HercuLine® 2000 Series Motor Kits
Replacement Instructions
50011455-501, 50011455-502, & 50011455-503
Document Number
Form: 62-86-33-36
Effective: 5/06
Supersedes: 10/05
Summary
®
These kits contain the motor, resistor and cable, capacitor and hardware for your HercuLine 2000 Series Actuator. Kit
50011455-501 is for 120V, 60 Hz Actuator. Kit 50011455-502 is for 120V, 50Hz Actuator. Kit 50011455-503 is for
240V, 50/60Hz Actuator.
Tools Needed
To perform the installation procedure, you will need the following tools:
• #2 Phillips 6” long holding screwdriver
• 3/16” slotted holding screwdriver
• 4mm 6” long hex key
• 5mm hex key
Procedure
See Table 1 for HercuLine
See Table 2 for HercuLine
See Table 3 for HercuLine
See Table 4 for HercuLine
See Table 5 for HercuLine
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2000 Actuator 120V, 50/60Hz procedure.
Page 2
2000 Actuator 240V, 50/60Hz procedure.
Page 4
2001/2002 Actuator 120V, 50/60Hz procedure.
Page 6
2001/2002 Actuator 240V, 50/60Hz preferred procedure.
Page 8
2001/2002 Actuator 240V, 50/60Hz alternate procedure.
Page 10
WARNING
Disconnect power before accessing components inside the actuator.
ATTENTION
When working with circuit cards always protect against electrostatic discharge by wearing a grounded wrist strap.
5/06
Kit Number 62-86-33-36
1
Table 1 HercuLine 2000 Series Motor Installation Procedure
Model 2000
Kits 50011455-501 (120V, 60Hz) and 50011455-502 (120V, 50Hz)
Step
2
Action
1
Remove the top cover.
2
Remove the four screws holding the terminal board bracket. Move the bracket away from the
capacitor mounted on the bottom cover. Remove the two screws and the capacitor holdown
bracket. Disconnect the wires from the capacitor. Remove and discard the capacitor.
3
Disconnect the white wire from terminal 2 on the terminal board.
4
Remove the socket head cap screws holding the resistor-mounting bracket.
5
Remove the socket head cap screws holding the motor to the center housing.
6
Disconnect the two wires connected to the switches closest to the center housing. Pull the wires
through the cable clamp
7
Disconnect the motor connector from the cable connector, if connectors are present.
8
Remove and discard the motor and the resistor-mounting bracket.
9
Mount the resistor, supplied as part of new cable, to the new resistor-mounting bracket using the
two M3 x 5mm screws supplied.
10
Mount the new resistor bracket. Do not tighten the screw holding the cable clamp at this time.
11
Connect the yellow and red wires to the capacitor (insulated fastons)
12
Install the new capacitor (3uf, 60Hz) or (4uf, 50Hz) using the existing capacitor holdown bracket.
Turn the capacitor holdown bracket over with the bends facing up, place a slight bend in the
middle of the bracket and install.
13
Reinstall the terminal board bracket
Kit Number 62-86-33-36
5/06
Step
Action
14
Connect the white wire to terminal 2 on the terminal board.
15
Run the red (terminal 6) and black (Terminal 5) wires through the cable clamp and tighten the
screw holding the cable clamp.
16
Connect the red and black wires to the limit switches. The black wire is connected to the switch
closest to the switch mounting bracket.
BLACK
RED
17
Install the new motor using the new socket head cap M5 x 12mm screws supplied. Position the
motor with the motor leads and connector opposite the switch cams.
18
Connect the cable connector to the motor connector. Tuck the motor wires and the connector
down between motor and the center housing.
19
Install the new top cover gasket.
20
Reattach the top cover.
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Kit Number 62-86-33-36
3
Table 2 HercuLine 2000 Series Motor Installation Procedure
Model 2000
Kit 50011455-503 (240V, 50/60Hz)
Step
Action
1
Remove the top cover.
2
Disconnect the wires from the capacitor.
3
Disconnect the white wire from the terminal board.
4
Remove the socket head cap screws holding the resistor-mounting bracket.
5
Remove the socket head cap screws holding the motor to the center housing.
6
Disconnect the two wires connected to the switches closest to the center housing. Pull the wires
through the cable clamp
7
Disconnect the motor connector from the cable connector, if connectors are present.
8
Remove and discard the motor and the resistor-mounting bracket.
9
Mount the two resistors, supplied as part of new cable, to the new resistor-mounting bracket
using the four M3 x 5mm screws supplied. Mount with the red and black wires closest to the
bracket bend.
10
Mount the new resistor bracket. Do not tighten the screw holding the cable clamp at this time.
11
Connect the yellow and red wires to the capacitor (insulated fastons)
12
Run the red and black wires through the cable clamp and tighten the screw holding the cable
clamp.
13
Connect the red and black wires to the limit switches. The black wire is connected to the switch
closest to the switch mounting bracket.
BLACK
4
Kit Number 62-86-33-36
RED
5/06
Step
Action
14
Install the new motor using the new socket head cap M5 x 12mm screws supplied. Position the
motor with the motor leads and connector opposite the switch cams.
15
Connect the cable connector to the motor connector.
16
Install the new top cover gasket.
17
Reattach the top cover.
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Kit Number 62-86-33-36
5
Table 3 HercuLine 2000 Series Motor Installation Procedure
Model 2001/2002
Kits 50011455-501 (120V, 60Hz) and 50011455-502 (120V, 50Hz)
Step
6
Action
1
Remove the top cover.
2
Remove 10 point terminal board on CPU PWA.
3
Remove connectors on CPU PWA. 1 connector if no auto/manual switch. 2 connectors if there
is an auto/manual switch
4
Remove CPU PWA
5
Remove connectors on the Power Distribution PWA. There are 5 connector on the Power
Distribution PWA.
6
Remove the Power Distribution PWA
7
On the Backplane PWA, remove both card guides and the 2 additional mounting screws.
8
Move backplane PWA to expose the motor capacitor.
9
Remove the two screws and the capacitor holdown bracket.
capacitor. Remove and discard the capacitor.
10
Install the new capacitor (3uf, 60Hz) or (4uf, 50Hz) using the existing capacitor holdown bracket.
Turn the capacitor holdown bracket over with the bends facing up, place a slight bend in the
middle of the bracket and install.
11
Disconnect the white wire from the terminal board.
12
Remove the socket head cap screws holding the resistor mounting bracket.
13
Remove the socket head cap screws holding the motor to the center housing.
14
Remove and discard the motor and the resistor mounting bracket.
15
Mount the resistor, supplied as part of new cable, to the new resistor mounting bracket using the
two screws supplied.
16
Mount the new resistor bracket.
17
Connect the yellow and red wires to the capacitor (insulated fastons)
18
Reassemble the Backplane PWA, the Power Distribution PWA and the CPU PWA in reverse
order to disassembly.
Kit Number 62-86-33-36
Disconnect the wires from the
5/06
Step
Action
19
Connect the white wire to terminal 2 on the terminal board.
20
Run the red and black wires through the cable clamp and connect to the limit switches. The
black wire is connected to the switch closest to the switch mounting bracket.
BLACK
RED
21
Install the new motor using the new socket head cap screws supplied. Position the motor with
the motor leads and connector opposite the switch cams.
22
Connect the cable connector to the motor connector.
23
Install the new top cover gasket.
24
Reattach the top cover.
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Kit Number 62-86-33-36
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Table 4 HercuLine 2000 Series Motor Installation Procedure
Model 2001/2002
Kit 50011455-503 (240V, 50/60Hz)
Preferred Installation – Table 5 gives alternate installation
Step
8
Action
1
Remove the top cover.
2
Remove 10 point terminal board on CPU PWA.
3
Remove connectors on CPU PWA. 1 connector if no auto/manual switch. 2 connectors if there is an
auto/manual switch
4
Remove CPU PWA
5
Remove connectors on the Power Distribution PWA. There are 5 connectors on the Power Distribution
PWA.
6
Remove the Power Distribution PWA
7
On the Backplane PWA, remove both card guides and the 2 additional mounting screws.
8
Move backplane PWA to expose the motor capacitor.
9
Disconnect the wires from the capacitor.
10
Disconnect the white wire from the terminal board.
11
Remove the socket head cap screws holding the resistor mounting bracket.
12
Remove the socket head cap screws holding the motor to the center housing.
13
Remove and discard the motor and the resistor mounting bracket.
14
Mount the 2 resistors, supplied as part of new cable, to the new resistor mounting bracket using the four
screws supplied.
15
Mount the new resistor bracket.
16
Connect the yellow and red wires to the capacitor (insulated fastons)
Kit Number 62-86-33-36
5/06
Step
17
Action
Reassemble the Backplane PWA, the Power Distribution PWA and the CPU PWA in reverse order to
disassembly.
Power Distribution PWA
Make sure the position white connector is put back in the correct position.
18
Connect the white wire to terminal 2 on the terminal board.
19
Run the red and black wires through the cable clamp and connect to the limit switches. The black wire
is connected to the switch closest to the switch mounting bracket.
BLACK
RED
20
Install the new motor using the new socket head cap screws supplied. Position the motor with the motor
leads and connector opposite the switch cams.
21
Connect the cable connector to the motor connector.
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Kit Number 62-86-33-36
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Step
10
Action
22
Install the new top cover gasket.
23
Reattach the top cover.
Kit Number 62-86-33-36
5/06
Table 5 HercuLine 2000 Series Motor Installation Procedure
Model 2001/2002
Kit 50011455-503 (240V, 50/60Hz)
Alternate Procedure
Step
Action
1
Remove the top cover.
2
Disconnect the white wire from the terminal board.
3
Remove the socket head cap screws holding the resistor mounting bracket.
4
Remove the socket head cap screws holding the motor to the center housing.
5
Cut the two wires from the motor capacitor (red and yellow wires) as close to the connector as
practical. If actuator does not have a motor connector then cut the twisted pair of wires between
the motor and the printed circuit card guide as close the the crimps as practical.
6
Remove and discard the motor and the resistor mounting bracket.
7
Mount the 2 resistors, supplied as part of new cable, to the new resistor mounting bracket using
the four screws supplied.
8
Mount the new resistor bracket.
9
Cut the insulated fastons off the twisted pair of yellow and red wires. Connect the red wire to the
previously cut red wire with crimp supplied and connect the yellow wire to the other previously cut
wire with the crimp supplied.
10
Connect the white wire to terminal 2 on the terminal board.
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Step
12
Action
11
Run the red and black wires through the cable clamp and connect to the limit switches. The
black wire is connected to the switch closest to the switch mounting bracket.
12
Install the new motor using the new socket head cap screws supplied. Position the motor with
the motor leads and connector opposite the switch cams.
13
Connect the cable connector to the motor connector.
14
Install the new top cover gasket.
15
Reattach the top cover.
Kit Number 62-86-33-36
5/06