SIPOS Seven Aktorik Ecotron 2SA7 User manual

1
Issue: 05.19 SIPOS Aktorik GmbH Y070.485/EN
Subject to changes without notice! 1
Contents
1 General information��������������������������������� 1
1.1 Safety information ................................... 1
1.2 Transport and storage ............................. 2
1.3 Disposal and recycling ............................ 2
EU Declaration of conformity........................... 2
2 Assembly and connection���������������������� 2
2.1 Mount to valve/gear ................................. 2
2.2 Separate mounting .................................. 4
2.3 Remote control unit ................................. 4
2.4 Electrical connection ............................... 4
3 Operation��������������������������������������������������� 5
3.1 Manual operation ..................................... 5
HiMod PROFITRON
1 General information
1�1 Safety information
General information
The devices referred to in this document 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 qualied personnel.
Qualied personnel within the meaning of the relevant safety instructions of this documentation
are all persons authorized to perform the required tasks according to the standards of safety
technology and who 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.
Introduction
These operation instructions contain concise information required for assembly, operation and
commissioning. Extensive operation instructions for PROFITRON/HiMod are available on the
Internet: www.sipos.de ► ►Product documents ►Instruction manuals.
■Leakage currents
As standard, the leakage current of the actuators exceeds 3.5 mA. Therefore, xed
installation in accordance with IEC 61800-5-1 is required.
■Residual current circuit breaker or monitoring devices
Due to the integral frequency converter, a direct current within the protective ground-
ing conductor can be generated.
Should a residual current-operated protective (RCD) or monitoring (RCM) device be
used upstream the network, it must be of type B.
The distribution of this product is restricted according to IEC 61800-3.
and may cause radio interferences in domestic environments. In this case it may be necessary to
take additional measures.
The following is of particular importance:
■The technical data and indications on permissible use (assembly, connection, environmental
and service conditions).
■The general installation and safety guidelines as well as the local, plant-specic provisions and
requirements.
■The proper use of tools and lifting and transport equipment.
■The use of personal protective equipment, especially in high ambient temperatures and with
potential high actuator surface temperatures.
Prior to starting the assembly:
■Make sure that the intended measures (possible operation of the valve, etc.) are not likely to
cause any injuries to persons or to interfere with the equipment.
■Heed the local ambient conditions, in particular the vibration load, which can be caused when
mounting an actuator to a vibrating valve.
Should supplements be required for certain versions, applications, environmental conditions or
software functions of the actuator, they will be included within the scope of delivery.
Operation instructions
Assembly, operation and commissioning
of 2SA7, 2SQ7
electric actuators
3.2 Indications of the LEDs ........................... 6
3.3 Status indication ...................................... 6
3.4 Display – position bar .............................. 6
3.5 Navigation through the menus ................ 6
4 Commissioning ���������������������������������������� 7
4.1 User management ................................... 7
4.2 End position adjustment .......................... 8
4.3 Mech. position indicator adjustment ...... 10
5 Maintenance, inspection, service ������� 10
5.1 General safety information .................... 10
5.2 Notes on inspection ............................... 10
5.3 Spare parts ............................................ 10

2
Warnings on the device
Fig�: Danger of crushing
EU Declaration of conformity
Explanation Applied standards and directives
SIPOS Aktorik GmbH as manufacturer declares
herewith that the 2SA7 and 2SQ7 actuators
meet the basic requirements of the following
Directives:
2014/30/EU (EMC Directive)
2006/42/EC (Machinery Directive)
The following harmonized standards in terms of the
specied directives have been applied:
Directive 2014/30/EU: EN 61800 -3: 2004 /A1: 2012
Directive 2006/42/EC: EN ISO 12100:2010,
EN ISO 5210:1996; EN ISO 5211:2001,
DIN 3358:1982
SIPOS actuators are designed for the operation of industrial valves. Putting into service is prohibited
until the nal machinery has been declared in conformity with the provisions of Directive 2006/42/EC.
The following basic requirements in compliance with Annex I of the Directive are respected:
Annex I, articles 1.1.2, 1.1.3, 1.1.5, 1.2.1, 1.2.6, 1.3.1, 1.3.7, 1.5.1, 1.6.3, 1.7.1, 1.7.3, 1.7.4
The manufacturer shall be obligated to electronically submit the documents for the partly completed
machinery to national authorities on request. The relevant technical documentation pertaining to the
machinery described in Annex VII, part B has been prepared.
Authorized person for documentation: Dr. Thomas Suckut, Im Erlet 2, 90518 Altdorf, Germany
The latest versions are available for download at http://www.sipos.de.
2 Assembly and connection
If the devices are used in non-industrial applications with increased safety requirements, they
have to be ensured by additional safety measures during assembly.
2�1 Mount to valve/gear
2�1�1 General assembly instructions for all output shaft types
■Mounting and operation is possible in any position. Heed the local ambient conditions, in
particular the vibration load, which can be caused when mounting an actuator to a vibrating
valve.
■Do not apply force and avoid shocks!
■Check that the end connection ange and the output shaft type match the valve/gear.
■Thoroughly clean mounting faces of output mounting anges at actuator and valve/gear.
■Slightly grease the connection points.
■The bolts used upon delivery are not greased. Use bolts with at least 8.8 quality. If similar
stainless steel bolts are used, they should be greased slightly using petroleum jelly.
Use screws with a depth of engagement of at least 1.25 x the thread diameter.
■The housing of the SIPOS SEVEN actuator 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.
1�3 Disposal and recycling
1�3�1 Packaging
The packaging of our products consists of environmentally friendly materials which can easily be
separated and recycled. We use the following packaging materials: Wood-based panels (MSB/
OSB), cardboard, paper, PE foil. For the disposal of the packaging material, we recommend
recycling and collection centers.
1�3�2 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.
Fig�: Transport
Danger of crushing. When pressing in the crank
handle or the hand wheel ensure that neither the
hand nor the ngers are crushed, refer to gure.
Applicable for devices of the 2SA7.5/6/7/8 series
(size 4): Indicates which type of lubricant was used,
refer to also to “Lubricant assignment and quantity”
section in these operation instructions.
Hot surface. Risk of hot surface temperatures
(caused by high ambient temperature and frequent
operation as well as long activation times).
1�2 Transport and storage
■The device must be supplied in sturdy packaging.
■For transport, loop the rope around the hand wheel housing,
refer to illustration. Only use the eyes (1) on the electronics
unit to lift the actuator's own weight, without neither addi-
tional gear nor valve.
■Do not attach the ropes and hooks at the crank handle or
hand wheel for the purpose of lifting.
■Store in well-ventilated, dry room
at -30 °C – +80 °C.
■Protection against damp oors: Either store actuator in a
shelf or pallet.
■Keep connection hood/cover and cable glands as well as the
cover of the electronics unit and position recording closed.

3
2�1�2 Output shaft type A
Assembly instruction
The stem nut is screwed onto the valve stem by turning the crank handle or the hand
wheel.
Spring-loaded A end shafts are subject to high pre-tension. Fitting and removal of
the stem nut for thread cutting must be performed in accordance with assembly
instructions!
1. Place the actuator on the valve/gear, making sure it
is properly centered.
2. The bolts used upon delivery are not greased.
Tighten screws evenly crosswise.
3. If required, mount stem protection tube:
a) Unscrew threaded plug.
b) Remove threaded plug.
c) Apply sealing compound to the thread.
d) Screw in the stem protection tube.
1
2
3
Fitting and removing the stem nut
If the stem nut was not ordered with a trapezoidal thread (sufx "Y18" to order number), or
if the stem nut is worn, it must be dismantled/replaced:
Assembly procedure (see illustration):
1. Unscrew centering ring from
output mounting ange and
take off stem nut together with
axial needle-roller assembly
and axial bearing washers.
– If the stem nut was delivered
without thread, cut thread
into the stem nut.
– Replace worn stem nut.
2. Assembly is performed in
reversed order. Lubricate axial
needle-roller assembly and
axial bearing washers with ball
bearing grease and make sure
that the radial shaft seal (6) is
inserted correctly.
3. Using a grease gun, press ball
bearing grease into the nipple
until lubricant is discharged
between the centering ring and
the stem nut.
For output shaft form A, ensure that the valve stem must be greased separately!
1
2
3
4

4
■Dangerous voltages are also applied when the
motor is at standstill.
Before opening the connection hood, disconnect
supply voltage from the actuator. Allow approx�
1 min� for the capacitors to discharge and do not
touch any contacts.
■The supply voltage must always lie within the
voltage range specied on the name plate.
■On site fuses and disconnect switches are required
for short circuit protection and enabling the
actuator. For the current values for sizing, refer to
the “Technical data”.
■Mains cable: Use metal cable glands for mains
connection.
■Signal cable: Use metal cable glands with cable
shielding for the connection of the signal cable
to avoid the occurrence of electronic faults. The
signal cable must be shielded and the shield must
be xed on both sides. Ensure careful connection
of the screen within the cable gland!
■It must be ensured that the cable glands and seals
(O-rings) are tted 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.
2�2 Separate mounting
If the ambient conditions such as extreme vibration, high temperature and/or if access is difcult, the
electronics unit is to be mounted separately from the gear unit. The required assembly kit can be ordered
directly with the actuator or separately as accessory (2SX7300-. . .). The kit is available with different versions
of the connecting cables:
■Standard lengths: 3 m, 5 m, 10 m;
■With additional equipment (lter) up to 150 m.
Assembly procedure
Before starting the work, disconnect
actuator from the mains!
1. Install mounting bracket at the mounting
location of the electronics unit.
2. Mount electronics unit with O-ring at
mounting bracket.
3. Screw connection hood of the connecting
cable to the mounting bracket.
4. Mount connection hood of the connecting
cable to the gear unit:
– Standard assembly, refer to A.
– For assembly with stem protection tube,
rotate connection hood by 90° or 180°,
refer to B.
5. If equipped with lter: Set “> 10 m with LC
lter“ for parameter “Separate mounting” in
the ‘Special parameters’ menu.
1
2
3
4
5
Fig�: Remote control unit
functional principle
■During installation ensure that the O-
rings are tted correctly.
■Movable parts, e.g those of the swing
lever of the part-turn actuator, must
not be impaired by the cables.
■The cables should not touch the mo-
tor. The motor might become very hot.
1. Unscrew connection hood.
2. Dismantle plug element from connection hood.
3. Connect connecting cables to plug element in accor-
dance with the terminal plan enclosed in the connection
hood. Fasten plug element and connection hood again.
4. For eldbus connection: Unscrew cover and connect
data cables. Fit cover and tighten screws.
5. Ground actuator if required.
1
2
3
4
5
2�4 Electrical connection
Assembly procedure (refer to illustration on the
next page):
2�3 Remote control unit
The actuator can also be equipped with a
remote control unit that allows local operation in
distances up to 100 m. The remote control unit
has the function of a second local control unit,
refer to illustration on the right. For more detailed
information, refer to ”Operation instructions
PROFITRON/HiMod“.
Fig�: Separate mounting
A = Standard, B = with stem protection tube

5
3 Operation
3�1 Manual operation
Fig�: Manual operation for 2SA7
Fig�: Manual operation for 2SQ7

6
3 Indication during operation:
3a = The value indicates how far the actuator has been operated to position OPEN.
The position bar indicates the progress during operation (opening and closing the valve).
3b = The symbol of the end position into which the actuator is currently being operating is ashing.
4 Should a block occur during operation, the respective status message is indicated and the remaining
travel is represented as red hatched area.
5 If an EMERGENCY position or a setpoint is being
approached, the target position is indicated by
a symbol (vertical line on the position bar).
6 If the actuator is in one of the end positions,
the respective symbol is shaded in blue.
in our example end position OPEN (g. 2, item 6):
3�5 Navigation through the menus
Operation of the Drive Controller
= Turn Drive Controller (rotary/push button):
Selection (selected menu item is shaded
in orange).
= Press Drive Controller:
Conrm selection.
Navigation
a= Select ‘main menu‘
and conrm .
Display changes to ‘Main
menu’.
b= Select ’Parameter‘
and conrm .
Display changes to
‘Parameter’ menu.
c= Select ’Valve‘ and
conrm .
Display changes to "Valve"
menu.
d= Select ’Back‘, or
and conrm :
– = Display changes to status indication.
– = Display changes one level back to ‘Parameter’ menu.
Fig� 1: End position symbols and progress
bar
3�2 Indications of the LEDs
1 Depending on the actuator ordered, the colors of
the light emitting diodes might vary:
a) Standard, b) with add. version C73.
2 LED (CLOSE);
– is ashing = Actuator operates in
CLOSE direction;
– is continuously illuminated = Actuator is in
end position CLOSED.
3 LED (LOCAL);
is illuminated = LOCAL control is selected.
4 LED (REMOTE);
is illuminated = REMOTE control is selected.
5 LED (OPEN);
– is ashing = Actuator operates in
OPEN direction;
– is continuously illuminated = Actuator is in
end position OPEN.
3�3 Status indication
1 Actuator status signals.
2 Position indicator:
Actuator position in end position OPEN.
In the end position, the respective end position
symbol is displayed instead of the number.
3 Symbol for end position OPEN , end position
CLOSED .
4 Color-shaded symbol indicates the
selected control type:
LOCAL , REMOTE or OFF .
5 Flag of the selected language.
6 Start menu.
3�4 Display – position bar
The position bar provides information on the cut-off
mode in the end positions and on the current status of
the actuator.
1 Cut-off mode in end positions:
1a = Orange closed circle means 'torque-depen-
dent cut-off mode'.
1b = Green open circle means 'travel dependent
cut-off mode'.
2 End position range indication:
2a = End position range of end position CLOSED.
2b = End position range of end position OPEN.
The length of the indication bar represents
the scope of the end position range.
Fig�: Status indication
Fig�: LEDs
1a = Standard
1b = add� version C73
Fig� 2: Indication Actuator in end
position OPEN

7
4 Commissioning
4�1 User management
Many functions as well as parameterization can only be accessed using an access authorization (4-digit
code). This prevents unauthorized persons from changing parameters inadvertently or advertently.
Functions and parameters are grouped in user levels. Possible user levels are listed in the following
table: Access to each user level, except for ‘Observer’ requires authorization, i.e. an individual password.
User
level Authorization
required
Default
password
Reading
parameters
Operate
actuator
Write
"simple"
parameters
Write
"expert"
parameters
1 Observer No X --- --- ---
2 Operator YES 0000 X X --- ---
3 Supervisor YES 9044 X X X ---
4 Expert YES 9044 X X X X
The password can only be changed for the current user and/or a lower user level.
6� Once
Assign a password (4-digit code) to the
desired user level:
17� Pior to each session
Enable authorization for desired user level:
2
The following generally applies:
Once work is complete
Reset user access level: ‘User management' --> Set 'Observer'.
‘Observer' is the user level (default setting) the actuator changes to when not operated for some time.
Exception: If a user level is assigned the password "0000", this user level remains enabled, even if the
password ‘0000’ has also been assigned for lower user levels.

8
10 possible settings (scale)
for the valve travel [rev/stroke]
without additional gear
For actuator type 2SA7.1/2/3/4/5/6
0.8 2.1 5.5 14 36* 93 240 610 1575 4020
For actuator type 2SA7.7/8
0.2 0.52 1.37 3.5 9* 23.2 60 152 393 1005
*Standard
5. Approach and accept rst end position (OPEN).
6. Adjust central wheel position on signaling gear
(only for actuators with signaling gear).
7. Approach and accept second end position (CLOSED).
8. Change over to REMOTE control.
5
6
7
8
1. Select end position ’New setting‘; with or without
valve parameter.
2. If required; set valve parameter.
3. Adjust signaling gear reduction ratio
(only for actuators with signaling gear).
4. Adapt signaling gear reduction ratio to valve
(only for actuators with signaling gear).
1
2
3
4
3Adjust signaling gear ratio
An adjustment of the signaling gear ratio is not
required, if
– the actuator was delivered mounted on a
valve and the end positions were already
adjusted at the valve manufacturer's factory
or
– the values for revolutions/stroke or mm/travel
or degrees were already specied in the
order.
A check has to be performed at any rate!
If nothing has been specied, the default
values (refer to values with* in table above)
are adjusted.
4�2 End position adjustment
The complete commissioning procedure including
parameterization is described in detail in the
”Operation instructions PROFITRON/HiMod“.
End position adjustment is divided into 8 main steps:
If LOCAL control is changed to "remote“ control,
the actuator is operated if an operation command
by the automation system (DCS) is present!

9
5

10 Issue: 05.19 SIPOS Aktorik GmbH Y070.485/EN
Subject to changes without notice! Im Erlet 2 • D-90518 Altdorf
www.sipos.de
It is recommended that the services of the local SIPOS Aktorik service centers are
utilized for this purpose, refer to www�sipos�de. You may also send your requests
directly via e-mail to service@sipos�de.
5�2�3 Lubricant assignment and quantity
Actuator type u2SA7�1/2 2SA7�3/4 2SA7�5/6/7/8
Gear oil Lubricant quantity 760 cm31600 cm32400 cm3
Filling level1max. 46 mm max. 58 mm 23 – 27 mm
Lubricant2Klübersynth GH 6 – 220 N (by Klüber)3or
Alphasyn PG 220 Polyglycol (by Castrol),
Berusynth EP 220 (by Bechem),
Panolin EP gear synth 220 (by Kleenoil).
Mobil SHC
Gear 2203
Other lubrication
points4Lubricant quantity 50 cm3
Lubricant2Lubrication grease AR1 (ZEPF)
Output shaft
type A5 (2SA7)
Lubricant quantity 2 cm3
Lubricant2Commercial ball bearing grease
2SQ7 part-turn actuator virtually maintenance-free
■The manufacturer's instructions and relevant regulations are to be observed when
handling and disposing of lubricants.
■Prior to using a new alternative lubricant (compared to lubricant used in the factory),
ush and clean the gear and the gear parts. (Avoid mixing the oils!)
___________________________
1 Measured from the lubricant surface to the external wall of the housing at oil lling screw.
2 Ambient temperature range -20 °C – +70 °C.
3 Lubricant used in the factory.
4 E.g. sealing rings, gear systems, bearings, feather keys, uncoated surfaces etc.
5 If applicable.
5�3 Spare parts
With the exception of standardized, generally available components, only original spare parts may
be used. Spare parts are usually supplied as complete sub-assemblies (see list below).
When ordering spare parts, always provide the following information:
1. Order number and serial number of the actuator (refer to name plate),
2. Spare parts designation 2SY7 (refer to following list),
3. Quantity required.
No� Designation No� Designation
2SY7001 Electronics unit (010 – 042) 2SY7220 Signaling gear
2SY7041 Cover for electronics unit 2SY7225 Signaling gear cover
2SY7218 Sealing kit 2SY7250 Manual drive
2SY7219 Non-intrusive position encoder (niP) 2SY7252 Handle
Refer also to exploded views in “Operation instructions PROFITRON/HiMod”.
For further information on spare parts refer also to the ”Recommend spare parts and often used
accessories“ document (www.sipos.de ►►Product documents ►Ordering data).
5 Maintenance, inspection, service
5�1 General safety information
Prior to any intervention on the actuator,
ensure that the action(e.g. possible operation
of valves, for example) will not result in injury to
persons or faults in the plant.
■Disconnect all poles of the actuator or plant
section in accordance with the regulations
(including 24 V DC).
■Prevent accidental reconnection.
This can also be achieved by removing the
connection hood.
Furthermore, the general safety regulations
have to be observed, t barriers or covers to
neighboring live components.
5�2 Notes on inspection
5�2�1 Inspection
After commissioning and after approx� 50
operating hours or 1 year, submit the
actuator to a general inspection to verify that
■correct functioning is guaranteed,
■no unusual noises/vibration occur,
■the xing components are not loose,
■no leakages occur.
To touch up potential damage to paint, original
paint is supplied in small quantities
at SIPOS Aktorik.
Further checks may be necessary in accor-
dance with the plant-specic conditions.
5�2�2 Service or inspection
Performing the following maintenance work
every 8 years under standard device operation
conditions, including storage time:
■Replace lubricant within gear housing,
■replace seals,
■check all parts within the direct power drive
for wear,
■tighten screw connections of electrical con-
nections.
Depending on the operation conditions, shorter
maintenance intervals may be required. This
applies in particular to actuators in high tem-
perature version, which have to serviced at
least every 2 years.
4�3 Mechanical position indicator adjustment
23 1