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  9. ZPA Pečky MODACT MTN 15 User manual

ZPA Pečky MODACT MTN 15 User manual

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Type numbers 52 442, 52 443
Electric Linear (Pull-rod)
actuators
4/15
MOUNTING INSTRUCTIONS
3
APPLICATION
The MODACT MTN, MTP actuators are used for remote two-position or three-position control of the valves by
a reverse rectilinear motion.
The MODACT MTN, MTP Control actuators are fitted with an electronic position controller. In association with
the valve exhibiting a suitable control characteristic, they form a position servo-loop. The output pull-rod of these
actuators is automatically brought into a position corresponding to the input signal value of the controller.
The actuators can be used even for other devices for which they are in respect of their characteristics and parameters
suitable. In some special cases, the contemplated use of the actuators should be consulted with the manufacturer.
OPERATING CONDITIONS, OPERATING POSITION
Operating conditions
The MODACT MTN, MTP (MODACT MTN, MTP Control) actuators should withstand the effect of operating
conditions and external influences, Classes AC1, AD5, AD7, AE4, AE6, AF2, AG2, AH2, AK2, AL2, AM-2-2, AN2,
AP3, BA4 and BC3 according to ČSN 33 2000-5-51 ed. 3.
When placed on an open area, the actuator is recommended to be fitted with a light shelter to protect it
against direct action of atmospheric effects. The shelter should overhang the actuator contour by at least 10 cm
at the height of 20 – 30 cm.
If the actuator is used at a location with an ambient temperature under -10 °C and/or relative humidity above
80 %, at a sheltered location, or in the tropical atmosphere, the anti-condensation heater which has been built in all
actuators, should be always used. One or two heater elements should be connected, as required.
Installation of the actuators at a location with incombustible and non-conducting dust is possible only if this has no adverse
effect on their function. It is advisable to remove dust whenever the layer of dust becomes as thick as about 1 mm.
Notes:
A sheltered location is considered a space where atmospheric precipitations are prevented from falling at an angle
of up to 60° from the vertical.
The location of the electric motor should be such that cooling air has free access to the motor and no heated-up
blown-out air is drawn in the motor again. For air inlet, the minimum distance from the wall is 40 mm. Therefore,
the space in which the motor is located should be sufficiently large, clean and ventilated.
Surrounding temperature
Operating temperature for MODACT MTN actuators is from -25 °C to +70 °C or from -40 °C to +60 °C, for MODACT
MTP actuators from -25 °C to +60 °C.
Classes of external influences – as extracted from ČSN Standard 33 2000-5-51 ed. 3.
Class:
1) AC1 – Altitude ≤ 2,000 m above sea level
2) AD5 – Spouting water; water can spout in any direction
AD7 – Shallow dipping; possibility of occasional partial or complete covering (for the type MTP only)
3) AE4 – Light dustiness
AE6 – Heavy dustiness, (MTP only)
4) AF2 – Corroding atmosphere and pollutants; the presence of corroding pollutants is significant
5) AG2 – Average mechanical stress; in current industrial plants
6) AH2 – Medium vibrations; in current industrial plants
7) AK2 – Serious risk of growth of vegetation and moulds
8) AL2 – Serious danger of the occurance of animals (insects, birds, small animals)
9) AM2-2 – Normal level of signal voltage. No additional requirements.
10) AN2 – Medium solar radiation with intensities > 500 W/m2 and ≤ 700 W/m2
11) AP3 – Medium seismic effects; acceleration > 300 Gal ≤ 600 Gal
12) BA4 – Personal abilities; instructed people
13) BC3 – Frequent contact with the earth potential; persons coming frequently into contat with “live” parts or
standing on a conducting base
Operating position
The actuators MODACT MTN, MTP, type no. 52 442, 52 443 can be used in any operating position.
4
OPERATION MODE,
SERVICE LIFE OF ACTUATORS
Operation mode
According to ČSN EN 60 034-1, actuators can be operated in S2 load category (the course of load is
shown in the picture). The operation time at +50 °C shall be 10 minutes, the average mean load thrust value
shall be below or equal to 60 per cent of the maximum tripping thrust Fv. According to ČSN EN 60 034-1,
the actuators can also be operated in the S4 mode (interrupted operation with acceleration intervals). The load
factor N/N+R shall be maximum 25 per cent, the longest operation cycle N + R is 10 minutes. The maximum
number of switching actions in automatic control mode is 1200 actions per hour. The average mean load thrust
at load factor of 25 per cent and 50 °C shall not exceed 40 per cent of the maximum tripping thrust Fv.
The maximum average mean of the load thrust equals the rated thrust of the actuator.
Service life of actuators
The actuator intended for shut-off valves must be able to perform at least 10,000 operating cycles (C - O - C).
The actuator intended for regulating purposes must be able to perform at least 1 million cycles with operation time
(during which the output shaft is moving) at least 250 hours. Service life in operating hours (h) depends on load and
number of switching. Not always, high frequency of switching influences positively accuracy of regulation. For attaining
the longest possible faultless period and service life, frequency of switching is recommended to be set to the lowest
number of switching necessary for the given process. Orientation data of service life derived from the set regulation
parameters are shown in the following table.
Service life of actuators for 1 million starts
Service life [h] 830 1 000 2 000 4 000
Number of starts [1/h] Max. number of starts 1200 1 000 500 250
TECHNICAL DATA
Supply voltage
The rated supply voltage of the actuators is 3 x 230 / 400 V, 50 Hz (3 x 220 / 380 V, 50 Hz) with permissible line
voltage fluctuations between +10 % and -15 % and frequency shift within ±2 %. Over these ranges, the rated values
of all parameters are retained except for the readjusting speed of the output part and the starting thrust; the latter is
directly proportional to the square of line voltage variation. Actuators employing another voltage and/or frequency are
available upon special request. The basic technical parameters should be determined individually for each supply voltage
and frequency.
Protective enclosure
Protection of the actuators MODACT MTN (MODACT MTN Control) – IP 55
MODACT MTP (MODACT MTP Control) – IP 67
Course of working cycle
Fz Starting thrust ≥ 1,3 . Fv
Fstř Average mean load thrust
Fv Maximum mean tripping thrust
Fz
Fstř
Fv
Cycle period
Operating time N Idling time R
5
Noise
Acoustic pressure level A max. 85 dB (A)
Acoustic power level A max. 95 dB (A)
Tripping thrust
At the factory, the tripping thrust has been adjusted within the min./max. range giving in Table 1, according
to the customer’s requirements. If no tripping thrust adjustment is required the actuator is adjusted to its
maximum tripping thrust.
Starting thrust
The starting thrust of the actuator is a calculated value determined by the starting torque of the electric motor
and the total gear ratio and efficiency of the actuator. After run reversation, the actuator can produce a starting
thrust for the duration of 1 to 2 revolutions of the output shaft when torque-limit switching is locked. This can take
place in either end position or in any intermediate position.
Self-locking
The actuator is self-locking provided that the load only acts in the direction against motion of the actuator
output shaft. Self-locking is ensured by a roller arrest immobilizing the electric motor rotor even in the case
of manual control.
In order to observe safety regulations, the actuators cannot be used for driving transportation lifting devices
with possible transport of persons or for installations where persons can stand under the lifted load.
Working stroke
The ranges of working stroke are given in Table No. 1.
Manual control
Manual control is performed by a hand wheel directly (without a clutch) and it is also possible when the electric
motor is running. By rotating the hand wheel in the clock-wise direction the actuator output pull rod is thrown out
(closes).
Torque-limit switches in the actuator are set and work when the actuator is under voltage.
When using the manual control, ie. actuator is controlled mechanically, the torque-limit switches doesn´t
work and the valve can be damaged.
ACTUATOR OUTFIT
Torque-limit switches
The actuator is fitted with two torque-limit switches (MO – OPEN, MZ – CLOSE) each of which acts only
in one direction of motion of the actuator output shaft. The torque-limit switches can be set to operate at any
point of the working stroke except the region in which they are locked (see Starting thrust).
The tripping torque can be adjusted within the range shown in Table No. 1. The torque-limit switches are locked
if the load torque is lost after they have been brought into the OFF-position. This feature secures the actuator
against the so-called “pumping”.
Position-limit switches
The PO – OPEN and PZ – CLOSE position-limit switches limit the actuator working stroke, each being adjusted
to operate in either end position.
Position signalling
For signalling position of the actuator output shaft, two signalling switches, i.e. the SO – OPEN signalling
switch and the SZ – CLOSE signalling switch, are used. Each of these switches acts only in one direction
of output shaft rotation. The operating point of the microswitches can be set within the whole working stroke
range except the narrow band before the operating point of the microswitch used to switch off the electric
motor.
6
Position transmitters
The MODACT MTN, MTP electric actuators can be supplied without position transmitter can be fitted with position
transmitter:
a) Resistance transmitter 2 x 100
Ω
.
Technical parameters:
Position scanning resistance
Turning angle 0° – 160°
Non-linearity ≤ 1 %
Transition resistance max. 1.4
Ω
Permitted voltage 50 V DC
Maximum current 100 mA
b) Type CPT 1A passive current transmitter. Power supply to the current loop is not a part of the actuator.
Recommended feeding voltage is 18 – 28 V DC, at maximum loading resistance of the loop 500
Ω
. The current loop
should be earthed in one point. Feeding voltage need not be stabilized; however, it must not exceed 30 V or else
the transmitter could be damaged.
Range of CPT 1A is set by a potentiometer on the transmitter body and its starting value by corresponding partial
turning of the transmitter.
Technical parameters of CPT 1A:
Scanning of position capacity
Working stroke adjustable 0° – 40° to 0° – 120°
Non-linearity ≤ 1 %
Non-linearity, including gears ≤ 2.5 % (for a maximum stroke of 120°)
Hysteresis, including gears ≤ 5 % (for a maximum stroke of 120°)
(The non-linearity and hysteresis are related to a signal value of 20 mA).
Loading resistance 0 – 500
Ω
Output signal 4 – 20 mA or 20 – 4 mA
Supply voltage for R load = 0 – 100
Ω
10 to 20 V DC
for R load = 400 – 500
Ω
18 to 28 V DC
Maximum supply voltage ripple 5 %
Maximum transmitter power demand 560 mW
Insulation resistance 20 M
Ω
at 50 V DC
Insulation strength 50 V DC
Operational environment temperature -25 °C to +60 °C
Operational environment temperature - extended range -25 °C to +70 °C (additional on demand)
Dimensions ø 40 x 25 mm
c) Type DCPT active current transmitter. Power supply to the current loop is not a part of the actuator. Maximum
loading resistance of the loop is 500
Ω
. For variants MODACT MTN, MTP Control with the regulator ZP2.RE5, it is
used as a position sensor.
DCPT can be easily set by two push-buttons with LED diode on the transmitter body.
Technical parameters of DCPT:
Scanning of position contact-less magneto-resistant
Working stroke adjustable 60° – 340°
Non-linearity max. ±1 %
Loading resistance 0 – 500
Ω
Output signal 4 – 20 mA or 20 – 4 mA
Power supply 15 – 28 V DC, < 42 mA
Working temperature -25 °C to +70 °C
Dimensions ø 40 x 25 mm
For the transmitters CPT 1A as well as DCPT, a two-wire connection is used, i.e., the transmitter, the power
supply and the load are connected in series. The user should secure that the two-wire circuit of the current transmitter
is connected to the electric earth of the associated regulator, computer, etc. This connection should only be made
at a single point in any section of the circuit, outside the actuator.
7
Position indicator
The actuator is fitted with a local position indicator.
Anti-condensation heater
The actuators are fitted with an anti-condensation heater preventing condensation of water vapour. It is connected
to the AC mains of voltage 230 V.
Local control
Local control serves for controlling the actuator from the site of its installation. It includes two change-over switches:
one with positions “Remote control - Off - Local control”, the other “Open - Stop - Close”.
The former change-over switch can be built-in as two-pole or four-pole. The change-over switches are installed
in a terminal-board box and the control elements on the lid of this terminal-board box.
Position regulator
The position regulator built-in in the actuator enables to control position of the output shaft of the actuator and thus
also the valve by the input analog signal.
The control unit is microprocessor-based programmed for regulating the actuator, ascertaining and repairing error
conditions, and for simple setting of regulation parameters.
The regulator design enables to switch off the regulator feeding. If the regulator is not under voltage it does not
regulate but, after its feeding is switched on, the regulator function is automatically restored; the parameters and
diagnostic data stored in the regulator memory are retained.
The regulator circuits compare the input signal with the feedback signal from the position transmitter of the actuator
output shaft. If there is a difference between the input and feedback signals the regulator closes one of the built-in
contactors in the actuator so that the actuator shaft is reset to the position corresponding to magnitude of the input
signal. When the feedback signal is equal to the input signal the actuator stops.
The control parameters are set by functional push-buttons on the regulator or by PC connected to the regulator via
a serial interface for the period of setting the parameters or during the communication module .
Dynamic brake
The brake is an optional accessory to the actuators MTN, MTP Control. After opening the contactor, it induces
dynamic braking moment in the electric motor lasting for several tenths of second. It reduces dramatically the run-down
time and regulation is thus more precise. When the actuator is in a standstill no braking moment is exerted.
The actuators without regulator are fitted with autonomous brake BAM-002. For its function, it requires
auxiliary contacts of the contactors and auxiliary contact of the over-current relay. It is dimensioned for electric
motors 3 x 230 / 400 V, output up to 550 W.
The actuators with regulator ZP2RE5 are fitted with simpler controlled brakes BR2. They are interconnected
with the regulator that provides impulse for action.
According to the electric motor output, corresponding variant is chosen:
BR2 550 of output up to 550 W,
BR 2.2 of output up to 2.2 kW.
If outputs higher than 2.2 kW are to be braked, electric motors of special version with an electromagnetic brake
should be used.
Switching of electric motor, contactor unit
The actuators in variants Control are fitted with built-in reversing contactor combinations. These are assembled
of two contactors and an over-current relay. The combination also includes mechanical blocking that prevents both
contactors from being closed at the same time. This could, for instance, happen in case of wrong connection of
jumpers on the terminal board. The blocking is not dimensioned for long-term action. The over-current relays protects
the electric motor against over-loading and is dimensioned with respect to its output. According to the actuator
version, the contactors are controlled by the regulator, change-over switch of local control or external input. Control
voltage is 230 V / 50 Hz as a standard; it is supplied via contacts of position and/or moment micro-switches. Thus,
these micro-switches need not be led out of the actuator.
The contactors used have a long mechanical service life and great reserve in switching ability; consequently,
the electric service life is also sufficient for particular use. The thermal relay is chosen so that it would reliably
protect the electric motor against overload. Set-up and outfit of the actuators provide for simple connection to
power-supply and control circuits.
The power-supply circuits can be common for the whole group of actuators, which will save the cabling.
8
ELECTRIC PARAMETERS
External electric connection
a) Terminal board
The electric actuator is equipped with a terminal board for connection to external circuits. This terminal
board uses screw terminals allowing conductors with a maximum cross-section 4 mm2 to be connected.
Access to the terminal board is obtained after removal of the terminal box cover. All control circuits of
the electric actuator are brought out to the terminal board. The terminal box is fitted with cable bushings for
connecting the electric actuator. The electric motor is fitted with an independent box with a terminal board and
a bushing.
b) Connector
According to the customer's requirements the MODACT MTN, MTP actuators can be fitted with the connector
to provide for connection of control circuits. This connector uses screw terminals allowing conductors with
a maximum cross-section 4 mm2 to be connected. ZPA Pečky, a.s. also supplies a counterpart for the cable.
In order to connect the cable to this counterpart it is necessary to use special crimping pliers.
Actuator internal wiring
The internal wiring diagrams of the MODACT MTN, MTP actuators with terminal designation are shown in this
Mounting and operating instructions.
Each actuator is provided with its internal wiring diagram on the inner side of the terminal box. The terminals
are marked on a self-adhesive label attached to a carrying strip under the terminal block.
Current rating and maximum voltage of microswitches
Maximum voltage of mikroswitches is 250 V AC as well as DC, at these maximum levels of currents.
MO, MZ 250 V AC / 2 A; 250 V DC / 0,2 A
SO, SZ 250 V AC / 2 A; 250 V DC / 0,2 A
PO, PZ 250 V AC / 2 A; 250 V DC / 0,2 A
The microswitches can only be used as single-circuit devices. Two voltages of different values and phases cannot
be connected to the terminals of the same microswitch.
Isolation resistance
Isolation resistance of electric control circuits against the frame and against each other is min. 20 MΩ.
After a dump test, isolation resistance of control circuits is min. 2 MΩ. Isolation resistance of the electric motor
is min. 1.9 MΩ. See Technical specifications for more details.
Electric strength of electric circuits isolation
Circuit of the resistance transmitter 500 V, 50 Hz
Circuit of the current transmitter 50 V DC
Circuits of microswitches and anti-condensation heater 1,500 V, 50 Hz
Electric motor Un = 3 x 230/400 V 1 800 V, 50 Hz
Deviations of basic parameters
Tripping thrust ±12 % of the maximum value of the range
Adjusting speed -10 % of the maximum value of the range
+15 % of the rated value (in no-load operation)
Setting of signalling switches ±2.5 % of the maximum value of the range
(for the ranges, refer to the Mounting instructions).
Hysteresis of signalling switches max. 4 % of the maximum value of the range
Setting of position-limit switches ±0.2 mm of the output pull-rod displacement
(without the influence of running-down)
Hysteresis of position-limit switches max. 1.2 mm of the output pull-rod displacement
Clearance of output part max. 1 mm
9
Protection
The actuators are fitted with one internal and one external protection terminal for ensuring protection
against electric shock injury according to ČSN 33 2000-4-41. One protection terminal is also installed on
the electric motor. The protection terminals are marked according to ČSN EN 60 417-1 and 2 (013760).
If isn´t the actuator equipment with overcurrent protection when purchased is needed to ensure
that the protection is added externally.
DESCRIPTION
In respect of their basic connecting dimensions, the actuators have been engineered for direct mounting to the valve.
The connection of the actuator to the valve is provided by means of columns according to ČSN 18 6314, art. 1.3, or by
means of columns and a flange (in non-standard design MTN, MTP 40 only).
For transmission of the output pull-rod motion of the actuator to the valve, the actuator is provided with a coupling,
according to ČSN 18 6314, Type A, art. 1.3 (with female thread), or Type B, art. 1.3 (with male thread) - see dimensional
sketches and Tab. 2.
Actuator configuration (Fig.1)
The three-phase asynchronous motor 1 drives via countershaft gearing 2 the sun gear of a differential gear unit
enclosed in the supporting actuator box (power gear transmission) 3. In the mechanical power control mode, the
crown gear of the planet differential unit is held in a steady position by a self-locking worm gear drive. The handwheel
4, which is connected with the worm, allows manual control to be accomplished even during motor operation.
The output hollow shaft is fixably coupled to the planet-gear carrier. The output shaft of the actuator is extended to
the rectilinear mechanism 11 which converts the rotary shaft motion to the rectlilinear motion of a pull-rod. The output
shaft goes into the control box 5 in which all control devices of the actuator have been concentrated, including position-
-limit, signalling and torque-limit switches, a position transmitter and the anti-condensation heater. The operation of the
position-limit and signalling switches is derived from output shaft rotation via mechanisms.
The operation of the torque-limit switches is derived from the axial displacement of a “floating worm” of the manual
control unit which is sensed and transferred to the control box by means of a lever. All controls are accessible
after removal of cover 6 of the control box. Access to the terminal box 7 (9) is obtained after removal of cover 8.
Cable inlets are secured by cable bushings 10.
The electric motor has its own terminal board 14 with a cable leadthrough. The position of the output shaft can be
read on a position indicator mounted on the pull-rod. In addition, it can be read on a local position indicator enclosed in
the control box cover. The individual operating functions of the actuator, e.g., torque-limit switching,position-limit swit-
ching, auxiliary signalling, remote position indication (potentiometer position transmitter), are provided by mechanical
groups (units), which are accommodated on the control board enclosed in the control box (Figs 2 and 2a).
Fig.1 - Configuration of the actuator
Legend:
1 – Three–phase asynchronous motor
2 – Countershaft gear box
3 – Power transmission gear
4 – Handwheel
5 – Control box
6 – Control box cover
7 – Terminal box – design with terminal box
8 – Terminal box cover
9 – Terminal box – design with connector
10 – Cable bushings for control
11 – Rectilinear mechanism
12 – Grease cup
13 – Dust seal
14 – Terminal board of electric motor
15 – Local controller
14 2 3 5 6 4 15 8 15 8
9
10
7
10
13
12
11
1
10
Control units (Figs 2, 2a)
a) Torque-limit switching unit (12)
b) Signalling unit (13)
c) Adjusting mechanism of potentiometer or gear wheel of current transmitter (14)
d) Potentiometer position transmitter with mechanical position indicator or current transmitter of 4 to 20 mA without
position transmitter (15)
e) Position-limit switching unit (16)
f) Anti-condensation heater (17)
Caution!
The microswitches used in the individual units do not allow two voltages of different values or phases to be applied to
contacts of the same microswitch. Thus, they can be used as a switch, cut-out or change-over switch for a singlecircuit only.
Legend:
12 – Torque–limit switching unit
13 – Signalling unit
14 – Transmitter adjusting mechanism
15 – Potentiometer position transmitter
with mechanical position indicator
16 – Position–limit switching unit
17 – Anti–condensation heater
66 – Fixing screws
67 – Basic control board
Legend:
14 – Drive wheel
15 – Current position transmitter
75 – Shim plates
Other items are identical to those used on the
control board with potentiometer shown in Fig.2.
The same applies to the numbers of microswitch
terminals. In the actuator, Type No. 52 442, the
transmitter support is positioned at an angle of
180 °C with respect to the illustrated position.
The encircled numbers correspond to
the numbers of terminals on the terminal board
of the actuator.
The microswitches can be used as one-circuit
devices only.
Fig.2 - Base plate - desing with potentiometer
Fig.2a - Base plate - design with current transmitter
14 66 13
17 67
15
66
16
75
66
12
14 67 66 22
15
15
12
13
66
17
16
20 21 24 23 25
14 16
18
17
19