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TO PREVENT POTENTIAL INJURY OR DAMAGE TO PROPERTY, READ THIS MANUAL CAREFULLY AND COMPLETELY.

INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTIONS

HRSN4FS Series with Battery Backup

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WARNING - Read and follow all instructions in this IOM manual and on the equipment. Failure

to follow instructions can cause severe injury and/or death.

WARNING – Risk of Electric Shock. All electrical wiring MUST be in conformance with

applicable local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can

shock, burn, and cause death or serious property damage. To reduce the risk of electric shock, do

NOT use an extension cord to connect unit to electric supply. Provide a properly located electrical

receptacle. Before working on any electrical equipment, turn off power supply to the equipment.

WARNING – To reduce the risk of electric shock replace damaged wiring immediately.

WARNING – Ground all electrical equipment before connecting to electrical power supply.

Failure to ground all electrical equipment can cause serious or fatal electrical shock hazard.

WARNING – Do NOT ground to a gas supply line.

WARNING – To avoid dangerous or fatal electrical shock, turn OFF power to all electrical

equipment before working on electrical connections.

WARNING – Failure to bond all electrical equipment to system structure will increase risk for

electrocution and could result in injury or death. To reduce the risk of electric shock, see installation

instructions and consult a professional electrician on how to bond all electrical equipment. Also,

contact a licensed electrician for information on local electrical codes for bonding requirements.

CAUTION – Potential pinch point. Equipment connected to or driven by this device may start

unexpectedly and may cause personal injury or entrapment in linkage systems.

Basic safety precautions should always be followed, including the following: Failure to follow instructions

can cause severe injury and/or death.

This is the safety-alert symbol. When you see this symbol on your equipment or in this manual, look

for one of the following signal words and be alert to the potential for personal injury.

WARNING warns about hazards that could cause serious personal injury, death or major property

damage and if ignored presents a potential hazard.

CAUTION warns about hazards that will or can cause minor or moderate personal injury and/or

property damage and if ignored presents a potential hazard. It can also make consumers aware of

actions that are unpredictable and unsafe.

A notice indicates special instructions that are important but not related to hazards.

Notice:

IMPORTANT SAFETY INSTRUCTIONS

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Important Safety Instructions ......................2

Table of Contents ................................3

Actuator Operational Concepts ..................3

Technical Information ............................4

Conventions Used in this Manual ................4

Actuator Handling and Installation ..................5

Shipping and Handling ........................5

Installation Notes .............................5

Product Mounting and Setup ......................6

Torque Switches ................................7

Component Identication .........................8

120/230V Transformer Mounting and Setup ...........9

Power Supplies ..............................9

Adjusting CW End of Travel ......................10

Adjusting CCW End of Travel .....................11

Adjusting Auxiliary Switches ......................12

Cam Behavior ...............................12

Auxiliary Switch Cam Mapping ..................12

Commissioning ................................13

On/Off Control ..............................13

Battery System Connection ......................14

On/Off Control ..............................14

Calibration ....................................16

On/Off Control ..............................16

Commissioning ................................18

Proportional Control .........................18

Battery System Connection ......................19

Proportional Control .........................19

Calibration ....................................20

Proportional Control .........................20

Troubleshooting ................................22

On/Off Models ..............................22

Proportional Models .........................23

Battery System .............................24

Mechanical Data ...............................25

Dimensional Data ...........................25

Exploded View ..............................26

Wire Sizing Chart ...............................27

Wiring Diagrams ...............................28

HRSN4A~4D..20 ............................28

24VAC/VDC On/Off Control .................28

HRSN4A~4D..20 ............................29

24VAC/VDC Proportional Control ............29

HRSN4A~4D..20 ............................30

120/230VAC All Control Types ...............30

Notice: The actuator is shipped with the battery system disconnected until the unit is commissioned after all

installation procedures have been completed (see pg 14 or 19).

Notice: Read the project specications and understand the application before making an actuator selection. If

in doubt, consult with the project engineer to clarify what is actually required for a fully operational installation.

We have provided in this document all the tools necessary to determine how the various levels interface to the

outside world. If there are any questions, please contact Hayward Flow Control Technical Services.

The HRSN4 Series actuators ending in “20” or in “2X” have an internal battery backup system and are quarter-

turn industrial electric actuators designed to operate valves and dampers in municipal, heavy commercial

or industrial applications. These units are NEMA 4/4X, IP67 rated, and feature on/off or proportional control

versions to interface to most eld control signals. The HRSN4 Series with battery backup operate on 24vac or

24vdc power supplies. Hayward offers 120v and 230v transformers packaged in stainless steel wall mounted

enclosures sized to provide the required power for the actuator and the battery system.

The battery pack and charge controller are housed in a side-mounted enclosure that is integral to the actuator

lower housing. Wiring of the actuator and battery system is completed through access to a single terminal

location. The battery system is designed to provide a minimum of two years of eld service (depending on

application and actual conditions of use). The battery pack is eld replaceable.

Notice: HRSN4 Series actuators are fully assembled, calibrated and tested prior to leaving our factory. In most cases, after

you have mounted the actuator to your device, you should be able to operate the actuator from fully CLOSED (CW) to fully

OPEN (CCW) and back again, and nd that no adjustments are needed. The assembly can be put into service immediately.

However, should it be necessary to make adjustments to the end-of-travel positions to overcome any device related issues

(i.e. valve shaft incorrectly timed to the drive stem), the procedures outlined below should be followed to put the assembly

into service. Note that there is a maximum adjustment range of +/- 3° at each end of travel.

Pages 10-11 - Travel limits for CW (CLOSED) & CCW (OPEN) positions, HRSN4 Series

Page 12 - Auxiliary switch cams for CW & CCW positions, HRSN4 Series

TABLE OF CONTENTS

HRSN4FS Series

Battery Backup

ACTUATOR OPERATIONAL CONCEPTS

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Control Voltage Torque Switches Fail Safe Local Control Station IOM Wiring Diagram Page

On/Off 24VDC/VAC XTS/TS FS None This IOM 28

Proportional 24VDC/VAC XTS/TS FS None This IOM 29

On/Off 120VAC * XTS/TS FS None This IOM 30

Proportional 120VAC * XTS/TS FS None This IOM 30

On/Off 230VAC * XTS/TS FS None This IOM 30

Proportional 230VAC * XTS/TS FS None This IOM 30

* Requires use of a transformer to convert supply voltage to 24V.

ACTUATOR OPTIONS

Below are Terms and Denitions used throughout this manual.

1. XTS/TS product manufactured without/with Torque Switches.

2. FS product manufactured with Fail Safe built-in.

3. LCS is an industry acronym for a Local Control Station.

4. CW is Clockwise and CCW is Counterclockwise.

CONVENTIONS USED IN THIS MANUAL

Use this table to efciently select the actuator and wiring diagram you require.

ACTUATOR SPECIFICATIONS

(20 SERIES)

Supply Torque Output (lbf-in / Nm) 3540 / 400 5310 / 600 7080 / 800 8850 / 1000

24VAC

24VDC

Current Draw (Start / Run / LRA) 7.0A / 5.8A / 15A 7.0A / 5.8A / 15A 7.0A / 5.8A / 15A 10.5A / 7.8A / 22A

Speed (90°) DC-60Hz/50Hz, seconds 21 / 21

28 / 28 34 / 34 34 / 34

Motor - 24V DC Perm Magnet 2 Pole Brush

40W 40W 40W 90W

On/Off /

Proportional

Duty Cycle (IEC60034) 75% (S2-15 min) /

75% (S4-75%)

Motor Protection, Temp / Class All - 130°C / Class B

Motor Starts, per hour, Max All - 600

Requires 120:24 Transformer Pack, 500VA HRSBBC120-500 HRSBBC120-500 HRSBBC120-500 HRSBBC120-500

120VAC

Transformer Current Draw (Inductive) 1.75A 1.75A 1.75A 2.63A

Speed (90°) 60Hz / 50Hz, seconds 21 / 21

28 / 28 34 / 34 32 / 34

Motor - 24V DC Perm Magnet 2 Pole Brush

40W 40W 40W 90W

On/Off /

Proportional

Duty Cycle (IEC60034) 75% (S2-15 min) /

75% (S4-75%)

Motor Protection, Temp / Class All - 130°C / Class B

Motor Starts, per hour, Max All - 600

Requires 230:24 Transformer Pack, 500VA HRSBBC230-500 HRSBBC230-500 HRSBBC230-500 HRSBBC230-500

230VAC

Transformer Current Draw (Inductive) 0.55A 0.55A 0.55A 0.55A

Speed (90°) 60Hz / 50Hz, seconds 21 / 21

28 / 28 34 / 34 32 / 34

Motor - 24V DC Perm Magnet 2 Pole Brush

40W 40W 40W 90W

On/Off /

Proportional

Duty Cycle (IEC60034) 75% (S2-15 min) /

75% (S4-75%)

Motor Protection, Temp / Class All - 130°C / Class B

Motor Starts, per hour, Max All - 600

All

Environmental Rating

NEMA 4/4X & IP67

Electrical Entry (2) 3/4" EMT or Polyamide gland

Control On/Off or Proportional

Auxiliary Switch - End of Travel (2) Form A Volt-Free, Rated 10A @ 250vac

Ambient Operating Range -22°F to +158°F / -30°C to +70°C

Humidity Range 0-95% RH

Altitude Limit 9850 ft / 3000 m

BATTERY

SPECIFICATIONS

Type Lithium Ion 22.2v pack with charge / discharge control

Cell Arrangement Bank of 8 (eight) x 2.8V w/ logic control

Service Life - @ Rated Torque Cycle Drain 10,000 cycles @ 5% Stored energy drain per cycle

Enclosure Entire Battery System under Main Cover

HRSN4A HRSN4B HRSN4C HRSN4D

HRSN4A~4D (20 SERIES)

TECHNICAL INFORMATION

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1. Position on arrival:

• A separate actuator arrives in the FULLY CLOSED (CW) position. The

red/green position indicator (see illustration) shows RED.

• A 2 way ball valve assembly arrives in the FULLY OPEN (CCW) position

and the position indicator shows GREEN.

• A 2 way buttery valve assembly arrives nearly CLOSED (5°) position

and the position indicator shows mostly RED.

2. Storage: This unit should not be stored outside unless it is powered up and

has proper conduit terminations. When not powered up, it should be stored

in a clean, dry environment at all times.

3. This quarter-turn actuator has been factory tested and calibrated to operate

between 0° and 90°. Most products will not require recalibration of these

settings. If any travel adjustment is necessary, please refer to the Adjusting

CW/CCW End of Travel section for instructions.

4. Notice: The HRSN4 Series actuators have mechanical stops which limit

rotation. Do not attempt to operate with a rotation greater than 95°.

5. Notice: Protect the actuator from moisture by installing it with water tight

EMT ttings and proper conduit drainage. Supply power to the unit to keep

the internal heater warm at the time of installation.

The actuator has a red and green position

indicator. RED color in the indicator

window means the actuator is fully

CW, while GREEN means it is fully CCW.

The manual override handwheel

allows a user to position the valve or

damper with or without power. Turn

the handwheel CW to make the output

drive move CW (when viewed from

above). Turning the handwheel CCW

makes the output drive turn CCW.

WARNING – To avoid dangerous or fatal electrical shock,

turn OFF power to all electrical equipment

before working on electrical connections.

CAUTION – Please follow the following guidelines for proper installation.

• WARNING – Do NOT install battery backup units in direct sunlight.

• These actuators are designed to be used between a horizontal and

upright position. Do NOT mount the assembly with the actuator top

below a horizontal position (i.e. upside down).

• When installing conduit, use proper techniques for entry into the actuator.

Use drip loops to prevent conduit condensate from entering the actuator.

• Mechanical travel stops are factory calibrated for 90 degree operation.

These stops are NOT designed to adjust mechanical rotation by more

than +/- 3 degrees, they are for positioning the handwheel only.

• Both EMT conduit ports MUST use proper equipment to protect the

NEMA 4X integrity of the housing.

• The internal heater is to be used in ALL applications.

• Do NOT install the actuator outdoors or in humid environments unless it

is powered up and the heater is functioning.

• Use proper wire size to prevent actuator failure (see Wire Sizing Chart for

proper wire sizing).

• All terminals accept 12-18AWG solid/stranded wire.

• Notice: Do NOT parallel wire multiple battery backup actuators. Battery

Backup units are designed to operate as stand-alone devices.

ACTUATOR HANDLING AND INSTALLATION

SHIPPING AND HANDLING

INSTALLATION NOTES

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CAUTION –

This device may be connected to multiple power

sources (mains power and internal battery) and may start

unexpectedly unless both power sources are disconnected.

Removable terminal blocks facilitate

ease of eld wiring and testing.To

remove a terminal block from the PCB

receiver,pull straight OUT in a direction

parallel to the PCB. Use caution

when reinserting block - make sure

all pins are aligned before seating.

Torque Switch (TS) equipped

products have a secondary set

of cams/switches to protect the

actuator, equipment and processes.

CCW

Notethattherotation seen frombelowisa

mirrorof the direction viewed fromabove.

1. The battery system should remain UNPLUGGED until AFTER the actuator

has been mounted and tested for proper travel and end stop calibration.

• The battery system will be connected during the Commissioning Procedure.

1. Fully CLOSE the valve or damper to which the actuator is to be mounted.

2. Assemble necessary linkage hardware and attach the actuator to the valve

or damper.

3. Center the actuator on the valve or damper drive shaft and tighten all hardware.

4. Before applying power to the unit, rotate the manual override handwheel

from the fully CW to the fully CCW position to check for unobstructed manual

operation of the valve or damper.

5. HRSN4 Series actuators utilize a removable terminal block to simplify eld

wiring and testing.

• To remove a terminal block from the PCB receiver, pull straight out in a

direction parallel to the PCB.

• In the photo at right, the RIGHT side of either terminal block (between the

PCB mounting screws) is pulled out to the RIGHT.

• After wiring, reinsert the terminal strip into the receiver.

This is a keyed pair and can only be inserted one way.

• Screw terminals are rated to accept 14AWG down to 18AWG solid or

stranded wire. TERMINAL NUMBERING HAS #1 AT THE BOTTOM.

6. Refer to your product part number to determine which wiring diagram to

follow when wiring up the actuator.

CAUTION – Be sure to make eld connections to the proper terminal

as identied by the LABEL and not the position!

Notice: Torque switches are factory set and are not adjustable.

7. Note that although terminals are labeled as 1-8 and A-D, not all terminals are

used on all models.

8. Make the electrical connections per the appropriate Wiring Diagram for

your actuator.

9. Connect POWER and CONTROL to the correct terminals.

10. Terminals A~D on each actuator are for the (adjustable) auxiliary switches.

These are dry type (volt free) Form A contacts rated 10A @ 250VAC Max.

11. Select actuators covered in this manual are equipped with torque switches

which protect the actuator motor and gear train. Torque switches protect

controlled valves or actuators from damage in the event of a high torque

condition. More information can be found throughout this manual.

Notice: All HRSN4 Series actuators rotate CW to close the output shaft

out the bottom of the actuator when viewed from above. On all HRSN4

models, the cam shaft and the indicator rotate CW to close as well.

PRODUCT MOUNTING AND SETUP

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Torque Switch Operation

Select HRSN4 units have torque switches to protect the actuator and any attached equipment from possible damage

which can occur in a high torque event. In such an event the valve or damper being driven encounters some blockage

or impediment to travel. In the case of an actuator without torque switches, the actuator will attempt to drive until it

Torque Switch cams and switches are shown

in the normal operating position.

Upper torque switch and

cam for actuator drive CW

rotation

Lower torque switch and

cam for actuator drive

CCW rotation

Upper cam has rotated

counter clockwise from its

neutral position and has

engaged the switch.

Torque Switch cams shown with the

upper cam tripping the upper switch

(Actuator was driving CW before this trip)

WARNING – Torque switches are factory set and are NOT ADJUSTABLE.

Changing these settings will void the actuator warranty.

either reaches the end of travel or (likely) the motor

overworks and trips on a thermal overload. Units

with torque switches will cease supplying power

to the motor when a high torque event occurs.

Torque Switch (Normal Mode)

1. In normal operating mode, the torque switch

and drive cam are in the neutral position

shown in the photo.

2. Internal gearing in line with the output drive

provide the rotational action for the cams.

3. Upper torque switch protects CW rotation.

4. Lower torque switch protects CCW rotation.

Torque Event (CW)

1. The photo at left shows a high torque event in

the CW direction

2. The torque switch CW drive cam (upper) and

switch are in the tripped position.

3. When the torque switch trips, it immediately

cuts off power ow to the motor for that

direction of travel.

Torque Event (CCW)

1. The photo at left shows a high torque event in

the CCW direction

2. The torque switch CCW drive cam (lower) and

switch are in the tripped position.

3. When the torque switch trips, it immediately

cuts off power ow to the motor for that

direction of travel.

Lower cam has rotated

clockwise from its neutral

position (above) and has

engaged the switch.

Torque Switch cams shown with the

lower cam tripping the lower switch

(Actuator was driving CCW before this trip)

TORQUE SWITCHES

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Battery Pack

Bracket

Battery Disconnect

Control Board

All eld terminations are made here

Introduction:

The HRSN4 Series Battery Backup units are tted

with a battery storage enclosure mounted to a

bracket inside the actuator as shown.

All wiring for the battery pack is complete and an

internal disconnect for the battery system is provided.

Notice:The batterysystemshould remain UNPLUGGED

until AFTER the actuator has been mounted and

tested for proper travel and end stop calibration.

WARNING –

Do NOT install battery backup

units in direct sunlight.

COMPONENT IDENTIFICATION

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Notes:

The enclosure, while NEMA 4X rated, should NOT

be installed in direct sunlight. If installed outdoors,

it should be installed in the shade under a rain hood

using rain-tight conduit ttings and connectors.

The Enclosure is a sealed NEMA 4X type stainless steel

type without conduit holes or knock-outs. This allows

complete exibility when mounting. The enclosure can

be oriented in any direction, and can be mounted on

wall, oor, ceiling, uni-strut or any other xed surface.

Conduit penetrations by others. Interconnect wiring

between transformer panel and actuator by others per

the supplied wiring diagram.

Power Supply:

The HRSN4 Series Battery Backup units require a

500VA 24vac / 20A 24vdc power supply directly into the

actuator terminal block.

To facilitate various site power availability, an optional

enclosure is offered which houses an appropriately sized

toroidal transformer to supply the 24V power to the

actuator. Mounted separately, the enclosure is a NEMA

4X / IP65 9 x 7 x 6 hinged door cabinet.

Mounted to a back plane, the transformer primary

and secondary are pre-wired to a six position dual

terminal block.

HRSN4 Series Transformer Enclosure

(120/230VAC Installations)

HRSN4 Series Transformer

(120/230VAC Installations)

HRSN4 Series Transformer Enclosure

Dimensional Data

Notice: All HRSN4 Series Battery Backup units require a 500VA 24vac / 20A 24vdc power supply directly

into the actuator terminal block.

9.0 / 228.66.0 / 152.4

7.0 / 177.8

Model Line Power Size

in / mm

Weight

lbs / kg

HRSBBC120-100 120VAC 100VA

9.0 W x 7.0 H

x 6.0 D

228.6 W x 177.8 H

x 52.4 D

12 / 5.5

HRSBBC120-250 120VAC 250VA 14 / 6.4

HRSBBC120-500 120VAC 500VA 20 / 9.1

HRSBBC230-100 230VAC 100VA 12 / 5.4

HRSBBC230-250 230VAC 250VA 14 / 6.4

HRSBBC230-500 230VAC 500VA 20 / 9.1

POWER SUPPLIES

120/230V TRANSFORMER MOUNTING AND SETUP

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CAUTION! - The mechanical

stop screw limits handwheel

operation ONLY and is NOT to

be used as an electrical travel

limiting device.

CAUTION! - There are dual power

sources in this actuator. Disconnect both

sources of power.

This actuator has been factory calibrated and tested to stop at 0 degrees for CW position and to stop at 90 degrees

for CCW position. Most installations onto valves or dampers will likely not require recalibration of these settings. Please

mount the valve or damper and proceed on these pages only if adjustments are required.

WARNING – Serious Damage to the actuator will result if the motor is allowed to drive the gear train into the

mechanical stop! Remove power from this device BEFORE making any travel adjustments.

CW Mechanical Stop

Cam 1 - CW Cam

CW Mechanical Stop

Reposition Mechanical Stop

1. Disconnect power.

2. Loosen the RIGHT SIDE mechanical stop. This is the CW mechanical stop

limit adjustment. Using a 17mm wrench and a 5mm hex key (22mm wrench

and a 6mm hex key for 4E and 4F units), hold the jam nut and turn the stop

screw 5-6 turns CCW so it clears the mechanical boss inside the actuator.

• This will allow you to adjust the cam/switch stop position without

running into the mechanical stop screw.

3. Use the manual override handwheel to position the actuator to your required

CW position. Keep all changes within +/- 3 degrees of the factory setting.

Adjust CW Cam (Bottom)

4. Cam 1 is the bottom cam (red) and is the end-of-travel adjustment for the

actuator CW position. With POWER OFF and the actuator at its required

CW position, use a sharp 2.5mm hex key to free up the cam set screw.

Take care not to let the hex key slip at this stage, it can easily strip out.

Once it is free adjust it as described below:

• Rotate the hex key to the RIGHT 10-15

degrees until you hear a click. This will

reset the switch roller arm.

• Gently tighten (CW) the set screw only

until slight pressure is felt. Ideally the

set screw rides along the camshaft.

• Now SLOWLY rotate the hex key to the

LEFT, pushing the cam, until you hear

the “click” on the bottom switch. The

click means correct adjustment has

been achieved.

• Tighten the cam set screw.

5. Apply power and test for the correct CW position:

• Drive the actuator CCW at least 15-20 degrees.

• Drive the actuator CW until the cam stops the electrical travel.

• Check to be sure this is the correct CW position you require

6. Repeat the steps of item 4 if further adjustment is needed.

Tighten Mechanical Stop

1. With the actuator in the proper position. Hold the 17mm wrench (22mm for

4E and 4F units), on the RIGHT SIDE jam nut to prevent the jam nut from

locking and turn the 5mm hex key (6mm for 4E and 4F units) CW until the

end of the stop screw bottoms out against the internal stop boss.

2. Turn the hex key ONE FULL TURN CCW and lock this position with the jam

nut. Now the actuator will reach its end of travel electrically before there is

any interference from the mechanical stop.

3. CW position calibration is now complete.

COM

NO NC

COM

NO NC

CW Limit Switch

Shown in CCW Position

CCW Limit Switch

Shown in CCW Position

Adjust for

Less CW

Adjust for

More CW

Adjust for

More CCW

Adjust for

Less CCW

COM

NO NC

Will drive 90°CW

CCW Limit Switch

Shown in Full CW Position

COM

NO NC

CW Limit Switch

Shown in Full CW Position

Will drive 90°CCW

ADJUSTING CW END OF TRAVEL

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