ZPA Pecky Modact MOKP 100 Ex, Modact MOKP 250 Ex, Modact MOKP 600 Ex Assembly And Operation Manual

INSTRUCTION FOR ASSEMBLY

Electric actuators, rotating,

single speed,

in non-explosive version, with constant

velocity of changing-over the output part

- coverage IP67

Type numbers 52 320 - 52 322

AND OPERATION

10/13

The instructions for assembly and operation lay down basic principles of fitting, connection, adjustment, operation,
maintenance and repairs of electric explosion-proof actuators. The principle assumption is that assembly, operation,
maintenance, and revisions are carried out by skilled experts authorized for operation of and works on explosion-proof
electric installations, and professional supervision is performed by a person professionally qualified and demonstrably
instructed.

APPLICATION

MODACT MOKP Ex electric actuators in non-explosive version are intended for control and operation in an environment

with danger of explosion of explosive gaseous atmosphere in zone 1 and zone 2 according to ČSN EN 60079-10-1, and for
areas with flammable dust in zone 21 and zone 22 according to ČSN EN 60079-10-2. The actuators are designed in compliance
with the standards ČSN EN 60079-0:2010 a ČSN EN 60079-1:2008 for explosive gaseous atmosphere and with the standard
ČSN EN 60079-31:2010 for areas with flammable dust.

The actuators are used for control of fittings by reverse rotation movement in remote control and automatic control circuits.
They can be used for other appropriate units as well. Special applications should be discussed with the manufacturer.

Actuators MODACT MOKP Ex Control are fitted with an electronic position controller and, in case of the three-phase
version, also with a built-in reversing contactor and a protecting thermal relay. They serve as power terminal elements of
control circuits in regulating physical variables.

The actuators are marked with a label of protection against explosion and symbols of the group and category of the device
according to the type of certification as follows:

II 2GD Ex d IIC T6 Gb -25 ≤ Ta ≤ 55 °C
Ex d IIB T6 Gb -50 ≤ Ta ≤ 55 °C
Ex tb IIIC T80 °C Db -50 ≤ Ta ≤ 55 °C

Nomenclature

Environment with a risk of explosion – environment in which explosive atmosphere can be formed.
Explosive gaseous atmosphere – mixture of flammable substances (in the form of gases, vapours or mist) with air under

atmospheric conditions in which, after initialization, combustion spreads into the non-consumed mixture.
Explosive dust atmosphere – a mixture of flammable substances in the form of dust or fibres with air under atmospheric

conditions where, after ignition, the fire spreads into the non-burnt-out mixtur
Maximum surface temperature – the highest temperature created during operation under the most unfavourable conditions

(however within accepted tolerances) on any part of surface of an electric device which could cause ignition of the surrounding
atmosphere.

Closure – all walls, doors, covers, cable bushings, shaft, bars, pull rods, etc. contributing to the type of protection against
explosion and/or to the degree of protective enclosure (IP) of the electric device.

Explosion-proof closure “d” – type of protection in which parts capable of igniting explosive atmosphere are installed
inside this closure; in case of explosion of the explosive mixture inside the closure, this closure withstands pressure of
explosion and prevents transferring explosion into the surrounding atmosphere.

Zone 1 – is an area in which, in normal operation, probability of occurrence of explosive atmosphere of a mixture of flammable
substance in the form of gas, vapour or mist with air is occasional.

Zone 21 – is an area in which the explosive atmosphere is created by a cloud of whirled flammable dust in air formed
in normal operation is occasional.

e.

Standards

The following basic standards are related to the explosion-proof actuators:
ČSN EN 60 079-14 Regulations for electric devices in areas with a risk of explosion of flammable gases and vapours.
ČSN IEC 60 721 Types of environment for electric devices.
ČSN EN 60 079-0 Electric devices for explosive gaseous atmosphere. General requirements.
ČSN EN 60 079-1 Electric devices for explosive gaseous atmosphere. Explosion-proof closure “d”.
ČSN EN 60 079-10 Electric devices for explosive gaseous atmosphere. Specification of dangerous areas.
ČSN 33 0371 Non-explosive mixtures. Classification and testing methods.
ČSN 34 3205 Operation of electric rotating machines and work with them.
ČSN EN 1127-1 Explosive environments – prevention of and protection against explosion.
ČSN EN 60079-31 Explosive atmospheres. Equipment dust ignition protection by enclosure “t”

3

Marking of explosion-proof properties

It includes the following marks:
Ex The electric device corresponds to the standard ČSN EN 60079-0 and associated standards for various types

of protection against explosion.

d

Marking of type of protection against explosion, explosion-proof closure, according to the standard ČSN EN 60 79-1

tb protection by enclosure “t” according to ČSN EN 60079-31.
IIC, IIB
IIIC
T6 Designation of temperature class of explosion-proof electric device of the Group II, according to ČSN EN 60 079-0.

T 80 °C Maximum surface temperature T of an explosion-proof electric device of group III, according to ČSN EN 60079-0.
Gb Designation of an explosion-proof electric device for explosive gas atmospheres with a “high” level of protection and

according to ČSN EN 60079-0.
Db Designation of an explosion-proof electric device for areas with flammable dust with a “high” level of protection and is

according to ČSN EN 60079-0.
IP 67 Designation of protective enclosure, according to ČSN EN 60079-0 and ČSN EN 60529.

Designation of the group of explosion-proof electric device for explosive gaseous atmosphere, according to ČSN EN 60 079-0.
Designation of the group of explosion-proof electric device for areas with flammable dust, according to ČSN EN 60 079-0.

is not a source of ignition in normal operation or during expected malfunctions,

not a source of ignition in normal operation or during expected malfunctions,

Data on actuators

The actuators are fitted withthe following plates:

1) Plate with data of non-explosive closures:

or

2) Rating and instrument plate contains:

– manufacture's name and address
– type designation of product (type number)
– serial number
– year of production
– rated value of tripping torgue Nm
– rated speed of shifting s/90°
– rated working stroke 90°
– designation of protective enclosure of actuator IP
– weight of actuator kg
– mark of conformity CE
– electrical data of power circuits (voltage and frequency, current and output of electric motor);
– electrical data of control circuit of micro-switches (voltage, current);
– position transmitter (resistance, voltage and/or current)

3) Warning plate

4) Plates on covers with marking of used protection against explosion

or

4

OPERATING CONDITIONS, OPERATING POSITION

The actuators MODACT MOKP Ex (MODACT MOKP EX Control) should withstand the effect of operating conditions

and external influences, classes AC1, AD7, AE6, AF2, AG2, AH2, AK2, AL2, AM-2-2, AN2, AP3, BA4, BC3 a BE3,
according to ČSN 33 2000-5-51 ed. 3.

Surrounding temperature

Operating temperature for the MODACT MOKP Ex is from -25 °C to +55 °C or from -50 °C to +55 °C.

Classes of external influences

Basic characteristics – as extracted from ČSN 33 2000-5-51 ed. 3.

1) AC1 – elevation above sea level ≤ 2000 m

2) AD7 – water occurrence – shallow dipping

3) AE6 – occurrence of foreign solid bodies – strong dustiness. Thick dust layers.

4) AF2 – occurrence of corrosive or polluting substances from atmosphere. Presence of corrosive polluting
substances is significant

5) AG2 – medium mechanical stress by impacts – common industrial processes

6) AH2 – medium mechanical stress by vibrations – common industrial processes

7) AK2 – serious risk of growth of vegetation and moulds

8) AL2 – serious danger of the occurance of animals (insects, birds, small animals)

9) AM-2-2 – normal level of the signal voltage. No additional requirements

2

10) AN2 – medium solar radiation with intensities > 500 W/m

11) AP3 – medium seismic effects; acceleration > 300 Gal ≤ 600 Gal

12) BA4 – personal abilities. Instructed people.

13) BC3 – frequent contact with the earth potential. Persons coming frequently into contat with “live” parts or standing
on a conducting base.

14) BE3 – danger of explosion, production and storage of explosive substances

MODACT MOKP Ex electric actuators in version for surrounding temperature from -50 °C do +55 °C must be
resistant against effect of process conditions characterized by surrounding temperature ranging between -50 °C
and +55 °C.

This version of actuators is fitted with three-phase motors and outfit without a transmitter or with the current transmitter
CPT1/AF.

The above mentioned actuators will be marked with letter F at the last place of the complementary type number,
i.e. 52 32x.xxxxF.

In all markings of non-explosiveness of the actuators type no. 52 32x.xxxxF, the marking of sub-group of the group II
of a non-explosive electric device according to the standard ČSN EN 60079-0 will be changed from IIC to IIB, i.e. to Ex d
IIB 80 °C (T6).

and ≤ 700 W/m

2

When placed on a free area, the actuator should be fitted with a light roofing against direct action of atmospheric
effects. The roof should overlap the contour of the actuator by at least 10 cm at the height 20 – 30 cm.

If the actuator is used at a location with an ambient temperature under -10 °C and/or relative humidity above 80 %, at
a sheltered location, or in the tropical atmosphere, the anti-condensation heater which has been built in all actuators,
should be always used.

The anti-condensation heater is a resistor of rating 10 W and resistance 6.8 kΩ. The feeding circuit of the

anti-condensation heater includes the thermal switch type 228 – 2563 (series 2455R) that opens at temperature 25 °C

±3 °C and closes again when temperature drops to 15 °C ±4 °C.

Note:

A space is considered sheltered if it prevents falling of atmospheric precipitations under angles up to 60° from the vertical.

Working position

The electric actuators MODACT MOKP Ex (MODACT MOKP Ex Control) can operate in any working position.

5

OPERATION MODE, SERVICE LIFE OF ACTUATORS

Operation mode

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.

Mz

starting torque ≥

M

mean value of loading torque

stř

Mv

maximum value of tripping torque

1,3 . Mv

Run time

N

Cycle time

Course of working cycle

Idle time

R

Service life of actuators

The actuator intended for shut-off valves must be able to perform at least 10,000 operating cycles (C - O - C).

The actuator intended for regulating purposes must be able to perform at least 1 million cycles with operation time (during
which the output shaft is moving) at least 250 hours. Service life in operating hours (h) depends on load and number of switching.
Not always, high frequency of switching influences positively accuracy of regulation. For attaining the longest possible faultless
period and service life, frequency of switching is recommended to be set to the lowest number of switching necessary for the given
process. Orientation data of service life derived from the set regulation parameters are shown in the following table.

Service life of actuators for 1 million starts

Service life [h] 830 1 000 2 000 4 000
Number of starts [1/h] Max. number of starts 1200 1 000 500 250

TECHNICAL DATA

Supply voltage

– rated value of alternating electric voltage is 1 x 230 V or 3 x 230/400 V (according to version);
– permitted deviation of feeding voltage is -10 % to + 6 % of rated value;
– rated frequency of feeding voltage is 50 Hz;
– permitted deviation of frequency of feeding voltage is ±2 % of rated value.

In this range of feeding voltage, rated values of all parameters are maintained, except for starting torque that changes
with the second power of deviation of feeding voltage from its rated value. The change is directly proportional to
the change in feeding voltage. Larger deviations of feeding voltage and frequency are not permitted.

Protective enclosure

Protective enclosure of actuators MODACT MOKP Ex IP 67 according to ČSN EN 60 529 (33 0330).

Noise

Level of acoustic pressure A max. 85 dB (A)

Level of acoustic output A max. 95 dB (A)

6

Tripping torque

At the factory, the tripping torque has been adjusted as shown in Table 1, according to the customer’s requirements.
If no tripping torque adjustment has been specified by the customer the maximum tripping torque is adjusted.

Self-locking

Actuator self-locking capacity is provided by mechanical electric motor brake, at actuator type no. 52 320 by mechanic
gearbox brake.

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

The working stroke of MODACT MOKP Ex actuators is 90°.

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 closesthe 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.

ACTUATOR OUTFIT

Torque-limit switches

The actuator is fitted with two torque-limit switches (MO – OPEN, MZ – CLOSE) each of which acts only in one direction of
motion of the actuator output shaft. The torque-limit switches can be set to operate at any point of the working stroke.

The tripping torque can be adjusted within the range shown in Table 1. The torque-limit switches are locked if
the load torque is lost after they have been brought into the OFF-position. This feature secures the actuator against
the so-called “pumping”.

Position-limit switches

The PO – OPEN and PZ – CLOSE position-limit switches limit the actuator working stroke, each being adjusted to
operate in either end position.

Position signalling

For signalling position of the actuator output shaft, two signalling switches, i.e. the SO – OPEN signalling
switch and the SZ – CLOSE signalling switch, are used. Each of these switches acts only in one direction of
output shaft rotation. The operating point of the microswitches can be set within the whole working stroke range
except the narrow band before the operating point of the microswitch used to switch off the electric motor.

Position transmitters

The MODACT MOKP Ex electric actuators can be supplied without position transmitter or can be fitted with position
transmitter:

a) Resistance transmitter 2 x 100 Ω.

Technical parameters:

Position scanning resistance

Turning angle 0° – 160°

Non-linearity ≤ 1 %

Transition resistance max. 1.4 Ω

Permitted voltage 50 V DC

Maximum current 100 mA

7

b) Type CPT 1A passive current transmitter. Power supply to the current loop is not a part of the actuator.
Recommended feeding voltage is 18 – 28 V DC, at maximum loading resistance of the loop 500 Ω. The current
loop should be earthed in one point. Feeding voltage need not be stabilized; however, it must not exceed 30 V or
else the transmitter could be damaged.

Range of CPT 1A is set by a resistance transmitter on the transmitter body and its starting value by corresponding
partial turning of the transmitter.

Technical parameters of CPT 1A:

Scanning of position capacity

Working stroke adjustable 0° – 40° to 0° – 120°

Non-linearity ≤ 1 %

Non-linearity, including gears ≤ 2.5 % (for a maximum stroke of 120°)

Hysteresis, including gears ≤ 5 % (for a maximum stroke of 120°)

(The non-linearity and hysteresis are related to a signal value of 20 mA).

Loading resistance 0 – 500 Ω

Output signal 4 – 20 mA or 20 – 4 mA

Supply voltage for R

for R

Maximum supply voltage ripple 5 %

Maximum transmitter power demand 560 mW

Insulation resistance 20 MΩ at 50 V DC

Insulation strength 50 V DC

Operational environment temperature -25 °C to +60 °C

Operational environment temperature – extended range -25 °C to +70 °C (additional on demand)

Dimensions ø 40 x 25 mm

= 0 – 100 Ω 10 to 20 V DC

load

= 400 – 500 Ω 18 to 28 V DC

load

Type DCPT active current transmitter. Power supply to the current loop is not a part of the actuator. Maximum

c)

Ω

loading resistance of the loop is 500
used as a position sensor.

DCPT can be easily set by two push-buttons with LED diode on the transmitter body.

Technical parameters of DCPT:

Scanning of position contact-less magneto-resistant

Working stroke adjustable 60° – 340°

Non-linearity max. ±1 %

Loading resistance 0 – 500 Ω

Output signal 4 – 20 mA or 20 – 4 mA

Power supply 15 – 28 V DC, < 42 mA

Working temperature -25 °C to +70 °C

Dimensions ø 40 x 25 mm

For the transmitters CPT 1A as well as DCPT, a two-wire connection is used, i.e., the transmitter, the power
supply and the load are connected in series. The user should secure that the two-wire circuit of the current transmitter
is connected to the electric earth of the associated regulator, computer, etc. This connection should only be made at
a single point in any section of the circuit, outside the actuator.

. For variants MODACT MOKP Ex Control with the regulator ZP2.RE4, it is

Position indicator

The actuator is fitted with a local position indicator.

Anti-condensation heater

The actuators are fitted with an anti-condensation heater preventing condensation of water vapour. It is connected to
the AC mains of voltage 230 V.

Local control

Local control serves for controlling the actuator from the site of its installation. It includes two change-over switches:
one with positions “Remote control - Off - Local control”, the other “Open - Stop - Close”.

8

Position regulator

The position regulator built-in in the actuator enables to control position of the output shaft of the actuator and thus
also the valve by the input analog signal.

The control unit is microprocessor-based programmed for regulating the actuator, ascertaining and repairing error
conditions, and for simple setting of regulation parameters.

The regulator design enables to switch off the regulator feeding. If the regulator is not under voltage it does not regulate
but, after its feeding is switched on, the regulator function is automatically restored; the parameters and diagnostic data
stored in the regulator memory are retained.

The regulator circuits compare the input signal with the feedback signal from the position transmitter of the actuator
output shaft. If there is a difference between the input and feedback signals the regulator closes one of the built-in
contactors in the actuator so that the actuator shaft is reset to the position corresponding to magnitude of the input signal.
When the feedback signal is equal to the input signal the actuator stops.

The control parameters are set by functional push-buttons on the regulator or by PC connected to the regulator via
a serial interface for the period of setting the parameters or during the communication module .

ELECTRIC PARAMETERS

External electric connection

The actuators have terminal boards for external connection. The terminal board has terminals for connection of one
1,5 mm

2

conductor or two conductors with the same cross-section 0,5 mm2 each.

Connecting of actuators with connector – on special request.

Actuator internal wiring

The internal wiring diagrams of the MODACT MOKP Ex actuators with terminal designation are shown in this catalogue.

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.

Current rating and maximum voltage of microswitches

Maximum voltage of mikroswitches is 250 V AC as well as DC, at these maximum levels of currents.

MO, MZ 250 V AC / 2 A; 250 V DC / 0,2 A

SO, SZ 250 V AC / 2 A; 250 V DC / 0,2 A

PO, PZ 250 V AC / 2 A; 250 V DC / 0,2 A

The microswitches can only be used as single-circuit devices. Two voltages of different values and phases cannot be
connected to the terminals of the same microswitch.

Isolation resistance

Isolation resistance of electric control circuits against the frame and against each other is min. 20 MΩ. After
a dump test, isolation resistance of control circuits is min. 2 MΩ. See Technical specifications for more details.

Electric strength of electric circuits isolation

Circuit of resistance transmitter 500 V, 50 Hz

Circuit of current transmitter 50 V DC

Circuits of microswitches and 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 ±15 % of the maximum tripping torque

Operating time of the output shaft +10 %

-15 %

Hysteresis of position limit and signalling switches

(working travel) ≤4°

Adjustment of position limit and signalling switches ±1°

Clearance of the output part max. 1,5°

9

of the rated value (in no-load operation)

Protection

The actuators have external and internal protection terminal against electric shock voltage.

The terminals are identified in compliance with ČSN IEC 417 (34 5550).

If isn´t the actuator equipped with overcurrent protection when purchased is needed to ensure that the
protection is secured externally.

TECHNICAL DESCRIPTION

The entire servo drive consists of solid lock “d” marked Ex d IIC 80 °C (T6). If the servo drive is with local control
system, the local control makes another solid lock “d”. Both solid locks are in such case separated by a bushing.

The electric actuators MODACT MOKP Ex consist of two parts:
– Power part -is composed of a single- or three-phase asynchronous electric motor (see table no. 1), countershaft gear

box, planet gear box with output shaft, device for manual control with a hand wheel and floating screw.
– Control part - is identical for the electric actuators MODACT MOKP 250 and 600 Ex. For these types, it differs only in

partial turning of units on the main plate. For the electric actuators type no. 52320 the unit of position and signalling
switches is arranged according to Fig. 1. The control part is composed of the position unit 1, -transmitter of position 2,
moment unit 3, terminal board 4 and heating element 5. The position unit is fitted with four micro-switches, always two for
each direction of the output shaft rotation. The point of switching-over of each micro-switch can be separately adjusted
within the working stroke of the electric actuator. The moment unit has independently adjustable micro-switches - one for
each direction of rotation. The moment switches are not blocked against disconnecting at the engagement moment.
The position transmitter is fitted with a slipping clutch enabling its automatic adjustment with the output shaft. The heating
element 8 (Fig. 1) prevents condensation of water vapour under the control part cover. The position unit and the position
transmitter derive their motion from the output shaft of the electric actuator via a drive wheel or a drive segment - 7.
The moment unit is driven by a “floating screw” of manual control wherein the screw displacement is directly proportional
to twisting moment on the output shaft of the electric actuator. In this way the electric motor can be switched off when
a value of twisting moment is reached to which the moment unit is adjusted.

Warning:

The micro-switches used are of a single-chamber type, i.e. they can operate as a single-position cut-out switch, contact
maker or change-over switch, the moment switches as cut-out switch only - see particular wiring scheme.

If isn´t the actuator equipped with overcurrent protection when purchased is needed to ensure that the protection is
secured externally.

ADJUSTMENT OF ELECTRIC ACTUATOR

a) Stop screws

The stop screws are used to limit the working stroke of the electric actuator to a required value in compliance with and
positions “Closed” or “Opened” of the piping fittings which do not have their own stops. The stop screws are located on
the external side of the electric motor where the external protective terminal is also fitted. When viewing the stop screws,
the right stop screw is intended for the position “Closed” and the left one for the position “Opened”. Herewith, it is assumed
that, when viewed in the direction to the local position indicator, the output shaft moves in the clockwise sense if it rotates in
the direction to “Closed”. Adjustment of the stop screws is carried out in such a way that the stop screws are first released,
the electric actuator with the piping fitting is moved to the position “Closed” and the particular stop screw is rotated until there
is a perceptible increased resistance as the screw strikes against the contact plate of the output shaft of the electric actuator.
The stop screw is secured by proper tightening of its safety nut. Then, the output shaft of the electric actuator is turned to
the position “Opened” and the stop screw is adjusted for the position “Opened” in a similar way.

When adjusting the stop screws of the type no. 52321 care should be taken that the geared segment of drive of
the position and signalling unit in the limit position “Closed” or “Opened” does not strike against the electric motor jacket.

If a tight closure is required in the end position of the piping fitting and, hence, cutting-out of the electric actuator by
means of the moment switches the cutting-out moment should be transferred to the piping fitting. In such case
the particular stop screw is set so that the piping fitting is properly tight when the trips of the output shaft strike against
the stop screw with cutting-out of the moment switch.

The particular moment switch is used for cutting-out the electric actuator. If the stops are to be used for securing
the electric actuator and the piping fitting against damage in case of the position switch failure the stop screws should be

10

set to such a position when reliable cutting out of the position switch takes place and which is still acceptable for the piping
fitting. Herein, the position and moment switches are connected in series. This can only be realized in the case when
a tightly closed piping fitting is not required.

b) Position switches

Position end switches PO, PZ are used for cutting out the electric actuator when it reaches the position of the output
shaft of the electric actuator for which it is set.

The signalling switches SO, SZ are used for signalling the position of the output shaft of the electric actuator.

The position switches are adjusted in such a way that the output shaft is first set to the position where the switch being
adjusted should cut out. Then, the micro-switch cam is released by a particular releasing screw. Releasing is carried out
by turning the releasing screw counterclockwise. The releasing screw should only be turned to the extent sufficient for
releasing the cam. Further turning of the releasing screw would result in retightening the cam.

The signalling switch should be set so that it switches over earlier than the particular position end or moment switch. When
adjusting the position and signalling switches of the electric actuator type no. 52 321, care should be taken that the geared
segment of drive of the position and signalling unit in the limit position “Closed” or “Opened” does not strike against the electric
motor jacket. For the electric actuator type no. 52 320 the cams are secures by friction and by a central grooved nut with
a safety nut which should be released during adjusting. After adjusting they should be properly retightened.

c) Position transmitters

Resistance transmitter

For setting the resistance transmitter of position it is sufficient to reset the output shaft of the electric actuator to either
of the end positions “Opened” or “Closed”. In this way the transmitter of position is automatically set. This is usually done
in setting the stop screws or the position end switches.

Setting of current position transmitter CPT 1A.

Before starting setting the current transmitter it is necessary to set the end-limit positions (torque or position switches)
of the actuator and connect them into the tripping circuit of the electric motor. In case of an external source of feeding
voltage, verification must be carried out that it does not exceed the maximum value 30 V DC (limit value when CPT 1A is
still not damaged). Recommended value is 18 – 28 V DC.

Positive pole of the source is connected to the positive pole of the transmitter CPT 1A; a milli-ammeter of precision at
least 0.5 % connected into the circuit. The current loop must be earthed in one point. The figure does not show the earthing
that can be made at any point of the circuit.

1. Shift the output shaft into the position Closed. During closing, the current signal value should decrease. If it increases

release the transmitter body and, by turning of about 180°, shift to the descending part of the outputcharacteristics. Set

4 mA by fine turning. Tighten the shim plates to secure the transmitter against spontaneousturning.

2. Shift the output shaft to the position Open and set 20 mA using a potentiometer on the transmitter body.

The potentiometer has a range of 12 revolutions and it has no stops so that it cannot be damaged by furtherturning.

3. Once again verify the current value in the position Closed. If it has changed too much repeat the points 1. and 2. If the

required corrections are large this procedure should be repeated several times. After the setting, securethe transmitter

against turning and drip the screws with varnish.

4. Use a voltmeter to check the voltage on the CPT1 terminals. In order to keep linearity of the output signal the voltage

must not drop below 9 V, not even with off-take 20 mA. If this condition is not met it is necessary to increase the feeding

voltage (within the range of recommend values) or to decrease total resistance of the current loop R.

CPT 1A

CPT 1A

red

white

515152

mA V

U UR

11

red

white

52

R

Caution!

The transmitter CPT 1A must not be connected without checking the supply voltage. The transmitter outlet conductors
must neither be connected to the electric actuator frame nor to the earth, not even accidentally.

Before the supply voltage is checked, it is fi rst necessary to disconnect the transmitter from the supply mains.
Measure the voltage on terminals of the electric actuator to which the transmitter is connected – this canbest be done
using a digital voltmeter of input resistance at least 1 MΩ. This voltage should fall within the range of 18 – 25 V DC; in
no case may it exceed 30 V (otherwise the transmitter can be damaged). Then, connect the transmitter so that the
positive pole of the power source is connected to the positive pole of the transmitter, i.e. to the pin with red insulator (r)
+ (nearer to the transmitter centre). The terminal with white coating (wired to the terminal 52) is connected to the
negative pole of the transmitter (white insulator). In the latest design variants the red conductor is plus and the black
one is minus.

A milli-ammeter, preferentially a digital one with accuracy at least 0.5 %, is temporarily connected in series with the
transmitter. The output shaft is moved to the position CLOSE. The signal value should decrease. If this is not the case,
the output shaft should be rotated in the CLOSE direction until the signal starts decreasing and the output shaft reaches
the CLOSE position.

Then, loosen the screws of the transmitter shim plates so that the whole transmitter can be turned to set the current
to 4 mA, and retighten the screws of the shim plates. Thereafter, move the output shaft of the electric actuator to the
position OPEN. Using the resistance trimmer on the transmitter face (nearer to the edge) set the current to 20 mA.
The trimmer has 12 turn and no stops. Hence, it cannot be damaged.

In case the correction of the current 20 mA was considerable repeat adjustment for 4 mA and 20 mA once again.
Disconnect the milli-ammeter. The screw secured by a drop of varnish situated nearer to the centre must not be turned.
Retighten the countershafts fi xing the transmitter shim plates and secure with a drop of varnish against loosening.

After completing the adjusting procedure, check voltage on the transmitter terminals using a voltmeter. The voltage
should fall within the range of 9 – 16 V with current 20 mA.

Note:

The transmitter characteristics has two branches: the descending one and the ascending one with respect to
the CLOSE position. The characteristics is selected by turning the transmitter body.

Setting of current position transmitter DCPT.

1. Set of end-limit positions

Before starting the setting, verification must be carried out that the end-limit positions are within the range 60° – 340°
of revolution DCPT. Otherwise, after setting, an error arises (LED 2x).

1.1. Position “4 mA”

Set the drive into the required position and press the push-button “4” until LED blinks (about 2 s).

1.2. Position “20 mA”

Set the drive into the required position and press the push-button “20” until LED blinks (about 2 s).

2. Setting of sense of rotation

The sense of rotation is specified by viewing from the side of the panel DCPT.

2.1. Rotating anti-clockwise

Press the push-button “20”, then the push-button “4” and keep them depressed until LED blinks.

2.2. Rotating clockwise

Press the push-button “4”, then the push-button “20” and keep them depressed until LED blinks.

When the sense of rotation is changed the end-limit positions “4 mA” and “20 mA” remain valid but the working range
(track DCPT) between these points is changed to a complement of the original working range. In this way, the permitted
working range can be exceeded (LED 2x) – it can be smaller than 60°.

3. Error messages

In case of an error the diode LED blinks an error code:

1x Sensor position out of working range

2x Working range incorrectly set

3x Off the tolerance level of magnetic field

4x Wrong parameters in EEPROM

5x Wrong parameters in RAM

4. Calibration of currents 4 mA and 20 mA.

On switching-on the power supply, keep the push-buttons “4” and “20” depressed and release them after a single
blink of LED. In this way the option menu 4.1 Calibration of current 4 mA is entered.

12

4.1. Calibration of current 4 mA

Connect the ammeter to testing terminals. Press the push-button “20”. Keep depressed the push-button to evoke
the auto-repeat of current decrease. Release the push-button to make record of the present value.

4.2. Calibration of current 20 mA

Connect the ammeter to testing terminals. Press the push-button “4”. Keep depressed the push-button to evoke
the auto-repeat of current increase. Release the push-button to make record of the present value.

4.3. Switching-over between option of calibration 4 mA and 20 mA

Entry of option of calibration 4 mA:

Press the push-button “4”, then the push-button “20” and keep them depressed until LED blinks.

Entry of option of calibration 20 mA:

Press the push-button “20”, then the push-button “4” and keep them depressed until LED blinks.

5. Record of standard parameters

On switching-on the power supply, keep the push-buttons “4” and “20” depressed and release them after a double
blink of LED.

ATTENTION! With this record, the transmitter calibration is also overwritten and, therefore, it must be repeated!!

Parameter setting

Position "4 mA“

Set the actuator to required position (usually Closed)
and keep the push-button 4 depressed until LED
blinks.

Position "20 mA“

Set the actuator to a required position (usually Open)
and keep the push-button 20 depressed until LED
blinks.

- L
+ L

- U
+ U

1

DCPT

EHL elektronika

v.č. 000106

- L
+ L

- U
+ U

1

DCPT

EHL elektronika

v.č. 000106

20

4

20

4

2 s

2 s

d) Moment switches

The moment switches are factory-set to a prescribed moment. If the moment switches are to be readjusted to another
moment a particular cam is released by a releasing screw (numbers of releasing screws are given in the legend on Fig. 3).
By linear division of the section of a particular scale between zero and maximum cutting-out moment, which is depicted
on the scale by a special mark - colour, a point is received for the required cutting-out moment against which the cam
arrow is set. The releasing screw is then retightened. In manipulating the releasing screws of the moment switches
the same applies as for the releasing screws of the position unit. After setting the moment switches their proper cutting out
function is verified by a neon tester.

Warning: The releasing screws marked 2 and 4 must not be manipulated.

Tripping torque cannot be set to a higher value than those that corresponding to the type No. in tables 1 and 1A.

REGULATOR ZP2.RE4

a) Description

The basic part of the regulator ZP2.RE4 is a microcomputer with control program in its internal memory. The regulator
has its own supply source with mains transformer and stabilizer. Supply voltage is also connected to contacts
of the output relays FO, FZ which are employed by the regulator in controlling the contactor combination. Electronics
of the regulator is protected by a fuse 160 mA, phase for controlling the contactors by a fuse 1.6 A.

The power input circuits of the regulator receive the signals MO and MZ from the limit switches and the signal TP from
the tripping contact of the thermal protection.

13

The control and feedback signals are lead to the A/D converters of the regulator. The regulator compares the value of
the control signal with the value of the feedback signal from the position transmitter. If a regulation deviation is found the
regulator activates one of the output signals FO, or FZ, until the output shaft of the actuator is shifted to a position
corresponding to the magnitude of the control signal.

The regulator sets the position but it does not influence the shifting speed. This is given by the type and version of
the actuator.

Parameters of the regulator are set by the push-buttons SW1 and SW2; the response is monitored on the pilot lights
D3 and D4 (see Fig.1). During the operation, the pilot lights indicate the course of regulation and depict the type of
possible error.

Setting of parameters and monitoring of the actuator run can also be accomplished by the computer with service
program connected to the communication connector of the regulator. The computer can also continuously monitor the
magnitude of the control signal and the current position of the actuator, and read diagnostic data (total operation time and
number of closing of the output relays) which are stored by the regulator in its memory during the operation. Two plates
are fitted on the regulator. One indicates the date of production and serial number of the regulator and the other the
software version. In case of an inquiry or a comment on the regulator function, it is appropriate to state the version of
the software programmed in the given regulator:

The plate with the indicated type and version of the regulator:

ZP2.RE4
“Sixth piece in the seventh month of 2008”.

006/0708

The plate indicating the software version:

EHL SERVO

“Version 4.27 from 2005”.

V 4.27 (c) 2005

b) Technical parameters

Supply voltage: 230 V + 10 % -15 %, 50 – 60 Hz (different voltage on demand)
Protected: 160 mA regulator electronics

1.6 A output control phase

Regulator linearity: 0.5 %
Regulator insensitivity: 1 – 10 % (adjustable)

Input signals, two-parameter:

TEST Connection to /disconnection from OV of direct supply voltage
MO, MZ State of limit switches of actuator (N / 230V)
TP State of thermal relay (N / 230V)
U Inlet of control phase from BMO (-/ 230V)

Input signals, analog:

Control signal: 0/4 – 20 mA (input impedance 250 Ω), 0 – 10 V (input impedance 20 kΩ);
by shielded cable
Feedback signal: Current transmitter 4 – 20 mA (e.g. DICONT CPT1)

Output signals, two-parameter:

FO, FZ Control phase via contacts of relay 5 A / 230 V; protected by fuse 1.6 A
Relay contact OK Error message; contact 24 V / 2 W
Brake control signal 2 mA (for brake module ZP3-BR)
Actuator position I

Output signal, analog:

CPT Current loop of feedback signal (maximum loading resistance 100 Ω)

Signalization:

D3 (yellow) displayed menu / failure message
D4 (red) displayed selection / failure message
D5 (green) feeding
D7 (green/red) drive opens / closes

Setting elements:

push-button SW1 parameter choice
push-button SW2 parameter value selection
Communication connector for connecting the computer with service program ZP2RE4

Range of working temperatures: -25 °C – +75 °C
Dimensions: 75 x 75 x 25 mm

2

C bus bar (signal for additional module)

14

J1 - signal terminal board J2 - power terminal board
1 test input of logic control signal test A OPEN power output "Open"

2 GND control signal - negative pole B CLOSE power output "Close"
3 IN control signal - positive pole C MZ limit switch "Closed"
4 KOK switching contact of error report D MO limit switch "Open"
5 KOK switching contact of error report E TP thermal fuse
6 F S feeding of power outputs
7 1) one-phase electric motors L1
8 2) three-phase electric motors N
9 +24 V feeding of current position transmitter G TR1 feeding of regulator
10 IN IS signal from current position transmitter H TR2

Notes:

The signals MO, MZ, TP and "Test" are input, neither the signal TP nor the signal "Test" need to be connected.
Set the active level (the level of which the regulator evaluates the error status) of signals (TP) and the "test" differently than as set by
the manufacturer of the regulator or by ZPA Pečky a.s. can be done just by computer.

Fig. 1 - Regulator ZP2.RE4 - layout of indicator LEDs, push-buttons, terminals and connectors

Connection of regulator

Mains connection

The actuators MODACT Control with the position regulator ZP2.RE4 are connected and tested in the factory with
the position feedback so that their behaviour is stable. In case the actuator is in a position corresponding to the control
signal and is diverted from this position by an external intervention (for instance by the hand wheel) it is automatically
returned to this position by action of the regulator.

If the actuator is connected to a reverse sequence of phases than that in which it has been set and tested, it will
start behaving unstably. The output shaft is shifted to one of the limit positions and, on reaching it, the actuator is
switched off as, in this case, the limit micro-switch acts on the contactor for motion in the opposite direction. The valve
is thus loaded with maximum torque that the electric motor is able to exert. The loading lasts until the thermal relay
disconnects the motor. The acting torque is higher than the set rated torque and the valve and/or the actuator can be
damaged.

After connecting the actuator to the supply voltage, make sure that the regulator reacts correctly to the changed control
signal and that the drive is switched off by particular limit micro-switches.

15

In case the actuator is not stable, it should be immediately stopped. The best way of doing it is changing over the block
of local control BMO “Local” / “0” / “Remote” to the position “0”. If the actuator is not fitted with BMO the motor can be
stopped by pressing the red push-button O/I on the thermal protection. For some types of protection, the motor stops only
for the period when the push-button is depressed. After releasing, it starts running again.

ATTENTION!

Even after this stopping, the actuator circuits are under voltage. Before any further work on the actuator, the supply
voltage must be switched off!!

The change in sequence of phases causing unstable behaviour can also occur during repairs and/or modifications in
the distribution of the three-phase mains supply!

Low-voltage connection

Galvanic interconnection of the circuits of the current position ttransmitter CPT 1A, the circuits of the control signal,
and the circuits of the terminal TEST is realized in the regulator. Connection of these circuits with the electric earth can
only be realized in one of them. The remaining circuits must not be connected to the earth.

In external circuits, galvanic isolation of the active feedback signal from the circuits of the control signal and the signal
TEST must be established. In case this condition cannot be met, it must be brought out as passive signal via the additional
module (on special order).

The control signal should be lead in by a shielded conductor.

Shielding of the cable of the control signal must be earthed out of the actuator – on the side of the superior system.
On the actuator side, on contrary, its earthing must be prevented.

Setting of regulator ZP2RE4

Adjustable parameters

After fitting to the valve and mechanical adjust­ment, the correct function of the actuator is provided
for by setting the regulator parameters and starting the
auto-calibration. The regulator parameters can be set
by the push-buttons and/or by the computer.
The push-buttons can be used for setting:

Control signal (P1)

Response to the signal TEST and lost control
signal (P2)

Mirroring (P3)

Insensitivity of regulator (P4)

Type of regulation (P5)
In addition, the computer can be used for setting:

Active level of signal TEST

Active level of signal TP

In the push-button setting, the changed parame­ters are stored in the regulator memory in the regime
Auto-calibration. In setting by the computer, the
parameters can also be stored without auto-calibra­tion.

The auto-calibration is an automatic process during
which the regulator detects additional necessary data:

Check of the position transmitter and the sense of
rotation of the output shaft.

Shifting of the shaft to the limit positions Opened
and Closed and recording of particular value from the
position transmitter.

Measurement of the shaft inertia for both directions
of rotation.

In case of an error-free run, it will store the set
parameters and found-out data in the memory. The
auto-calibration is the most precise when the piping
with the valve is filled with the working medium. Before
starting the auto-calibration, the limit switches

Scanning of parameters

Regulation regime

(Type of error signalized by D4)

In case of an error, the auto-calibration regime is abandoned

Storage
in memory

Auto-calibration regime

Fig. 2 - Regime of setting ZP2.RE4

Automatic transition after error-free run

16

(position- and/or torque-limit) of the actuator must be connected and set, and the position transmitter adjusted. If the
torque-limit switches are used as the limit switches it is necessary to verify that the actuator is able to exert required
tripping torque.

The auto-calibration should be started in each case of changed conditions, which can influence error-free function of
the regulator.

For instance, if adjustment of the actuator limit switches is changed or in case of a change in mechanical properties
of the valve (tightened packing, replaced valve, etc.).

Function of push-buttons SW1 and SW2

The regulator parameters are set by means of the push-buttons SW1 and SW2.

Long pressing of the push-button SW1 (L) results in gradual change of the regimes Regulation, Setting and
Auto-calibration.

Long pressing of the push-button SW2 (L) is only used in common function with SW1 (L) in setting the backup parameters.

In the regime Setting, short pressing of the push-button SW1 results is changing over between respective parameters;
short pressing of the push-button SW2 is used for choosing required value of the current parameter.

The procedure of setting the parameters is shown in the Graph.

The pilot lights D3 and D4 indicate the regulator response. In the regime Setting, blinking of D3 signalizes the number
of current parameter and D4 its chosen value.
Table shows in detail meaning of the signalization pilot lights and survey of values of respective parameters.

Values of parameters P1 – P5

Parametr

Response to signal

P1

Control signal

P2

TEST and lost

control signal

P3

Mirroring

P4

Regulator

insensitivity

P5

Regulation

method

D3

(yellow)

1x

2x

3x

4x

5x

D4

(red)

1x 0 – 20 mA

2x 4 – 20 mA

3x 0 – 10 V

1x opens

2x closes

3x drive stop

1x yes

2x no

1x 1 %

2x 2 %

... …

10x 10 %

1x narrow, to torque

2x narrow, to position

3x wide, to torque

4x wide, to position

Value of parameter Note

lower signal opens
higher signal opens

see Notes under
the table
FS - feedback signal
CS - control signal

Note to parameter P5:
“Narrow” – the actuator moves and/or steps exactly to the position determined by CS; parameter P4 is inactive.
“Wide” –

the actuator moves and/or steps to the zone of insensitivity (see parameter P4) of the position determined

by CS.

“To torque” – i n the vicinity of the limit values (for the control signal 4 – 20 mA these values are smaller than 4.2 mA

a higher than 19.8 mA) the actuator does not stop when the control and feedback signalsare identical but goes
on moving until the particular limit switch is activated. If the torque-limitswitch is connected as the limit switch
the valve is thus tightly closed.

“To position” – the actuator is always, even in the vicinity of the limit position, stopped in the position where FS = CS (“narrow”)

or FS = CS – zone of insensitivity (“wide”)

Recommended setting is “narrow, to position”.

Auto-calibration

The auto-calibration is started by shifting the position in the direction Open. To prevent an error, the actuator
should be set in advance to an intermediate position sufficiently distant from the limit positions. If the auto-calibration
is completed without errors the parameters are stored in the regulator memory and the regulator changes

17

automatically to the regime Regulation. In case that an error occurs the parameters are not stored and the actuator
should be reset. After repairing the error and switching-on the feeding, the parameters should be reset and the
auto-calibration repeated.

Operation and error messages in the regime Auto-calibration

Parameter

P6

Auto-calibration

D3

(yellow)

6x no

6x

D4

(red)

3x

4x

5x

8x

Parameter value Note

A. error-free run

A. start on the limit switch or
failure of limit switch

incorrectly connected limit

switch

incorrectly connected or defective
current position sensor CPT

wrong direction of rotation, opposite
connection of the R position sensor

The name "limit switch" indicates
the torque- or position-limit witch,
which is connected in the control
circuit.

Regime of regulation

During the operation, the actuator reacts to the changed control signal. During the regulation intervention, the pilot
light D3 is lit on; during the delay, neither D3 nor D4 is lit on. In case of an error, D4 is lit on and the pilot light D3 blinks
the code of error (see table 1.5.1). After repairing the error, the regulator returns to the regime Regulation.

Operation and error messages

Message

Operation

D3

(yellow)

lit on regulation intervention in progress

no

1x

2x

D4

(red)

no

no

State or type of defect Response to error

Normal operation state
regulation deviation in
the insensitivity zone

Regime TEST According to setting P2.

Voltage control signal missing According to setting P2.

Error

4x

5x

6x

7x

lit on

The actuator switched off by the
limit switches in an intermediate
position (obstacle in the valve)

Error of position transmitter Actuator without response.

Action of TP Actuator without response.

Error in current control signal
(control current < 3.5 mA)

Actuator without response.

Regulation only if the opposite

direction is required.

According to setting P2.

Relay KOK.

An error output from the regulator is, in addition to optical signalization, also the relay KOK contact. If any of the
specified errors occurs the lighting on of the pilot light D4 is accompanied by closing the contact (connectors J1-4 and
J1-5) of the error relay KOK.

Auxiliary functions

Function Test

By connecting terminal connector (J1-1) to the terminal (J1-2) GND, the actuator will shift into a predefined state given
by setting of the parameter P2. If the function TEST is not used terminal J1-1 is not connected. The regulator will shift into
the state given by the parameter P2 also in case of the lost control signal.

Reset

It is applied in case of a suspicion of a software error and for releasing the regulator in an erroneous course of the
Auto-calibration. The function Reset consists in short-time switching off of the regulator feeding (ca 20 s, to allow for
discharging the filtration capacitors in the supply source) and restarting.

18

Setting back-up parameters

If the regulator comes into a state to be cancelled (for
instance, after a larger number of parameters has been
changed) the system can be returned to the basic factory

setting:
Control signal (P1) 4 – 20 mA
Response to signal
Mirroring (P3) no
Insensitivity (P4) 2 %
Type of regulation (P5) narrow, to position
Level of signal TEST active Low
Level of signal TP active High
The last two characteristics may be altered by means of
a computer only.

TEST (P2) stop

Switch off power supply

Press SW1(L)

and SW2(L)

Switch on power supply

Parameters will be stored

in the regulator memory

The standby characteristics setting mode is apparent on
Fig. 3.

Switch off the controller power input.

Press SW 1(L) and SW2(L) at the same time.

Switch on the controller power input and hold the keys
pressed for approx. 2 seconds until the (yellow) signal
light flashes.

Release the keys; the controller changes into Setting
mode.

blinking D3

release

SW1(L) i SW2(L)

Regime *)

Setting

Fig. 3 - Graphic representation of setting

backup parameters

ASSEMBLING AND PUTTING THE ELECTRIC ACTUATOR INTO OPERATION

After receiving the actuators from the manufacturer, the customer should check whether they have not been damaged
during transportation. Check should be made whether data on the plates of the actuator agree with the order and with
the accompanying documentation. Possible discrepancies, defects and damages should be immediately reported to the
supplier. In this case, the actuator cannot be put into operation. If the unpacked actuator is not mounted immediately,
it should be stored in a dust-free room with temperature ranging between -25 °C and +50 °C and relative humidity up to
80 %; the room should be free of caustic gases and vapours and protected against harmful climatic effects. Any manipulation
at temperatures below -25 °C is prohibited. The actuators must not be stored in the open area or in rooms not
protected against rain, snow and frost. Surplus conserving grease should be removed just before putting the actuator into
operation. When unpacked actuators are to be stored for a period longer than 3 months, it is recommended to insert
a sachet with silicagel or another suitable desiccant under the actuator cover.

The user can only put into operation the electric devices in satisfactory conditions documented by a report on initial
revision. Before fitting, the actuator should be carefully inspected, particularly in case it has been stored for a longer time;
the following check should be made:
– conditions of parts and connections forming explosion-proof closure,
– insulation resistance of motor winding,
– absence of any damage to the actuator during storage.

It should again be verified whether placement corresponds to provisions of the paragraph “Working conditions”.
If different way of assembly is necessary due to local conditions, an agreement with the manufacturer is required.

The protective conductor must be connected to the protection terminal marked according to ČSN IEC 417. The actuator
is fitted with protection terminals on the frame and inside the actuator on the control panel at the terminal board.

Connection

The actuator is connected according to the wiring diagram located inside the cover in such a way that the mains supply
wires have permanent good contact with the connecting terminals. The mains voltage should correspond to
the voltage specified on the rating plate of the actuator. The Internal space of the cover must be clean and dry. There must
not be any freely protruding wires on the connected cables.

19

Protection

Electric motors of the actuators are fitted with a built-in automatically restoring thermal protection according to ČSN
EN 600034-11. For the actuators type no. 52320 with single-phase electric motors ES 7150-2AL, ES 7130-4AL and
FCJ2B52D, it is connected in series with the electric motor winding; hence, it controls the motor directly and is not con­nected to the terminal board of the actuator. For other electric motors, the thermal cut-out is connected by two separate
outlet wires to the terminal board of the electric motor and the motor is controlled by means of another device (contactor,
relay, etc.). The actuator must be protected by a current circuit breaker with characteristics C set to rated current In according
to table no.1.

Insulation resistance

Before putting into operation or starting an actuator that has not been used for a longer period of time, it is necessary
to check whether insulation conditions have not been deteriorated and whether this cannot cause any risk of damaging to
the winding or an electric shock. Insulation conditions should also be checked during inspections in compliance with provisions
of ČSN 34 3205 and standards valid for explosion-proof electric devices. Insulation resistance of electric control circuits
against frame as well as against each other is min. 20 MΩ. Insulation resistance of the electric motor is min

1.9 MΩ. Insulation resistance of the transmitter CPT 1A is min. 20 MΩ with 50 V DC.

The actuators of lower insulation resistance must not be put into operation. The reason can be in a damaged winding
or excess humidity. Moist motors, the insulation resistance of which is lower than the specified value, must be carefully
dried before being put into operation. The purpose of drying the winding is to get rid of moisture from the insulation and
thus increase insulation resistance to the prescribed value. Drying can be carried out in various ways. Directives for drying
are laid down in the standard ČSN 35 0010 or local recommended methods can be used.

Supply line and wiring

Cable entries into actuators flameproof enclosure are equipped with the followings threaded holes:
a) Actuator - has 2 or 3 threaded entries M20x1,5 or M25x1,5 (see dimensional drawing of actuator)
b) Local control - has 2 threaded entries M20x1,5.

Threaded holes for cable entries are marked M20x1,5 or M25x1,5 in accordance with article 13 of ČSN EN 60079-1.
These entries are sealed by plugs M20x1,5 or M25x1,5.
The customer is obliged to establish electrical connection for direct entry to the flameproof enclosure, that corresponds to the
requirements of ČSN EN 60079-14 and the protective enclosure is at least IP67.
At the customer's request, the manufacturer can supply motors with cable bushing system that meets the requirements of
ČSN EN 60079-14 Article 10.4.2.d for direct entry into flameproof enclosure of group IIC. For entry into actuators flameproof
enclosure are used certified sealed bushings appropriate sizes.
ICG 623/A M20x1,5; cable diameter 11,0 – 14,3 mm
ICG 623/B M25x1,5; cable diameter 13,0 – 20,2 mm
In case of using bushings ICG customer is obligated to follow the following instructions of sealing individual cable cores when
connecting the actuator.

20

CR-U* Compound-Filled Cable Gland

- ASSEMBLY INSTRUCTIONS FOR SAFE USE

Where cable gland CR-U* is used customer is obliged to follow the following instructions

with sealing individual cable cores when connecting the actuator.

Brief Description

The Peppers CR-U* type Compound-filled cable gland is for outdoor use in the appropriate Hazardous Areas with unar­moured cable of any construction, with or without braids or screens, where the braids or screens pass trough the compound.
A variant giving electrical continuity to a lead sheath is available. It gives environmental protection to IP 66, IP 68 and Deluge.

Warning:

PLEASE STUDY CAREFULLY THESE INSTRUCTIONS BEFORE INSTALLATION. These glands should not be used
in any application other than those mentioned here or in Peppers Data Sheets, unless Peppers states in writing that the
product is suitable for such application. Peppers can take no responsibility for any damage, injury or other consequential
loss caused where the glands are not installed or used according to these instructions. This leaflet is not intended to
advise on the selection of cable glands. Further guidance can be found in the standards listed below.

MONTÁŽNÍ NÁVOD PO JEDNOTLIVÝCH KROCÍCH

ROZDĚLENÍ

SPLIT GLAND

VÝVODKY

Continuity washer

K

ontinuální těsnění

(CR-U2* types)

(

typ

ZADNÍ

REAR ASSEMBLY

SESTAVA

CR-U2*)

STEP-BY-STEP FITTING INSTRUCTIONS

TABLE 1

Entry

Vstupní

body

díl

Gland

Velikost

size

vývodky

U A

Compound
lenght

élka
těsnicí
hmoty

Protimatice

Back nut Union nut

P

ŘÍPRAVA

CABLE

K

ABELU

PREPARATION

COMPOUND

V

YTLAČENÍ TĚSNICÍ

EXTRUSION

HMOTY

Středový

Mid cap

uzávěr

Převlečná matice

COMPOUND PACKING

STLAČENÍ TĚSNICÍ

COMPLETED INSTALLATION

DOKONČENÁ

M

H

ONTÁŽ

MOTY

O

lověný plášť

Lead sheath

STEP-BY-STEP FITTING INSTRUCTIONS

1. Split gland as shown.

2. Fit Entry Body. Hand-tighten, then using wrench tighten a further 1/2 turn. DO NOT EXCEED MAX TORQUE FOR
ENCLOSURE.

3. Slide Rear Assembly (Back Nut, Mid Cap and Union Nut) onto cable as shown.

4. CABLE PREPARATION

Strip jacket so that cores are fully exposed in the compound chamber, length to suit installation. Lead sheath must be

cut to push through the continuity washer. Remove protective foils, and any cords/fillers from around and between the
cores. Take care not to cut the insulating sleeves of the cores. Pigtail and sleeve any screens to be passed through
compound.

21

HEALTH AND SAFETY WARNING The resin used in the compound can cause eye and skin irritation. For your

personal protection, wear the gloves supplied while mixing and applying. The uncured compound should not
be allowed to come into contact with foodstuffs.

A COMPREHENSIVE SAFETY DATA SHEET PROVIDED BY THE COMPOUNDMANUFACTURER IS AVAILABLE

ON REQUEST.

5. Check compound has not passed its “Use By” date. Installation at temperatures below 10 °C should be avoided if possible.

6. Trim any hardenes pieces from ends of stick. Mix the compound by rolling, folding and breaking. Ease mixing by cutting
large sticks in half. Fully mixed compound has a uniform yellow colour with no streaks.

7. Support the cable and Rear Assembly, holding them roughly concentric. Any lead sheath should be pushed through the
continuity washer - ensure that contact has been made. Splay out the cores. Starting at the middle, pack small amounts
of rolled-out compound between the cores. Restraighten each core and work outwards untill all gaps are filled. Bundle
the cores with cord or tape so they are not disturbed. Pack around the outside of the outer cores to completely fill the
Rear Assembly cup. Build up compound around the outside of the cores, with a slight taper & to approximate compound
lenght shown in diagram & Table 1 column 7.

8.

Pass cores through & push compound into Entry Body until Rear Assembly engages. Remove squeezed out compound at
arrow A. Screw Union Nut 7 full turns onto Entry Body (arrow B). Ensure that compound emerges at entry thread (arrow C).

9. Clean off excess compound from Entry Body to allow withdrawal when cured (arrow C). Cores may be disturbed after
1 hour. Leave to cure for 4 hours when working at 21 °C.

10. To release and pull back joint for inspection, unscrew Union Nut. Ensure that the compound is uniform and full form to
fit into the entry body.

11.

Hand-tighten Union Nut to remake joint. Then refer to table below table and tighten Union Nut using wrench to the given amount.

12. Hold Mid Cap with wrench and tighten Back Nut onto cable. Ensure seal makes full contact with cable sheath, then
tighten 1 extra turn.

13. The equipment should not be energised until the compound has been left to cure for at least 4 hours when working
at 21 °C. See chart ´Energising Time vs. Temperature´ for further guidance.

Wrench tightening information (Instruction 11), cable sizes (mm) & permitted cores

size

Tighten Union

Nut using

wrench up to

Gland

16 ½ -turn 8,4 7 3,4 8,4
20S ½ -turn 10,4 8 4,8 11,7
20 ½ -turn 12,5 14 9,5 14,0
25 ½ -turn 17,8 25 11,7 20,0
32 ¼ -turn 23,5 50 18,1 26,3
40 ¼ -turn 28,8 80 22,6 32,2
50S ½ -turn 34,2 100 28,2 38,2
50 ½ -turn 39,4 100 33,1 44,1
63S ½ -turn 44,8 120 39,3 50,1
63 ½ -turn 50,0 120 46,7 56,0
75S ½ -turn 55,4 140 52,3 62,0
75 ½ -turn 60,8 140 58,0 68,0
80 ½ -turn 64,4 160 61,9 72,0
85 ¾ -turn 69,8 180 69,1 78,0
90 ¾ -turn 75,1 200 74,1 84,0
100 ¾ -turn 80,5 220 81,8 90,0

Max

Diameter

over Cores

Max No

of Cores

Outher sheath

Min. Max.

Doba zapnutí

Energising Time

proudu v závislosti

vs. Temperature

na těplotě

hrs

hodin

Installation Guidance

Point Advice

1. BS EN 60079-10:2003 Classification of Hazardous areas

BS EN 60079-14:1997 Electrical Installations in hazardous areas (other than mines)
BS 6121, Part 5 Selection, Installation and Maintenance of Cable Glands
IEC 60079-31:2008 Ignitable dust - Protection by enclosure

2. Installation should only be carried out by a competent electrician, skilled in cable gland installation.

3. NO INSTALLATION SHOULD BE CARRIED OUT UNDER LIVE CONDITIONS.

4. To maintain Ingress Protection ratings above IP64, use IP washers or O-rings for parallel threads. For taper threads

use thread sealand. Also see page 1 diagram and Hole Data above.

5. To ensure the stated IP rating is maintained, at the point of interface the surface of the enclosure should be flat, free

from debris and rigid with the hole drilled straight and to an appropriate diameter.

22

6. Where an earth contact is required the surface of the enclosure should be sufficiently flat and rigid. With painted

enclosures a serrated star washer should be fitted to break through the paint and make a satisfactory earth contact.

7. Once installed do not dismantle except for routine inspection. A detailed inspection should be conducted as per IEC/

EN 60079-17. After inspection the gland should be re-assembled as detailed in points 11 and 12, ensuring the Mid
Cap is fully tightened.

8. Parts are not interchangeable with any other design. If manufacturers parts are mixed, certification will be invalidated.

The gland is not serviceable and spare parts are not supplied.

Limitations on Usage. Be sure your installation complies with the following:

Feature Comment

Enclosure entry thread The female thread in the entry enclosure must comply with clause 5.3 of IEC/EN 60079-1. Do not

damage threads on assembly . Check that the number of fully engaged threads is at least 5.

Interpretation of Markings. Markings on the outside of this gland carry the following meanings:

Cable Gland Type and Size
CR Product range
U Gland over the counter for unarmoured cable

Seal type: epoxy resin-based sealant
(temperature -60 °C to +85 °C)

2 Continuity washer option for lead sheathed cable
B Main component material, B=brass, S=stainless

steel

20S Gland size
PG16 Entry thread type and size Year code: XX

ATEX marking (directive 94/9/ES)
Ex European explosive atmosphere symbol
I M2 Mining equipment, category 2

Non-mining equipment,

II 2

G Type of explosive atmosphere - gas
D Type of explosive atmosphere - dust

suitable for use in category 2, zone 1, 2, 21, 22

CENELEC certification marks
E Conformity with European standard
Ex Symbol of protection against explosion
d Type of protection: d=flameproof

Code for group of gases suitable for group I

(for example Methane) and group IIC (for example

I & IIC

hydrogen) flammable gases/ air mixtures and also
groups IIA and IIB

03 Year of certifications
ATEX Certified conformity with standard ATEX 94/9/ES
1479 Serial number of certification

These glands must not be used with enclosures

where the temperature at the point of mounting

X

exceeds -60 °C to +85 °C

The supply line to the actuator and connection with its switching, protective, and securing instruments can only be installed

by technicians with a required qualification; herewith, particular standards should be observed and wiring diagrams followed
as they are referred to in these Instructions for assembly and operation. After connecting the supply cables,all screws of
connecting terminals should be checked for tightness so that they are not heated up during operation due to higher transition
resistance. The connected conductors must not exert either tensile or bending stress on the connecting terminals. The following
measures should be adopted when connecting aluminium conductors. Immediately before connection of an aluminium
conductor, the oxidized layer should be removed from the conductor and new oxidation should be prevented by conserving
the connection with a neutral vaseline.

After connection, start the actuator in an intermediate position of the working stroke for a short time to make sure that the

output shaft of the actuator is rotated in a correct direction. For the actuators with single-phase electric motor, the sense of rotation
of theactuator output shaft is changed by mutual exchanging the inlet conductors on the terminal board of the electric motor.

For the actuators with three-phase electric motor, any two conductors are mutually exchanged on the terminals U, V, W

of the actuator terminal board. Checking of function is then repeated. After correct electric connection of the actuator has
been verified, fit it onto the valve and adjust according to the paragraph Actuator Setting. The adjustment is best carried out
in the manual control mode.

Important warning!

1. During adjustment, repair, and maintenance, the actuator should be secured in a prescribed way in order to prevent its
connection to the mains supply and, thus, risk of injury by electric shock voltage or rotating actuator.

2. During reversing rotation of the actuators with single-phase electric motor, phase must not, even for a moment, be
present on both outlets of the starting capacitor; otherwise, the capacitor can be discharged via the contacts of
the torque-limit switches which can be baked together.

After adjustment of the actuator, check its function by means of the control circuit. Particular attention should be paid to

checking whether the actuator starts in a correct sense of rotation and whether, after tripping of the particular microswitch,
the electric motor is without voltage. If this is not the case, switch off the supply mains to the actuator immediately in order
to prevent damaging the electric motor; the failure should then be detected.

23

Instruction for Use no. N740052 – issue no.1
Non-explosive cable bushings, type lCG 623

Assembly Instructions for cable gland: ICG 623 Exd IIC/Exe II

Certifi cate BASEEFA No. BAS 01 ATEX 2079X (Ex) II 2 GD IP66 CE 623 EExd I/EExe I
Certifi cate BASEEFxA No. BAS 02 ATEX 0177X (Ex) IM 2 IP66 CE

Operating temperature range -60 °C +80 °C

1. Backnut

1.1 Rear Compression Spigot

1.2 Rear Seal

2. Middle Nut

3. Pot Cap

1

2

4. Rubber Pot

5. Entry

3

1.1

1.2

4

5

Assembly Instructions

AI 305 / Issue L - 08/06

HAWKE International

Detail for specifi cation.
The parts 1 and 2 should not
be dismounted.

Cable Preparation Gland Preparation

I

3

2

1

Shroud Option

Shroud Option

A

Strip Cable to suit equipment as
shown above,
removing all cable fi llers.
Length I to suit equipment.
If required, fi t shroud.
See Notes re. Drain Wires.

3

B

Position rear of pot cap (3) level with
prepared face
of cable insulation, ensuring that
the cap remains
concentric to cable at all times.

Compound

Compound

3

C

Spread the cable cores out for
the compound packing.
Pack the compound between
the cores as shown.
See notes overleaf and Fig. 7
for compound preparation.

24

Tape

5

4

Remove
surplus
compound

4

5

Compound

3

D

With all gaps and voids fi lled, bring
the conductors back together and
pack more compound around the
outside of the conductors. Tape
the conductors together to prevent
disturbance of the compound seal.
Pass the rubber pot (4) over pot cap
(3) and remove any surplus com­pound from the top of rubber pot (4)
and joint faces as indicated.

Remove

surplus

compound

Remove
surplus
compound

E

Replace the entry (5) over the rubber
pot (4) ensuring that compound does
not cover end of rubber pot (4).

2

1

F

Locate and hand tighten the sub-as­sembly (1) and (2) to the entry (5).

2

1

G

To further locate and support the
compound and rubber pot assem­bly, while holding the middle nut (2)
with a spanner/wrench, tighten the
backnut (1) until the seal grips
the cable to prevent movement of
the cable gland.

Important note:

The conductors must not be moved
for a minimum of four hours.

5

4

3

2

1

H

Allow the compound to cure. (See
Fig. 7 for Curing Times).
Untighten fi rstly the backnut (1) from
(2) and secondly the middle nut (2)

from the entry (5). The rubber pot (4)
may be removed for inspection to en­sure that the packing is satisfactory.
Add further compound if necessary.

5

2

1

I

Re-assemble rubber pot (4) and the
entry (5). Hand tighten the sub-assem­bly (1) and (2) to the entry (5) and add
half a turn to (2) with a spanner/wrench.
Tighten the backnut (1) to form a seal
around the cable, then tighten a further
half to full turn using a spanner/wrench.
Ensure that the middle nut (2) does not
rotate when tightening the backnut (1).
Locate the shroud over the cable gland
if

applicable.

25

EPOXY COMPOUND PREPARATION

When handling this material, the gloves supplied must be worn. The epoxy compound is supplied in the form of
a two part package. These should be mixed into the ratio of I: I until both colours have blended into one, without any
streaks. Rolling and folding is the most satisfactory method of obtaining an even blend. Once mixed, the compound
must be used within 30 minutes. After this time it will begin to stiffen. The compound should be kept at an ambient
temperature of no less than 20 °C prior to using.At lower temperatures it becomes diffi cult to mix. Should any compound
come into contact with the skin it should be cleaned off with skin cleaner and not allowed to dry on the skin. Only
compound for immediate terminations should be mixed.

The mixing and installation of the compound at an ambient temperature below 4 °C is not recommended due to
extended curing period.

The following instructions are the various BASEEFA approved methods of passing drain wires etc. through the com­pound barrier and should be followed if permitted by cable installation specifi cations.

Drain wire preparation

1.0. Insulating drain wires with heat shrink or cold shrinktubing

1.1. Fold back the armour I braid and bend it to right angles from the inner sheath.

1.2. Remove foils and tape level with the outer sheath. exposing the drain wires and insulated conductors. Cut

back a further 10 mm of inner sheath.

1.3. Pass 100 mm length of heat shrink or cold shrink tubing over the drain wire until it comes into contact with the

foils, then shrink the tubing evenly down onto the drain wire so that no air pockets occur.

1.4. To insulate the joint between the foils and the tubing a suitable piece of 10 mm long shrink tubing or neoprene

stretch tubing or a 10 mm wide lap of PVC tape may be used.

1.5. After completing 1.1 to 1.4 on each drain wire, lay the armour I braid parallel to the cable, if applicable, then

carry out instruction B.

2.0. Insulating drain wires i screens with separate insulated crimped conductors or soldered connection

2.1. Fold back the armour I braid and bend to right angles from the inner sheath.

2.2. Remove a further I 5mm of inner sheath (See Fig. I).

2.3. Unravel one or two groups of wires from the screen wires, then remove the remainder of the screen wires

(See Fig. 2).

2.4. Twist the group of screen wires into a pigtail and cut to 15 mm long.

2.5. Crimp an insulated conductor to the pigtail wih a suitable insulated butt ferrule (or soldered connection),

leaving enough length of the insulated conductor to enable the remote end to be connected to the earth
terminal in the equipment. (See Fig. 3).

Note: There shall be a minimum of I Omm of compound on both ends of the crimped I soldered joint.

2.6. To insulate the joint between the screen wires and the insulated conductor, place one lap of PVC insulating

tape over the exposed metallic joint.

2.7. After completing 2.1 to 2.6 on each drain wire. lay the armour I braid parallel to the cable. Then carry out

instruction B.

Armour / braid

Inner Sheath

Screan Wires

One or two groups of
screen wires

Crimp or Solder

Fig. 1 Fig. 2 Fig. 3

26

Insulated
Conductor

3.0. Insulating drainwireswith insulating varnish or paint

3.1. Fold back the armour I braid and bend it at right angles from the inner sheath.

3.2. Remove the foil and tape level with the inner sheath exposing the drain wires and conductor pairs.

3.3. Cut back a further 10 mm of inner sheath (See Fig. 4).

3.4. Spray or paint the drain wires with insulating varnish or paint, then leave to dry (See Fig. 5)

3.5. To insulate the foil ends a suitable piece of 10 mm long shrink tubing or neoprene stretch tubing or a 10 mm
wide lap of PVC tape may be used (See Fig. 6).

3.6. After completing 3.1 to 3.5 on each drain wire, lay the armour I braid parallel to the cable. Then carry out
instruction B.

Armour / braid

Inner Sheath

Foils

Outer Sheath

Fig. 4

Drain Wire

Insulated Drain Wire

Fig. 5 Fig. 6

Epoxy Compound Cure Time Vs. Temperature

- The compound may be adversely affected by some sol­vent vapours.lf such vapours are likely to be present in the
vicinity of the cable gland in service, suitable precautions
may be necessary. (Contact Hawke's Technical Dept).

- The compound cures at a Shore D hardness of 85, when
it can be handled. The compound when fully cured is sui­table for use at a temperature range of -60 °C to +80 °C.

Fig. 7

Sleeving

CABLE GLAND SELECTION TABLE

Cable Acceptance Details

Hexagon

Dimensions

Across

Flats

Across

Corners

Size
Ref.

Entry Thread Size

Metric NPT

Inner Sheath/Cores

Max. Over

Max. Inner

Cores

Sheath

Max. No.

of

Cores

Outer Sheath

Standard Seal

Alternative

Seal (5)

Min. Max. Min. Max.

Max.

Length

Os M20 ½" 8.0 8.0 6 3.0 8.0 - - 66 24.0 27.7
O M20 ½" 8.9 10.0 6 7.5 11.9 - - 66 24.0 27.7
A M20 ½" – ¾" 11.0 12.5 10 11.0 14.3 8.5 13.4 63 30.0 34.6
B M25 ¾" – 1" 16.2 18.4 21 13.0 20.2 9.5 15.4 68 36.0 41.6
C M32 1" – 1¼" 21.9 24.7 42 19.0 26.5 15.5 21.2 70 46.0 53.1
C2 M40 1¼" – 1½" 26.3 29.7 60 25.0 32.5 22.0 28.0 72 55.0 63.5
D M50 1½" – 2" 37.1 41.7 80 31.5 44.4 27.5 34.8 87 65.0 75.1
E M63 2" – 2½" 48.8 53.5 100 42.5 56.3 39.0 46.5 90 80.0 92.4
F M75 2½" – 3" 59.0 65,3/66,2 120 54.5 68.2 48.5 58.3 92 95.0 109.6

27

Limiting conditions:

1. Cable bushings OS and O can only be used for braided cables and firm instruments; the cable should be
properly fixed to prevent its possible pulling out or twisting.

2. Operating temperature of the cable bushing is -60 °C to +80 °C.

3. The space between the equipment and the cable bushing should be sealed in order to preserve particular
degree of protection against penetration of dust, solid particles, and water.

Accessories:

Before assembling or dismounting the cable bushing, become familiar with accessories of the cable bushing
which include, for instance:
– coat providing additional protection against corrosion;
– safety nut securing position of the cable bushing;

sealing washer under the additional protection of the cover of the cable bushing front part against penetration;

–
– knurled washer damping vibrations that could loosen the safety nut or the cable bushing assembly

The inlet to the actuator and connection to its switching, protection and securing instruments can only be installed

by technicians with particular qualification who must follow pertaining standards and wiring diagrams as provided in
these Instructions for Use. After connecting the inlet cables, all screws of the connecting terminals should be checked
for tightness so that they do not get warm during operation due to increased transition resistance. The connecting
terminals must not be under tension or bending stress from the connected conductors. In case of connection with
aluminium conductors the following measures are recommended. One-step before connecting the conductor,
the oxidized layer should be removed from the conductor and new oxidation should be prevented by smearing
the connection with a neutral vaseline.

After the connection, make sure, by short starting of the actuator in the intermediate position of the working

stroke, that the output shaft of the actuator rotates in a proper direction. If this is not the case, reconnect any
two conductors on the terminals U, V, W of the motor (actuator) terminal board. Then, repeat the functional
check. After verifying correct electric connection, the actuator is fitted to the valve and adjusted according to
the paragraph Actuator Setting. The adjustment is best carried out using the manual control regime.

Important warning!

1) During adjusting, repair, and maintenance, secure the actuator in the prescribed way in order to rule out its

connection to the power supply and thus to prevent possibility of an injury due to electric shock or the actuator
rotation.

After adjusting the actuator, check its function using the control circuit. In particular, make a check that the

actuator is correctly starting and that there is no voltage on the electric motor after particular relays has been
switched off. If this is not the case, switch the actuator power supply immediately so that damage to the electric
motor is prevented, and seek for the failure.

28

OPERATION AND MAINTENANCE OF ELECTRIC ACTUATORS

Operation of the electric actuators results from the operating conditions and, as a rule, it is limited to giving impulses
to respective functional tasks. The electric actuator can be controlled electronically in remote way as well as manually on
site of their installation. Manual control is possible by means of a hand wheel of the electric actuator, it does not require
any change-over switch and can be used without any danger to the staff even in case that the electric motor is running.

The operator should take care that a prescribed maintenance is carried out, the electric actuator is protected against
dangerous effects of the environment and weather conditions which are not listed in the chapter “Working Conditions”.
Moreover, care should be taken to prevent abnormal heating-up of the surface of the solid closure of the electric actuator.
It is also necessary to monitor that the rated values are not exceeded and that abnormal vibrations of the electric actuator
do not occur.

Maintenance

The maintenance of electric actuators lies in possible replacement of defective parts. Grease filling is stable for the
electric actuator service life, i.e. 6 years. If the electric actuator is capable of operating even after 6 years the old grease
should be taken out from the power part and new grease filled in.

After 6 months at most from putting the electric actuator into operation and then at least once a year, the connecting
screws between the piping fitting and the electric actuator should be retightened. The screws are tightened
in a crosswise manner.

Cleaning - general inspection

The electric actuators ex should be kept clean and care should be taken to prevent their clogging by impurities and
dust. Cleaning should be carried out regularly and as often as required by operating conditions. Surface temperature
of the actuator 80 °C (T6) should be determined without a dust layer. From time to time, it should be verified whether all
connecting as well as earthing clamps are duly tightened to prevent their heating up during operation. General inspection
of the electric actuator is recommended to be carried out once a year unless otherwise stated in revision regulations
of electric devices.

Checking the parts of non-explosive closure

The parts of the electric actuator forming the solid closure are inspected for possible ruptures or other damages
(attacked by corrosion, abrades etc.). With the electric actuator disconnected, sealing rings of cable outlets should be
inspected. Material of the sealing rings undergoes ageing and its hardness increases. Therefore, after 3 years they should
be replaced during the reassembly. Defective parts of the closure must not be used again during assembly of the electric
actuator.

In all relevant repairs of the non-explosive closure which effect its safety it is recommended to have the electric actuator
ex repaired at the manufacturer who can, on the basis of approved documentation and prescribed tests, put the closure
into a state corresponding to ČSN EN 60079-1.

29

Table No. 1 – MODACT MOKP Ex electric actuators

– basic technical parameters

Type number

Basic Complem.

Type

12345 6789

52320

MOKP 100 Ex

52321

MOKP 250 Ex

52322

MOKP 600 Ex

xx1x
xx2x
xx3x
xx4x
xx5x
xx6x
xx7x
xx1x
xx2x
xx3x
xx4x
xx5x
xx6x
xx7x
xx8x
xx1x
xx2x
xx3x
xx4x
xx5x
xx6x
xx7x
xx8x
xx9x

Adjusting

time

s/90 °

10
20
40
80
10
20
40
10
20
40
80
10
20
40
80
10
20
40
80

160

20
40
80

160

Tripping

torgue range

Nm

25 – 100

25 – 85

25 – 100

16 – 32

25 – 80
25 – 100
63 – 125

100 – 250

63 – 200

100 – 250

250 – 510

250 – 600

250 – 450
250 – 550

250 – 600

Power

W

74
74
15
17
15
15
15
90
90
40
40
90
90
60

20
180
120

60

20

20
180

90

40

40

Type

ES 7150-2AL
ES 7150-2AL

FCJ2B52D

ES 7130-4AY

FT2B52D
FT2B52D

FT2B52D
EAMRB56N02
EAMRB56N02

EAMRB56N04A
EAMRB56N04A

EAMR56N02L
EAMR56N02L
EAMR56N02A
EAMR56N04A

EAMR63N04
EAMR63N04L
EAMR63L02A
EAMR63L04A
EAMR63L04A
EAMRB63N04
EAMRB63L02

EAMRB63L04A
EAMRB63L04A

Electric motor

Rpm

-1

1.min

2750
2750
2780
1300
2680
2680
2680
2780
2780
1380
1380
2790
2790
2790
1440
1370
1390
2790
1440
1440
1320
2780
1380
1380

Voltage

V

1 x 230
1 x 230
1 x 230
1 x 230
3 x 400
3 x 400
3 x 400
1 x 230
1 x 230
1 x 230
1 x 230
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
1 x 230
1 x 230
1 x 230
1 x 230

CurrentACapacity

μF

0,67
0,67
0,37
0,27
0,10
0,10
0,10

0,9

0,9
0,55
0,55
0,25
0,25
0,20
0,20

0,6
0,45
0,20
0,20
0,20
1,35
0,90
0,55
0,55

7

7
3,5
3,5

-

-

­8
8
5
5

-

-

-

-

-

-

-

-

-

10

8
5
5

Weight

kg

9,7

18,5

31

30

The type number indikates

Place 6:

stroke 90°

6
7
8
9

Place 7: 0 version without built-in regulator of position and without BMO (block of local control)
1 version with built-in regulator of position and without BMO (Note 1)
2 version without built-in regulator of position and with BMO
3 version with built-in regulator of position and with BMO (Note 1)
4 version with power relays, without regulator of position and without BMO (Note 2)
5 version with power relays, with regulator of position and without BMO (Note 2)
6 version with power relays, without regulator of position and with BMO (Note 2)
7 version with power relays, with regulator of position and with BMO (Note 2)

Place 8: adjusting time, tripping torgue (digit according to Table 1)

Place 9: number or letter is written according to Table 2

The actuators for surrounding temperature -50 °C to +55 °C will be marked with letter F at the last place

of the complementary type number: namely 52 32x.xxxxF.

In all markings of explosion-proofness of actuators type no. 52 32x.xxxxF, the marking of sub-groups of group II of an explosion-

proof electric device according to standard ČSN EN 60079-0 will be changed from IIC to IIB, namely Ex d IIB T6 Gb.

stroke 60°

­B
C
D

stroke 120°

­F
G
H

stroke 160°

­J

K

L

Using transmitter

with resistance transmitter 2x100
with CPT 4-20 mA without built-in feeding source
without transmitter
with DCPT 4-20 mA with built-in feeding source

Ω

Notes:

1) This version is delivered with single-phase electric motor only

2) This version is delivered with three-phase electric motor only

3) Electric actuators type no. 52 320 are not delivered in version with built-in contactors for three-phase type

4) The version 52 32x.xxxxF is only available with three-phase electric motors and without transmitter or with current
transmitter CPT1/AF.

31

Table 2 – Way of connecting MODACT MOKP Ex electric actuators

– specifying of the 9th place in type number

Flange size Connection

Type number 52 320

F05
F05
F04
F04
F05
F04
F04
F04
F05
F05

Type number 52 321

F10
F07
F07
F10
F07
F07
F07
F10
F10
F10
F10

Type number 52 322

F12
F12
F10
F10
F12
F10
F10
F10
F10
F10
F12
F12

keyway

square

keyway

square

square

keyway

square

keyway

square

keyway

square

Square size

s [mm]

14

11
14
11
12
12
16
16

22

17
22
17
19
19
24
24
27
27

27

22
27
22
24
24
27
27
32
32

Square position

basic

basic
positioned at a 45°
positioned at a 45°

basic
positioned at a 45°

basic
positioned at a 45°

basic

basic
positioned at a 45°
positioned at a 45°

basic
positioned at a 45°

basic
positioned at a 45°

basic
positioned at a 45°

basic

basic
positioned at a 45°
positioned at a 45°

basic
positioned at a 45°

basic
positioned at a 45°

basic
positioned at a 45°

Marking of the

9th position

in the type number

0
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8

9
A
B

0

1

2

3

4

5

6

7

8

9
A
B

Structural design

of output

collar

exchangeable

inserts

exchangeable

inserts

collar

exchangeable

inserts

Actuator
output shaft position

(when viewing towards the local
position indicator).

The handwheel tallies
with the CLOSED position

Another connection of electric actuators on demand.

Keyway connection

open

closed

Square
basic position positioned at a 45°

(to DIN 3337) (to ISO 5211)

duct
axis

32

Dimensional sketch of MODACT MOKP 100 Ex and 250 Ex electric actuators

F

E

98

A

B

H

D

K

G

Block of local control (BMO)

Not applied for version with BMO

Odpadá u provedení s MO

C

2x Cable bushing M20 x 1.5

2 x kabelový vstup M20x1,5

2x cable bushing
MOKP 100 Ex – M20x1,5
MOKP 250 Ex – M25x1,5

1x cable bushing M20x1,5
for MOKP 100 Ex and MOKP 250 Ex

for local control

pro místní ovládání

Type

MOKP 100 Ex

MOKP 250 Ex

A

253

306

B

276

312

C

297

368

33

D

308

385

E

311

376

F

316

363

G

160

200

H

170

183

K

72

72

Dimensional sketch of MODACT MOKP 600 Ex electric actuators

400

ø 250

72

Cable bushing M20x1,5

463

362

346

264

80

403

Block of local control (BMO)

2x cable bushing M20x1,5
for version with BMO

Not applied for version with BMO

125

2x cable bushing M25x1,5

Threaded holes for cable entries are marked M20x1,5 or M25x1,5 in accordance with article 13 of ČSN EN 60079-1.
These entries are sealed by plugs M20x1,5 or M25x1,5.
The customer is obliged to establish electrical connection for direct entry to the flameproof enclosure, that corresponds

to the requirements of ČSN EN 60079-14 and the protective enclosure is at least IP67.

At the customer's request, the manufacturer can supply motors with cable bushing system that meets the requirements
of ČSN EN 60079-14 Article 10.4.2.d for direct entry into flameproof enclosure of group IIC. For entry into actuators
flameproof enclosure are used certified sealed bushings appropriate sizes.

ICG 623/A M20x1,5; cable diameter 11,0 – 14,3 mm

ICG 623/B M25x1,5; cable diameter 13,0 – 20,2 mm

34

Fig. 1: Control plate (Type No. 52 321)

10

3

P2

12

9

7

2

1

8

11

4

6

5

Legend:

1 – position unit
2 – position transmitter
3 – moment unit
4 – terminal board
5 – electric motor
6 – internal protective connector
7 – drive wheel (or segment)
8 – heating element
9 – starting capacitor
10 – protective resistance
11 – thermal switch
12 – regulator

P1 P2

Note:

The numbers in circles are identical with the numbers of releasing screws of cams of the position unit.

35

Fig. 1a: Control plate (Type No. 52 322)

10

P2

3

8

9

12

7

11

2

5

Legend:

1 – position unit
2 – position transmitter
3 – moment unit
4 – terminal board
5 – electric motor
6 – internal protective connector
7 – drive wheel (or segment)
8 – heating element
9 – starting capacitor
10 – protective resistance
11 – thermal switch
12 – regulator

1

6

P1

4

P2

Note:

The numbers in circles are identical with the numbers of releasing screws of cams of the position unit

36

12

Fig. 2: Control plate (Type No. 52 320)

8

3

9

2

1

10

5

Legend:

1 – position unit
2 – position transmitter
3 – moment unit
4 – terminal board
5 – electric motor
6 – internal protective connector
7 – drive wheel (or segment)
8 – heating element
9 – starting capacitor
10 – protective resistance
11 – thermal switch
12 – regulator

6

78

7

411

P

37

Fig 3: Moment switches

1

2

3

4

6

5

Legend:
1 – cam of switch MO
2 – cam of switch MZ
3 – moment switch MO
4 – moment switch MZ
5 – releasing screw of cam switch MZ
6 – releasing screw of cam switch MO

38

Connecting dimensions of MODACT MOKP Ex electric actuators

– connecting with square

I3

h2

h1

The position of the square
hole in end position
of electric actuator.
The position “Opened”
is to the left of the position
“Closed” when viewing
in the direction to the local
indicator of position.
The square hole is according
to DIN 79:2013-02.
Connecting dimensions are
according to
DIN 3337 or ISO 5211.
The position “Z” (“C”)
of the square hole for spindle
is identical
with the position “Z” (“C”)
on the local
indicator of position.

“O”

ø d1

A

ø d5

ø d2

“Z” (“C”)

ø d3

h4

s

“Z” (“C”)

s

e

d4

“O”

B

A – connection by square in basic position
B – connection by square turned by 45 °

e

Flange

F04

F05

F07

F10

F12

ø d1

65

65

90

125

150

ø d2

f8

30

35

55

70

85

ø d3

42

50

70

102

125

d4

M6

M6

M8

M10

M12

min.

1,5

3

3

3

3

h4

max.

0,5

0,5

0,5

1

1

39

h2 min.

12

12

13

16

20

h1 max.

3

3

3

3

3

I 3 min.

15,1
16,1
19,1
22,1
23,1
26,1
30,1
33,1
37,1
37,1
44,1

s

H 11

11
12
14
16
17
19
22
24
27
27
32

e min.

14,1
16,1
18,1
21,2
22,2
25,2
28,2
32,2
36,2
36,2
42,2

ø d5

25

28

40

50

70

Connecting dimensions of MODACT MOKP Ex electric actuators

– connecting with keyway

I1

The position of groove for
keyway according to ISO
5211 and DIN 3337 is in
the position “Closed”.
The position “Opened” is to
the left of the position
“Closed” when viewing in
the direction to the local
indicator of position.

The position “Z” (“C”) of
the groove for keyway is
identical with the position
“Z” (“C”) on the local
indicator of position.

h2

h1

“O”

ø

d1

ø

d7

ø

d5

ø

d2

“Z” (“C”)

b4

ø

d3

h3

t3

Flange

F04

F05

F07

F10

F12

ø d1

65

65

90

125

150

ø d2

f8

30

35

55

70

85

ø d3

42

50

70

102

125

d4

M6

M6

M8

M10

M12

d7

H9

18

22

28

42

50

h3 max.

3

3

3

3

3

40

h2 min.

12

12

13

16

20

d4

h1 max.

3

3

3

3

3

I1 min.

26

30

35

45

55

b4

Js 9

6

6

8

12

14

+0,4

t3

+0,2

20,5

24,5

30,9

45,1

53,5

ø d5

25

28

40

50

70

Wiring diagrams of MODACT MOKP Ex electric actuators

Legend:

SQ1 (MO) – moment switch for direction “opens”
SQ2 (MZ) – moment switch for direction “closes”
SQ3 (PO) – position switch for direction “opens”
SQ4 (PZ) – position switch for direction “closes”
SQ5 (SO) – signalling switch for direction “opens”
SQ6 (SZ) – signalling switch for direction “closes”
EH, ST – heating element with thermal switch
BQ1, BQ2 – double resistance transmitter of position

2 x 100 Ω
CPT1 – current position transmitter CPT 1A
DCPT – current position transmitter DCPT
DCPZ – feeding source for DCPT

Wiring diagram:

Number of
diagram

P0816

P0817
P0818-E
P0819
P0820
P0821-E
P0822-E
P0823-E

Electric motor

single-phase
single-phase
single-phase
three-phase
three-phase
three-phase
single-phase
three-phase

Feed-back transmitter

2x100 Ω
CPT1 or without transmitter
DCPT + source
2x100 Ω
CPT1 or without transmitter
DCPT + source
DCPT
DCPT

M1 ~, TH – electric motor, single-phase, with thermal

protection
C – motor capacitor
M3~, TH – electric motor, three-phase, with thermal

protection
SA1 – change-over switch “local” – “remote”
SA2 – change-over switch “opens” – “closes”
ZP2 – electronic position regulator
KO – power relay for direction “opens”
KZ – power relay for direction “closes”
F – thermal relay
BMO – block of local control
R1, R2 – 2x resistance protection 10 Ω

for single–phase motors

Others

regulator ZP2
regulator ZP2, thermal relay, reversing power relay

Box of local control with bushing

Space under the actuator cover

The actuators can be fitted with the block of local control (dashed lined in the diagrams). The actuator MOKP Ex has two cable
bushings. If the actuator is in the version with the block of local control, one bushing is on the actuator body,
the other on the body of local control. In order that the actuator can meet requirements for the version Ex, the conductors between
the actuator and the local control are imbedded into an insulation material. In addition to conductors for connection of the local control,
the insulation material also imbeds additional five conductors which are at disposal to the customer. In the actuator these conductors
are designated with the numbers 1 - 5 and their ends are insulated. In the block of local control they are connected to the row terminal
board on the terminals 1 - 5, (the terminal no. 6 is free).

41

Wiring diagrams of MODACT MOKP Ex electric actuators,

Type No. 52 320 - 52 322

P0816

P0817

C

O

Note:

The position and signalling switches can work as a single-circuit type. State of contacts in the scheme is valid for the
intermediate position.

In the version with the current transmitter the user shall ensure connection of the double-wire circuit of the current
transmitter to electric earth of the linked-up regulator, computer, etc. The connection should only be realized at one point
in any part of the circuit outside of the electric actuator. The voltage between the electronics and the transmitter case must
not exceed 50 V DC.

control voltage

P0818-E

42

P0819

P0820

switched

contactors

Note:

The position and signalling switches can work as a single-circuit type. State of contacts in the scheme is valid for the
intermediate position.

In the version with the current transmitter the user shall ensure connection of the double-wire circuit of the current
transmitter to electric earth of the linked-up regulator, computer, etc. The connection should only be realized at one point
in any part of the circuit outside of the electric actuator. The voltage between the electronics and the transmitter case must
not exceed 50 V DC.

C

O

43

control voltage

P0821-E

Wiring diagram of MODACT MOKP Ex Control electric actuators,

Type No. 52 320 - 52 322

PE

M

1~

U2

TH

C

R2R1

NL1

SQ1

SQ2

SQ3 SQ5

(MZ)

768

(PO)

9

(MO)

UZ2N

5

3

2

Variants without BMO,

Varianty bez BMO, propoj. U-29

interconnect U-29

Varianty s BMO, propoj. U-30

Variants with BMO,
interconnect U-30

10

11

SQ4

(PZ)

12

(SO)

13

15

14

Terminals 23 - 24
interconnect with
mA or with jumper

P0822-EZ

SA2

O / C L / R

O/Z

1

3

BMO

16

svorky 23 – 24
propojit mA,
nebo propojkou

17

SQ6
(SZ)

18

42

192221

20

4

SA1
M/D

3

2

1

STEH

mA

+L-L

-U +U

24

25

+U -U

26

DCPT

23

+

-

max 24V/2W

DCPZ

NL

27

I

+

Control

řídící

signal

signál

28

J2.E

TP

J2.D

MO

J2.C

MZ

J2.B

FO

J2.A

FZ

J2.H

Ureg

J2.G

N

J2.F

Uovl

J1.1

TEST

J1.9

+24V

Regulator ZP2.RE4

J1.10

INcpt

GND

J1.2

IN(+)

J1.3

KOK

J1.4

KOK

J1.5

30

29

REGULÁTOR ZP2.RE4

-

P0822-EZ

44

Wiring diagram of MODACT MOKP Ex Control electric actuators,

Type No. 52 320 - 52 322

M

3~

Motors 60, 90W

Motory 60, 90W

RZ

č
č

U2N2W2

RO

r

h

r

b

V2

BMO

L1 L2 L3

F

Z

PE

O

T1 T2

L1L2L3 N

T3

96

95

U

V

W

52 320 – relé Finder 56.34
52 321 a 52 322 – relé Schrack RM735730 + tepelné relé Lovato

52 320 - relay Finder 56.34
52 321 a 52 322 - relay Schrack RM735730 + thermal relay Lovato

SQ1

SQ2

SQ3 SQ5

(MZ)

768

(PO)

9

10

(MO)

N

5

4

3

Variants without BMO,

Varianty bez BMO, propoj. 4 – 29

interconnect 4 – 29

Varianty s BMO, propoj. 4 – 30

Variants with BMO,
interconnect 4 – 30

11

SQ4

(PZ)

12

(SO)

13

15

14

Terminals 23 – 24

svorky 23 – 24

interconnect with

propojit mA,

mA or with jumper

P0823-EZ

O/Z

1

3

42

SQ6
(SZ)

17

16

18

192221

nebo propojkou

20

4

SA1SA2
M/D

3

2

1

STEH

DCPT

+L-L

23

24

mA

max 24V/2W

-U +U

25

DCPZ

+U -U

26

+

-

NL

27

28

I

+

-

Control

řídící
signál

signal

TP

J2.E

MO

J2.D

MZ

J2.C
J2.B

FO

J2.A

FZ

J2.H

Ureg

J2.G

N

J2.F

Uovl

J1.1

TEST

J1.9

+24V

INcpt

GND

IN(+)

KOK

KOK

REGULÁTOR ZP2.RE4

Regulator ZP2.RE4

J1.10

J1.2
J1.3

J1.4
J1.5

30

29

P0823-EZ

Note:

Analog input signal and analog feedback signal (if brought out of the actuator) must be conducted by shielded cables.
The shielding must be connected to the signal source frame.

45

Spare parts for MOKP Ex

Name: Actuator type no.: Using, note:

“O” – ring 180x3 52 320 Between cover and box of power part

“O” – ring 210x3 52 321 Between cover and box of power part

“O” – ring 250x3 52 322 Between cover and box of power part

Micro-switch CHERRY DB1G-A1LC 52320 – 25322 MO,MZ; PO,PZ; SO,SZ

46

Development, production and services of electric actuators and switchboards.
Top-quality sheet-metal processing (TRUMPF equipment), powder paint shop.

SURVEY OF PRODUCED ACTUATORS

KP MINI, KP MIDI

Electric rotary (90°) actuators (up to 30 Nm)

MODACT MOK, MOKED, MOKP Ex, MOKPED Ex

Electric rotary (90°) actuators for ball valves and flaps

MODACT MOKA

Electric rotary (90°) actuators for nuclear power stations

application outside containment

MODACT MON, MOP, MONJ, MONED, MOPED, MONEDJ

Electric rotary multi-turn actuators

MODACT MO EEx, MOED EEx

Explosion proof electric multi-turn actuators

MODACT MOA

Electric multi-turn actuators for nuclear power stations

application outside containment

MODACT MOA OC

Electric multi-turn actuators for nuclear power stations

application inside containment

MODACT MPR Variant

Electric rotary (160°) lever actuators with a variable output speed

MODACT MPS, MPSP, MPSED, MPSPED

Electric rotary (160°) lever actuators with a constant output speed

MODACT MTN, MTP, MTNED, MTPED

Electric linear thrust actuators with a constant output speed

Deliveries of assembled actuator + valve (or MASTERGEAR gearbox) combinations

TRADITION

•

QUALITY

•

RELIABILITY

ZPA Pečky, a.s.
tř. 5. května 166
289 11 PEČKY, Czech Republic
www.zpa-pecky.cz

tel.: [phone]
fax: [phone]
[phone]
e-mail: [e-mail]