 and P1-2

on Mod 20 II board.

2. Bad Mod 20 II board 2a. Check board for burnt or broken components. Bypass Mod 20 II board using Pushbuttons to verify proper operation. See your specific wiring diagram for bypassing Mod 20 II board.

3. Command Signal Leads 3a. (L120 Interconnect PC Board) reversed Check that the Command Signal

Leads are wired to terminal TB16(+) and TB17(-).

continued on next page




(continued)Symptom Possible Cause Corrective ActionUnit will not operate 4. Bad Potentiometer 4a. Check the Potentiometer with an electrically in AUTO ohm meter electrically in AUTO.

Unplug the Pot from the Integral PC Board and take a meter reading between pins 7-1 and 7-2 or 7-2 and 7-3. The meter should have a steady reading. If the meter reading goes to zero or jumps around, verify that the Pot is centered. Replace the Pot if needed. Check for Cables that may have been pinched between the Housing Cover or Integral Assembly.

5. All DIP switches turned 5a. Check DIP switches. Refer to Off Calibration Procedure on page 6-4,

Step 15a.Units run in one 1. Shorted output 1a. Verify proper MANUAL directiondirection only operation. Using ammeter, verify

proper command signal, verify all calibrations have been completed properly. If you still have difficulty calibrating the Mod 20 II after verifying the above settings, replace the Mod 20 II.

No LOCK-IN-LAST 1. Missing JP1 Jumper 1a. Locate JP1 Jumper on the POSITION Mod 20 II board and verify

connections.Unit will not follow 1. Bad Potentiometer 1a. Check Pot as discussed in signal or Potentiometer is item #7. If Pot is OK, place the

not centered actuator at 50% and check the resistance between terminals 7-1 and 7-2 or 7-2 and 7-3 with an ohm meter. See “Adjusting the Actuator Feedback Potentiometer” procedure on page 4-3.

Input signal does not 1. Mod 20 II not 1a. See pages 6-1 through 6-5 resultresult in full travel of calibrated correctly to review the calibration the valve procedure for the Mod 20 II.

2. ZERO and SPAN 2a. Recalibrate according to adjustments incorrect procedure on pages 6-1 through 6-5.




(continued)Symptom Possible Cause Corrective ActionLarge input signal 1. Improper analog 1a. Check for proper Input Signalvariations result in little Input Signal value value.or no actuator 2. Limit Switch 2a. Check for proper setting. movement (See appropriate actuator manual

for setting the Limit Switches.)3. DEADBAND 3a. Check the DIP Switch adjustment accuracy adjustments shown in

Table 6.1.4. ZERO and SPAN 4a. Recalibrate according to adjustments procedure in Section 6.




8 Wiring Diagram

Please see page 8-2 for Modutronic 20 II Typical 3-Phase Wiring Diagram.




Figure 8.1 – Modutronic 20 II Typical 3-Phase Wiring Diagram

Drawing No. 17-500-0001-3

- Green indicating- Red indicating

- Opening coil- Closing coil

Motor

7

3(7) (7C)

(3) (3C)

R

G

(18) (18C)

(17) (17C)

(5) (5C)

(1) (1C)

(8) (8C)

8

1

Local Remote

O

CO

C

C

C

C

O

O

O

T1

T2

T3

L1

L2

L3

4

5(4) (4C)

Th.O l

By-pass cir.

Ind lightOpen limitBy-pass ci r

Ind lightClose limit

SpareSpareSpareSpareSpareSpareSpareSpare

FullyOpen

FullyClosed

Valve shown in full open position

SsOff

Spare

Spare

3. See certification sheet for voltage supplied. Transformer unused wired to be separately Covered with insulating heat shrink tubing.

JumpSee note#5

A B

Gnd

Cpt

18V115V 18V

Pb1Open

Pb2Stop

Pb3Close

Elec htr

Mtr htr

O

C

(Open)

4

2(Close)

3

(Common )

1

11

12

13

H2H1

6

5

Remote ind

Remote ind

21/22

10

19/20

A B C D E

4-20MaInputSignal

(+)

(-)

Blue

Yellow

Orange

1000Oh m

Pot

10

9

8765

4

3

12

Open

Close

CommonCwSweeperCcw

(+)

(-) Inpu

tSi

gnal

18V acPower

18

1

Yellow

Blue

Orange

17

18

LEGEND

2.1.

Close contactOpen contact

NOTESLimit switch contact development

Valve positionRotor

Open

Close

Int.1

Int.2

Function

1234567

910111213141516

Cont

act

Opening torque switch interrupts control circuit ifMechanical overload occurs during opening cycle

Closing torque switch interrupts control circuit ifMechanical overload occurs during closing cycle

18

17

YellowRed

BlueWhite

YellowWhite

Brown

YellowBlack

BlueBlack

P1

P1

BrownRed

Red

Red

White

BlueRed

P1

Purple

Black

Black

Blac

k

Red

Black

P2

Gray

Black

Yellow

Green/white Green/white

Green

230V500H1 and

To l1H2 and

To l2

480460415380

1ABEDE

AlternateTransformer types

600575550

--

32

Taps

Brown

Orange

Gray

Pink

Blue

L1f

L2f

Res

Res

BlackYellow

Green/white

Blue

Blue

Yellow

RedBrownBlack

Yellow/black

Blue/black

Mod

-20

mod

el II

Yellow

4. Rotors int.1 & Int.2 Can be set at valvePosition full open, full closed or anyPosition in between as indicated byPoints a and b.

5. Add jumper on ls#8 between terminals (8)& (8C) for torque seating valves

O-open contactC-close contact

Cpt-control power transformer+-Mechanical interlockTh.Ol-thermal overload contacts

Ss-selector switch (local-off-remote)Pb1-open pushbuttonPb2-stop pushbuttonPb3-close pushbuttonElec htr-compartmentMtr htr-motor heaterPot-potentiometerRes-lamp resistors

Red

Whi

te

Blue

Fuse

Fuse

Fus

Yello

w

Blue

8




Figure 8.1 – Modutronic 20 II Typical 3-Phase Wiring Diagram (continued)

Electrical compartment

18

17

Open

Close

(17C) (17)

(18C) (18)

TorqueSwitch

Th.O l

Motor

Limit switches

Mtr htr

T1

T2

T3P1

H1H2P2

Limit switches

Cpt

Pb3Close

Pb2Stop

Pb1Open

LocalOf f

Remote

Wht Blk

(Note#3 )

Blu

Yel

Brn

Org

Gry

Pnk

Blk/wht

Red/wht

Blk

P2Grn/wht

Blk

WhtH2

H1

Grn/wht

L1

L2

L3

Wht

Blk

Wht

Blk

Blu/blk

Yel/blk

Blu

Yel

Org

Brn

Feedback pot1000 Ohm

For signalConverter use

When supplied

Blu

Yel

Org

Primary

Secondary

Wht

RedBlk

BrnPur

Gry Pnk

Blu Yel

Org

Brn

RedBrn

Blk

Red Wht GrnWht

ElecHt r

BlueYellowPurpleBlackOrangeBrow nWhiteRedGreenPinkGrayColor/striped

Wire color legend

Motor ground lug

Grn/wht

1

L1

L2

Fuses

ChassisGround

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

Selector switch inRemote indication

For signalConverter use

When supplied

Incoming power ground

L3 incoming power

L2 incoming power

L1 incoming power

Spare

: Blu: Yel: Pur: Blk: Org: Brn: Wht: Red: Grn: Pnk: Gry

L1f

L2f Reversing starter

L2f

L1f

Close rotor Open rotor123

1

23

4

12

34

YelYel

Yel/blkBlu/blk

BlkBrnRedOr gYelBlu

123456789

10

4-20MaInputSignal

(-)

(+)

Spare

Spare

Spare

1

2

3

4

123

BlkBrnRed

BlkBrnRed

Yel

Red/whtBlk/wht

Blu

Blu

21

12

BluBlu1

2

18V

10Va

Yel

18V

10Va

115V

75Va

(1)

(1C)5

(5C)

(5)

(4)

(4C)(3)

(3C)(2)

(2C)

(8)8

(8C)

7(7C)(6)

6

(6C)

(12)12

(12C)(11)11

(11C)(10)10

(10C)(9)

9(9C)

(16)16

(16C)(15)15

(15C)(14)14

(14C)(13)13

(13C)

1

2

3

4

(7)

Yel/blk

Yel/red

Grn

Blk

Blu/red

Blue

Red

Blk

Yel/red

Yel

Int.2 Rotor Int.1 Rotor

Blu/blk

Blu/red

Yel/blk

Yel/red

Mod-20-

Model II

Fuse

RedWht

Blk

BluPurYel

PnkOrg

Brn

Gry

Grn

Lights

Buttons

Aux. Term.

Res

Res

Sw323 pushbutton station

Blu/wht

L3T3

L2T2

L1T1

Yel/wht

P1

L1T3

L2T2

L3T1

CO

Yel

Pur

Blu

Blu

Blk

Yel

Blk

Pur

R G

Red

Drawing No. 17-500-0001-3




9 Schematic

Please see page 9-2 for Modutronic 20 II Schematic Diagram.




Figure 9.1 – Modutronic 20 II Schematic Diagram

R1

CW

3.74K

-15Vdc

200K

47.5K

R4

C1

10K

R6

10K

R5U1A 1

R27.5K R7

20KC2

1.2/25SPAN

5K

R10+15Vdc

47/25

P1-7

1K

47/2

R1351K

FEEDBACKPOTENTIOMETER

1000 OHM

ZERO

C6

10/25

-15Vdc

+15Vdc

5KR11

150K

R12

LM7815BT-

U5LM7915BT-

.1/25

C111.2/

R16

R17

R18

2M 3.3

1/21%6%

R939K

1N4454 CR1

7.15KR20

2N440

30.1KR2

CR31N445

CR41N4454

-15Vdc7.15K

1N445Q22N4401

R2830.1K

1%

21

LM1558

10K

U2A

C13.022/25

2.2M CR51N445

5 U2

R2610K

7

LM15

R210K

R210K

CR1N44

OH

CW

GAINR295K

.22/25

.22/25

INPUTCIRCUIT

C12

+15V

C7

R155.1K

P1-2

P1-1CR171N40

1N40

C8200/

200/

HLMP47

+15Vdc

-15Vdc

CW

Controller

Deadband

Close Command

Open Command

-15Vdc

18 Vac

P1-6

P1-5

-15Vdc

(Page 9-3)

+15Vdc

AnalogInverter

Input Impedance (Zin)Zin (4mA) = 850�

Zin (8mA) = 550�

Zin (12mA) = 450�

Zin (16mA) = 400�

Zin (20mA) = 370�




Figure 9.1 – Modutronic 20 II Schematic Diagram (continued)

RESET

CONT V

4

TRIG

R38

R350K

C133/25

56

8

THOL

OU37

1DISC

+15Vdc

U7

9U6A1

4023

+15Vdc

R46

65

40231.5K

R52

JP1

3

12

U6C

13

11

40231.5K

+15Vdc

10K

10K

R50

1.5K

R49+15Vdc

4N2

U8

249.9 K1%

R59

To customer's 4-20ma signal

To input circuit (Page 9-2)

CR12

1N44

Jumper pins 1 to 2 for lock in last positionJumper pins 2 to 3 for fail to 4ma position

NOTE:

CLOSELED

+15Vdc

200,1K

COUPLERS:MAX I

MOC3010

OUTPU TTRIAC

Q4010L4

U11

U12

U9

U10

C1.01/

R3510K

5K

100,1K

R5

100,1K

R61200K

R60

C160.04

0.04

C2.01/

P1-3 P1-4

LED4

+15Vdc

P1-10

P1-8

(+)

7.1K

756

LM15510K

U1

470K

R39

CR11MBR03

R338.25K

+15Vdc

12

LM1558U3

8

+15Vdc

-15Vdc

CR13

1N445

CR1

1N44

20K

R4CR9

1N44 221K C14.22/25

756

LM1558

CR15

1N445

CR1

1N44

20K

R43CR1

1N44221K

R48

C15.22/2

150K

R42

7.5K

R44

-15Vdc

R447

10K

R4

Signal DetectorPulseControl

P1-9

Close Enable

Open Enable

Pulse, if error is withinproportional band

Open Command

Close Command

Off Time

On Time

ProportionalBand Detector

SignalStatus

Input Impedance (Zin)Zin (4mA) = 850�

Zin (8mA) = 550�

Zin (12mA) = 450�

Zin (16mA) = 400�

Zin (20mA) = 370�



Australian Distributor for Limitorque

Acrodyne Pty Ltd14/11 Havelock RoadBayswater, Victoria 3153AustraliaPhone 03-8727-7800Fax 03-9729-8699



limitorque...limitorque actuation systems vi modutronic 20 ii installation & maintenance manual...

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