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Installation, Operation and Maintenance Manual

MAN-10-04-100-0711-EN Rev. 0

October 2020

3

General Safety Instructions

Section 1: General Safety Instructions

1.4

Identification

1.4.1

Water - Dust-Proof Version

Keystone EPI2 actuators are designed and manufactured according to EN 60529 standards.

Specific types of protection are printed on the label, as follows:

•

IP66/68

•

NEMA 4/4X/6 according to NEMA ICS6 / NEMA 250

Figure 1

Label for Application in Water - Dust-Proof Areas

A.  Manufacturer logo
B.  Product model
C.  Nominal output torque value
D.  Product code
E.  Serial number
F.  Stroking time range
G.  Power supply data
H.  Max current absorption in ampere
I.  Environmental data
L.  Actuator duties
M.  Weather-proof protection degree (EU and US)

N. Weather-proof certificate reference (EU and US)

O. Manufacturer details
P. Year of construction

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Summary of Contents for Keystone EPI2 1000

Page 1: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 Keystone EPI2 Electric Actuator ...

Page 2: ...Notes October 2020 Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 This page intentionally left blank ...

Page 3: ... 2 7 Options Label 10 Section 3 Storage and Pre Installation 3 1 Checks to be Carried Out when the Actuator is Received 11 3 2 Storage Procedure 11 3 2 1 General 11 3 2 2 Storage for a Brief Period less than one year 12 3 2 3 Long Period Storage more than one year 12 Section 4 Installation 4 1 Checks to be Performed Before Installation 13 4 2 Working Condition 13 4 3 Coupling Block 14 4 4 Installa...

Page 4: ...erse Mode Configuration 35 6 2 13Actuator Model Selection 36 6 2 14Blinker Local Selector Configuration 37 6 2 153 WIRES 2 WIRES Remote Control Configuration 38 6 3 Configuration of the Keystone EPI2 by a PDA PC and A Manager Software 38 6 4 Hardware Configuration for Monitor Relay 39 Section 7 Maintenance and Troubleshooting 7 1 Maintenance 40 7 1 1 Routine Maintenance 40 7 1 2 Special Maintenanc...

Page 5: ...ation adjustment and maintenance of the machine Such risks lie entirely with the user Depending on the specific working conditions additional precautions may be requested Considering that Emerson has no direct control over particular applications operation or maintenance conditions it is the operator s responsibility to comply with all applicable safety rules Please inform Emerson urgently if you ...

Page 6: ...tronic parts of the Keystone EPI2 and all the optional modules can be damaged by a discharge of static electricity Before you start touch a grounded metal surface to discharge any static electricity 1 2 Terms and Conditions Emerson guarantees each single product to be free from defects and to conform to current goods specifications The warranty period is one year from the date of installation by t...

Page 7: ...f protection are printed on the label as follows IP66 68 NEMA 4 4X 6 according to NEMA ICS6 NEMA 250 Figure 1 Label for Application in Water Dust Proof Areas A Manufacturer logo B Product model C Nominal output torque value D Product code E Serial number F Stroking time range G Power supply data H Max current absorption in ampere I Environmental data L Actuator duties M Weather proof protection de...

Page 8: ...fic types of protection are printed on the label as follows ATEX Ex de IIB T5 with enclosures in explosionproof version and terminal board enclosure in increased safety version FM rated as flameproof for Class I Zone 1 Group IIB T5 Class II III Div 1 Groups E F and G T4 NEMA 7 and NEMA 9 The above versions of Keystone EPI2 prevent the risk of explosion in the presence of gas or ignitable dusts Key...

Page 9: ...rer logo B Product model C Nominal output torque value D Product code E Serial number F Stroking time range G Power supply data H Max current absorption in ampere at 24 V DC I Environmental data L Actuator duties M Explosion proof protection degree N Weather proof certificate reference IP66 NEMA types 4 4X and 6 when labelled FM O ATEX certificate reference P Manufacturer details Q Year of constru...

Page 10: ...or design Part 2 Technical principles and specification EN 60204 1 Electrical equipment of industrial machines Part 1 General requirements 98 37 EC Machinery Directive 2014 35 EU Low Voltage Directive 2014 53 EU RED Directive 2014 34 EU ATEX Directive 1 6 Extract from the Standard Table 1 1 7 Manufacturer Manufacturer with respect to Machinery Directive 98 37 is Biffi Italia as specified on the ac...

Page 11: ...annulus a means of manual operation is provided which needs no declutch An end of travel position detection device is operated via a position sensor directly linked to the output shaft The valve position is continuously monitored in electric mode by means of a position sensor directly connected to the Keystone EPI2 output drive 2 3 Electrical Operation Control command open counter clockwise or clo...

Page 12: ... the actuator will restart its operation and move the valve to the requested position Figure 3 2 5 Description of the Main Parts The Keystone EPI2 actuator consists of five main parts Base flange for coupling the actuator to the valve Terminals enclosure for power and signal cable connection through four available cable entries Mehanical gearing internal epicyclical gear reduction which increases ...

Page 13: ... optional module OMx will be provided with its own Installation and Maintenance Instructions All modules except OM13 are available for both 1 phase and 3 phase voltage versions 2 Bluetooth component is integrated in the OM1 OM9 and OM11 card not available for integration by local organizations as a stand alone unit 3 OM13 is not available wit h 3 phase supply Not available for LV version 1 phase v...

Page 14: ...Description Section 2 Machine Description 2 7 Options Label A label is always provided with base actuators where optional modules will have to be checked out once they are installed after delivery at local organisations care Figure 4 Figure 5 Please make sure the label is stuck where shown in the picture below Options Label ...

Page 15: ... case all the setting operations described in this Instruction and Operating Manual must be carried out Check that the actuator was not damaged during transport in particular inspect the local position indicator area glass If necessary repair all damages to the paint coat etc Check that the fitted accessories comply with those listed in the order acknowledgement and the delivery note 3 2 Storage P...

Page 16: ...protected from dust In very humid environments a moisture absorbent desiccant packet should be introduced in the motor enclosure Desiccant is not included in the actuator package If the actuators are supplied with standard plastic plugs remove them from the cable entries and replace them with weather proof plugs 3 2 3 Long Period Storage more than one year 3 2 3 1 Indoor Storage In addition to the...

Page 17: ...lve so that the shaft output drive enters the groove of the stem extension This coupling must take place without forcing and only with the weight of the actuator When the actuator output shaft and the valve stem are connected check the holes of the valve flange If they do not meet with the holes of the spool piece flange or the stud bolts screwed into them the actuator shaft output drive must be r...

Page 18: ...erature NOTE In case the screws of the cover of the terminal compartment and of the OM3 must be replaced SS Aisi 316 Class A4 grade 80 screw must be used with minimum yield strength 600 N mm The screw size is M6 X 25 mm Other screws used for the assembly of the other various parts of the explosionproof enclosure shall be a SS AISI 316 Class A4 Grade 70 with minimum yield strength of 450 N mm Every...

Page 19: ... the bracket and the adapter onto the valve then insert the valve shaft into the actuator bottom flange taking care to correctly connect the insert Fix the screws between the bracket and the valve flange and the actuator coupling block 4 5 Manual Operation Keystone EPI2 electric actuators are supplied with a handwheel for manual override as standard to operate the actuator in case of power supply ...

Page 20: ... 1 clockwise to find the correct position then block it by means of the nut Screw 2 close To set the mechanical stop in closing manually bring the actuator to the completely close position then tighten screw 2 If the actuator angular stroke is stopped before reaching the end position fully open or closed proceed as follows Unscrew the stop screw by turning it anticlockwise until the valve reaches ...

Page 21: ...nt applicable regulations Setting must be done while the actuator is powered on As a consequence all setting operations must be carried out by specifically qualified personnel for operations on powered electronic cards 4 8 Plant Requirements Protection devices over current breakers magneto thermal switches or fuses must be provided by the customer to protect the main lines in case of motor over cu...

Page 22: ... 48 V AC 90 V AC 110 V AC 230 V AC 264 V AC 24 V DC 48 V DC 90 V DC 110 V DC 230 V DC 264 V DC 063 E006 8 15 2 26 1 01 0 590 0 473 0 334 0 289 2 02 1 01 0 605 0 476 0 222 0 196 6 28 1 60 0 84 0 405 0 334 0 253 0 217 1 53 0 75 0 415 0 343 0 158 0 138 4 48 1 38 0 73 0 317 0 265 0 209 0 176 1 30 0 64 0 318 0 260 0 120 0 106 125 E013 8 15 4 20 1 70 0 980 0 810 0 430 0 420 4 50 1 81 1 040 0 820 0 390 0...

Page 23: ...tober 2020 19 Installation Section 4 Installation 4 9 Removal of the Terminal Board Enclosure Using a 5 mm Allen key loosen the four screws and remove the cover Figure 9 Removal of the Terminal Board Enclosure WARNING Pay attention not to damage the joint surfaces of the cover ...

Page 24: ...ply voltage and current shown on the nameplate and on the attached wiring diagram are correct for the installation Figure 10 Overview of the Electrical Connections WARNING Do not remove earth connection X while connecting the actuator to plant earthing NOTE All the accessories which equip the Keystone EPI2 in particular the cable glands must be certified according to the Standard Directive and spe...

Page 25: ...nal cables to the actuator by linking them to the terminal blocks termination as per diagram Replace the plastic plugs of the unused cable entries by metal ones to guarantee perfect weatherproof tightness and to comply with the explosionproof protection codes where applicable Once the connections are completed check that the controls and signals work properly Two ground studs one internal and one ...

Page 26: ...V AC or DC Control signal minimum duration 600 ms 6 Blinker or Local Selector monitoring function when OM3 is present to be configured Internal supply 24 V DC Internal supply 24 V DC Contact open for actuator closing Contact close for actuator opening Contact open for actuator closing Contact close for actuator opening External supply 24 120 V AC or 24 120 V DC External supply 24 120 V AC or 24 12...

Page 27: ... the necessary connections To guarantee the proper weatherproof fit degree IP66 68 must be ensured screw the cable glands tightly and block them with a thread sealant The use of a thread sealant is necessary in case of explosionproof application If some parts of the cable glands have been removed while working on the cable entries put them back into place in order to avoid losing the dismantled pa...

Page 28: ...grease Proceed as follows Do not damage the explosionproof mating surfaces on the housing and on the electrical enclosure covers Reinstall all the screws that go with the dismantled parts and block them with a thread sealant after spreading them with a film of copper or molybdenum based grease This will keep screws from sticking and make maintenance operations easier Check that the bolts and screw...

Page 29: ...be supplied by Emerson NOTE Keystone EPI2 electric actuators must be installed and maintained according to the applicable rules regarding the electrical installation in hazardous areas other than mines classified as zone 21 and or 22 dust according to EN 60079 10 hazardous area classification Example installation and maintenance according to EN 50281 1 2 Special attention is requested to the follo...

Page 30: ...tion Section 5 Lubrication 5 1 Lubrication Inspection The actuator is grease lubricated for life therefore under normal working conditions no grease needs to be replaced or added In case of maintenance the following grease is recommended AEROSHELL GREASE 7 or equivalent for ambient temperature 40 C to 70 C 40 F to 158 F ...

Page 31: ...ly could cause permanent damage to the electrical components The configuration of the Keystone EPI2 actuator can be carried out through the control panel inside the actuator control system To access the panel remove the actuator cover and when the configuration is complete replace the cover following the procedures indicated on next page NOTE When optional local control panel OM3 is installed and ...

Page 32: ... and remove the cover NOTE When setting the actuator parameters do not operate the actuator neither remotely nor locally WARNING Pay attention not to damage the joint surfaces of the cover NOTE In case the screws of the cover must be replaced SS Class A4 grade 80 screw must be used with minimum yield strength 600 N mm2 Once the configuration is completed reassemble the actuator cover Figure 14 Rem...

Page 33: ...0 45 s for model 1000 and 100 s for model 2000 Torque limiting device in CL set at about 100 of nominal torque Torque limiting device in OP set at about 100 of nominal torque Reverse mode off Monitor Relay NC in normal condition i e without alarms Blinker Local Selector relay off always Open If the application requires different actuator configurations please proceed as described in this chapter N...

Page 34: ...osing speed 4 4 ON PUSH 6 4 6 ON PUSH 4 8 ON PUSH Opening speed 5 4 ON PUSH 6 5 6 ON PUSH 5 8 ON PUSH Closing torque 6 2 50 ON PUSH 9 6 5 75 ON PUSH 6 9 100 ON PUSH Opening torque 7 2 50 ON PUSH 9 7 5 75 ON PUSH 7 9 100 ON PUSH CW CCW 8 0 CW ON PUSH 0 8 1 CCW ON PUSH Size 9 0 63 Nm 250 Nm ON PUSH 0 9 1 125 Nm 500 Nm ON PUSH 9 3 1000 Nm ON PUSH 9 4 2000 Nm ON PUSH Nm in lb 0 8 Nm ON PUSH 8 0 9 in l...

Page 35: ... 6 2 3 Close Limit Configuration Move switch SW3 to position ON Drive the actuator to the close position using the handwheel Move switch SW4 to position 0 Move switch SW6 to position 0 Confirm by pushing ENTER pushbutton SW5 When pushing SW5 the red LED switches on for confirmation Exit set up configuration moving switch SW3 to position 1 or proceed with the next parameter 6 2 4 Open Limit Configu...

Page 36: ...witch SW6 to position 0 Move switch SW3 to position ON Confirm by pushing ENTER pushbutton SW5 red LED switch on Operate the actuator to closing direction by local remote control and wait until it stops by torque When the setting is completed the red LED switches off Exit set up configuration moving switch SW3 to position 1 or proceed with the next parameter 6 2 7 Open Limit Configuration by Torqu...

Page 37: ...lose configuration by torque c SW4 1 and SW6 0 stroke limit of open configuration by position d SW4 0 e SW6 0 stroke limit of close configuration by position The alarm is then reset by a Switching off and on the actuator b Doing a new correct stroke limit setup in one of the 4 possible combinations WARNING In configuration phase touch only the configuration area of the logic board don t touch the ...

Page 38: ...rque corresponding to 100 is set in house and stated in the name plate Enter set up configuration move switch SW3 to position ON configuration function Move switch SW4 to position 6 Move switch SW6 to positions 2 5 or 9 for the requested torque value in percentage in closing Push ENTER pushbutton SW5 to confirm When pushing SW5 the red LED switches on for confirmation The setting of the torque lim...

Page 39: ...ushing SW5 the red led switches on for confirmation The setting of the torque limiting device in opening is now complete Exit set up configuration move switch SW3 to position 1 or proceed with the next parameter WARNING Torque switches setting must be done only with the authorization of the valve manufacturer considering the specific valve figures 6 2 12 Reverse Mode Configuration Enter set up con...

Page 40: ... red LED switches on for confirmation Exit set up configuration move switch SW3 to position 1 or proceed with the next parameter Actuator model 125 Enter set up configuration move switch SW3 to position ON configuration function Move switch SW4 to position 9 Move switch SW6 to position 1 Confirm by pushing ENTER pushbutton SW5 When pushing SW5 the red LED switches on for confirmation Exit set up c...

Page 41: ...tion for Blinker Local Selector relay is off always Open In Blinker configuration during actuator movement the relay changes their status each 500 ms Motor Running function In Local Selector configuration with Local Interface OM3 installed the relay is CLOSE when OM3 switch is on REMOTE while it is OPEN when OM3 switch is on LOCAL To configure Blinker or Local Selector monitoring function when OM3...

Page 42: ...tion 5 3 WIRES or 6 2 WIRES Confirm by pushing ENTER pushbutton SW5 When pushing SW5 the red LED switches on for confirmation Exit set up configuration move switch SW3 to position 1 or proceed with the next parameter 6 3 Configuration of the Keystone EPI2 by a PDA PC and A Manager Software If one of the optional module OM1 OM9 or OM11 is installed on the Keystone EPI2 and this card features Blueto...

Page 43: ... module present A Manager local control if Bluetooth is present The Monitor relay contacts can be set as CLOSE or OPEN by changing the welding of JUMPER J31 on logic board As a default setting pins 2 and 3 are welded together and the Monitor relay contact operates as follows contact CLOSE in normal condition with relay energized and OPEN in case of malfunction relay is de energized In case of requ...

Page 44: ...for individual item numbers Repaint all areas where paint is missing In chemically aggressive or saline environments remove rust from surfaces and protect with a rust preventative Check that all nuts and bolts securing the actuator to the valve are tight If necessary re tighten with a dynamometric key For severe applications or if actuator operation is infrequent perform maintenance checks more of...

Page 45: ...ition of the dip switch SW3 it must be 1 7 2 1 The Electronics do not Switch on When Powered Check that the value of the main voltage on terminals L1 and L2 and in the same case L3 is correct Remove the cover assembly Check the continuity of the wires between terminals L1 L2 L3 and the connector of the power card If there is no continuity on the L1 L2 L3 cables replace the terminal board If contin...

Page 46: ...heck the causes of abnormal operation 7 2 5 The Motor Runs but the Actuator does not Move the Valve Verify that the drive insert correctly fits in the actuator base Verify that the drive insert has enough engagement with the valve stem Verify that the key correctly fits in bore keyways applications Check that the valve works in manual operation If not it is necessary to check the manual control ar...

Page 47: ...agnostic LED For more detailed alarms check the diagnostic led status on the logic board It has the coding shown in the table Table 7 Sensor Alarm 5x blinks of the diagnostic led Check that the position sensor cable is connected Check that the position sensor enclosure is not mechanically damaged If it is broken replace the entire electronic group Bad CRC Alarm 7x blinks of the diagnostic led Rest...

Page 48: ...hey have been checked or replaced by qualified personnel and declared unsuitable for use NOTE In all cases check local authority regulation before disposal Subject Hazardous Recyclable Disposal Electrical and electronic equipment Yes Yes Use specialist recyclers Glass No Yes Use specialist recyclers Metals No Yes Use licensed recyclers Plastics No Yes Use specialist recyclers Rubber seals and O ri...

Page 49: ...ction includes the drawings and parts list of each component and subassembly of Keystone EPI2 actuators NOTE When ordering spare parts please indicate the serial number embossed on the actuator nameplate NOTE When ordering spare parts please refer to the marked part list items on the attached drawings NOTE Recommended spares for routine maintenance are marked with this sign on parts list ...

Page 50: ... 4 15 HSSC screw UNI 5933 M4x10 1 16 Cover assembly 1 17 Drive and control unit 1 18 Handwheel 1 19 Output drive assembly 1 20 Standard housing 1 21 Stopper 2 22 Terminal block 1 23 Worm shaft flange 1 24 Anti loosening washer UNI 8842 J6 1 25 Base plate ISO 5211 F05 F07 1 26 Cover gasket 1 27 Dowel pin UNI EN 22338 1 28 Earth stud 1 29 Fixed anulus 1 30 Gasket 1 31 Indicator 1 32 Indicator shaft ...

Page 51: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 47 Parts List and Drawings Section 9 Parts List and Drawings Figure 16 ...

Page 52: ... 4 15 HSSC screw UNI 5933 M4x10 1 16 Cover assembly 1 17 Drive and control unit 1 18 Handwheel 1 19 Output drive assembly 1 20 Standard housing 1 21 Stopper 2 22 Terminal block 1 23 Worm shaft flange 1 24 Anti loosening washer UNI 8842 J6 1 25 Base plate ISO 5211 F07 F10 1 26 Cover gasket 1 27 Dowel pin UNI EN 22338 1 28 Earth stud 1 29 Fixed anulus 1 30 Gasket 1 31 Indicator 1 32 Indicator shaft ...

Page 53: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 49 Parts List and Drawings Section 9 Parts List and Drawings Figure 17 ...

Page 54: ... UNI 5933 M4x10 1 16 HSSC screw UNI 5933 M5x12 3 17 Cover assembly 1 18 Handwheel 1 19 Housing 1 20 Motor pinion 1 21 Output drive assembly 1 22 Stopper 2 23 Terminal block 1 24 Anti loosening washer UNI 8842 J6 2 25 Base plate ISO 5211 F07 F10 F12 1 26 Cover gasket 1 27 Dowel pin UNI EN 22338 1 28 Earth stud 1 29 Fixed anulus 1 30 Gasket 1 31 Indicator 1 32 Indicator shaft 1 33 Manual worm shaft ...

Page 55: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 51 Parts List and Drawings Section 9 Parts List and Drawings Figure 18 ...

Page 56: ...ew UNI 5933 M4x10 1 16 HSSC screw UNI 5933 M5x12 3 17 Cover assembly 1 18 Drive and control assembly 1 19 Handwheel 1 20 Housing 1 21 Motor pinion 1 22 Output drive assembly 1 23 Stopper 2 24 Terminal block 1 25 Anti loosening washer UNI 8842 J6 2 26 Base plate ISO 5211 F10 F12 1 27 Cover gasket 1 28 Dowel pin UNI EN 22338 1 29 Earth stud 1 30 Fixed anulus 1 31 Gasket 1 32 Indicator 1 33 Indicator...

Page 57: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 53 Parts List and Drawings Section 9 Parts List and Drawings Figure 19 ...

Page 58: ...4x10 1 16 HSSC screw UNI 5933 M5x12 3 17 Cover assembly 1 18 Drive and control assembly 1 19 Handwheel assembly 1 20 Output drive assembly 1 21 Stopper 2 22 Terminal block 1 23 Terminal cover gasket 2 24 Anti loosening washer UNI 8842 J6 2 25 Base plate ISO 5211 F10 F14 1 26 Cover gasket 1 27 Dowel pin UNI EN 22338 1 28 Earth stud 1 29 Fixed anulus 1 30 Housing 1 31 Indicator 1 32 Indicator shaft ...

Page 59: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 55 Parts List and Drawings Section 9 Parts List and Drawings Figure 20 ...

Page 60: ...e 61908 1 5 HSHC screw UNI 5931 M6x16 3 6 HSHC screw UNI 5931 M12x30 4 7 HSHC screw UNI 5931 M12x65 4 8 HSHC screw UNI 5931 M8x25 A4 70 6 9 Keystone EPI2 actuator 1 10 Base housing 1 11 Base plate F12 F16 EN ISO 5211 1 12 Bearing support 1 13 Bushing 2 14 Bushing 1 15 Bushing 1 16 Bushing 1 17 Dowel pin UNI EN 22338 D 8x20 type B 4 18 Gasket 1 19 Hex head screw UNI EN 24017 M20x80 2 20 Idle wheel ...

Page 61: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 57 Parts List and Drawings Section 9 Parts List and Drawings Figure 21 ...

Page 62: ...0 1 14 HSSC screw UNI 5933 M5x12 3 15 Cover assembly 1 16 Drive and control assembly 1 17 Handwheel assembly 1 18 Housing 1 19 Output drive assembly 1 20 Terminal block 1 21 Terminal cover gasket 1 22 Worm shaft flange 1 23 Anti loosening washer UNI 8842 J6 2 24 Bushing 1 25 Cover gasket 1 26 Dowel pin UNI EN 22338 1 27 Earth stud 1 28 Fixed anulus 1 29 Hex head screw UNI EN 24017 M16x30 2 30 Indi...

Page 63: ...Installation Operation and Maintenance Manual MAN 10 04 100 0711 EN Rev 0 October 2020 59 Parts List and Drawings Section 9 Parts List and Drawings Figure 22 ...

Page 64: ...ow Business Estate East P O Box 6908 Greenstone 1616 Modderfontein Extension 5 South Africa T 27 11 451 3700 EUROPE Holland Fasor 6 Székesfehérvár 8000 Hungary T 36 22 53 09 50 Strada Biffi 165 29017 Fiorenzuola d Arda PC Italy T 39 0523 944 411 www emerson com VCIOM 15516 EN 2020 Emerson All rights reserved The Emerson logo is a trademark and service mark of Emerson Electric Co KeystoneTM is a ma...

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