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Karl Dungs, Inc3890 Pheasant Ridge Dr. NE, Suite 150, Blaine, MN 55449 U.S.A.

Phone: (763) 582-1700 Fax: (763) 582-1799 E-mail: info@karldungsusa.com

Ambient Temperature -40°F to +160°F (-40˚C to +71˚C)Enviroment NEMA TYPE 4 (weathertight)Open circut Input Drives actuator to lowSeries Operation No offset in control point when operated in tandemApprovals UL Listed

CP-9302-702ActuatorDriveInstallationInstructions

SPECIFICATIONSTheCP-9302-702electronicactuatordriveprocessesavariableinputsignalfromacontrollertoprovideproportionalcontrolofanelectricactuator.TheCP-930-702ispresetforcurrentinput(4-20mA)andhasadditionalwiringforconnectiontoanoverrideswitchforapplicationsrequiringanexternaloverrideoftheinputsignal.TheCP-9302-702isequippedwithbuiltinjumpersandadjustablepotentiometers,sothatthetypeofinputsignal,deadband,inputspan,andstartpointmayberead-justedinthefieldwhennecessary.

Electrical Ratings Power supplied by the actuator Input: 4-20 mA Electrical Connection 1/2” conduit knockoutDeadband Adjustability (Hysteresis) Factory set at 5%, adjustable to 3%Grounded Input Grounding either or both input wires will not cause damage

•Inspectunitbeforeinstalling,lookforbentorbrokenpartsoroilleaksfromactuator.•UseNEMATYPE4compatibletypeconnectors.•Observethebarrierthatseparatesthelinevoltageter-minalsfromthelowvoltagewhichcontrolstheactuator motor.•Allconnectionstothelinevoltagesideofthebarrier(L1andL2,1,5and6terminals)mustbemadewithClass1wiring;connectionstotheremainingterminalscanbeClass2thermostatcableifdesired.•Allow6inches(152mm)clearanceabovetheactuatorwiringcompartment.

Installationmustbedonebyaqualified,licensedtechnician.Thesystemmustmeetallapplicablecodes.Impropersystemdesignorsetupmaycauseexplosions,propertydamage,andinjuries.

• Disconnect all power to the valves before wiring to prevent electrical shock and equipment damage.• Do not exceed the electrical ratings given in the specifications and on the actuator.• Attach a flexible 1/2” conduit to the actuator.• Route the wires through the conduit.• Use 14 or 16 guage wire for at least 75˚C (167˚F).• Connect the wiring to the appropriate screw terminals.• Remove the appropriate knock out on the side you wish to mount the sidebox.• Insert the sidebox into the actuator and leaving the O-ring on the sidebox.• Secure the sidebox to the actuator with the conduit locknut provided.

CP-

903-

702

Inst

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Man

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P/N

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ATTENTION•Readtheseinstructionscarefully.•Failuretofollowthemand/orimproperinstallationmaycauseexplosion,propertydamageandinjuries.•Installationmustbedonewiththesupervisionofalicensedburnertechnician.•ThesystemmustmeetallapplicablenationalandlocalcoderequirementssuchasbutnotlimitedtoNFPA86,CSD-1,ANSIZ21.13,UL795,NFPA85,orCSAB149.3.

•Checktheratingsinthespecificationstomakesurethattheyaresuitableforyourapplication.•Neverperformworkifgaspressureorpowerisapplied,orinthepresenceofanopenflame.•Onceinstalled,performacompletecheckout.•Verifyproperoperationafterservicing.

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WIRING

WARNING:Overridingtheimputsignalwilldrivetheactuatortothemechanicalendoftravel.

WARNING:Donotapplylinevoltagetoterminals“X”,2,3,4,7or8orthemotorwillbepermanentlydamaged.

Inspectunitbeforeinstalling,lookforbrokenpartsorleaks.UseNEMATYPE4compatibletypeconnectors.

Observethebarrierthatseparatesthelinevoltageterminalsfromthelowvoltagewhichoperatestheactuatormotor.Allconnections to the line voltage side of the barrier (L1 andL2,1,5and6terminals)mustbemadewithClass1wiring;connectionstotheremainingterminalscanbeClass2ther-mostatcableifdesired.

Allow6inches(152mm)clearanceabovetheactuatorwiringcompartment.

INSTALLATION

• Disconnect all power to the valves before wiring to prevent electrical shock and equipment damage.• Do not exceed the electrical ratings given in the specifications and on the actuator.

• Attach a flexible 1/2” NPT conduit to the actuator.• Route the wires through the conduit.• Use 14 or 16 guage wire for at least 105˚C (221˚F).• Connect the wiring to the appropriate terminals.

Donotadjustthelimitswitchbeyond90°unlessthestandardslidewirehasbeenreplacedwitha180°slidewire;donotadjustbeyond180°forproportioningcontrol.

Insomeapplications,aFlameSafeguard(FSG)mayhaveoneortwooverridingcircuits.Onebeingalowfirepurgestartandtheotherahighfirepre-purge.Thefunctionoftheviolet/whiteandvioletwiresaretoprovideanelectricalconnectionsothattheFSGcanoverride,thetemperaturecontrolleranddrivetheairdamperactuatorwithouta4mAsignal.Ifsuchconnectionsarenotneededintheapplica-tion,simplytapethemoff,andsafelystowaway.

Low Voltage

Internal wiring

Internal wiring

FACTORYCONFIGURATION REVEARSECONFIGURATION

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ADJUSTMENT

CAUTION:DonotapplyavoltagesourceinputtoCP-9302actuatordrivethatisconfiguredforcurrentinput.Doingsomaydamagethedrive.

CAUTION:Staticchargesproducevoltageshighenoughtodamagetheelectroniccomponents.Fol-lowstaticelectricityprecautionswhenservicingthedevice(s).

Figure 2

IfaCP-9302-702requiresadjustmentstoitsstartpoint,orinputspan,makeadjustmentsaccordingtothefollowing:CP-9302-702Adjustment(Preparation)

Fromthefactory,theactuatoriscalibratedsuchthatitdrivesto90degreeswith20mAappliedand0degreeswith4mAapplies.Toreducethe90degreepositionorincrease0degreeposition,followingtheprocedurebelow.

InitialSetup1.Turnoffallpowerandinputsignalstotheactuaton.2.Removethemetalcover.Thisallowsaccesstothepo-

tentiometersandtheinput/deadbandjumpers.3.Disconnectthedrive’syellowandblueleadsfromthe

controller. 4.Connectthedrive’sleadstothecorrespondingleadon

aninstrumentcapableofproducing4-20mA+/-0.1mA(currentcalibrator).

MinimumPositionCalibration1.Applypowertotheactuator,thenturnonthe“current

calibrator”.2.Adjustthe“currentcalibrator”untilthemAinputequals

thedesiredzeropointcurrent.Thisistypically4mA.

NOTE:Theminimumpositioncurrentinput(zeropoint)po-tentiometerandmaximumpositioncurrentinput(span)potentiometercanbephysicallyturnedindefinitely;buttheyhaveaneffectivelimitof25turns.Relativetothestartpoint(4mA/0degrees),rotatingthepostCWcausestheactuatortodrivetoward90degrees.Con-verselyrotatingthepotsCCWcausestheactuatortodrivebacktowardzero.ThisistrueofboththeSTARTPOINTandSPANadjustments.

NOTE:Thereisaslightdelay(approx.3seconds)inactua-tormovementwhenapotentiometerisadjusted.Makefinaladjustmentsslowlytopreventoveradjusting.Ifadjustedproperly,whentheunitjustbeginstodrive,itshouldstopwithin5degrees.Overadjustingwilllowertheactualstartpoint.

3.Withthedesiredcurrentinputfortheminimumpositionapplied(typically4mA),adjustthezeropointpotentiome-tersotheactuatorshaftdrivestoit’szeropoint(minimumposition).Itisbesttoadjustthestartpointpotentiometeruntiltheactuatorshaftjuststartstomoveoffitszeropoint.

MaximumPositionCalibration1.Applypowertotheactuator,thenturnonthe“current

calibrator”.2.Adjustthe“currentcalibrator”untilthemAinputequalsthe

desiredfinishpoint(maximumposition).Thisistypically20mA.

3.Withthedesiredcurrentinputformaximumposition(typi-cally20mA),theactuatorwilldrivetowards90degrees.Oncetheactuatorstops,adjustthespanpotentiometersotheactuatorshaftdrivestothemaximumposition.Itisbesttoadjustthespanpotentiometeruntiltheactuatorshaftjustmovestoitsfinishpoint.

4.Removethecurrentcalibratorandturnoffpowertotheactuator.Then,reconnectthedrive’sleadstothecontrol-

ler.5.Reinstallthecover.6.Reapplypowertotheactuatorandturnonthecontroller.

NOTE:Occasionally,anadjustmenttotheinputspanset-tingresultsinachangetothestartpointsetting,duetoasmallinteractionbetweenthesetwosettings.Afteradjustingtheinputspanpotentiometer,ensurethatbothsettingsmeetrequirementsbyrepeatingsteps7-9.

NOTE:Whensettingthepotentiometers;onlymovetheactuatorshaftinonedirection.Iftheshaftismovedinthe

oppositedirrection,thedeadbandwillaffectthesetting.

MetalcoverofCP-9302-702

Locationofpot.adjustments and jumpersundermetalcover

TopviewofCP-9302-702(theblackbox)

PotentiometerAdjustmentsandJumpers

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DIMENSIONS

TESTING

WhenreplacingaCP8391-703controlunitwithaCP9302702inNEMATYPE4applicationsasealmustbeinstalledintotheunusedconduitknockouttomaintainNEMATYPE4rating.

Test1:Connectthedrive’sleadstothecorrespondingleadofasuitablecurrentsignalsource(currentcalibrator).Applypowertotheactuator,thenturnonthecurrentsignalsource(currentcalibrator).Adjustthecurrentsignalsource(currentcalibrator)untilthemAmeterreadingequalsthedesiredzeropointcurrent(2to16mA).Adjustthecurrentsignalsource(currentcalibrator)untilthemAmeterreadingequalsthefinishpointcurrent.Withthedesiredfinishpointcurrentapplied,theactuatorshaftshoulddrivetothefinishpoint.IftheactuatorfailsthistestrepeattheCP-9302-702Adjustmentsection.ShorttheViolet/WhitewiretotheVioletwire;theactuatorshaftshouldturncounterclockwise.ShorttheViolet/WhitewiretotheBluewire;theactuatorshaftshouldturnclockwise.WhenyoubreaktheconnectionbetweentheViolet/WhiteandVioletwires,theshaftshouldreturnfullyclockwise.Iftheactuatorfailsthistest,performTest2.

Test2:DisconnecttheYellow/Blackwirefromterminal“X”.Jumperactuatorterminal“X”toterminal2;theactuatorshaftshouldturnclockwise.Whentheconnectionbetweentermi-nals“X”and2isbroken,theshaftshouldremainstationary.

Thenjumperterminal“X”toterminal3;theshaftshouldturncounterclockwise.Iftheactuatorpassesthistest,butfailedTest1,theside-mountedcontrolboxisdefectiveandmustbereplaced.

Iftheunitfailedbothtests,theactuatoritselfisdefectiveandmustbereplaced.ContactDungsforreplacementinforma-tion.