Water Tight

Quarter Turn
Electric Actuators
 Fail-Safe FS-800

Intelligent Fail-Safe
The Electra FS-800 actuator provides fail-safe
operation when the electrical supply main power is
not present. When the supply main power is present
the actuator operates like a standard quarter-turn
electric actuator, using the supply main power to
open or close under powered operation. Upon loss
of supply main power the actuator automatically
senses this voltage drop in the supply main power
and switches to the capacitor stored energy power,
to open or close the valve to the predetermined
failsafe position.

Cutting Edge Capacitor

Technology
State of the art capacitors can achieve over 600
“fully charged to discharge” life cycles, for reliable
fail-safe operation.

Modular Construction
Truly modular design allows the actuator to be easily
field modified and serviced.

High Strength Transmission

One piece worm gear and segment are precision
machined for efficient energy transfer, quiet operation
and long service life.

Guaranteed Minimum Torques

All actuators are torque tested under load before
shipment. We guarantee that the output torque meet
the rating on the tag.

NEMA 4 Enclosure
Actuators contain o-rings to ensure no ingress
of moisture. The ceramic heater is standard and
protects the actuator against condensation.

Extended Duty Cycle

Electra actuators are rated for extended duty service,
with extended performance of starts and stops
per hour.

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 FS-800 / Operation

Operation
The Electra fail-safe actuator can be configured to respond to loss
of power in either:
Automatic close on loss of power / Fail Closed
Automatic open on loss of power / Fail Open

The fully charged capacitor stores enough power to cycle the

actuator (1) full cycles upon loss of supply main power. Once supply
main power is restored to the actuator, the capacitor will trickle
charge until it has reached a full charge.

Both modulating and on/off actuators have LED lamps to identify the
actuator diagnostics. The actuator LED diagnostics signal closed /
FS 800-02 open/ over-torque or charging status.
4th Generation
Modulating actuators have additional LCD display for detailed
modulating control diagnostics.

Local Control Station (Optional)

The Electra fail-safe actuator is available with optional local control
station for local control of the actuator functions.

Simple to operate (2) control knobs for:open/close and stop/local/

remote control.
Knobs can be padlocked to ensure tamper proof operation.
Designed to withstand high vibration environments.
Recessed control knob design for added moisture resistance in
outdoor applications.

Modulating Digital High Resolution

The high resolution modulating control card (MCC) makes the
Electra fail-safe the most intelligent actuator on the market today.

Features:
Dip switch adjustable input signal of 4-20 ma, or 0-10 / 2-10 /
0-5 / 1-5 VDC.
Feedback is standard 4-20 ma output.
Dip switch adjustable fail position on loss of control signal.
LED light indication for Power / Fault / Closed and Open diag-
nostics at the modulating card.
Cycle time delay adjustment from 1.0- 8.5 seconds that acts as
a governor to protect the motor against to excesive re-positions.
The tolerance between the input signal and the position of the
actuator dead band adjustment to reduce hunting.
Auto-scan mode allows for 1-touch automatic calibration from
the open to closed mechanical limit switches.

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 FS-800 / Features
Capacitor Pack - Detail

6
2

4
FS-800-03 7

3
9 8 1

Design Features
1. Enclosure 4. Terminal Strip
Die cast aluminum alloy housing is light, compact and durable. Highly visible labeling for every connection to help avoid wiring
The housing is hard anodized inside and out, then polyester mistakes. Maximum 25 points are standard. Spring loaded
powder coated on the exterior for superior corrosion protection terminal strip is proven reliable way to keep a tight wiring
in all environments. The housing is engineered with overlaying connection.
lips that form a barrier ring that allows the water to shed off
and not enter the housing. The housing is rated NEMA 4 for 5. LED Indication
protection from ingress of dirt or moisture. LED Indication for on/off and modulating actuators for open and
closed end of travel position, torque faults and charging status.
2. Motor
Advanced DC motors are engineered for high-torque, low 6. Modulating LCD Display
current draw, and extended duty ratings. DC motors eliminate LCD Display gives the operator real time actuator diagnostics
noise and electrical sparks to increase the number of starts on a bright easy to view screen. The LCD display allows for
and stops per hour. DC motors are equipped with reduction simple one step calibration of modulating actuators.
spur gearing for maximum mechanical advantage. The in-
coming 120 VAC power is converted to DC power through 7. Digital High Resolution Servo Card
the transformer inside the fail-safe compartment. Modulating digital high resolution printed circuit board (PCB)
achieves 1000 points of resolution per 90°.
3. Fail-Safe Compartment
Houses the capacitor pack is easily field serviceable and 8. Electrical Tag
consists of the printed circuit board and capacitors. The PCB The UL approved label details electrical rating and enclosure type.
allows for intelligent capacitor trickle charging of the 120 VAC
incoming power. Located behind the PCB is the capacitors 9. Weather Seals
which store the energy for fail-safe operation. Elastomer o-ring seals prevents the ingress of moisture and debris.

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 FS-800 / Mechanical
2

1 6
4

1. Self Locking Gearing 4. Actuator Mounting

High efficiency, self locking double reduction gearing consists Drilling is in accordance with ISO 5211 allowing easy mechanical
of a worm and segment gear output mechanism. Precision installation of the actuator directly to other ISO flanged valves.
cut steel worm wheel and bronze segment are engineered to Each actuator is supplied with a blank drive insert, machining
withstand locked rotor conditions. When electrical power is by others.
off, the gearing provides exact and stable positioning of the
actuator without a brake. All gearing is greased and lubricated 5. Mechanical Travel Stops
for life. Externally adjustable stainless steel mechanical travel stops
are provided to permit precise travel adjustment of the actuator
2. Position Indicator movement. The settings of the mechanical stops provides travel
The position indicator is mechanically driven by the output limitation for both electrical and manual operation in the open
drive shaft for reliable opening and closing status of the and closed position.
valve. The movement of the valve can be easily viewed from
the top of the actuator. The lens is permanently sealed to 6. Declutching Override
guard against condensation. For manual positioning of the valve when power is off.

3. Disc Springs 7. High Cycle Mechanical Bearing

Located at each end of the main worm wheel these “Belleville Located under the motor to allow smooth energy transfer from
washers” detect axial torque movement in either the open or the motor to the gear train.
the closed location and translate the movement to the torque
switch for motor protection.

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 FS-800 / Mechanical

Manual Operation
Allows the valve to be rotated when power is not present. The hand/auto
declutch lever makes manual valve operation simple, no cheater bar is
needed even for tightly sealed valves. With very low effort the lever pulls
towards the handwheel and locks perpendicular. The casting marks on
the handwheel show the rotation direction of handwheel. Once power
is restored to the actuator, the internal clutch mechanism automatically
returns to the original position. The clutch ensures that the handwheel
can’t be rotated by the motor. The hand lever can be pad locked in either
auto or hand mode for safety.
Actuator shown in auto mode

Torque Limit Switches

Torque switches (2) are factory calibrated and provided standard with
each actuator. For the open and close ends of travel each torque limit
switch independently responds, and are used to stop the travel of the
valve if the output torque of the actuator exceeds a preset amount. The
switches sense the movement of the worm shaft, and interrupts electrical
power to the motor, this allows for protection of the valve and actuator.

Heater and Thermostat

The pre-wired space heater is installed in every actuator to prevent dam-
age caused by condensation. The heater is equipped with a thermostat
to prevent overheating.

• On/Off actuators need to be wired to supply power to the heater and

thermostat.

• Modulating actuators are pre-jumpered so when power is supplied to the

actuator, the heater and thermostat will function properly.

Travel Limit Switch

The series FS800 Fail-Safe actuator is standard with (2) SPDT travel limit
switches and (2) SPDT auxiliary switches for the open/closed positions.
The (2) travel limit switches are used to shut the motor down at end of
travel. The (2) auxiliary switches are used to communicate with other ap-
pliances. Cams for each of the four switches are intermittently adjustable
by hand with an allen wrench. Each cam is labeled for simple field
calibration. Once the cam is set it locks in place and is engineered to
withstand plant induced vibration.

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 FS-800 / Modulating MCC Card
Fig A
The Electra fail-safe modulating “control card” MCC,
is a digital high resolution servo card for reliable
1 2 3 4
intelligent control. The incoming power is connected
to the board with male and female connectors to allow
for quick and easy field serviceability.

Failsafe FS-800 Modulating Control Card

MCC Features:
• Push button “Zero / Span” and “Auto Scan”
(ASCN) control for easy calibration.
• Dip switch selectable “Fail Position” and “Reverse
Acting Mode”.
• “Dead Band” and “Time Delay” trim pots.
• LED onboard diagnostics for real time indication
of the actuator status.

1 Push Button Control (see fig A) 3 Trim Pots (see fig A)

2 Dip Switch Action Settings (see fig A) 4 LED Diagnostics (see fig A)

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 FS-800 / Modulating LCD

The Electra fail-safe modulating actuator contains a 32 bit LCD screen. LCD Layout
This LCD display provides real time actuator status and diagnostics in
an easy-to-use, easy to read, graphical format.
1
The large user friendly LCD display allows for easy set up of the
high resolution digital servo card. Once the appropriate setting or 2
7
dip switch is confirmed on the digital servo card, it will display this 3
information on the LCD screen.
4 6
Failsafe FS-800 modulating LCD Display features: 5
• Direction of travel monitoring:
Full Closed / Closing / Stop / Opening / Full Open
• Predetermined fail position: Fail Open or Fail Closed 1 Full Closed / Closing / Stop / Opening / Full Open
• Dead Band sensitivity setting (factory set to 1.3%) 2 Loss of Signal: F-CL (Closed) / F-OP (Open)
• Confirmation of input signal 3 Dead Band
• Actuator percentage open / closed position
• Reverse acting mode: 4 Delay Time
Switches the start point of the input signal position. 5 Input Signal
• Loss of input control signal 6 Actuator Position
• Auto scan mode:
This feature allows for 1-touch automatic calibration from the 7 Reverse Acting
open to closed mechanical limit switches.

Direction of Travel Monitoring Reverse Acting Mode

Loss of Input Signal Auto Scan Mode

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 FS-800 / Performance
Sample Model #: FS800-02 (120 VAC Electric, Output Torque of 2124 - In LB)
Torque Model / Amp Draw
Speed of Actuator Number of Handwheel
120 VAC Number of Actuator Weight lbs.
In-Lb nm 60 HZ Turns 90°
Series 44
2124 240 2.4 02 33 12 39
3098 350 3.8 03 34 14 50
4426 500 5.0 05 34 14 50

Specification
Enclosure Weather proof enclosure NEMA 4X / IP66
Power Supply 120 VAC, Single Phase 50 / 60 Hertz ± 10%
Duty Cycle 70% / 30 minute continuous rating
Motor 24 VDC advanced high torque output
Limit Switches 2 SPDT open and closed, 250 VAC 10 Amp rating
Auxiliary Limit Switches 2 SPDT open and closed, 250 VAC 10 Amp rating
Torque Switches Open / close, SPDT, 250 VAC 10 Amp rating
Thermal Overload Protection Open 302°F ± 40°F / close 206°F ± 59°F
Rotation 90°F ± 10°F (0° - 110°)
Indicator Continuous Position Indicator
Manual Override Declutching Mechanism
Self Lockig Gears Provided by double reduction warm gearing
Mechanical Stop (2) External Adjustable Hex Head Bolts
Space Heater 7-10 Watt for Anti-Condensation
Conduit Entries (2) 3/4” NPT Tapped Entrances
Lubrication Grease Moly (EP type)
Terminal Strip Spring Loaded Push Lever Type
Operating Temperature -4° to + 140°F
Humidity 90% RH maximum non-condensing
Anti-Vibration & Shock XYZ AXIAL 10g / Frequency: 0.2 - 34 Hz within 30 min.
External Coating Anodized treated and polyester powder
Capacitor Charging Full charge and discharge 600 times
Stored Energy Cycles Minimum (1) Full Cycle for emergency operation
FS800-02 Never needs to be replaced
Capacitor Life Cycles
FS800-03 and FS800-05 After 2 Years Replace capacitor Pack
Modulating Control Card (optional) MCC Resolution is 1/1000 - Digital MCC achieves 1000 points of resolution

LED Capacitor Pack Indication

Led Lamp Signal

Green Close Yellow Over Torque

Red Open White Fully Charged Capacitor
Flashing Light Capacitor Charging

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 FS-800 / Dimensional

Đ
Y

4
R K L

0
Đ
01ĐĐĐ
01ĐĐ P
S
ĐĐ04Đ

M
Z
X

N
R H I J
O
Q

7.0

4.0
Auto Hand

G
F
D
4-A*B
E C
FS-800-02-04 Gen IV Detail

4-A*B

Inches
Base ISO
5211 A
Model D E F G H I J K L M N O P Q R S X Y Z
ØC B
F07/F10 M8/M10
FS800-02 .86 4.92 .12 1.65 2.87 7.87 2.55 5.59 3.43 7.56 2.68 2.13 3.07 6.30 6.33 8.00 13.31 9.02 10.24
Ø70/Ø102 12/15
F10/F12 M10/M12
FS800-03 1.37 5.82 .12 1.93 3.23 8.70 2.55 6.30 3.90 8.70 2.72 2.56 3.07 7.09 6.33 8.00 14.49 10.20 11.42
Ø70/Ø102 15/18
F10/F12 M10/M12
FS800-05 1.37 5.82 .12 1.93 3.23 8.70 2.55 6.30 3.90 8.70 2.72 2.56 3.07 7.09 6.33 8.00 14.49 10.20 11.42
Ø102/Ø125 15/18

Notes: 1. The “D” dimension is the maximum allowable bore that can be machined into the insert.
2. The machining is done by others, as the standard inset is blank.
3) FS-800 = 120 VAC

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 FS-800 / Assembly Number

Model Number
Series Size Enclosure Controls Options

FS800 03 04 E

1 2 3 4 5

1. Series 3. Enclosure

FS800 = Electra Fail-Safe Actuator 04 = NEMA 4 Housing

2. Size 4. Controls

O = Open / Closed
02 = 2124 In-Lb Torque
E= 0-10 VDC or 4-20 ma
03 = 3098 In-Lb Torque
05 = 4340 In-Lb Torque

5. Options

L = Local Control Station

A. Warranty
The seller warrants its product against defects in material or workmanship, under normal conditions of use, for a period of one
year from the date of original shipment. The seller’s obligation under this warranty is limited to repair or replacement at seller’s
option. Shipping charges are prepaid to factory and all goods must have a return authorization number.

B. Storage
The actuator must be stored in a clean, dry, temperature controlled area. The unit shall be stored with the cover installed and
with the conduit openings sealed. Storage must be off the floor, covered with an unsealed dust protector that will allow side and
bottom ventilation. Care must be taken to guard the actuator from condensation in extreme temperature variations. If actuators
sit for an extended period of time it is recommended that the heaters be hooked up.

C. Moisture Warning
Series 44 actuators are rated NEMA 4. The only way moisture can enter the actuator is through the conduit entrance.
Extra precaution should be used to stop moisture from entering the actuator. Seal tight fittings as well as drip legs
and potting compounds should be installed to protect the actuator against condensation. If moisture migrates up the
conduit entrance and damages components, the parts are not covered under warranty.

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 Electrical On/Off FS800-02

120 VAC

MODEL FS 800-02 Generation IV / 7-18-12

TORQUE AND LIMIT SWITCHES OPERATION
CLS : CLOSE LIMIT SWITCH (250VAC 10A) SWITCH CLOSE INTERMEDIATE OPEN
CLS 1-2
OLS : OPEN LIMIT SWITCH (250VAC 10A)
CLS 1-3
CTS : CLOSE TORQUE SWITCH (250VAC 10A)
OLS 1-2
OTS : OPEN TORQUE SWITCH (250VAC 10A)
OLS 1-3
ACLS : AUX. CLOSE LIMIT SWITCH (250VAC 10A) ACLS 1-2
AOLS : AUX. OPEN LIMIT SWITCH (250VAC 10A) ACLS 1-3
TP : THERMAL PROTECTOR (250VAC 15A OPTION) AOLS 1-2
*EACH ACTUATOR SHOULD BE POWERED THROUGH ITS OWN AOLS 1-3
INDIVIDUAL SWITCH OR RELAY CONTACTS TO PREVENT * CLOSING TORQUE SWITCH INTERRUPTS CONTROL IF
CTS 1-3
MECHANICAL OVERLOAD OCCURS DURING CLOSING CYCLE
CROSS FEED BETWEEN TWO OR MORE ACTUATORS.
* OPENING TORQUE SWITCH INTERRUPTS CONTROL IF
OTS 1-3
MECHANICAL OVERLOAD OCCURS DURING OPENING CYCLE

Electrical Notes:
The capacitor power plug located in the fail-safe compartment is disconnected from the capacitor printed circuit board (PCB) for
safety. Before operation the user must connect the power plug back to the PCB. The capacitor needs to be fully charged for a
minimum of 6 hours before the first operation. Seal tight water tight conduit connectors must be used to maintain NEMA 4 rating.

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 FS800-03
FS800-05 Electrical On/Off

120 VAC

CAPACITOR PACK

MODEL FS 800-02 / FS 800-05 Generation IV / 7-18-12

TORQUE AND LIMIT SWITCHES OPERATION
CLS : CLOSE LIMIT SWITCH (250VAC 10A) SWITCH CLOSE INTERMEDIATE OPEN
CLS 1-2
OLS : OPEN LIMIT SWITCH (250VAC 10A)
CLS 1-3
CTS : CLOSE TORQUE SWITCH (250VAC 10A)
OLS 1-2
OTS : OPEN TORQUE SWITCH (250VAC 10A)
OLS 1-3
ACLS : AUX. CLOSE LIMIT SWITCH (250VAC 10A) ACLS 1-2
AOLS : AUX. OPEN LIMIT SWITCH (250VAC 10A) ACLS 1-3
TP : THERMAL PROTECTOR (250VAC 15A OPTION) AOLS 1-2
*EACH ACTUATOR SHOULD BE POWERED THROUGH ITS OWN AOLS 1-3
INDIVIDUAL SWITCH OR RELAY CONTACTS TO PREVENT * CLOSING TORQUE SWITCH INTERRUPTS CONTROL IF
CTS 1-3
MECHANICAL OVERLOAD OCCURS DURING CLOSING CYCLE
CROSS FEED BETWEEN TWO OR MORE ACTUATORS.
* OPENING TORQUE SWITCH INTERRUPTS CONTROL IF
OTS 1-3
MECHANICAL OVERLOAD OCCURS DURING OPENING CYCLE

Electrical Notes:
The capacitor power plug located in the fail-safe compartment is disconnected from the capacitor printed circuit board (PCB) for
safety. Before operation the user must connect the power plug back to the PCB. The capacitor needs to be fully charged for a minimum
of 6 hours before the first operation. Seal tight water tight conduit connectors must be used to maintain NEMA 4 rating.

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 Electrical Modulating FS800-02

MCC
Modulating
Control Card

MODEL FS 800-02 Generation IV / 7-18-12

TORQUE AND LIMIT SWITCHES OPERATION
CLS : CLOSE LIMIT SWITCH (250VAC 10A) SWITCH CLOSE INTERMEDIATE OPEN
CLS 1-2
OLS : OPEN LIMIT SWITCH (250VAC 10A)
CLS 1-3
CTS : CLOSE TORQUE SWITCH (250VAC 10A)
OLS 1-2
OTS : OPEN TORQUE SWITCH (250VAC 10A)
OLS 1-3
ACLS : AUX. CLOSE LIMIT SWITCH (250VAC 10A) ACLS 1-2
AOLS : AUX. OPEN LIMIT SWITCH (250VAC 10A) ACLS 1-3
TP : THERMAL PROTECTOR (250VAC 15A OPTION) AOLS 1-2
*EACH ACTUATOR SHOULD BE POWERED THROUGH ITS OWN AOLS 1-3
INDIVIDUAL SWITCH OR RELAY CONTACTS TO PREVENT * CLOSING TORQUE SWITCH INTERRUPTS CONTROL IF
CTS 1-3
MECHANICAL OVERLOAD OCCURS DURING CLOSING CYCLE
CROSS FEED BETWEEN TWO OR MORE ACTUATORS.
* OPENING TORQUE SWITCH INTERRUPTS CONTROL IF
OTS 1-3
MECHANICAL OVERLOAD OCCURS DURING OPENING CYCLE

Electrical Notes:
The capacitor power plug located in the fail-safe compartment is disconnected from the capacitor printed circuit board (PCB) for
safety. Before operation the user must connect the power plug back to the PCB. The capacitor needs to be fully charged for a minimum
of 6 hours before the first operation. Seal tight water tight conduit connectors must be used to maintain NEMA 4 rating.
7

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 FS800-03
FS800-05 Electrical Modulating

MCC
Modulating
Control Card
CAPACITOR PACK

MODEL FS 800-02 / FS 800-05 Generation IV / 7-18-12

TORQUE AND LIMIT SWITCHES OPERATION
CLS : CLOSE LIMIT SWITCH (250VAC 10A) SWITCH CLOSE INTERMEDIATE OPEN
CLS 1-2
OLS : OPEN LIMIT SWITCH (250VAC 10A)
CLS 1-3
CTS : CLOSE TORQUE SWITCH (250VAC 10A)
OLS 1-2
OTS : OPEN TORQUE SWITCH (250VAC 10A)
OLS 1-3
ACLS : AUX. CLOSE LIMIT SWITCH (250VAC 10A) ACLS 1-2
AOLS : AUX. OPEN LIMIT SWITCH (250VAC 10A) ACLS 1-3
TP : THERMAL PROTECTOR (250VAC 15A OPTION) AOLS 1-2
*EACH ACTUATOR SHOULD BE POWERED THROUGH ITS OWN AOLS 1-3
INDIVIDUAL SWITCH OR RELAY CONTACTS TO PREVENT * CLOSING TORQUE SWITCH INTERRUPTS CONTROL IF
CTS 1-3
MECHANICAL OVERLOAD OCCURS DURING CLOSING CYCLE
CROSS FEED BETWEEN TWO OR MORE ACTUATORS.
* OPENING TORQUE SWITCH INTERRUPTS CONTROL IF
OTS 1-3
MECHANICAL OVERLOAD OCCURS DURING OPENING CYCLE

Electrical Notes:
The capacitor power plug located in the fail-safe compartment is disconnected from the capacitor printed circuit board (PCB) for
safety. Before operation the user must connect the power plug back to the PCB. The capacitor needs to be fully charged for a minimum
of 6 hours before the first operation. Seal tight water tight conduit connectors must be used to maintain NEMA 4 rating.

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4575 Damascus Road • Memphis, Tennessee • Phone 901-794-5790 Fax 901-363-1123
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