80-1400-02 Rev. 06.
INTRODUCTION TO THE MANUAL This manual contains the information needed to install, operate, and maintain the Beck 14-100 & 14-200 linear electronic control drives, manufactured by Harold Beck & Sons, Inc. of Newtown, Pennsylvania. The Group 14 linear drive is a powerful control package designed to provide precise position control of globe valves and other devices requiring up to 4,000 lb of thrust. NOTICE: This manual includes information that will make installation simple, efficient, and trouble-free.
CONTENTS Product Description ...........................................................................................................................4 General Specifications .....................................................................................................................5 Outline Drawings ..............................................................................................................................6 Installation ..........................................................
PRODUCT DESCRIPTION Beck Group 14 linear control drives are engineered for precise, reliable operation of globe valves requiring up to 4,000 lbs of thrust. The cool, stable operation of Beck’s control motors coupled with the powerful gear train provide the tight, responsive control required by modern control loops to keep operating costs low.
GENERAL SPECIFICATIONS Input Power Max. Current and Power 120 V ac single phase 50 or 60 Hz; 48, 72 or 180 watts 240 V ac single phase 50 or 60 Hz Model 120 V ac 240 V ac 14-100 14-200 .56 A 72 W 1.5 A 180 W .33 A 80 W .86 A 210 W Operating Temperature Input Signal Electronic Signal Receiver (ESR-4) -40 to 85°C. (-40 to 185°F.
PRODUCT DESCRIPTION OUTLINE DRAWING -- 5/16” to 2 1/8” travel (ALL DIMENSIONS IN INCHES) MODEL 14-100 MODEL 14-200 NOTE: Drives may be mounted in any orientation.
OUTLINE DRAWING -- 3/4” to 4 1/2” travel (ALL DIMENSIONS IN INCHES) MODEL 14-100 MODEL 14-200 NOTE: Drives may be mounted in any orientation.
PRODUCT DESCRIPTION TABLE 2: SUMMARY OF GROUP 14 CONTROL OPTIONS 8
INSTALLATION SAFETY PRECAUTIONS WARNING Installation and service instructions for use by qualified personnel only. To avoid injury and electric shock do not perform any servicing other than contained in the operation instructions unless qualified. STORAGE INFORMATION The drive should be stored in its shipping carton in a clean, dry area. If it is necessary to store the drive outdoors for a long period of time, it should be removed from its shipping carton and stored above ground.
INSTALLATION MOUNTING THE DRIVE, CONT’D. INSTALLATION—ELECTRICAL 5. Place the jam nut (7) and travel index (6) over the valve stem (11) before mounting the drive on the valve. 6. Remove the boss nut (8) from the valve and place the drive and yoke over the stem and onto the boss (12). Secure the yoke with the boss nut, finger-tight. 7. Using the drive Handwheel, lower the drive output shaft to contact the valve stem. Thread the valve stem into the end of the drive output shaft.
INSTALLATION WIRING The Group 14 drive is available with six separate control configurations which are provided to match the control requirements for your system. Typical functional wiring connections for each control option are described in the following paragraphs and diagrams. The wiring diagram specific to each drive is attached to the inside of the wiring terminal cover.
INSTALLATION WIRING Option 8, Modulating without External Feedback Signal Analog Position Control with Contactless Position Sensing Customer must supply two wires to power the drive: One 120 V ac line (terminal C), and one neutral (terminal B). Customer must supply two wires for the modulating analog control signal: Connect to terminal AA (+) and to terminal BB(-).
Option 4, Multi-Position Direct AC Control with Cam-Operated Switches to Stop Drive Travel Customer must supply three wires to directly control the drive motor direction: One 120 V ac line for Retraction (terminal M), one 120 V ac line for Extension (terminal N), and one neutral (terminal B). Up to five intermediate stop positions may be specified, each requiring an additional 120 V ac line.
INSTALLATION WIRING CPS-2 Model 20-3400-03, -13 Current Feedback Terminal Connections The universal model has current sensing terminals, which allow for various current signal ranges. Current output is available between terminals DD (+) and CC (-) with the proper ranging resistor connected across terminals DD and EE. Units are factory-calibrated for specified signal ranges and are provided with proper resistors installed.
INSTALLATION WIRING OPTIONS INPUT SIGNAL OPTIONS Beck Group 14 drives configured for milliamp or dc analog modulating applications include an Electronic Signal Receiver (ESR-4). Several control options are available with the ESR-4, such as operating more than one drive with a single signal source. The instructions below apply to applications that require a signal change or to situations calling for operation of multiple drives from a common input signal.
INSTALLATION WIRING OPTIONS Split Range Operation Two or three Beck drives may be operated over their full range by a portion of the controller’s output signal range. The most common arrangement involves two drives operating on equal halves of the input signal range. For example, if a 4–20 mA control signal is used, the first drive would move 100% of its stroke on a signal range of 4–12 mA, while the second operates on the 12–20 mA portion of the signal.
INSTALLATION START-UP START-UP INSTRUCTIONS After the drive is mounted and its wiring connections are made, it is ready to be tested for proper operation. Turn on the power supply. Operate the drive with the Handswitch and run it through its full stroke, both directions. Observe that the driven device travels through its desired stroke. If satisfactory, set Handswitch at the “auto” position.
OPERATION HOUSING All models of the Beck Group 14 electronic control drive have individual, cast aluminum compartments for the main components: The control motor, wiring terminal board, drive train, electronic signal receiver, and feedback section. Gasketed covers and sealed shafts make this product ideally suited to outdoor and high-humidity environments. CONTROL MOTOR The Beck control motor is a synchronous inductor motor that operates at a constant speed of 72 RPM in synchronism with the line frequency.
CONTROL OPTIONS Two basic types of control are available: 120 V ac contact closure (options 3, 4, 5, and 6) and milliamp or dc analog modulating (options 7 and 8). Each option is described below. Figure 4 Tight-Seater™ HANDWHEEL Every Beck Group 14 linear drive is furnished with a Handwheel for operation of the valve without electrical power. Its solid construction design includes no spokes or projections, and turns at a safe, slow speed.
OPERATION INPUT: ESR-4, CONT’D. signal. The difference between these signals— the error—is amplified and used to actuate either of two electronic motor power switches. These switches drive the motor in the proper direction to force the error to zero. The input signal is adjustable from 50% to 400% of the 4 volt span, with the zero adjustable from -100 to +275% of span. The ESR-4 permits two or more Beck drives to be operated by a single signal source, for series, parallel, or split range operation.
POSITION FEEDBACK: FILM POTENTIOMETER The film potentiometer produces a voltage that is some fraction of the voltage applied across its resistive element. That voltage fraction is determined by the position of the wiper on the resistive element. The potentiometer assembly also includes two fixed resistors, one on each end of the resistive element. These resistors permit suppressed ranges as well as zero-based position feedback voltages.
CALIBRATION SWITCHES SWITCH ADJUSTMENTS All Group 14 control drives are shipped with end-of-travel limit switches and all auxiliary switches factory adjusted for 100% of travel unless otherwise specified at time of order. Limit switches must be set inside the range of the built-in mechanical stops to prevent stalling of the motor.
1. Remove the top cover (15/16" bolt head). The O-ring seal will remain in the rim of the top cover when removed. Open the terminal block cover (1/2" bolt head). 2. Use the electric Handswitch to drive the control shaft so that the EXT switch cam is accessible. Using a 7/64" hex wrench, loosen the screw so that the cam is just snug to the shaft. See Figure 5, page 22. 3.
CALIBRATION STROKE CHANGE STROKE CHANGE—CALIBAR Adjustment of the total drive stroke within the factory-set travel range is easily accomplished by the use of the Beck Calibar, Figure 7. The switches and feedback device are simultaneously adjusted to maintain full input span when the Calibar setting is changed. For stroke lengths longer than the factory-set travel limits, consult the factory. Adjust the drive stroke as follows: 1. Remove the top cover.
CALIBRATION CHANGING DIRECTION OF TRAVEL CHANGING DIRECTION OF TRAVEL 5. Replace the top cover. Tighten the cover bolt just enough to compress the O-ring seal. Retracting direction of travel is defined as the direction of output shaft motion produced by an increasing signal. Unless otherwise specified at the time of order, the output shaft is factory set to retract in response to an increasing signal to open the valve.
CALIBRATION FEEDBACK SIGNAL FEEDBACK SIGNAL CALIBRATION Feedback signal calibration is necessary to ensure that signal current or voltage correctly corresponds to the drive’s output shaft position. All Group 14 drives are shipped with the feedback calibrated for full retraction of the output shaft unless otherwise specified at time of order. The procedure to check and set feedback calibration varies by model number. The model number is listed on the drive name plate.
CPS-2 Calibration Model 14-_06 and 14-_08 These models are equipped with a Contactless Position Sensor (CPS-2) for position sensing and feedback. On model 14-_08, the CPS-2 also delivers a feedback signal to the Electronic Signal Receiver (ESR-4). Adjusting the remote feedback signal also automatically adjusts the ESR-4 signal. CPS-2 units are designed to provide position feedback without contacting or wiping surfaces.
CALIBRATION FEEDBACK SIGNAL CPS-2 CALIBRATION, CONT’D. ends. CCW movement of the Potentiometer decreases the span equally at both ends (see Figure 9, page 29, for location of Span Potentiometer). 8. Loosen the rotor clamp and reset its position (use the thickness gauge; see Figure 8, page 29) to achieve the desired value of maximum output signal. For example, 20 mA. NOTE: Rotor adjustment moves the entire span up or down.
Figure 8 CPS-2 POSITION SENSOR MODELS 20-3400-02, -04, -05, -12, -14, -15 CPS-2 MONITOR / ISOLATOR ASSEMBLY Figure 10 CPS-2 POSITION SENSOR MODELS 20-3400-03, -13 Figure 9 29
CALIBRATION INPUT SIGNAL INPUT SIGNAL CALIBRATION All Group 14 drives equipped for milliamp or dc analog modulating applications include a fourth generation Electronic Signal Receiver (ESR-4). The ESR-4 board consists of a voltage regulator, a signal amplifier, an error amplifier, and three solid state output switches. The ESR-4 board controls the position of the Beck drive according to the input signal it receives.
12. Repeat steps 10 and 11 until satisfied with adjustment. Reinstall the input signal wires, remove the test box (if used), close the compartment covers and tighten cover bolts to 10 lb-ft torque. Span The basic span adjustment of the ESR-4 is 2 volts to 6 volts dc. This is adjustable with the 20 turn span potentiometer. To make the span adjustable from 2 to 9.5 volts dc, remove resistor R4. To make the span adjustable from 9.5 to 16 volts dc, remove R4 and cut jumper wire J-1.
MAINTENANCE ROUTINE The Beck Group 14 drive requires only minimal routine maintenance. Periodic lubrication of the gearing is recommended to extend gear life. Periodic visual inspections are recommended to verify that the connection to the valve is intact and operating normally. If vibration is present, check the electrical terminal connections and other hardware for tightness.
MAINTENANCE COMPONENT REPLACEMENT This section covers replacement of many components of the Group 14 drive. Note that some components are not field repairable. If it should ever be necessary to replace the output gear, shaft, or output shaft bearings, a major overhaul is required and the drive should be returned to the factory. MOTOR GASKETS Before removing the motor assembly, while the process is running, block the valve stem to prevent the gear train from moving when the motor is removed.
MAINTENANCE COMPONENT REPLACEMENT LIMIT AND AUXILIARY SWITCHES Complete switch assemblies may be replaced. It is not possible to replace individual switches. To replace switch assemblies, remove the top cover (15/16” bolt head). Remove the #6-32 socket head cap screws holding the switch assembly to the plate. Transfer the wires one at a time to the replacement assembly using the push-on lugs provided.
Figure 13 Handswitch To replace the Handswitch, remove the terminal cover, ESR-4 board and ESR-4 bracket. Clip the five wires from the old Handswitch. Remove the knob and the nut under the knob to remove the switch. Install the new Handswitch as shown in Figure 13, above. Splice the wires color for color. Replace the ESR-4 bracket, board and the terminal cover. Torque bolts to 10 lb-ft. NOTE: The AUTO position on the Handswitch knob must be straight up when the switch is fully clockwise.
MAINTENANCE TROUBLESHOOTING If your unit contains a Stall Protection Module (SPM) refer to publication 80-0017-03, page 7, “Troubleshooting”. CONDITIONS 1. Control drive will not run in either direction with input signal applied to ESR-4 Board. No lamps lit on ESR-4 board. POSSIBLE CAUSES a. Handswitch left in wrong position. b. No 120 V ac line supply. c. Fuse F-1 open. d. External auto / man switch in wrong position (Position-AII). e. ESR-4 board failure. f.
CONDITIONS POSSIBLE CAUSES CORRECTIONS a. Check polarity of input signal. Terminal AA (+), terminal BB (-). b. See page 25 for changing direction of travel. 5. Control drive runs in the wrong direction with input signal applied. a. Input signal reversed. 6. Control drive does not follow input signal until maximum or minimum signal is reached, then drives uncontrollably to limit. a. Yellow and black wires on RET and EXT limit switches reversed or potentiometer end connections reversed. b.
MAINTENANCE TROUBLESHOOTING CONDITIONS 13. Loss of input signal feature does not function. POSSIBLE CAUSES a. CPS-2 equipped control drive used with ESR-4 board calibrated for slidewire. b. Incorrectly set potentiometer. c. CPS-2 calibration incorrect. 14. Control drive runs to RET limit with small change in input signal. a. Feedback potentiometer power supply shorted. b. ESR-4 circuit board failure of 2.7 V power supply (feedback potentiometer only). c.
CONDITIONS POSSIBLE CAUSES CORRECTIONS 19. Potentiometer or CPS-2 output decreases when it should increase. a. CPS-2 rotor position not set for proper rotation. b. End connections on potentiometer reversed. a. Reset CPS-2 rotor position. See page 35. b. See potentiometer calibration, page 26. 20. CPS-2 output nonlinear. a. CPS-2 rotor position not set properly. b. CPS-2 zero potentiometer misadjusted. a. Reset CPS-2 rotor position. See page 35. b. Refer to factory. 21.
APPENDIX SPARE PARTS RECOMMENDED SPARE PARTS HOW TO ORDER SPARE PARTS 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 Table 5, below. Select the needed spare parts from Table 5, below. Specify the drive’s model / serial number (example: 14-108-031891-01-02) given on the nameplate to allow the factory to verify the part selection.
APPENDIX COMPONENTS TABLE 6: MOTORS, CAPACITORS, AND RESISTORS TABLE 7: GEARS 41
APPENDIX CONTROL ASSEMBLY TABLE 8: PARTS FOR MODEL 14-100 CONTROL ASSEMBLY AND DRIVE TRAIN 42
CONTROL ASSEMBLY AND DRIVE TRAIN 43
APPENDIX CONTROL ASSEMBLY TABLE 9: PARTS FOR MODEL 14-200 CONTROL ASSEMBLY AND DRIVE TRAIN 44
CONTROL ASSEMBLY AND DRIVE TRAIN 45
APPENDIX CPS-2 DATA TABLE 10: CPS-2 SYSTEM APPLICATION DATA SUMMARY TABLE 11: CPS-2 SIGNAL OUTPUT TERMINAL CONNECTIONS AND LOADING 46
CPS-2 FUNCTIONAL BLOCK DIAGRAM 47
APPENDIX CONTROL DRIVE SCHEMATICS TYPICAL SCHEMATIC FOR CONTROL OPTION 7 OR 8 48
TYPICAL SCHEMATIC FOR CONTROL OPTION 7 OR 8 WITH STALL PROTECTION MODULE INSTALLED 49
NOTES 50
INDEX Adjusting the zero ...................................... 28, 31 Application reviews ........................... Back cover Applications, typical ........................................... 4 Calibar adjustment........................................... 24 CPS-2 calibration............................................. 27 CPS-2 functional block diagram ...................... 47 CPS-2 output terminal connections and loading .................................................... 46 CPS-2, replacement .....
SERVICES PRODUCT DEMONSTRATIONS SPECIFICATION WRITING 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 office, contact Beck’s Sales Department. Beck provides specification writing assistance in order to help you specify and order the right drives for your applications.
