Schneider Electric AV-632 Adapter Kit F/Honeywell & Johnson Valve Link. & Honeywell Aux. Switch User Guide

AV-632

Adaptor Kit for Honeywell & Johnson Valve

Linkage & Honeywell Auxiliary Switch Kit

General Instructions

APPLICATION

For mounting MM-400/500 Modular Motors to Honeywell

Q618A and Johnson Y20EBD valve linkages.

The kit is also used to mount Honeywell Q607 auxiliary switch and Q181A auxiliary potentiometer kits MM-400/500 Modular

Motors.

Each Av-632 package contains:

One (1) Mounting bracket for mounting MM to

Honeywell Q618A valve linkage, Johnson

Y20EBD valve linkage, and mounting

Honeywell shaft mounted auxiliary switches or potentiometer

Three (3)

Four (4)

One (1)

#8-32 x 7/16" pan head screws with integral lock washers.

1/4"-20 x 7/8" hexhead bolts with lock washers and nuts.

Spacer collar for use with Honeywell Q618A valve linkage.

Shaft extension kit for mounting auxiliary kits to “Load” shaft of MM-400 or “Normally

Closed-CCW” shaft of MM-500. Kit contains shaft extension, washer, and screw.

General Instruction Sheet

Other Schneider Electric Components Required:

MM or MM Modular Motor, MMC Control Module, and other required accessories.

Other Schneider Electric Components That May Be

Required:

None

PRE-INSTALLATION

Inspection

Visually inspect the carton for damage. If damaged, notify the appropriate carrier immediately. If undamaged, open the carton and visually inspect the device for obvious defects.

Return damaged or defective products.

Required Installation Items

Wiring diagram.

•

Tools (not provided):

Volt-ohm meter.

Appropriate screwdriver or wrench for mounting screws or bolts.

•

Mounting screws or bolts (not provided).

Printed in U.S.A. 6-10

INSTALLATION

Caution:

AV-632 Adaptor Kit is intended for mounting of MM-400 and

MM-500 series motors to Honeywell and Johnson products

-ONLY.

Read General Instruction sheets for Modular Motor and

Accessories for additional specific information on modular motor installations.

Installer must be a qualified, experienced technician.

Disconnect power supply before installation to prevent electrical shock and equipment damage.

Make all connections in accordance with the wiring diagram, and in accordance with national and local electrical codes.

Use copper conductors only that are suitable for 85°C. Use

Class 1 wiring only.

Do not exceed ratings of the devices.

Avoid locations where excessive moisture, corrosive fumes or vibrations are present. NEMA Type 1 housings are intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment.

NEMA Type 3R housings (with factory installed weather resistant gaskets in place and motor mounted vertically - top up) are intended for outdoor use primarily to provide a degree of protection against windblown dust, rain, sleet and external ice formation.

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REPLACEMENT OF A HONEYWELL MOTOR

Use the following table to confirm that the proper MM or MMR motor, MMC control module, and other required accessories have been selected.

Table-1 Honeywell Motor Competitive Cross Reference.

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Table-1 Honeywell Motor Competitive Cross Reference (Continued).

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Table-1 Honeywell Motor Competitive Cross Reference (Continued).

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Mounting Honeywell Q607 Auxiliary Switch

Kit To MM Modular Motor.

If a Honeywell motor is replaced that has an Q607 auxiliary switch kit that will continue to be used, use the following instructions to mount device to MM motor.

Removing Auxiliary Switch Kit From

Honeywell Motor

1. Remove cover of auxiliary kit by prying off cover housing.

2. Remove auxiliary kit housing from mounting bracket by removing the two (2) screws from inside the housing.

3. With slotted screwdriver, depress wire spring on the bottom of the housing and slip housing out of the mounting bracket tab.

4. Remove screws and auxiliary kit mounting bracket from

Honeywell motor.

Installing Auxiliary Switch Kit On MM For

Damper Applications

1. Slide the formed side of the bracket onto the motor shaft and secure the motor base to the straight side of the bracket with the 1/4"-20 X 7/8" hexhead bolts provided.

(Refer to Figure-1).

Note: The square shaft extender with #8-32 X 5/8" screw and washer must be mounted to motor shaft if the kits are to be mounted to the “Load” or “Normally Closed CCW” end of the MM motor.

2. Mount the Honeywell mounting bracket onto the

Schneider Electric mounting bracket by using the three

(3) #8-32 screws provided.

3. Mount the Honeywell switch kit (Q607) to the mounting bracket using the two (2) existing Honeywell screws.

4. Reconnect electrical wires and re-assemble Q607 cover after the modular motor has been securely mounted.

5. Reset, if necessary, switch cams to original specifications.

Installing Auxiliary Switch Kit On MM For

Valve Applications:

When Mounting MM Motor To Honeywell Q601E

Linkage (See Figure-1).

1. Slide the formed side of the bracket onto the motor shaft and secure the motor base to the straight side of the bracket with the 1/4"-20 X 7/8" hexhead bolts provided.

(Refer to Figure-1).

Note: The square shaft extender with #8-32 X 5/8" screw and washer must be mounted to motor shaft if the kits are to be mounted to the “Load” or “Normally Closed CCW” end of the MM motor.

2. Mount the Honeywell mounting bracket onto the

Schneider Electric mounting bracket by using the three

(3) #8-32 screws provided.

Figure-1 Mounting Auxiliary Kits to Modular Motor.

Figure-2 Installation of Modular Motor and Auxiliary Kits on

Honeywell Q618A Valve Linkage.

3. Mount the Honeywell switch kit (Q607) to the mounting bracket using the two (2) existing Honeywell screws.

4. Reconnect electrical wires and re-assemble Q607 cover after the modular motor has been securely mounted.

5. Reset, if necessary, switch cams to original specifications.

When Mounting MM Motor To Honeywell Q618A

Linkage (See Figure-2).

1. Mount the formed side of the Schneider Electric mounting bracket to the MM and the Q618A linkage (the Q618A is mounting previous to the auxiliary kit installation).

Note: The square shaft extender with #8-32 X 5/8" screw and washer must be mounted to motor shaft if the kits are to be mounted to the “Load” or “Normally Closed-CCW” end of the MM motor.

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2. Mount the Honeywell mounting bracket onto the straight side Schneider Electric mounting bracket by using the three (3) #8-32 x 7/16" screws provided. The formed side of the bracket is used to mount the MM to the Q618A linkage.

3. Mount the Honeywell switch kit (Q607) to the mounting bracket using the two (2) existing Honeywell screws.

4. Reconnect electrical wires and re-assemble Q607 cover after the modular motor has been securely mounted.

5. Reset, if necessary, switch cams to original specifications.

Mounting Honeywell Q181A Auxiliary

Potentiometer Kit To MM Modular Motor.

If a Honeywell motor is replaced that has an Q181A auxiliary potentiometer kit that will continue to be used, use the following instructions to mount device to MM motor.

Removing Q181A Auxiliary Potentiometer Kit From

Honeywell Motor

1. Loosen cover screws and remove cover of Q181A potentiometer kit.

2. Remove potentiometer kit from the motor by loosing the two (2) #8-32 screws in the back of the mounting case.

Note: Be careful not to loosen the drive pin coupling that rests against the drive pin.

3. Loosen the two (2) Allen head screws with an appropriate

Allen head wrench and remove the shaft coupling from the Honeywell motor output shaft.

Installing Q181A Auxiliary Potentiometer Kit On

MM For Damper Applications:

1. Slide the formed side of the bracket onto the motor shaft and secure the motor base to the straight side of the bracket with the 1/4"-20 X 7/8" hexhead bolts provided.

(Refer to Figure-1).

Note: The square shaft extender with #8-32 X 5/8" screw and washer (from the MM) must be mounted to motor shaft if the potentiometer kit is to be mounted to the “Load” or “Normally

Closed CCW” end of the MM motor.

2. Install the shaft coupling on the motor shaft so the slots are on the top and bottom when the motor is in the fully

CCW position. Tighten both set screws.

3. Make certain that the cam follower is on the low side of the cam. Fit the drive pin coupling over the drive pin and put the Q181A in place on the mounting bracket. The drive pin shaft should engage the shaft coupling.

4. Mount the Q181A on the mounting bracket with the two

(2) #8-32 screws provided with the kit.

5. Run the modular motor over its entire travel to make certain the potentiometer wiper arm is not driven beyond the windings.

6. Replace the cover of the kit.

Installing Auxiliary Potentiometer Kit On MM For Valve

Applications:

When Mounting MM Motor To Honeywell Q601E

Linkage.

1. Slide the formed side of the bracket onto the motor shaft and secure the motor base to the straight side of the bracket with the 1/4"-20 X 7/8" hexhead bolts provided.

(Refer to Figure-1).

Note: The square shaft extender with #8-32 X 5/8" screw and washer (from the MM) must be mounted to motor shaft if the potentiometer kit is to be mounted to the “Load” or “Normally

Closed CCW” end of the MM motor.

2. Install the shaft coupling on the motor shaft so the slots are on the top and bottom when the motor is in the fully

CCW position. Tighten both set screws.

4. Mount the Q181A on the mounting bracket with the two

(2) #8-32 screws provided with the kit.

5. Run the modular motor over its entire travel to make certain the potentiometer wiper arm is not driven beyond the windings.

6. Replace the cover of the kit.

When Mounting MM Motor To Honeywell Q618A

Linkage.

1. Mount the formed side of the Schneider Electric mounting bracket to the MM and the Q618A linkage (the Q618A is mounting previous to the auxiliary kit installation).

Note: The square shaft extender with #8-32 X 5/8" screw and washer (from the MM) must be mounted to motor shaft if the potentiometer kit is to be mounted to the “Load” or “Normally

Closed CCW” end of the MM motor.

2. Install the shaft coupling on the motor shaft so the slots are on the top and bottom when the motor is in the fully

CCW position. Tighten both set screws.

4. Mount the Q181A on the mounting bracket with the two

(2) #8-32 screws provided with the kit.

5. Run the modular motor over its entire travel to make certain the potentiometer wiper arm is not driven beyond the windings.

6. Replace the cover of the kit.

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Use the following table to confirm that the MM motor selected can be used on the Honeywell valve in the system.

Table-2 Honeywell Valve and Linkage Cross Reference.

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* CAUTION:

The common port of the Honeywell valve is a side port and the replacement is the bottom port.

Dimension “A” = The face to face dimension on the valve.

Dimension “B” = The dimension from the centerline of the pipe to the bottom of the lower (“B”) port.

NOTE: Ratings per Honeywell valve specification data sheets.

Figure-3 Honeywell Q618A Valve Linkage (shown with cover removed).

Mounting MM Motor to Honeywell Q618A

Valve Linkages: (See Figure-2 thru 4)

The MM modular motor can be mounted to Honeywell Q618A valve linkage by using the mounting bracket, spacer collar, and four (4) 1/4"-20 x 7/8" hexhead screws, lockwashers and nuts provided.

The following step by step instructions define the procedure for removal of Honeywell Modutrol Series motors from Q618A linkage on 2-Way and 3-Way Globe Valves and replacement with the appropriate Schneider Electric Modular Motor.

Removing Honeywell Motor

1. Disconnect power.

2. Remove top cover of motor.

3. Label leads by terminal designation (EG. R, W, B, TR1,

TR2 etc.) and remove wiring from Motor. Be sure and also label wires for auxiliary switches or devices.

4. Remove any auxiliary equipment attached to the auxiliary end or motor housing.

5. Remove conduit connection.

6. Remove linkage cover.

7. Remove Stem Button Clamp screw.

8. Remove Stem Button Clamp.

Note: On Spring Return motors insert heavy duty screwdriver at the top or bottom of the linkage slide in the back slot of linkage frame. Pry the linkage slide upward of downward to free Stem Button Clamp. (See Figure-4).

Figure-4 Removal of Stem Button Clamp.

9. Loosen the two (2) setscrews and lift the linkage and motor assembly from the valve bonnet.

Note: The two captive screws are located at the back of the cam assembly behind the cam. If the screws are not visible, power the motor until the cam is completely up or down so the screws can be accessed.

10. Loosen the two (2) captive mounting screws and remove from linkage.

11. Remove motor mounting bolts.

12. Separate motor from linkage. Compress slide mechanism slightly to release cam.

13. Loosen Hex Set Screw and remove cam.

Installing Schneider Electric MM Modular Motor

1. Select the appropriate modular motor, plug-in control module and accessories and install using instructions in

Section 1 - GENERAL INSTRUCTIONS.

2. On non-spring return motors (MM-400) select “Load” end of modular motor. On spring return motors (MM-500) select “Normally Closed-CCW” end when installing to a

N.C. Honeywell valve and select “Normally Open-CW” end when installing to a N.O. Honeywell valve. (See

Figures-5 & 6).

Figure-5 Output Shaft Designation for MM and MMR-400

Series.

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Figure-6 Output Shaft Designation for MM and MMR-500

Series.

Note: Auxiliary kits should be installed to mounting bracket before MM motor is installed to valve linkage.

3. Place spacer collar (provided with MM motor on motor shaft.

4. Push cam on shaft.

Note: Key on cam must fit into keyway on motor shaft.

5. Snug spacer to cam and secure setscrew.

6. Place MM motor on the formed end of the bracket and insert two (2) 1/4"-20 X 7/8" hexhead bolts in the auxiliary end (See Figure-2) Snug bolts but do not tighten.

7. Insert Q618 mounting foot between motor base and bracket.

8. Depress top roller of slide mechanism (See Figure-3).

9. Slip cam into linkage slide mechanism and loosely secure modular motor and adaptor bracket to motor mounting holes in Q618 linkage assembly with two (2) 1/4"-20 X

7/8" hexhead bolts.

10. Push motor forward to engage cam fully on linkage.

11. Tighten the four (4) 1/4" motor mounting bolts securely.

12. Secure linkage to valve bonnet by tightening the two (2) setscrews.

13. Insert stem button clamp and secure with screw.

Note: If motor is in full N.O. (clockwise) or N.C.

(counterclockwise insert heavy duty screwdriver at the top or bottom of the linkage slide in the back slot of linkage frame and pry upward or downward to set Stem Button Clamp.

14. Reconnect appropriate control and power wiring. (See

Table-1 Wiring Terminations).

15. Replace top cover on modular motor.

16. Checkout: a. Motor should run freely through complete stroke.

b. Linkage should operate without binding.

c. Valve must close off tightly at bottom of stroke (both ends of stroke on 3-Way application). Check for 1/32" deflection of the roller bracket in closed position.

17. Replace linkage cover - secure with screw.

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REPLACEMENT OF A JOHNSON MOTOR

Use the following table to confirm that the proper MM motor, MMC control module, and other required accessories have been selected.

Table-3Johnson Motor Cross Reference.

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Mounting to Johnson Y20EBD Valve Linkages (See Figures 7 thru 10):

A Schneider Electric modular motor can be mounted to Johnson Y20EBD valve linkage by using mounting bracket, two (2) #8-32 x 7/16" panhead screws with integral lock washers and four (4) 1/4"-20 x 7/8" hexhead screws, lockwashers and nuts.

The following step by step instructions define the procedure for removal of Johnson M100 Series Motors from Y20 linkage on

2-Way and 3-Way Globe Valves and replacement with the appropriate Schneider Electric Modular Motor.

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Removing Johnson Motor

1. Disconnect power.

2. Remove top cover of motor.

3. Label leads by terminal designation (EG. R, W, B, TR1,

TR2, etc.) and remove wiring from switch. Be sure and include wire for auxiliary switches or devices.

4. Remove any auxiliary equipment attached to the auxiliary end or motor housing.

5. Remove conduit connection.

6. Remover the 4 (four) 1/4" yoke mounting bolts holding motor to mounting yoke.

7. Remove 2 (two) gear housing screws so gear housing can be removed from motor and gear housing then from rack.

8. Remove gear cover by loosening the two gear cover screws, do not remove screws, rotate cover and remove gear.

Installing Schneider Electric MM Modular Motor

1. Select the appropriate modular motor, plug-in control module and accessories

Note: Mechanical travel on motor is factory set at 160° and no field adjustment is required. The MMC-468 requires no adjustment. The MMC-90 and MMC-8000 cards should be set at 160° travel. Connect appropriate colored wire leads to tabs.

Note: On MMC-90 and MMC-8000 cards the travel adjustment should be made according to the GI sheets for these cards.

11. On three way valves, the new motor must be rotated 15° from the shipped position (CW on MM-400 or MM-500) for proper spring compression on the valve stem.

12. Checkout: a. Motor should run freely through complete stroke.

b. Linkage should operate without binding.

c. Valve must close off tightly at bottom of stroke for

2-Way applications (both ends of stroke on 3-Way application). If not achieving full travel or close-off with MMC-90 card recheck travel adjust potentiometer.

Note: Check plunger compression. The length of the valve stem should be adjusted so that the valve disc seats before the motor reaches the end of the closing stroke. Balance of motor travel is taken up in linkage spring compression and should be approximately 1/10" (2.5 mm). This provides pressure on the disc in closed position and also compensates for disc and seat wear. Three-way valve spring compression must be provided on both upper and lower seats.

13. Replace cover on modular motor.

2. Select “Load’ end of modular motor (See Figures-5 & 6).

3. Take the mounting bracket (See Figure-10) and mount the Johnson gear housing on the formed side of the mounting bracket. Do Not Tighten.

Note: Make sure gear housing rack opening is in the same location as on the original installation and rack is inserted into gear housing.

4. Place “Normally Closed-CCW” end of spring return motor or “Load” end of non-spring return motor so shaft goes through gear housing hole.

5. Pull rack attached to valve stem all the way up. Then slowly push rack down with square end of drive gear lined up with motor shaft. Press gear on to shaft (see Figure-9).

Note: This should occur before rack has moved the distance of 1 (one) tooth on the rack; if not, realign the square hole of gear on motor shaft.

6. Bolt the motor down by loosely putting all 4 (four) 1/4" bolts through base of motor and mounting yoke.

7. Tighten the two screws holding the gear housing assembly, replace gear cover plate and tighten the 2

(two) gear cover screws (See Figures 7 or 8).

8. With a slight force applied to gear housing, make sure motor assembly is back away from rack gear.

9. Tighten all 4 (four) 1/4" bolts in motor at base yoke.

10. Reconnect appropriate control and power wiring. (See

Table- 3 - Wiring Termination).

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Figure-7 Johnson Valve Linkage CCW Stem Up.

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Figure-8 Johnson Valve Linkage CCW Stem Down.

Figure-9 Operation of the Y20EBD Valve Linkage (CW - Stem Down, CCW - Stem Up).

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Figure-10 Mounting MMR to Johnson Y20EBD Valve Linkage.

CHECKOUT

After the entire system has been installed, the following check for proper operation can be made:

1. Be sure that the system power is connected and ON.

2. Be sure control (manual or automatic) is operating the modular motor properly per system requirements.

3. Check action of (optional) internal and external auxiliary switches.

4. Be sure there is no binding of the linkage at any point in the stroke.

5. If the motor fails to run, check the field wiring to insure proper voltage supply.

MAINTENANCE

Regular maintenance of the total system is recommended to assure sustained optimum performance.

FIELD REPAIR

None. Replace with a functional unit.

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On October 1st, 2009, TAC became the Buildings business of its parent company Schneider Electric. This document reflects the visual identity of Schneider Electric, however there remains references to TAC as a corporate brand in the body copy. As each document is updated, the body copy will be changed to reflect appropriate corporate brand changes.

All brand names, trademarks and registered trademarks are the property of their respective owners. Information contained within this document is subject to change without notice.

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Schneider Electric

1354 Clifford Avenue

P.O. Box 2940

Loves Park, IL 61132-2940

www.schneider-electric.com/buildings

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