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SIPOS 5 Flash: Electric Actuators Technology

SIPOS 5 Flash: Electric Actuators  Technology
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SIPOS 5 Flash: Electric Actuators Technology

Product catalog summary
Introduction
The SIPOS 5 Flash electric actuators are designed to enhance process automation by decentralizing control system functionality to field devices. They are applicable across various sectors, including energy, water management, and industrial plants. The modular design allows for flexibility in installation and operation, accommodating extreme conditions and space constraints.
Product Range
The product range includes rotary, linear, and part-turn actuators, each with software-configurable settings for positioning speed and torque. The actuators are available in standard and modulating versions, suitable for different duty cycles as per DIN EN 60034 standards.
Mechanical Interface
The actuators feature a robust mechanical connection with valve interfaces and gear unit attachments, ensuring compatibility with various valve types and operational requirements.
Electronics
Equipped with an integrated frequency converter, the actuators offer electronically adjustable speed and torque limitations. Two electronic variants, ECOTRON and PROFITRON, cater to different control needs, with PROFITRON providing advanced monitoring and diagnostic capabilities.
Commissioning
Commissioning is simplified with a local control station and menu-driven display, particularly in the PROFITRON version. The COM-SIPOS program facilitates operating and parameterization.
Control Functions
The actuators support various control modes and interfaces, including PROFIBUS DP and MODBUS RTU. They offer precise control with high repeatability, speed reduction in end positions, and process optimization capabilities.
Functions
Key functions include speed reduction in end positions, positioner capabilities, split-range control, and travel-dependent output speed adjustment. The actuators maintain output torque and speed independent of supply voltage and frequency variations, ensuring reliable performance.
Features and Benefits
The SIPOS 5 Flash actuators integrate power and control circuits, reducing system costs and enhancing reliability. They are adaptable to both conventional and fieldbus systems, offering flexibility in control system integration. The design minimizes mechanical components, reducing maintenance needs and ensuring trouble-free operation.
Mechanical Specifications
The SIPOS 5 Flash actuators are designed with various mechanical interfaces to accommodate different valve types, including rotary, linear, and part-turn actuators. The document describes the output shaft designs (A, B1, B2, B3, B4, C, D, and E) and their compatibility with DIN standards. The actuators feature interchangeable gearbox options and are capable of handling large torque ranges.
Control and Electronics
The actuator system incorporates a frequency converter for precise control of motor speed, direction, and torque. The electronics include integrated control units, microcontrollers for motor and position monitoring, and options for fieldbus or relay card interfaces. The system supports both ECOTRON and PROFITRON configurations for standard and high-specification applications, respectively.
Operational Features
Key features include soft start-up, automatic phase sequence correction, continuous current and torque monitoring, and temperature compensation. The system is designed for flexibility in planning and operation, with adjustable speed and torque settings to optimize process performance.
Construction and Durability
The SIPOS 5 Flash actuators are built with corrosion-resistant materials, including a special aluminum alloy for the housing and stainless steel fasteners. They are rated for IP67 environmental protection, with options for IP68 and additional paint coatings for harsh conditions.
Installation and Maintenance
The document outlines the modular design that allows for easy installation and maintenance. The electronics unit can be detached from the gear unit, and connections are facilitated through plug-in terminals and connectors. The system is designed to minimize spare parts inventory through its modularity.
Conclusion
The SIPOS 5 Flash actuator system is a versatile and reliable solution for controlling various valve types in industrial settings. Its advanced electronic controls, robust mechanical design, and ease of installation make it a preferred choice for applications requiring precise and adaptable actuator solutions.
Specifications and Features
The document describes the SIPOS 5 Flash actuator, highlighting its self-locking mechanism for modulating and standard actuators, and the use of long-life gear oil for maintenance-free operation. Manual operation is facilitated by a hand wheel, with safety ensured by a motor isolation switch. Large actuators include a centrifugal lock for safety.
Mechanical and Electronic Interface
The actuator features a mechanical position indicator visible through a cover, and a local control station with buttons for OPEN, CLOSE, and STOP operations. The SIPOS 5 Flash ECOTRON and PROFITRON models offer different interfaces for configuration, with PROFITRON providing a user-friendly LCD display.
Commissioning and Control Functions
Commissioning involves setting tripping torques and output speeds via potentiometers and DIP switches. The actuator supports both torque and travel-dependent cut-off modes. The PROFITRON model allows non-intrusive configuration with a PIN security code.
Diagnostics and Monitoring
The COM-SIPOS software facilitates parameterization and diagnostics, allowing for easy monitoring of actuator status and valve behavior. It supports preventative maintenance by recording torque curves and other critical data.
Control System Interfaces
The actuator interfaces with control systems via binary, analog, or fieldbus signals. It supports various control modes, including permanent contact, pulse contact, two-wire, and positioner control. Fieldbus systems offer advantages in terms of reduced cabling and enhanced diagnostics.
Fieldbus Technology
Fieldbus systems provide efficient communication with complex field devices, allowing for remote parameterization and detailed diagnostics. They offer significant advantages over conventional wiring, including reduced cabling and improved troubleshooting capabilities.
Specifications and Procedures
Regular inspection and examination of actuators and valves are necessary. Cables from the control system to the actuator may need to be re-laid, and I/O control modules supplemented. The control system must be modified accordingly, and costly electrical isolation might be required due to EMC interference risks.
Installation and Commissioning
Commissioning involves parameterization, actuator state information, fault diagnostics, preventive maintenance, and expandability considerations. Fieldbus systems are replacing conventional controls, offering improved interference susceptibility management.
Control Electronics and Bus Connection
Control electronics include protocol evaluation and bus parameterization. Bus connections feature integrated, switchable bus termination for one or two channels, with separate bus and power supply connections. Fieldbus modules provide electrical isolation, protocol processing, and buffer memory storage.
Fieldbus Systems
Fieldbus systems like PROFIBUS DP and MODBUS RTU are supported by SIPOS 5 Flash, offering direct device connection via RS485 bus or fiber-optic cable. PROFIBUS DP provides high-speed data exchange and supports various functional levels (DP-V0, DP-V1, DP-V2) for cyclical and acyclical data exchange, time synchronization, and redundancy.
Control System Integration
SIPOS 5 Flash ensures compatibility with control systems through device master data files (GSD), electronic device descriptions (EDD), and device type managers (DTM) for FDT interfaces. Network configuration is straightforward, supporting both cyclical and acyclical processes.
MODBUS Communication
MODBUS RTU offers fast, straightforward connections between a master and multiple slaves, supporting various data access protocols. SIPOS 5 Flash supports MODBUS functions like reading coil status, input registers, and diagnostic telegrams.
Automation Solutions
The SIMA MASTER STATION provides a total concept for automation, ensuring safety and availability through redundancy strategies. It offers easy commissioning, comprehensive diagnostics, and flexibility in system options, supporting integration with various field devices and control systems.
Power Supply Solutions
SIPOS 5 Flash actuators can operate with single-phase power supplies, benefiting from integral frequency converters. The low power consumption allows for reduced power specification designs, making UPS or solar power systems more economical.
Overview
The document provides a detailed technical description of the SIPOS 5 Flash actuator, focusing on its mechanical interface, electronic details, commissioning, and control functions. It highlights the actuator's capabilities in optimizing valve operations, reducing wear, and enhancing process control.
Specifications
The SIPOS 5 Flash actuator features an integrated frequency controller that reduces motor speed near valve end positions to prevent seat damage and minimize maintenance costs. It offers seven adjustable speeds within selectable ranges.
Positioner
The actuator includes an adaptive three-step controller that optimizes process control by adjusting the dead zone based on setpoint and actual-value signals. This reduces switching cycles and protects valves and pipelines from wear. Additional features include soft start, electronic braking, and speed reduction before stopping.
Split Range Control
The document describes the split-range control function, which divides the output signal among multiple actuators for applications with wide flow ranges. This improves control accuracy and prevents issues like water hammer.
Travel-Dependent Valve Speed Adjustment
The actuator allows for travel-dependent speed adjustments, enabling linearization of valve characteristics. This function is useful for achieving a proportional relationship between valve travel and flow rate.
Process Controller
The SIPOS 5 Flash integrates a process controller, reducing the need for separate controllers and offering cost savings. It supports various control modes, including conventional, BUS, and fixed setpoint control.
Monitoring and Maintenance
The actuator facilitates condition-based maintenance by recording valve operating torque levels and storing torque curves. This allows for efficient maintenance scheduling and early detection of valve issues.
Analog Output Speed Control
The actuator can adjust output speed during operation based on an external analog signal, enhancing fluid control precision and preventing pressure surges.
Additional Information
The document includes contact details for SIPOS Aktorik GmbH and information on available catalogs and product selection CDs.
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Catalog excerpts

SIPOS 5 Flash: Electric Actuators  Technology-1

SIPOS 5 Flash Electric Actuators Technology Product range Mechanical interface

 Open the catalog to page 1
SIPOS 5 Flash: Electric Actuators  Technology-3

Product range Mechanical interface SIPOS 5 Flash Features and benets at a glance Output torque and speed are independent of the supply voltage / frequency (within a wide tolerance) Actuator torque and positioning speed are unaffected by voltage variations of ±15 % of the specified voltage range (transitional voltage tolerance ±20 %) and frequency variations from 40 Hz to 70 Hz. Low starting current – always below nominal rated current Allows lower cable rating / longer cable lengths More actuators can be connected to a given cable size UPS systems can be specified with a lower power rating Enhanced...

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SIPOS 5 Flash: Electric Actuators  Technology-4

SIPOS 5 Flash Setting new generation actuator standards Over a number of years there has been an increasing trend in process automation to distribute control system functionality away from central control to actual field devices close to point of application. SIPOS 5 Flash actuators are setting the standard in pioneering product development that supports this change. Wide ranging actuator applications The SIPOS 5 Flash actuator series has proven field reliability and constant further development has opened up a wide variety of applications including: – The energy sector – from the power plant...

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SIPOS 5 Flash: Electric Actuators  Technology-5

Product range Mechanical interface Integrating power and control circuits within the actuator, means components traditionally mounted in separate control cabinets such as circuit breakers, reversing contactors and thyristors have been designed out, thus resulting in lower system costs, simplied installation and increased reliability. Flexible electronics also enables the actuators to be used with both conventional and eldbus systems – the SIPOS 5 Flash is extremely adaptable to the respective control system. The modular structure of the SIPOS 5 Flash allows it to be upgraded from simple conventional...

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SIPOS 5 Flash: Electric Actuators  Technology-6

SIPOS 5 Flash One for all The intelligent approach to actuator design Modern process engineering requires valves which will operate at precisely defined speeds. The SIPOS 5 Flash actuator range incorporates an electronic frequency converter driving a robust induction motor (instead of the conventional motor plus reduction gear arrangement) which allows software congurable speed control (ratio 1:8) for valve open/closure rates. Changing speeds rates is therefore an extremely simple procedure either at time of valve specification or later on-site. Electronics replaces mechanical components Replacement...

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SIPOS 5 Flash: Electric Actuators  Technology-7

Product range Mechanical interface Actuators for every application Whatever the industrial processing application, both standard and modulating duty, the SIPOS 5 Flash actuator range provides a solution. SIPOS 5 Flash Product range Rotary actuators Linear actuators Standard actuators Modulating actuators Modulating actuators Part-turn actuators Standard actuators Modulating actuators For applications where torques exceed the standard range specication, combinations of 2SA5 rotary actuators and larger gear units provide the necessary solution. Other products of SIPOS Aktorik Rotary actuators for...

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SIPOS 5 Flash: Electric Actuators  Technology-8

Control and regulation Suitable for every process SIPOS 5 Flash actuators are available both as standard and modulating actuators. The standard actuators are designed for S2 duty cycles (short-time duty) 15 min, the modulating actuators are designed for S4/S5 intermittent operation with a minimum of 25 % relative duty to a maximum of 1200 cycles per hour in accordance with DIN EN 60034. Two electronics variants SIPOS 5 Flash actuators can be supplied with two different electronic versions: ECOTRON and PROFITRON. Common features • Integrated frequency converter • Electronically adjustable speed...

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SIPOS 5 Flash: Electric Actuators  Technology-9

Product range Mechanical interface

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SIPOS 5 Flash: Electric Actuators  Technology-10

SIPOS 5 Flash Mechanical interfaces for all valve types The output shaft for rotary actuators is designed as hollow B1-/B shaft. The torque is transmitted to the valve via a featherkey. Other output shaft forms are achieved by means of inserts or extension modules. Various forms of mechanical interfaces are available which can be used to connect the actuator to different control elements (valves, butterfly valves, gate valves, ball valves). Rotary actuators can be supplied with flange connections and couplings in accordance with DIN ISO 5210 and DIN 3338 or DIN 3210 with output shaft forms A,...

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SIPOS 5 Flash: Electric Actuators  Technology-11

Mechanical interface Large torque capability Large torque ranges for rotary movements, linear actuators and part-turn actuators are created by fitting precisely matched mechanical components to the rotary actuators. These components continue the concept of modularity seen with the electronics units through the mechanical design of the actuator, thus keeping spare part inventory to a minimum. There are three completely interchangeable gearbox options which are described below: Worm gearbox for direct mounting and worm gearbox with base and lever 2SC5... part-turn actuator Part-turn actuators are...

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SIPOS 5 Flash: Electric Actuators  Technology-12

Flexible control by means of a frequency converter Using a frequency converter in the actuator allows complete control of the motor i.e.: speed and direction of rotation together with torque. The voltage applied to the motor by the frequency converter determines the output torque, whilst the frequency determines the output speed. A number of benets offered by this unique combination of frequency converter and controller specially designed for service in electrical actuators includes: – Voltage variation compensation Actuator designed for “80 % nominal voltage”, valve design for torque at “110...

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SIPOS 5 Flash: Electric Actuators  Technology-13

Product range Mechanical interface The frequency converter – How it works Frequency converters with a DC voltage link are now standard devices employed by a wide range of industry users. The frequency converter generates a three-phase voltage of variable frequency and amplitude from a single-phase or three-phase voltage with a fixed frequency (e.g. 50 Hz) and amplitude (e.g. 400 V). The following is a brief description of how these devices function: 1. Rectification The single-phase or three-phase alternating voltage is rectified by means of a diode bridge: The voltage is smoothed in the so-called...

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.