Instruction/ maintenance manual of the product 11-4_9 Beck, R&J
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1 ELECTRIC ACTUA TORS FOR INDUSTRIAL PROCESS CONTROL 80-1 103-00 Rev . 01.1 INSTR UCTION MANU AL 11-1_9 11-2_9 11-3_9 11-4_9 MODELS R.
2 INTR ODUCTION T O THE MANU AL This manual contains the information needed to install, operate and maintain Beck Model Group 1 1 Electronic Control Drives equipped with the Digital Control Module (DCM-2), manufactured by Harold Beck & Sons, Inc. of Newtown, Pennsylvania.
3 CONTENTS Product Description ............................................................................................................................. ...... 4 General Speci fi cations ...........................................................
4 PR ODUCT DESCRIPTION Beck control drives are engineered for precise, reliable operation of dampers, quarter-turn valves and fl uid drives. The cool, stable operation of Beck’s control motors coup.
5 TYPICAL APPLICA TIONS Beck control drives are ideally suited for use on ball, plug and butter fl y valves, as well as dampers and fl uid drives. When equipped with a sheave and multi-turn option (consult your Beck Sales Engineer for details), the drive can be used to raise and lower a weight-balanced damper .
6 PR ODUCT DESCRIPTION GENERAL SPECIFICA TIONS—ALL MODELS Drive Power 120 V ac single-phase 50 or 60 Hz Allowable T olerance +10% 240 V ac single-phase 50 or 60 Hz -15% Max. Current and Power Model 120 V ac 240 V ac 1 1-159, -169 .40 A 48 W .20 A 48 W 1 1-209, -269 .
7 GENERAL SPECIFICA TIONS—ALL MODELS (cont’d) Overtorque Protection If the output torque of the drive exceeds 150% (adjustable from 70% (Optional) to 150%) of the drive rating, the motor will shut off (feature can be enabled/disabled). Alarm Annunciation Available at terminal E.
8 OUTLINE DIMENSION DRAWINGS NOTE: All dimensions subject to change. MODEL 1 1-159 SPECIFICA TIONS Recommended Bolt T orques 6 8 10 4 2 0 1 0 8 6 4 2 0 51 / 4 " (133 mm) 67 / 8 " (175 mm) 4&.
9 MODEL 1 1-169 SPECIFICA TIONS Recommended Bolt T orques NOTE: All dimensions subject to change. BASIC CONTROL DRIVE TYPICAL V AL VE MOUNTING 71 / 2 " (191 mm) 1/2" N.
10 OUTLINE DIMENSION DRAWINGS NUT PLATE CLAMP PLATE CRANK PIN / STUD ROD END LOCK NUT CRANK PIN BOLT CRANK ARM BOLT (2) Crank Arm AUX.SWITCH RATING: 10A 240 Vac 1" N.P .T . CODUIT , POWER CONNECTION 6 7/32" (158 mm) 4 25/32" (121 mm) 1/2" N.
11 MODEL 1 1-269 SPECIFICA TIONS Torque Size (in.) (lb-ft) (N•m) Cover Bolts 5/16-18 10 14 Gear Module Bolts 5/16-18 10 14 Motor Bolts 1/4-20 6 8 Body Bolts 3/8-16 20 27 Body Bolts 1/2-13 50 68 Cont.
12 OUTLINE DIMENSION DRAWINGS MODEL 1 1-369 SPECIFICA TIONS Torque Size (in.) (lb-ft) (N•m) Cover Bolts 5/16-18 10 14 Gear Module Bolts 5/16-18 10 14 Motor Bolts 1/4-20 6 8 Body Bolts 3/8-16 20 27 B.
13 MODEL 1 1-409 SPECIFICA TIONS Recommended Bolt T orques 15 1/4" (387 mm) R L ROD END ADJUST ABLE RADIUS "R" 6" (152 mm) T O 12" (305 mm) CRANK ARM BOL T (4) WASHER (2) NUT PLA TE CRANK PIN BOLT (2) CRANK PIN ROD END LOCK NUT Torque Size (in.
14 OUTLINE DIMENSION DRAWINGS MODEL 1 1-469 SPECIFICA TIONS Recommended Bolt T orques NOTE: All dimensions subject to change. BASIC CONTROL DRIVE TYPICAL V AL VE MOUNTING Torque Size (in.
15 INST ALLA TION SAFETY PRECAUTIONS W ARNING Installation and service instructions are for use by quali fi ed personnel only . T o avoid injury and electric shock, do not perform any servicing other than that contained in this manual. ST ORAGE INFORMA TION The drive should be stored in its shipping carton in a clean, dry area.
16 INST ALLA TION INST ALLA TION—MECHANICAL Beck Group 1 1 drives may be installed in any convenient orientation, because the gearing does not require an oil bath. Refer to the outline dimension drawings on pages 8–14 for physical dimensions and required clearances.
17 INST ALLA TION SIGNAL WIRING Each Beck drive is custom built to match the control requirements of your system speci fi ed at the time of order . Each drive has a speci fi c wiring diagram attached to the inside of the wiring terminal cover . T ypical wiring connections are described below .
18 INST ALLA TION ST AR T -UP LINKAGE REQUIREMENTS (If Applicable) In most applications, the best control will result when the linkage is adjusted so that the full 100° angular travel of the Beck drive output shaft is used, even though the valve or damper may travel less than 100°.
19 ST ART -UP INSTRUCTIONS After the drive is mounted and its wiring connections are made, it is ready to be tested for proper operation. NOTE: All Beck drives are shipped from the factory ready for installation; no electrical adjustments are required before placing them in operation.
20 OPERA TION HOUSING Beck electronic control drives have individual cast aluminum compartments for each of the fi ve main components: The control motor , wiring terminal block, drive train, digital control module, and control end. Gasketed covers and sealed shafts make the drives ideally suited to outdoor and high humidity environments.
21 LOSS OF DEMAND INPUT SIGNAL (L.O.S.) When the Demand input signal drops to approximately –5%, the DCM-2 considers the Demand input signal to be invalid.
22 INPUT : DIGIT AL CONTROL MODULE (DCM-2) Beck modulating drives are equipped with a precision, digital control module (DCM-2) designed to receive conventional 4–20 mA or 1–5 V dc control signals directly—eliminating the need for contact protection devices, relays, switches and reversing starters.
23 DCM-2 L OCAL INTERF ACE Operation OVERVIEW The DCM-2 customer interface panel (pictured below) allows the user to easily calibrate the drive and troubleshoot conditions. The following information provides an overview of the DCM-2 customer interface panel features.
24 Pushbutton Controls The fi ve pushbuttons (pictured below) on the DCM-2 customer interface panel are used for calibration. When pressing a pushbutton, pressure should be maintained until the “ACKNOWLEDGE” LED lights; this con fi rms receipt of the pushbutton command.
25 All Beck drives are shipped completely calibrated to the customer ’s speci fi cations that were written into the equipment order and are ready to be installed. If the need arises to change the drive calibration, fi rst con fi rm that the drive is installed as speci fi ed and operating properly before proceeding with the change.
26 NOTE: Y our Beck drive was shipped from the factory ready for installation; no electrical adjustments are required before placing it in operation. Each drive is set up and calibrated to the speci fi cations that were written into the equipment order .
27 1. Remove the control end cover and terminal block cover (1/2" bolt heads). 2. Use the electric Handswitch to drive the control shaft so that the CW switch cam screw is accessible. Using a 7/64" hex wrench, loosen the screw so that the cam is just snug on the shaft (see illustration below).
28 DEMAND CALIBRA TION DCM-2 boards are designed to accept a 4–20 mA (or 1–5 V dc) analog demand signal. Narrower spans within this range can also be accommodated for split range operation (see page 29). The input comes calibrated from the factory for the full range unless otherwise speci fi ed by the customer .
29 Split Range Operation It is sometimes desirable or necessary to have more than one fi nal control element controlling a single process. Often, this type of control strategy requires that two to four Beck drives each respond to different portions of one 4–20 mA Demand signal from the control system.
30 POSITION CALIBRA TION In order to correctly position the drive output shaft in response to the Demand input signal, the DCM-2 receives a position signal from the drive’s position sensor and compares this actual position to the Demand input.
31 DIRECTION OF OUTPUT SHAFT ROT A TION (CW vs. CCW) Direction of output shaft rotation is determined by observing the end of the output shaft (see illustrations below). Direction of rotation is de fi ned as the direction of output shaft rotation produced by an increasing Demand signal.
32 START Is there a jumper from terminal A to terminal C? Does drive work with Handswitch? Does drive work properly CW? Does drive work properly CCW? Does output shaft move with Hand- switch in “STO.
33 Does Handwheel shudder about one position? Is the “TEMP °F” LED lit? Is the “STALL” LED lit? Is the “TEMP °F” LED still lit? Is binding or an obstruction present? Clear obstruction Move Handswitch to CW/CCW per direction drive does not move Check SLM for damage; rebuild or replace as necessary.
34 DCM-2 HART INTERF A CE Communication * THIS V ALUE CAN BE EDITED ** INDICA TES AN ACTION RA THER THAN THE VIEWING OR EDITING OF A P ARAMETER THIS IS THE MENU DISPLA YED BY THE HART COMMUNICA TOR A .
35 HANDHELD COMMUNICA TOR WIRING CONNECTIONS.
36 The DCM-2 board is the control center of the drive. Drive configuration and calibration are accessed and set through the DCM-2 board. Using the HART interface requires a HART ® compatible communicator .
37 MENU DESCRIPTIONS (See Figure 1, Page 34) Online Menu (Block 1) When communications are established with the communicator , the Online menu is displayed. This is the gateway to all the other menus and it also provides current information about the drive.
38 DCM-2 HART INTERF A CE Communication Con fi guration Menu (Block 3C) The Configuration menu serves as the gateway to all of the drive operating setup parameters. The user can select any of five different setup submenus that can be used to configure the drive based on the physical layout and the desired operation.
39 Demand Setup Submenu (Block 4D) This menu is where all the Demand input signal related drive parameters are set. The eight parameter entries are as follows: 1. DemRngLwr - The value of the Demand signal (in mA) that corresponds to 0%. Normally set to "4.
40 Statistics Menu (Block 3D) This menu is where all the drive’s stored operating statistics are available. There are eight different statistics available: 1.
41 Diagnostics Menu (Block 3F) This menu provides access to all the DCM-2 stored online diagnostic information about drive operation. The menu provides six submenus accessing drive statistics and online drive status.
42 DCM-2 HART INTERF A CE Communication 3. Identify Device - This command will cause the Acknowledge LED to blink for two seconds. Used to verify proper HART communications as well as an aid in identifying which drive is being addressed when con fi guring multiple drives for split range operation.
43 RealTimeClock Submenu (Block 4M) This menu allows the date and time to be set. The settings are as follows: 1. RTC Day - Numerical entry sets the day of the month. 2. RTC Month - Numerical entry sets the month. 3. RTC Y ear - Numerical (4 digit) entry sets the year .
44 DCM-2 HART INTERF A CE Con fi guration and Setup All drives are shipped completely con fi gured to the customer ’s speci fi cations and are ready to be installed.
45 W ARNING Carefully follow the on-screen warnings and messages when proceeding, because changing drive setup parameters can cause the drive to reposition.
46 DCM-2 HART INTERF A CE Con fi guration and Setup 0% and an over-travel limit switch is open. This eliminates the nuisance message, but does not eliminate the message for other scenarios like the Handswitch being in the STOP position.
47 Changing Characterization STEP 1 - From the HAR T ® communicator “Online” menu, move to the “Demand Setup” menu and select the “Dem Curve” parameter . This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key .
48 DCM-2 HART INTERF A CE Con fi guration and Setup W ARNING Carefully follow the on-screen warnings and messages when proceeding, because changing this parameter online could cause the drive to reposition. This can adversely affect the process and cause potentially dangerous conditions.
49 Enabling T orque Functions STEP 1 - From the HAR T ® communicator “Online” menu, move to the “T orque Setup” menu and select the “T rq/Thrust” parameter . This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key .
50 DCM-2 HART INTERF A CE Calibration All Beck drives are shipped completely calibrated to the customer speci fi cations, and are ready to be installed. If the need arises to change the drive calibration, confirm that the drive is installed as specified and operating properly before proceeding with the change.
51 DIRECTION OF SHAFT ROT A TION (CW VERSUS CCW) Direction of shaft rotation is determined when looking at the end of the output shaft (see fi gures below). Direction of rotation is de fi ned as the direction of output shaft rotation produced by an increasing demand signal.
52 NOTE: Y our Beck drive was shipped from the factory ready for installation; no electrical adjustments are required before placing it in operation. Each drive is set up and calibrated to the speci fi cations that were written into the equipment order .
53 1. Remove the control end cover and terminal block cover (1/2" bolt heads). 2. Use the electric Handswitch to drive the control shaft so that the CW switch cam screw is accessible. Using a 7/64" hex wrench, loosen the screw so that the cam is just snug on the shaft (see illustration below).
54 POSITION SENSOR SETUP In order to correctly position the drive output shaft in response to the input Demand signal, the DCM-2 board receives a position signal from the drive’s position sensor (CPS) and compares this actual position to the desired Demand input.
55 Short-stroke Operation (Reducing Full T ravel) T ypically , it is best to use the full 100% travel of the drive in response to the 0–100% Demand input signal. In certain applications, as a last resort, it may become necessary to reduce the full travel of the drive.
56 DCM-2 HART INTERF A CE Calibration - Feedback FEEDBACK SIGNAL CALIBRA TION DCM-2 boards have the capability of providing a 4–20 mA output signal so that the drive’ s true output shaft travel can be monitored remotely . The signal comes calibrated from the factory to provide a precise 4–20 mA signal corresponding to 0–100% drive travel.
57 DEMAND SIGNAL CALIBRA TION DCM-2 boards are designed to accept a 4–20 mA (or 1–5 V dc) analog Demand signal. Narrower spans within this range can also be accommodated for split range operation (see explanation following). The input comes calibrated from the factory for the full range unless otherwise speci fi ed.
58 DCM-2 HART INTERF A CE Calibration - T orque Measurement TORQUE MEASUREMENT CALIBRA TION DCM-2 boards have the capability of measuring the drive output torque and providing several torque-related features. The torque measurement is calibrated to the drive’s rated output at the factory .
59 DCM-2 HART INTERF A CE Maintenance - Alarm Messages COMMON HART ® MESSAGES HART ® protocol maintains both standard and device speci fi c informational messages that are displayed on the 275/375 Handheld Communicator when various conditions occur .
60 DCM-2 HART INTERF A CE Maintenance - Alarm Messages Message Description “The T orque/Thrust is greater than the output rating” “Motor power has been removed due to excessive output torque” .
61 “Analog output 1 and its digital representation are outside the operating range limits, and not responding to input” “The Position Signal is less than –5% or greater than 105%” “Positio.
62 DCM-2 HART INTERF A CE Maintenance - Troubleshooting CHECK DRIVE R / C NETWORK PER TABLE 5, PG. 79 CHECK SLM FOR WEAR FROM PAGE 65 GO TO PAGE 63 GO TO PAGE 63 DOES DRIVE WORK PROPERLY WITH THE HAND.
63 CONNECT WIRE CORRECTLY CONNECT WIRE CORRECTLY REPLACE FUSE REPLACE DCM BOARD WITH POWER ON, IS THE AC VOLTAGE ACROSS DCM-H FUSE “F1” ABOUT 0 V (SEE FIG., PG.78)? ARE JUMPERS INSTALLED FROM FT ON&DT OM ? ARE EITHER OF THESE LEDs LIT? GO TO CHART 2, PG.
64 DCM-2 HART INTERF A CE Maintenance - Troubleshooting ELECTRONICS DIAGNOSTICS -- CHART 2 WILL BOARD COMMUNICATE? IS POWER (”PWR”) LED LIT? WILL DCM BOARD COMMUNICATE? HAS ERROR BEEN ELIMINATED? .
65 HAS ERROR BEEN ELMINATED? IS “BAD POS SIG” PARAMETER “ON”? HAS ERROR BEEN ELIMINATED? REVIEW THE MESSAGES PRESS NEXT USING THE NEXT KEY PAGE THROUGH ADDITIONAL MESSAGES GO TO THE “DETAILE.
66 COMMUNICA TIONS The Beck Digital Control Module (DCM-2) is equipped with a serial interface which allows for direct communication with a computer . Using a communication cable, connect the DCM-2 to the computer using the DCM-2’s RS-232 (J20) connector (see illustration on this page) and the computer ’s COM port.
67 DCM-2 SERIAL INTERF ACE Commands COMMANDS AND ARGUMENTS Commands can be used for a variety of functions including changing the operating con fi guration of the drive, verifying operation settings, calibration and accessing diagnostic information. There are essentially four different types of commands: 1 .
68 DCM-2 SERIAL INTERF ACE Commands SERIAL COMMANDS General Con fi guration Commands (p. 69) stepsize drvdir stalltime sernum Reset Factory Settings Commands (p. 69) restoremodes harttype Demand Signal Commands (p. 69 & 70) dem0pctma dem100pctma trimdem4ma trimdem20ma demfunc demlos demlosgtp Position & Feedback Signal Commands (p.
69 Note: For speci fi c information on the following functions, see the HART interface section of the manual. Command stepsize n drvdir n stalltime n sernum n Description Sets and/or displays the size (in degrees) of one incremental movement of the output shaft.
70 DCM-2 SERIAL INTERF ACE Commands Note: For speci fi c information on the following functions, see the HART interface section of the manual. Command dem100pctma n trimdem4ma 4 trimdem20ma 20 demfunc n demlos n demlosgtp n Description Sets the Demand signal value that corresponds to 100% drive position.
71 Command travel n fdbk0pctma n fdbk100pctma n fdbkfunc n posis n trimfdbk4ma n trimfdbk20ma n Description Sets and/or displays the value that represents 100% travel. Sets and/or displays the mA value of the Feedback signal that represents the 0% drive position.
72 DCM-2 SERIAL INTERF ACE Commands Note: For speci fi c information on the following functions, see the HART interface section of the manual. Command torqconst n torqenable n Description Assigns the count value to be associated with the torque span.
73 DCM-2 SERIAL INTERF ACE Command Error Codes Code 2 3 4 5 6 9 10 14 32 64 Description Invalid selection V alue too big V alue too small Data length error General error Process too high Process too low Span too small Busy Not implemented Information Displayed when an unknown command has been entered.
74 Beck drives require only a minimum of routine maintenance. A visual inspection is in order to verify that the connection to the fi nal control element is intact and operating normally . If vibration is present, check the electrical terminal connections and other hardware for tightness.
75 This section covers replacement of many components of the drive. Note that some components are not fi eld-repairable. Refer to the drive outline dimension drawings on pages 8–14 and to the cutaway illustration on page 4 for location of components on the drive.
76 OVER-TRA VEL LIMIT AND AUXILIAR Y SWITCHES Complete switch assemblies may be replaced. It is not possible to replace individual switches. T o replace switch assemblies, remove the control end cover (1/2" bolt heads) and extensions, if applicable.
77 HANDSWITCH T o replace the Handswitch, remove the terminal cover , and then remove the terminal plate (1 1-209/-269, -309/-369, and -409/-469 only). Clip the fi ve wires from the old Handswitch. Remove the knob and the nut under the knob to remove the switch.
78 T o remove the CPS-2 : 1. Run the control drive to its midpoint of travel with the local Handswitch. (If the standard rotation of 100° has been reduced to 80°, the midpoint of travel is 40°.) 2 . Disconnect 120 V ac power to the drive. Remove the terminal, DCM-2 compartment and control end covers (1/2" bolt heads).
79 RECOMMENDED SP ARE P ARTS It is recommended that certain replacement parts be stocked for quick availability in the event that service of your Beck control drive is required. The types of parts are listed in T able 4, below . HOW TO ORDER SP ARE P ARTS Select the needed parts from the spare parts list given below .
80 T ABLE 6: DRIVE COMPONENTS FOR MODEL 1 1-159 / -169 ITEM ITEM NO. DESCRIPTION NO. DESCRIPTION 1 Body rear 11 Terminal / DCM compartment cover 2 Body front 12 Gasket, body 3 Output shaft assembly an.
81 T ABLE 7: DRIVE COMPONENTS FOR MODEL 1 1-209 / -269 / -309 / -369 ITEM ITEM NO. DESCRIPTION NO. DESCRIPTION 1 Body rear 13 Terminal / DCM compartment cover 2 Body front 14 Gasket, body 3 Output sha.
82 T ABLE 8: DRIVE COMPONENTS FOR MODEL 1 1-409 / -469 ITEM ITEM NO. DESCRIPTION NO. DESCRIPTION 1 Body rear 12 Handwheel 2 Body front 13 Gasket, control motor 3 Output shaft assembly and main gear 14.
83 T ABLE 9: GEARS, TORQUE AND TIMING OPTIONS Models Models Motor -159 & -_09 -_69 Drive Maximum Current @ Gear Timing Timing Model Approx. Overhung Motor Part 120 V ac, Module (sec/100°) @ (sec/90°) @ Number Weight Load Number 60 Hz* Number Torque 60 Hz** 60 Hz** 11-159 50 lbs 750 lbs (340 kgs) 20-2700-20 .
84 NO TES.
85.
86 Application reviews .......................................... 87 Beck linkage kits .......................................... 5, 18 Components .............................................. 80–82 Component replacement ...........................
87 SER VICES PRODUCT DEMONSTRA TIONS Each of Beck’s Sales Engineers has access to a complete set of drive models so that he can demonstrate virtually any of their features at your location. In order to arrange to see a Beck drive in your plant or of fi ce, contact Beck’s Sales Department.
88 12/06 1 1 TERR Y DRIVE NEWTOWN, PENNSYL V ANIA 18940 USA PHONE: 215-968-4600 F AX: 215-860-6383 www .haroldbeck.com HAROLD BECK & SONS, INC. R Ser ving the Process Industries since 1936 .
An important point after buying a device Beck, R&J 11-4_9 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Beck, R&J 11-4_9 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Beck, R&J 11-4_9 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Beck, R&J 11-4_9 you will learn all the available features of the product, as well as information on its operation. The information that you get Beck, R&J 11-4_9 will certainly help you make a decision on the purchase.
If you already are a holder of Beck, R&J 11-4_9, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Beck, R&J 11-4_9.
However, one of the most important roles played by the user manual is to help in solving problems with Beck, R&J 11-4_9. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Beck, R&J 11-4_9 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
