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Operation instructions Electric actuators SIPOS 5 ECOTRON

1. 28 6 Status and fault signals 35 7 Maintenance inspection SOVICE nei 37 7 4 General E 37 7 2 Lubrication intervals and lubricants 38 8 Spare DAWES deen egene geedEdeugeb 39 8 1 Belur 39 82 Spare parts list manns 39 8 3 Exploded views ccccccccsseeseeeeseees 40 9 MAE E 48 Original Declaration of Incorporation of Partly Completed Machinery EC Directive 2006 42 EC and EC Declaration of Conformity in compliance with the Directives on EMC and Low Voltage 51 Y070 019 GB 1 1 A Operation instructions 1 General information SIPOS 5 ECOTRON General information Safety information General The devices referred to in this document applies are components of installations conceived for industrial applications They are designed in accordance with the recognized engineering rules All work involved in transport assembly installation commissioning maintenance and repair has to be performed by qualified personnel Qualified personnel within the meaning of the safety instructions of this documentation are all persons authorized to perform the required tasks according to the standards of safety technology and which may recognize and avoid potential hazards They must be thoroughly familiar with the warnings at the device and the safety instructions of these operation instructions For work on power installations the prohibition of the use of non qualified persons or s
2. 12 Page 48 Operation instructions SIPOS 5 ECOTRON Electrostatically ssietcnionsioeniasleiteintierssanentsovianawane 4 End position adjustment 30 Prerequisite 00 30 Exploded views 40 F Ile 18 Fieldbus FT avse 7 Siesta ele VE 6 H Hand Cla NE NESTEEEOURENSUESEEHRE 19 Danger of crushing Refer to Safety information Operation 15 Hand WEE WE 15 Indication Valve position 34 Indications PEDD 16 17 SG gt EE EE deren 17 SIE EE EE 30 L BR 16 Reie EE 16 Local control station Functions of the push buttons 16 Baier 16 06 155 1 PE 38 Lubrication Intervals a eraravnrarrsranererrvannnre 38 M Maintenance EE ernennen 37 Mechanical connection ersrornvrvarnavervnnnnrer 9 Mechanical position mdcator 34 EE 18 MODBUS operation Imstruchons 5 Motor al ales i G RE EE 27 Motor temperature protection 27 Motor temperature warning rrrrrnrrrnvnnrrnnnr 27 Y070 019 GB Operation instructions SIPOS 5 ECOTRON N NONE NN 4 O Output drive shaft rrrrrnnrnrnnrrrarerranenranennn 41 GT fe GE 9 General assembly instructions 9 Version type A 9 Output signal set 25 P Keren ao EEE ES rt 4 Permanent contact uns 26 Pol 8 Position indicator u 244424 Rennen 32 34 Potential Conductor external 13 Potentiometer ae 20 POWEL MOQU En 7 Procedures
3. 219U99 I N 2 1 2 General Operation instructions SIPOS 5 ECOTRON General Functional principle Description The electronics with integral frequency converter 1 controls the motor 2 The motor turns the output drive shaft 4 via the worm shaft 3 The output drive shaft 4 drives a gear or a valve stem 5 via a stem nut The motion of the worm shaft 3 is transferred via the signaling shaft 6 to the signaling gear 7 The signaling gear reduces the movement and turns the potentiometer or the magnetic travel sen sor 8 From the position of the potentiometer or the magnetic travel sensor the electronics recognizes the position of the output shaft 9 and therefore the position of the operated valve The motor is controlled according to the process requirements The torque detection DE is performed electronically Fig Functional priniciple Page 6 Y070 019 GB 2 2 Operation instructions SIPOS 5 ECOTRON Sub assemblies The actuators of the SIPOS 5 series comprise two main assemblies gear unit and electronics unit For details see chapter 9 Spare parts The main sub assembly gear consists of the following sub assemblies 1 Plug element electronic connection 2 Motor 3 Gear unit 4 Signaling gear not for 2565 with cover 5 Manual drive with crank or hand wheel 6 Possible mechanical extensions depending on the version For the small 2565 part turn actuator the sig
4. Unscrew connection hood fig item 1 and cover for electronic housing 7 Unscrew screw plugs from the required cable glands in the connection hood Screw in the cable glands 2 only slightly and insert the connecting cables 3 AA Q N gt Take off terminal plug X1 4 from the power control PCB and terminal plugs X3 1 X3 2 6 from the control board If a relay board is used then remove terminal plugs X2 1 X2 2 5 If required use a screw driver to carefully eject the plugs from the sockets 5 Connect the connecting cables in accordance with the circuit diagram enclosed in the connection hood connecting the earth lead conductor to the provided terminal in the connection box 6 Reconnect all terminal plugs 7 Fit connection hood fig item 1 and cover for electronic housing 7 again 8 Tighten cable glands 2 Y070 019 GB Page 11 3 Assembly and connection Operation instructions SIPOS 5 ECOTRON 3 2 2 Connection with round plug 1 Unscrew connection hood fig item 2 with plug element 1 2 Unscrew screw plugs from the required cable glands in the connection hood 3 Unscrew plug element 1 from connection housing 2 4 Screw in the cable gland 3 only slightly and insert the connecting cables 4 5 Connect the connecting cables in accordance with the circuit diagram enclosed in the con nection hood connecting the earth lead to the provided terminal in the connection box 6 Screw p
5. 121 136 152 u e Standard 50 Page 22 Y070 019 GB Operation instructions 5 Commissioning SIPOS 5 ECOTRON Tripping torques for part turn actuator 2SC5 Possible values for setting Nm Standard actuator 2SC50 150 250 150 200 Deren 150 500 300 330 1100 660 770 660 Tripping range OT O 8 OT CH NO N O1 QD O1 gt WEI gt a QI O N O a CO gt N S 5 N O CH gt N CO We O O S 330 1100 330 5 77 690 1840 690 920 1150 1380 161 690 2300 690 920 1150 1380 161 1440 3840 336 1440 4800 Tripping torque in Standard 30 og WW Modulating actuator 25C55 1800 3600 Tripping torque in Standard 50 gt gt OT CO CO O 184 184 O O GO 00 00 gt OO OO OO N OT NO Ba O D O1 CO CH QD OT 8 O1 O O oO O co QD N N NO CO i gt gt O Setting The tripping torques forces for CLOSE are set via the middle potentiometer for OPEN via the right of the three potentiometers The setting range for the standard actuator ranges from 30 100 and for the modulating actuator from 50 100 of the maximum torque in 10 steps each Potentiometer Setting in end position CLOSED of the tripping torques for rotary and pa
6. 1 or 2 depends on the rotation direction of the central wheel when approaching the end position see important in step 6 counter clockwise adjust to mark 1 clockwise adjust to mark 2 If the central wheel has already reached the end stop turn in the opposite direction 8 Confirm the setting of end position OPEN S7 ON set DIP switch S7 ope Kl ez A S7 LAFA LAFA v to ON and then to OFFagain LEDs H1 and H2 are blinking Ze Lo The first end position is set and therefore the potentiometer or the magnetic position sensor are adjusted The system chan ges over to setting the other end position 9 If the actuator is equipped with a mechanical position indicator we recommend setting it now Separate approaching of the end position can thereby be avoided For the setting refer to the following chapter 5 3 4 10 Now set end position CLOSED Depending on whether the tripping in end position CLOSED is travel dependent DIP switch S2 ON see also chapter 5 3 2 Setting the cut off modes or torque dependent DIP switch S2 OFF the following ope ration sequence has to be selected accordingly Travel dependent cut off mode E Sir Nit Use the CLOSE button to operate the actuator until the valve 0 RE has reached the end position da SE Pay attention to the valve during operation Continue with operation step 11 Note If the actuator trips torque dependently prior to r
7. 49 70 98 140 196 280 40 30 40 56 80 112 160 224 320 el fa fs elr Standard 4 Positioning times for part turn actuators 2SC5 and 2SG5 2805 160 20 160 112 80 56 40 28 20 2865 80 10 80 Positioning time steps Standard A Setting The speed is set via the left potentiometer Potentiometer Setting the output speed for rotary actuators positioning speed for linear actuators positioning time for part turn actuators Seven 7 setting steps are possible within a type dependent range the actuator type can also be determined from the name plate Setting Turn potentiometer to the desired level 1 7 For the setting values per level refer to the table above In case no further settings are performed set DIP switch S8 to ON and then to OFF again and fit the cover of the electronics unit using screws Y070 019 GB Page 21 JEG BUIUOISSIUWIUIO 5 2 2 5 Commissioning Operation instructions SIPOS 5 ECOTRON Setting tripping torques forces Tripping torque force The setting of the tripping torque for the rotary and part turn actuator and of the tripping force for the linear actuator determines which torque or which force has to be reached until the motor trips This applies to torque force dependent tripping in the end position as well as to a block For this reason tripping torque or force also have to be set for travel dependent trippi
8. fit the cover of the electronics unit using screws 23 If the control is to be performed via PROFIBUS this control mode has to be set with the COM SIPOS PC parameterization program click on Remote control in the Input output menu Page 26 Y070 019 GB 5 4 Operation instructions 5 Commissioning SIPOS 5 ECOTRON Other valve specific settings via COM SIPOS Other parameters can be set using the COM SIPOS PC parameterization program Some are de scribed in the following For further information refer to chapter 4 4 Retry torque block If the actuator is blocked in move block outside the end position ranges the actuator is tripped and a sum fault is set The actuator continues to signal ready since it can still be operated into the opposite direction If the value for the retry torq block parameter is not equal to zero the actuator is automatically operated into the opposite direction once a block has been detected and then again in the direction of the block The partial stroke for this opposite movement will be corresponding to the setting of the end position range it was moving to but not longer than 2 seconds Then the movement reverses automatically back This happens until the block has been overcome or the programmed number of tries has been reached Default setting is 0 Motor temperature warning A warning is issued once the motor temperature has reached a preset value A value between 0 and 155 C can be
9. in the indicator glass of the cover 4 Operate actuator to position OPEN 5 Hold white disc in position and turn transparent disc 1 so that the green symbol for OPEN and the arrow 3 are aligned 6 Fit signaling gear cover with screws Page 34 Operation instructions SIPOS 5 ECOTRON 1 2 K Fig 1 Symbols at position indicator Fig 2 Setting the position indicator Fig 3 Position indicator 25G5 Y070 019 GB Operation instructions 6 Status and fault signals SIPOS 5 ECOTRON 6 Status and fault signals LEDs H1 and H2 signal the device status and the fault signals This enables a fault analysis Some of the fault signals can be reset refer to right column fault type in the following table The letters below have the following meanings S self resetting fault signals Once the cause of the fault is eliminated the fault signal is automatically reset R resettable fault signals Fault signal remains present even after eliminating the cause of the fault until it has been finally acknowledged S8 ON OFF N Non resettable fault signals The cause of the fault must be eliminated Fig LEDs H1 and H2 The following table shows the status of the LEDs H1 and H2 the respective meaning as well as the corrective measures The states of the LEDs off on blinking are represented as follows C LED is not illuminated A de e B LED is illuminated aF te N
10. set The warning signal can be provided via binary signal and fieldbus protocol Default value is 135 C This parameter is not available for the part turn actuator 2565 Motor heating To prevent condensation while the motor is at standstill the motor can be heated with DC current when the heater is activated The heating up depends on the difference between motor temperature and ambient temperature The heater is switched off as standard If exposed to strong climatic fluctuations the actuator should be operated with the motor heater switched on Motor temperature protection The motor is equipped with full electronic motor protection against thermal damage The motor protection is activated in the factory Y070 019 GB Page 27 er Q T D Comm 5 Commissioning Operation instructions SIPOS 5 ECOTRON 5 5 Adjusting the signaling gear ratio and the end positions JEG If actuators are delivered mounted to a valve this step has been done in the valve manufacturer s factory The setting has to be checked during commissioning For the part turn actuator 2SG5 the signaling gear ratio does not have to be set The actuator is not equipped with an adjustable signaling gear Continue with chapter 5 5 3 5 5 1 General BUIUOISSIUWIUIO By setting the signaling gear ratio and the end positions it is ensured that the length as well as start and end of the valve travel end positions OPEN and CLOSED are correctl
11. surface temperatures caused by frequent operation and long activation times Warnings on the device Danger of crushing When pressing in the hand crank or the hand wheel ensure that neither the hand nor the fingers are crushed refer to figure Applicable for devices of the 2SA5 5 6 7 8 and 2SB555 6 series Indicates the lubricant used Refer also to chapter 7 2 Lubrication intervals and lubricants Fig Danger of crushing Mobilgear 4 SHC XMP 220 Y070 019 GB Page 3 General information uoljeunojui je ausg 1 2 1 3 1 4 1 4 1 A Ry A Arad 1 General information Operation instructions SIPOS 5 ECOTRON Transport and storage The dispatch must be performed in sturdy packaging For transport loop the rope around the hand wheel housing refer to illustration Only use the eyes on the electronic unit fig item 1 to lift the actuator s own weight Do not attach the ropes and hooks at the hand crank or hand wheel for the purpose of lifting Store in well ventilated dry room Protect against damp floors by storing on a shelf or pallet Keep connection hood cover and cable glands as well as the cover of the electronic unit closed p Fig Transport Disposal and recycling Packaging The packaging of our products consists of environmentally friendly materials which can easily be separated and recycled We use following packaging materials Woo
12. we recommend setting it now refer to chapter 5 5 4 13 Fit the cover of the electronics unit using screws Ensure the O ring seals properly fig item 1 14 If the mechanical position indicator was set see operation steps 9 and 12 fit the cover of the signaling gear with screws f the Local Remote button is pressed the actuator changes to the Remote state and operates if there is an command from the DCS Once the end positions have been adjusted during commis sioning the central wheel must not be moved Otherwise a complete readjustment of the end positions is required Y070 019 GB Page 33 JEG BUIUOISSIUWIUIO 5 5 4 5 Commissioning Adjusting the mechanical position indicator The mechanical position indicator indicates the valve posi tion The green symbol stands for OPEN and the red symbol for A CLOSED refer to illustration The mechanical position indicator is an option and not included in all devices If the actuator was delivered mounted on a valve the setting was already performed by the manufacturer How ever the setting must be checked during commissioning If the mechanical position indicator was not yet set with the end positions set the indicator as follows Operation sequence 1 Operate the actuator into the end position CLOSED 2 Remove signaling gear cover 3 Turn white disc with red symbol fig item 2 until the symbol for CLOSED and the arrow 3 are aligned
13. 0 or 180 to ensure cables are not impaired by the spindle protec tion tube Remove screws 7 from round plug turn round plug by 90 to 180 and fix screws again Continue as described in section 3 Fig Separate mounting A Standard B with spindle protection tube During installation it is important to ensure that the O rings are fitted correctly in order to gua rantee the degree of protection Generally it has to be ensured that movable parts e g those of the swing lever are not im paired by the cables In exceptional cases the motor might become very hot Therefore the cables should not touch the motor Specification of the connecting cable between the electronics unit and the gear unit Power supply Shielded and UV resistant e g TOPFLEX 611 C PUR 4G1 5 11 3 TOPFLEX is a trade mark of HELUKABEL Control connection shielded and UV resistant e g L IY11Y 7x2x0 5 11 4 S The crimp contacts of the signal cables are gold plated The connecting cables are available in different versions Standard lengths 3 m 5 m 10 m with additional device filter up to 50 m if separate mounting of more than 10 m with fi Iter the Sep mounting parameter must be set to value gt 10m with filter Page 14 Y070 019 GB Operation instructions 4 Instructions on operator control and operation SIPOS 5 ECOTRON Instructions on operator control and operation Hand crank hand wheel Moto
14. Before opening the minutes for the capacitors to discharge and do not touch any contacts 2 The supply voltage must always lie within the voltage range specified on the rating plate Mains cable Use metal cable glands for mains connection Signal cable Use metal cable glands with cable shielding for the connection of the control cable to avoid the occurrence of electronic faults The signal cable must be shielded and the shield must be fixed or earthed on both sides Ensure careful connection of the screen within the cable gland t must be ensured that the cable glands and seals O rings are fitted carefully and correctly in order to guarantee the enclosure protection For details of the permissible conductor cross sections see wiring diagram Cable glands and cables are not included in the scope of delivery Page 10 Y070 019 GB Operation instructions 3 Assembly and connection SIPOS 5 ECOTRON es 3 2 1 Direct connection c O ab O D O O bd gt 2 O 7 7 lt 3 Fig Direct connection l Highly sensitive CMOS semiconductor components extremely sensitive to static electricity are t mounted on the printed circuit boards Avoid touching tracks or components on the boards with the fingers and prevent tracks or components coming into contact with metal objects Only the screws of the terminal blocks may be touched in order to make the connections and only with an insulated screw driver
15. EE aaa 4 PROFIEU See 18 PROFIBUS operation instructions 5 Pulse contact EE ennn 26 Push button CEOS EN 16 LOCAL L NEE 16 OPEN ee eege nesten 16 STOR eres ner 16 Push NE vr 16 R Recommended spare parts 39 Relay ole e EE T REMOTE NE 16 Remote ut e REN 18 Retry ele UN ele 27 Revolutions stroke Refer to Signaling gear S Safety miormatton n 3 Separate MOUNTING rrrrrrrrnnrrvrrnnnrrenrnnnnrennr 14 Y070 019 GB 9 Index Seperate mounting Cable lengths 005 14 Connections 14 Specification 2 2 222222 14 EE OF Setting positioning speede 21 Setting positioning Des 21 Setting remote Control 26 Settings at the DIP switch 20 Setting the cut off modes ccc 24 Setting tripping Ioroues 22 Signal Cable sene 10 Signaling gear Prerequistes for the adjustment 29 Setting the transmission 29 T NSMISSION aar ene oes 29 Signals En 35 Spare DAMS ine 7 39 Spare partelet 39 Spindle protection tube 10 State indications rrrrnrnnnnrvnrvnnnnnnnnnnnnnn 17 30 Status indications insert 35 EE EE E E eee ee eco 4 Sub assembliesS AAR 7 FOGN Sa nr ER ER T EN 7 SS 910 gt RE EE 4 7 Torque dependent 2220220002202220 20 32 Transmission ratio aussen 29 TANN 4 Travel dependent 222022002220 220000 31
16. GB Operation instructions 3 Assembly and connection SIPOS 5 ECOTRON Od 3 2 4 Connection with galvanic separation Binary inputs and outputs are galvanically separated via opto couplers Analog signals can be galvanically separated as an option This is required to avoid overlapping currents and voltages by means of equalization potentials When ordering Actual position analog output galvanically separated state add version C10 1 Unscrew fieldbus connection housing fig item 2 and connection cover 4 2 Unscrew plug element 1 from connection hood 2 3 Unscrew screw plugs from the required cable glands in the connection housing 4 Screw in the cable gland 5 only slightly and insert the connecting cables 6 5 Connect the connecting cables in accordance with the circuit diagram enc losed in the connection hood connecting the earth lead to the provided terminal in the connection box Connect the wire for analog signals actual position value to the connection board 3 Lead shielding under the metal clamp c O O D O O gt gt 2 D N 7 lt ia j ith aal 6 Screw plug element 1 into connection Fig Connection with galvanic separation housing 2 7 Fit connection housing 2 and connection cover 4 again 8 Tighten cable glands 5 3 2 5 External potential conductor connection The external potential conductor connection can be used for fu
17. I L O LED is flashing continuously I U U U U U L fol ER LED flashes periodically The flashing here 3 times is repeated after a pause of lt Q 3x l S en 1 s 3 flashes pause 1 period J U LJ L__J LI LJ L_ r Corrective measures KLA red Slide BOOT switch 1 to OFF position away from BOOT and press RESET 2 2 m Actuator does not react to commands from e oe remote or to push buttons locally ei Fault Device failure Service repair necessary Fault Commissioning is invalid Perform commissioning Check valve for sluggishness Reduce number of starts Ambient temperature impermissibly high m Verify Separate mounting parameter via COM SIPOS parameterization program Fault Mains failure or excessive mains voltage Check supply voltages fluctuations Y070 019 GB Page 35 A 90 kel N kg 8 fen CH L 90 N fed 90 Dei N 6 Status and fault signals Operation instructions SIPOS 5 ECOTRON LED Fault ner H2 Corrective measures Bes green red Fault vas Open circuit of Check cables of separate mounting kit H 4x m travel potentiometer or temperature Check input cables sensor fieldbus if applicable e m cables from REMOTE Fault Check valve for sluggishness e ei Blocked in move i e tripping torque Set higher torque values S X reached within the travel outside end a Verify Separate moun
18. Page 24 Y070 019 GB Operation instructions 5 Commissioning SIPOS 5 ECOTRON Setting travel dependent default setting unless required otherwise by the customer er Q T D customer Wi Cut off mode end position OPEN torque dependent In case no further settings are performed at the DIP switch ON Cut off mode end position OPEN travel dependent default setting unless required otherwise by the Comm set DIP switch S8 to ON and OFF again to accept the setting of the cut off mode and set the end positions refer to the following chapter 5 5 3 5 3 3 Selecting an output signal set It can be defined which output signals are present at the 5 output signal outputs Hereby it can be chosen between 4 output signal sets consisting of predefined output signals for each of the 5 signaling outputs The selection is made via the DIP switches S4 and S5 Output signals Signaling outputs Travel OPEN Travel CLOSE NC Torque OPEN CLOSE Torque OPEN CLOSE NC Warning motor temperature End position OPEN End position CLOSED 3 NO Blinker o OFF 4 NO Ready REMOTE 5 NC Warning motor temperature 4 no end postion OPEN 2 NO EndpositionOPEN SSS 3 NC Fat NO Ot o 5 NC Warming motor emperature 1 NO Travel OPEN o 2 N Travel CLOSE 3 NO Ready REMOTE gt Z O O Oo O 4 NC Torque OPEN O 5 NC Torque CLOSE In case no furthe
19. SIPOS AKTORIK Operation instructions Electric actuators SIPOS 5 ECOTRON Issue 11 15 Y070 019 GB Subject to changes without notice Contents Contents 1 General information een 3 1 1 Safety information 3 1 2 Transport and storage rrrrrrrnrnrrvnnrrnnnn 4 1 3 Disposal and recycling 4 1 4 Notes to the operation instructions 4 1 5 Supplementary operation instructions 5 2 GENT 6 2 1 Functional principle rrrrorerrorernnnnnnr 6 2 2 Sub assemblies rrnrrnrernonnnnnnernrnvnnnnneer 7 2 3 Block diagram electrical connections 8 3 Assembly and connection 9 3 1 Mounting to valve gear 9 3 2 Electrical connection s 10 3 3 Separate MOUNTING rrrrrrnnnnrenrrnnnnnnn 14 4 Instructions on operator control and Operation cccscceeseeeseeeeeeeeeeees 15 4 1 Hand crank hand wheel 15 4 2 Local control station 16 4 3 Remote control rrvsrrrearvanrrrersnnenvevsnne 18 4 4 COM SIPOS ENNEN 18 Page 2 Operation instructions SIPOS 5 ECOTRON 5 COMMISSIONING een 19 5 1 General information u 19 5 2 Setting speeds tripping torques 20 5 3 Setting closing direction cut off modes Laksen 24 5 4 Other valve specific settings via COM SIPOS zu 27 5 5 Adjusting the signaling gear ratio and the end positions _
20. V Valve travel urnen 29 W VG 4 Warnings on the device rrrnnrrrnrrrrnrrnnnnrnnn 3 Page 49 Index IO Operation instructions SIPOS 5 ECOTRON Page 50 Y070 019 GB SIPOS AKTORIK Original Declaration of Incorporation of Partly Completed Machinery EC Directive 2006 42 EC and EC Declaration of Conformity in compliance with the Directives on EMC and Low Voltage SIPOS Aktorik GmbH as manufacturer declares herewith that the above mentioned electric actuators meet the following basic requirements of the EC Machinery Directive 2006 42 EC Annex I articles 1 1 2 1 1 3 121 02 12 1 122 6 131 132 7 1 5 1 1 63 17 1 1 7 3 1 744 Manufacturer SIPOS Aktorik GmbH Im Erlet 2 90518 Altdorf Germany Type of product Electric actuator Authorised person for documentation Dr Thomas Suckut Im Erlet 2 90518 Altdorf Germany Type range 2SA5 25B5 25C5 2565 The product complies with the following harmonised standards with respect to the EC Machinery Directive EN 12100 2010 EN 60204 1 2006 A1 2009 AC 2010 Furthermore the following safety relevant standards are regarded ISO 5210 1996 ISO 5211 2001 DIN 3358 1982 With regard to the partly completed machinery the manufacturer commits to submitting the documents to the competent national authority via electronic transmission upon request The relevant technical documentation pertaining to the machinery described in Annex VII part B has been prep
21. ared SIPOS actuators are designed to be installed on industrial valves SIPOS actuators must not be put into ser vice until the final machinery into which they are to be incorporated has been declared in conformity with the provisions of the EC Directive 2006 42 EC As partly completed machinery the actuators further comply with the requirements of the following directives and the respective approximation of national laws as well as the respective harmonised standards as listed below Directive relating to Electromagnetic Compatibility EMC 2004 108 EC EN 61800 3 2004 A1 2012 Low Voltage Directive 2006 95 EC EN 60204 1 2006 A1 2009 AC 2010 EN 60034 1 2010 EN 50178 1997 EN 61010 1 2010 Year of affixing of the CE marking 2015 Altdorf 12 11 2015 r Thom s Suckut General Manager This declaration does not contain any guarantees The safety instructions in product documentation supplied with the devices must be observed Non concerted modification of the devices voids this declaration 23 Certificates are valid as from the indicated date of issue Subject to changes without notice The latest versions are available for download at http www sipos de Y070 019 GB Page 51 Issue 11 15 SIPOS Aktorik GmbH Y070 019 GB Subject to changes without notice Im Erlet 2 D 90518 Altdorf www sipos de
22. ars The lubricant in the gear enclosure has to be changed the seals have to be exchanged and all parts within the direct flux of force have to be checked for wear depending on the operation conditions shorter maintenance intervals may be required This is especially important for actuators in high temperature version additional order code T09 These must be inspected every two years by the SIPOS Service and wear parts must be replaced It is recommended that the services of the local SIPOS Aktorik service center are utilized for this purpose Please contact SIPOS Aktorik GmbH for any service requests You can find the address and the phone number of your competent contact at www sipos de You may also send your requests directly via e mail to service sipos de Y070 019 GB Page 37 y 2 2 o Q Maintenance inspect UOI99dsul 99uRUuSJUle f N VIIAIOS 7 Maintenance inspection service Operation instructions SIPOS 5 ECOTRON 7 2 Lubrication intervals and lubricants 7 2 1 Lubrication intervals Perform service or inspection after approx 8 years refer to chapter 7 1 After 50 operating hours or 1 year regrease coupling shaft A if available at the greasing nipple A N For output shaft form A ensure that the valve stem is greased separately These intervals are valid for normal load When exposed to more intensive loads the maintenance intervals are reduced accordingly Actuators in high temp
23. as been done in the valve manufacturer s Please pay attention to the safety information see chapter 1 1 2 It is recommended that the services and support of the responsible SIPOS Aktorik service centers 3 1 2 Operation instructions 3 Assembly and connection SIPOS 5 ECOTRON Gd Assembly and connection Mounting to valve gear factory However the setting has to be checked during commissioning Before starting the assembly please make sure that the intended measures possible operation of the valve etc is not likely to cause any injuries to persons or to interfere with the equipment are utilized for all planning installation commissioning and service task General assembly instructions for all output shaft versions Mounting and operation is possible in any position c O 2 O D O O gt gt 2 o o 7 lt Avoid all shocks do not attempt to use force m Check that the end connection flange and the output shaft type match the valve gear Thoroughly degrease mounting faces at actuator and valve gear Slightly grease the connection points Place the actuator on the valve gear making sure it is properly centered Use bolts with at least 8 8 quality If other similar stainless steel bolts are used they should be greased slightly with petroleum jelly The depth of engagement should be at least 1 25 x the thread diameter Position the actuator on the valve gea
24. available see note below For the required setting of the signaling gear refer to the Signaling gear adjustment table below Intermediate values of rev stroke or travel mm or degrees are rounded up to the next incremental value e g for 30 rev stroke the incremental value 36 has to be set Signaling gear adjustment fe LN Valve travel r e actuator 2SA5 7 8_ stroke 0 2 0 52 1 37 3 5 9 23 2 60 152 393 1005 4 105 27 5 70 180 a mm 48 12 6 33 84 216 558 travel 56 14 7 38 5 98 252 651 1 258556 64 168 44 n 288 m Partturn 5505 1 2 3 4 5 6 an M 120 240 360 actuator 10 possible settings at the Default setting unless required otherwise by the customer 2 If the number of revolutions per stroke is not known because for example the actuator is to be operated on an available old valve operate the actuator over the whole travel and note the num ber of revolutions of the output drive shaft If it is not possible to watch the output drive shaft skip this chapter Observe the note on the signaling gear in the Prerequisite for end position adjustment section in chapter 5 5 3 Adjusting the end positions Procedure 1 Loosen 4 screws item 1 from the signaling gear cover and remove cover 2 Round up revolutions stroke or mm travel or de grees to the next incremental value for incremental values refer to table abov
25. closing direction If the output drive shaft has to turn counter clockwise in CLOSE direction the closing direction has to be changed If the current closing direction is to be retained continue with chapter 5 3 2 A N After each change of the closing direction the end position setting has to be performed again Setting m CLOSE direction counter clockwise output drive shaft turns counterclockwise CLOSE direction clockwise output drive shaft turns clockwise default setting unless required mor otherwise by the customer In case no further settings are performed at the DIP switch set DIP switch S8 to ON and OFF again to accept the setting of the closing direction set the end positions refer to the following chapter 5 5 3 5 3 2 Setting the cut off modes Cut off mode If the actuator operates the cut off mode can be travel dependent or torque dependent Travel dependent cut off mode Travel dependent cut off means the actuator trips once the valve has reached a defined position Torque dependent cut off mode Torque dependent cut off means the actuator trips after reaching a pre defined torque when mo ving into the end position range Default value for the cut off mode of both end positions OPEN and CLOSED is travel dependent If the current values are to be retained continue with chapter 5 3 3 A N l After each change of the cut off mode the end position setting has to be performed again
26. ctronics unit motor up to 1 5 kW LU OD 5 D A 5 D i HASAN WN 3 Noa 7 Sa SS Page 46 Y070 019 GB Operation instructions SIPOS 5 ECOTRON 8 3 8 Electronics unit motor from 3 kW ALTES LEE N NW d V Y070 019 GB RAN AN S Szeen OG SS PETTTET TE TUNA Sy 8 Spare parts Page 47 Spare parts co xX pu l 9 Index Index A Adjustment Signaling gear 19 Analog lie 8 Assembly kit for seperate mounting 14 B Block Aeneas 8 C Cable Gland x seccccccspcsncetesssacessenetaceesuncieiaeess 10 Central wee 28 31 Closing direction cccccssseeeeceeseeecseaeeeens 24 Commissioning General information 19 Prerequisites ee 19 Sequence 1 aana 19 OMSPILL 18 Connection Direkt connection v4 ci bound eae eed be 11 External potential conductor 13 Fieldbus 0 0 0 00 eee eee 12 Galvanic seperation 13 Round eil Vie BEER 12 Connection electrical A 10 Connection mechanical 0 cessseseeeeees 9 Control panel nee 16 Control remote A 18 Control remote nn 18 Cut off mode 0 cece eeceeceececeeeeeeeeneeeens 31 32 Cut off modes en 24 D Deorees ees Refer to Signaling gear Direct connection EE 11 Deala e EN 4 E Electrical COMME CUOM nnnnnnene 10 Connection with round plug 12 13 Direct connection 15 8 ivan seg A wa de 11 Fieldbus connection
27. d based panels MSB OSB cardboard paper PE foil For the disposal of the packaging material we recommend recycling and collection centers Actuator Our actuators have a modular design and may therefore be easily disassembled separated and sorted according to materials i e electronic parts different metals plastics greases and oils The following generally applies Collect greases and oils during disassembly As a rule these are substances hazardous to water and must not be released into the environment Arrange for controlled waste disposal of the disassembled material or for separate recycling according to materials Observe the national local regulations for waste disposal Notes to the operation instructions Safety instructions Used symbols and their meanings The following symbols which have different meanings are used in the operation instructions Non observance may lead to serious injuries or property damage Warning marks activities which if not carried out correctly can affect the safety of persons or material Notice marks activities which have major influence on the correct operation Non observance of these notes may lead to consequential damage Electrostatically endangered parts are located on circuit boards which may be damaged or de stroyed by electrostatic discharges If the boards need to be touched during setting measurement or for exchange it must be assured that immediately before touc
28. e 3 Adjust the slide wheel 2 so that the gear rim faces the desired incremental value on the scale Push the slide wheel in the right direc tion applying only little pressure Adjusting the slide wheel is facilitated by a slight movement of the central wheel 3 Do not yet fit the signaling gear cover The end positions have to be set and if available the mechanical position indicator Fig Adjusting the signaling gear ratio Y070 019 GB Page 29 er Q T D Comm JEG BUIUOISSIUWIUIO 9 5 3 5 Commissioning Operation instructions SIPOS 5 ECOTRON Adjusting the end positions The end positions are set directly at the actuator Prerequisite for end position adjustment The valve must not be jammed Use the hand crank hand wheel to release it if necessary For the operation of the hand crank refer to chapter 4 The signaling gear should be set refer to previous chapter Adjusting the signaling gear ratio If the signaling gear ratio was not set because the number of revolutions stroke is not known proceed nevertheless as described in the following Observe the note for operation step 11 Settings at the DIP switches S1 S6 must be completed prior to setting the end positions and may not be modified during this end position setting process The end position setting OPEN and CLOSED will only become effective after DIP switch S7 was switched ON and OFF again As lon
29. e operation via a fieldbus interface is also de scribed in the separate operation instructions refer also to chapter 1 5 Supplementary operation instructions The change over from Remote to Local can be disabled via fieldbus An EMERGENCY command sent from the DCS is always executed by the actuator irrespective of the selected control mode and signal source even if the actuator is conventionally controlled and the EMERGENCY command is sent via fieldbus and vice versa Observing Observing from remote is only possible with fieldbus control PROFIBUS DP The device parameterization can be read via cyclic and acyclic services A large variety of software tools is available for simple integration Manufacturer independent project planning and parameterization tools SIMATIC PDM Process Device Manager The SIPOS 5 Flash device description EDD Elect ronic Device Description is stored in this parameterization and project planning tool FDT DTM Field Device Tool Device Type Manager The SIPOS 5 Flash device description DTM is available for the integration in the parameterization tool FDT MODBUS RTU The device parameters can be read via so called Holding Registers and Coils Observing and diagnosis is possible via Input Register and Discrete Input COM SIPOS The COM SIPOS parameterization program is a software tool for operation operation of the actuator in local operation m ob
30. eaching the end position due to a block e g in case of a sluggish MOV an unfavorable torque curve or approaching a mecha nical end stop press the OPEN button to return to the desired end position Page 32 Y070 019 GB Operation instructions 5 Commissioning SIPOS 5 ECOTRON Er DIP switch LED 25 nstruction push button H1 H2 c C O Torque dependent cut off mode Eu WE MA o Hold down CLOSE button for more than 2 s QD V i fun FAN T The actuator moves automatically until reaching the end position When reaching the end position the flashing signal of LED H2 Sr Nit changes to a periodical flashing signal SE O fas fu 3 X Oo After reaching the end position the actuator moves shortly in Zeckt Ni the opposite direction to return to the end position again As SE GE soon as the actuator has stopped automatically the flashing PES Ge signal changes 11 Confirm the setting of end position CLOSED S7 u ON ON pr A set DIP switch S7 pf u S7 Ae O to ON and then to OFF again LED H2 is no longer illuminated m I 0 OFF Note If LED H2 red is still illuminated permanently the end position setting is not correct Fault during commissioning e g signaling gear ratio not correct Set S8 to OFF select proper signaling gear ratio and restart end position adjustment set S8 to ON ON 12 Set DIP switch S8 orr LED H1 is illuminated If the actuator is equipped with a mechanical position indicator
31. eration se quence description an error or a fault has occurred refer to the Status and fault signals chapter Page 30 Y070 019 GB Operation instructions 5 Commissioning SIPOS 5 ECOTRON Operation sequence DIP switch LED Instruction push button H1 H2 1 If the signaling gear cover is fitted unscrew cover er Q T D 2 Important Turn central wheel until marks 1 and 2 point in upward direction see illustration on the right Comm 3 If the cover of the electronics unit is not removed unscrew cover Local 4 Switch actuator to the Local state ei ON 5 Set DIP switch S8 to ON 58 EF a OFF ON e E LED H1 green is flashing LED H2 red is illuminated for A FEN SEN invalid end position setting 6 End position OPEN is set first Depending on whether the tripping in end position OPEN is travel dependent DIP switch S3 ON see also chapter 5 3 2 Setting the cut off modes or torque dependent DIP switch S3 OFF the following opera tion sequence has to be selected accordingly Travel dependent cut off mode d Observe the valve position and operate the actuator using N ay e the OPEN button until the valve has reached end position aa ane OPEN Note When pressing the CLOSE or OPEN buttons for a short time lt 2 s the actuator is operated as long as the push button is pressed When held down for a longer time the actuator operates until the STOP ENTER b
32. erature version additional order code T09 must be inspected every two years by the SIPOS Service and wear parts are must be replaced IEY Whenever the covers and hoods are removed the seals must be inspected for damage Replace and regrease if necessary 7 2 2 Lubricant assignment and quantity 2505012814 25055112 Fees een Kl bersynth GH 6 220 N Kl ber or Alphasyn PG MOBIL SHC Gear 2204 Lubricant 220 Polyglycol Castrol Berusynth EP 220 Bechem refer to identification at the Panolin EP gear synth 220 Kleenoil equipment nections inside Lubricant Petroleum jelly DAB 10 V10 Tru 7 maintenance free Part turn unit for 2805 lie recommendations for the actuators should also be observed here disposing of lubricants Technical information concerning lubricants is available on request Before using an alternative new lubricant other than that filled in the factory the gear units 3 The manufacturer s instructions and relevant regulations are to be observed when handling and and gear parts have to be rinsed and cleaned avoid mixing of the oils 1 Measured from the lubricant surface to the external earth of the housing at oil filling screw 2 Ambient temperature range 20 60 C 3 Lubricant used in the factory 4 Filling of the actuators until approx October 2004 with Kluber Syntheso D 220 EP until approx October 2011 with Mobilgear SHC XMP 220 eg sealing rings gear sy
33. g as position of the central wheel friction coupling was not altered and or the DIP switch S7 not operated the setting of the end positions may be canceled by resetting the DIP switch S8 to OFF The end positions have to be set in a specific order The OPEN end position must be set first Operation during the end position setting The end positions are set while the cover of the electronics unit is removed When the electronics unit cover is removed the actuator is operated via the push buttons on the electronics board see figure items 3 to 6 1 LED H1 green 2 LED H2 red 3 CLOSE button 4 OPEN button 5 Push button for selection between local remote 6 STOP button 1 2 3 4 5 6 Fig Arrangement of the push buttons on the electronics board LED signals When setting the end positions O the LEDs H1 green and H2 red LED is not illuminated indicate the current status of the 17 actuator by being illuminated and or LED le illuminated flashing SEIN The following description operation Ww sequence presents the possible gen g states of the LEDs not illuminated illuminated flashing as shown on 5 LED flashes pen the right 3x 3flashes pause 1 period l furs e De Only applies to LED H2 red when setting aa the end positions It is not important whether the LED is illuminated or not Should the indicated LED pattern differ from the representation in the following op
34. hing an electrostatic discharge through contact with an earthed metallic surface e g the housing has taken place If actuators are delivered mounted to a valve this step has been done in the valve manufacturer s Procedures may have been performed by the valve manufacturer factory The setting has to be checked during commissioning Page 4 Y070 019 GB 1 4 2 1 5 Operation instructions 1 General information SIPOS 5 ECOTRON Scope For the sake of clarity not all details of all versions of the product are described in these operation instructions nor can they cover all conceivable cases regarding installation operation and mainte nance For this reason the operation instructions only contain instructions for qualified personnel refer to section 1 1 that are necessary when the equipment is used for the purpose for which it is intended or in industrial applications If the devices are used in non industrial applications with increased safety requirements they have to be ensured by additional safety measures during assembly In case of any questions and especially where detailed product information is not available contact the SIPOS Aktorik sales representative in charge Always state the type designation and the works number of the respective actuator see rating plate It is recommended that the services and support of the responsible SIPOS Aktorik service centers are utilized for all planning installation commissioning a
35. ice a Sieger Electronics unit 012 042 2SY5250 Handle hand crank with handle aan The last three digits indicate the part numbers in the exploded views Y070 019 GB Page 39 Spare parts 09 syed a1eds len 8 Spare parts Operation instructions SIPOS 5 ECOTRON 8 3 Exploded views 8 3 1 Gear unit 2SA5 1 2 3 4 Output drive shaft B1 t SE Output shaft inserts Reducing flange Output drive shaft A Page 40 Y070 019 GB 8 Spare parts Operation instructions SIPOS 5 ECOTRON cO sjied dJEds put drive shaft B1 213 Out 212 Output drive shaft A 8 3 2 Gear unit 2SA5 5 6 7 8 Reducing flange Output shaft insert Page 41 Y070 019 GB syed a1eds len 8 Spare parts 8 3 3 Gear unit with thrust unit 2SB551 2 3 4 Page 42 Operation instructions SIPOS 5 ECOTRON Y070 019 GB 8 Spare parts Operation instructions SIPOS 5 ECOTRON G i syed dJEdg Cs Ve Ou o GE N GIG A A Des et 8 3 4 Gear unit with thrust unit 2SB555 6 Page 43 Y070 019 GB 8 Spare parts Operation instructions SIPOS 5 ECOTRON 8 3 5 Small part turn gear unit 2SG5 Ssjied opdeele Page 44 Y070 019 GB 8 Spare parts Operation instructions SIPOS 5 ECOTRON G i syed a1eds 8 3 6 Gear unit with part turn unit 2SC5 Page 45 Y070 019 GB 8 Spare parts Operation instructions SIPOS 5 ECOTRON LO 8 3 7 Ele
36. imilar is stipulated in EN 50110 1 formerly DIN VDE 0105 or IEC 60364 4 47 VDE 0100 part 470 u Leakage The leakage current of the actuators is typically greater than 3 5 mA Therefore a fixed installati on according to IEC 61800 5 1 is required Residual current circuit breakers or monitoring devices Due to the integrated frequency inverter a direct current can be induced in the protective earthing conductor If the network an upstream residual current device RCD or residual current monitor RCM is used then it must be of type B Correct transport proper storage mounting and installation as well as careful commissioning are essential to ensure a trouble free and safe operation The availability of this product is restricted according to IEC 61800 3 and may cause radio interfe rences in domestic environments In this case it may be necessary to take additional measures The following is of particular importance the technical data and information concerning the proper use installation connection ambient and operating conditions provided in the catalog order documents operation instructions rating plate data and in the other product documentation m the general installation and safety guidelines the local plant specific regulations and requirements the proper use of tools lifting and transport equipment the use of personal protective equipment especially in high ambient temperatures and with high actuator
37. imilar to push button OPEN Pressing push buttons OPEN and CLOSE at the same time activates the EMERGENCY function The actuator moves at the set output speed positioning speed positioning time to the EMERGENCY position end position CLOSED If the Local Remote button is pressed in the Local state the actuator changes to the Remote state and moves in case of an operation command from the DCS Page 16 Y070 019 GB 4 2 2 Operation instructions SIPOS 5 ECOTRON Indication of the actuator state 4 Instructions on operator control and operation By means of their state illuminated or flashing the LEDs indicate the current actuator state The states of the LEDs off on flashing are represented in the operation instructions as follows LED is not illuminated LED is illuminated D LED is flashing Explanation The CLOSE and OPEN LEDs indicate whether the actuator is at standstill m moves and in which direction OPEN or CLOSE is in end position and in which OPEN or CLOSED Both LEDs are off Actuator is at standstill and in mid travel The CLOSE LED is flashing The actuator operates in direction CLOSE The OPEN LED is flashing The actuator operates in direction OPEN The CLOSE LED is illuminated The actuator is in end position CLOSED Remote ellow The OPEN LED is illuminated The actuator is in end position OPEN The Local and Remote LED
38. indicate the state the actu ator is in Local or Remote The actuator is in the Local state The actuator is in the Remote state The H1 and H2 LEDs indicate ready for operation or fault and the states during commissioning The H1 LED is illuminated The actuator is ready for operation The H1 LED is flashing The actuator is in the commissioning state For the states during commissioning refer to the fol lowing chapters Y070 019 GB The H1 LED is off Fault Refer to Status and fault signals chapter Page 17 da C O Ke 90 O Ke C 90 O S fe a O Be O nd 90 a O C O N C O Ben fe N 5 T er 3 c aa e 5 T O 5 O CH D o er O O O 5 er Q o 5 Q O CH D o O 5 4 3 4 3 1 4 3 2 4 4 4 Instructions on operator control and operation Operation instructions SIPOS 5 ECOTRON Remote control Control The control of the actuators depends on the automation system and can be performed via conventional connection 24 V binary or Fieldbus e g PROFIBUS DP or MODBUS RTU Each actuator device on the bus is accessed via its bus address On delivery the bus address is preset for all devices 126 for PROFIBUS and 247 for MODBUS unless ordered otherwise using the programming form add version Y11 Th
39. ints after assembly or during revision and inspection The actuator is correctly assembled All fixing screws and connecting elements are firmly tightened The grounding and equipotential bonding has been correctly implemented The electrical connections have been correctly implemented All protection against accidental contact has been implemented for moving or live parts Neither the actuator nor the valve is damaged The permitted temperature range for the actuator is maintained and heat dissipation from the final control element is also taken into account Further checks are also necessary in accordance with the plant specific conditions The commissioning steps have to be performed in the following sequence and are described in detail below You do no have to perform all settings Depending on whether settings have already been spe cified when ordering the actuator or whether the actuator was delivered mounted on the valve checking the settings will be sufficient After changing the settings the DIP switch S8 has to be set to ON and then to OFF again to accept the changes 1 Set check output speed or positioning speed positioning time and tripping torques forces 2 Set check closing direction cut off mode and control mode 3 Select one of the 4 output signal sets and determine the predefined signals at the 5 signaling outputs 4 Check adjust signaling gear ratio and end positions The signaling gear rati
40. l and Remote LEDs The LEDs indicate the state of the actuator m Remote LED Remote yellow is illuminated m Local LED Local yellow is illuminated LEDs OPEN and CLOSE The OPEN LED green is flashing if the actuator moves in OPEN direction and is continuously illuminated if the actuator is in end position OPEN The same applies to the CLOSE LED yellow LEDs H1 and H2 The LEDs H1 green and H2 red indicate status and fault signals see following chapter 6 Status and fault signals In addition these LEDs indicate the status in the end positions Function of the push buttons in the Local state In the Local state the actuator can be operated on site OPEN CLOSE as well as STOP control from Remote is disabled Fig Local control panel 1 STOP ENTER push button The STOP ENTER push button stops the actuator 2 Local Remote push button The Local Remote push button allows selection between Local and Remote 3 Push button OPEN When pressed the actuator moves in the OPEN direction For short operation lt 2 s the actua tor moves as long as the push button is pressed If the push button is held down for more than 2 seconds the actuator moves up to the end position once the push button is released or the push button STOP or CLOSE is pressed self locking 4 Push button CLOSE When pressed the actuator moves in the CLOSE direction Behavior s
41. ll bearing grease and fit them on the new or machined stem nut 4 6 Insert stem nut 4 with axial needle roller as sembly into output flange claws have to engage properly into the groove of the output shaft of the actuator 7 Screw in the centering ring 5 and tighten it as far as the stop Make sure the radial seal is inser d 2 3 4 3 6 5 ted correctly 6 8 Using a grease gun press ball bearing grease Ege tnetanec output shart types into the grease nipple 2 until lubricant is dis charged between the centering ring 5 and the stem nut 4 A N For output shaft form A ensure that the valve stem is greased separately UOI D9UUOD pue Ajquwiassy LG 3 1 3 Mount spindle protection tube 1 Remove fastener fig item 1 2 Check that the extended stem does not exceed the length of the protective tube 3 Apply sealing compound to the thread and the sealing faces e g 732 RTV from Dow Corning Munich Germany 4 Screw in the spindle protection tube 2 Fig Mounting the spindle protection tube 3 2 Electrical connection The components are designed as to ensure that once connected correctly uninsulated live parts cannot be touched directly i e protection against electric shock is provided in accordance with IP2X or IPXXB terminal cover or the connection hood disconnect the supply voltage from the actuator Allow 5 Dangerous voltages are also present when the motor is at a standstill
42. lug element 1 into the connection hood 2 and then fix connection hood 7 Tighten cable glands 3 Fig Connection with round plug UOI D9UUOD pue Alqw assy LG 3 2 3 Fieldbus connection 1 Dismantle fieldbus connection housing fig item 2 and connection cover 4 2 Unscrew plug element 1 from fieldbus housing 2 3 Unscrew screw plugs from the required cable glands in the fieldbus connection housing 4 Screw in the cable glands 5 only slightly and insert the connecting cables 6 For fieldbus cables cable glands without shield are suffici ent refer to point 7 below 5 Connect the mains cables and if required signal cables in accordance with the circuit diagram enclosed in the connection hood connecting the earth lead conductor to the provided terminal in the connection box 6 Fit plug element 1 into fieldbus housing 2 again 7 Connect fieldbus connecting cables to the bus termination PCB 3 Lead shielding 7 under metal clamp 8 8 Fit connection cover 4 and fieldbus housing 2 again 9 Tighten cable glands 5 Fig Fieldbus connection a If the actuator is the last device of the bus segment the termination resistor must be set to ON or a termination must be done externally b Connection for external 24 V power supply Enables communication even if the mains are disconnected c Connection for PROFIBUS DP bus motor protcol analyzer Page 12 Y070 019
43. naling gear is omitted gear unit and manual drive have a different shape The main sub assembly electronics unit consists of the following sub assem blies 1 Electrical connection there are three versi ons 2 Plug element gear connection 3 Electronic housing with cover 4 Power control PCB with Power module 2 Fig Electronics unit sub assembly Y070 019 GB Fig Gear sub assembly 5 Fieldbus board option or 6 Relay board option 7 Control board 2 General Page 7 NO General 219U99 I N gt GA 2 General Operation instructions SIPOS 5 ECOTRON Block diagram electrical connections The block diagram shows the electronic sub assemblies and the inputs and outputs for possible customer specific connections Local control station PC interface RS 232 Sub D Position 0 4 20 mA 3 binary inputs OPEN CLOSE STOP Control unit PCB output Se torque CLOSE _ Relay card _ He at F i PCB er power et aren Powe ues 5 binary outputs 5 relay outputs CPU Channel 1 Output 24 V DC Printed circuit board plugs Plug element not for Position SG5 signaling goa unit A ntiome ma Input 24 V DC for additional supply of the electronics Power supply 1 KG _ Asynchronous Motor Fig Block diagram SIPOS 5 ECOTRON Page 8 Y070 019 GB 3 3 1 If actuators are delivered mounted to a valve this step h
44. nctional grounding not for protective grounding 1 Remove plastic fastener 1 from the electro 1 nic housing 2 Fit potential conductor 3 with M5 screw 2 and gripping disc 4 Fig Fitting the potential conductor Y070 019 GB Page 13 UOI D9UUOD pue Ajquwiassy LG 3 3 3 Assembly and connection Operation instructions SIPOS 5 ECOTRON Separate mounting If the ambient conditions such as extreme vibra tion high temperature and or if access is difficult the electronics unit is to be mounted separately from the gear The assembly kit for mounting the gear unit and electronics unit separately can be ordered directly with the actuator or separately as accessory 25X5300 The assembly kit is preassem bled If the assembly kit is ordered directly with the actuator it is included separately with the actuator 44 5 48 3 mm Before starting the work disconnect actuator i BG from the mains Procedure 1 Install mounting bracket fig item 3 at the mounting location of the electronics unit 2 Remove electronic housing 1 from the gear unit 6 and mount it on the mounting bracket 3 with the O ring 2 3 Standard assembly refer to A Mount Separate mounting kit Plug cover with contact pins 4 on lower side of wall bracket 3 and plug cover with contact sockets 5 on the gear unit 6 4 Assembly with spindle protection tube refer to B Turn connection hood by 9
45. nd service task The contents of these operation instructions and product documentation shall not become part of or modify any prior or existing agreement commitment or legal relationship The Purchase Agreement contains the complete and exclusive regulation on material defect liability of SIPOS Aktorik These contractual regulations are neither amended nor limited by the descriptions contained in these ope ration instructions and documentation Supplementary operation instructions 2SB5 linear actuator 2SC5 part turn actuator 2SG5 small part turn actuator COM SIPOS computer parameterization software PROFIBUS operation instructions MODBUS operation instructions HART operation instructions Enclosure protection IP68 K51 Increased vibration resistance K57 K58 Increased vibration resistance according to seismic class S2A K59 Very high corrosion protection corrosivity category C5 with long protection time L38 SIPOS 5 actuator with USP Binary and analog inputs freely available via bus Short instructions ECOTRON and others Y070 027 Y070 028 Y070 029 Y070 024 Y070 023 Y070 022 Y070 221 Y070 047 Y070 048 Y070 049 Y070 162 Y070 053 Y070 050 Y070 149 Any special installation and operation instructions furnished by the suppliers of subcontracted components attachments or fixtures are attached to the set of instructions and have to be observed Y070 019 GB Page 5 General information
46. ng The setting range for the standard actuator ranges from 30 100 and for the modulating actuator from 50 100 of the maximum torque in 10 steps each for some part turn actuators other limit values apply Default setting is the lowest possible value typically 30 of the maximum value for the standard actuator and 50 for the modulating actuator The following tables show the possible setting values For the 2SG5 part turn actuator the tripping torque cannot be changed Tripping torques for rotary actuator 2SA5 Possible values for setting Nm Standard actuator 2SA50 09 30 9 1 12 15 18 21 24 27 30 18 60 18 24 30 36 42 48 54 60 aas ar so 62 75 87 100 42 125 E EE EE ETE ETE 400 500 600 700 800 900 1000 600 2000 600 800 1000 1200 1400 1600 1800 2000 mel e o o a ojm Standard 30 Modulating actuator 2SA55 ee ee ee u per 408 428 440 467 175 175 350 175 210 245 280 315 1350 30 00 350 420 490 560 630 700 700 1400 700 840 980 1120 1260 11400 1400 2800 1400 1680 1960 2240 2520 2800 m r lelvlelele Standard 50 Tripping forces for linear actuator 2SB5 a EA 77 4 77 92 107 123 138 15 4 125 25 s 1 a6 20 25 25 225 45 225 27 315 36 405 45 45 90 LL 45 54 68 72 81 90 76 106
47. o only has to be set if the setting was not specified when ordering the actuator and the default setting does not meet the requirements 5 Check set mechanical position indicator if available Y070 019 GB Page 19 er Q T D Comm JEG BUIUOISSIUWIUIO 5 2 5 Commissioning Operation instructions SIPOS 5 ECOTRON Potentiometer and DIP switches The settings are made at the potentiometers and the DIP switch on the electronics board Unscrew the cover of the electronics unit PH dh D ve 1 Fig Removing the cover Arrangement of the potentiometer and the DIP switch on the electronics board 1 DIP switches Settings see below 2 Potentiometer Output speed positioning speed positioning time 3 Potentiometer Tripping torque force in end position CLOSED 4 Potentiometer Tripping torque force in end position OPEN 1 2 3 4 Fig Arrangement of the DIP switches potentiometer and the DIP switches S1 Closing direction clockwise or counter clockwise S2 Cut off mode CLOSE Travel or torque dependent S3 Cut off mode OPEN Travel or torque dependent S4 and S5 output signal sets Four sets can be selected S6 Control mode REMOTE Permanent contact or pulse contact self retaining 51 52 S3 S4 S5 S6 S7 S8 S7 Acceptance of end position setting Fig DIP switches S8 Acceptance in general Unless required otherwise by the customer the potentiometer settings indicated here and
48. r and tighten the bolts evenly in diagonally opposite sequence The housing of the SIPOS 5 actuators consists of an aluminum alloy which is corrosion resistant under normal environmental conditions If the paint was damaged during assembly it can be touched up with original paint supplied in small quantity units by SIPOS Aktorik Output shaft type A Assembly instruction 1 NS N The stem nut is screwed onto the valve stem by turning the A GO V hand crank or the hand wheel Fitting and removing the threaded bush If the stem nut was not ordered with a trapezoidal thread suffix Y18 to ordering number or if the stem nut is worn and has to be replaced proceed as follows Output flange fig item 1 does not have to be removed from the rotary actuator 1 Unscrew centering ring fig item 5 from output flange 2 Take off stem nut 4 together with axial needle roller assem 3 Ss SE bly and axial bearing washers 3 3 Remove the axial needle roller assembly and the axial bea ring washers 3 from the stem nut 5 me es 4 Only if the stem nut was delivered without thread Machine NIS a thread in the stem nut 4 check the concentricity and the axial run out when it is clamped and clean it 6 EE SE Fig Output shaft type A assembly Y070 019 GB Page 9 3 Assembly and connection Operation instructions SIPOS 5 ECOTRON 5 Lubricate axial needle roller bearings and axial bearing washers 3 with ba
49. r driven operation of the hand crank hand wheel is not permitted After commissioning the actuator must not be operated beyond the parameterized end posi tions using the hand crank hand wheel When pressing in the hand crank the hand wheel make sure that the hand is not between the hand crank the hand wheel and the housing Danger of crushing See the following operation step 3 During motor operation the hand crank the hand wheel does not turn Operation Operation of all actuators except for 2865 1 The actuator must be at standstill 1 2 Remove the clamp option 2 The clamp is used as protection against accidental engaging of the hand crank the hand wheel if the actuator is exposed to heavy vibration or water pressure enclosure protection IP 68 3 Press hand crank hand wheel in direction of the gear housing against the spring force 3 and turn 4 Caution Danger of crushing when engaging The hand wheel has priority over motorized operation The actuator can only be operated el cally once the hand crank hand wheel is released Only for 2865 Fig Operating the crank handle ectri Turn hand wheel without pressing it in Manual operation interferes with motor operation If the hand wheel is turned during motor operation the positioning time is either extended or reduced depen ding on the direction of rotation Direction of rotation Clockwise turning of the hand crank hand wheel leads
50. r settings are performed set DIP switch S8 to ON and then to OFF again and fit the cover of the electronics unit using screws NO normally open contact active high DC 18 30 V NC normally closed contact active low DC 0 4 V The active high or active low levels are set when a status is reached for 2565 Motor temperature too high Y070 019 GB Page 25 5 Commissioning Operation instructions SIPOS 5 ECOTRON 5 3 4 Setting remote control JEG Depending on the version there are different options for the DCS to control the actuator Either via pulse contact or permanent contact Pulse contact After an OPEN CLOSE pulse the actuator operates until a STOP command is present or the end position has been reached A signal for the opposite direction leads to a direct change of the direction of operation The pulse contact function is also called self retaining BUIUOISSIUWIUIO Permanent contact The actuator operates as long as an OPEN or CLOSE signal is present The actuator stops if the signal is deactivated the end position has been reached or the OPEN and CLOSE commands are present simultaneously Setting DiPswitch Function S Control mode Remote Pulse contact Control mode Remote Permanent contact default setting unless required otherwise by the customer In case no further settings are performed set DIP switch S8 to ON and then to OFF again and
51. result in injury to persons or faults in the plant the actuator or plant section is properly isolated In addition to the main circuits also check that any additional or auxiliary circuits are disconnected Furthermore the general safety regulations have to be observed Disconnect all poles also 24 V DC Prevent accidental reconnection Confirm that equipment is not live Earth and short circuit equipment Fit barriers or covers to neighboring live components General The actuators are virtually maintenance free for the lubrication intervals refer to chapter 7 2 We recommend submitting the actuators to a general inspection after commissioning or after approx 50 operation hours to verify that correct functioning is guaranteed no unusual noises vibration occur the fixing elements have not become loose E no leakages occur The housing of the SIPOS 5 actuators consists of an aluminum alloy which is corrosion resistant under normal environmental conditions If the paint was damaged during assembly it can be tou ched up with original paint supplied in small quantity units by SIPOS Aktorik This list cannot cover every eventuality Further checks may be necessary in accordance with the plant specific conditions Any impermissible deviations or changes detected during inspection must be rectified immediately Under normal operation conditions service or inspection of the devices is recommended every 8 ye
52. rt turn actuators tripping forces for linear actuators Setting Turn potentiometer to the desired level standard CLOSED actuator 30 100 modulating actuator 50 100 For the setting values per level refer to the table above Setting in end position OPEN of the tripping torques for rotary and part turn actuators tripping forces for linear actuators Setting Turn potentiometer to the desired level standard actuator 30 100 modulating actuator 50 100 For the setting values per level refer to the table above In case no further settings are performed set DIP switch S8 to ON and then to OFF again and fit the cover of the electronics unit using screws Y070 019 GB Page 23 oD Q T D Comm 5 Commissioning Operation instructions SIPOS 5 ECOTRON 5 3 Setting closing direction cut off modes JEG New actuators are set in the factory Unless required otherwise by the customer the default set tings are as follows closing direction clockwise cut off mode in OPEN and CLOSE direction travel dependent If the current setting should be retained continue with chapter 5 5 Adjusting the signaling gear ratio and the end positions The closing direction and the cut off mode are set via DIP switches see below BUIUOISSIUWIUIO 5 3 1 Setting the closing direction Unless required otherwise by the customer the actuators are delivered with clockwise
53. serving reading the actuator parameters the device state in the Local and Remote state diagnosis trouble shooting loading new firmware software update to the state of the art archiving saving the actuator parameters COM SIPOS allows enhanced programming at the actuator The connection between computer and actuator is established via a standard null modem cable COM SIPOS is available including null modem cable USB serial adapter and user manual on CD ordering number 2SX5100 3PC02 Page 18 Y070 019 GB 5 1 2 Operation instructions 5 Commissioning SIPOS 5 ECOTRON Commissioning General information Before performing any work on the installed actuator check with the plant personnel in charge that the commissioning may not cause any fault of the plant or hazards to persons f a cut off mode is selected that is not appropriate for the valve the valve may be damaged There are hazardous voltage steps within the actuator f the Local Remote button is pressed in the Local state the actuator changes to the Remote state and moves if there is an operation command from the DCS m Change to the Local state before commissioning It is recommended that the services and support of the responsible SIPOS Aktorik service cen ters are utilized for all planning installation commissioning and service task Ensuring prerequisites for commissioning Check and ensure the following po
54. stems bearings feather keys bright surface etc 6 If applied Page 38 Y070 019 GB 8 1 8 2 Operation instructions 8 Spare parts SIPOS 5 ECOTRON Spare parts General With the exception of standardized generally available components only original spare parts may be used Spare parts are usually supplied as complete subassemblies see the list below In the following representation drawings designations with 3 digits are listed These numbers are prefixed with 2SY5 to give the full spare parts designation When ordering spare parts always provide the following information 1 Order number and works number of the actuator refer to rating plate 2 Spare parts designation 2SY5 see following list 3 Quantity required All external metallic housing parts are made of a corrosion resistant aluminum alloy painted with color similar to RAL 7037 silver gray as standard and meet the requirements up to corro sivity category C5 Other finish paint color add order code Y35 Very high corrosion protection corrosivity category C5 with long protection time add order code L38 Spare parts list Our actuators are designed for fault free operation within the maintenance intervals As we know from experience external causes may damage the actuator already during the commissioning sta ge For such events the recommended spare parts are listed in the following table If you require other parts please contact our serv
55. the underlined settings of the DIP switches are the default settings Setting speeds tripping torques New actuators are set in the factory Unless required otherwise by the customer the default para meters are as follows Output speed positioning speed positioning time for operation in CLOSE and OPEN direction Level 4 of the 7 level setting range step up factor 1 4 Tripping torques forces in OPEN and CLOSE direction lowest device dependent setting value for the standard actuator 30 for the modulating actuator 50 of the maximum value cannot be changed for the 2565 If the current setting should be retained continue with chapter 5 3 Closing direction setting the cut off modes Page 20 Y070 019 GB Operation instructions 5 Commissioning SIPOS 5 ECOTRON 5 2 1 Setting speeds positioning speeds positioning times Setting the output speeds determines the actuator speed Depending on the actuator type different values can be set for the output speed Speeds for rotary actuator 2SA5 Speed ranges Possible values for output speed rpm Standard actuator 1 25 10 2 5 20 5 28 5 40 10 80 20 112 20 28 40 56 80 12 20 160 Modulating actuator D Q T V Comm Speed steps Standard 4 Positioning speeds for linear actuator 2SB5 Positioning speed ranges Possible values for positioning speed mm min 25 200 30 240 30 42 60 84 120 168 240 3 280 35
56. ting parameter via position ranges COM SIPOS parameterization program Recommissioning Check signaling gear and travel potentiometer Check valve for sluggishness N Set higher torque values Verify Separate mounting parameter via COM SIPOS parameterization program Commissioning active End position setting not OK Commissioning active Terminate commissioning and perform it 1 End position setting not OK once again 58 gt OFF FK ON Commissioning active 0 1x End position OPEN is set approach end position CLOSED wy Commissioning active Terminate commissioning S8 gt OFF mal No Commissioning not possible evaluate flash pattern Commissioning active Actuator moves automatically with torque dependent cut off mode to the end position Commissioning active Hand crank hand wheel operated during Release hand wheel crank commissioning A I Fault a 6x End positions were exceeded Fault during runtime monitoring sjeu is ne pue Commissioning active Commissioning via serial interfaced or fieldbus interface active i e on site com missioning and operation via local control unit not possible Page 36 Y070 019 GB 7 1 Operation instructions 7 Maintenance inspection service SIPOS 5 ECOTRON Maintenance inspection service Before any work is carried out on the actuator ensure that the planned measures possible operation of valves etc will not
57. to m 2SA5 rotary actuator Clockwise rotation of the output drive shaft exception 2SA5 7 and 2SA5 8 m 2SB5 linear actuator Extension of the thrust rod 2SC5 part turn actuator With view on the pointer cover of the worm gearbox clockwise move ment of the coupling or lever arm with the worm gearbox versions RR or LR 2SC5 part turn actuator With view on the mechanical position indicator clockwise rotation at the coupling or at the swing lever Y070 019 GB Page 15 da C O 90 O Ke C 90 O j mur L O O fed 90 O ce O N C O Ben fe N 5 T er c O aa O 5 T O 5 O D Q er O O O 5 ep Q o 5 Q O D wm Q O 5 4 2 4 2 1 4 Instructions on operator control and operation Operation instructions SIPOS 5 ECOTRON Local control station On local control station the operation can be made directly at the actuator via 4 push buttons refer to fig Local control panel By pressing the Remote Local push button you can change between two states Remote and Local Depending on the state the actuator is in the push buttons have different functions The COM SIPOS parameterization program enables convenient operation of the actuator refer to chapter 4 4 The actuator can be controlled from the computer laptop via a cable Meaning of the LEDs and functions of the push buttons Loca
58. utton or the button for the opposite direction is pressed Important When approaching to the end position observe the direction of rotation of the central wheel This is important for operation step 7 Press CLOSE button to return to the desired end position Continue with operation step 7 If the actuator has switched off automatically before reaching the end position two causes are possible Sluggish MOV or unfavorable torque curve In this case cancel procedure Set DIP switch S8 to OFF or valve has reached the mechanical stop in this case return to desired end position Y070 019 GB Page 31 5 Commissioning Operation instructions SIPOS 5 ECOTRON JEG DIP switch LED Instruction push e button H1 H2 3 Torque dependent cut off mode og Nor SES dy Hold down OPEN button for more than 2 s The actuator ope W Ore du rates automatically CT JE oO When reaching the end position range the permanent signal KEFA NZ of LED H2 changes to a periodical flashing signal s t We JAN 3x After reaching the end position the actuator operates shortly Nat Se in the opposite direction to return to the end position again Of fu Z As soon as the actuator has stopped automatically the blink signal of LED H2 changes over to a permanent signal for 2SG5 continue with step 8 7 Slowly turn the central wheel shortly before mark 1 or 2 until LED H2 red is no longer illuminated To which mark
59. y signaled to the electronics Signaling gear adjustment table A n E Q EH 3 El O gt gi SE x x oO _ Se Geh i Fig Schematic representation of the signaling gear ratio and end position settings Explanation The signaling gear 7 reduces the rotations of the output shaft 4 required for the complete travel 5 X Y to a rotary movement of less than a full revolution max rotation angle of the potentio meter or the magnetic position sensor x y Setting a refer to following chapter Adjusting the signaling gear ratio From the position of the potentiometer or the magnetic position sensor for reasons of simplicity only called potentiometer in the following the electronics recognizes the position of the output drive shaft and therefore the position of the connected valve To this end the potentiometer has to be set so that one of the mechanical end positions of the valve X or Y corresponds to one limit of the electric setting range of the potentiometer x or y Setting b refer to the following chapter Adjusting the end positions Page 28 Y070 019 GB Operation instructions 5 Commissioning SIPOS 5 ECOTRON 5 5 2 Adjusting the signaling gear ratio The number of rotations required to cover the whole travel must be known The data is provided by the valve manufacturer If this information is not

Operation instructions Electric actuators SIPOS 5 ECOTRON

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