Asahi/America 94 Series User manual

ASAHI/AMERICA, INC 655 ANDOVER STREET LAWRENCE, MA. 01843 TELEPHONE [phone]
File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Series 94 Actuator For
A/C Modulating Service
Installation, Operation
and
Maintenance Manual

ASAHI/AMERICA, INC 655 ANDOVER STREET LAWRENCE, MA. 01843 TELEPHONE [phone]
File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Table of Contents
DHC-100 Introduction ...........................................................................................3
FEATURES .......................................................................................................3
Series 94 Electric Actuator Introduction ................................................................4
Description ........................................................................................................4
Electrical Requirement ......................................................................................4
Installation.............................................................................................................5
Electrical............................................................................................................5
Type 21 Ball Valve ............................................................................................6
Type 23 Ball Valve (3-way) ...............................................................................6
Type 56 Butterfly Valves ...................................................................................6
Actuator Mounting Dimensions..........................................................................7
Operation ..............................................................................................................8
Manual Override Operation ...............................................................................8
Setting Limit Switches .......................................................................................8
Calibration .........................................................................................................9
Outline Diagram.............................................................................................9
QuickCal Procedure ........................................................................................10
Aux Open/Close Option Setup.....................................................................11
Aux Position Option Setup...........................................................................11
Power / Signal (J2)...................................................................................12
Actuator (J1).............................................................................................12
Override (J7) ............................................................................................12
Mode ........................................................................................................13
Adjust up and Adjust down.......................................................................13
Override Mode .........................................................................................13
Auto..........................................................................................................14
Manual/FB Pot Cal ...................................................................................15
Close........................................................................................................15
Open ........................................................................................................15
Auxiliary Close Output..............................................................................16
Auxiliary Open Output ..............................................................................16
Command Type........................................................................................16
Loss of Command ....................................................................................17
Position Out Cal .......................................................................................17
Fault Indicators.........................................................................................18
Command Out of Range ..........................................................................19
Stall Detection Feature.............................................................................19
Electronic Brake Feature..........................................................................20
Duty Cycle Control ...................................................................................20
Option Modules ...............................................................................................21
Series 94 Options Codes for Serial # Tags..................................................22
Specifications ..................................................................................................22
DHC-100 Specs...........................................................................................22
Series 94 Specs...........................................................................................23

ASAHI/AMERICA, INC 655 ANDOVER STREET LAWRENCE, MA. 01843 TELEPHONE [phone]
File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Troubleshooting...............................................................................................24
Maintenance .......................................................................................................27
Spare Parts .....................................................................................................27
DHC-100 Introduction
The DHC-100 is a high performance digital positioner intended to control AC
actuators, providing 450 points of resolution with quarter turn actuators ranging
from 2 sec to 120 sec and rated for 25% duty or more. The DHC-100 has many
automatic advanced features that will enhance any actuator while making it easy
to install and set up.
The simple three button control is used to configure all parameters the unit needs
for a wide variety of applications, and allows the open and closed positions to be
easily set for direct or reversing acting without any rewiring. The unit can be
configured for various command types (4-20mA, 1-5V, 0-5V, 0-10V, or a digital
command) and its default operation upon loss of command.
Various option modules are easily plugged into the unit, providing other features
such as a position feedback signal (current or voltage), auxiliary switches, fault
relay contact, or digital communications. A wide range of data is accessible
through a digital communications module, providing additional control or
information.
The unit is of single solid construction and is easily mounted with two screws.
FEATURES
Positions to ±0.1with quarter-turn actuators ranging from 2 sec to 90 sec.
Three button control provides easy setup and eliminates the need for
instrumentation.
Polarity Detection feature allows direct or reverse acting operation without
re-wiring.
Electronic Brake feature can eliminate need for a mechanical brake in
many applications, and extends mechanical brake life when used.
Stall Detection feature protects actuator motor from a stall condition.
Automatic Duty Cycle Control feature prevents shutdown of a process
due to a thermal overload of the actuator motor, and allows actuators rated
for 25% duty or more to be safely used.
Operating temperature range of 0 to 60

ASAHI/AMERICA, INC 655 ANDOVER STREET LAWRENCE, MA. 01843 TELEPHONE [phone]
File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Series 94 Electric Actuator Introduction
Description
The Series 94 electric actuators feature a reversing,capacitor run motor, and a
permanently lubricated gear train. These actuators are equipped with integral
thermal overload protection (AC models) with automatic reset, independently
adjustable limit switches, declutchable manual override, visual position indication,
Zytel FR50 enclosure with stainless steel trim, ISO bolt circle, and 2 (two) ½”
NPT conduit entries.
Standard models are offered in 120 VAC, feature a Nema Type 4X enclosure,
and provide up to 300 in-lbs. of output torque.
The DHC-100 is easily mounted with 2 screws and is equipped with removable
screw terminals that provide for easy field wiring.
A simple three button control allows the user to perform a complete set-up from
the unit itself without the need for any instrumentation. The adaptive control
feature of the DHC-100 eliminates the need for any calibration steps. In the
simplest application, only the closed and open positions need to be set and the
unit automatically and continuously sets all other parameters when placed in the
AUTO mode.
CAUTION: These units are intended to be mounted in an appropriate enclosure
to avoid electrical shocks. High voltages are present on the outside of the unit
when power is applied. AC power should be disconnected prior to any wiring of
these units. A heater and thermostat should be used where condensation may
occur.
Electrical Requirement
CAUTION: Proper voltage must be supplied to actuator/positioner package or
the result could be a damaged positioner, a damaged actuator, or both.
NOTE: To conform to various electrical codes, a green grounding screw has
been installed (on the baseplate) inside of actuator.
The DHC-100 is rated for motors with up to 5A running currents and comes in
three versions to accommodate different voltage applications. The DHC-100 is
rated for 117 VAC 10%; the DHC-100A is rated for 234 VAC 10%, and the
DHC-100B is rated for 24 VAC 10%.

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File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Installation
Electrical
Reference Drawing #297QM
1. To gain access to terminal strip (Part #8 & 9) it is necessary to remove
manual override handle (Part #34) by loosening slotted setscrew (Part #35).
Remove 8 cover screws and cover.
2. Make electrical connections to terminal strip as shown on wiring schematic
located inside the cover (per various electrical codes there is a green screw
on the actuator base plate for grounding purposes). All units are completely
calibrated prior to shipment, and no internal adjustments should be required.
3. Install 1/2" NPT conduit fitting(s) to actuator base. Please ensure that proper
conduit fitting is used to maintain NEMA 4X enclosure rating.
NOTE: We recommend sealing conduit openings on units installed outdoors or
exposed to large temperature swings (15ºF or more).
We also recommend the heater and thermostat option in these applications.
4. Replace actuator (gasket if removed) cover, and install 8 cap screws supplied
and tighten securely. For outdoor or wet locations it is recommended prior to
replacing the cover that the top shaft seal be cleaned and coated with silicone
grease. Also clean shaft and lightly coat seal area of shaft with silicone
grease. Unit is now ready for operation.
120 Vac 220 Vac 12 Vdc 24 Vdc 24 Vac Cycle
Time per
90
Degrees
(Seconds)
Weight
(lbs)
Model Torque
(in/lbs)
Amp
Draw
Duty
Cycle
Amp
Draw
Duty
Cycle
Amp
Draw
Duty
Cycle
Amp
Draw
Duty
Cycle
Amp
Draw
Duty
Cycle
A94 150 0.5 100% 0.4 100% 2.0 75% 4.0 75% 4.0 75% 5 3.5
B94 300 0.8 75% 0.6 75% 2.0 75% 4.0 75% 4.0 75% 5 3.5
Note: Amp rating is considered locked rotor
Duty cycles are for ambient temperature (73º F)

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File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Type 21 Ball Valve
Position the valve and the actuator to corresponding positions (either OPEN or
CLOSED). The flats on the actuator shaft extension indicate valve position
Type 21 Ball Valves (See Drawing #0106BV sizes ½” – 2”)
Install mounting bracket #3 to actuator #2 using bolts #8 and washers #9. Insert
coupling #4 on stem of valve #1 and then bolt valve #1 to mounting bracket #3
using bolts #5, nuts #7, and washers #6.
Note: All bolts should be snug and not excessively over tightened.
Type 21 Ball Valves (See Drawing #0112BV sizes 2-1/2” - 3")
Install mounting bracket #3 to actuator #2 using bolts #8 and washers #9. Insert
coupling #4 on stem of valve #1 and then bolt valve #1 to mounting bracket #3
using bolts #5, nuts #7, and washers #6.
Note: All bolts should be snug and not excessively over tightened.
Type 23 Ball Valve (3-way)
Position the valve and the actuator to corresponding positions (either OPEN or
CLOSED). The flats on the actuator shaft extension indicate valve position
Type 23 Ball Valves (3-way): (See Drawing #0129BV, sizes ½” - 3”)
Install mounting bracket #3 to actuator #2 using bolts #8 and washers
#9. Insert coupling #4 on stem of valve #1 and then bolt valve #1 to
mounting bracket #3 using bolts #5, nuts #7, and washers #6.
Type 56 Butterfly Valves
CAUTION: If valve is in line, system must be shut down and have no line
pressure before removing throttle plate and retaining washer.
Position the valve and the actuator to corresponding positions (either OPEN or
CLOSED). The flats on the actuator shaft extension indicate valve position
Butterfly Valves (See Drawing # 0203BF sizes 1-1/2” - 4”)
No specially machined stem or valve body drilling required. Remove handle
(remove handle cap and hex head bolt) to expose throttle plate screws. Remove
throttle plate and retaining washer to expose existing bolt pattern.
Mount bracket #3 to actuator #2 with bolts #8 and washers #9 and tighten evenly.
Insert coupling #4 into actuator #2.Install valve #1 onto mounting bracket #3 and
align stem of valve to engage with coupling. (Line scribed on top of stem

ASAHI/AMERICA, INC 655 ANDOVER STREET LAWRENCE, MA. 01843 TELEPHONE [phone]
File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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indicates disc orientation). Install bolts #5, washers #6 and nuts #7 and tighten
evenly. Flats on actuator shaft indicate valve position. (Disc Orientation)
CAUTION: If mounted unit is installed other than straight up, the actuator should
be supported independently to prevent side loading and loosening up of
fasteners.
Actuator Mounting Dimensions

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File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Operation
Manual Override Operation
Reference Drawing #279QM
Push down on handle (Part #34) and rotate within labeled limits.
To re-engage simply rotate actuator handle in opposite direction until it moves up
and re-engages.
CAUTION: The manual override should only be used when there is no power
applied to actuator. When power is restored the actuator will automatically
resume normal operation.
Setting Limit Switches
Reference Drawing #279QM
Disconnect power!
Open Travel Limit Switch (SW-2 Part #14):
Using declutchable manual override, move the valve approximately 2 degrees
beyond the full open position. Then loosen set screws on top cam (Part #21) and
rotate cam (CCW) into limit switch arm until a click is heard, this designates the
switch circuit has opened and defines a full open position. Tighten 2 set screws
(Part #22) on cam.
Close Travel Limit Switch (SW-1 Part #14):
Using declutchable manual override, move the valve approximately 2 degrees
beyond the full closed position, loosen set screws on bottom cam (Part #21) and
rotate cam (CW) into limit switch arm until a click is heard, this designates the
switch circuit has opened and defines a full closed position. Tighten 2 set screws
(Part #22) on cam.
CAUTION: The limit switches inside of the unit are for loss of signal conditions;
NOT for normal operation of the modulating actuator.
Manually position valve to midstroke. Reapply power to actuator and drive to
open or closed position. Actuator motor will run. The shaft will not turn until
internal gearing re-aligns with drive gear. This could take up to 10 seconds.

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File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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Calibration
Outline Diagram

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File: assembly/manuals/Series 94 Gen II A/C Modulating Svc Manual Rev. A 11/19/19
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QuickCal Procedure
The following is a quick calibration procedure. For more details regarding the
calibration and features of your DHC-100, please see the pages following this
procedure.
General
The MODE button selects a particular function, or mode, and the indicator for the
selected mode turns on steady. Pushing the MODE button saves any new setting
of the current mode before switching to the next mode. The adjust up () and
adjust down () buttons are used to make adjustments to current mode.
1. Apply power to the actuator on Connector J2: terminal #1 (neutral), terminal
#2 (line), and terminal #3 (earth). There is no need for a signal connection during
calibration.
2. Push the MODE button until the yellow “MANUAL/FB POT CAL” LED is
illuminated. The LED may be flashing (at different speeds) through the next
several steps. This is expected and will be explained.
3. Use the adjust buttons (and ) to move the actuator and verify that the
limit switches are set past the desired open and closed positions; then move the
actuator to mid stroke.
4. If LED is solid, proceed to step 7.
5. If LED is flashing, loosen the gear on the actuator shaft and rotate the
potentiometer gear until the LED is no longer flashing, but on solid - this indicates
the center of the potentiometer’s travel. Note that the LED will flash at a slower
rate the farther away from the mid position it gets. Once the LED is on solid
tighten all gears.
6. Push the MODE button until the “CLOSE” LED is illuminated. Use the adjust
buttons (and ) to drive the actuator to the desired closed position. Ensure
that the close limit switch does not engage.
7. Push the MODE button until the “OPEN” LED is illuminated. Use the adjust
buttons (and ) to drive the actuator to the desired open position. Ensure that
the open limit switch does not engage.
8. Please skip to Aux Open/Close Setup if optional Transmitter with Relays is
installed; otherwise continue to the next step.
9. Push the MODE button until the “COMMAND TYPE” LED is illuminated. Use
the adjust buttons (and ) to select appropriate input signal (4-20mA, 1-
5VDC, 0-5VDC, 0-10VDC, 2-10VDC or Digital). If 0-5VDC or 0-10VDC is