ZPA MODACT MOPED 52 039 User manual

Electric Multi-turn
Actuators
Type number 52 039
MOUNTING INSTRUCTIONS
10/18

ZPA Pečky, a.s. is certified company in accordance with ISO 90001 as amended.

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1. APPLICATION
The electric actuators MODACT MOPED are designed for shifting control elements by a reversible rotary motion
(e.g. slide valve and other elements) for which they are suitable with their properties. Typical example of using is remote
two-position or multi-position control of elements where tight closure in end positions is required.
The electric actuators are also suitable for automatic regulation in the regime S4 - see Working regime.
2. OPERATING CONDITIONS, OPERATING POSITIONS
Operating conditions
The actuators MODACT MOPED are resistant against influence of operating conditions and external effects of classes
AC1, AD7,AE6, AF2, AG2, AH2, AK2, AL2, AM-2-2, AN2, AP3, BA4 and BC3 according to ČSN 33 2000-5-51 ed. 3.
When the actuator is installed on a free area it is recommended to fit it with a light shelter against direct impact of
atmospheric effects. The shelter should overlap the actuator contour by at least 10 cm at the height of 20 – 30 cm.
When actuators are to be installed in the working environment with temperature below -10 °C and in the environment
with relative humidity above 80 %, it is always necessary to use an anti-condensation heater fitted to all actuators.
The electric actuators can be installed in areas with non-flammable and non-conductive dust, provided that this does not
adversely influence their function. Here, it is necessary to strictly observe ČSN 34 3205. It is recommended to remove dust
as soon as its layer is about 1 mm thick.
Notes:
The area under a shelter means the one where falling of atmospheric precipitations under and angle up to 60° from the
vertical is prevented.
The electric actuator must be installed in a place where cooling air has a free access. Minimum distance from a wall for access
of air is 40 mm. Therefore, the area where the electric actuator is installed must be sufficiently large, clean and ventilated.
Surrounding temperature
Operating temperature for the MODACT MOPED 52 039 is from -25 °C to +60 °C.
Classes of external influences – as extracted from ČSN Standard 33 2000-5-51 ed. 3.
Class:
1) AC1 – above-sea level ≤ 2000 m
2) AD7 – shallow immersion, possible sporadic partial or full coverage
3) AE6 – strong dust formation
4) AF2 – occurrence of corrosive or polluting agents is atmospheric; presence of corrosive pollutants is significant
CONTENS
1. Application ........................................................................................................................ 3
2. Operating conditions; Operating position .................................................................................. 3
3. Working regime; Service life of actuators .................................................................................. 4
4. Technical parameters ............................................................................................................ 5
5. Actuator outfit .................................................................................................................... 6
6. Electric parameters .............................................................................................................. 6
7. Electronic outfit .................................................................................................................. 7
Table – basic parameters ......................................................................................................32
Dimensional sketch of electric actuators MODACT MOPED ...................................................... 33–34
8. Packing and storing ............................................................................................................35
9. Checking of the instrument function and its location ...................................................................35
10. Attachment to a valve ..........................................................................................................35
11. Adjustment of the actuator with a valve ...................................................................................35
12. Operation and maintenance ..................................................................................................35
13. Failures and their removal ....................................................................................................36
List of spare parts .....................................................................................................................37

5) AG2 – mean mechanical strain; in normal industrial operations
6) AH2 – mean vibrations; in normal industrial operations
7) AK2 – serious risk of plant and moulds growth
8) AL2 – serious risk of occurrence of animals (insects, birds, small animals)
9) AM-2-2 – normal level of signal voltage. No additional requirements.
10) AN2 – mean solar radiation. Intensity > 500 and ≤ 700 W / m2
11) AP3 – mean seismic impacts; acceleration > 300 Gal ≤ 600 Gal
12) BA4 – capability of persons; instructed persons
13) BC3 – frequent contact of persons with ground potential; persons often touch foreign conductive parts or stand on
conductive substrate
Operating position
The actuators can be operated in any operating position.
3. WORKING REGIME, SERVICE LIFE OF ACTUATORS
The actuators can be operated with the type of loading S2 according to ČSN EN 60 034-1. The run period at
temperature +50 °C is 10 minutes; the mean value of loading torque should not exceed 60 % of the value of maximum
tripping torque Mv.
The actuators can also work in the regime S4 (interrupted run with start-up) according to ČSN EN 60 034-1. Load
factor N/N+R is max. 25 %; the longest working cycle (N+R) is 10 minutes (course of working cycle is shown in the
figure). The highest number of closing operations in automatic regulation is 1200 cycles per hour. Mean value of
loading torque with load factor 25 % and surrounding temperature +50 °C is not higher than 40 % of maximum
tripping torque Mv.
The highest mean value of loading torque is equal to rated torque of the actuator.
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Corrosion
aggressiveness
level
Example of typical environment
Outdoor Indoor
C1 Heated buildings with clean atmosphere
(very low) e.g. offices, shops, schools, hotels.
C2 Atmosphere with low level of pollution. Unheated buildings, in which may occur
(low) Mostly outdoor areas. condensation, e.g. stocks, sports halls.
C3 Urban industrial atmospheres, Production areas with high humidity and low air
(middle) mild pollution of sulfur dioxide. pollution, e.g. food industry, processing
Seaside areas with middle salinity. factories, breweries.
C4 Industrial areas and seaside areas Chemical plants, swimming pools,
(high) with middle salinity. seaside shipyard.
C5-I
(very high Industrial areas with high humidity Buildings or areas with predominantly continuous
– industrial) and aggressive atmosphere. condensation and high air pollution.
C5-M
(very high Seaside areas with high salinity. Buildings or areas with predominantly
– seaside) continuous condensation and high air pollution.
Corrosion protection
Actuators are standardly delivered with surface treatment corresponding to category of corrosion aggressiveness C1,
C2 and C3 according to ČSN EN ISO 12944-2.
On customer's request is possible to do surface treatment correcponding to category of corrosion aggressiveness C4,
C5-I and C5-M.
In following table is provided and overview of environment for each categories of corrosion aggressiveness
according to ČSN EN ISO 12944-2.

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Service life of actuators
The actuator designed for shut-off valves must be able to perform at least 10,000 working cycles (Close-Open-Close).
The actuator designed for regulation purposes must be able to perform at least 1 million cycles with running time (when the
output shaft is moving) at least 250 hours. Service life in operating hours (h) depends on loading and number of switching
actions. High frequency of switching is not always beneficial for precision of regulation. For reaching the longest possible
faultless period and service life, it is recommended to set frequency of switching to the lowest possible number of switching
actions necessary for the given process. Orientational data of service life derived from the set regulation parameters are shown
in the following table.
Service life of electric 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
4. TECHNICAL PARAMETERS
Supply voltage
Supply voltage of electric motor – 1 x 230 V +10 %, -15 %, 50 Hz ±2 %
– 3 x 230/400 V, +10 %, -15 %, 50 Hz ±2 %
(or as shown on the motor rating plate)
Protective enclosure
Protective enclosure of actuators – IP 67 according to ČSN EN 60529.
Noise
Level of acoustic pressure A max. 85 dB (A)
Level of acoustic output A max. 95 dB (A)
Tripping torque
Tripping torque is set at the manufacturer according to the customer's requirements within the range given in Table No. 1.
If setting of tripping torque is not required maximum tripping torque of the required type number of the electric actuator is set.
Breakaway torque
Breakaway torque is a calculated value, determined by electric motor’s breakaway torque, actuator's total ratio and
effectiveness. Actuator can produce breakaway torque after run reversing operation for 1 to 2 revolutions of the output
shaft, while torque tripping is interlocked. This may occur either in end position or in any optional intermediate position.
Self-locking
Actuator is self-locking provided that load acts against the motion of the actuator's output shaft. Self-locking function
is provided by a roller lock, which immobilizes actuator’s rotor even in case of manual operation.
With respect to safety regulations, it is unacceptable to apply actuators for operating transport lifting equipment
with possible transport of persons, or for equipment where persons may be present below the lifted load.
Run time N
Idle time R
Cycle time
Course of working cycle
Mz starting torque ≥ 1.3 Mv
Mstř mean value of loading torque
Mv maximum value of tripping torque

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Sense of rotation
When looking at the output shaft in the direction towards the control box, the CLOSE direction of rotation is identical with
the clockwise sense.
Working stroke
According to Table No. 1.
Manual control
Manual control is performed directly by a handwheel (without clutch). It can be used even when the electric motor is
running (the resulting motion of the output shaft is determined by the function of the differential gear). When the handwheel is
rotated clockwise the output shaft of the actuator also rotates clockwise (when looking at the shaft towards the control box).
On condition that the valve nut is provided with left-hand thread, the actuator closes the valve.
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.
5. ACTUATOR OUTFIT
Position indicator
The actuator can be fitted with a display as an option for electronic system DMS2 ED. Actuator with electronic system
DMS2 is equipped with two-line display.
Anti-condensation heater
Anti-condensation heater is connected to DMS and DMS ED electronic circuit. Switching of the anti-condensation
heater is controlled by a thermostat. From the factory is the switching temperature set to 10 °C. The temperature is
adjustable by adjusting software DMS2. Input power of the anti-condensation heater is 10W / 230V.
6. ELECTRIC PARAMETERS
External electric connection
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 actuator cover. All control circuits of the electric actuator are brought out to the terminal board.
Connecting of actuators with connector – on special request.
Actuator internal wiring
The internal wiring diagrams of the MODACT MOPED, 52 039 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 actuator cover. The terminals are marked
on a self-adhesive label attached to a carrying strip under the terminal block.
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. See Technical specifications for more details.
Current-carrying capacity and maximum voltage of micro switches
Micro switches maximum voltage is 250 V AC and DC at the following maximum current values:
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
Micro switches can be used only as single-circuit micro switches. Two voltages of varying values or phases must not be
connected to the terminals of one micro switches.
Electric strength of electrical circuits isolation
Circuits of anti-condensation heater 1 500 V, 50 Hz
Electric motor Un = 1 x 230 V 1 500 V, 50 Hz
Un = 3 x 230/400 V 1 800 V, 50 Hz

Deviations of basic parameters
Tripping torque ±10 % of max. value of range
Adjusting speed -10 % of max. value of range
+15 % of rated value (in idle run)
Protection
Actuators are provided with one internal and one external protective terminal serving as protection from electric shock.
Protective terminals are identified with a sign complying with ČSN IEC 417 (34 5555).
If actuator is not provided with over-current protection when purchased, such protection must be provided externally.
7. ELECTRONIC OUTFIT
Electro-mechanical control board is replaced with the electronic system DMS2 or DMS2 ED. Both systems scan
position of the output shaft and torque of the electric actuator by contact-free magnetic sensors. Long service life is
guaranteed for the contact-free sensors that do not get mechanically worn.
The sensor of the output shaft position is absolute and does not require any backup power supply in case supply
voltage is disconnected during operation of the electric actuator. Both systems can be set and monitored by a computer
with controlling program (set parameter can be backed up on a computer) or manually without a computer (for the
electronics DMS2, parameters can be manually set and it can be checked without computer only if the system is equipped
with a display and local control). They contain diagnostic functions - error messages on the display, memory of recent
failures and number of occurrences of respective failures.
The more simple system DMS2 ED substitutes the electro-mechanical board and/or provides for controlling the electric
actuator by input analog signal as in the version Control.
The system DMS2 enables the electric actuator to be used for two-position and three-position regulation or to be
connected to the industrial bus bar Profibus.
DMS2 ED
Basic outfit:
Control unit Main part of the system DMS2.ED - includes microcomputer, position sensor, 3 signal lamps LED,
4 push-buttons for simple setting and checking the actuator, connectors for connecting the torque
sensor, source board, and interface RS 232 (connection of computer for setting and diagnostics).
Torque unit
Source unit Electronic power supply, user's terminal board (connection of power supply and control signals),
2 torque relays, 2 position relays, 2 signalling relays, 1 relay for signalling errors (READY), switch
of resistance anti-condensation heater, connectors for connecting electronic brake, resistance
heater of analog module, and connector for interconnection with the control unit.
Optional outfit:
Analog module output of feed-back signal 4 – 20 mA, in version CONTROL input of control signal
0/4 – 20 mA
Position indicator LED display
Local control
Contactors
or contactless block
Electronic brake
Parameters:
Scanning of position Contact-less, magnetic
Scanning of torque Contact-less, magnetic
Working stroke according Table 1
Torque blocking 0 – 20 s at reversing in limit positions
Input signal 0(4) – 20 mA with switched on regulator function
Local/Remote control, Local open/close
Output signal 7 x relay 250 V AC, 3 A (MO, MZ, PO, PZ, SO, SZ, READY)
Position signal 4 – 20 mA max. 500 ohm, active/passive, galvanic-isolated,
LED display
Power supply of electronic 230 V AC, 50 Hz, 4 W, over-voltage category II
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Realization:
Replacement of electric- The provided relay contacts substitute position, torque and signalling micro-switches ;
mechanical board current feed-back signal 4 – 20 mA can also be brought out; the actuator is controlled by the
superior control system with signals "open" and "close".
CONTROL The electronics covers also function of the regulator; the output shaft position is controlled
by analog input signal.
Function and setting of output relays
The output relays replace end-limit micro-switches; to some extent, function of the output relays differs according to
chosen mode of electronics or it can be selected, preferably by the setting program.
Relé MO, MZ, PO, PZ
In the version Control, the function of relay MO/MZ is same as that of motor relays.
Their operation is controlled by:
- regulation loop (deviation of required and actual position)
- active errors
Any induced active error will change over both relays to a standstill position (coils not energized). In case of errors,
the relays with a function of torque relays (in both versions DMS2 ED and DMS2 ED Control) are also controlled.
Relay SZ, SO, READY
Relay 3/SZ Relay 4/SO
OFF
position O
position Z
torque O
torque Z
torque + position O
torque + position Z
opening
closing
motion
position
negated position
local control
remote control
control OFF
torgue O or Z
motion - blinker
Ready Relay
OFF
warning
errors
warning or errors
errors or no remote
errors or warning or no remote
torgue O or Z
Relay READY
- It usually signalizes errors + warning + not remote,
it can be changed-over to any offered signalization
Relay 3/SZ
- It usually signalizes position closed, it can be changed-over
to any offered signalization
Relay 4/SO
- It usually signalizes position open, it can be changed-over to
any offered signalization
MO torque open
(also changes-over to errors ) motor open
MZ torque closed
(also changes-over to errors ) motor close
PO position open torque open (also changes-over to errors ) + optional
tripping in position open (parameter Tripping)
PZ position closed torque closed (also changes-over to errors ) + optional
tripping in position closed (parameter Tripping)
Relay DMS2 ED DMS2 ED Control

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Setting program
The setting program is same for communication with the electronics DMS2ED and DMS2. The users' version
can be freely downloaded.
Note: In the window "Parameters“ of the setting program, column "Access“, the word "NO“ designates parameters that
cannot be changed by the user (change of these parameters is blocked).
PROCEDURE OF SETTING PARAMETERS BY MEANS OF PUSH-BUTTONS
For simple programming of required operating parameters, the control unit is fitted with four push-buttons:
MENU, P, O, C and three signal lamps.
Yellow Red Green State
- - - System without feeding
- - lit on Everything OK - working regime (remote, local or switched-off control)
- blinking lit on Error or warning – working regime (remote, local or switched-off control)
lit on - lit on Input or output for setting parameters with push-buttons or setting
parameters by means of PC
blinking - lit on
blinking blinking lit on Setting parameters with push-buttons
blinking blinking lit on
In adjustment, follow the paragraphs “VERIFICATION of APPARATUS FUNCTION And its LOCATION”, “fitting
on VALVE” and “ADJUSTMENT of ACTUATOR with VALVE” of these instructions.
For safety reasons, the system is delivered in the state of induced error of Calibration when the functions are
limited in order to reduce the risk of damage to the actuator by wrong wiring.
Record of position CLOSED, OPEN and AUTOCALIBRATION
– The actuator must be adjusted in such a way that the recorded position would switch off the actuator before it is
switched off by torque. For tight closure, the torque relay for torque Closed is only connected into the control circuit.
The actuator can be shifted either manually or electrically. The actuator in version CONTROL can be started from
menu MOTOR in program DMS2. In this case, the actuator does not react to the set position and can only be stopped
by the torque relay. In controlling from menu MOTOR, no torque may be induced. The torque must be left manually.
If, during adjustment, the torque is reached in the end-limit position, the torque must be left by means of a hand wheel.
– The actuator is set to position Closed and position Closed is stored by long pressing of push-button C (without entering
the Menu).
– The actuator is set to position Open and position Open is stored by long pressing of push-button O.
– The calibration routine is started by means of push-button P (in remote control) that, in the three-position regulation,
will measure actual inertial masses of the system and store them into the memory of the control unit. In the twoposition
regulation, pressing of push-button P only cancels the error of Calibration.
– In recording the end-limit positions, signalling relays and the position transducer are also set.
COM POWER TORK
AIN
LED1 LED2 LED3
MENU POC
Colours of diodes:
LED1 – yellow (menu number)
LED2 – red (parameter value)
LED3 – green
Push-buttons and signal lamps LED on control unit DMS2.ED.S and DMS2.ED.S90
Parametr – Parameter
Změna – Change
Chyba – Error
Přístup – Access
Setrvačnost (0,1 %) – Inertia [0.1 %]
Setr. Doběh (0,1 s) – Inertial run-out [0.1 s]
Necitlivost (%) – Insensitivity [%]
NE – NO

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– In case the actuator stroke is to be increased and the switching off is set to “from position”, the actuator will switch off during
shifting in position O or 100 %. To further change the position, press C or O, and, while keeping it depressed, the actuator
can be further shifted. After required position is reached, it is stored to memory by pressing push-button C or O.
Parameters that can be changed by user are set by manufacturer as follows:
1. Tripping torques: 100% or required value (it is not recommended to change the value
without consulting the supplier of the valve, etc.).
2. Relay 3 and relay 4: signalization SZ 1 % and SO 99 % of stroke
3. Time of blocking: 2 – 8 s according to rate of actuator shifting
4. Position of blocking: 5 % of stroke from end-limit positions (it is not recommend to change
the value by more than 10 %)
5. Characteristics of position transducer: closed 4 mA, open 20 mA
6. Relay READY: errors + warning + not remote
In version CONTROL:
1. Setting of control signal: closed 4 mA, open 20 mA
2. Insensitivity of actuator in regulation: 1 % (it is not recommended to set insensitivity higher than 3 %)
3. Response in case of loss of control signal - stop
4. Way of switch off in end-limit positions - torque + PO + PZ
Overview of MENU
LISTING THROUGH MENU
– The setting regime is opened by keeping depressed the push-button MENU for at least 2 s; the LED1 is then lit up.
– By short pressing of MENU, select basic MENU – menu M1 through M8 (LED1 signalizes the menu number);
by short pressing of P, O, C you will open them (LED2 signalizes particular parameter).
– By short pressing of P, select required value of the parameter. If the parameter can be set to several values
they will be changed by short pressing of P (number of LED2 blinking indicates its value). By long pressing of P,
the selected parameter is entered; the entry is confirmed by lit-up LED2.
– By short pressing of MENU, gradually set the required menu and parameters.
– After setting all required parameters, the setting menu is left by keeping depressed the push-button MENU
for at least 2 s. The setting Menu will also be terminated in case that no push-button is depressed within one minute.
MENU 1 – Setting of tripping torques:
– After opening the menu by means of the push-button C or O, select the torque to be set.
– By short pressing of P, select the value of the parameter 50 – 100 % to be set (5 – 10 blinking of LED2) and by long
pressing of the push-button P the parameter is stored into the memory.
MENU 2 – Setting of function of signalling relays:
– Basic setting of the signalling relays is SZ 1% and SO 99% of the stroke.
– In case that a different setting is required, it can be changed after shifting the actuator to the required position by
means of the push-button C or O.
– By means of the push-button P, basic setting SZ 1% and SO 99% of the stroke is performed.
MENU 3 – Setting of torque blocking in limit positions:
– By short pressing of P, select the value of blocking time 0 – 20 s to be set (0 – 20x blinking of LED2) and by long press-
ing of the push-button P the parameter is stored into the memory.
– By long pressing of the push-button C, store the actual position for torque blocking on the Closed side into the
memory.
– By long pressing of the push-button O, store the actual position for torque blocking on the on the Open side.
MENU 4 – Setting of transducer characteristics:
– By short pressing of P, select the value 4 – 20 mA – 1 blinking of LED2 or 20 – 4 mA – 2x blinking of LED2 and by long
pressing of the push-button P, store the parameter into the memory.
The menus below serve only for setting the board in the version Control.
MENU 5 – Setting of control signal in 3P regulation:
– By short pressing of P, select the value
4 – 20 mA - 1x blinking of LED2,
or 20 – 4 mA - 2x blinking of LED2,
or 0 – 20 mA - 3x blinking of LED2,
or 20 – 0 mA - 4x blinking of LED2
and by long pressing of the push-button P, store the parameter into the memory.