ECON ELECTRIC ACTUATOR Fig. 7907, type ELA80

ECON ELECTRIC ACTUATOR Fig. 7907, type ELA80
Installation & Operation Manual
Proven Quality since 1892
ECON ELECTRIC ACTUATOR
Fig. 7907, type ELA80 - 3000
Compact quarter turn actuator
Mechanical position indicator
High output torque
Multi mounting base
Manual override
Operating and Instruction Manual for actuator type:
ELA80, 100, 150, 200, 300, 500, 600, 800, 1200, 2000 & 3000o, Republic of 869:
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
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Installation & Operation Manual
Proven Quality since 1892
Contents
1. INTRODUCTION
1.1
1.2
3
Purpose
Safety notices
3
3
2. PRODUCT IDENTIFICATION
2.1
2.1.1
2.1.2
2.2
2.3
4
Product Identification
Marking
Certification
Initial Inspection
Storage
4
4
5
5
5
3. GENERAL INFORMATION AND FEATURES
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.17
3.2
3.2.1
3.2.2
3.3
3.3.1
General Information
Standard Technical Data
ELA Actuator Versions and additional technical data
ELA-Series Options
Duty Cycle
Heater
Hand Wheel and Declutching
Lubrication
External Parts for Standard Models
ELA80-1200
ELA2000 - 3000 (Actuator + Gear Box)
Internal Parts for Standard Models
ELA80-3000
4. INSTALLATION
4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.6
4.7
4.8
4.8.1
4.8.2
4.9
4.10
4.10.1
4.10.2
4.11
4.12
4.12.1
4.12.2
4.12.3
4.12.4
4.12.5
6
6
6
7
8
8
8
8
9
9
9
10
10
11
Pre-installation
Use in general service
Use in potentially explosive atmosphere
Actuator Mounting
Actuator Mounting Base Details (ISO 5211)
Actuator Drive Bushing
Limit Switch Setting
Torque Switch Setting
Counter-Clockwise to Close Setting
Mechanical Travel Stop Adjustment
Setting Potentiometer (Optional)
Current Position Transmitter – CPT (Optional)
Standard Features
Calibration of Zero and Span – CPT
PCU-A Proportional Control Unit Alternating Current (Optional)
PCU-D Proportional Control Unit Direct Current (Optional)
LED Signal Indication
Setting PCU Functions
AC/DC Multi-Board (Optional)
Rechargeable Battery Pack – RBP (Optional)
General
Features
Specifications
PCB layout
Operations
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
6
1
11
11
11
11
12
12
13
14
14
14
15
15
15
16
17
18
19
19
24
25
25
26
26
27
29
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5. OPERATION
5.1
30
Electrical Connections and Preliminary Test
6. MAINTENANCE
6.1
6.2
30
31
Maintenance
Tools
31
31
7. TROUBLE SHOOTING
32
8. INSTALLATION AND MAINTENANCE TIPS
33
APPENDIX I : Wiring Diagram
34
APPENDIX II : Grounding
54
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
2
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Installation & Operation Manual
1
1.1
Proven Quality since 1892
INTRODUCTION
Purpose
The purpose of this manual is to introduce and explain the installation, operation and maintenance of
ELA-series electric actuators.
1.2
Safety Notices
This manual contains safety notices and precautions the user must take to reduce the risk of personal
injury and damage to the equipment. The user(s) must read these instructions before the installation,
operation or maintenance of the ELA-series electric actuators.
DANGER: Refers to personal safety and alerts the user for danger and/or injury.
Hazardous or unsafe practice may result in severe injury or death.
WARNING: Refers to personal safety. Alerts the user for potential danger.
Not following warning notices could result in personal injury or death.
CAUTION:
Directs the user’s attention to general precautions that, if not followed,
could result in personal injury and/or equipment damage.
Note: Information in this manual is critical to the user’s understanding of the actuator’s installation
and operation.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
3
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Installation & Operation Manual
2
PRODUCT IDENTIFICATION
2.1
Product Identification
Proven Quality since 1892
The actuator name plate is located on the opposite side of the conduit entry. The name plate
contains the following:
2.1.1
Marking
A) General










ECON logo (trade mark)
Electrical power supply
Model
Type
Rated current
Torque
Operation time (seconds)
Serial No.
Options
Only applicable for North-American markets
B) Explosion proof
Only applicable for North-American markets








ECON logo (trade mark)
CE ATEX mark
Model
Motor specification
Ambient temperature
Serial number
Manufacturer’s address
Warning
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
4
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Installation & Operation Manual
2.1.2
a)
2.2
Proven Quality since 1892
Certification
EX ǁ2g Ex d IIB T4 Gb
Initial Inspection
Upon on the receipt of the actuator, the user should inspect the condition of the product and
ensure that the product specification stated on the name plate matches with the order sheet.
 Remove the packing wrap or wooden box carefully. Inspect the product for any physical
damage that may have occurred during shipment.
 Check the product specification of the received product. If a wrong product has been
supplied, please immediately report this to the distributing company.
2.3
Storage
Actuators must be stored in a clean, cool and dry area. The unit should be stored with the cover
installed and the conduit openings sealed. Storage must be off the floor, covered with a sealed
dust protector.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
5
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Installation & Operation Manual
Proven Quality since 1892
3
GENERAL INFORMATION AND FEATURES
3.1
General Information
ECON ELA-series electric actuators are designed for the operation of industrial valves; e.g. butterfly
valves and ball valves.
The actuator has a torque output range from 80 Nm to 3,000 Nm (708 in-lbs to 26,552 in-lbs).
3.1.1
Standard technical data
Enclosure Rated
Enclosure
Power Supply
Duty Type
Motor
Limit Switches
Auxiliary Limit Switches
Torque Switches
Stall Protection
Travel Angle
Indicator
Manual Override
Self-Locking
Mechanical Travel Stops
Space Heater
Conduit Entries
Lubrication
Ambient Temperature
External Coating
3.1.2
Weatherproof IP67, NEMA 4, 4X & 6
High grade aluminum alloy, corrosion coated
115 / 230VAC 1Ph, 380 / 440 VAC 3Ph 50/60Hz
24VDC
S4 70% (IEC 60034)
Squirrel caged induction motor
2 x open/close SPDT, 250V AC 16A rating
2 x open/close SPDT, 250V AC 16A rating
Open/close SPDT, 250VAC 10A Rating
Built –in thermal protection
90 degree +/- 10%
Continuous position indicator
Declutchable manual override
By means of worm gear
2 x external adjustable mechanical travel stops
10W ceramic housed
2 x PF3/4” , 2x M25x1,5 or 2x NPT 3/4 (North-American versions)
Grease moly EP
-20°C (-4°F) up to +80°C (176°F)
Explosion proof: -20°C (-4°F) up to +60°C (140°F)
Anodized, with dry Polyester powder coating
ELA Actuator versions and additional technical data
Power Supply 115 and 230VAC
Fig. 7907
Maximum
Operating
Duty cycle
Valve top flange
115VAC
115VAC
115VAC
230VAC
230VAC
230VAC
torque in
time in
according to
connection
Rated
Max. torque
Stall
Rated
Max. torque
Stall
s/90°
IEC 60034-1
according to
current in
current in A
current in
current in A
current in A
current in
S4
ISO 5211
50/60Hz
50/60Hz
50/60Hz
115/230VAC
Type
Nm (lb-in)
(50 /60Hz)
ELA80
80 (708)
16/13
70%
ELA100
100 (885)
20/17
ELA150
150 (1,328)
ELA200
A
A
Weight in
kg (lbs)
A
50/60Hz
50/60Hz
F07, V17
0,97/0,91
1,18/1,11
1,30/1,40
0,47/0,42
0,63/0,56
0,70/0,70
102/103
7,5 (16,5)
70%
F07, V17
0,97/0,91
1,19/1,12
1,30/1,40
0,47/0,42
0,65/0,58
0,70/0,70
103/107
7,5 (16,5)
25/21
70%
F07/F10, V17
1,46/1,38
2,12/2,00
2,40/2,50
0,69/0,69
0,97/0,97
1,10/1,20
184/179
16,5 (36,4)
200 (1,770)
25/21
70%
F07/F10, V17
1,46/1,38
2,22/2,10
2,40/2,50
0,69/0,69
1,05/1,05
1,10/1,20
193/193
16,5 (36,4)
ELA300
300 (2.665)
31/26
70%
F10/F12, V22
1,16/1,32
2,11/2,40
3,00/2,90
0,52/0,65
1,00/1,25
1,50/1,40
211/230
22 (48,5)
ELA500
500 (4.425)
31/26
70%
F10/F12, V27
2,30/2,95
3,28/4,20
4,90/5,00
1,00/1,10
1,70/1,87
2,50/2,40
386/344
23 (50,7)
ELA600
600 (5.310)
31/26
70%
F10/F12, V27
2,30/2,95
3,43/4,40
4,90/5,00
1,00/1,10
1,85/2,04
2,50/2,40
405/375
23 (50,7)
ELA800
800 (7,080)
37/31
70%
F12/F14, V27
3,25/3,45
5,39/5,72
7,40/7,30
1,65/1,75
2,59/2,75
3,90/3,80
526/506
29 (63,9)
ELA1200
1200 (10,260)
37/31
70%
F12/F14, V27
3,25/3,45
6,50/6,90
7,40/7,30
1,65/1,75
2,83/3,00
3,90/3,80
635/552
29 (63,9)
ELA2000
2000 (17,701)
112/93
70%
F16, V36
3,25/3,45
5,39/5,72
7,00/7,30
2,59/2,55
3,05/3,00
4,80/4,70
526/552
75 (165,3)
ELA3000
3000 (26,552)
112/93
70%
F16, V36
3,25/3,45
6,50/6,90
7,00/7,30
1,65/1,75
2,83/3,00
3,90/3,80
635/552
75 (165,3)
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
6
50/60Hz
Power in W
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Installation & Operation Manual
Proven Quality since 1892
Power Supply 24VDC
Fig. 7907
Maximum
Operating
Duty cycle
Valve top flange
Rated
Max.
Stall current
Power
Weight in kg
torque in
time in
according to
connection
current
torque
in A
in W
(lbs)
s/90° at
IEC 60034-1
according to
in A
current in
maximum
S4
ISO 5211
7,5 (16.5)
A
torque*
Type
Nm (lb-in)
ELA80
80 (708)
19
70%
F07, V17
2,80
3,70
12,80
89
ELA100
100 (885)
23
70%
F07, V17
2,80
4
12,8
96
7,5 (16.5)
ELA150
150 (1,328)
30
70%
F07-F10, V17
2,40
5,30
16,90
127
16,5 (36.4)
ELA200
200 (1,770)
35
70%
F07-F10, V17
2,40
6,50
16,90
156
16,5 (36.4)
ELA300
300 (2,655)
42
70%
F10-F12, V22
2,50
8,60
30,80
206
22 (48.5)
*The exact operating time for 24VDC actuators depends on the effective load.
Power Supply 380 and 440VAC, 3Ph
Fig. 7907
Maximum
Operating
Duty cycle
Valve top flange
380VAC
380VAC
380VAC
440VAC
440VAC
440VAC
torque in
time in
according to
connection
Rated
Max. torque
Stall current
Rated
Max. torque
Stall
s/90°
IEC 60034-1
according to
current in A
current in A
in A
current in
current in A
current in
S4
ISO 5211
50/60Hz
50/60Hz
50/60Hz
50/60Hz
50/60Hz
50/60Hz
380/440VAC
A
Power in W
Weight in
kg (lbs)
A
Type
Nm (lb-in)
50 /60Hz
ELA80
80 (708)
16/13
70%
F07, V17
0,25/0,32
0,24/0,31
0,60/0,50
0,57/0,42
0,56/0,41
0,60/0,60
163/250
ELA100
100 (885)
20/17
70%
F07, V17
0,25/0,32
0,23/0,29
0,60/0,50
0,57/0,42
0,57/0,42
0,60/0,60
153/256
7,5 (16.5)
ELA150
150 (1,328)
25/21
70%
F07-F10, V17
0,35/0,23
0,64/0,42
0,70/0,70
0,59/0,33
0,63/0,35
0,80/0,80
221/213
16,5 (36.4)
ELA200
200 (1,770)
25/21
70%
F07-F10, V17
0,35/0,23
0,73/0,48
0,70/0,70
0,59/0,33
0,63/0,35
0,80/0,80
253/213
16,5 (36.4)
ELA300
300 (2,665)
31/26
70%
F10-F12, V22
0,23/0,19
0,63/0,52
0,80/0,80
0,32/0,21
0,37/0,24
0,90/0,90
274/146
22 (48.5)
ELA500
500 (4,425)
31/26
70%
F10-F12, V27
0,37/0,31
0,91/0,76
1,40/1,40
0,51/0,34
0,75/0,50
1,60/1,50
400/305
23 (50.7)
ELA600
600 (5,310)
31/26
70%
F10-F12, V27
0,37/0,31
1,03/0,86
1,40/1,40
0,51/0,34
1,35/0,90
1,60/1,50
453/549
23 (50.7)
ELA800
800 (7,080)
37/31
70%
F12-F14, V27
0,88/0,64
1,29/0,94
2,50/2,40
1,47/0,81
1,69/0,93
2,80/2,70
495/567
29 (63.9)
ELA1200
1200 (10,620)
37/31
70%
F12-F14, V27
0,88/0,64
1,53/1,11
2,50/2,40
1,47/0,81
1,80/0,99
2,80/2,70
584/604
29 (63.9)
ELA2000
2000 (17,701)
37/31
70%
F16, V36
0,88/0,64
1,38/1,00
2,50/2,40
1,47/0,81
1,69/0,93
2,80/2,70
527/567
75 (165.3)
ELA3000
3000 (26,552)
112/93
70%
F16, V36
0,88/0,64
1,53/1,11
2,50/2,40
1,47/0,81
1,80/0,99
2,80/2,70
584/604
75 (165.3)
3.1.3
7,5 (16.5)
ELA-Series Options
EXA
WTA
PIU
PCU
CPT
Explosion proof enclosure (Ex d II B T4 Gb IP67)
Watertight enclosure (IP68 (10m/24hr) Nema 6P
Potentiometer unit (0~1KΩ)
Proportional control unit (input, output 0~10 VDC, 4~20mA DC)
Current position transmitter (output 4~20mA DC)
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
7
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3.1.4
Proven Quality since 1892
Duty Cycle 2)
Duty cycle rated IEC60034 – S4 70%
Exceeding the actuator’s rated duty cycle may cause thermal overload.
Note:
2)
Type of duty according to VDE 0530 / IEC 60034-1
Intermittent duty S4
The duty is a sequence of identical cycles
which consist of starting time, operation time
with constant load and rest period. The rest
period allows the machine to cool down so
that thermal equilibrium is not reached. The
relative on-time at S4-25% or S4-50% is
limited to 25% and 50% respectively.
3.1.5
Heater
Condensation in the actuator is possible due to wide fluctuation of the ambient temperature. The
heater integrated in the control unit prevents this in general.
Ceramic housing with thermostat to prevent over heating with 60℃ set temperature.
Heating Element
Voltage Range (ELA80~100)
(based on the control power)
Self-regulating
115V
230V
24V DC
12V DC
115V
230V
24V DC
12V DC
Voltage Range (ELA150~3000) (based on the
control power)
3.1.6
5W 4.5KΩJ
5W 18KΩJ
5W 200ΩJ
5W 47ΩJ
10W 2KΩJ
10W 8KΩJ
10W 100ΩJ
10W 27ΩJ
Hand Wheel and Declutching
ELA-series actuators are provided with a declutchable manual override
system.



In order to manually operate the actuator, pull the manual
override lever towards the hand-wheel until. It will remain in position.
Turn the hand-wheel until the valve reaches the required position.
Turn clockwise to close and counter-clockwise to open.
Note:
The manual override lever returns automatically to autoposition when the actuator is operated electrically.
3.1.7
Lubrication
ELA-series are totally enclosed units with a permanent lubricated gear train (Moly EP Grease). Once
installed, lubricating the actuator should not be required. However, periodic preventative maintenance
will extend the operating life time of the actuator.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
8
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Installation & Operation Manual
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3.2
External Parts for Standard Models
3.2.1
ELA80 - 1200
1.Top Cover
6. Window & Indicator
External Parts
ELA80 - 1200
1
Top Cover
2
Body
3
Lever
4
Hand wheel
5
Mechanical Travel Stops
6
Window & Indicator
7
Conduit Entries
8
Base
3. Lever
3.2.2
7+8.Conduit Entries and Base
ELA2000 - 3000 (Actuator + Gear Box)
2.Body
9+10.Driving Bushing + Gear Box
External Parts
ELA2000 - 3000
1
Top Cover
2
Body
3
Lever
4
Hand wheel
5
Mechanical Travel Stops
6
Window & Indicator
7
Conduit Entries
8
Base
9
Driving Bushing
10
Gear Box
4.Handwheel
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
9
5.Mechanical Travel Stops
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Installation & Operation Manual
3.3
Internal Parts for Standard Models
3.3.1
ELA80 - 3000
Proven Quality since 1892
Note: ELA80 and ELA100 do not have a torque switch provision!
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
10
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Installation & Operation Manual
4
INSTALLATION
4.1
Pre-installation
Proven Quality since 1892
 Please check if the electric power supply corresponds with your specification and the information on
the actuator type plate.
 Make sure the power supply has been switched off before you start wiring the actuator.
4.1.1
Use in general service
Verify the actuator’s nameplate to ensure that model number, torque output, operating speed, voltage
and enclosure type are correct before installation or use.
It is important to verify that the torque output of the actuator is appropriate for the torque requirements
of the valve and that the duty cycle of the actuator is appropriate for the intended application.
Make sure the power supply has been switched 0ff before you start wiring the actuator.
4.1.2
Use in potentially explosive atmosphere
Model
ELA80 - ELA3000
Type of Enclosure
II 2G Eex d IIB T4
Ambient Temperature -20°C (-4°F) up to +60°C (140°F)
Installation, commissioning, maintenance, repairs and modification work may only be performed by
qualified personnel with extensive knowledge on how to work on explosion-proof electrical equipment.
WARNING:
Read this installation, operation and maintenance manual carefully
and completely before attempting to install, operate, or troubleshoot
the ELA actuator.
4.2
Note:
Actuator Mounting
Prior to mounting, the part-turn actuator must be checked for any damage
Damaged parts must be replaced by original spare parts
Mounting is most easily done with the valve shaft pointing vertically upwards. But mounting is also
possible in any other position.
The ELA-series electric actuators are supplied with a female double square drive output. The
ISO5211 bolt patterns are provided for actuator mounting. The actuator drive bush can be replaced or
removed for machining easily.
It is mandatory for the actuator to be firmly secured to a robust mounting bracket or to be mounted
directly to the valves’ ISO mounting pad. High tensile bolts or studs with spring locking washers must be
used.
The valve stem must be in line with the actuator output drive to avoid side loads to the shaft. To avoid
backlash play between the actuator, mounting bracket and valve is not allowed.
CAUTION:
Do not attempt to work on your ECON actuator without first shutting off the power supply
Do not attach ropes or hooks to the hand wheel for lifting purposes
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
11
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Installation & Operation Manual
4.2.1
Proven Quality since 1892
Actuator Mounting Base Details (ISO 5211)
4-M10TAP D.P15
P.C.D Ø 102
(ISO 5211 F10)
4-M8TAP
D.P12
P.C.D Ø 70
(ISO 5211 F07)
4-M8TAP
D.P12
P.C.D Ø 70
(ISO 5211 F07)
ELA80/100
ELA150/200
4-M12TAP D.P18
P.C.D Ø 125
(ISO 5211 F12)
4-M12TAP
D.P18
P.C.D Ø 125
(ISO 5211 F12)
4-M16TAP D.P24
P.C.D Ø 140
(ISO 5211 F14)
4-M10TAP D.P15
P.C.D Ø 102
(ISO 5211 F10)
ELA300/500/600
ELA800/1200
4-M20TAP D.P30
P.C.D Ø165
(ISO 5211 F16)
ELA2000/3000
4.2.2
Actuator Drive Bushing
ELA actuators have a Double Square (star) driving bush. This means that the actuators are suitable for
valves with a parallel or diagonal stem connection. Hereunder the ELA-versions with standard
connection and possible options can be found:











ELA80
ELA100
ELA150
ELA200
ELA300
ELA500
ELA600
ELA800
ELA1200
ELA2000
ELA3000
Standard
DS 17mm
DS 17mm
DS 17mm
DS 17mm
DS 22mm
DS 27mm
DS 27mm
DS 27mm
DS 27mm
DS 36mm
DS 46mm
Optional
DS 9-11-14-16mm
DS 9-11-14-16mm
DS 11-14-19-22mm
DS 11-14-19-22mm
DS 14-17-19-27mm
DS 14-17-19-27mm
DS 14-17-19-27mm
DS 22mm
DS 22-30mm
DS 27-46-55mm
DS 27-36-55mm
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
12
Threaded bolt
holes 4x
Pitch
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4.3
Proven Quality since 1892
Limit Switch Setting








Rotate the hand wheel of the actuator manually to the fully closed position of the valve.
Use an Allen key, loosen the set screw of the CLOSE limit switch cam
Rotate the CLOSE cam CW until the limit switch ‘clicks’ (see Figure 1)
Tighten the set screw with the Allen key
Manually rotate the hand wheel of the actuator to the fully opened position of the valve
Use an Allen key to loosen the set screw of the OPEN limit switch cam
Rotate the OPEN cam CCW until the limit switch ‘clicks’ (see Figure 2)
Tighten the set screw with the Allen key.
DANGER:
HAZARDOUS VOLTAGE.
Make sure all incoming power is disconnected before setting the limit switches
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
13
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Torque Switch Setting
The torque spring, which detects the variation of torque during the operation, is installed to prevent
damaging the valve and actuator under overload conditions. If an overload of the actuator occurs, the
torque switch will be activated and the actuator stops immediately.
The torque switches are set by manufacturer on the production site. If re-setting is necessary, please
contact the ECON actuator distributer before setting the torque switch.
CAUTION:
Do not reset the torque switch to a setting higher than the maximum setting
stated by the manufacturer.
4.5
Counter-Clockwise to Close Setting
Standard actuators are normally set to clockwise rotation to close. However, the rotation can be
reversed to counter-clockwise to close by simply reconfiguring the wiring as follows:


Reverse wiring on the main terminal block: 9 & 10 as well as 11 & 12.
Adjust the visual indicator to suit the counter-clockwise rotation.
If a PCU card is installed:
 Reverse P1 (orange) and P3 (grey) on the PCU board.
 Move the actuator manually to the half-open position and push the auto-reset button once.
4.6
Mechanical Travel Stop Adjustment





Loosen both (open and close) travel stopper bolt nuts.
Operate the actuator manually by turning the hand wheel (the clutch lever must be
switched to “manual” first) to the closed position until the “close” open limit switch is being
activated.
Tighten the close travel stopper bolt until resistance is felt. (in this position the close travel
stopper bolt should not be able to travel any further).
Loosen back the close travel stopper bolt by only one turn and tighten the close travel stopper
bolt nut.
Repeat the same operation for setting of the open travel stopper bolt.
CLOSE TRAVEL
STOPPER BOLT
OPEN TRAVEL
STOPPER BOLT
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
14
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Setting Potentiometer (Optional)
The potentiometer has been calibrated at the factory. However, if re-calibration is required, proceed as
follows:
 Manually rotate the hand wheel of the actuator to the fully closed position.
 Loosen the locking bolts of the Potentiometer Gear by using an Allen key.
 While measuring the resistance between P1 (orange) and P2 (grey), gently rotate the
Potentiometer Gear until it reaches between 80 - 120 Ω (100 Ω preferred), by using a flat head
screw driver.
 Fasten the locking bolts of the Potentiometer Gear by using an Allen key.
DANGER: HAZARDOUS VOLTAGE.
Make sure all incoming power is disconnected before setting the potentiometer
4.8
Current Position Transmitter – CPT (Optional)
The potentiometer is used for the actuator signal feedback . It reads a resistance value w h i c h
corresponds with the current position of the actuator and transfers i t to the CPT card. The CPT
indicates the current position of the actuator throughout the c o m p l e t e stroke by a 4 – 20mA
output signal.
4.8.1




Standard Features

Model
Power
Output Signal
Output Impedance
Resolution
Position Conversion Accuracy
CPT
230(115)VAC, 50/60Hz 2VA Max
4~20mA DC
750Ω Max
Min 1/1000
±0.5 ~ ±1.5%





Ambient Temperature
Ambient Humidity
Dielectric Strength
Insulation Resistance
Vibration
-20°C (-4°F) up to +70C (158°F)
90% RH Max (Non-condensing)
1500V AC 1 min (Input to output to power ground)
Above 500V DC 30MΩ
10g, 0~34Hz
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
15
15 | P a g e
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DANGER: HAZARDOUS VOLTAGE.
Make sure all incoming power is disconnected before setting the actuator
4.8.2
Calibration of Zero and Span - CPT
The settings of Zero and Span have been calibrated at the factory. However, if re-calibration is required,
proceed as follows:
 Use the manual override to put the actuator in the half open position.
 Apply power (or use the manual override) to move the actuator to its fully closed position
(clockwise rotation).
 When the actuator is in the fully closed position, adjust the ZERO close setting on the CPT board
until an output value of 4mA is achieved.
 Apply power (or use the manual override) to move the actuator to its fully open position
(counter- clockwise rotation).
 When the actuator is in the fully open position, adjust the SPAN open setting on the CPT board until
an output value of 20mA is achieved.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
16
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PCU-A – Proportional Control Unit Alternating Current (Optional)
PCU-Rev-4 High Performance Controller, using 10 bit A/D
converter and 8bit microprocessor technology
PCU-Rev-4 Features
Model
PCU-Rev-4
Power
85 ~ 260 VAC Free Voltage ± 10%, 50/60Hz
Input Signal
4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Input Impedance
250Ω
Output Signal
4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Output Impedance
750Ω Max
Output Contact
1 (Fault monitor)
Delay Time Adjustment
0.05~7.5 seconds
Deadband Adjustment
0.12mA DC Max
Resolution Adjustment
0.0625~1mA (0.0625mA + step no. x 0.0625mA, 15 steps total)
Ambient Temperature
-10°C (14°F) up to +70°C (158°F)
Ambient Humidity
90% RH Max (non-condensation)
Dielectric Strength
1500V AC 1 Minute (input to output, power to ground)
Insulation Resistance
Minimum 500V DC 30MΩ
4 VA Max
The factory settings of the PCU card are normally set according to the customer requirements at the
time of order. However, we strongly recommend that input power, signal input selection and dip switches
are to be verified prior to the actuator start up.
DANGER: HAZARDOUS VOLTAGE.
Turn off all power before setting the actuator.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
17
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PCU-D – Proportional Control Unit Direct Current (Optional)
PCU-Rev-D1 High Performance Controller, using 10 bit
A/D converter and 8bit microprocessor technology
PCU-Rev-D1 Features
Model
PCU-Rev-D1
Power
24V DC Voltage ± 15% (36V DC Max)
Input Signal
4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Input Impedance
250Ω
Output Signal
4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Output Impedance
750Ω Max
Output Contact
1 (Fault monitor)
Delay Time Adjustment
0.05 ~ 7.5 seconds
Deadband Adjustment
0.12mA DC Max
Resolution Adjustment
0.0625~1mA (0.0625mA + step no. x 0.0625mA, 15 steps total)
Ambient Temperature
-25°C (-13°F) up to +80°C (176°F)
Ambient Humidity
90% RH Max (non-condensation)
Dielectric Strength
1500V AC 1 Minute (input to output, power to ground)
Insulation Resistance
Minimum 500V DC 30 MΩ
The factory settings of the PCU card are normally set according to the customer requirements at the
time of order. However, we strongly recommend that input power, signal input selection and dip switches
are to be verified prior to the actuator start up.
DANGER: HAZARDOUS VOLTAGE.
Turn off all power before setting the actuator.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
18
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4.10.1
LED
Blue
Green
Red
Yellow
4.10.2
Proven Quality since 1892
LED Signal Indication
State
On
Flickering
On
Flickering
On
Flickering
On
Flickering
Indication
Power on (auto)
Auto calibrating
Fully closed
Closing
Fully open
Opening
Manual mode
Fault indication, either:
- no input signal
- wrong input wiring
- wrong PIU setting
Setting PCU Functions
A) Selecting Input Signal
User can select different types of input signal by adjusting the DIP switches as follows:
4 - 20mA DC
1 - 5V DC
Input Signal
Switch
2 - 10V DC
0 - 5V DC
0 - 10V DC
60 Hz
50 Hz
Note: If not specified, the factory setting of the input signal is 4 - 20mA.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
19
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B) Selecting Output Signal
 User can select different types of output signal by adjusting the DIP switch as follows:
Output Signal
Switch
4 - 20mA DC
Input signal
switch 3 “ON”
Input signal
switch 3 “OFF”
Input signal
switch 3 “ON”
Input signal
switch 3 “OFF”
0 – 10V DC
2 – 10V DC
0 – 5V DC
1 – 5V DC
Note: If not specified, the factory setting of the output signal is 4 - 20mA.
C) Fail Position Setting
User can select the fail position of the actuator in case of control signal failure by adjusting
the DIP switches as follows:
Fail Close
Fail Position
Setting
Switch
Fail Open
Fail Last Position
Fail Close Switch
Fail Open Switch
Auto-Full Switch
CH 1 Switch
CH 2 Switch
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
20
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D) Special Signal Setting for Fully Open and Fully Closed
Auto-Full Switch
(Switch 3) On (up)
Auto-Full Switch
(Switch 3) Off (down)
Signal: 4.3mA
Signal: 19.7mA
Fully Closed
Fully Open
Signal: 4mA
Signal: 20mA
Fully Closed
Fully Open
E) Auto Setting
This function is used for automatic setting of
the PCU card to the predefined limits.
First make sure that the actuator has been
mounted correctly on the valve. Secondly check
the input power and also the input and output
signals. Press t h e ASCAN button once.
Regardless the position of the actuator, the
actuator will now perform the Auto Setting motion:
ASCAN
Button
1) The blue LED starts flickering
2) The red LED starts flickering for 5 seconds
indicating that the actuator is moving to the
open position
3) Pause for 2 seconds
4) The green LED starts flickering, indicating
that the actuator is moving to the fully
closed position
5) Pause (the green LED on) for 3 seconds
6) The red LED starts flickering, indicating
that the actuator is moving to the fully
open position
7) Pause (the red LED on) for 3 seconds
8) Moving back to the previous position
Note:
Since the actuator is already set at the factory, no further settings are required
unless the user has made adjustments to the Limit Switch or the Potentiometer
settings.
F) Manual Operation
 This function allows the user to manually operate the actuator.
 To access this function, press the ZERO (black) and SPAN
(white) buttons simultaneously for 2 seconds and the yellow
LED will be lit to indicate that the actuator is in Manual
Operation mode.
 Pressing the ZERO button will move the actuator to the
close position and pressing the SPAN button will move the
actuator to the open position.
 If no operation occurs within 5 seconds, the PCU
automatically terminates the Manual Operation mode or
alternatively press the ZERO and SPAN buttons
simultaneously for 2 seconds. In both cases, the yellow LED
will be lit off to indicate the termination of the Manual Operation
Mode.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
21
Zero
Button
Span
Button
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Note: During the Manual Operation mode, the input signal is ignored.
G) Customizing Set-points (CH 1 Switch)
 This function is used when the user wants to
set different set-points for fully open and fully closed
positions.
 For example, if the user wants to assign 5mA as
the set-point for t h e fully closed position, first of
all switch- on (move up) the CH1 switch (switch
4). Supply a 5mA signal and push the ZERO
button
once. Hereafter, the actuator will
acknowledge the 5mA signal as the set-point for
the fully closed position and transmits a 4mA
feedback signal. Similarly, for setting the set-point
for the fully open position, supply the desired
signal (for example, 19mA) and push the SPAN
button once. Switch-off (move down) the CH1
switch to complete the setting.
Set-points
Adjustable Range
Fully Closed
Fully Open
3 – 8mA DC
16 – 21mA DC
CH 1 Switch
(Switch 4)
ZERO SPAN
Button Button
H) Reversal Acting (CH 2 Switch)
 This function allows the user to reverse the input
and output signals for the operation of the actuator.
 For standard operation (CH 2 switch down), the
input signal of 4mA operates the actuator to the fully
closed position and the actuator transmits the
output signal of 4mA. However, if the CH 2 switch
is on ( up) the input signal of 4mA operates the
actuator to the fully open position and still transmits
a 4mA output signal.
 Manually move the actuator to the half-open
position and push the ASCAN button once to
execute the Auto Setting (see 4.8.2 E). Supply
signal and check the operation.
I)
CH 2 Switch
(Switch 5) On (up)
CH 2 Switch (Switch
5) Off (down)
4mA DC
20mA DC
4mA DC
20mA DC
ASCAN
Button
Fully Open
Fully Closed
Fully Closed
Fully Open
CH 2 Switch
(Switch 5)
Delay Time
 The actuator will only start to move if the change of
the input signal value is greater than the
resolution set value (see 4.8.2 J) and when the
signal value is maintained for the duration of the
delay time.
 This prevents malfunction of the actuator caused
by unwanted signals in the input signal such as
noise and interferences.
 Turning the Delay Time Dial in clockwise
direction will increase the delay time (Range 0.05 to
7.5 seconds).
Dial
sec
0
0.05
1
0.2
2
0.4
3
0.6
4
0.8
5
2.5
6
3.0
7
3.5
Dial
sec
8
4.0
9
4.5
A
5.0
B
5.5
C
6.0
D
6.5
E
7.0
F
7.5
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
22
Delay Time Dial
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J) Resolution
 The dead band adjusts the limits of the
valve’s deviation between an actual position and a
target position. The dead band is set to 0.12mA DC
Max.
 Resolution indicates the extent of the reaction on
the input signal.
 Low resolution setting may cause the actuator to
hunt or to unnecessarily respond to a fluctuating
input signal. If so, the resolution must be increased.
 Turning the Resolution Dial in clockwise direction
will increase the resolution (Range 0.0625mA to
1mA).
Dial
mA DC
Dial
mA DC
Dial
mA DC
Dial
mA DC
0
0.0625
4
0.3125
8
0.5625
C
0.8125
1
0.125
5
0.375
9
0.625
D
0.875
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
2
0.1875
6
0.4375
A
0.6875
E
0.9375
Resolution
Dial
3
0.25
7
0.5
B
0.75
F
1
23
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AC/DC Multi-Board (Optional)
Power and open/ close terminal
Electric motor terminal
Power input switch
A) Terminal block
1
2
3
4
5
6
Power 24V AC/DC (DC + signal block)
None
None
Open signal
Close signal
Power 24V AC/DC (DC – signal block)
B) Power input switch
For AC Mode, #1 switch turn “ON” and #2 switch turn “OFF”
For DC Mode, #1 switch turn “OFF” and #2 switch turn “ON”
* NOTICE: Don’t operate both switch #1 and #2 at the same time. It may damaged the board
C) Motor connect Block


Red motor wire must be connected to block # 1
Black motor wire must be connected to block # 2
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
24
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Proven Quality since 1892
RECHARGEABLE BATTERY PACK – RBP (Optional)
Warning






Please check if the electric power supply corresponds with your specification and the information on the actuator type
plate.
Make sure the power supply has been switched off before you start wiring the actuator.
The life time of the battery is 2 years, subject to operating time and environment. It should be replaced after 2 years in
order to guarantee a good working product.
After electric power has been supplied on terminal strip number 2 and 3, please connect number 1 and 4 with a jumper
as shown on the wiring diagram. Please make sure that number 1 and 4 are connected. This connection must be
maintained as long as the electric power supply is connected.
If the actuator will not be operated for a long period of time, please disconnect terminal strip number 1 and 4 in order to
extend battery life.
The battery must be discharged and charged regularly every 2 to 3 months.
4.12.1
General
The ECON actuator with Rechargeable Battery Pack (RBP) can be operated in Local or
Remote mode by using two selector switches on the local control unit. During power failure the actuator
can be operated 5 times by the battery pack. The actuator shows high reliability due to its self-checking c
apability. The local control unit shows the position of the valve,
status of the actuator and errors if occurring.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
25
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Installation & Operation Manual
4.12.2




4.12.3
Proven Quality since 1892
Features
The actuator unit can be operated in Local or Remote mode, also during power failure.
The DIP switch settings and functions can be found in the table in paragraph 4.
NORMAL MODE (on AC POWER): Battery LED blinks 1.5 seconds ON and 0.5 seconds OFF
BATTERY MODE (on BATTERY POWER) : Battery LED blinks 0.25 seconds ON and 1.75
seconds OFF
Specification
Items
Electric Power Supply
Internal Voltage
Power Consumption
Temperature / Humidity
Condition
1 Phase – AC 115 V / 230 V 50/60Hz
Control Voltage : DC 24 V / 30 V
Voltage for Space Heater : AC 115/230 V
40 VA
-20 ~ 70°C / 60 % RX, MAX.
DIP Switch setting
OFF
INCHING
ON
HOLD
OFF
Fault Contact Normal Open
ON
Fault Contact Normal Close
DIP switch 1
DIP switch 2
Actuator functions by DIP
switch settings
Power Fail action
DIP switch 3
DIP switch 4
FUNCTION
OFF
OFF
STOP
OFF
ON
CLOSE
ON
OFF
OPEN
ON
ON
NO POWER FAIL ACTION
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
26
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4.12.4
Proven Quality since 1892
PCB Layout
1. DC Power Connector
2. Battery Connector
3. Battery Switch Connector
4. Limits / Torque Signal Connector
5. Remote Control Signal
6. Status Contactor
7. PCU Signal
8. Motor Connector
9. AC Power Monitor (option)
10. DIP Switches
11. Power check
12. Battery active switch
7
8
6
11
9
1
2
3
12
10
5
4
NOTE:
If the actuator does not work on battery power, despite of a fully charged battery and a jumper
has been placed on terminal strip connection number 1 and number 4, please press the battery
active switch (12).
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
27
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1 6 2
LED status
1. BLUE
3 5
ON
OFF
2.WHITE
ON
BLINK
3.GREEN
ON
BLINK
4.RED
ON
OFF
5. AMBER
ON
GREEN
6.BATTERY BLUE
(BLINKING)
RED
RED STEADY ON
4
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
BLINK
28
REMOTE MODULATING
MODE
REMOTE MANUAL MODE
AC POWER OFF
AC POWER ON
CLOSING
FULLY CLOSED
OPENING
FULLY OPEN
NO ERROR/FAULT
ERROR message
HIGH CHARGING
MIDDLE CHARGING
LOW CHARGING
NO BATTERY
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4.12.5
Proven Quality since 1892
Operations
Local Operation
1. Put the selector switch into Local Mode.
2. Use the open/close switch to operate the actuator.
3. In Local Mode the LED indicators will show the below status:
RED LED
– ON : Fully Open
GREEN LED
– ON : Fully Close
RED or Green LED – Blinking : Opening or closing
Remote (Manual mode) Operation
1. Put the selector switch into Remote Mode.
2. Manual Mode is functional if terminal strip number 5 and 9 are NOT wired.
3. In Manual Mode the LED indicators will show the below status:
BLUE LED
– Steady ON : Manual mode
For wiring diagrams see drawings D7907-3 RBP and D7907-4 RBP on page 41-49
Remote (Modulating mode) Operation
1. Put the selector switch into Remote Mode.
2. Modulating Mode is functional if terminal strip number 5 and 9 are wired.
3. In Modulating Mode the LED indicators will show the below status:
BLUE LED
– Blinking: Modulating mode
4. For actuator operation please refer to the paragraph 4.10 (PCU settings).
For wiring diagram see drawing D7907-4 RBP+PCU on page 50
Battery Mode Operation
1. If the power supply has been switches off, the actuator will be powered by the battery.
2. LOCAL MODE: Operate the Open/Close switch in order to put the actuator in the open or closed
position.
3. REMOTE MODE: During power failure, the actuator will follow the power failure settings (DIP
switch settings – see paragraph 4.12.4)
4. NO FAIL ACTION : The actuator will operate the same way as if there was not power failure.
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
29
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Installation & Operation Manual
5
Proven Quality since 1892
OPERATION
5.1
Electrical Connections and Preliminary Test
WARNING:
If working in potentially explosive areas, observe the European
Standards EN 60079-14 “Electrical Installation in Hazardous Areas” and
EN 60079-17 “Inspection and Maintenance of Electrical Installations in
Hazardous Areas”. Work on the electrical system or equipment must
only be carried out by a skilled electrician himself or by specially
instructed personnel under the control and supervision of such an
electrician and in accordance with the applicable electrical engineering
rules.
For cable gland or conduit entries that are not used, user or installer
shall close those entries by certified blanking elements in order to
maintain the flameproof properties of the enclosure.
Flameproof enclosure! Treat cover with care. Seals and sealing
surfaces may not be damaged in any way.








For testing purposes, loosen the bolts of the actuator cover and remove the cover.
Make sure that the power supply voltage is in accordance with the information on the
nameplate of the actuator.
Put the cables through the cable glands: M25x1,5 – NPT ¾ (North-American versions) – G3/4”
(Eexd versions)
Connect wires according to the enclosed wiring diagram (See Appendix I)
Manually move the valve to the half-open position. Then electrically operate the actuator to
the fully open position and check if the motor rotates in the correct direction. According to the
applicable standards, the actuator must be closing in counter-clockwise direction.
Test the actuator and check whether the limit switches work correctly
After testing, check if all cable glands are correctly tightened. Applicable cable glands must be
selected to meet the application’s condition. It is recommended to use at least IP67 cable glands.
Put the cover back on the actuator and tighten the bolts.
DANGER:
HAZARDOUS VOLTAGE. Electrical power must not be connected until
all wiring and limit switch adjustments have been completed. Once
the power is supplied to the actuator, precautions must be taken if
the cover is not mounted.
Note:
For more information, refer to Appendix II
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
30
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Installation & Operation Manual
6
MAINTENANCE
6.1
Maintenance
Proven Quality since 1892
CAUTION:
Turn off all power before performing maintenance on the actuator.
POTENTIALLY HIGH PRESSURE VESSEL. Before removing
or disassembling your actuator, ensure that the valve or other
actuated device is isolated and not under pressure.
Under normal conditions, maintenance should be carried out at six month intervals. But when the
conditions are more severe, more frequent inspections may be advisable.











Ensure that the actuator is properly aligned with the valve (stem) or other actuated device
Ensure that all wires are insulated and connected properly
Ensure that all screws are present and tightened
Ensure that all internal electrical devices are clean (dry and free of dust)
Ensure that conduit connections are properly installed and are dry
Check the internal devices for any condensation
Check the power supply of the internal heater
Check the enclosure O-ring seals and verify that the O-rings are not pinched
Check the declutch mechanism
Visually inspect the open/close cycle
Inspect the identification labels for wear and replace it if necessary
WARNING:
Flameproof Enclosure! Before opening, ensure the absence of any
gas and voltage
Treat cover with care. Seals and sealing surfaces may not be damaged
or dirty in any. Do not jam the cover during mounting.
6.2
Tools








Metric Allen Key (Hex Wrench) × 1
Screw Driver × 1
Metric Spanner × 1
Wrench 200mm × 1
Wrench 300mm × 1
Wire Stripper Long Nose × 1
Multi-meter (AC, DC, Resistance) × 1
PCU Board Option: DC Signal Generator (4 – 20mA DC) × 1
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TROUBLE SHOOTING
The following instructions are listed in the order of the most common difficulties encountered
during the installation and start-up.
! The actuator does not respond




Visually inspect the actuator and check if no damage has occurred during shipping and handling of
the actuator.
Verify the line voltage supplied to the actuator; it must match with the rating on the actuator’s
nameplate
Compare and check the internal wiring with the supplied wiring diagram of the actuator
Check the limit switch cams
! The actuator is supplied with power but does not operate








Verify the line voltage supplied to the actuator; it must match with the rating on the actuator’s
nameplate.
Check if the actuator torque is greater than the valve torque
Check the limit switch cams
Check if the torque switches have not been tripped
Check the mechanical travel stop adjustment
Check if the rotating direction matches (According to the applicable standards, valves and actuators
must open in counter-clockwise direction)
Check for any corrosion and condensation. Electrical or mechanical devices may have been
affected
Verify if coupler/bracket is correctly installed and may not block the actuator rotation
! Actuator runs erratically



Check the ambient temperature
Verify that the duty cycle has not been exceeded
Check the position of the manual override lever
! Optional Equipment(s)
1) Potentiometer Current Position Transmitter




Check the resistance value
Check the potentiometer gear for jamming
Check the ZERO and SPAN calibration
Check the board for any damage
2) Current Position Transmitter



Verify the input signal
Check the configuration of the dip switches
Check the board for any damage
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INSTALLATION AND MAINTENANCE TIPS
CAUTION:
Regular inspection and maintenance should be performed by qualified and
trained personnel
If working in potentially explosive areas, be sure to comply with the standard
EN 60079-14 “Electrical Installations in Hazardous Areas”.
Working on the actuator that is in open position and under voltage must only
be performed if it is assured that there is no danger of explosion for the duration
of the work.
Pay attention to national regulations
For any installation and maintenance work, the followings should be noted:









Check the actuator visually. Ensure that no external damage or changes are visible. The
electrical cables must not be damaged and wired correctly.
Cable entries, cable glands, plugs, etc. have to be checked whether they are correctly
tightened and sealed.
Check if the Ex-connections are correctly fastened.
Check for possible discoloration of the terminal strip and wires as this may indicate an
increased temperature.
Check the flame path seals of the flameproof enclosures for any dirt and corrosion.
Since the dimensions of all Ex seals are strictly defined and inspected, no mechanical work shall
be performed on them.
All cables and motor protection elements have to be checked.
If any defects are detected during maintenance that may affect the safety, repair measures have
to be taken immediately.
Any kind of coating for sealing surfaces is not permitted.
When replacing parts, seals, etc., only original spare ones must be used.
WARNING:
Flameproof Enclosure! Before opening, ensure the absence of any
gas and voltage
Treat cover with care. S e a l s a n d s e a l i n g surfaces may not be
damaged or dirty in any way. Do not jam the cover during fitting
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Rev.8
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Proven Quality since 1892
APPENDIX 1 : Wiring Diagrams
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DANGER:
HAZARDOUS VOLTAGE. No electrical power should be connected until all wiring
and limit switch adjustments have been completed
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APPENDIX II :
Proven Quality since 1892
Grounding
ELA80 - 100 Grounding
Internal Ground
External Ground
Terminal Block #1 should be used for internal ground
ELA150 - 3000 Grounding
Internal Ground
External Ground
Terminal Block #1 should be used for internal ground
DANGER:
Flameproof Enclosure! Before opening, ensure that there
is no explosive gas or voltage
ECON actuator Fig 7907, type ELA80 – 3000
Rev.8
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If you have questions about this product,
Please contact your nearest supplier in
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REV.7
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