OPERATION MANUAL - Koei Ind M L Manual.pdf · 2012-04-20 · ACT－U05E－3 OPERATION MANUAL BATTERY BACK-UP ROTARY ACTUATOR ESD-BB-S ESD-BB-M ESD-BB-L >

ＡＣＴ－Ｕ０５Ｅ－３

OPERATION MANUAL

BATTERY BACK-UP ROTARY ACTUATOR

ESD-BB-S ESD-BB-M ESD-BB-L

<< FOR YOUR SAFETY >> In order for better and safety use of the product

for a long period, please observe this “WARNING AND CAUTION” carefully.

Koei Industry Co.,Ltd.


In order for better and safety use of the product for a long period, please observe this “WARNING AND CAUTION” carefully. Here are the specification and operation manual for the product to prevent suffering injury or loss by accidents. The contents are divided into “WARNING” and “CAUTION” for different degree of risks. Please strictly observe them, as both of them are very important for your safety.

WARNING : Improper handling of the product disregarding the notes under this mark may cause injury or death to a human.

CAUTION: Improper handling of the product disregarding

the notes under this mark may cause injury or material loss.

WARNING

* This product is not of explosion- proof. Do not use it in the environment with flammable gas ( gasoline etc.)or corrosive gas.

* Do not dismantle the actuator from the valve during power operation.

* Do not make wiring work when power is being supplied.

CAUTION

* Do not drop the product or give a shock to the product,for it may cause defects to the product. Do not get on the actuator, or it may cause defects or an accident of falling down.

* Do not make wiring work in the rain or in splashing water.

FOR YOUR SAFETY


*** CONTENTS ***

1.ACTION PRINCIPLE 2.CONFIGURATION

2-1 ESD-BB-S 2-2 ESD-BB-M 2-3 ESD-BB-L

3.FUNCTIONAL SPECIFICATION 3-1 ACTUATOR SPECIFICATION 3-2 BATTERY CHARGE / DISCHARGE CONTROL SPECIFICATION

4.STANDARD WIRING DIAGRAM 4-1 ESD-BB-S 4-2 ESD-BB-M ,L

5.MODE SELECTION DURING POWER “ OFF ” AND INTERLOCK 5-1 MODE DURING POWER “ OFF ” ( Control unit ) 5-2 INTERLOCK

6.CONTROL UNIT COMPONENTS( Battery and terminal block ) 6-1 ESD-BB-S 6-2 ESD-BB-M 6-3 ESD-BB-L

7.BATTERY CHARGE/DISCHARGE TIME

8.ADJUSTMENT( Position switches and contact output switches ) 8-1 ESD-BB-S 8-2 ESD-BB-M 8-3 ESD-BB-L

9.ASSEMBLY WITH A VALVE

10.INSTALLATION AND WIRING 10-1 INSTALLATION PLACE 10-2 AMBIENT TEMPERATURE / FLUID TEMPERATURE 10-3 WIRING WORK

11.TEST OPERATION 11-1 MANUAL OPERATION 11-2 POWER OPERATION( Battery )

12.MAINTENANCE AND INSPECTION


1 / 21

1. ACTION PRINCIPLE

< BLOCK DIAGRAM >

(Operation principle) Commercial power is converted to DC power and charged into the battery. Charge control unit performs control of charge current, trickle current, protection timer, status LED etc. It also diagnosis battery conditions, and stops charging when the battery is faulty. When commercial power is supplied, the battery will be preliminary charged for 3 minutes, then rapidly charged. When the battery becomes full, or protection time(180minutes) is up, charge control unit stops rapid charge, and shifts it to trickle charge mode. Status LED winks during preliminary charge/rapid charge modes, and lights while battery full, or trickle charge. If the motor is drived battery-full or trickle modes, the system repeats the above action preliminary charge-rapid charge. When battery potential is down to terminal voltage (about 14V), it also shifts to rapid charge mode. Power interruption detector always monitors power supply, and functions as an emergency shutdown or emergency open valve according to the interlock unit status. Shut/open is optionally settable at emergency mode switch. While commercial power is being supplied, open/close is switchable with customer control signals disregard of interlock status. Even while commercial power is “OFF”, open/close is controlable by releasing interlock.


2 / 21

2.CONFIGURATION 2-1 ESD-BB-S

(Output Shaft: Male Drive)

(Output Shaft: Female key Drive)


3 / 21

2-2 ESD-BB-M

(Output Shaft: Male Drive)



4 / 21

2-3 ESD-BB-L

<Output Shaft: Male Drive)



5 / 21

3.FUNCTIONAL SPECIFICATION 3-1 ACTUATOR SPECIFICATION

MODEL ESD-BB-S ESD-BB-M ESD-BB-L

POWER SUPPLY AC 85V~260V DC110V~370V 47Hz~440Hz or DC

While charging : 3W While charging :10W While charging : 10W POWER CONSUMPTION Full battery: less than 0.1W TRAVEL ANGLE 0~90° TRAVEL SPEED *1 5 secs. *1 7.5secs. *1 7.5secs. RATED TORQUE *1 5 kgf·m *1 20 kgf·m *1 100 kgf·m MOTOR(DC) 20W 50W 200W

OUTPUT SIGNAL Full open, Full close No-voltage contact output Contact capacity: Resistance load AC250V, 1A. Inductive load AC250V 0.5A

INSULATION RESISTANCE More than 500V DC/100MΩ WITHSTAND VOLTAGE *2 1500V AC/1 minute BATTERY (CAPACITY)

Ni-Cd 12/500mAH

Ni-Cd 12/1200mAH

Ni-Cd 12/2800mAH

BATTERY OPERABLE TIME 7 days 14 days 20 days

CONTROL UNIT ESD-BB-S ESD-BB-M ESD-BB-L CONNECTION TERMINAL 11 pole-terminal block

PROTECTIONS Overload protection circuits, OP/CL limit Switches, OP/CL mechanical stoppers.

WIRE INLET (CONDUIT) G1/2×2

MANUAL DRIVE Crank handle(Standard accessory) WATER TIGHTNESS NEMA-4･4X(to IP-65,66) EXPLOSION- PROOF Non explosion-proof

CONDITIONS FOR USE

Temperature: 0~45°C Humidity: 10~90%RH Vibration: 2G/5~100Hz Shock:30G/11ms

MOUNTING ANGLE All 360°

ADC12 ADC12 ADC12 ADC12 ADC12 ADC12

AC4A ADC12 AC4A

MATERIALS Body Drive Unit Control Unit Output Shaft SUS304 COATING COLOR Baking coat WEIGHT 4.0kg 7.7kg 19.5kg

Remarks: *1 Version types with special speed or special output shaft torque may be acceptable at request.

*2 Withstand voltage is measured with the unit which is open from motor and battery LED


6 / 21

3-2 BATTERY CHARGE/DISCHARGE CONTROL SPECIFICATION

ITEM SPECIFICATION Charge controlsystem Peak voltage detection system Sensor sensitivity 0-3 mV/cell Charge current 100-400 mAH Tickle current 10-28 mAH Charge time 2-180 minutes(variable) Charge capacity 100%(to nominal capacity) Number of tandem battery 12 pcs. Discharge terminal voltage 14V(12 cell)

Charge LED: In charge Full Abnormal or “OFF”

(Winks) (On) (Off)

Battery status Empty LED: Below terminal voltage Over terminal voltage

(On) (Off)

Safety function *Short battery detection *Open battery detection *Protection timer

Temperature for use *Charge *Discharge: -20 to 60°C *Storing

* Commercial supply will be converted into DC for charge.

WARNING

*Do not heat battery, nor throw batteries into fire, for it may explore, or electrolyte may spout from relief valves.

*Do not break battery coating tube, nor disassemble battery, for it may spark and heat, or alkaline electrolyte in battery may damage skins or clothes.

HELP RECYCLE Ni-Cd CHARGE BATTERY

Used Ni-Cd charge batteries are valuable. Bring them to recycle stores. Paste a tape etc. At (+)terminal for short-circuit prevention when bringing.

Ni-Cd


7 / 21

4.STANDARD WIRING DIAGRAM

4-1 ESD-BB-S [Connection with OP / CL control input and interlock input]

Input at no-voltage contact (Relay contact, open collector, open drain)

<Relay contact> <Open collector> < Contact capacity of open / close no-voltage contact output > Resistance load: AC250V, 1A max. Inductive load: AC250V, 0.5A max. Be sure to use the contact within the above range.


8 / 21

4-2 ESD-BB-M, L [Connection with OP / CL control input and interlock input]

Input at no-voltage contact (Relay contact, open collector, open drain)

<Relay contact> <Open collector> < Contact capacity of open / close no-voltage contact output > Resistance load: AC250V, 1A max. Inductive load: AC250V, 0.5A max Be sure to use the contact within the above range.


9 / 21

5.MODE SELECTION DURING POWER “OFF” AND INTERLOCK

5-1 MODE DURING POWER “OFF” (CONTROL UNIT) An action mode during power “OFF” is selectable at emergency mode switch (EMERGENCY MODE).

[Emergency Mode Switch]

<The drawing shows ESD-BB-M type) [ CONTROL UNIT ]

< ESD-BB-S > < ESD-BB-M,L >

Note: Control units ESD-BB-M and ESD-BB-L cannot be used instead each other, because the internal circuits are different, though their external shapes are identical.

5-2 INTERLOCK

Interlock is the switch to select whether or not to make emergency action effective during power “OFF”. When interlock terminal is open, emergency action will be effective. When it is short-circuited, emergency action will be in effective, but only external control signals will be effective.

Caution for use


10 / 21

6.CONTROL UNIT COMPONENTS (Battery and terminal block) 6-1 ESD-BB-S

[ Terminal block for external wiring ] Terminal No, name and function

* POWER--------------Power supply * FG---------------------Frame ground * INPUT ---------------OP-CL control input signal * INTERLOCK ------Interlock input signal * OUTPUT------------OP-CL no-voltage contact output signal

Note: COM1,COM2 are not commonly useable with COM3.

Caution for use


11 / 21

6-2 ESD-BB-M

[ Terminal block for external wiring ] Terminal No, name and function



Caution for use


12 / 21

6-3 ESD-BB-L

[ Terminal block for external wiring ]

Terminal No, name and function



Caution for use


13 / 21

7.BATTERY CHARGE / DISCHARGE TIME Discharge characteristic Number of days required from full battery until terminal voltage( EMPTY LED-on ). Charge characteristic From deep discharge until full battery.

* At the initial charge time after deep discharge( complete discharge ), there may be a trend of difficulty in recovering the capacity due to the inactivity of battery. In such a case, repeat charge/discharge a few times and capacity will recover.

* The above charts show typical characteristics. The characteristics will vary depend on surrounding temperature and conditions for use.

ESD-BB-M

0

5

10

15

20

0 4 8 12 16 20Days

Bat

tery

Voltag

e(V

)

ESD-BB-M

0

5

10

15

20

0 4 8 12 16 20Days

Bat

tery

Voltag

e(V

)

ESD-BB-L

0

5

10

15

20

0 5 10 15 20 25 30Days

Bat

tery

Voltag

e(V

)ESD-BB-S

0

5

10

15

20

0 60 120 180 240

Mins.

Bat

tery

Voltag

e(V

)

ESD-BB-M

0

5

10

15

20

0 60 120 180 240Mins.

Bat

tery

Voltag

e(V

)

ESD-BB-L

0

5

10

15

20

0 120 240 360 480Mins.

Bat

tery

Voltag

e(V

)


14 / 21

8.ADJUSTMENT( Position switches and contact output switches ) 8-1 ESD-BB-S

Adjustment of position switches 1) Remove electric unit cover.

The switch and dog are fitted as shown left. 2) The upper is for close, the lower is for open. 3) Set output shaft in position by manual handle.

If it touches at mecha-stopper before the set position, put stopper bolt back with loosened locknut.

4) Loosen dog screw and turn the dog to the position where it clicks. Adjust both open and close in the same way.

5) After setting, confirm that the switch properly functions before it touches at mecha-stopper.

Adjustment of contact output switches 6) Both the open and close have 2 independent

circuits. Once the functional position is set, they will output synchronized signals. Therefore, no adjustment is required.

7) Set opening meter to match opening position.

Mecha-stopper setting method * Structure

As shown left, output shaft will be mechanically constrained when the stopper fixed on the output shaft touches at stopper bolt.

1) Set stopper so as to touch at stopper bolt at a

half handle-turn( about 3 ﾟ ) beyond motor stopping position( position switch functional point ). Secure the locknut.

Caution for adjustment

Adjustment of the open/close limit switches should be made after the stopper bolts are put back.



15 / 21

8-2 ESD-BB-M


The switch and dog are fitted as show left. 2) The upper for open/close contact output,the

lower for open/close positions. 3) Remove opening meter, loosen upper dog

screws and pull out dog upward. 4) Set output shaft in position by manual handle.

If it touches at stopper before setting position, put stopper bolt back with loosened nut.

5) With loosened dog adjustment screw, turn the dog and fix it at the position where it clicks. Make the same adjustment for both open and close sides.

6) After setting is over, confirm that the switches properly function before they touch mechanical- stoppers.

Adjustment of contact output switches 7) Set the switches (open/close) at a half

handle-turn before their functional positions. 8) Insert upper dog, and fix it at the position

where it clicks. 9) Set the another side in the same way. 10) After setting is over, confirm that they

function properly. Finally, fit the opening meter to match opening position.


As shown left, output shaft will be mechanically constrained when the stopper fixed on the output shaft touches at stopper bolt.


half handle-turn( about 3°) beyond motor stopping position( position switch functional point ). Secure the locknut.

Caution for adjustment Adjustment of the open/close limit switches should be made after the stopper bolts are put back.



16 / 21

8-3 ESD-BB-L


The switch and dog are fitted as show left. 2) 1,2 dogs are for open/close contact output.

3,4 are for open/close positions. 3) As shown left,there are 2 switches each for both

open and close. 4) Set output shaft in position by manual handle.

If it touches at mecha-stopper before the setting position, loosen and put stopper bolt back.

5) Loosen and turn the dog,then fix it at the position it clicks. Set the another side in the same way.

6) After setting is over, confirm that switches properly function before they touch at mecha-stopper. Adjustment of contact output switches

7) Set both open/close switches at a half-turn before their function points.

8) Loosen and turn the dog,and fix it at the position where it clicks.

9) Adjust the contrary side in the same way. Turn the dog with loosened adjuster screw, and

fix it at the position where the switch clicks. 10) After setting is over, confirm that they properly

function. Set the opening meter to match opening position and finish the work.


As shown left, shaft will be mechanically constrained when the stopper fixed on the output shaft touches at stopper bolt.


half handle-turn( about 3°) beyond motor stopping position ( position switch functional point ). Secure the locknut.

Caution for adjustment Adjustment of the open /close limit switches should be made after thestopper bolts are put back.



17 / 21

9.ASSEMBLY WITH A VALVE

Actuator and valve are separate structures, so that actuator is replaceable with ease whenever it is faulty.

< ASSEMBLY PROCEDURES > Confirm that power is off before making assembly work. 1) Confirm manually that valve moves normally, then position it at full close. 2) First fix a yoke on the valve with bolts, then tentatively bolt an actuator above the yoke. 3) Manually position the actuator at 0%( close position ),then joint valve stem and actuator

shaft with coupling. 4) Secure the bolts on the yoke and fix the actuator. 5) Confirm manually that the actuator turns smoothly without eccentricity .

* Note 1. The shape of coupling may vary depend on fluid temperature. 2. Standard actuator is male drive.( Mounting on valve may be made with yoke and

coupling.) Female key type ( special version )actuator for direct mount is available at option. Female drive is available at option.

CAUTION: Make sure that power is off when making manual operation.

Caution for assembly with a valve


18 / 21

10.INSTALLATION AND WIRING 10-1 INSTALLATION PLACE

Caution for indoor installation * The actuator is not an explosion-proof type.

Do not use it in hazardous environment with flamable gas ( gasoline etc.),corrosive gas etc.

* Cover whole the actuator when using it in place where water/materials are always splashing.

* Reserve a space for wiring and manual operation. Caution for outdoor installation * Cover whole the actuator from rainwater or direct sunlight.

( Direct sunlight may heat actuator internal temperature. Rainwater may degrade seals and packing.)

Actuator surface materials and treatment

ESD-BB-S ESD-BB-M ESD-BB-L

HOUSING Material : ADC12 Surface : Oxidation treatment

Electrostatic coating DRIVING

UNIT COVER

Material : ADC12 Surface : Oxidation treatment

Electrostatic coating ELECTRIC

UNIT COVER

Material : ADC12 Surface : Oxidation treatment

Electrostatic coating CONTROL

UNIT COVER

Material:AC4A Surface:Electrostatic

coating

Material:AC4A Oxidation treatment Surface: Electrostatic

coating

Material:AC4A Surface: Electrostatic

coating

OUTPUT SHAFT Material: Stainless steel

NUT/BOLT Material: Stainless steel 10-2 AMBIENT TEMPERATURE/FLUID TEMPERATURE

Ambient temperature * Ambient temperature range for use is 0~45 .

Under minus temperature( below 0 ),battery internal pressure may raise due to insufficient gas consumption reaction ,allowing the safety valve to function. Moreover, in temperature over 45°C, not only battery charge efficiency may decline ,battery materials may also degrade.

* For use in temperature below 0°C, condensation –protected actuator is available. For use in higher temperature than 45 ,high temperature type battery may be required. For details, please inquire our Sales Dept.

* Heat radiation type yoke and coupling are suppliable for application with high temperature fluid. Fluid temperature below 65°C… Standard yoke and coupling High temperature 65°C … High temperature type yoke and coupling

Caution on installation environment


19 / 21

10-3 WIRING WORK

Caution when making wiring work * Wiring work shall be made by a qualified person according to the electrical equipment

technical standards. * Do not make wiring work in the rain or in high humidity environment. * Make a proper connection according to the relative connection diagram . * For all connections use fork crimped-on terminals. * Use a cable of outer diameter φ9~11 for the standard KOEI conduit.

Otherwise, select a proper size conduit to just match the cable outer diameter. Unmatched conduit and cable may allow water ingress through the gap, resulting defective unit.

After power and external signal input are connected, screw up the conduits firmly, then secure control unit cover with 4 fixing screws. Insufficient screwing may cause water ingress and defect to the unit.

* Poly-vinyl tube etc.,if they are used, shall be well treated with water-prevention. Do not make such a piping or wiring as water flows along the tube or cable.

Caution after connection is over

Caution when making wiring work


20 / 21

11.TEST OPERATION

11-1 MANUAL OPERATION 1) Before making manual operation, cut off the

Commercial supply, also pull off the battery connector.

2) Insert the manual lever handle into the hexagonal hole on the front cover (driving unit cover).

3) Direction is CW for close action, CCW for Open action. Confirm that the shaft turns smoothly without eccentricity.

< HANDLE DIMENSIONS >

Do not apply any excessive force on the handle beyond the action range (full close full open),for it may cause troubles.

11-2 POWER OPERATION( BATTERY ) 1) Confirm manually before making power operation that valve position is matching the

opening meter. 2) Confirm that battery is correctly connected, then supply commercial power. 3) Confirm that the unit makes open/close action with external switch. 4) Open interlock circuit, and make commercial supply off.

The unit now makes either “Shut(full close)” or “Open(full open)” action as preset at the emergency mode switch on the control unit . Confirm that it makes emergency action correctly . If the emergency circuit is short-circuited, emergency action will be disregarded. In this case ,only external open/close switch will be effective .

After power and external signal connection is completed, secure the conduit, also screw up the control unit cover with 4 screws firmly . Insufficient screwing may cause water ingress and defect to the unit .

Caution

Caution after wiring is completed

Caution for operation

Type Item BB-S BB-M BB-L

Hex. hole (mm) 5 6 10 No. of handle turns 15 15 15 Length (mm) 100 120 230 Materials SCS13 SCS13 SCS13


21 / 21

12. MAINTENANCE AND INSPECTION

Lubrication As the unit is lubricated with long life, anti- corrosive and water-protective lubricant ( “Gleitmo” 805K ) before shipment, lubrication is in principle not required.

Battery

As the unit is perfectly sealed against electrolyte leakage, maintenance( refilling ) is not required . However, it is recommended to check every 3 months that there is no deformation, or rusting of the battery. It is difficult to determine how long the battery life is, because there are complex factors for it . However, it is suggested that the battery be changed about 4~5 years .

Periodical operation

In case a valve is very seldom operated, make periodical operation about every 3 months and confirm it is normal.

Documents

OPERATION MANUAL - Koei Ind M L Manual.pdf · 2012-04-20 · ACT－U05E－3 OPERATION MANUAL BATTERY BACK-UP ROTARY ACTUATOR ESD-BB-S ESD-BB-M ESD-BB-L >