Direct Coupled Actuators ENGINEERING GUIDE Actuator Selection Deciding what actuator will best fit your damper needs can seem like a difficult task. However, these quick steps will help you find the actuator you need quickly and effectively. Use the procedure detailed below to find the total torque requirements in pound-inches (lb-in.) and then proceed to the following pages for simple questions to help select the proper model to best suit your application. STANDARD ACTUATOR SIZING 1. 2. 3. Determine the Rated Torque Loading (lb-in. per sq ft): a. If the manufacturer-specified rated torque loading is known, enter that in Table 2. b. If the manufacturer-specified rated torque loading is unknown, use Table 1. Enter this value in Table 2. 2 Determine Damper Area (sq ft): π×r a. For round dampers, use the equation: -------------144 b. For rectangular dampers ( length × width ) use the equation: --------------------------------------144 NOTE: 144 sq in. = 1 sq ft 4. Enter the damper area value in Table 2. Table 1. Rated Torque Loading Determination. Rated Torque (lb-in. per sq ft) Parallel Blades Opposed Blades Round Air Velocity feet per minute With Without With Without Damper (fpm)a Seals Seals Seals Seals up to 1000 7 4 5 3 10 1000-2500 10.5 6 7.5 4.5 14 2500-3500 14 8 10 6 20 a Assumes x pressure differential of less than or equal to 2 in. w.c. For larger differentials, consult the damper manufacturer. / 144 = Table 2. Torque Requirements Calculation. Rated Torque Loading lb-in. per sq ft x Damper Area sq ft = NOTE: Honeywell recommends adding 20 percent safety factors Total Required Torque (lb-in.) ® U.S. Registered Trademark © 2004 Honeywell International Inc. All Rights Reserved x 1.20 = 63-2623 ACTUATOR SELECTION ASKING THE RIGHT QUESTIONS ABOUT YOUR ACTUATOR Table 3 provides questions to address before selecting your actuator. Table 3. Actuator Selection Checklist. 1. Is Fail Safe Required? Yes ! Spring Return 2. 3. No ! Non-spring Return What torque rating is needed for this application? (See Table 2.) ! 44 lb-in. ! 35 lb-in. ! 88 lb-in. ! 70 lb-in. ! 175 lb-in. ! 175 lb-in. ! 350 lb-in. ! 300 lb-in. What control signal is needed for this application? ! 24 Vac, 2 Position ! 24 Vac, 2 Position and Floating ! 24 Vac, 2 Position with Auxiliary Switches ! 24 Vac, Proportional ! 24 Vac, Floating and Proportional ! 24 Vac, 2 Position and Floating with Auxiliary Switches ! 24 Vac, Floating and Proportional with Auxiliary Switches ! 24 Vac, Proportional with Auxiliary Switches ! 24 Vac, Floating and Proportional with Auxiliary Switches and Adjustable Zero and Span ! 120 Vac, 2 Position ! 120 Vac, 2 Position with Auxiliary Switches Table 4. Fire and Smoke Actuator Selection Checklist. IMPORTANT — Always use a torque rating equal to or greater than the calculated need. — For Example: With a Total Required Torque (calculated from Table 2) of 158 lb-in., select an actuator rated for 175 lb-in. — Selecting a Fast-Acting Two-Position Actuator requires selecting a spring return direction (clockwise or counterclockwise). Fast-Acting Two-Position Actuators 1. Required torque rating (see Table 2). ! 30 lb-in. (3.4 N•m) ! 80 lb-in. (9 N•m) ! 175 lb-in. (20 N•m) 2. Required voltage ! 24 Vac 3. ! 120 Vac ! 230 Vac Required control signal for the application. ! Two-Position (NOTE: All Fast-Acting Two-Position Actuators are Two-Position) 4. Required actuator spring direction ! Clockwise Rotation ! Counterclockwise Rotation ! Rotation By Orientation 63-2623 2 ACTUATOR SELECTION FIRE AND SMOKE APPLICATIONS Table 5. Fire and Smoke Application Two-Position Actuators (Spring Return Fail-safe Mode). Torque Rating in lb-in. (N•m) 30 (3.4) 80 (9) Voltage (in Vac) 175 (20) 24 120 230 X X X X X X X X X X X X b ML4115D1006 b ML8115A1005 X b ML8115B1004 X b MS4209F1007 b MS4309F1005 b MS4709F1014 b MS4809F1012 b MS8209F1003 b MS8309F1001 — MS4120F1006 X X X X X X ML4115C1007 X X X ML4115B1008 b X X X b X X Model Number ML4115A1009 X X Internal Switches b X X X CW or CCWa X X X CCW X X X a Depends CW X X X Rotation to Open X X X MS4120F1204 X X — MS4620F1005 X X X MS4620F1203 X X X — MS8120F1002 X X X X MS8120F1200 on type of installation. External Auxiliary Switch Package. b 32003532-005 3 63-2623 ACTUATOR SELECTION ACTUATOR FEATURES Use Table 6 to determine what features best fit your actuator needs. For more information on actuators, see the Product Data or Specification Data literature for the corresponding actuator. Table 6. Actuator Features. X X X X X X Switches Adjustable Zero and Span Special Features Proportional Two Position 100-200 Vac 24 Vac X Floating Control Signal Voltage 300 lb-in. (34 N•m) 175 lb-in. (20 N•m) 88 lb-in. (10 N•m) 70 lb-in. (8 N•m) 44 lb-in. (5 N•m) Torque Rating 35 lb-in. (4 N•m) Spring Return Non-Spring Return Fail Safe Mode X X X X X X X X X X X X X X X X X X X X MS7505A2008 S05010 MS8110A1008 S1024-2POS X MS8110A1206 S1024-2POS-SW2 MS4110A1002 S10120-2POS X X X X X X X X X X X X X X X X Catalog Number MS4105A1002 S05120-2POS X X Model Number MS8105A1008 S0524-2POS MS4110A1200 S10120-2POS-SW2 MS7510A2008 S10010 X MS7510A2206 S10010-SW2 X X X X X X X X X X X X X X X X X X X X X MS7520A2205 S20010-SW2 X X X X X X MS7520H2208 S20010-SER-SW2 X X X X X X X X X X X X X MS7510H2209 S10010-SER-SW2 X MS8120A1007 S2024-2POS X X X X X X X X X ML6161B2024 ML6161B2024 ML6174B2019 ML6174B2019 X X X X X X X X X X MN6120A1002 N2024 X X X X X X X X X X X X 63-2623 X ML7174A2001 ML7174A2201 X X X ML7161A2008 ML7161A2008 X X MS4120A1209 S20120-2POS-SW2 MS7520A2007 S20010 X X MS8120A1205 S2024-2POS-SW2 MS4120A1001 S20120-2POS X MN6120A1200 N2024-SW2 MN7220A2007 N20010 X MN7220A2205 N20010-SW2 MN6134A1003 N3424 X 4 MN7234A2008 N344010 CRANK ARM LINKAGES Crank Arm Linkages APPLICATION EXTERNAL VS. INTERNAL MOUNTING Some installations physically prohibit direct coupling the actuator to the damper shaft. Direct-coupled mounting is preferable. Remote mounting of Honeywell Direct Coupled Actuators (DCA) can be done using a damper linkage. Installation can require the actuator mounting to be either external or internal to the damper frame. In most cases, this corresponds to external or internal to the ductwork. This section discusses damper linkage installations, how to install a damper linkage and explanations of special applications, including: • Modification of damper linkages to achieve faster response times at the damper. • Modification of damper linkages so that the angle of rotation can be limited. Damper Crankarms External External mounting requires fitting the damper shaft with a crankarm and a ball joint. One crankarm is Honeywell’s part number 26026G. Installation examples that can prohibit direct-coupled mounting: • Dampers installed in a wall section. • Dampers installed inside a roof-top unit with no room left outside the damper frame. • Replacing foot-mounted motor(s). • Dampers without provision for external damper shaft. Fig. 1. 26026G Crankarm. DAMPER LINKAGE A basic damper linkage includes a damper shaft crankarm, an actuator crankarm, a pushrod, and ball joints. In addition, a DCA can require a remote mounting kit such as Honeywell’s part number 50001194-001. This kit allows the actuator to be mounted to either the duct or the damper frame. IMPORTANT — The actuator crankarm must be able to complete its full stroke unobstructed. — The actuator travel limits must correspond to the damper full open or full closed position. — Short pushrods can be difficult to adjust. — Lengthy pushrods often lack rigidity, resulting in poor damper response. 5 Internal Internal mounting requires fitting the damper blade with a damper blade lever. It is typical to order the damper with a factory-installed blade lever. If the damper is not already fitted with a blade lever, use Honeywell part number 32007205-002 (for dampers less than 24 in. high) or 32007205-003 (for dampers greater than 24 in. high). See Fig. 2. 63-2623 CRANK ARM LINKAGES 32007205-003 shown 32007205-002 shown M20861 M20860 Fig. 2. Damper blade levers. Actuator Crankarms Depending upon the installation, the actuator crankarm might be part of a remote mounting kit, such as the 50001194-001. It can also be an independent part, such as the 205830A. In either case, fit the actuator with a crankarm and balljoint. Fig. 3. 27518 Balljoint. Ball Joints Pushrods Each crankarm requires a balljoint to facilitate connection between the damper and actuator. Honeywell part number 27518 is sized for 5/16 in. diameter pushrods and 103598 is sized for 1/4 in. diameter pushrods. Connecting the damper shaft crankarm and the actuator crankarm requires a pushrod. The pushrod connects to the balljoint of each crankarm. Pushrods, such as Honeywell part number 25720, can be ordered in various lengths or cut to length by the installer. 25720 is a 5/16 in. diameter rod. Table 7. Suggested Parts List Mounting Type External Internal Damper Crankarm 26026G 32007205-002 or -003 Ball Joints 27518 (5/16 in. diameter) 27518 (5/16 in. diameter) Pushrod 25720x (5/16 in. diameter) 25720x (5/16 in. diameter) Actuator Crankarm 50001194-001 Foot/Frame Mounting Kit, or see actuator accessories for appropriate crankarm 63-2623 6 50001194-001 Foot/Frame Mounting Kit, or see actuator accessories for appropriate crankarm CRANK ARM LINKAGES TYPICAL INSTALLATIONS The basic damper linkage installation addresses the need for damper remote operation through a 90 degree stroke using a DCA with a 90 degree stroke (nominal). DUCT B B A C C A DAMPER REMOTE MOUNTED ACTUATOR M22568 Fig. 4. Externally mounted actuator and linkage to a damper. DUCT A B B A DAMPER REMOTE MOUNTED ACTUATOR M22569 Fig. 5. Internally mounted actuator and linkage to a damper. 7 63-2623 CRANK ARM LINKAGES Standard Applications (90° actuator travel and 90° damper travel) NOTE: The crankarms will be parallel to each other. In order to achieve the same 90° of travel, special care should be taken in deciding the position of the two crankarms: 1. Position the damper blade at mid-position. See Fig. 6. 2. Position the actuator at mid-position (see Fig. 7): a. Non-spring return: Declutch the DCA. b. Spring return: Manually wind the DCA. 3. With the actuator mounted in place, create an imaginary line which connects the center of the damper crankarm and the center of the actuator crankarm. (See Fig. 8.) 4. Position each crankarm perpendicular to the imaginary line. (See Fig. 9.) 5. 6. Install a balljoint (finger-tight) on each crankarm. Adjust the balljoints so that they are equidistant from the corresponding crankarm centers. (See Fig. 10.) Install pushrod and tighten retaining screws. Ensure tight damper closure by exercising the assembly through the entire travel: a. If damper closure is not tight, adjust the actuator crankarm balljoint to lengthen the effective length. b. If damper closes early, adjust the actuator crankarm balljoint to shorten the effective length. Tighten all balljoints. 7. 8. 9. IMAGINARY LINE CONNECTING CENTERS OF CRANKARMS M22572 Fig. 8. Line connecting crankarm centers. M22570 Fig. 6. Damper blade at mid-position. 90° IMAGINARY LINE CONNECTING CENTERS OF CRANKARMS 90° M22573 Fig. 9. Crankarm perpendicular positioning. La = L d Ld La M22571 IMAGINARY LINE CONNECTING CENTERS OF CRANKARMS Fig. 7. Actuator at mid-position. M22574 Fig. 10. Balljoint adjustment. 63-2623 8 CRANK ARM LINKAGES Non-Standard Applications With crankarms parallel at mid-position the difference in effective crankarm lengths is inversely proportional to: — the difference in full rotation angles. — the difference in timing. Faster Response Time Some applications require faster than normal actuator response time. It is possible to configure a linkage to cause faster damper travel than actuator stroke. EXAMPLE: La is twice the length of Ld. (See Fig. 11.) — Travel of the damper is half that of the actuator. — Control is more precise. Limited Damper Travel Some applications require limiting damper travel (to less than 90 degrees). It is possible to configure a linkage to cause less damper travel than actuator stroke. L a < Ld 1 NOTE: With some actuators, travel limitation can be achieved using mechanical travel limits. 2 PUSHROD Ld Non-Standard Application Setup Setup is the same for both faster response time and limited damper travel. To accomplish either, the effective crankarm length must be adjusted. As with all crankarm applications the two variables, crankarm angle and length are critical. NOTE: Faster damper timing setup limits DCA travel. 1. 2. Follow standard application steps 1 through 5. Adjust the crankarm effective lengths to achieve faster timing or limited travel. NOTES: — — Many variations are possible using this basic guideline. Experimentation is typically necessary to achieve the required travel/timing. La IMAGINARY LINE CONNECTING CENTERS OF CRANKARMS 1 ACTUATOR TRAVELS 90° IN 90 SECONDS. 2 DAMPER TRAVELS LESS THAN 90° IN 90 SECONDS, DEPENDING UPON THE LENGTH OF THE DAMPER CRANKARM RELATIVE TO THE LENGTH OF THE ACTUATOR CRANKARM. M22576 Fig. 12. Faster timing. (Shown with both actuator and damper at mid-position.) EXAMPLE: La is half the length of Ld. (See Fig. 12.) — Damper timing is half that of the actuator. La > Ld 1 PUSHROD 2 Ld La IMAGINARY LINE CONNECTING CENTERS OF CRANKARMS 1 ACTUATOR TRAVELS 90° IN 90 SECONDS. 2 DAMPER TRAVELS LESS THAN 90° IN 90 SECONDS, DEPENDING UPON THE LENGTH OF THE DAMPER CRANKARM RELATIVE TO THE LENGTH OF THE ACTUATOR CRANKARM. M22575 Fig. 11. Limited travel dynamics. (Shown with both actuator and damper at mid-position.) 9 63-2623 CRANK ARM LINKAGES NOTES 63-2623 10 CRANK ARM LINKAGES 11 63-2623 Automation and Control Solutions Honeywell International Inc. 1985 Douglas Drive North Golden Valley, MN 55422 63-2623 B.B. 11-04 Honeywell Limited-Honeywell Limitée 35 Dynamic Drive Scarborough, Ontario M1V 4Z9 www.honeywell.com