Keystone EPI2
Electric Actuator
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
October 2020
Notes
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
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Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Table of Contents
Section 1: General Safety Instructions
1.1 Intended Use ............................................................................................... 1
1.2 Terms and Conditions ................................................................................. 2
1.3 Manufacturer's Liability ............................................................................... 2
1.4 Identication .............................................................................................. 3
1.4.1 Water - Dust-Proof Version ............................................................... 3
1.4.2 Explosion-Proof Version .................................................................... 4
1.5 Applicable Standards And Regulations ........................................................ 6
1.6 Extract From The Standard .......................................................................... 6
1.7 Manufacturer .............................................................................................. 6
Section 2: Machine Description
2.1 General ....................................................................................................... 7
2.2 Principle of Operation ................................................................................. 7
2.3 Electrical Operation .................................................................................... 7
2.4 Manual Operation ....................................................................................... 8
2.5 Description of the Main Parts ...................................................................... 8
2.6 Optional Modules ....................................................................................... 9
2.7 Options Label ............................................................................................ 10
Table of Contents
October 2020
Section 3: Storage and Pre-Installation
3.1 Checks to be Carried Out when the Actuator is Received ........................... 11
3.2 Storage Procedure .................................................................................... 11
3.2.1 General........................................................................................... 11
3.2.2 Storage for a Brief Period (less than one year) ................................. 12
3.2.3 Long Period Storage (more than one year) ...................................... 12
Section 4: Installation
4.1 Checks to be Performed Before Installation ............................................... 13
4.2 Working Condition.................................................................................... 13
4.3 Coupling Block .......................................................................................... 14
4.4 Installation of the Keystone EPI2 Unit Onto a Valve .................................... 15
4.5 Manual Operation ..................................................................................... 15
4.6 Setting Of The Angular Stroke: Mechanical Stops ...................................... 16
4.7 Electrical Connections ............................................................................... 17
4.8 Plant Requirements ...................................................................................17
4.9 Removal of the Terminal Board Enclosure .................................................. 19
4.10 Cables Connections .................................................................................. 20
4.11 Base Wiring Diagram ................................................................................ 22
4.12 Cable entries ............................................................................................. 23
4.13 Safety Instructions for Installation in Hazardous Area ................................ 24
4.13.1 Instructions for Explosion-Proof Enclosures .................................... 24
Table of Contents
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Table of Contents
October 2020
Section 5: Lubrication
Section 6: Actuator Conguration
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
5.1 Lubrication Inspection .............................................................................. 26
6.1 Removal of the Control Unit Cover ............................................................ 28
6.2 Local Conguration of the Keystone EPI2 .................................................. 29
6.2.1 Keystone EPI2 Default General Conguration.................................. 29
6.2.2 Close Limit Conguration by Position.............................................. 31
6.2.3 Close Limit Conguration ............................................................... 31
6.2.4 Open Limit Conguration by Position ............................................. 31
6.2.5 Open Limit Conguration ............................................................... 32
6.2.6 Close Limit Conguration by Torque ............................................... 32
6.2.7 Open Limit Conguration by Torque ............................................... 32
6.2.8 Stroking Time Selection in Closing .................................................. 33
6.2.9 Stroking Time Selection in Opening ................................................ 34
6.2.10 Setting of the Torque Limiting Device in Closing ............................. 34
6.2.11 Conguration of the Torque Limiting Device in Opening ................. 35
6.2.12 Reverse Mode Conguration .......................................................... 35
6.2.13 Actuator Model Selection ............................................................... 36
6.2.14 Blinker / Local Selector Conguration ............................................. 37
6.2.15 3-WIRES/2-WIRES Remote Control Conguration ........................... 38
6.3 Conguration of the Keystone EPI2 by a PDA / PC
and ‘A Manager’ Software ......................................................................... 38
6.4 Hardware Conguration for Monitor Relay ................................................ 39
Section 7: Maintenance and Troubleshooting
7.1 Maintenance ............................................................................................. 40
7.1.1 Routine Maintenance ...................................................................... 40
7.1.2 Special Maintenance ....................................................................... 40
7.2 Trouble-Shooting ...................................................................................... 41
7.2.1 The Electronics do not Switch on When Powered ............................ 41
7.2.2 24 V DC Output Voltage not available at the Terminals ................... 41
7.2.3 The Actuator does not work from Remote Controls ........................ 42
7.2.4 The motor is Very Hot and does not Start ........................................ 42
7.2.5 The Motor Runs but the Actuator does not Move the Valve ............. 42
7.2.6 The Valve does not Seat Correctly ................................................... 42
7.2.7 Excessive Torque for Valve Operation .............................................. 43
7.2.8 The Actuator does not Stop in Fully Open or Fully Closed Position ... 43
7.2.9 Diagnostic Led ................................................................................ 43
Section 8: Decommissioning
8.1 Disposal and Recycling .............................................................................. 44
Section 9: Parts List and Drawings
Parts Lists and Drawings ............................................................................ 45
II
Table of Contents
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 1: General Safety Instructions
Section 1: General Safety Instructions
1.1 Intended Use
The Keystone EPI2 electric actuators covered in this Instruction and Operating Manual are
designed for the operation of any kind of quarter-turn industrial valves (ie., ball, buttery,
plug and control valves) used in a wide range of applications ranging from heavy
industrial, chemical, petrochemical plants, waterworks, water pipelines, waste paper
plants and power plants to food, brewing and heating, ventilation, air conditioning, etc.
Emerson Valves & Controls will not be liable for any possible damage or physical injury
resulting from use in other than the designated applications or by lack of care during
installation, operation, adjustment and maintenance of the machine. Such risks lie
entirely with the user. Depending on the specic working conditions, additional
precautions may be requested. Considering that Emerson has no direct control over
particular applications, operation or maintenance conditions, it is the operator's
responsibility to comply with all applicable safety rules.
October 2020
Please inform Emerson urgently if you face unsafe situations not described in this IOM.
It is the sole responsibility of the operator to ensure that the local health and safety
regulations are adhered to. Keystone EPI2 are tested according to EN 21680. Noise level is
less than 65 dB (grade A) at 1 m distance.
WARNING
!
It is assumed that the installation, conguration, commissioning, maintenance and repair
works are carried out by qualied personnel and checked by responsible specialists.
WARNING
!
Any repair work, other than the operations ou/Uned in this manual, is strictly reserved to
qualied Emerson personnel or to personnel directly authorized by the company itself.
General Safety Instructions
1
Section 1: General Safety Instructions
October 2020
Keystone EPI2 electric actuators are designed in accordance with the applicable
international rules and specications, but the following regulations must be observed in
any case:
• The general and safety regulations
• The plant specic regulations and requirements
• The proper use of personal and protective devices (glasses, clothing, gloves, etc.)
• The proper use of tools, lifting and transport equipment
• Electrical installation, use and maintenance on Keystone EPI2 has to be carried out
in accordance with the National Legislation and statutory requirement related to
the safe use of Keystone EPI2 actuators, applicable to the site of installation
• Should further information and guidance related to the safe use of Keystone EPI2
actuators is requested, please contact Emerson
WARNING
!
The electronic parts of the Keystone EPI2 and all the optional modules can be damaged
by a discharge of static electricity. Before you start, touch a grounded metal surface to
discharge any static electricity.
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
1.2 Terms and Conditions
Emerson guarantees each single product to be free from defects and to conform to
current goods specications. The warranty period is one year from the date of installation
by the rst user, or eighteen months from the date of shipment to the rst user,
whichever occurs rst.
No warranty is given for products which have been subject to improper storage, improper
installation, misuse, or corrosion, or which have been modied or repaired by unauthorized
personnel. Repair work due to improper use will be charged at standard rates.
1.3 Manufacturer's Liability
Emerson declines all liability in the event of:
• Use of the actuator in contravention of local safety at work legislation
• Incorrect installation, disregard or incorrect application of the instructions
provided on the actuator nameplate and in this manual
• Modications without Emerson's authorization
• Work done on the unit by unqualied or unsuitable persons
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General Safety Instructions
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
1.4 Identication
1.4.1 Water - Dust-Proof Version
Keystone EPI2 actuators are designed and manufactured according to EN 60529 standards.
Specic types of protection are printed on the label, as follows:
• IP66/68
• NEMA 4/4X/6 according to NEMA ICS6 / NEMA 250
Figure 1 Label for Application in Water - Dust-Proof Areas
Section 1: General Safety Instructions
October 2020
A. Manufacturer logo
B. Product model
C. Nominal output torque value
D. Product code
E. Serial number
F. Stroking time range
G. Power supply data
H. Max current absorption in ampere
I. Environmental data
L. Actuator duties
M. Weather-proof protection degree (EU and US)
N. Weather-proof certicate reference (EU and US)
O. Manufacturer details
P. Year of construction
General Safety Instructions
3
Section 1: General Safety Instructions
October 2020
1.4.2 Explosion-Proof Version
The version of Keystone EPI2 suitable for installation in hazardous areas is designed and
manufactured according to EN 60079-0, EN 60079-1, EN IEC 60079-7, EN 60079-31 standards.
Different types of protection are available, depending on the requirements of the
installation site.
The driven valve or associated gear reducer will form part of a separate risk analysis according
to Directive 2014/34/EU and following the EN ISO 80079-36 and EN ISO 80079-37 norms.
Specic types of protection are printed on the label, as follows:
• ATEX Ex de IIB T5 with enclosures in ‘explosionproof’ version and terminal board
enclosure in ‘increased safety’ version
• FM rated as ameproof for Class I, Zone 1, Group IIB, T5; Class II, III, Div. 1,
Groups E, F and G, T4
• NEMA 7 and NEMA 9
The above versions of Keystone EPI2 prevent the risk of explosion in the presence of gas or
ignitable dusts.
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Keystone EPI2 actuators have IP66/68 protection degree in accordance with EN 60529.
WARNING
!
Whenever Keystone EPI2 actuators must be installed in a HAZARDOUS AREA as dened by
the applicable rules, it is mandatory to check whether the actuator nameplates indicate their
suitability to a hazardous area, and the appropriate protection degree. Maintenance and repair
works must be carried out by qualied personnel and checked by responsible specialists.
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General Safety Instructions
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 2 Atex Label for Application in Hazardous Areas
Section 1: General Safety Instructions
October 2020
B
R
S
F
L
O
P
C
G
M
D
N
E
I
H
KEYSTONE
Q
A
A. Manufacturer logo
B. Product model
C. Nominal output torque value
D. Product code
E. Serial number
F. Stroking time range
G. Power supply data
H. Max current absorption in ampere (at 24 V DC)
I. Environmental data
L. Actuator duties
M. Explosion-proof protection degree
N. Weather-proof certicate reference (IP66/NEMA types 4, 4X and 6 when labelled FM)
O. ATEX certicate reference
P. Manufacturer details
Q. Year of construction
R. Notied body for ATEX quality assurance (Ineris)
S. ATEX Marking
General Safety Instructions
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Section 1: General Safety Instructions
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
1.5 Applicable Standards and Regulations
EN ISO 12100-1 Safety of machinery
Basic concepts, general principles for design
Part 1: Basic terminology, methodology
EN ISO12100-2 Safety of machinery
Basic concepts , general principles for design
Part 2: Technical principles and specication
EN 60204-1 Electrical equipment of industrial machines
Part 1: General requirements
98/37/EC Machinery Directive
2014/35/EU Low Voltage Directive
2014/53/EU RED Directive
2014/34/EU ATEX Directive
1.6 Extract from the Standard
Table 1.
Type of hazardzone Zone Categories according to 94/9/EC Directive
Gas, mist or vapors 0 1G
Gas, mist or vapors 1 2G
Gas, mist or vapors 2 3G
Dust 20 10
Dust 21 20
Dust 22 30
1.7 Manufacturer
Manufacturer with respect to Machinery Directive 98/37 is Bif Italia, as specied on the
actuator label.
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General Safety Instructions
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 2: Machine Description
2.1 General
The Keystone EPI2 is an electric quarter-turn actuator suitable to operate a valve in a
90° maneuver.
2.2 Principle of Operation
The electric motor drives the input to an epicyclical gear train via a spur reduction.
The input member of the epicyclical gear train carries two compound planet gears which
meshes with one internally toothed gears: the xed annulus. The xed annulus gear has
external helical teeth meshing with a transversely xed worm gear. Since the annulus
cannot drive the worm gear this provides a xing point for the annulus, and since the
worm gear can drive the annulus, a means of manual operation is provided which needs
no declutch.
Section 2: Machine Description
October 2020
An end-of-travel-position detection device is operated via a position sensor directly linked
to the output shaft. The valve position is continuously monitored in electric mode by
means of a position sensor directly connected to the Keystone EPI2 output drive.
2.3 Electrical Operation
— Control command 'open': counter-clockwise or clockwise rotation
(selectable on the logic board) moves the valve to a completely or
partially open position.
— Control command 'closed' : clockwise or counter-clockwise rotation
(selectable on the logic board) moves the valve to a completely or
partially closed position.
— Control system details are shown in the specic wiring diagram.
NOTE
Handwheel rotation
In standard applications clockwise rotation of the handwheel moves the valve to
close position and counter-clockwise rotation moves the valve to open position.
Different operation are clearly indicated on the handwheel.
Machine Description
7
Section 2: Machine Description
October 2020
2.4 Manual Operation
To be used in case of power supply failure or during actuator setting. The manual operating
device is completely independent of the motor drive and can be operated at any time,
whether or not the motor is running, without danger to the operator. The handwheel
does not rotate during power operation. To close the valve turn the handwheel clockwise.
To open the valve, turn the handwheel counter clockwise. If the handwheel is turned during
electric operator, an error will occur and the actuator will stop. After few seconds the
actuator will restart its operation and move the valve to the requested position.
Figure 3
Local position indicator
Installation, Operation and Maintenance Manual
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Control unit
Manual override
Mechanical gearing
Base ange
Cable entries
2.5 Description of the Main Parts
The Keystone EPI2 actuator consists of ve main parts:
• Base ange: for coupling the actuator to the valve
• Terminals enclosure: for power and signal cable connection through four
available cable entries
• Mehanical gearing: internal epicyclical gear reduction, which increases the torque
of the electric motor
• Control unit: integral control unit inclusive of electric motor with the relevant
driver, power and logic electronic card. By way of the mechanical gearing,
the electric motor operates the valve in normal working conditions
• Manual override: for actuator manual operation in case of power supply failure or
during actuator setting
Terminals enclosure
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Machine Description
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
2.6 Optional Modules
Keystone EPI2 actuators can be provided with several optional modules, as listed in the
table below. Please refer to this table for possible combinations of available modules.
Table 2. Optional Modules Selection Table
Section 2: Machine Description
October 2020
Order
code
P1
PA
P6
P7
P3
5P
6P
5D
6D
PG
OM1 I/O
additional module
OM3
local interface
Bluetooth
component
OM9
PDP V0/V1
OM11
DeviceNet
OM13
3 wires module
NOTE
1. Each optional module (OMx) will be provided with its own Installation and
Maintenance Instructions. All modules except OM13 are available for both
1-phase and 3-phase voltage versions.
2. Bluetooth component is integrated in the OM1, OM9 and OM11 card: not
available for integration by local organizations, as a stand alone unit.
3. OM13 is not available wit h 3-phase supply. Not available for LV version
1-phase voltage from 24 to 48 V DC/V AC.
Machine Description
9
Section 2: Machine Description
October 2020
2.7 Options Label
A label is always provided with base actuators where optional modules will have to be
checked out once they are installed after delivery at local organisations care.
Figure 4
Installation, Operation and Maintenance Manual
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Options Label
S/N:
OM1OM3 OM9
OM11 OM13
Figure 5
Please make sure the label is stuck where shown
in the picture below.
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Machine Description
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 3: Storage and Pre-Installation
Section 3: Storage and Pre-Installation
3.1 Checks to be Carried Out when the
Actuator is Received
NOTE
Not performing the following procedures will invalidate the product guarantee.
First of all check if the data on the nameplate (model, serial number, nominal torque,
nominal voltage range, protection degree, operating speed range, protection class, etc.)
correspond to the expected product data.
If the actuator is received already assembled onto the valve, the setting of the mechanical
stops and of the electric end-of- travel should have been already done during actuator
assembly onto the valve. An additional check is anyway recommended to verify that all
the requested settings have been completed as indicated in the present Instruction and
Operating Manual.
October 2020
If the actuator is received separately from the valve, the setting of the mechanical stops
and of the electric end-of-travel must be checked and, if necessary, carried out while
assembling the actuator onto the valve. In any case, all the setting operations described in
this Instruction and Operating Manual must be carried out. Check that the actuator was
not damaged during transport: in particular, inspect the local position indicator area glass.
If necessary, repair all damages to the paint-coat, etc. Check that the tted accessories
comply with those listed in the order acknowledgement and the delivery note.
3.2 Storage Procedure
3.2.1 General
The actuators leave the factory in perfect working conditions and with an excellent
nish, in order to maintain these characteristics until the actuator is installed on site, it is
necessary to observe a few rules and take appropriate measures during the storage period.
The basic version of Keystone EPI2 actuators is weather-proof to IP66/68. This condition
can only be maintained if the units are correctly installed and connected on site, and if
they were previously correctly stored. The standard plastic plugs used to close the cable
entries are not weather-proof, they just prevent the entry of undesired objects during
transport. Emerson can not accept responsibility for deterioration caused on site when
the covers are removed.
NOTE
The actuator handwheel is removed for transport. If the actuator must be shipped fully
assembled, please make sure the handwheel is packed securely to avoid all possible damage.
Storage and Pre-Installation
11
Section 3: Storage and Pre-Installation
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
3.2.2 Storage for a Brief Period (less than one year)
3.2.2.1 Indoor Storage
• Make sure the actuators are kept in a dry place, laid on a wooden pallet
(not directly on the oor surface) and protected from dust
• In very humid environments, a moisture absorbent desiccant packet should be
introduced in the motor enclosure. (Desiccant is not included in the actuator package)
3.2.2.2 Outdoor Storage
• Make sure the actuators are protected from the direct action of weather agents
(protection by a canvas tarp or similar).
Environment temperature: - 20 °C to +65 °C (-4 ° F to 149 °F)
• Place the actuators on a wooden pallet, or some raised plat form, so that they are
not in direct contact with the ground, and protected from dust
• In very humid environments, a moisture absorbent desiccant packet should be
introduced in the motor enclosure . (Desiccant is not included in the actuator package)
• If the actuators are supplied with standard plastic plugs, remove them from the
cable entries and replace them with weather-proof plugs
3.2.3 Long Period Storage (more than one year)
3.2.3.1 Indoor Storage
In addition to the instructions at point 3.2.2.1:
• If the actuators are supplied with standard plastic plugs, replace them with
weather-proof plugs
• The coupling parts (i.e. ange, etc.) must be coated with a protective oil or
grease; (if possible, blank off the ange by a protection disk)
3.2.3.2 Outdoor Storage
In addition to point 3.2.2.2:
• If the actuators are supplied with standard plastic plugs, replace them with
weather-proof (metal) plugs
• The coupling parts (i.e. ange, etc.) must be coated with a protective oil or
grease; (if possible, blank off the ange by a protection disk)
• Check the actuator general conditions, paying particular attention to the
terminal board
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Storage and Pre-Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 4: Installation
October 2020
Section 4: Installation
4.1 Checks to be Performed Before Installation
To assemble the actuator onto the valve proceed as follows:
• Check that the coupling dimensions of the valve ange and stem, or of the
relevant extension, meet the actuator coupling dimensions
• The electrical supply cables must be suitable for the power rating
• Gather the necessary tools for the assembly and conguration of the actuator controls
• Lubricate the valve stem with oil or grease to make the assembly easier: pay
attention not to contaminate with lubricant the ange surfaces which transmit
the actuator torque
• Clean the valve ange and remove anything that might prevent a perfect
adherence to the actuator ange and especially all traces of grease
• Install the actuator onto the valve so that the shaft output drive enters the
groove of the stem extension. This coupling must take place without forcing and
only with the weight of the actuator. When the actuator output shaft and the
valve stem are connected, check the holes of the valve ange. If they do not meet
with the holes of the spool piece ange or the stud bolts screwed into them, the
actuator shaft output drive must be rotated. Actuate the manual override until
coupling is made possible. Tighten the nuts of the connecting stud bolts evenly
• If possible, operate the actuator to verify it moves the valve smoothly
If a long storage period has occurred, before reinstalling the actuator, please:
• Check the status of the O-ring seals
• Check the installation of the plugs or cable glands on the cable entries
• Check whether the enclosure covers or the actuator body are cracked or broken
4.2 Working Condition
Standard Keystone EPI2 actuators are suitable for the following environment temperatures:
• -25 °C to +70 °C (-13 °F to +158 °F)
Special versions are available for extreme environment temperatures:
• -40 °C to +70 °C (-40 °F to +158 °F)
Installation
13
Section 4: Installation
October 2020
4.3 Coupling Block
The electric actuator is delivered with drive details and ange in accordance with the
technical characteristics required by the customer, ready to be installed onto the valve.
Only one insert is included in the actuator package delivered to end users.
NOTE
Check the ‘ambient temperature range’ printed on the nameplate, for the correct
utilisation with respect to the ambient temperature. Installation in ambient with
temperature range outside the specied values will invalidate the warranty.
WARNING
!
During normal operation the temperature of the actuator surface can reach 30 °C (86 °F)
above the ambient temperature.
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
NOTE
In case the screws of the cover, of the terminal compartment and of the OM3 must be
replaced, SS Aisi 316 Class A4 grade 80 screw must be used with minimum yield strength
600 N/mm², The screw size is M6 X 25 mm. Other screws used for the assembly of the other
various parts of the explosionproof enclosure shall be a SS AISI 316 Class A4 Grade 70, with
minimum yield strength of 450 N/mm². Every time the main cover, the terminal compartment
cover and the OM3 are reassembled, make sure to tight all the screws with 5 Nm torque.
NOTE
For the model E171 and 2000 of the Keystone EPI2 Series only: during installation, the
user shall take into consideration that the actuator was assessed at a low risk impact
energy at 2J.
Figure 6 Overview of one type of insert and drive details of the Keystone EPI2
14
WARNING
!
Never lift the valve/actuator assembly without securing slings to both the valve and the
actuator. Never use the handwheel to lift the actuator.
Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 4: Installation
4.4 Installation of the Keystone EPI2 Unit
onto a Valve
Move the valve to the completely open position. Manually bring the Keystone EPI2 to the
completely open position (verify the local mechanical indicator) and check the rotation
direction of actuator and valve. The actuator should be mounted for counter-clockwise
rotation to open and clockwise to close. The Keystone EPI2 unit can be installed onto the
valve in two different ways:
Direct mounting
Insert the valve shaft into the actuator bottom ange, taking care to correctly connect
the insert. Fix the screws on the valve ange to the actuator coupling block.
Bracket mounting
Install the bracket and the adapter onto the valve; then insert the valve shaft into the
actuator bottom ange, taking care to correctly connect the insert. Fix the screws
between the bracket and the valve ange and the actuator coupling block.
October 2020
4.5 Manual Operation
Keystone EPI2 electric actuators are supplied with a handwheel for manual override
as standard, to operate the actuator in case of power supply failure or during setting.
The handwheel is always engaged. For safe operation, the handwheel does not rotate
during electric operation. Turn the handwheel clockwise to close and counter-clockwise
to open. During manual operation, check the actuator maneuver on the local
mechanical indicator.
WARNING
!
Do not manually operate the actuator with devices other than the handwheel. Using
cheater bars, wheel wrenches, pipe wrenches, or other such devices on the actuator
handwheel may cause serious personal injury and/or damage to the actuator or valve.
Figure 7 Manual Operation
Installation
15
Section 4: Installation
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
4.6 Setting of the Angular Stroke: Mechanical Stops
It is important for the mechanical stops to end the angular stroke at both extreme
valve positions (fully open and fully closed). The setting of the angular stroke is
performed by adjusting the travel stop screw mounted on the actuator housing.
For the adjustment of the stop screw proceed as follows:
• Loosen the lock nut
• Screw 1: open
To set the mechanical stop in opening, manually bring the actuator to the
completely open position, then turn screw 1 clockwise to nd the correct
position, then block it by means of the nut
• Screw 2: close
To set the mechanical stop in closing, manually bring the actuator to the
completely close position, then tighten screw 2
If the actuator angular stroke is stopped before reaching the end position
(fully open or closed), proceed as follows:
• Unscrew the stop screw by turning it anticlockwise until the valve reaches
the correct position
• When unscrewing the stop screw, keep the lock nut still with a wrench so that
the sealing washer does not withdraw together with the screw
• Tighten the lock nut
If the actuator angular stroke is stopped beyond the end position (fully open or closed),
proceed as follows:
• Screw the stop screw by turning it clockwise until the valve reaches the correct position
• Tighten the lock nut
Figure 8 Setting of the Mechanical Stop
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Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
4.7 Electrical Connections
Before powering the actuator, check that the supply voltage details on the nameplate
are correct for the plant. Access to terminals for electrical connections is through the
terminal cover.
WARNING
!
After electrical on-eld installation, please make sure all removal of the cover assembly is
done in total observance of the applicable safety rules. All the accessories (cable glands
in particular) must be certied according to the requirements of the installation area and
the relevant applicable regulations. Setting must be done while the actuator is powered
on. As a consequence, all setting operations must be carried out by specically qualied
personnel for operations on powered electronic cards.
Section 4: Installation
October 2020
4.8 Plant Requirements
Protection devices (over-current breakers, magneto-thermal switches or fuses) must be
provided by the customer to protect the main lines in case of motor over-current or loss of
insulation between phases and earth.
NOTE
The following circuit breakers were identied on the basis of the actuator technical features:
— Reference: IEC EN 60947-2
— Characteristic: K
It is the plant engineer’s or installer’s responsibility to select the most appropriate
electric protection.
NOTE
For actuators certied according to CSA standards the eld connections shall be done
with certied crimp-on ring terminals.
Installation
17
Section 4: Installation
October 2020
Table 3. Current Absorption - Single Phase and DC Voltage
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Current Absorption (A)
Model
063/E006
125/E013
250/E025
500/E051
1000/E091
2000/E171
Selected
Step
Op er.
Time
(
secs/90
8 15 2.26 1.01 0.590 0.473 0.334 0.289 2.02 1.01 0.605 0.476 0.222 0.196
6 28 1.60 0.84 0.405 0.334 0.253 0.217 1.53 0.75 0.415 0.343 0.158 0.138
4 48 1.38 0.73 0.317 0.265 0.209 0.176 1.30 0.64 0.318 0.260 0.120 0.106
8 15 4.20 1.70 0.980 0.810 0.430 0.420 4.50 1.81 1.040 0.820 0.390 0.340
6 28 2.60 1.28 0.780 0.630 0.370 0.340 2.65 1.27 0.810 0.640 0.300 0.260
4 48 2.04 1.00 0.680 0.560 0.340 0.290 2.10 0.96 0.720 0.570 0.270 0.220
8 15 10.30 4.90 2.440 1.970 0.920 0.800 9.70 4.80 2.520 1.950 0.900 0.780
6 28 8.20 3.80 1.650 1.350 0.640 0.570 7.20 3.60 1.650 1.320 0.630 0.540
4 48 6.40 3.30 1.440 1.170 0.560 0.500 6.80 3.20 1.460 1.140 0.540 0.470
8 15 14.50 6.80 3.200 2.520 1.150 1.000 14.00 7.00 3.220 2.530 1.120 0.980
6 28 9.50 4.60 1.900 1.550 0.760 0.670 9.30 4.50 1.920 1.540 0.720 0.620
4 48 7.00 3.40 1.550 1.240 0.600 0.530 7.10 3.40 1.510 1.240 0.580 0.500
8 24 14.50 6.80 3.200 2.520 1.150 1.000 14.00 7.00 3.220 2.530 1.120 0.980
6 45 9.50 4.60 1.900 1.550 0.760 0.670 9.30 4.50 1.920 1.540 0.720 0.620
4 80 7.00 3.40 1.550 1.240 0.600 0.530 7.10 3.40 1.510 1.240 0.580 0.500
8 53 14.50 6.80 3.200 2.520 1.150 1.000 14.00 7.00 3.220 2.530 1.120 0.980
6 100 9.50 4.60 1.900 1.550 0.760 0.670 9.30 4.50 1.920 1.540 0.720 0.620
4 180 7.00 3.40 1.550 1.240 0.600 0.530 7.10 3.40 1.510 1.240 0.580 0.500
24 V AC48 V AC90 V AC110 V AC230 V AC264 V AC24 V DC48 V DC90 V DC110 V DC230 V DC264 V
°)
Table 4. Current Absorption - Three Phase Voltage
Model
063/E006
125/E013
250/E025
500/E051
1000/E091
2000/E171
Selected
Oper. Time
Step
(secs/90°)
8 15 0.226 0.176 0.107
6 28 0.165 0.101 0.080
4 48 0.132 0.083 0.057
8 15 0.344 0.227 0.171
6 28 0.295 0.180 0.143
4 48 0.245 0.155 0.125
8 15 0.800 0.73 0.52 0.49 0.37 0.340
6 28 0.590 0.56 0.41 0.35 0.29 0.280
4 48 0.530 0.50 0.37 0.30 0.27 0.250
8 15 1.073 0.97 0.65 0.58 0.46 0.430
6 28 0.720 0.64 0.47 0.39 0.32 0.310
4 48 0.590 0.55 0.41 0.32 0.29 0.280
8 24 1.073 0.97 0.65 0.58 0.46 0.430
6 45 0.720 0.64 0.47 0.39 0.32 0.310
4 80 0.590 0.55 0.41 0.32 0.29 0.280
8 53 1.073 0.97 0.65 0.58 0.46 0.430
6 100 0.720 0.64 0.47 0.39 0.32 0.310
4 180 0.590 0.55 0.41 0.32 0.29 0.280
208 V AC 240 V AC 380 V AC 400 V AC 480 V AC 500 V AC 575 V AC
Current Absorption (A)
DC
18
NOTE
1. A = absorbed current (Amp) at nominal conditions (output torque 100%)
2. Max current (Amp) at stall conditions = 1.2 x A
3. Power factor for V AC supply = 0.60
4. Peak current: max 8xIn
5. Peak current duration: less than 0.1 s
Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 4: Installation
4.9 Removal of the Terminal Board Enclosure
Using a 5 mm Allen key, loosen the four screws and remove the cover.
Figure 9 Removal of the Terminal Board Enclosure
October 2020
WARNING
!
Pay attention not to damage the joint surfaces of the cover.
Installation
19
Section 4: Installation
October 2020
4.10 Cables Connections
Before applying voltage to the Keystone EPI2 check that the electrical parameters
(supply voltage and current) shown on the nameplate and on the attached wiring
diagram are correct for the installation.
Figure 10 Overview of the Electrical Connections
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
NOTE
All the accessories which equip the Keystone EPI2, in particular the cable glands, must be
certied according to the Standard Directive and specic Rules applying to the products.
WARNING
!
Do not remove earth connection X while connecting the actuator to plant earthing.
20
Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Remove the plugs from the cable entries. For electrical connections use components
(cable glands, cables, hoses, conduits) which meet the requirements and the applicable
codes of the plant specications (mechanical protection and/or explosionproof protection).
Screw the cable glands (or the conduits) tightly into the threaded entries, in order to
guarantee the weatherproof and explosionproof protection (when applicable).
Insert the connection cables into the electrical enclosures through the cable glands (or
conduits) and, according to the wiring diagram in the main terminal board enclosure,
connect the electrical supply, the control and the signal cables to the actuator, by linking
them to the terminal blocks termination as per diagram. Replace the plastic plugs of the
unused cable entries by metal ones, to guarantee perfect weatherproof tightness and to
comply with the explosionproof protection codes (where applicable).
Once the connections are completed, check that the controls and signals work properly.
Two ground studs, one internal and one external, are provided to meet all local electric and
safety regulations.
Terminate the ground connections at least to the external stud marked ground.
Connect the motor supply cable previously sized in accordance with:
Section 4: Installation
October 2020
• The absorbed current correspondent to the actuator nominal torque with the
torque limiting device set at 100 percent
• Cable size; 1 power: 4 mm2/AWG12 (max) 2 controls: 1.5 mm2/AWG 16 (max)
• The applicable plant and safety norms
• For actuators certied according to CSA standards the eld connections shall be
done with certied crimp-on ring terminals.
Installation
21
Section 4: Installation
October 2020
4.11 Base Wiring Diagram
Figure 11
BLINKER LOCAL
MONITOR
RELAY
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
SELECTOR
RELAY
CLC1 CLC2 OPC1 OPC2
L1 L2 L3 35 36 32 33 34 20 21
GROUND
Note 1 Note 4, 6Remote commands
(Note 2, 5)
22 23 24 25 26 27 28 29 30 311 2 3 4
Output contacts
(Note 3, 4)
Optional
module OM3
NOTE
1. Power connection L1-L2 for V DC or V AC single phase motor supply from 24 V to
48 V or from 100 V to 240 V.
Power connection L1-L2-L3 for 3-phase motor supply from 208 V to 575 V
(check the actuator label for the correct voltage to be applied).
2. Remote command options.
Figure 12
a. Standard conguration
Internal supply 24 V DC
b. 2 wires setting (to be congured)
External supply 24 / 120 V AC or 24 / 120 V DC
22
Contact open for actuator closing
Contact open for actuator closing
Contact close for actuator opening
Internal supply 24 V DC
Contact close for actuator opening
External supply 24 / 120 V AC or 24 / 120 V DC
3. Contacts shown in intermediate position CLC1-CLC2 end of travel signaling in closing.
Contacts shown in intermediate position OPC1-OPC2 end of travel signaling in opening.
4. Output contact rating 240 V AC / 5 A ; 30 V DC / 5A ; 120 V DC / 0.5 A.
Output contacts (when used) have to be feed with the same external voltage.
5. Control command rating 24 to 120 V AC or DC.
Control signal: minimum duration>600 ms
6. Blinker or Local Selector monitoring function (when OM3 is present) to be congured
WARNING
!
It is under user responsibility to limit the rated impulse voltage level at 1500 V.
Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
4.12 Cable Entries
The sealing of cables and conduit entries should be carried out in accordance with
National Standards or the Regulatory Authorities that have certied the actuators.
This is particularly true for units that are certied for use in hazardous areas where the
method of sealing must be to an approved standard, and cable glands, reducers, plugs
and adapters must be approved and separately certied.
NOTE
• To prevent any water inltration through the cable conduits, make sure the cable
glands have the minimum protection degree required by the plant.
• If rigid conduits are used, we suggest placing a exible pipe connection between the
conduit and the terminal board.
In order to properly connect the cables, remove the cable entry plugs and make all the
necessary connections. To guarantee the proper weatherproof t, degree IP66/68 must
be ensured: screw the cable glands tightly and block them with a thread sealant. The use
of a thread sealant is necessary in case of explosionproof application.
Section 4: Installation
October 2020
If some parts of the cable glands have been removed while working on the cable entries,
put them back into place in order to avoid losing the dismantled parts. Unused entries:
• For explosionproof construction: unused entries must be plugged with metal
explosionproof plugs and blocked with a thread sealant
• For weatherproof construction: replace the standard plastic protection plugs
supplied with the actuator with suitable plugs to guarantee the requested
protection degree
NOTE
In order to physically separate the power from the signal terminal, place the power
clamps protection (provided with the actuator) on the power terminal, once you have
completed the power cable connection. This will avoid any accidental contact with the
power terminals during the cabeling operation on the signal terminals.
Figure 13 Overview of the Cable Entries Conduits
Installation
23
Section 4: Installation
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
4.13 Safety Instructions for Installation in
Hazardous Area
4.13.1 Instructions for Explosion-Proof Enclosures
NOTE
Keystone EPI2 electric actuators must be installed and maintained according to the
applicable Rules regarding the electrical installation in hazardous areas (other than mines)
classied as zone 1 and/or 2 (gas) and zone 21 and/or 22 (dust) according to EN 60079-10
(hazardous area classication). Example: EN 60079-14 (electrical installation),
EN 60079-17 (maintenance).
During the dismantling and subsequent reassembling of the explosionproof enclosures
(covers, cable glands, joints) be careful to bring these enclosures back to their original
condition to maintain their integrity. In particular, be sure the joint surfaces of all
enclosures are spread with a lm of recommended grease.
Proceed as follows:
• Do not damage the explosionproof mating surfaces on the housing and on the
electrical enclosure covers
• Reinstall all the screws that go with the dismantled parts, and block them with a
thread sealant after spreading them with a lm of copper- or molybdenum-based
grease. This will keep screws from sticking and make maintenance operations easier
• Check that the bolts and screws are the same dimension and quality as the
original ones (as stated on the nameplate), or a better quality
• Replace the weatherproof seals that may have been removed (O-ring for the covers)
NOTE
In case the screws of the cover, of the terminal compartment and of the OM3 must be
replaced, SS Aisi 316 Class A4 grade 80 screw must be used with minimum yield strength
600 N/mm², The screw size is M6 X 25 mm. Other screws used for the assembly of
the other various parts of the explosionproof enclosure shall be a SS AISI 316 Class A4
Grade 70, with minimum yield strength of 450 N/mm².
Every time the main cover, the terminal compartment cover and the OM3 are
reassembled, make sure to tight all the screws with 5 Nm torque.
24
Installation
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
WARNING
!
Do not electrically operate the Keystone EPI2 when the electrical enclosures are removed.
Do not open the actuator covers when an explosive atmosphere may be present.
Ignoring the above precautions could cause personal injury.
NOTE
Each time the covers are opened or removed the condition of the seals must be checked.
In case the seals are replaced, original spares must be supplied by Emerson.
NOTE
Keystone EPI2 electric actuators must be installed and maintained according to the
applicable rules regarding the electrical installation in hazardous areas (other than
mines) classied as zone 21 and/or 22 (dust) according to EN 60079-10 (hazardous area
classication). Example: installation and maintenance according to EN 50281-1-2.
Section 4: Installation
October 2020
Special attention is requested to the following:
• Before the assembly the joint surfaces must be greased with silicone oil or equivalent
• Cable glands must have minimum protection degree IP66/68 (EN 60529)
• Periodically verify the quantity of dust deposited on the enclosure and clean it if
more than 5 mm using a damp cloth to avoid static electricity
Installation
25
Section 5: Lubrication
October 2020
Installation, Operation and Maintenance Manual
Section 5: Lubrication
5.1 Lubrication Inspection
The actuator is grease lubricated for life, therefore under normal working conditions no
grease needs to be replaced or added.
In case of maintenance the following grease is recommended:
• AEROSHELL GREASE 7 or equivalent, for ambient temperature -40 °C to +70 °C
(-40 °F to +158 °F).
MAN-10-04-100-0711-EN Rev. 0
26
Lubrication
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 6: Actuator Conguration
Section 6: Actuator Conguration
Before connecting power to the actuator, check that the voltages are correct and
according to the indications on the nameplate. Wrong power supply could cause
permanent damage to the electrical components.
The conguration of the Keystone EPI2 actuator can be carried out through the control
panel inside the actuator control system. To access the panel, remove the actuator cover
and when the conguration is complete replace the cover, following the procedures
indicated on next page.
NOTE
When optional local control panel OM3 is installed and the actuator setting is done by means
of the pushbuttons on the logic board, the remote controls do not have to be energized.
October 2020
Actuator Conguration
27
Section 6: Actuator Conguration
October 2020
Installation, Operation and Maintenance Manual
6.1 Removal of the Control Unit Cover
Using a 5 mm Allen key, loosen the four screws and remove the cover.
NOTE
When setting the actuator parameters do not operate the actuator neither remotely nor locally.
WARNING
!
Pay attention not to damage the joint surfaces of the cover.
NOTE
In case the screws of the cover must be replaced, SS Class A4 grade 80 screw must be used
with minimum yield strength 600 N/mm
2
.
MAN-10-04-100-0711-EN Rev. 0
Once the conguration is completed, reassemble the actuator cover.
Figure 14 Removal of the Control Unit Cover
28
Actuator Conguration
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 6: Actuator Conguration
6.2 Local Conguration of the Keystone EPI2
WARNING
!
The conguration must be done while the actuator is powered on. As a consequence,
all conguration operations must be carried out by specically qualied personnel for
operations on powered electronic cards.
6.2.1 Keystone EPI2 Default General Conguration
NOTE
The actuators are set in the workshop with the following conguration (default value):
• CL limit switch by position
• OP limit switch by position
• Stroking time in CL (6): 28 s for models 063/125/250/500, 45 s for model 1000 and
100 s for model 2000
• Stroking time in OP (6): 28 s for models 063/125/250/500, 45 s for model 1000 and
100 s for model 2000
• Torque limiting device in CL set at about 100% of nominal torque
• Torque limiting device in OP set at about 100% of nominal torque
• Reverse mode off
• Monitor Relay NC (in normal condition, i.e. without alarms)
• Blinker / Local Selector relay off (always Open)
October 2020
If the application requires different actuator congurations, please proceed as described
in this chapter.
NOTE
Please note that the actuator conguration does not need to be done in succession as
indicated in the following pages. Each parameter can be set independently.
The conguration of the actuator parameters is done through the following tools:
• Two rotary selector switches SW6 and SW4 for actuator conguration
• Enter pushbutton SW5 (conrmation pushbutton)
• Dip switch SW3 (enable conguration function)
• Green LED indicating power ON (switched on when power supply is available)
• Red LED for Enter conrmation (ON onceconguration is conrmed)
• Mechanical stops
Actuator Conguration
29
Section 6: Actuator Conguration
October 2020
Figure 15 Conguration of the actuator parameters
Table 5. Set-up Base Card
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Set-up
Close limit 0 0 ON PUSH n.d.
Open limit 1 0 ON PUSH n.d.
L/S close
L/S open
Closing speed
Opening speed
% Closing
torque
% Opening
torque
CW/CCW
Size
Nm / in-lb
Blinker /
Local Selector
Heater
Inversion
colours LED of
local control
Remote
control
Rotary switches position Dip switch Enter button
SW4 SW6 SW3 SW5
2 1: by position ON PUSH
2 0: by torque ON PUSH
3 1: by position ON PUSH
3 0: by torque ON PUSH
4 4 ON PUSH
4 8 ON PUSH
5 4 ON PUSH
5 8 ON PUSH
6 2: 50% ON PUSH
6 9: 100% ON PUSH
7 2: 50% ON PUSH
7 9: 100% ON PUSH
8 0: CW; ON PUSH
8 1: CCW; ON PUSH
9
9
9 3: 1000 Nm ON PUSH
9 4: 2000 Nm ON PUSH
0 8: Nm ON PUSH
0 9: in-lb ON PUSH
4 0: Off ON PUSH
4 2: Local Selector ON PUSH
8 9: Active ON PUSH
8 8: Not active ON PUSH
9 2 ON PUSH
9
0: 63 Nm / 250 Nm
1: 125 Nm / 500 Nm
5 = 3 wires
6 = 2 wires
ON PUSH
ON PUSH
ON PUSH 5
LED Open: Green
LED Close: Red
Default
1
1
64 6 ON PUSH
65 6 ON PUSH
96 5: 75% ON PUSH
97 5: 75% ON PUSH
0
0
8
04 1: Blinker ON PUSH
9
30
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Installation, Operation and Maintenance Manual
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Section 6: Actuator Conguration
6.2.2 Close Limit Conguration by Position
Enter set up conguration:
• Move switch SW4 to position 2
• Move switch SW6 to position 1
• Move switch SW3 to position ON
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration, moving switch SW3 to position 1 or proceed with the
next parameter
6.2.3 Close Limit Conguration
• Move switch SW3 to position ON
• Drive the actuator to the close position using the handwheel
• Move switch SW4 to position 0
• Move switch SW6 to position 0
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration, moving switch SW3 to position 1 or proceed with the
next parameter
October 2020
6.2.4 Open Limit Conguration by Position
• Move switch SW4 to position 3
• Move switch SW6 to position 1
• Move switch SW3 to position ON
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration, moving switch SW3 to position 1 or proceed with the
next parameter
Actuator Conguration
31
Section 6: Actuator Conguration
October 2020
Installation, Operation and Maintenance Manual
6.2.5 Open Limit Conguration
• Move switch SW3 to position ON
• Drive the actuator to the open position using the handwheel
• Move switch SW4 to position 1
• Move switch SW6 to position 0
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration, moving switch SW3 to position 1 or proceed with the
next parameter
6.2.6 Close Limit Conguration by Torque
• Move switch SW4 to position 2
• Move switch SW6 to position 0
• Move switch SW3 to position ON
• Conrm by pushing ENTER pushbutton SW5 (red LED switch on)
• Operate the actuator to closing direction by local/remote control and wait until it
stops by torque
• When the setting is completed, the red LED switches off
• Exit set up conguration, moving switch SW3 to position 1 or proceed with the
next parameter
MAN-10-04-100-0711-EN Rev. 0
6.2.7 Open Limit Conguration by Torque
• Move switch SW4 to position 3
• Move switch SW6 to position 0
• Move switch SW3 to position ON
• Conrm by pushing ENTER pushbutton SW5 (red LED switch on)
• Operate the actuator to opening direction by local/remote control and wait until
it stops by torque
• When the setting is completed, the red LED switches off
• Exit set up conguration, moving switch SW3 to position 1 or proceed with the
next parameter
32
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NOTE
During the new stroke limit setup, the minimum range between open and close limit
position has to be at least 45 degree of the valve position; if the above condition is not
respected, the setup will not be successful and stroke limit error alarm will be signalized
(red LED blinking). The red LED will continuously ash when the actuator is in setup
functionality (dip switch SW3 in ‘on’ position) and rotary switches SW4 and SW6 are in
one of the following positions:
a. SW4=3 and SW6=0
(stroke limit of open conguration by torque)
b. SW4=2 and SW6=0
(stroke limit of close conguration by torque)
c. SW4=1 and SW6=0
(stroke limit of open conguration by position)
d. SW4=0 e SW6=0
(stroke limit of close conguration by position)
The alarm is then reset by:
a. Switching off and on the actuator
b. Doing a new correct stroke limit setup in one of the 4 possible combinations.
Section 6: Actuator Conguration
October 2020
WARNING
!
In conguration phase, touch only the conguration area of the logic board; don’t touch
the actuator in its other parts.
6.2.8 Stroking Time Selection in Closing
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 4
• Move switch SW6 to positions 4, 6, 8 for the requested stroking time according
to the table below
• Push ENTER pushbutton SW5 to conrm
• When pushing SW5, the red LED switches on for conrmation
• The selected stroking time in closing is now set
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
Actuator Conguration
33
Section 6: Actuator Conguration
October 2020
Installation, Operation and Maintenance Manual
6.2.9 Stroking Time Selection in Opening
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 5
• Move switch SW6 to positions 4, 6, 8 for the requested stroking time according
to the table below
• Push ENTER pushbutton SW5 to conrm
• When pushing SW5, the red LED switches on for conrmation
• The selected stroking time in opening is now set
• Exit conguration (move switch SW3 to position 1) or proceed with
the next parameter
Table 6. Operating Times
MAN-10-04-100-0711-EN Rev. 0
Model
063/E006 63/600 15 28 48
125/E013 125/1300 15 28 48
250/E025 250/2500 15 28 48
500/E051 500/5100 15 28 48
1000/E091 1000/9100 24 45 80
2000/E171 2000/17700 53 100 180
NOTE: Time is guaranteed with +/- 10% tolerance on 90° stroke
Nominal torque
(Nm / lb.in.)
Operating time (secs 90°) at selected step
8 6 4
6.2.10 Setting of the Torque Limiting Device in Closing
Closing torque limits: 50%, 75% and 100% of the nominal torque. The nominal torque
corresponding to 100% is set in-house and stated in the name plate.
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 6
• Move switch SW6 to positions 2, 5 or 9 for the requested torque value
(in percentage) in closing
• Push ENTER pushbutton SW5 to conrm
• When pushing SW5, the red LED switches on for conrmation
• The setting of the torque limiting device in closing maneuver is now complete
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
34
WARNING
!
Torque switches setting must be done only with the authorization of the valve manufacturer,
considering the specic valve gures.
Actuator Conguration
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 6: Actuator Conguration
October 2020
6.2.11 Conguration of the Torque Limiting Device in Opening
Opening torque limits: 50%, 75% and 100% of the nominal torque. The nominal torque
corresponding to 100% is set in-house and stated in the name plate.
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move SW4 switch to position 7
• Move switch SW6 to positions 2, 5 or 9 for the requested Torque value
(in percentage) in opening
• Push ENTER pushbutton SW5 to conrm
• When pushing SW5, the red led switches on for conrmation
• The setting of the torque limiting device in opening is now complete
• Exit set up conguration (move switch SW3 to position 1) or proceed
with the next parameter
WARNING
!
To
rque switches setting must be done only with the authorization of the valve manufacturer
considering the specic valve gures.
6.2.12 Reverse Mode Conguration
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 8
• Move switch SW6 to position:
1 counter-clockwise (CCW) ON
0 counter-clockwise
• Push ENTER pushbutton SW5 to conrm
• When pushing SW5, the red LED switches on for conrmation
• Reverse mode (CCW) set is now completed
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
(CCW) OFF
,
Actuator Conguration
35
Section 6: Actuator Conguration
October 2020
Installation, Operation and Maintenance Manual
6.2.13 Actuator Model Selection
The frames relevant to models 63/125 and 250/500 can be set to operate with a 63 Nm
or 125 Nm motor and a 250 Nm or 500 Nm motor respectively. The difference is based on
the technical characteristics of the electric motor itself.
Actuator model 63
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 9
• Move switch SW6 to position 0
• Conrm by pushing ENTER pushbutton, SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
Actuator model 125
MAN-10-04-100-0711-EN Rev. 0
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 9
• Move switch SW6 to position 1
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
Actuator model 250
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 9
• Move switch SW6 to position 0
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
36
Actuator Conguration
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 6: Actuator Conguration
Actuator model 500, 1000, 2000
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 9
• Move switch SW6 to position 1
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
6.2.14 Blinker / Local Selector Conguration
Default conguration for Blinker / Local Selector relay is off (always Open). In Blinker
conguration, during actuator movement the relay changes their status each 500 ms (Motor
Running function). In Local Selector conguration (with Local Interface OM3 installed), the relay
is CLOSE when OM3 switch is on REMOTE, while it is OPEN when OM3 switch is on LOCAL.
October 2020
To congure Blinker or Local Selector monitoring function (when OM3 is present):
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 4
• Move switch SW6 to position 1 (Blinker) or 2 (Local Selector)
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
• Exit set up conguration (move switchSW3 to position 1) or proceed with
the next parameter
Actuator Conguration
37
Section 6: Actuator Conguration
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
6.2.15 3-WIRES/ 2-WIRES Remote Control Conguration
Remote Control in 3-WIRES conguration works as follow: command on terminal 35 to OPEN,
command on terminal 36 to CLOSE. Remote Control in 2-WIRES conguration works as
follow: command present on terminal 35 to OPEN, command absent on terminal 35 to CLOSE;
terminal 36 not used. As default, remote command parameter is congured as 3-WIRES.
To congure Remote Control parameter:
• Enter set up conguration: move switch SW3 to position ON (conguration function)
• Move switch SW4 to position 9
• Move switch SW6 to position 5 (3-WIRES) or 6 (2-WIRES)
• Conrm by pushing ENTER pushbutton SW5
• When pushing SW5, the red LED switches on for conrmation
•
Exit set up conguration (move switch SW3 to position 1) or proceed with
the next parameter
6.3 Conguration of the Keystone EPI2 by a
PDA / PC and ‘A Manager’ Software
If one of the optional module OM1, OM9 or OM11 is installed on the Keystone EPI2 and
this card features Bluetooth interface, the actuator conguration can be performed by
means of the ‘A Manager’ software installed on the PDA or PC.
Only Blinker/ Local Selector relay and heater cannot be congured by means ‘A Manager’
software. The relevant Instruction and Operating Manual is available with the
‘A Manager’ software.
WARNING
!
The controls available via Bluetooth allow full actuator operability at a distance.
Emerson will not accept any responsibility for damages or injuries caused by an improper
use of your Bluetooth PDA.
38
Actuator Conguration
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 6: Actuator Conguration
6.4 Hardware Conguration for Monitor Relay
The Monitor Relay indicates the followings failures:
• Loss of power
• Stop by Torque out of limits
• Direction failure
• Temperature too high
• Position sensor failure
• Local control panel with selector in local position
• Valve jammed
• Hardware malfunction
• Alarm on the local control panel (if present)
• Stroke failure
• Missing input 4-20 mA (if OM1 optional module present)
• A Manager local control (if Bluetooth is present)
The Monitor relay contacts can be set as CLOSE or OPEN by changing the welding of
JUMPER J31 on logic board. As a default setting, pins 2 and 3 are welded together, and the
Monitor relay contact operates as follows:
October 2020
— contact CLOSE in normal condition with relay energized, and OPEN in
case of malfunction (relay is de-energized).
In case of request, if contact must be OPEN in normal condition and CLOSE in case of
malfunction, the contact of JUMPER J31 must be modied welding pins 1 and 2 together.
WARNING
!
Conguration of Monitor Relay by means JUMPER J31 is a hardware conguration. For this
reason, to congure Monitor Relay is mandatory manage actuator without power supply.
Actuator Conguration
39
Section 7: Maintenance and Troubleshooting
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 7: Maintenance and Troubleshooting
7.1 Maintenance
7.1.1 Routine Maintenance
Approximately every 2 years:
Under normal operating conditions, the Keystone EPI2 is maintenance-free: no actuator
maintenance is formally required, even though visual inspection for grease leakage or
external visible damages is recommended every two years. When conditions are severe
(frequent operation or high temperatures), replace all seals that allow grease leakage or
water inlet.
NOTE
Before starting any maintenance operation, make sure that the mains and all other
service voltage connected to the terminal board are switched-off.
The following checks will assure optimum performance:
• Make sure there are no grease leaks from the actuator housing
• Check the external parts for possible damage and replace them immediately,
if necessary. In case the window glass is broken, the complete cover must be
replaced (see Chapter 8 for individual item numbers)
• Repaint all areas where paint is missing. In chemically aggressive or saline
environments, remove rust from surfaces and protect with a rust preventative
• Check that all nuts and bolts securing the actuator to the valve are tight.
If necessary, re-tighten with a dynamometric key
• For severe applications or if actuator operation is infrequent,
perform maintenance checks more often
7.1.2 Special Maintenance
In case of actuator failure, please refer to Section ‘Trouble shooting’, Chapter 7.2, for
possible causes. Spare parts can be required from Emerson: please refer to the individual
item number shown in Chapter 8.
In case of malfunction in the mechanical / electronic components, in case of grease leaks
through the seals or in case of scheduled preventive maintenance, the actuator must be
disassembled: any damaged parts can be requested from Emerson with reference to the
attached exploded view drawings and parts lists.
40
It is essential that for every component to be required from Emerson the serial number of
the actuator together with the item number of the component are indicated in the request.
NOTE
After maintenance work a few operations must be performed to make sure that
movement is regular and there is no grease leakage through the seals.
Maintenance and Troubleshooting
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
NOTE
Special maintenance is also recommended when, during operations, the actuator
generates an excessive noise.
7.2 Troubleshooting
All Keystone EPI2 actuators have passed the functional test performed by Emerson
Quality Assurance personnel.
If the actuator does not work, before troubleshooting make sure that:
• The main supply is the same as stated in the name plate menu
• The green LED for available power supply is switched on
• Power supply is available to the actuator and no protective device has declutched
in the plant
• Check the position of the dip switch SW3; it must be ‘1’
Section 7: Maintenance and Troubleshooting
October 2020
7.2.1 The Electronics do not Switch on When Powered
• Check that the value of the main voltage on terminals L1 and L2
(and in the same case L3) is correct
• Remove the cover assembly
• Check the continuity of the wires between terminals L1, L2, L3 and the connector
of the power card
• If there is no continuity on the L1-L2-L3 cables, replace the terminal board
• If continuity on the L1, L2, L3 cables is ok, replace the entire drive and control unit
7.2.2 24 V DC Output Voltage not Available at the Terminals
• Switch the main power supply off and disconnect all wires from terminals 33 and 34
• Switch the main power supply on and check if the voltage on terminals 33 and 34
is between 22 and 26 V DC
• If the voltage is correct check the external wiring and the electrical load. It should
not exceed 4 W
• If the voltage is not correct, replace the entire drive and control unit
Maintenance and Troubleshooting
41
Section 7: Maintenance and Troubleshooting
October 2020
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
7.2.3 The Actuator does not work from Remote Controls
Check that:
• The wiring to terminals 32, 35 and 36 is correct
• There is no short circuit between wires
• The electrical load does not exceed 4 W
• If external voltage is used, the value has to be in the 24-120 V AC/DC range
7.2.4 The motor is Very Hot and does not Start
• Wait until the motor cools down before trying to operate the actuator again
• Check that the number of operations per hour and their duration is suitable for
the actuator service (see the name-plate)
• Check that the valve operating torque is within the range of the unit’s designed
operating torque
• Always check the causes of abnormal operation
7.2.5 The Motor Runs but the Actuator does not
Move the Valve
• Verify that the drive insert correctly ts in the actuator base
• Verify that the drive insert has enough engagement with the valve stem
• Verify that the key correctly ts in bore/ keyways applications
• Check that the valve works in manual operation. If not, it is necessary to check
the manual control area as follows:
— Loosen the handwheel security dowel
— Remove the handwheel
— Check the integrity of the internal parts
— Proceeding with the assembly, follow the reverse order of the disassembly
— Make sure there are no foreign bodies. Pay attention not to damage the
O-ring seals
7.2.6 The Valve does not Seat Correctly
• If the valve is stopped by torque in closing, increase the actuator output torque limit
• If the valve is stopped by position in closing, check that the valve reaches its seat
position, then readjust the setting of the position limit
42
• The internal trim of the valve may be damaged
Maintenance and Troubleshooting
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 7: Maintenance and Troubleshooting
7.2.7 Excessive Torque for Valve Operation
• Clean, lubricate and check the valve stem
• Valve packing too tight: loosen the gland bolt nuts
• Check that the internal valve trim or the reducer gears are well lubricated
and not damaged
7.2.8 The Actuator does not Stop in Fully Open or
Fully Closed Position
• Check that the actual open and close positions of the valve respectively
correspond to 100% and 0%
• Make sure that the torque and travel limits are correctly set (see Chapter 6)
7.2.9 Diagnostic LED
October 2020
For more detailed alarms, check the diagnostic led status (on the logic board).
It has the coding shown in the table:
Table 7.
Number of blinks of the diagnostic LED Description
1x Actuator in intermediate position (NO ALARM)
2x Actuator on CLOSE limit (NO ALARM)
3x Actuator on OPEN limit (NO ALARM)
4x Under-voltage warning on Internal secondary voltage
5x Sensor alarm (no SPI communication)
6x High temperature alarm
7x Bad CRC alarm
8x Motor over-current alarm
9x Stroke limit alarm
10x Jammed alarm
11x High Torque alarm
Sensor Alarm (5x blinks of the diagnostic led).
Check that the position sensor cable is connected.
Check that the position sensor enclosure is not mechanically damaged.
If it is broken, replace the entire electronic group.
Bad CRC Alarm (7x blinks of the diagnostic led).
Restart the power supply: turn off and turn on the actuator.
Maintenance and Troubleshooting
43
Section 8: Decommissioning
October 2020
Installation, Operation and Maintenance Manual
Section 8: Decommissioning
8.1 Disposal and Recycling
At the end of the life of Keystone EPI2, the device must be disassembled. Do not dump
non-biodegradable products, lubricants and non-ferrous materials (rubber, PVC, resins etc.)
into the environment.
Dispose of all such materials as indicated in the following table:
Table 8.
Subject Hazardous Recyclable Disposal
Electrical and
electronic equipment
Glass No Yes Use specialist recyclers
Metals No Yes Use licensed recyclers
Plastics No Yes Use specialist recyclers
Rubber
(seals and O-rings)
Oil and grease Yes Yes
Batteries Yes Yes
Yes Yes Use specialist recyclers
Yes No
MAN-10-04-100-0711-EN Rev. 0
Will require special treatment before
disposal, use specialist waste
disposal companies
Will require special treatment before
disposal, use specialist recyclers or waste
disposal companies
Will require special treatment before
disposal, use specialist recyclers or waste
disposal companies
WARNING
!
Do not re-use parts or components which appear to be in good condition after they have
been checked or replaced by qualied personnel and declared unsuitable for use.
NOTE
In all cases check local authority regulation before disposal.
44
Decommissioning
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Section 9: Parts List and Drawings
Section 9: Parts List and Drawings
This section includes the drawings and parts list of each component and subassembly of
Keystone EPI2 actuators.
NOTE
When ordering spare parts, please indicate the serial number embossed on the
actuator nameplate.
NOTE
When ordering spare parts, please refer to the marked part list items on
the attached drawings.
October 2020
NOTE
Recommended spares for routine maintenance are marked with this sign *on parts list.
Parts List and Drawings
45
Section 9: Parts List and Drawings
October 2020
Table 9. Keystone EPI2 Model 063 - General Assembly
Pos. Description Quantity
1 Nut UNI 5588-M6 2
2 Nut UNI 5588-M8 2
3 Eccentric 1
4 Planocentric gear 2
5 Spacer 1
6 Ball bearing type 16002 1
7 Ball bearing type 16004 2
8 Ball bearing type 6001 1
9 ESH screw UNI 5931-M6x8 1
10 HSHC screw UNI 5931-M6x16 4
11 HSHC screw UNI 5931-M4x14 7
12 HSHC screw UNI 5931-M6x18 2
13 HSHC screw UNI 5931-M6x25 4
14 HSHC screw UNI 5931-M8x20 4
15 HSSC screw UNI 5933-M4x10 1
16 Cover assembly 1
17 Drive and control unit 1
18 Handwheel 1
19 Output drive assembly 1
20 Standard housing 1
21 Stopper 2
22 Terminal block 1
23 Worm shaft ange 1
24 Anti-loosening washer UNI 8842-J6 1
25 Base plate ISO 5211 / F05-F07 1
26 Cover gasket 1*
27 Dowel pin UNI EN 22338 1
28 Earth stud 1
29 Fixed anulus 1
30 Gasket 1*
31 Indicator 1
32 Indicator shaft 1
33 Manual worm shaft 1
34 Motor pinion 1
35 O-ring Di=10.77/W=2.62 1*
36 O-ring Di=18.77/W=1.78 1*
37 O-ring Di=52.07/W=2.62 1*
38 O-ring Di=6.07/W=1.78 1*
39 Plug 1
40 Position label 1
41 Power clamps protection 1
42 Ring 2
43 Ring for pins alignement 1
44 Ring RW 7 UNI 7433 2
45 Seal washer 8.3 2
46 Sliding ring 1
47 Snap ring for shaft D.6 1
48 Terminal block cover 1
49 Terminal board gasket 1*
50 Wheel 1
* Indicates recommended spare parts
46
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 16
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
47
Section 9: Parts List and Drawings
October 2020
Table 10. Keystone EPI2 Model 125 - General Assembly
Pos. Description Quantity
1 Nut UNI 5588-M6 2
2 Nut UNI 5588-M8 2
3 Eccentric 1
4 Planocentric gear 2
5 Spacer 1
6 Ball bearing type 16002 1
7 Ball bearing type 16004 2
8 Ball bearing type 6001 1
9 ESH screw UNI 5931-M6x8 1
10 HSHC screw UNI 5931-M6x16 4
11 HSHC screw UNI 5931-M4x14 7
12 HSHC screw UNI 5931-M6x18 2
13 HSHC screw UNI 5931-M6x25 4
14 HSHC screw UNI 5931-M8x20 4
15 HSSC screw UNI 5933-M4x10 1
16 Cover assembly 1
17 Drive and control unit 1
18 Handwheel 1
19 Output drive assembly 1
20 Standard housing 1
21 Stopper 2
22 Terminal block 1
23 Worm shaft ange 1
24 Anti-loosening washer UNI 8842-J6 1
25 Base plate ISO 5211 / F07-F10 1
26 Cover gasket 1*
27 Dowel pin UNI EN 22338 1
28 Earth stud 1
29 Fixed anulus 1
30 Gasket 1*
31 Indicator 1
32 Indicator shaft 1
33 Manual worm shaft 1
34 Motor pinion 1
35 O-ring Di=10.77/W=2.62 1*
36 O-ring Di=18.77/W=1.78 1*
37 O-ring Di=52.07/W=2.62 1*
38 O-ring Di=6.07/W=1.78 1*
39 Plug 1
40 Position label 1
41 Power clamps protection 1
42 Ring 2
43 Ring for pins alignement 1
44 Ring RW 7 UNI 7433 2
45 Seal washer 8.3 2
46 Sliding ring 1
47 Snap ring for shaft D.6 1
48 Terminal block cover 1
49 Terminal board gasket 1*
50 Wheel 1
* Indicates recommended spare parts
48
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 17
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
49
Section 9: Parts List and Drawings
October 2020
Table 11. Keystone EPI2 Model 250 - General Assembly
Pos. Description Quantity
1 Nut UNI 5588-M12 2
2 Nut UNI 5588-M6 2
3 Eccentric 1
4 Planocentric gear 2
5 Spacer 1
6 Ball bearing type 6005 2
7 Ball bearing type 6202 1
8 Ball bearing type 16002 1
9 ESH screw UNI 5931-M6x8 1
10 HSHC screw UNI 5931-M6x16 4
11 HSHC screw UNI 5931-M10x25 4
12 HSHC screw UNI 5931-M4x14 7
13 HSHC screw UNI 5931-M6x20 2
14 HSHC screw UNI 5931-M6x25 4
15 HSSC screw UNI 5933-M4x10 1
16 HSSC screw UNI 5933-M5x12 3
17 Cover assembly 1
18 Handwheel 1
19 Housing 1
20 Motor pinion 1
21 Output drive assembly 1
22 Stopper 2
23 Terminal block 1
24 Anti-loosening washer UNI 8842-J6 2
25 Base plate ISO 5211 F07-F10-F12 1
26 Cover gasket 1*
27 Dowel pin UNI EN 22338 1
28 Earth stud 1
29 Fixed anulus 1
30 Gasket 1*
31 Indicator 1
32 Indicator shaft 1
33 Manual worm shaft 1
34 O-ring Di=10.77/W=2.62 1*
35 O-ring Di=18.77/W=1.78 1*
36 O-ring Di=6.07/W=1.78 1*
37 O-ring Di=69.52/W=2.62 1*
38 Plug 1
39 Position label 1
40 Power clamps protection 1
41 Ring 1
42 Ring for pins alignement 1
43 Ring RW 10 UNI 7433 2
44 Seal washer 12.3 2
45 Sliding ring 1
46 Snap ring for shaft D.12 1
47 Terminal block cover 1
48 Terminal board gasket 1*
49 Wheel 1
50 Worm shaft ange 1
51 Drive and control assembly 1
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
50
* Indicates recommended spare parts
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 18
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
51
Section 9: Parts List and Drawings
October 2020
Table 12. Keystone EPI2 Model 500 - General Assembly
Pos. Description Quantity
1 Nut UNI 5588-M12 2
2 Nut UNI 5588-M6 2
3 Eccentric 1
4 Planocentric gear 2
5 Spacer 1
6 Ball bearing type 6005 2
7 Ball bearing type 6202 1
8 Ball bearing type 16002 1
9 ESH screw UNI 5931-M6x8 1
10 HSHC screw UNI 5931-M6x16 4
11 HSHC screw UNI 5931-M10x25 4
12 HSHC screw UNI 5931-M4x14 7
13 HSHC screw UNI 5931-M6x20 2
14 HSHC screw UNI 5931-M6x25 4
15 HSSC screw UNI 5933-M4x10 1
16 HSSC screw UNI 5933-M5x12 3
17 Cover assembly 1
18 Drive and control assembly 1
19 Handwheel 1
20 Housing 1
21 Motor pinion 1
22 Output drive assembly 1
23 Stopper 2
24 Terminal block 1
25 Anti-loosening washer UNI 8842-J6 2
26 Base plate ISO 5211 F10-F12 1
27 Cover gasket 1*
28 Dowel pin UNI EN 22338 1
29 Earth stud 1
30 Fixed anulus 1
31 Gasket 1*
32 Indicator 1
33 Indicator shaft 1
34 Manual worm shaft 1
35 O-ring Di=10.77/W=2.62 1*
36 O-ring Di=18.77/W=1.78 1*
37 O-ring Di=6.07/W=1.78 1*
38 O-ring Di=69.52/W=2.62 1*
39 Plug 1
40 Position label 1
41 Power clamps protection 1
42 Ring 1
43 Ring for pins alignement 1
44 Ring RW 10 UNI 7433 2
45 Seal washer 12.3 2
46 Sliding ring 1
47 Snap ring for shaft D.12 1
48 Terminal block cover 1
49 Terminal board gasket 1*
50 Wheel 1
51 Worm shaft ange 1
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
52
* Indicates recommended spare parts
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 19
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
53
Section 9: Parts List and Drawings
October 2020
Table 13. Keystone EPI2 Model 1000 - General Assembly
Pos. Description Quantity
1 Nut UNI 5588-M16 2
2 Nut UNI 5588-M6 2
3 Eccentric 1
4 Planocentric gear 2
5 Spacer 1
6 Ball bearing type 6305 2
7 Ball bearing type 16002 1
8 Ball bearing type NJ202ECP 1
9 ESH screw UNI 5931-M6x8 1
10 HSHC screw UNI 5931-M12x65 4
11 HSHC screw UNI 5931-M4x14 7
12 HSHC screw UNI 5931-M6x25 4
13 HSHC screw UNI 5931-M8x25 A4-70 2
14 HSSC screw UNI 5933-M6x20 1
15 HSSC screw UNI 5933-M4x10 1
16 HSSC screw UNI 5933-M5x12 3
17 Cover assembly 1
18 Drive and control assembly 1
19 Handwheel assembly 1
20 Output drive assembly 1
21 Stopper 2
22 Terminal block 1
23 Terminal cover gasket 2*
24 Anti-loosening washer UNI 8842-J6 2
25 Base plate ISO 5211 F10-F14 1
26 Cover gasket 1*
27 Dowel pin UNI EN 22338 1
28 Earth stud 1
29 Fixed anulus 1
30 Housing 1
31 Indicator 1
32 Indicator shaft 1
33 Manual worm shaft 1
34 Motor pinion 1
35 O-ring Di=13.94/W=2.62 1*
36 O-ring Di=25.12/W=1.78 1*
37 O-ring Di=6.07/W=1.78 1*
38 O-ring Di=82.22/W=2.62 1*
39 Plug 1
40 Position label 1
41 Power clamps protection 1
42 Ring 1
43 Ring for pins alignement 1
44 Ring RW 14 UNI 7433 2
45 Seal washer 16.3 2
46 Sliding ring 2
47 Terminal board gasket 1*
48 Washer 1
49 Wheel 1
50 Worm shaft ange 1
51 Terminal block cover 1
52 HSHC screw UNI 5931-M6x18 4
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
54
* Indicates recommended spare parts
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 20
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
55
Section 9: Parts List and Drawings
October 2020
Table 14. Keystone EPI2 Model 2000 (Gear Reducer) - General Assembly
Pos. Description Quantity
1 Nut M20 ISO 4032 EN 24032 2
2 Ball bearing type 6006 1
3 Ball bearing type 16004 1
4 Ball bearing type 61908 1
5 HSHC screw UNI 5931-M6x16 3
6 HSHC screw UNI 5931-M12x30 4
7 HSHC screw UNI 5931-M12x65 4
8 HSHC screw UNI 5931-M8x25 A4-70 6
9 Keystone EPI2 actuator 1
10 Base housing 1
11 Base plate F12-F16 EN ISO 5211 1
12 Bearing support 1
13 Bushing 2
14 Bushing 1
15 Bushing 1
16 Bushing 1
17 Dowel pin UNI EN 22338 D.8x20 type B 4
18 Gasket 1*
19 Hex head screw UNI EN 24017-M20x80 2
20 Idle wheel shaft 1
21 Needle bearing type NKI 22/16 2
22 O-ring Di=82.22/W=2.62 1*
23 Position wheel 1
24 Seal washer 20.3 2
25 Sector gear 1
26 Sliding ring 1
27 Upper cover 1
28 Wheel 2
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
* Indicates recommended spare parts
56
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 21
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
57
Section 9: Parts List and Drawings
October 2020
Table 15. Keystone EPI2 Model 2000 (Actuator) - General Assembly
Pos. Description Quantity
1 Nut UNI 5588-M6 2
2 Eccentric 1
3 Planocentric gear 2
4 Spacer 1
5 Ball bearing type 6305 2
6 Ball bearing type 16002 1
7 Roller bearing type NJ202ECP 1
8 ESH screw UNI 5931-M6x8 1
9 HSHC screw UNI 5931-M4x14 7
10 HSHC screw UNI 5931-M6x25 4
11 HSHC screw UNI 5931-M8x25 A4-70 2
12 HSSC screw UNI 5933-M6x20 1
13 HSSC screw UNI 5933-M4x10 1
14 HSSC screw UNI 5933-M5x12 3
15 Cover assembly 1
16 Drive and control assembly 1
17 Handwheel assembly 1
18 Housing 1
19 Output drive assembly 1
20 Terminal block 1
21 Terminal cover gasket 1*
22 Worm shaft ange 1
23 Anti-loosening washer UNI 8842-J6 2
24 Bushing 1
25 Cover gasket 1*
26 Dowel pin UNI EN 22338 1
27 Earth stud 1
28 Fixed anulus 1
29 Hex head screw UNI EN 24017-M16x30 2
30 Indicator 1
31 Indicator shaft 1
32 Manual worm shaft 1
33 Motor pinion 1
34 O-ring Di=13.94/W=2.62 1*
35 O-ring Di=25.12/W=1.78 1*
36 O-ring Di=6.07/W=1.78 1*
37 O-ring Di=82.22/W=2.62 1*
38 Plug 1
39 Position label 1
40 Power clamps protection 1
41 Ring 1
42 Ring for pins alignement 1
43 Seal washer 16.3 2
44 Terminal board gasket 1*
45 Washer 1
46 Wheel 1
47 Terminal block cover 1
48 HSHC screw UNI 5931-M6x18 4
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
58
* Indicates recommended spare parts
Parts List and Drawings
Installation, Operation and Maintenance Manual
MAN-10-04-100-0711-EN Rev. 0
Figure 22
Section 9: Parts List and Drawings
October 2020
Parts List and Drawings
59
World Area Conguration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers.
Choose the WACC or sales ofce nearest you:
NORTH & SOUTH AMERICA
19200 Northwest Freeway
Houston TX 77065
USA
T +1 281 477 4100
Av. Hollingsworth
325 Iporanga Sorocaba
SP 18087-105
Brazil
MIDDLE EAST & AFRICA
P. O. Box 17033
Jebel Ali Free Zone
Dubai
T +971 4 811 8100
P. O. Box 10305
Jubail 31961
Saudi Arabia
T +966 3 340 8650
T +55 15 3413 8888
24 Angus Crescent
ASIA PACIFIC
Longmeadow Business Estate East
P.O. Box 6908 Greenstone
No. 9 Gul Road
#01-02 Singapore 629361
T +65 6777 8211
No. 1 Lai Yuan Road
1616 Modderfontein Extension 5
South Africa
T +27 11 451 3700
EUROPE
Wuqing Development Area
Tianjin 301700
P. R. China
T +86 22 8212 3300
Holland Fasor 6
Székesfehérvár 8000
Hungary
T +36 22 53 09 50
Strada Biffi 165
29017 Fiorenzuola d’Arda (PC)
Italy
T +39 0523 944 411
For complete list of sales and manufacturing sites, please visit
www.emerson.com/actuationtechnologieslocations or contact us at
info.actuationtechnologies@emerson.com
www.emerson.com
VCIOM-15516-EN ©2020 Emerson. All rights reserved.
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TM
Keystone
is a mark of one of the Emerson family of companies.
All other marks are property of their respective owners.
The contents of this publication are presented for informational purposes
only, and while every effort has been made to ensure their accuracy,
they are not to be construed as warranties or guarantees, express or
implied, regarding the products or services described herein or their use
or applicability. All sales are governed by our terms and conditions, which
are available upon request. We reserve the right to modify or improve the
designs or specifications of such products at any time without notice.
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