Kollmorgen 16097-06B FSA45 Absolute Feedback Servo Actuator

Description

Technical Specifications:

• Model Number: 16097-06B
• Manufacturer: Kollmorgen (Regal Rexnord / Fortive)
• Series: FSA45 (Quarter-Turn Servo Actuator)
• Actuator Type: Electric Quarter-Turn (90°) Rotary Servo Actuator
• Motor Type: Brushless DC (BLDC) Servo Motor
• Gearbox Type: Planetary Gearbox (15:1 ratio)
• Continuous Torque: 6 Nm (53 in-lb)
• Peak Torque: 18 Nm (159 in-lb)
• Rotation Angle: 90° (adjustable to 0–90° via software)
• Operating Speed: 0° to 90° in 2.5 seconds (no load)
• Bus Voltage: 24 VDC nominal (18–32 VDC range)
• Feedback Type: Multi-turn absolute encoder (12-bit, 4096 counts/rev)
• Encoder Resolution: 12-bit (0.088° per count)
• Position Accuracy: ±0.1°
• Position Repeatability: ±0.05°
• Control Input: 0–10 VDC or 4–20 mA (PWM)
• Feedback Output: 0–10 VDC or 4–20 mA (proportional to position)
• Limit Switches: 2× SPDT dry contacts (open/close indication)
• Protection Rating: IP67 (dust-tight, waterproof to 1 m for 30 min)
• Operating Temperature: -20°C to +70°C (-4°F to +158°F)
• Storage Temperature: -40°C to +85°C (-40°F to +185°F)
• Humidity: 5% to 95% (non-condensing)
• Mounting: Direct mount to valve shaft (ISO 5211 top flange)
• Dimensions (L×W×H): Approximately 200 × 90 × 90 mm (7.87 × 3.54 × 3.54 in)
• Weight: Approximately 2.8 kg (6.17 lbs)

Functional Features:

• Quarter-Turn Operation: Rotates 0° to 90° for on/off valve control; adjustable rotation angle via software (0–90°)
• Absolute Position Feedback: 12-bit multi-turn encoder provides exact position at power-on; no homing sequence required
• Integrated Motor Driver: Built-in PWM driver accepts 0–10 VDC or 4–20 mA control signal; no external drive required
• Proportional Position Feedback: Outputs 0–10 VDC or 4–20 mA proportional to shaft position for SCADA/DCS integration
• Limit Switch Outputs: 2× SPDT dry contacts indicate fully open and fully closed positions for interlocking
• Fail-Safe Position: Configurable fail-to-open or fail-to-close on power loss via internal spring return or motor holding
• Modulating Control: Supports proportional positioning (0–90°) for throttling and flow control applications
• IP67 Sealed Housing: Fully sealed against dust and water ingress; suitable for outdoor and washdown installations
• Low Maintenance: Brushless motor eliminates brush wear; planetary gearbox rated for >50,000 cycles
• Diagnostic Feedback: Provides position, torque, and fault status via analog outputs for predictive maintenance
• EMC Compliant: Meets EN 61326-1 (Industrial EMC) and EN 55011 Class B emissions standards
• Wide Voltage Range: Operates from 18 VDC to 32 VDC; tolerates industrial power supply fluctuations
• Adjustable Ramp Rates: Programmable acceleration and deceleration times (0.1–10 seconds) via external potentiometer or software

Performance Parameters:

Material Composition:

• Housing: Die-cast aluminum alloy (ADC12) with hard anodized finish (Type III, 50 µm)
• End Caps: Stainless steel (AISI 316L) with Viton O-ring seals for IP67 rating
• Gearbox: Hardened steel planetary gears (AISI 8620 case-hardened to 58–62 HRC) with synthetic lubricant
• Motor Stator: Silicon steel laminations (M19, 0.35 mm) with epoxy bonding
• Motor Rotor: Sintered NdFeB (Neodymium) permanent magnets with epoxy coating
• Shaft: AISI 4140 alloy steel, ground and polished, with keyway (DIN 6885)
• Bearings: Sealed ball bearings (608ZZ, 8 mm bore) rated for 10,000 hours L10 life
• Encoder: Optical multi-turn absolute encoder with stainless steel housing
• Terminal Block: Tin-plated phosphor bronze screw terminals (5.08 mm pitch)
• Cable Gland: Nickel-plated brass PG11 cable gland with silicone O-ring
• Internal Wiring: 22 AWG stranded tinned copper with silicone insulation (high-temp rated)
• Gaskets: Viton (FKM) O-rings on all housing joints for IP67 seal
• Label: Laser-etched stainless steel nameplate with model number, serial number, and ratings

Structural Features:

• Compact Cylindrical Housing: 90 mm diameter × 200 mm length; fits in tight valve mounting spaces
• ISO 5211 Mounting Flange: Top-mounted direct valve connection compatible with ISO 5211 F07/F10 valve flanges
• Front Panel: 4-pin connector for power/control input, 4-pin connector for feedback output, 2-pin connector for limit switches
• Rear Panel: Cable gland (PG11) for main power/signal cable entry; ventilation membrane for pressure equalization
• Shaft Output: 14 mm diameter keyed shaft (DIN 6885) with square drive (7×7 mm) for valve stem coupling
• Adjustable Rotation Limit: Mechanical stops adjustable via set screws on end caps (0–90° range)
• LED Indicators: Green LED (power on), Red LED (fault/alarm), Yellow LED (position feedback active)
• DIN Rail Clip (Optional): Snap-on DIN rail adapter (16097-DR) for panel mounting without valve connection
• Cable Gland: PG11 threaded cable gland with IP68-rated silicone seal
• Ventilation: Gore-Tex breathable membrane on rear cover for pressure equalization while maintaining IP67 seal

Working Principle:
The Kollmorgen 16097-06B FSA45 receives a control signal (0–10 VDC or 4–20 mA PWM) from a PLC, DCS, or controller. The integrated motor driver converts the PWM signal into 3-phase AC waveforms that drive the brushless DC motor. The motor rotates the planetary gearbox output shaft at a 15:1 reduction ratio, amplifying torque from 0.4 Nm (motor) to 6 Nm (output). The absolute multi-turn encoder mounted on the gearbox output shaft generates a 12-bit digital position value (0–4095) corresponding to the shaft angle (0° to 90° = 0 to 4095 counts). The encoder sends this value to the internal controller, which converts it to an analog feedback signal (0–10 VDC or 4–20 mA) proportional to position. The controller continuously compares the commanded position (from the input signal) to the actual position (from the encoder) and adjusts the motor drive PWM duty cycle to minimize the error. When the shaft reaches the target position, the motor holds position using closed-loop control with ±0.1° accuracy. The 2 limit switches are mechanically actuated by cams on the output shaft; when the shaft reaches fully open (90°) or fully closed (0°), the corresponding switch changes state, sending a dry contact signal to the controller for interlocking. On power loss, the actuator defaults to a configurable fail-safe position (fail-to-open via spring return or fail-to-close via motor holding brake).

Advantages and Highlights:

• Absolute Position Feedback: Exact position known at power-on; eliminates homing routine and reduces startup time
• IP67 Rated: Fully sealed against dust and water; suitable for outdoor, washdown, and marine installations
• Brushless Motor: Zero brush wear; MTBF >100,000 hours; maintenance-free operation
• 6 Nm Torque at 24 VDC: Sufficient for valves up to DN150 (6 inch) with high-pressure differential
• Proportional Control: Supports modulating valve positioning (0–90°) for flow and pressure control
• Integrated Driver: No external servo drive required; reduces wiring, cost, and panel space
• 50,000+ Cycle Life: Planetary gearbox rated for >50,000 full-stroke cycles at rated torque
• Fail-Safe Operation: Configurable fail-to-open or fail-to-close on power loss
• Diagnostic Feedback: Position, torque, and fault status available via analog outputs for predictive maintenance
• Wide Voltage Range: 18–32 VDC operation tolerates industrial power supply fluctuations
• No Pneumatic Infrastructure Required: Eliminates air compressors, filters, regulators, and air lines; reduces operating cost by 40–60% compared to pneumatic actuators
• Kollmorgen Ecosystem: Fully compatible with Kollmorgen AKM servo motors, AKD drives, and KM motion controllers
• ATEX Zone 2 Option: Available with intrinsically safe barrier for hazardous area installations (Zone 2, Class I Division 2)

Applicable Industries:

• Oil and Gas: Valve actuation on wellheads, pipeline block valves, flare system dampers, LNG terminal valves
• Power Generation: Steam turbine bypass valves, gas turbine fuel valves, cooling water control valves, damper actuation
• Water and Wastewater: Butterfly valve control, gate valve actuation, sludge valve positioning, chemical dosing valves
• Marine: Ship ballast valve control, seawater intake valves, fire suppression damper actuation, bilge pump valves
• Chemical Processing: Corrosive fluid valve control, high-pressure throttling valves, reactor feed valves
• Food and Beverage: Sanitary valve actuation (3A/EHEDG compliant variants available), CIP system valve control
• Pharmaceutical: Cleanroom valve actuation, sterile process valve control, HVAC damper positioning
• HVAC and Building Automation: Large damper actuation, chilled water valve control, cooling tower fan dampers
• Mining: Slurry valve control, dust suppression damper actuation, ventilation damper positioning
• Pulp and Paper: Stock valve control, white water valve actuation, dryer exhaust dampers

Model Series:

Installation Requirements:

• Mounting: Direct mount to valve shaft using ISO 5211 F07/F10 flange; torque mounting bolts to 25 Nm (18 ft-lb)
• Valve Shaft Coupling: Use 7×7 mm square drive coupling; do not use set-screw couplings (causes shaft damage)
• Cable Entry: PG11 cable gland on rear panel; use shielded cable (minimum 4-core, 0.5 mm²)
• Wiring: Connect 24 VDC power to terminals 1 (+) and 2 (−); connect control signal (0–10 VDC or 4–20 mA) to terminals 3 (signal +) and 4 (signal −); connect feedback output to terminals 5 (feedback +) and 6 (feedback −); connect limit switches to terminals 7 (common), 8 (NO), 9 (NC)
• Grounding: Connect chassis ground terminal (PE) to building equipment grounding conductor; ground resistance <1 Ω
• Ambient Temperature: Install in environment -20°C to +70°C; derate torque by 10% per 10°C above 50°C
• Clearance: Maintain minimum 50 mm (2 in) clearance around actuator for ventilation and cable routing
• Enclosure (Outdoor): Install in NEMA 4X or IP66 rated enclosure if ambient exceeds IP67 rating
• Torque on Fasteners: Tighten all terminal screws to 0.5 Nm (4.4 in-lb); re-torque after 72 hours
• Limit Switch Adjustment: Set mechanical stops on end caps to 0° (closed) and 90° (open); verify with multimeter on limit switch contacts
• Fail-Safe Configuration: Set fail-to-open or fail-to-close via internal DIP switches (SW1, SW2) before commissioning

Usage Precautions:

• Do not exceed 32 VDC supply voltage: Overvoltage above 120% of rated voltage (28.8 VDC) damages motor driver permanently
• Do not exceed 90° rotation angle: Forcing the shaft beyond mechanical stops destroys the gearbox and encoder
• Do not apply axial load exceeding 500 N (112 lbs): Excessive axial thrust damages bearings and reduces MTBF
• Do not apply radial load exceeding 200 N (45 lbs): Radial forces beyond rating destroy bearing preload
• Do not operate without control signal: The actuator requires a continuous PWM signal; loss of signal triggers fault condition and motor brake engagement
• Do not reverse polarity on 24 VDC power: Reverse polarity damages the internal motor driver; use a diode protection module if polarity reversal is possible
• Do not disassemble the actuator in the field: The actuator is sealed at the factory; opening the housing voids IP67 rating and warranty
• Do not use unshielded cable: Unshielded cables introduce EMI noise into the encoder signal; always use shielded twisted-pair cable
• Do not ground the cable shield at both ends: Ground the shield at the actuator end only (single-point grounding) to avoid ground loops
• Perform insulation test before first use: Measure >100 MΩ at 500 VDC between all terminals and chassis ground
• Test monthly per IEC 61508: Perform full functional test of actuator position, torque, and limit switches at least once per month
• Do not operate above 70°C ambient: Exceeding temperature range voids warranty and degrades encoder accuracy
• Replace every 10 years or 50,000 cycles: Even if functional, gearbox wear and magnet demagnetization reduce reliability; replace per Kollmorgen lifecycle recommendation
• Use only Kollmorgen-specified cables: Signal cable must be shielded twisted pair (STP), 4-core, 0.5 mm² minimum
• Record all fault events: Export diagnostic data via Kollmorgen WorkBench software after every fault for regulatory compliance
• Do not paint the housing: Paint covers ventilation membrane and nameplate; voids UL listing and IP67 rating
• Do not install in explosive atmospheres without ATEX variant: Standard model is not certified for Zone 1/2; use 16097-06B-ATEX for hazardous locations
• Verify valve torque requirement before selection: Ensure valve torque at operating pressure does not exceed 6 Nm (53 in-lb); oversizing the valve causes actuator stall and overheating
• Do not block the ventilation membrane: The Gore-Tex membrane must remain unobstructed for pressure equalization; blocking it causes seal failure