ZPA Pečky MODACT MOKA 63 User manual

MOUNTING INSTRUCTIONS
12/15
Electric rotary (90°) actuators
for ball valves and flaps
- outside containment of nuclear
power plants
with reactors VVER and RBMK
Type numbers 52 325 - 52 329

3

3
USING
Actuators MODACT MOKA manufactured in compliance with technical conditions 32-03/07 are intended
for controlling shut-off and regulating valves, including valves of protective systems installed in the non-
sealed part of nuclear power plants with reactors of type VVER and in attended rooms of nuclear power
plants with reactors of type RBMK. The actuators are used to control the valves by turning its control element
to the angle of 90°. The actuators meet requirements of the Russian Technical Inspection (Rostechnadzor)
NP-068-05 and NP-071-06.
The valves of safety classes 2, 3, 4 according to PNAEG-1-011-97 (OPB 88/97) can be fitted with
the mentioned actuators.
Climatic conditions: climatic version of actuators UChL, category of placement 3, type of atmosphere II
according to GOST 15150-69, unless otherwise stated in the order.
Working position of actuators – arbitrary.
Protective enclosure min. IP 65.
The actuators fitted with the position transmitter of unified signal 4 – 20 mA can also be used in circuits
of automatic regulation of regime S4.
OPERATING CONDITIONS
The actuators in version MODACT MOKA must operate reliably with the following parameters of envi-
ronment:
Temperature -25 °C to +55 °C
(up to 90 °C for 5 h, once in 6 months,
5 cycles for the period of the actuator operation*)
Pressure from under-pressure 50 Pa to over-pressure 0.1 MPa
Relative humidity up to 90 % (at 60 °C)
*) The actuator remains operational in this regime even after its termination. In case of the actuators, revision after
termination of the mentioned regime is not required.
Resistance against seismic effects. Resistance against vibrations
The actuators correspond to the I. category of seismic resistance according to NP-031-01 and maintain
their operating ability during as well as after the seismic effects of intensity up to MP3.
The actuators are resistant against vibrations and seismic shocks of acceleration 8 g in different directions
within the range of excitation frequency 20 to 50 Hz for the period of action 20 s. In addition, operation ability
is confirmed by seismic resonance test in the frequency range 5 to 20 Hz.
The actuators are resistant to shocks in the frequency range 5 to 100 Hz under the action of vibrational load
in two directions with acceleration up to 1 g and amplitude of oscillations up to 50 μm.
Resistance against action of deactivating solutions
The actuators must be resistant against the action of deactivation solutions. Composition of the solutions
is stated in the technical conditions. Composition of deactivation solutions in respective halls can be arbitrary
in compliance with NP-068-05.
Dipping of the actuators in a vat with the deactivation solution is inacceptable.
OPERATING REGIME
Maximum duration of the working cycle (closed – open – closed) is 10 min at surrounding temperature
+50 °C and with ratio of time in the state of operation to idle time 1:3 (repeated short-time regime with
the period of switching-off PV = 25 %). Mean value of loading moment during the period of switching-on is
60 % of the maximum tripping moment.
The actuators can also operate in a discontinuous regime (e.g. in controlling the regulating valve)
with frequency of switching-on up to 1200 h-1 with the ratio of time of operation to idle time 1:3. Mean value
of loading moment during operation is 40 % of the maximum tripping moment.

4
BASIC TECHNICAL DATA
Service life of actuators. Reliability
Service life of the actuators is min. 40 years.
The actuators belong to the category of restoring products of standardized reliability. During operation, pre-
ventative inspections are carried out with period of min. 15,000 hours. The interval between repairs is min. 4 years.
The specified service life in the interval between two repairs is 1500 cycles (open – closed), wherein probability
of faultless operation is min. 0.98. Probability of faultless operation with 25 working cycles per 4 years is 0.998.
Confidence probability for calculation of the lower confidence limit of faultless operation is 0.95.
Criteria of the actuators failure are as follows:
– discrepancy in output parameters of the actuators with parameters described in these technical conditions;
– failure to meet acceptable deviations of output parameters;
– failure to meet regulating range of output parameters;
– failure to meet insulation resistance;
– leakage of lubricants from the actuators.
Criteria of limit states of the actuators are as follows:
– rupture of integrity of the body parts that prevents normal function;
– changed shape and dimensions of parts (power kinematic circuits and control units;
– as a result of wear or deformation preventing normal function;
– elapsed specified period of service life.
Supply voltage of actuators
Supply voltage - alternating, three-phase 380/220 (415/240) V. Frequency of supply voltage 50 Hz. Possible emer-
gency deviations of frequency of mains voltage:
Course of working cycle
Load torque
M Mean value of moment
Mv Maximum tripping moment
Mz Starting moment
N Time of operation
R Idle time
N+R Time of working cycle
1%N 3%N
NN R
Time
N+R
M
Mv
Mz
Name of regime Number of load cycles of device per 30 years
Emergency deviation of frequency in the network:
51.5 to 52.5 Hz – for up to 5 min one-time,
but max. 750 min during operation period; 10 cycles per year
50.5 to 51.5 Hz – for up to 5 min one-time,
but max. 750 min during operation period; 10 cycles per year
49 to 47.5 Hz – for up to 5 min one-time,
but max. 750 min during operation period; 10 cycles per year
47.5 to 46 Hz – for up to 30 s one-time,
but max. 300 min during operation period; 40 cycles per year
Note:
1. With the mentioned emergency deviations of frequency, network voltage must stay at 380/220 (415/240) V.
2. With frequency in the range 51.5 to 52.5 Hz, starting and rated moment can decrease by max. 10 %.

5
The actuators of protective systems must be operational under the following conditions:
– Voltage decreased to 80 % of its rated value with simultaneously decreased frequency by 6 % of its rated value
for 15 s;
– Voltage increased to 110 % of its rated value with simultaneously increased frequency by 3 % of its rated value
during 15 s.
Herewith, the actuator must not stop and possibility of the valve functioning must be secured.
Self-locking
The actuators are self-locking. The self-locking of the actuator is ensured by the mechanical brake.
Manual control
The actuators must be fitted with a substitute manual control. When the electric motor turns, torque is not
transferred to the manual control device; in operation with the manual control device, its torque is not transferred
to the electric motor. The actuator design ensures safety of the operator during control by means of the manual
control device. When the hand wheel is turned in the clock-wise direction, the valve closes.
Force on the manual control device does not exceed 735 N at the maximum moment on the output shaft
and does not exceed 295 N at 0.4 of the maximum moment value.
Anti-condensation heater
The actuators are fitted with the anti-condensation heater preventing condensation of water vapour. Its resistance
in actuators MOKA 63 is 12 kohm and in actuators of other types 6.8 kohm. The element is connected to the supply
source (to one phase) of voltage 230 V.
Switches
The actuators are fitted with two end-limit, two position, and two moment micro-switches. The micro-switches
must have one opening and one closing contact. Each contact of the micro-switch has its outlet at the terminal
board. On agreement with the client, the end-limit and position micro-switches can have a single change-over con-
tact, and the moment switches – a single opening contact.
The end-limit, position, and moment switches must be functional under the following conditions:
In the circuits of alternating voltage up to 250 V of frequency 50 and 60 Hz. Current through the closed contacts
up to 500 mA, wherein the loss of voltage on the closed contacts must not exceed 0.25 V.
In the circuits of direct voltage 24 and 48 V with current through the closed contacts 1 to 400 mA, wherein the loss
of voltage on the closed contacts must not exceed 0.25 V.
The functional diagram of the position switches and the signalling circuits is shown on the page 20.
Position transmitters
In compliance with requirements of the client, the actuator can be fitted with the passive or active, current
or resistance position transmitters.
Passive current position transmitter CPT1AA
Rated output signal 4 – 20 mA or 20 – 4 mA
Rated working run from 0 – 40° to 0 – 120°, regulated
Loading resistance 0 – 500 ohm
Supply voltage 18 – 28 V DC
Dimensions ø 40 x 25 mm
Waviness of supply voltage ±5 %
Transmitter power input max. 560 mW
Insulation resistance 20 Mohm at 50 V DC
Electric strength of insulation 50 V DC
Temperature of operating environment -25 to + 80 °C,
for short time up to +110 °C (max. 2 hours)
The limit value of supply voltage (at surrounding temperature -25 to +60 °C) is 30 V. Voltage between the transmit-
ter box and the signalling wire must not exceed 50 V.
The user must provide for connecting the two-wire circuit of the current transmitter to electric earthing of particu-
lar regulator, computer, etc. The connection must be realized in a single point at any place of the circuit outside the
actuator. In the version with the current transmitter, the local indicator need not be supplied.

6
Active current position transmitter DCPT
Rated output signal 4 – 20 mA or 20 – 4 mA
Rated working run from 60° to 0 – 340°, regulated
Loading resistance 0 – 500 ohm
Non-linearity max. 1 %
Supply voltage 18 – 28 V DC
Dimensions ø 40 x 25 mm
Waviness of supply voltage ±5 %
Max. current consumption of transmitter max. 42 mA
Insulation resistance 20 Mohm at 50 V DC
Electric strength of insulation 50 V DC
Temperature of operating environment -25 to + 70 °C
Voltage between the transmitter box and the signalling wire must not exceed 50 V. The current loop is supplied
from the source DCPZ located inside the actuator.
Resistance position indicator
The resistance position indicator is formed of a double-wire resistor of variable resistance, each part of which
having resistance 100 ohm.
Total resistance 2 x 100 ohm with deviation +12 ohm
Maximum loading current 100 mA
Maximum direct voltage (against frame) 50 V
Working run 0° to 160°
Non-linearity max. 1 %
Local position indicator
The removable mechanically connected indicator of position of the actuator output shaft is fixed to the cam shaft
of the position unit. The local position indicator serves for orientational determination of position of the actuator out-
put shaft.
Actuator terminal board
The actuators are fitted with a common terminal board for connecting external electric circuits. The terminal board
is located under the actuator cover. All contacts of the micro-switches, circuits of the electric motor, and the earth-
ing terminal are connected to it. The terminal board enables connection of one wire of cross-section 2.5 mm2 or two
wires of cross-section up to 1 mm2. The actuators are fitted with two cable bushings providing for connection of:
– in actuators MOKA 63: one cable of outer diameter 10 – 14 mm for control circuits and one cable of outer diam-
eter 13 - 18 mm for circuits of the electric motor;
– in actuators MOKA 125, 250: two cables of outer diameter 13 – 18 mm for control circuits and circuits of the elec-
tric motor;
– in actuators MOKA 500, 1000: one cable of outer diameter 13 – 18 mm for control circuits and one cable of outer
diameter 13 - 20 mm for circuits of the electric motor.
The cross-sections and diameters of cables must be specified in the order.
The actuators are fitted with the earthing terminals including a device against spontaneous releasing. The design
prevents the control circuits from being influenced by the power circuits.
The actuators are supplied with blinded bushings.
Insulation resistance
At temperature 20 ±5 °C and humidity 30 to 80 %, the insulation resistance is min. 20 Mohm. Under the most
severe working conditions, resistance of the insulation of electric circuits against each other and against the frame is
min. 0.3 Mohm.
Electric strength of insulation
Insulation of electric circuits against frame as well as against each other at temperature 20 ± 5 °C and humidity
30 to 80 % must withstand testing alternating voltage of sinus shape of frequency 50 Hz for 1 minute:
Electric circuits of actuator Testing voltage
of rated voltage max. 250 V 1500 V, 50 Hz
Remote transmitter of rated voltage max. 50 V 500 V, 50 Hz
Electric motor of rated three-phase voltage 400 V (380 V) 1800 V, 50 Hz
According to GOST 183-74
Circuit of current transmitter CPT1AA 50 V DC

7
Noise
According to GOST P 51402-99, the value of mean level of acoustic pressure at a distance of 2 m (in no-load
operation of actuators) does not exceed 80 dB.
Run-out of output shaft
Motors of type no. 52325, 52 326, 52 328 max. 1.5°
Motors of type no. 52 327, 52 329 max. 2.5 °
Thermal protection of electric motor
Actuators MODACT MOKA 500, type no. 52 328.xx2x and MODACT MOKA 1000, type no. 52 329.xx3x are fitted
with the three-phase electric motor (400 V) of power 120 W without a thermal protection. Automatic fuses are built-
in in electric motors of other actuators listed in Table 1; they switch off power supply to the electric motor in case
of over-heating (after cooling down, the power supply is automatically switched on). Their circuits are not connected
to the terminal board of the electric motor. The built-in thermal fuses disconnect the electric motor from power supply
in case the temperature of the electric motor winding exceeds +155 °C.
Electric motor FT2B52D is fitted with an automatic fuse the circuit of which is connected to the terminal board
of the actuator (see the wiring diagram below). Switched-over load: current 2.5 A at voltage 250 V.
Deviations of basic parameters
Rated values of torques of the output shaft (with acceptable deviations) are given for rated supply voltage with
deviation from -15 % to +10 % and for rated frequency of supply voltage in the range ±2 %, wherein the deviations
of voltage and frequency must not have opposite signs.
Acceptable deviations of respective parameters:
Tripping moment ±15 % of maximum value
Time of turning by 90° +10 % to – 15 % of rated value (idle run)
For NPP “Kudankulam“ Time of turning ±10 % at rated supply voltage
Hysteresis of end-limit and position switches max. 4°
Setting of working run ±1°
Non-linearity of position transmitter ±2.5 % of rated value of transmitter output signal
Hysteresis of position transmitter does not exceed 2.5 % of rated value of transmitter output signal
TECHNICAL DESCRIPTION
The MODACT MOKA actuators consist of the following two parts:
– Power section constituted of a one-phase or three-phase asynchronous motor (see Tab. 1), a countershaft
gearbox, an epicyclic gear with the output shaft, a manual control mechanism with a handwheel
and a floating worm and, in the actuators, Type Nos 52 327 and 52 329, an output gearbox (with adapter) with
a 1:2 gear ratio.
– Control section which is identical for all MODACT MOKA actuators (Fig. 2), Types MOKA 125 to MOKA 1000
Type No., with the only exception that, it differs in angular displacement of units on the base plate. In the actuator,
Type No. 52 325, the unit of position-limit signalling switches is arranged as shown in Fig 1. The control section
consists of position-limit switching unit 1, resisence position transmitter 2, torque-limit switching unit 3, terminal
block 4 and anti condensation heater 8.
The position-limit switching unit uses 4 microswitches of which 2 are always used for either direction
of rotation of the output shaft. The switching point of each microswitch can be adjusted independently within
the working travel range of the actuator.
The torque-limit switching unit has independently adjustable microswitches, one for either direction
of rotation.The torque-limit switches are not secured against opening at the startig torque.

8
The potentiometer is fitted with a slipping clutch to permit automatic adjustment along with the output shaft.
The anti-condensation heater 8 (Fig.1, 2) prevents water vapours from condensing under the cover of
the control section. The position-limit switching unit and the position transmitter derive their movements from
the output shaft of the actuator via a driving gear (or in the actuators, Type Nos 52 326 and 52 327, via driving
segment 7, as shown in Fig 1). The torque-limit switching unit is driven by a “floating worm“of the manual
control mechanism where the worm displacement is directly proportional to the torque of the actuator output
shaft. This enables the actuator to be switched off immediately the torque on the output shaft to whichthe
torque-limit switching unit has been adjusted, is reached.
Note: The microswitches used are of a single-chamber type, i.e., they can operate as a one-pole cut-out switch
a contact maker or a change-ower switch, whereas the torque-limit switches can be used as cut-out switches
only (see the respective circuit layout).
ADJUSTMENT OF THE ACTUATOR
Stop screws
Stop screws are used to limit the actuator working travel to 90° in compliance with the CLOSED
and OPEN end positions of the valves having no trip dogs of their own. The screw stops are mounted on the
outside of the actuator along with the external protective terminal. When viewing the stop screws, the right-
hand stop screw is designedfor the CLOSED position, whereas the left-hand stop screw is designed for the
OPEN position under the assumption that, when viewing the local position indicator, the output shaft rotates
clockwise in the CLOSE direction of rotation. For adjustment of the stop screws, loosen the stop screws,
move the actuator with valve into the CLOSED position, and turn the corresponding stop screw till
an increased resistance is felt when the screw runs onto the stop face within the actuator. Secure the stop
screw in position by retightening its lock nut. Then, rotate the output shaft of the actuator through a 90° angle
to bring it into the OPEN position and set the OPEN-position stop screw by the same procedure.
Legend:
1 – Position-limit switching unit
2 – Position transmitter (potentiometr)
3 – Torque-limit switching unit
4 – Terminal board
5 – Electric motor
6 – Internal protective terminal
7 – Drive gear (or segment)
8 – Anti-condensation heater
9 – Starting capacitor
Fig. 1 - Control panel (type no. 52 325) Fig. 2 - Control panel (type no. 52 326 - 52 329)
Note:
The encircled numbers are identical to the numbers of the cam releasing screws of the position-limit switching unit.

9
When setting the stop screws in the actuators, Type Nos 52 326 ant 52 327, care should be taken to
ensure that, in the CLOSED or OPEN end position, the driving gear segment of the position-limit switching
and auxiliary signalling units cannot strike the electric motor. In either end position of the output shaft of the
actuator, the local position indicator should tally with the marks on the index plate.
If the valve is required to be tightly closed in the end position and thus the actuator is to be switched off
by means of the torque-limit switches, the tripping torque should be transferred to the valve. In this case, set
the corresponding stop screw so that the valve is properly sealed when the stops of the output shaft run
against the stop screw at which the torque-limit switch operates.
In this case, the respective torque-limit switch is used for switching off the actuator. If stops are required
to be used for protection of the acutator and the valve against damage in the case of a failure of the position-
limit switch set the stop screws to such a position which ensures dependable operation of the position-limit
switch and is still permissible for the valve. In this case, the position-limit switch and the torque-limit switch
should be connected in series. Nevertheless, this can only be done when no tight closure of the valve is
required.
Torque-limit switches
The torque-limit switches have been adjusted to the specified torque at the factory. If they are required to
be readjusted to another torque, release the corresponding cam by means of the cam releasing screws
whose numbers are given in the legend of Fig. 3. By the linear division of the respective scale section between
the zero and the maximum switching torque as marked on the scale in colour, we obtain a point for
the required switching torque with which the arrowhead on the cam should tally. Retighten the cam releasing
screw. For manipulation of the releasing screws of the torque-limit switches, the same applies as to
the releasing screws of the position-limit switching unit. After the torque-limit switches have been adjusted,
check that they operate using a lamp tester.
Caution! Any manipulation of the releasing screws numbered 2 and 4 is forbidden.
Position-limit switches
Position-limit switches PO, PZ switch off an electric actuator when the output shaft reaches the position
for which they are set. Signalling-limit switches SO, SZ signalise the position of electric actuator output shaft.
The setting of position-limit switches is carried out by positioning the output shaft into the position in
whichthe set switch should switch off. Then, loosen the micro-switch cam using the releasing screw.
Loosing will be done by turning the releasing screw counter-clockwise. Turn the releasing screw only until
the cam is released. By further turning of the releasing screw, you would tighten the cam again. Numbers of
relevant releasing screws are on a holder of position unit (Fig. 1) and they correspond to markings on a cam
shaft.
When loosened, turn the cam in the opposite direction to the motion of an electric actuator output shaft while set-
ting the position “open” or “closed” until the micro-switch switches over. In this position lock the cam by tightening
the releasing screw (clock-wise direction).
A signalling switch must be set so that it switches over sooner than a relevant position-limit switches
or torque-limit switches. When adjusting position-limit and signalling switches of electric actuators Type Nos.
Legend:
1 – OPEN torque-limit switch cam
2 – CLOSE torque-limit switch cam
3 – OPEN torque-limit switch
4 – CLOSE torque-limit switch
5 – Releasing screw of CLOSE
torque-limit switch cam
6 – Releasing screw of OPEN
torque-limit switch cam
Fig. 3 - Torque-limit switches
13
4
5
6
2

10
52 326 and 52 327, ensure that a gear segment of position and signalling unit drive in the extreme position
“open” or “closed” doesn’t hit the actuator case. A position unit of electric actuator Type No. 52 325 is not
equipped with the locking of cams using screws (Fig. 2). The cam’s position on the shaft is ensured only by
friction which has to be overcome when adjusting the cams. A design Type No. 52 325 has cams locked by
friction and central milled nut with contra-nut which must be loosened before adjusting and tightened prop-
erly again after adjusting.
Position transmitter
To adjust the potentiometer it is sufficient to set the actuator output shaft to any of the OPEN or CLOSED end
positions. In this way, the potentiometer is automatically preset. The automatic adjustment of the potentiometer is
usually provided already when the stop screws or the position-limit switches are adjusted.
Setting of current position transmitter CPT1AA
Before starting setting the current transmitter it is necessary to set the end-limit positions (torque or position
switches) of the actuator and connect them into the tripping circuit of the electric motor. In case of an external source
of feeding voltage, verification must be carried out that it does not exceed the maximum value 30 V DC (limit value
when CPT1 is still not damaged). Recommended value is 18 – 28 V DC.
Positive pole of the source is connected to the positive pole of the transmitter CPT1; a milli-ammeter of precision
at least 0.5 % connected into the circuit. The current loop must be earthed in one point. The figure does not show
the earthing that can be made at any point of the circuit.
1. Shift the output shaft into the position Closed. During closing, the current signal value should decrease.
If it increases release the transmitter body and, by turning of about 180°, shift to the descending part of
the outputcharacteristics. Set 4 mA by fine turning. Tighten the shim plates to secure the transmitter against
spontaneousturning.
2. Shift the output shaft to the position Open and set 20 mA using a potentiometer on the transmitter body.
The potentiometer has a range of 12 revolutions and it has no stops so that it cannot be damaged by furtherturning.
3. Once again verify the current value in the position Closed. If it has changed too much repeat the points 1. and 2.
If the required corrections are large this procedure should be repeated several times. After the setting, securethe
transmitter against turning and drip the screws with varnish.
4. Use a voltmeter to check the voltage on the CPT1 terminals. In order to keep linearity of the output signal
the voltage must not drop below 9 V, not even with off-take 20 mA. If this condition is not met it is necessary to
increase the feeding voltage (within the range of recommend values) or to decrease total resistance of the current
loop R.
Setting of current position transmitter DCPT
1. Set of end-limit positions
Before starting the setting, verification must be carried out that the end-limit positions are within the range
60° – 340° of revolution DCPT. Otherwise, after setting, an error arises (LED 2x).
1.1. Position “4 mA”
Set the drive into the required position and press the push-button “4” until LED blinks (about 2 s).
1.2. Position “20 mA”
Set the drive into the required position and press the push-button “20” until LED blinks (about 2 s).
2. Setting of sense of rotation
The sense of rotation is specified by viewing from the side of the panel DCPT.
2.1. Rotating anti-clockwise
Press the push-button “20”, then the push-button “4” and keep them depressed until LED blinks.
2.2. Rotating clockwise
Press the push-button “4”, then the push-button “20” and keep them depressed until LED blinks.
When the sense of rotation is changed the end-limit positions “4 mA” and “20 mA” remain valid but the work-
ing range (track DCPT) between these points is changed to a complement of the original working range. In this way,
the permitted working range can be exceeded (LED 2x) – it can be smaller than 60°.
3. Error messages
In case of an error the diode LED blinks an error code: