Dresser RCS Sure 24 User manual

RCS Actuators
RCS Sure 24/25
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 aminimum 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
24/25 (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 an allen 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
clockwise (fail) position. Ensure the end of travel stop
is properly adjusted. Rotate the screw clockwise to
move the actuator output shaft in a counter-clockwise
direction. Rotate the screw in a counter-clockwise
direction to move the actuator output shaft in a clock
wise direction. Loosen the setscrews on Cam2.
Rotate counter-clockwise until it clears the switch arm
roller of Switch 2.
b. Rotate Cam 2 clockwise until it comes in contact with
Switch 2’s arm roller and the switch “breaks”. A light
“click” can be heard. Tighten the set-screws on
Cam 2.
c. Energize the actuator. 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.
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. Upon reaching the opposite end of travel, Cam
7 should just engage the roller on Switch 7 so that
the switch just “breaks”. This action will stop the
actuator. Check that the actuator has properly
positioned the driven equipment.
e. If actuator travel is insufficient, rotate Cam 7
slightly clockwise until the cam just clears the roller
of Switch 7. 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.
f. If the actuator has over-traveled, rotate Cam 7
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 7 operates Switch 7 and the
actuator stops. Repeat this procedure until the
actuator is properly positioned. Tighten the
setscrews on Cam 7.
Switch adjustments for counter-clockwise spring fail
operation (viewed from the top of the actuator)
a. Ensure the actuator is de-energized and postioned
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 Cam 7. Rotate
clockwise until it clears the switch arm roller
of switch 7.
b. Rotate Cam 7 counter-clockwise until it comes in
contact with Switch 7’s roller arm and the switch
“breaks”. A light “click” can be heard. Tighten the
setscrews on Cam 7.
c. Energize the actuator. This will move the actuator
to the opposite end of travel.
d. 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.
e. If actuator travel is insufficient, rotate Cam 2
slightly counter-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.
f. If the actuator has over-traveled, rotate Cam 2
slightly 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. Tighten the setscrews
on Cam 2.
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.
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
4
2
3
1
CCW
CW
1
2
3
CCW
1
2
3
4
STOP
SP-3 POSITION
SNAP ACTION SWITCH
YELLOW
GREEN GROUND SCREW
BLUE/RED
PURPLE
SW.7
SW.2
RED
BROWN
BLACK
THERMAL OVERLOAD
MOTOR
BRIDGE
RECTIFIER
BRAKE
MOTOR
BLACK
RED
A.C.LINE A.C.LINE
SPOT SNAP
ACTION SWITCH
2
3
1
5
CCW
CW
1
2
3
CCW
1
2
3
5
STOP
SP-3 POSITION
SNAP ACTION SWITCH
CW
YELLOW
GREEN GROUND SCREW
BLUE/RED
PURPLE
SW.7
SW.2
BRIDGE
RECTIFIER
RED
BLACK
THERMAL OVERLOAD
MOTOR
BRAKE
MOTOR
BLACK
RED
BLUE
A.C.LINE
A.C.LINE
SPOT SNAP
ACTION SWITCH
Actuator Wiring Actuator Wiring
Field Wiring Field Wiring
Figure 2
• Power to terminals 1 and 2 will motor drive and
hold actuator in CCW position.
• Power to terminals 1 and 3 will motor drive and
hold actuator in CW position.
• Loss of power will spring drive and hold actuator
in CW position.
• Power to terminals 1 and 4 will hold actuator in
whatever position it is in at the time.
Figure 3
• Power to terminals 1 and 3 will motor drive and
hold actuator in CW position.
• Power to terminals 1 and 2 will motor drive and
hold actuator in CCW position.
• Loss of power will spring drive and hold actuator
in CCW position.
• Power to terminals 1 and 5 will hold actuator in
whatever position it is in at the time.
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 & 7 Dimensional Information
10.54 NEMA 4
10.95 NEMA 7
10.0 Clearance for
cover removal
TOP
3.28
CCW spring return,
adjustable stop
for end of travel
5/16 – 18 UNC – 2B x .375 DP.
Min. full thread
Typ. 4 places
0.875
0.873 Dia.
0.624
0.620 Across ats
2.25 Sq.
1.125 Typ.
CW spring return,
adustable stop
for end of travel
6.00
3.00
.953 .043
4.50
One Only,
3/4 N.P.T.
Conduit
Entrance
7.83
5
Figure 4
Mounting Geometry - Bottom View
Notes:
1. Direction of rotation is based on looking at actuator
from top.
2. This drawing shows actuator output shaft in clockwise
post position.
3. Standard unit has spring drive in clockwise direction.
4. NEMA 4 cover shown.
Dimensions given are accurate for NEMA 7.
Figure 5

CAUTION
To prevent the ignition of hazardous atmospheres,
do not remove actuator cover while circuits are live.
Operation
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. Brake gap is set at the factory. 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.
Duty Cycle
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 Sure 24 and 50% (1 “OFF” time for
every 1 “ON” time) for the Sure 25.
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.
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.
Isolation Relays
To operate multiple actuators in parallel from a single signal requires
isolating relays in the field wiring. Consult Factory.
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.
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.
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 replacement
parts, submit the following information from unit nameplate.
1. Serial Number
2. Model Number
3. Voltage
Industrial Products Group
RCS Actuators
16240 Port Northwest Drive
Houston, TX 77041
T: 832-590-2306
Toll Free: 1-800-945-9898
F: 713-849-2879
© 2018 Natural Gas Solutions North America, LLC – All rights reserved. Natural
Gas 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 Natural Gas 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,
a GE Company. www.dresserngs.com
RCS Sure 24 25 IOM Manual NGS.IPG.0040
11.18