Dresser RCS Sure 100 User manual

RCS Actuators
RCS Sure 100
Installation Manual
In the maintenance and operation of mechanical equipment, SAFETY
is the basic factor which must be considered at all times. Through
the use of the proper clothes, tools and methods of handling,
serious accidents causing injury to you or your fellow workers can be
prevented.
Throughout this manual are listed a number of safety precautions.
Study them carefully and follow them; also insist that those working
for you do the same. Remember, an accident is usually caused by
someone’s carelessness, neglect or oversight.
Safety First
CAUTION
To prevent the ignition of hazardous atmospheres,
do not remove actuator cover while circuits are live.
CAUTION
Loaded spring inside actuator. Do not attempt to
repair actuator below top gear plate, unless properly
trained on repair methods.
Installation
Note: SurePowr actuators can be supplied for clockwise or counter-clock-
wise spring driven rotation (viewed from the top of the actuator). The
spring drive rotation is noted on the actuator name tag and wiring
diagram. Ensure that the actuator has been supplied with the proper
spring drive operation for the application prior to installation on the
driven device.
1. The actuator is shipped in the power off (fail) position.
Ensure that the driven device is orientated to its fail position
prior to installation of the actuator.
2. Care should be taken to maintain proper alignment between
the actuator and the device shaft. If the actuator is not in the
correct alignment with the device shaft, repeat the
procedure in Step 1.
3. Mount the actuator to the device. Ensure the actuator is
centered properly with the device shaft, and then tighten all
bolts and nuts evenly.
4. Remove the cover bolts located around the actuator motor
and control cover flange.
5. Terminate field wiring per the appropriate RCS wiring
diagram, supplied with the actuator. Use a minimum of #18
AWG stranded wire.
Note: Ensure the driven device is properly positioned in its full fail position. If
it is not, use the adjustable end of travel stop on the Sure 100 (see figure 4) to
properly adjust the fail end of travel stop. Only the fail end of travel may be
adjusted. Loosen the lock nut to free the adjusting screw, then use a wrench
to turn the screw. The total adjustment available is +/- 5 degrees.
Figure 1
Switch adjustments for clockwise spring fail
operation (viewed from the top of the actuator)
a. Ensure actuator is de-energized and positioned in the clock
wise (fail) position. Ensure the end of travel stop is properly
adjusted. Loosen the jam nut, and then rotate the screw
clockwise to move the actuator output shaft in a
counter-clockwise direction. Rotate the screw
in a counter-clock wise direction to move the actuator
output shaft in a clockwise direction. Loosen the setscrews
on Cams 1 and 3. Rotate both counter-clockwise until they
clear the switch arm rollers of Switches 1 and 3.
b. Rotate Cam 1 clockwise until it comes in contact with Switch
1’s arm roller and the switch “breaks”. A light “click” can be
heard. Tighten the set-screws on Cam 1. Use care
to not over-tighten the set screws.
c. Rotate Cam 3 clockwise until it comes in contact with Switch
3’s arm roller and the switch just “breaks”. A light “click” can
be heard.
d. Rotate Cam 3 slightly further in the clockwise direction. This
ensures that Switch 3 will “break” just prior to the actuator
reaching the full fail position. Use care to not over-tighten
the set screws.Tighten the setscrews on Cam 3. Energize the
actuator. Use care to not over-tighten the set screws. This will
move the actuator to the opposite end of travel.
CAUTION
Closely monitor the electrical stroke, as the travel
limit switches are not yet properly adjusted. Ensure
the actuator does not over-travel and damage the
driven equipment.

e. Upon reaching the opposite end of travel, Cam
2 should just engage the roller on Switch 2 so that
the switch just “breaks”. This action will
stop the actuator. Check that the actuator has
properly positioned the driven equipment.
f. If actuator travel is insufficient, rotate Cam 2
slightly clockwise until the cam just clears the roller
of Switch 2. As soon as the cam clears the roller, the
actuator will “bump” electrically towards the end of
travel. Continue until the actuator reaches the full
end of travel.
g. If the actuator has over-traveled, rotate Cam 2
slightly counter-clockwise, then move the actuator
towards the fail position electrically. Stop and
electrically reverse the direction of travel. Move the
actuator until Cam 2 operates Switch 2 and the
actuator stops. Repeat this procedure until the
actuator is properly positioned.
h. Rotate Cam 4 until it comes in contact with Switch
4’s arm roller and the switch just “breaks”. A light
“click” can be heard. Rotate the cam slightly
counter-clockwise. This ensures that Switch 4 will
“break” just prior to the actuator reaching the
extreme opposite end of travel. Tighten the
setscrews on Cams 2 and 4.
Switch adjustments for counter-clockwise spring fail
operation (viewed from the top of the actuator)
a. Ensure the actuator is de-energized and positioned
in the counter-clockwise (fail) position. Ensure
the end of travel stop is properly adjusted. Rotate
the screw counter-clockwise to move the actuator
output shaft in a counter-clockwise direction.
Rotate the screw in a clockwise direction to move
the actuator output shaft in a clockwise direction.
Loosen the setscrews on Cams 2 and 4. Rotate
both clockwise until they clear the switch arm
rollers of switches 2 and 4.
b. Rotate Cam 2 counter-clockwise until it comes
in contact with Switch 2’s roller arm and the switch
“breaks”. A light “click” can be heard. Tighten the
setscrews on Cam 2.
c. Rotate Cam 4 counter-clockwise until it comes in
contact with Switch 4’s arm roller and the switch
just “breaks”. A light “click” can be heard
CAUTION
Closely monitor the electrical stroke, as the travel limit
switches are not yet properly adjusted. Ensure the
actuator does not over-travel and damage the driven
equipment.
d. Rotate Cam 4 slightly further in the counter-clock
wise direction. This ensures that Switch 4 will
”break” just prior to the actuator reaching the full
fail position. Tighten the setscrews on Cam 4. Use
care to not over-tighten the set screws.Energize
the actuator. This will move the actuator to
the opposite end of travel.
e. Upon reaching the opposite end of travel,
Cam 1 should just engage the roller on Switch 1 so
that the switch just “breaks”. This action will stop
the actuator. Check that the actuator has properly
positioned the driven equipment.
f. If actuator travel is insufficient, rotate Cam 1slightly
counter-clockwise until the cam just clears the
roller of Switch 1. As soon as the cam clears the
roller, the actuator will “bump” electrically towards
the end of travel. Continue until the actuator
reaches the full end of travel. If the actuator has
over-traveled, rotate Cam 1 slightly
counter-clockwise, then move the actuator
towards the fail position electrically. Stop and
electrically reverse the direction of travel. Move
the actuator until Cam 1operates switch 1 and the
actuator stops. Repeat this procedure until the
actuator is properly positioned.
g. If the actuator has over-traveled, rotate Cam 1
slightly clockwise, then move the actuator towards
the fail position electrically. Stop and electrically
reverse the direction of travel. Move the actuator
until Cam 1 operates switch 1 and the actuator
stops. Repeat this procedure until the actuator is
properly positioned.
h. Rotate Cam 3 until it comes in contact with Switch
3’s arm roller and the switch just “breaks”. A light
“click” can be heard. Rotate the cam slightly further
in the clockwise direction. This ensures that Switch
3 will “break” just prior to the actuator reaching the
extreme opposite end of travel. Tighten
the setscrews on Cams 1 and 3. Use care
to not over-tighten the set screws.
6. Operate the actuator electrically several times to ensure
proper operation and to verify that travel limits and stops are
correctly set.
7. De-energize the actuator to verify proper spring failure
operation. Ensure the driven device is properly positioned in
the spring failure position.
8. If the actuator is supplied with an optional feedback
potentiometer and/or position controller, verify proper
calibration of input and output signals after making cam and
stop bolt adjustments.
9. Replace the actuator cover and cover screws. Before
installing the cover, make sure both flange surfaces are clean
and free of any deris, and that the cover o-ring is in the
machined groove in the lower housing and properly seated.
Also make sure that the indicator beacon is in the proper
orientation.
10. The actuator is now ready for electrical operation.

Wiring Diagrams
Spring Drive CW On Loss of Power Spring Drive CCW On Loss of Power
STOP
CCW
CW
SP-3 POSITION
SNAP ACTION
SWITCH
HEATER
11
12
9
7
8SWITCH 3
NC
NO
3
2
5
4
NC
NC
NO
NO
NC
FIELD WIRING
10
SWITCH 4
NO
ACTUATOR WIRING
SCREW
GREEN
GROUNDING
M
CAPACITOR
AUTOMATIC RESET
THERMAL OVERLOAD
SWITCH 2
SWITCH 1
L1
A.C. LIN
E
(NEUTRAL)
L2
(OPT.)
1
6
+t
MOTOR
BRAKE
BRIDGE
RECTIFIER
COM
COM
COM
COM
M1
M2 M3
TB
SP-3 POSITION
SNAP ACTION
SWITCH
STOP
CCW
CW
HEATER
11
12
9
7
8SWITCH 3
NC
NO
3
2
5
4
NC
NC
NO
NO
NC
FIELD WIRING
10
SWITCH 4
NO
ACTUATOR WIRING
SCREW
GREEN
GROUNDING
M
CAPACITOR
AUTOMATIC RESET
THERMAL OVERLOAD
SWITCH 2
SWITCH 1
L1
A.C. LINE
(NEUTRAL)
L2
(OPT.)
1
6
+t
MOTOR
BRAKE
BRIDGE
RECTIFIER
COM
COM
COM
COM
M1
M2 M3
TB
Figure 3
Figure 2
• Power to terminal 1 & 3 will motor drive and brake hold actuator
in CW most position if the brake is energized at terminal 1 & 5
when switch N.O. of SW1 closes.
• Power to terminal 1 & 5 will brake hold actuator in whatever
position it is in at the time.
• Power to terminal 1 & 2 will motor drive and spring hold actuator
in CCW most position.
• Loss of power will spring drive and spring hold actuator in CCW
most position.
• Power to terminal 1 & 2 will motor drive and brake hold actuator
in CCW most position if the brake is energized at terminal 1 & 4
when switch N.O.of SW2 closes.
• Power to terminal 1 & 4 will brake hold actuator in whatever
position it is in at the time.
• Power to terminal 1 & 3 will motor drive and spring hold actuator
in CW most position.
• Loss of power will spring drive and spring hold actuator in CW
most position.
IMPORTANT
Direction of rotation is based on viewing actuator from top.
To operate multiple actuators in parallel from a single source
requires isolating relays in the field wiring.

NEMA 4, 6, 7 & 9 Dimensional Information
"
" "
""
""
"
"
"
"
"
"
"
"
"
Notes:
1. Direction of rotation is based on viewing actuator
from top.
2. Actuator shown in power fail position.
*3. Two keys are recommended for driving device.
Figure 4
Figure 5

Operation
CAUTION
To prevent the ignition of hazardous atmospheres,
do not remove actuator cover while circuits are live.
Power On: The electric motor drives the gear train, which in
turn winds the spring and turns the device. An internal limit switch
de-energizes the motor and the brake, which holds the return spring
and device in position.
Power Off: When the current is interrupted by either a control
signal or a power failure, the return spring drives the device to its
original position.
Note: It is recommended that the actuator be driven electrically in
both directions for normal operation to prolong cycle life.
Maintenance
Gear train is permanently lubricated at the factory for the average life
of the actuator. No further attention is required.
Thermal Overload
The internal thermal overload switch de-energizes the motor and
prevents overheating of the motor windings due to excessive
operation, stalling or high ambient temperatures.
D u t y C y c l e
The maximum duty-cycle to be expected without interruption by
thermal cut-off at an ambient temperature of 65C° is 25% (3 “OFF”
times for every 1 “ON” time) for the 10 second design, and 50% (1
“OFF” time for every 1 “ON” time) for the 30 second design.
Storage
The Surepowr actuator must be stored in a clean, dry, temperature
controlled building which is protected from the weather. Precautions
shall be taken to prevent condensation inside or outside the actuator.
If there is insufficient external temperature and humidity control,
internal heaters must be installed and energized to protect the unit
against condensation from extreme temperature variations. The
actuators shall be stored off the floor on suitable pallets and must be
covered with an unsealed dust protector allowing side and bottom
ventilation.
Isolation Relays
To operate multiple actuators in parallel from a single signal requires
isolating relays in the field wiring. Consult Factory.
Troubleshooting (New Unit)
Note: Most actuator problems occur due to incorrect cam/travel limit
switch setting, or the use of an external travel stop on the device
that the actuator is operating.
Problem 1: Actuator is receiving electric power but the motor
does not respond.
Instructions:
1a. Check actuator nameplate to insure correct model,
voltage type and spring return direction.
1b. Check all wiring against installation wiring diagram.
1c. Actuator with clockwise fail position: Using a volt
meter, check that power is available between terminals
1 and 2. Then check the voltage between terminal
1 (common) and the two legs of the motor and capacitor.
The meter should indicate a value equal to or greater than
the supply voltage indicated on the actuator nametag.
Actuator with counter-clockwise fail position: Using a volt
meter, check that power is available between terminals 1
and 3. Then check the voltage between terminal 1 (common)
and the two legs of the motor and capacitor. The meter
should indicate a value equal to or greater than the
supply voltage indicated on the actuator nametag.
If power is not present at the motor or capacitor leads:
• Cam adjustments are required
• Switch malfunction
• Improper wiring
Problem 2: Actuator is receiving electric power but the motor
only hums.
Instructions:
2a. Perform steps 1a through 1c listed above.
2b. Check to insure the brake is completely disengaged
when power is applied

Problem 3: Actuator runs but operation is erratic.
Instructions:
3a. Perform steps 1a through 1c listed above.
3b. Check ambient temperature. Standard Surepowr
actuators have a maximum ambient operating temperature
rating of 65°C.
3c. Check duty cycle (frequency of operation). See above for
details.
3d. Ensure that actuator is not continuously stalled.
3e. Ensure that all wiring connections are secure.
Problem 4: Motor runs continuously in spring return direction
after actuator output shaft has stopped.
Instructions:
4a. Adjust spring return side travel cam/switch so that the
cam trips the switch before the shaft stops motion.
Problem 5: Motor runs continuously but output shaft does not
turn.
Instructions:
5a. Check for power to the bridge rectifier and clutch
solenoid.
Note: Standard Surepowr actuators are manufactured with thermal
overload protectors in series with the motor common. Should
any of the above problems cause the protector to open, it will
automatically reset when the motor temperature is lowered to a
safe level.
Locating and Ordering Parts
For ease and accuracy in identifying and ordering spare or replace-
ment parts, submit the following information from unit nameplate.
1. Serial Number
2. Model Number
3. Voltage
RCS Actuators
16240 Port Northwest Drive
Houston, TX 77041
T: 832-590-2306
Toll Free: 1-800-945-9898
F: 713-849-2879
© 2021 Natural Gas Solutions North America, LLC – All rights reserved. Dresser
Utility Solutions reserves the right to make changes in specications and features
shown herein, or discontinue the product described at any time without notice
or obligation. Contact your Dresser Utility Solutions representative for the most
current information. The Dresser Logo and all Trademarks containing the term
“Dresser” are the property of Dresser, LLC, a subsidiary of Baker Hughes.
www.dresserutility.com
RCS Sure 100 IOM Manual NGS.IPG.0039b
06.21