SDI-No.: 111 6200 050 E Issue Date: 10/2001 Instructions to install Switches and Potentiometer with/without Position Feedback Assembly appropriate for: FA-33xx-741x (FA42/6000) General: This Service and Data Information (in brief SDI) comprises the prescribed instructions for safe installation and operation of the switches, feedback potentiometer and remote position feedback assembly. In the event of difficulties, which cannot be solved with the aid of this SDI, please consult the supplier. This SDI conforms to the relevant and valid EN-safety standards and the appropriate ordinances and control references of the EU. When operating the valve outside the Federal Republic of Germany, it is the responsibility of the operator or system administrator to ensure that valid national control standards are met. The manufacturer maintains all rights for technical changes and improvements at any time. Qualified personnel (see reference) are necessary to the application of this SDI. Operating personnel shall receive SDI instructions. Qualified personnel These are persons conversant with installation, mounting, commissioning, operation and servicing of the product, through their activities and functions, such as: Instructors with obligation to ensure adherence to regional and internal ordinances and requirements. Trainers and instructors on safety standards, maintenance and utilisation of adequate safety and protective operation facilities. Trainers in first aid, etc. (see TRB 700) Caution: Electrical wiring must be in conformance with directives for high-voltage installations; Line voltage and frequency must be identical with data on the product nameplate. Voltage supply line wiring: Voltage supply line fuse: Wires gauge min. 1mm 2 max. 6 A, 2 A at 24V, observe DIN VDE 116! Electrical isolation: Prior to the removal of the actuator cover, e.g. for mechanical maintenance and adjustment, line voltage supply must be disconnected by means of an isolation switch, safeguarded against inadvertent operation. Electrical connection: Select gland size of PG screw fitting, to DIN 46320, to match cable diameter. Lead cable through the PG cable connector to the respective terminals, and then remove insulation from wire tips. Inside the actuator, wires must be routed or fastened so that they are protected against damage by moving or rotating parts and removal or replacement of the actuator cover. Fasten ground wire to ground terminal. (Not applicable for 24V version ) Tighten PG connector gland nut to achieve a reliable strain relief. JCI Regelungstechnik GmbH Westendhof 3 D-45143 Essen Tel.: +49(0)201-2400-0 Fax: +49(0)201-2400-429 www.johnsoncontrols.com
2 E 111 6200 050 E Actuator mounting-and removal information: The control valve is normally supplied complete with actuator. It is not permitted to remove or replace an actuator on systems in operation, under operating temperature and pressure. For conversion or service, The actuator mounting procedure should follow the actuator SDI. During mounting procedure the plug should NOT be rotated with downward pressure. Ensure adherence to max. valve operating forces for actuator replacement. Commissioning: Prior to commissioning a new plant or re-commissioning of a plant after repairs or conversion, ensure that: All installation activities have been carried out correctly. Only qualified personnel carry out commissioning. Actuators are in the correct functional position. Existing protective facilities have been maintained. Mounting remote feedback assembly Drive valve stem to end position. Actuator power off. Remove actuator cover. Remove hexagonal recess head screws inside actuator cover (M4 x 8). Loosen position adjustment clamp (261) in slotted actuator lever and adjust to desired stroke. Fasten nut (278). Connect actuator lever (260) with positioning clamp (261) and lock washer (290) to valve linkage stem and fasten nuts (278) slightly. Fasten potentiometer base with 2 hexagonal recess head screws M4 x 10 supplied (275) and spring washers on actuator cover, and fit position adjustment clamp (261) in actuator lever into slot of potentiometer follower lever (259). Adjust actuator lever (260) connected to valve linkage stem by turning the two hexagonal nuts (287), until both actuator lever and potentiometer follower lever are positioned exactly parallel. Then tighten nuts and ensure that both levers are also parallel when viewed from above. Caution: When tightening the upper nut (287) hold the lower nut with a spanner to avoid torque force on valve linkage stem. Regulating range markings Bild 110
111 6200 050 E 3 E Fitting 2 travel limit switches with remote feedback assembly already installed in actuator Actuator power off. Remove cover. Remove nuts (276) from threaded stud (295). Remove washers (271). Remove insulation plate (267). Place switches S3 and then S4 onto threaded stud bolt with switch lever rollers pressed against the switch to avoid damage to switch levers. Observe switch lever centre of rotation. Always ensure that the switch cams (252) are operating the switches (282) from the direction of the switch lever fixation points. If necessary, the switch levers can be repositioned by opening the switches slightly. Place insulation plate (267) and washer (271) onto threaded stud bolt. Fasten switch block with nuts (276). Wiring of switches to existing terminals: From switch S3 Wire red to terminal 4 Wire green to terminal 5 Wire yellow to terminal 8 From switch S4 Wire red to terminal 7 Wire green to terminal 8 Wire yellow to terminal 9
4 E 111 6200 050 E Adjustment of travel limit switches Drive actuator in direction of desired switch point. Loosen knurled nut (273). Do NOT loosen counter nut (281). Hold potentiometer base gear wheel. Turn switch cam until the respective switch is actuated. (Check operation by measuring signal continuity between terminals 4 and 6 or terminals 7 and 9.) Fasten knurled nut, (273) holding potentiometer base gear wheel. Mounting of potentiometer when remote feedback assembly is already fitted Actuator power off. Remove actuator cover. Remove plastic gear (253) with lock rings (274) from potentiometer shaft. Remove hexagonal nut from potentiometer, leaving spacer ring (291) in place. Place potentiometer in opening of potentiometer base and fasten with hexagonal screw. Press plastic gear (253) with lock rings (274) onto potentiometer shaft and ensure accurate fit with gear wheel. Connect potentiometer wiring with existing terminals: Wire grey to terminal 10 Wire red to terminal 11 Wire yellow to terminal 12 Yell. Gray Red Seperation disk
111 6200 050 E 5 E Adjustment of feedback potentiometer Drive valve linkage stem from actuator to end position. Actuator lever (260) and potentiometer follower lever (259) must be in parallel position. Turn slotted potentiometer shaft with screwdriver left (counter clockwise) to stop, facilitated by slip between potentiometer shaft and plastic gear. Drive actuator through entire travel range. Ensure that the complete rotation of the potentiometer is claimed. If not, travel adjustment must be repeated. - If potentiometer rotation is exceeded increase travel stroke. - If potentiometer rotation is not fully claimed reduce travel stroke. Make adjustments only when stem is fully extended. Actuator lever (260) and potentiometer follower lever (259) must be in parallel position. When adjustment has been corrected, repeat check. With mounting, adjustment and checking procedure completed, replace actuator cover and fasten with sealing washer and cap-nut. Rights to make technical changes reserved JCI Regelungstechnik GmbH Westendhof 3 D-45143 Essen Tel.: +49(0)201-2400-0 Fax: +49(0)201-2400-429 www.johnsoncontrols.com