Schischek Exmax series User manual

EXPLOSIONPROOF

ExMax - ... - Y

ExMax - ... - YF

ExMax - ... - CTS

ExMax - ... - VAS

www.schischek.com

Schischek GmbH Germany, Muehlsteig 45, Gewerbegebiet Sued 5, 90579 Langenzenn, Tel. +49 9101 9081-0, Fax +49 9101 9081-77, E-Mail [email protected]

ExMax-S-Y_en

V01 – 16-Nov-2017

Subject to change!

Compact. Easy installation. Universal. Cost effective. Safe.

Product views and applications

Description Highlights

Ball valve Throttle valveSafety damper

Electrical, explosion proof rotary actuators

3-pos. / 0...10 V DC / 4...20 mA control mode, with feedback, 24...240 V AC/DC, 95° angle of rotation

5/10 Nm, 15/30 Nm without and 5/10 Nm, 15 Nm with safety operation (spring return)

ATEX tested in acc. with directive 2014/34/EU for zone 1, 2, 21, 22

Type Torque Supply Motor running time Spring return Control mode Feedback Wiring diagram

ExMax- 5.10 - Y 5 / 10 Nm 24...240 V AC/DC 7,5 / 15 / 30 / 60 / 120 s/90° – 3-pos., 0...10 V DC, 4...20 mA 0...10 V DC, 4...20 mA SB 5.0 – 5.3

ExMax-15.30 - Y 15 / 30 Nm 24...240 V AC/DC 7,5 / 15 / 30 / 60 / 120 s/90° – 3-pos., 0...10 V DC, 4...20 mA 0...10 V DC, 4...20 mA SB 5.0 – 5.3

ExMax- 5.10 - YF 5 / 10 Nm 24...240 V AC/DC 7,5 / 15 / 30 / 60 / 120 s/90° 3 or 10 s/90° 3-pos., 0...10 V DC, 4...20 mA 0...10 V DC, 4...20 mA SB 5.0 – 5.3

ExMax- 15 - YF 15 Nm 24...240 V AC/DC 7,5 / 15 / 30 / 60 / 120 s/90° 3 or 10 s/90° 3-pos., 0...10 V DC, 4...20 mA 0...10 V DC, 4...20 mA SB 5.0 – 5.3

ExMax- ... - CTS Types as above with aluminium housing and seawater resistant coating (cable glands brass nickel-plated)

ExMax- ... - VAS Types as above with stainless steel housing for aggressive ambient (cable glands brass nickel-plated)

ExMax ¼ turn actuators – size S

►For all type of gas, mists, vapours and dust for use in zone 1, 2, 21 and 22

►Universal supply unit from 24…240 V AC/DC

►5 different motor running times 7,5–15–30–60–120 s/90°, adjustable on site

►2 different spring return running times ~ 3–10 s/ 90°, selectable on site

►3-pos. and 0...10 V DC, 4...20 mA control mode with or without spring return function

► Feedback signals 0...10 V DC and 4...20 mA

► Reverse function

►5–10 –15– 30 Nm actuators in the same housing size

►100 % overload protected and self locking

►Compact design and small dimension (L × W × H = 210 × 95 × 80 mm)

►Direct coupling to the damper shaft with double square connection 12 × 12 mm

►95° angle of rotation inclusive 5° pretension

►Robust aluminium housing (optional with seawater resistant coating) or in stainless steel

►IP66 protection

►Simple manual override included + preparation for comfortable manual override

►Gear made of stainless steel and sinter metal

►Weight only ~ 3,5 kg

►Integrated heater for ambient temperatures down to −40 °C

►Integrated safety temperature sensor

►Integrated equipment for manual adjustment (push button, lamp, switch)

►Preparation for adaptable and adjustable auxiliary switches type ...Switch

The ExMax actuators are a revolution for safety, control and shut-off

dampers, VAV systems, ball valves, throttle valves and other motorized

applications for HVAC systems in chemical, pharmaceutical, industrial

and offshore/onshore plants, for use in Ex-areas zone 1, 2 (gas) and

zone 21, 22 (dust).

Highest protection class (ATEX) and IP66 protection, small dimensions,

only 3,5 kg weight, universal functions and technical data, an integrated

heater and an optional stainless steel housing guarantee safe operation

even under difficult environmental conditions. High quality brushless

motors guarantee long life.

All actuators are programmable and adjustable on site. Special tools or

equipment are not required. Motor running times and torques as well as

spring return times, according to the actuator type, are selectable or

adjustable on site. The integrated universal power supply is self adaptable

to input voltages in the range of 24...240 V AC/DC. Furthermore it is

possible to perform control signal inverting and compulsion control by

certain connections. The actuators are 100 % overload protected and

self locking.

...Max-...-YF actuators are equipped with spring return fail safe function.

Standard shaft connection is a double square direct coupling with

12 × 12 mm.

Different accessories are available to adapt auxiliary switches, terminal

boxes or adaptions for ball valves and throttle valves and other armatures.

1 / 4

EXPLOSIONPROOF

www.schischek.com

Schischek GmbH Germany, Muehlsteig 45, Gewerbegebiet Sued 5, 90579 Langenzenn, Tel. +49 9101 9081-0, Fax +49 9101 9081-77, E-Mail [email protected]

ExMax-S-Y_en

V01 – 16-Nov-2017

ExMax-...-Y ExMax-...-YF

Special options ... -CTS ... -VAS

Technical data ExMax- 5.10 -Y ExMax- 15.30 -Y ExMax- 5.10 -YF ExMax- 15 -YF

Approbations Special solutions and accessories

...-CTS Types in aluminium housing with seawater resistant coating,

parts nickel-plated

...-VAS Types in stainless steel housing, parts nickel-plated

ExBox-Y/S... Ex-e terminal boxes for zone 1, 2, 21, 22

MKK-S Mounting bracket for boxes type ...Box-... directly on actuator

ExSwitch 2 external aux. switches, adjustable for zone 1, 2, 21, 22

HV-S... Comfortable manual override for...Max actuators size S

KB-S Clamp for damper shafts Ø 10...20 mm and □10...16 mm

AR-12-xx Reduction part for 12 mm square connection to 11, 10, 9 or 8 mm shafts

Kit-S8 Cable glands nickel-plated

Adaptions for dampers and valves on request

Torque motor (min.) 5 / 10 Nm selectable on site 15 / 30 Nm selectable on site 5 / 10 Nm selectable on site 15 Nm

Torque spring (F) – – min. 10 Nm min. 15 Nm

Torque blockade In blockade and end positions torques are higher than above specified torques for motor and spring.

Dimensioning of external load Upon spring return the external load should be max. 80 % of torque spring (F).

Supply voltage / frequency 24...240 V AC/DC, ± 10 %, self adaptable, frequency 50...60 Hz ± 20 %

Power consumption max. starting currents see Extra information (in acc. with voltage, I start >> I rated ), approx. 5 W holding power, approx. 16 W for heater

Protection class Class I (grounded)

Angle of rotation and indication 95° incl. ~ 5° pretension, mechanical value indication

Working direction Selectable by left/right mounting to the damper/valve shaft

Motor running times 7,5 / 15 / 30 / 60 / 120 s/90° selectable on site

Motor Brushless DC motor

Control mode Y 3-pos., 0…10 V DC, 4…20 mA in acc. with wiring, selectable on site. Galvanic separation between supply and Y-signal

Feedback signal U 0…10 V DC, 4…20 mA in acc. with wiring, selectable on site, both signals are available at the same time

Resistance of Y and U signals Input signal: YU0...10 V DC at 10 kΩ, YI4...20 mA at 100 Ω. Feedback signal: UU 0...10 V DC at 2.000...∞ Ω, UI4...20 mA at 0...800 Ω

Reverse function Bridge between terminals 3–4 (signal line) effects a reverse function of input and output signals (Y and U)

Compulsion control In modulation mode an On-off compulsion control can be performed by external connection/wiring independently from the modulating signal

Adjustment of Y and U In case of external mechanical limitation of the angle of rotation, it is possible to perform an adjustment drive started by pushing the button (T)

Spring return (F) – – spring return upon voltage interruption

Spring return response time – – up to 1 sec. after voltage interruption

Spring return running time (F) – – ~ 3 or 10 s/90° selectable on site

3 sec. mode – spring return – – ~ 3 to 4 s/90° angle of rotation acc. to external load

Safety operations at 10 sec. (F) – – min. 10,000 acc. to construction of damper and ambient

at 3 sec. (F) – – min. 1,000 acc. to construction of damper and ambient

Axle of the actuator Double square 12 × 12 mm, direct coupling, 100 % overload protected and self locking up to 15 Nm

Electrical connection 2 cable glands ~ 1 m each, wire cross section 0.5 mm², equipotential bonding 4 mm².

Connections in hazardous areas require an Ex-e terminal box !

Diameter of cable ~ Ø 7.1 + 7.4 mm ~ Ø 7.1 + 7.4 mm ~ Ø 7.4 mm each ~ Ø 7.4 mm each

Cable gland M16 × 1.5 mm

Manual override Use delivered socket wrench, max. 4 Nm

Heater Integrated, controlled heater for ambient temperature down to −40 °C

Housing material Aluminium die-cast housing, coated. Optional with seawater resistant coating (...-CTS) or stainless steel housing,

№1.4581 / UNS-J92900 / similar AISI 316Nb (...-VAS)

Dimensions (L × W × H) 210 × 95 × 80 mm, for diagrams see Extra information

Weight ~ 3,5 kg aluminium housing, stainless steel ~ 7 kg

Ambients Storage temperature −40…+70 °C, working temperature −40…+40 °C at T6 and −40…+50 °C at T5

Humidity 0...90 % rH, non condensing

Operating 7,5 sec. motor run time at 24 V: S3 – 50 % ED intermittent mode (ED = duty cycle)

≥15 sec. motor run time at 15 / 30 / 60 / 120 s 100 % of ED is permitted

Accuracy electrically ~ 100 steps

Self adjustment Before initial operation you need to start the self adjustment mode for “gentle” blockade and adjustment of rotation angle

Wiring diagrams SB 5.0 / 5.1 / 5.2 / 5.3

Scope of delivery Actuator with 2 × 1 m cable, 4 screws M4 × 100 mm, 4 nuts M4, Allen key for simple manual override

Parameter at delivery 5 Nm, 30 s/90° 15 Nm, 30 s/90° 5 Nm, 30 s/90° 15 Nm, 30 s/90°

ATEX directive 2014/34/EU

EC type-approved PTB 04 ATEX 1028 X

IECEx certified IECEx PTB 07.0057X

Approval for gas II 2 (1) G Ex d [ia] IIC T6, T5

Types ...-CTS II 2 (1) G Ex d [ia] IIB T6, T5

Approval for dust II 2 (1) D Ex tD [iaD] A21 IP66 T80, T95°C

CE identification CE №0158

EMC directive 2014/30/EU

Low voltage directive 2014/35/EU

Enclosure protection IP66 in acc. with EN 60529

EAC № ТС RU С-DE.ГБ08.В.01510

2 / 4

EXPLOSIONPROOF

ExBox

Y: 0...10 V / 4...20 mA

U: 0...10 V / 4...20 mA

−

PE PE

1 1

2 2

3 3

5 5

4 4

6 6

1 1

2 2

3 3

5 5

4 4

PA PA

YmA

YmA YmA

YV DC

YV DC YV DC

V DC/mA

UmA

UmA UmA

UV DC

UV DC UV DC

www.schischek.com

Schischek GmbH Germany, Muehlsteig 45, Gewerbegebiet Sued 5, 90579 Langenzenn, Tel. +49 9101 9081-0, Fax +49 9101 9081-77, E-Mail [email protected]

ExMax-S-Y_en

V01 – 16-Nov-2017

ExMax-...-Y ExMax-...-YF

Special options ... -CTS ... -VAS

Important information for installation and operation

Electrical connection

All actuators are equipped with a universal supply unit working at a voltage range from

24...240 V AC/DC. The supply unit is self adjusting to the connected voltage!

The safety operation of the spring return function works if the supply voltage is cut.

For electrical connection inside hazardous areas an Ex-e terminal box, certificated in acc.

Installation

Ex area –

zone 1, 2, 21, 22 Safe area

Supply *

24...240 V AC/DC ± 10 %

* electrical wiring see diagrams

with ATEX is required (e.g. ExBox).

An over-current protection fuse < 10 A has to be provided by installer.

Note: the initial current is appr. 2 A for 1 second.

Modulating – with / without spring return (no feedback) SB 5.2 3-pos. – with / without spring return + feedback SB 5.3

Modulating / 3-pos. – with / without spring return SB 5.0 Modulating – with / without spring return (no enforcement) SB 5.1

Selection of running time for spring return:

Spring return in ~ 10 s = Standard wiring

Spring return in ~ 3 s = Additional wiring on terminal 5

Selection of running time for spring return:

Spring return in ~ 10 s = Standard wiring

Spring return in ~ 3 s = Additional wiring on terminal 5

Selection of running time for spring return:

Spring return in ~ 10 s = Standard wiring

Spring return in ~ 3 s = Additional wiring on terminal 5

Selection of running time for spring return:

Spring return in ~ 10 s = Standard wiring

Spring return in ~ 3 s = Additional wiring on terminal 5

3-pos. control mode:

▪a closed, bopen – ON (OFF) in acc. to left /right mounting of actuator

▪b closed, aopen – OFF (ON) in acc. to left /right mounting of actuator

Function and enforcement control of switch a and b in modulating mode:

▪a closed – Forced-ON (OFF) in acc. to left /right mounting of actuator

▪b closed – Forced-OFF (ON) in acc. to left /right mounting of actuator

Reverse function:

Bridge 3– 4 reverses

the input signals

Reverse function:

Bridge 3– 4 reverses

the output signals

Reverse function:

Bridge 3– 4 reverses the

input and output signals

Reverse function:

Bridge 3– 4 reverses the

input and output signals

Self adjustment:

To adjust the signal input /output to the angle of

rotation of the damper/ valve the button (T) must

be pushed for a minimum of 3 sec.

Self adjustment:

To adjust the signal input /output to the angle of

rotation of the damper/ valve the button (T) must

be pushed for a minimum of 3 sec.

Self adjustment:

To adjust the signal input /output to the angle of

rotation of the damper/ valve the button (T) must

be pushed for a minimum of 3 sec.

Self adjustment:

To adjust the signal input /output to the angle of

rotation of the damper/ valve the button (T) must

be pushed for a minimum of 3 sec.

Attention!

When changing 3-position

mode into modulating

regard function, see

page 4 – Parametrisation D)

24...240 V AC/DC 24...240 V AC/DC

A. Installation, commissioning, maintenance

All national and international standards, rules and regulations for hazardous Ex-areas

must be complied. Certified apparatus must be installed in accordance with manufacturer

instructions. If the equipment is used in a manner not specified by the manufacturer,

the safety protection provided by the equipment may be impaired. For electrical

installations design, selection and erection, EN/IEC 60079-14 can be used.

For electrical connection an Ex-e terminal box is required (e.g. ExBox-...).

Attention: If the actuator is put out of operation all Ex rules and regulationsmust be

applied. You have to cut the supply voltage before opening the terminal box!

The cablesof the actuator must be installed in a fixed position and protected against

mechanical and thermical damage. Connect potential earth. Avoid temperature transfer

from armature to actuator! Close all openings with min. IP66.

For outdoor installation a protective weather shield against sun, rain and snow should

be applied to the actuator as well as a constant supply at terminal 1 and 2 for the

integrated heater. During commissioning apply a self adjustment drive.

Actuators are maintenance free. An annual inspection is recommended. For electrical

installations inspection and maintenance, EN/IEC 60079-17 can be used. Ex-actua-

tors must not be opened by the customer.

B. Manual override

Manual override only if supply voltage is cut. Use delivered socket wrench with slow

motions, usage can be tight. Attention: Releasing or letting go the Allen key too fast

at manual operating actuators with spring return causes risk of injury!

C. Shaft connection, selection of running time

Actuators are equipped with a direct coupling double square shaft connection of

12 × 12 mm. For round shafts adaptors/clamping connection (accessories, e.g. KB-S)

are available. The housing of the actuator is axially symmetrically built to select Open-close

direction of the spring return function by left-right mounting. Using the 10-position switch

different motor running times and spring return running times can be selected on site

in acc. to the actuator type.

D. 3-position control mode

...Max actuators are in the best way suitable for the 3-pos. operation. To protect such

elements as gears and mounting elements against harmful influences like minimum

pulse time, ...Max actuators are protected via internal electronics. It ignores impulses

< 0.5 s, the cyclic duration must be min. 0.5 s. At changing direction the pause is 1 s.

E. Spring return

Spring return function works only if the supply voltage for terminal 1 or 2 is cut. In the

event of an electrical interruption, the spring returns to its end position even if supply

voltage is available again during return function. Thereafter operation will continue.

F. Operation at ambient temperatures below −20 °C

All actuators are equipped with a regulated integrated heating device designed for

employments down to −40 °C ambient temperature. The heater will be supplied

automatically by connecting the constant voltage supply on the clamps 1 and 2.

1. After mounting the actuator must bei immediately electrically connected.

2. The heater switches on automatically when actuator reaches internally −20 °C. It

heats up the actuator to a proper working temperature, then heater switches off auto-

matically. Actuator will not run during heating process.

3. The adjustment options are only ensured after this heating up period.

G. Excess temperatures

In acc. to the ATEX rules and regulations Ex actuators must be protected against excess

temperature. The internal thermostat works as a maximum limiter and, in the event of

failure at incorrect temperatures, shuts off the actuator irreversible. An upstream

connected temperature sensor stops the actuator before reaching its max. temperature.

This safety feature is reversible, after cooling down the actuator is completely functional

again. In this case the failure must be eliminated immediately on site!

H. Synchron mode

Do not connect several actuators to one shaft or link mechanically together.

I. Mechanical protection

Actuators must be operated with a minimum external load.

After installing the actuator to the damper/armature a self adjustment drive has to be

performed in order to protect the damper/armature against mechanical overload.

During operation the actuator reduces briefly its speed (motor power) before reaching

the end position for a “gentle” blockade/stop.

J. Intrinsically safe circuits

The actuator has a flameproof enclosure acc. to EN 60079. The supply of the push

button (adjustment drive), the 10-position switch (adjustment of torque and running

time) and the LED indicator is performed intrinsically safe!

continue next page

3 / 4

EXPLOSIONPROOF

! !

ExMax- 5.10-Y ►

ExMax- 15.30-Y ►

ExMax- 5.10-YF ►

ExMax- .15-YF ►

7,5 s/ 90° ►

15 s/90° ►

30 s/90° ►

60 s/90° ►

120 s/ 90° ►

5 Nm

15 Nm

5 Nm

15 Nm

▼

10 Nm

30 Nm

10 Nm

▼

www.schischek.com

Schischek GmbH Germany, Muehlsteig 45, Gewerbegebiet Sued 5, 90579 Langenzenn, Tel. +49 9101 9081-0, Fax +49 9101 9081-77, E-Mail [email protected]

ExMax-S-Y_en

V01 – 16-Nov-2017

ExMax-...-Y ExMax-...-YF

Special options ... -CTS ... -VAS

Important information for installation and operation Parameters, adjustments and failure indication

Parameter selection

Functions, adjustments and parameters

Type

Running times Position of switch (S)

Torques

Example:

ExMax-15.30-Y

Requested parameter:

Torque 30 Nm

Motor running time 30 s /90°

Result:

Switch position 07

Switch – Push button – Lamp

for adjustment

(behind the blanking plug)

10-position switch (S)

Push button (T)

3-colour LED

Attention

During commissioning apply a self adjustment drive.

Regard duty cycle at motor running times!

Never use spring return actuators without external load.

A) Self adjustment of angle of rotation

Turn switch (S) to position 02 (low torque) or 07 (high torque). Press button (T) for

a minimum of 3 seconds. The actuator drives to both end positions and detects the

blocking positions. The LED flashes GREEN during adjustment.

The adjustment takes about 60 seconds (30 sec. “On”, 30 sec. “Off”).

B) Selecting motor running time and torque

Adjust parameters only if actuator is in idle state or without applied potential.

Turn switch (S) to the position required for the intended operation acc. to table

above. The selected parameters will be carried out at the actuator’s next operation.

C) Selecting spring return time

Spring return time is selected by wiring.

D) Changing modulating operation to 3-pos. operation with feedback

Modulating mode: The LED lights GREEN, potential applied.

Press button (T) briefly 3 times:

▪ each for at least 0.2 seconds

▪altogether within max. 5 seconds

The LED changes from steady GREEN to steady YELLOW*.

E) Changing 3-pos. operation with feedback to modulating operation

3-pos. mode: The LED lights YELLOW*, potential applied.

Press button (T) briefly 3 times.

The LED changes from steady YELLOW* to steady GREEN.

F) Additional information for control in 3-pos. operation with feedback

a closed, b open = direction I a and b closed = motor doesn’t work

b closed, a open = direction II a and b open = motor doesn’t work

The rotation direction (I and II) depends on left/right mounting of the actuator to the

damper. To reverse the rotation direction (by motor) exchange the electrical wiring

of terminal 3 and 4.

In 3-pos. operation with feedback the Y-inputs are without function.

G) Inverting <=> Reverting

Bridging signal wires 3–4 (cable B) inverts the function of input signals Y and feed-

back signals U.

* Note: “YELLOW” may vary from yellowish to orange.

Extra information (see additional data sheet)

Additional technical information, dimensions, installation instruction, illustration

and failure indication