SIPOS 5 Flash

Electric
Actuators
Technology

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights
2

SIPOS 5 Flash
The new generation of actuators

The SIPOS 5 actuators series has now been developed into the high-
tech SIPOS 5 Flash generation, which enables a wide range of
applications as well as reliable and modulating control of your valves.
For example, in water management - from drinking-water processing
to sewage works -, in processing plants - from the cement factory
to the food industry - and in the energy sector - from the power
station to district heating - as well as in the chemical industry. Due
to integration of the complete controls including communications
and power electronics in the actuator, circuit-breakers like reversing
contactors or thyristor reversing controllers are obsolete and thus a
major part of the switchgear system.
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Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

The flexible electronics enable application in both conventional
and highly modern plants. The SIPOS 5 Flash shows versatility
towards actuator control and process control systems.
Thanks to its modular structure with just a few components, the
SIPOS 5 Flash can easily be modified for any application - from simple
actuation to PROFIBUS communication.
And if extreme shocks or ambient temperatures occur, there is not
enough space available or when local operator control is not possible,
the electronics can be mounted separately from the gear unit - quickly
and without complication.
In addition to these functions, the SIPOS 5 Flash actuator has other
outstanding features such as:
• No overtorque, even if a blockage occurs
• The starting current is never greater than the rated current
small cable cross-section
• Automatic phase-sequence correction
• Full motor protection
• Variable speeds etc.
As a valve manufacturer, factory planner, plant constructor or operator,
you can justifiably expect a great deal of a high-tech actuator - now
and in the future. The SIPOS 5 Flash definitely leads the way.
What else the high-tech SIPOS 5 Flash actuator generation can do
is revealed on the following pages.
 4

SIPOS 5 Flash
One for all -
Fully flexible with integrated electronics

Intelligence saves expenditure - this is a principle which the SIPOS 5 Your advantages
Flash actuators consequently apply. • electronic motor control
An example: An electronic frequency converter for motor control is – with full motor protection
included in each SIPOS 5 Flash, a concept surpassing the conventional – with automatic phase sequence correction
solution of motor plus reduction gear. – simplifies switching cabinets
– process optimation due to output speed variation
Process engineering requires that valves are operated at a precisely • big torque- and output speed range
stipulated speed. This speed was previously defined by components simplification of planning stage
motor and reduction gear. In contrast, the frequency converter of the • goes easy on your valve
SIPOS 5 Flash actuator controls the robust induction motor of the – by soft start-up
actuator while enabling the speed to be set in the range 1 : 8 without – by exclusion of overtorque
the need to modify the actuator. • easy commissioning
• covers most applications with few units
The SIPOS 5 Flash is thus an extremely flexible actuator - easily reduced spare parts stock
adaptable to new conditions and simple to incorporate in planning,
configuration, plant construction or commissioning. Even in the
warehouse, things are much easier as just a few variants of the
actuator can cover all your requirements.

Rotary actuator Linear actuator Part-turn actuators Electronics replaces mechanics,

2SA5... 2SB5...
Linear actuators consist of
a rotary actuator and an
attached thrust unit. The
actuator software takes the
physical values for positioning
speed (mm/min) and cut-off
force (kN) into account.
2SC5...
Part-turn actuators consist of
a rotary actuator and an attached
worm gearbox. The actuator
software takes the physical
values for positioning time
(sec/90°) and cut-off torque
(Nm) into account.
wherever possible.
It works wear-free and can be
programmed. It also replaces e.g.
limit and torque switches. Time
consuming adjustment work is
made obsolete. The SIPOS 5 Flash
PROFITRON does not even have
to be opened for recommissioning.
 5

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Actuators for all branches

Product range SIPOS 5 Flash

Rotary actuators Linear actuators Part-turn actuators

Standard actuators Modulating actuators Modulating actuators Standard actuators Modulating actuators

2SG50.. 2SG55..
2SA50.. 2SA55.. 2SB55.. 32-125 Nm 32-125 Nm
10-4000 Nm 15-2800 Nm 5.5-152 kN 2SC50.. 2SC55..
150-4300 Nm 250-3400 Nm

Spare parts Accessories

2SY5... 2SX5...

For standard and modulating duty the SIPOS 5 Flash actuators can Complete documentation is available for every actuator - ordering
deal with every task concerning industrial processing - our product data and spare parts lists, technical data, instruction manuals,
range can cope with all requirements. certificates and naturally the complete catalogue - to make planning
of your plant as efficient as possible.

Other products of SIPOS Aktorik GmbH

• 2SM5...- Actuator control systems SIMA
• 2SB6...- Small linear actuators for modulating duty Fc 2 - 25 kN
• Small part-turn actuators
M77325- for On-Off duty Tc 25 -200 Nm
M77326- for modulating duty Tc 30 - 200 Nm
• M76348- Double motor actuators for modulating duty Tc 750 - 3000 Nm
• Rotary actuators for nuclear applications acc. KTA 3504
M76361- / M76371- for On-Off duty
M76362- / M76272- for modulating duty

All our documentation is stocked in the Siemens AG logistics central For queries or technical support
storeage and can be obtained free of charge from there or from us. please contact:
The desired documents can be selected and ordered comfortably via SIPOS Aktorik GmbH
www.click4business-supplies.siemens.de worldwide. Electric actuators
Donaustr. 36
On our website www.sipos.de you will always find the current
D-90451 Nuremberg
version of our documentation - also dimensional drawings in dxf-
Tel. (0911) 63284-0
format and updates for our PC program COM-SIPOS. Furthermore the
Fax (0911) 63284-111
current version of our firmware, etc. and naturally your local contact
E-Mail info.sipos.de
and service centres all around the world.
www.sipos.de
 6

Control and regulation -

Suitable for every process

SIPOS 5 Flash actuators are available as standard and modulating SIPOS 5 Flash actuators are supplied with two different electronics
actuators. versions:
The standard actuators are designed for short-time duty of S2-15 ECOTRON and PROFITRON.
min, the modulating actuators are designed for S4/S5 intermittent • Both have the common concept:
operation with a minimum of 25% power-on duration at a maximum – Integrated frequency converter
of 1200 cycles per hour in accordance with DIN EN 60034. – Electronically adjustable speed
– Electronic limitation of cut-off torque/force
– Extensive internal monitoring functions, including full motor
ECOTRON

Same output speed for OPEN and CLOSE direction – can protection
be selected and set from 7 available speeds.
And last but not least:
Travel
OPEN
– Simple commissioning with user guidance.
• For operation, neither of them needs any external switching
devices, reversing controllers or control cabinets any more because
all the electronics for communication and control are already
integrated.
CLOSED
• Both have universal interfaces for conventional controls and,
Time
of course, for PROFIBUS DP to be connected to all automation
systems.
• And both have a built-in local control station.
PROFITRON

Different output speeds for OPEN and CLOSE direction –

can be selected and programmed from 7 available speeds.
The ECOTRON version is especially suitable for standard and simple
Travel modulating control functions with operation by means of the switching
OPEN
commands, OPEN, CLOSE and STOP. Position signaling to the control
system takes place by means of 5 signal outputs and an analog
4-20 mA feedback signal.
The more comfortable PROFITRON version is the ideal high-tech
modulating actuator which has also proved its worth for standard
CLOSED
applications.
Running Standstill Running Time
In addition to control by means of switching commands, the
PROFITRON has an input for emergency operation and a 0/4-20 mA
In addition to the different output speeds for OPEN and input for the integrated positioner. For position signaling to the control
CLOSE direction, further output speeds can be defined
and programmed for OPEN and CLOSE direction for system, there are 8 signal outputs and a 0/4-20 mA feedback signal.
EMERGENCY operation.
With the plain-text display, the PROFITRON electronics can be used
Travel
OPEN
to monitor, diagnose and, if necessary, perform parameterization.
The language of the display can be selected as required.

CLOSED in OPEN direction standstill

EMERGENCY Time
signal
in CLOSE direction running to EMERGENCY position
 7

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Standard actuator Modulating actuator

Functions SIPOS 5 Flash

PROFITRON

PROFITRON
ECOTRON

ECOTRON
Inputs and Outputs
Automatic phase sequence correction
Control inputs OPEN, CLOSE, STOP (galvanically separated)
Control input EMERGENCY (differential input)
24 V external power supply possible
Setpoint 0/4 … 20 mA (analog input)
Control via threshold switch
Two-wire control
Signaling outputs 24 V (galvanically separated) 5 8 5 8
Relay outputs (NC, NO each) 5 5 5 5
Position feedback signal 4..20 mA (analog output)
Position feedback signal 0/4..20 mA (analog output)
PROFIBUS DP, incl. V1-services
PROFIBUS DP-interface
Redundant PROFIBUS DP-interface
Adjustment / parameterization possibilities
Cut-off torque / force steps 8 8 4 4
Output speed 1) steps 7 7 7 7
Independantly adjustable output speeds1) for OPEN, CLOSE, EMERGENCY OPEN and CLOSE 1 4 1 4
Cut-off mode (travel / torque dependent)
Intermediate contacts 2 2
Motor protection bypass
Motor heater
Maintenance intervals
Other
Local control station (lockable with padlock)
Motor temperature monitoring
Torque cut-off bypass
Local / remote LED
OPEN / CLOSE LED
Soft start-up
Valve torque reference curve recording (3 reference curves)
Clear text display
Software options
Positioner integrated (adaptive three-point controller)
Stroke-speed curve (for valve characteristic linearization)
Analog output speed setpoint (for process optimation)

Legend: Standard
Option
1) stands also on behalf of positioning speed and positioning time
 8

SIPOS 5 Flash -
with variable connection for all valves

There are various forms of connection available which can be used The output shaft for rotary
to mechanically adapt the actuator to different control elements actuators is designed as
(valves, butterfly valves, gate valves, ball valves). Rotary actuators hollow B1-/B shaft.
can be supplied with flange connections and couplings in accordance The torque is transmitted to the
with DIN ISO 5210 and DIN 3338 or DIN 3210 with output shaft forms valve via a featherkey.
A, B1, B2, B3, B4 and C or A, B, C, D and E, depending on the Other output shaft forms are
customer's wishes. achieved by means of inserts or
Linear actuators are mechanically connected in accordance with extension modules.
DIN 3358 and part-turn actuators in accordance with DIN ISO 5211.

Depending on the type of valve, type-dependent flange reductions

can be supplied for the rotary actuators.

A output shaft B2, B3, B4 and E output shafts C output shaft D output shaft
Threaded bush for rising, non- A insert with bore and featherkey A claw coupling insert which is A free shaft end which is inserted
rotating valve stems. The rotary is inserted into the hollow B1/B inserted into the hollow B1/B shaft. into the hollow B1/B shaft and has
movement of the actuator is con- shaft. As with the hollow B1/B The torque is transmitted to the a featherkey. The torque is trans-
verted into linear movement of the shaft, the torque is transmitted to valve by means of the claws. mitted to the valve by means of the
stem by means of a threaded bush the valve by means of a featherkey. featherkey.
(spindle nut). This type of shaft can
also be supplied with a trapezoidal
thread according to DIN 103. The
connecting flange with threaded
bush and axial bearings is a unit
which is suitable for absorbing
thrust.

The output shaft forms A, B1 and C or A, B. C (if in accordance with DIN 3210) are suitable as hollow shafts for rising spindles. Spindle
protection tubes can be supplied in different lengths.
 9

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Large torque ranges for rotary movements, linear actuators and

part-turn actuators are created by fitting precisely matched me-
chanical components to the rotary actuators. An important advan-
tage for you because the gear units of the SIPOS 5 Flash actua-
tors only come in three sizes. All end types of actuators are cre-
ated by modular additions. Only few components therefore can
be kept in stock as spare parts. This modular add-on approach
is also used for the electronics unit, of which there are only two
basic versions.

1 2 3

1 Planetary gear
2SA5... rotary actuator
The planetary gear has a reduction
of 1:4 and thus achieves a quadruple
torque with reduced output speed.
In the case of standard actuators,
therefore, torque ranges of 700-
2000 Nm and 1400-4000 Nm are
available and, in the case of
modulating actuators, torque
ranges of 1000-1400 Nm and 2000-
2800 Nm.
2 Linear actuator
2SB5... linear actuator
The rotary movement of the rotary
actuator is converted into a linear
movement by means of the linear
thrust unit. The rotary actuator thus
becomes a linear actuator and the
torque becomes an axial force.
Different stroke lengths can be
supplied.
3 Worm gearbox for direct mounting and worm gearbox with
base and lever
2SC5... part-turn actuator
Part-turn actuators are used where operation of a final control element
requires a 90° or larger part-turn movement. Usually, the part-turn actuator
is built onto the valve. The connection to the valve shaft is achieved by
means of a coupling (bore with keyway, square bore or bore with two-
flats) with a splined shaft connection.
If direct mounting is not possible due to a lack of space or the design,
the movement is enabled by means of a rod. In these cases, the version
with a base and lever is available. The appropriate damper rods for this
can be supplied. The worm gear unit converts the rotary movement of
the rotary actuator into a part-turn movement. The rotary actuator thus
becomes a part-turn actuator.

In the actuator electronics, the respective add-on module is taken into account by a changed order number. The actuator software therefore
works with the physical quantities which are different due to the respective add-on module. In the case of a linear actuator, for example,
(rotary actuator + thrust unit) , the actuator-stroke speed [mm/min] and the cut-off force [kN] are used for calculating. If a rotary actuator
were used as the basic device, this would be the output speed [1/min] and the cut-off torque [Nm].
10

Variable speed by means of a

frequency converter -
so that your valve works perfectly as required
Variable speed by means of frequency converter - Why?

From a single or three-phase voltage with a fixed frequency (e.g.

50 Hz) and a fixed amplitude (e.g. 400 V), a frequency converter
generates a three-phase voltage of variable frequency and amplitude.
The advantages of this are numerous:

– With force out of the final position or blockage – Optimum position control
The SIPOS 5 Flash moves out of a blocked position for one second Quick compensation of large deviations resulting from setpoint jumps,
at the smallest speed and with a high torque. Even tensioned valves slow correction of small deviations. The positioner integrated in the
are released again. SIPOS 5 Flash PROFITRON uses the different speeds of the frequency
converter.
– Carefully into the end position
The SIPOS 5 Flash moves in the end position range with a fixed, low – Uncertainties in planning
speed. In the case of torque-dependent cut-off, therefore, overtorque Sometimes during the planning stage, it is good to have a little free
is avoided (low kinetic energy of motor and gears). In the case of play in terms of output speed and torque - some things look different
incorrectly set, distance-dependent cut-off, the danger of valve on site. A speed ratio of 1:8 offers many possibilities.
damage is reduced.
– Smaller spare-parts stock
– Motor starting without mains stress Due to the changeability of speed and cut-off torque, there are only
In the frequency converter of the SIPOS 5 Flash, speed jumps are a few variants of actuators for the whole output speed and torque
converted into ramp-shaped setpoints. The induction motor is quasi range. This simplifies stock-keeping of spare actuators and
always operated at the momentary rated point "beyond the stalling components.
point". There is therefore no "starting current" phenomenon. The
– OPEN or CLOSE, it doesn't matter
leads only have to be designed for the current at the rated running
Anyone who can have different speeds can also set different directions
torque. This allows smaller cable cross-sections and a smaller power
of rotation. The frequency converter here replaces the classical
reserve and thus saves money.
reversing contactor or the electronic load relay or thyristor controller.
– Being quick when an EMERGENCY is in the offing
In addition to altering the motor frequency ( speed) and the motor
EMERGENCY speeds which can be set separately for the OPEN and
voltage ( torque), the frequency converter performs a series of
CLOSE directions also help you to cope with critical situations when,
important tasks:
for example, a pipeline has to be opened quickly.
– Continuous current monitoring protects the motor and thus
– Process optimization, valve characteristic linearization
dispenses with the need for separate motor protection.
There are many cases in which different speeds are advantageous
– Continuous current monitoring means continuous monitoring of
in the valve stroke - e.g. opening a valve slowly at first in order to
torque.
avoid turbulence and then quickly moving to the final position OPEN.
– Automatic phase correction. The integrated rectifier works
independently of the connected phase sequence!
– Due to double conversion of the mains voltage, the actuator is
The most important advantages
completely insensitive to mains frequency fluctuations and largely
• Minimum stress on the valve, e.g. due to speed reduction in
insensitive to mains voltage fluctuations.
the end position range
• No overtorque
• Excellent control quality - soft starting and electronic braking
• Extremely fast and simple installation
• Low starting currents, therefore cost savings for wiring
• Fail-safe connection
• Full electronic protection for the motor
 11

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Variable speed by means of a frequency converter - How?

Frequency converters with a DC voltage link are now standard devices employed by a wide range of users in industry. 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:
1.
+ +

L1 L1
L2
N L3

– –

2. Precharging and smoothing 3. Pulse-width modulation

The voltage is smoothed in the so-called "DC link" by large capacitors.
In order to make sure that a voltage jump is not immediately transferred
to the capacitors when the mains voltage is switched on, precharging
resistors are connected in series. During operation, these resistors are
bridged by a relay.
2.
The DC voltage now in the DC link is to be converted into a three-phase
voltage of variable frequency and amplitude. In the three motor leads,
there are fast-acting electronic switches for this purpose, socalled IGBTs
(isolated gate bipolar transistors).
3.

Rv + +

M
C ZK 3-phas

– –

4. The switches connect each motor phase either to the POSITIVE or to
the NEGATIVE rail. The power-on duration and the polarity of the voltage
can be very finely adjusted so that the desired sinusoidal voltage is
produced as a fundamental of this chopped or "pulse-width-modulated"
DC voltage. The motor's inductance acts here quasi as a filter.
4.
U
5. For the permanently necessary calculation of the correct power-on
switching point in the three motor phases- each of the six IGBTs is
switched on and off up to 16 000 times per second! - a very fast computer -
the microcontroller - and application-specific integrated circuits are
necessary. The current is measured in the "classical" fashion by a
measuring shunt in the NEGATIVE rail.
5.

–
t
 12

Electronics
Intelligence in the actuator -
and everything works fluently

8 PROFITRON ECOTRON
Relay 7
card
Galvanical Position Motor temp. Hand wheel
separation

DC 24 V supply for binary

outputs (P24 ext.)
6 5 1
8 binary outputs
(5 binary outputs with green
ECOTRON)
Ground (M ext.) red
STOP
OPEN
CLOSE n (output speed)
EMERGENCY (only PROFITRON)
Ground (M ext.)
(torque
CLOSE)
Position feedback 0/4...20 mA
CPU CPU
2 analog inputs (torque
(only PROFITRON) OPEN)

Flash EEPROM

Control unit PCB EEPROM

Settings
9
Channel 1
4 4
PROFIBUS
PCB
Channel 2 Fuse
(self-resetting)
Output DC 24 V (P24 int.) 10
Switched
Input DC 24 V for additional power
supply of the electronics (P24) supply 3
Local control station Local control station

2
Power control PCB STOP

11 14 13 15
Power supply Asynchronous
motor Enter Enter

Local Remote Local Remote

SIPOS 5 Flash ECOTRON is prede-
stined for all standard tasks: for
standard actuators and simple
modulatings applications; and the
SIPOS 5 Flash PROFITRON is a
specialist for the highest
requirements for closed-loop and
open-loop control. Here, we show
you in detail how simply everything
can work with intelligent actuators.
The Microcontroller (central
processing unit CPU) 5
With the SIPOS 5 Flash, the micro-
controller performs all the control
functions.
It monitors the frequency converter
and the motor temperature,
determines the position of the
actuator by means of a conductive-
plastic potentiometer, regulates the
torque, evaluates the signals of the
overall instrumentation and control
system and reports them back
continuously.
The switched power supply
10
supplies the internal loads and also
provides an output voltage of 24 V
DC for supplying external switches
for the commands OPEN, CLOSE
and STOP.
A separate optional 24 V external
power supply to the electronics
enables communication even if the
mains supply is switched off.
 13

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Control PCB ECOTRON 8 Relay card

Firmware load
1
Parameterize/
observe
2
Operation for end
position adjustment

Control PCB PROFITRON 9 PROFIBUS PCB

4
3
Parameterize/ PC interface
observe

6
Controlsystem 5
interface Central
processing unit

7
Gearbox
interface

Power control PCB

The most important advantages
10 • Integrated control electronics
Switched power supply • Differentiated control electronics
– SIPOS 5 Flash ECOTRON for all
standard applications
– SIPOS 5 Flash PROFITRON for
highest requirements
12 • PROFIBUS interface or relay card
RFI-filter optional – also for SIPOS 5 Flash
ECOTRON
• Microcontroller for perfect motor
control, communication and
actuator monitoring
11 • Redundant 24 V DC supply
14
Power supply
Precharging possible for electronics
• Actuator parameters stored
in EEPROM (nonvolatile)
• Full RFI safety
16 • Data storage without battery or
Driver for storage cell
power module
14
13 DC link
Power module (IGBT)

15
Motor connection
14

New technology in the SIPOS 5 Flash

Down to the smallest detail -
Electronics instead of mechanical components

The SIPOS 5 Flash actuators are extremely

robust: With highly effective seals, they work
reliably wherever they are installed, even
under severe ambient conditions. All the
actuators have at least degree of protection
IP 67 in accordance with DIN EN 60529.

The housing material

consists of a special aluminum alloy which is
extremely corrosion resistant. This material
is characterized by its high strength,
comparable with ductile cast iron, but is
nevertheless extremely light.
Under normal atmospheric conditions, the
SIPOS 5 Flash can even be used outdoors
without having to be painted. For difficult
ambient conditions, the actuator is available
with different paint coverings, also "heavy-
duty anti-corrosion paint", e.g. for operation
in cooling towers.

Rust-free stainless steel screws

 19

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Local control for operating the

actuator by means of the OPEN,
CLOSE and STOP buttons
The SIPOS 5 Flash ECOTRON is set
and commissioned by means of DIP
switches and potentiometers. LEDs
indicate the operating status;
flashing patterns signal faults and
enable diagnosis.
The pushbuttons of the SIPOS 5
Flash PROFITRON are also used for
parameterizing on site and for
retrieving actuator information.

Changeover button
LOCAL/REMOTE
As protection against unauthorized
operation, changeover to local
operation can be prevented with a
padlock.

Inspection window
The mechanical position indicator is
visible through the cover over the
signaling gear. Two adjustable
symbols for OPEN and CLOSE
indicate the valve position.
Direct connection
The connecting cables are led through
cable glands into the housing and are
directly connected by means of PCB
terminals.
Control PCB ECOTRON

Round plug
The motor and plug-in cables are
connected by means of a 50-pin
connector element. Here, screw-type
terminals ensure reliable contact. If the
electrical connection is disconnected
for maintenance work, the wiring of the
control unit is always retained.

Control PCB PROFITRON

PROFIBUS connection
Simple connection of the PROFIBUS cables to
the separately accessible bus termination PCB.
The mains and control leads are connected in
the same way as with the round plug.
Asynchronous motors
in each SIPOS 5 Flash ensure the
necessary movement.
Among electric motors, they are
unsurpassed in terms of robustness,
reliability and operational safety and
they have a simple design as well.
Force is transmitted directly to the
worm shaft without intermediate
gears.
 SIPOS 5 Flash
Simple modular structure

Relay card

Power control PCB

Mechanical position indicator

PROFIBUS PCB
1- or 2-channel Precision potentiometer

Signaling gear
A precision potentiometer is operated by means
of the signaling gear in order to detect the current
position of the valve. The signaling gear reduces
the rotary movements of the output shaft to a
rotary movement smaller than 300 ° for a full
stroke from OPEN to CLOSE. The potentiometer
position is evaluated in the electronics. The
signaling gear can be set to between 0.8 and
4020 revolutions per stroke without any tools.
 Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Separate mounting
The electronics unit can be separated and installed
separately from the gear unit by undoing only 4
screws. The mounting kits necessary for this can
be supplied.

Spindle protection tube

for spindle acceptance

Worm shaft and output shaft

In the case of small and medium-sized
actuators, a combination of steel and ductile
cast iron is used. For large actuators, the
materials are steel and bronze.
The flow of force from the motor to the worm
wheel of the output shaft via the worm shaft
is self-blocking in the case of all modulating
actuators and most standard actuators.
The gear unit runs with long-life gear oil and
does not require any maintenance.
The worm wheel and the output shaft work
wear-free with constant efficiency.

Hand crank or hand wheel

This acts on the worm shaft. For manual operation,
the hand wheel is pressed in the direction of the
actuator. A switch blocks the motor before
engagement to the worm shaft takes place. This
reliably prevents the motor from starting in the
case of manual operation. Self-blocking of the
actuator is retained in the case of manual
operation.
With large actuators, a centrifugal coupling
prevents the hand wheel from engaging before
the motor has come to a standstill.

Flange and output shaft

20

The local control station:

Everything under control from the beginning

Settings for SIPOS 5 Flash ECOTRON SIPOS 5 Flash actuators have a local control station as a standard
Tripping torques and output speed are set via potentiometers, cut- feature for electrical operation and for commissioning. Most of the
off mode for each end position is set via DIP-switches. settings are pre-programmed in the factory and the actuators arrive
at site ready for operation.
LED CLOSE LED OPEN
Subsequent changes are possible at any time by means of simple
parameterization, without any additional equipment or special tools.
For this purpose, the SIPOS 5 Flash continually supplies all the
necessary information.
In the case of the ECOTRON, for example, LEDs always indicate the
current operating status and simple flashing patterns indicate faults
and enable diagnosis.

As with all electric actuators, the The SIPOS 5 Flash ECOTRON

cut-off mode - torque or travel
dependent - can be set for both
end positions. The settings
1 2 3 4 5 6 necessary have been automated
1 DIP-switches for valve specific values and the effort reduced to a
2 LEDs end position adjustment resp. status / fault display minimum by means of the
3 LED LOCAL microcontroller.
4 Potentiometer for setting of output speed and torques / forces
5 LED REMOTE Reliable travel detection and
6 Internal push-buttons OPEN, CLOSE, STOP, LOCAL/REMOTE torque limitation
With the SIPOS 5 Flash, the travel
The programming unit for SIPOS 5 Flash PROFITRON is detected with a precision
All settings can be made using the local control pushbuttons. The potentiometer via the adjustable
plain test display is self-explaining – with language selection. signaling gear.
Torque limitation and cut-off is
LED CLOSE LED OPEN performed by the frequency
converter.
Advantage: Torque and travel
switches are superfluous and so
create no effort to set.
The cut-off torque values in the
CLOSE and OPEN directions are
set with potentiometers
(ECOTRON) or, in the case of the
PROFITRON, by means of para-
meterization.
The microcontroller software
7 LED LOCAL automatically performs logical
8 LED REMOTE assignment of "torque before
9 Menu driven display travel" and vice versa.
is set by means of DIP switches
and potentiometers. LEDs
indicate the operating states and
are also used for indicating faults
and for diagnosis.
SIPOS 5 Flash PROFITRON
The PROFITRON actuators are
more comfortable to use: a two-
line LCD plain text display takes
you quickly to your goal; the
information is visible through the
window in the electronics cover.
The parameters are entered via
the user-friendly local control
station - i.e. parameterization can
be carried out without opening
the actuator, in other words "non-
intrusively“.
Commissioning
At the press of a button, the
OPEN and CLOSE end positions
are approached one after the
other. The microcontroller detects
the end positions from the setting
of the precision potentiometer
and stores them.
 21

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Menu driven display for PROFITRON

Language for display menu. 5 Reaction for detected line break: go to

languages are available at the moment emergency position or hold position.
(Ger., Eng., Fre., Esp., Ita.).

Close tightly means that when running

Output speeds separately for OPEN in direction “end position” within the
and CLOSE direction as also for end position range the actuator
EMERGENCY operation. Only the continues to run until the end position
output speeds possible for the specific is reached even if the control signal is
actuator type are displayed. terminated in advance.

Cut-off mode (torque or travel The EMERGENCY position can be

dependent) for OPEN and CLOSE chosen freely.
direction.

Tripping torque in OPEN and CLOSE Two freely programmable inter-

direction. mediate contacts are available.

Electronic motor heater prevents Slope for feedback signal, adjustable

condensation due to strongly varying 0 or 4...20 mA, rising or falling.
ambient temperatures.

8 freely programmable binary outputs

are assignable with a multitude of
Procedure for end position adjustment. signals. Level active high or active low
can be set freely.

Procedure for recording of up to 3 PROFIBUS address setting.

torque curves of the valve.

The end position range OPEN and Sub-menu for maintenance interval
CLOSE can be adjusted. Influence on setting.
output speed, “end position” signal,
torque dependent cut-off.

20-digit for actuator identification

Adjustment 0/4...20 mA and rising and tag.
falling slope for positioner operation.

Integrated positioner can be activated

subsequently. Other options that can
Level of inputs OPEN / CLOSE / STOP: be activated: stroke-speed curve and
active low or active high. analog speed setpoint (individual 4-
digit code).
Analog speed setpoint and stroke-
speed curve can be activated
Selection of the control input for independently for LOCAL and REMOTE.
REMOTE mode. Alternatively the actuator can be run
with the adjusted OPEN/CLOSE output
speeds.

General adjustments Valve specific adjustments Control system specific adjustments only mandatory adjustment
22

SIPOS 5 Flash -
Conventional control technique -
it’s so easy to control

“physical” Control modes

source

Positioner
0/4...20 mA
Tri-threshold
Control
mode
Permanent contact
24 V Pulse contact
Two-wire control

Positioner via BUS

PROFIBUS
Permanent contact via BUS

ECOTRON

1 2 3 4 Signal set

Travel OPEN End position OPEN End position OPEN Travel OPEN Control system output 1

Travel CLOSE End position CLOSE End position CLOSE Travel CLOSE Control system output 2

Torque OPEN/CLOSE Blinker Fault Ready + remote Control system output 3

Ready + remote Ready + remote LOCAL Torque OPEN Control system output 4

Warning mot. temp. Warning mot. temp. Warning mot. temp. Torque CLOSE Control system output 5
 23

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Positioner
Setpoint (0/4...20 mA signal)
100%

0%
t
Internal command OPEN
1
Setting the control mode 0
t
Internal command CLOSE
1
0
t
Actual value
100%

0%
0/4...20 mA position feedback t

Tri-threshold
0/4...20 mA signal
100%
70%
OPEN
STOP
30%
0%
CLOSE
t
Internal command OPEN
1
0
t
Internal command CLOSE
1
0
t

Permanent contact
Control system command OPEN
24 V/1
0 V/0
t
Control system command CLOSE
24 V/1 effects STOP

0 V/0
t
Internal command OPEN
PROFITRON 1
0
t
Internal command CLOSE
Control system output freely 1
assignable 0
t
NO Control system - Inactive
Pulse contact

Control system command OPEN

output 1 - Totally CLOSED
24 V/1
- Totally OPENED 0 V/0
-1 t
- Torque limit CLOSE direction Control system command CLOSE
NC - Torque limit OPEN direction 24 V/1

- TL OPEN or CLOSE direction 0 V/0

NO Control system Control system command STOP
t
- Fault
output 2 24 V/1
- Blinker 0 V/0
-1 - Ready t
Internal command OPEN
- Ready and REMOTE 1
NC
- LOCAL 0
t
- Intermediate contact CLOSE Internal command CLOSE
1
- Intermediate contact OPEN
0
- Fault motor temperature t

NO Control system
“OPEN” and “ground”

- Warning motor temperature Control system command OPEN

Two-wire control

output 8 - Fault external voltage 24 V/1

-1 - Maintenance 0 V/0
t
- Run. ind. OPEN Internal command OPEN
NC - Run. ind. CLOSE 1
0
t
Internal command CLOSE
1
0
t
24

Two cables connecting the world

Open communication via the PROFIBUS DP -
control can be so simple

No field device works solely for itself. Integrated in a process control
system, all the devices of an installation must communicate with
each other. Up to now, the conventional solution has been to use a
great many cables in order to wire up the input and output interfaces
to each field unit. With a standardized field bus such as the PROFIBUS
DP, a large part of the time-consuming and expensive wiring work -
which can easily lead to faults by the way - is no longer necessary.
And, of course, the BUS cable can be used to parameterize and
monitor the actuator.
SIPOS 5 Flash actuators are easy to integrate in any PROFIBUS-
controlled automation process.
Your advantages
• Greatly reduced wiring effort and expenditure
• Remote parameterization and diagnosis are also possible
• Function blocks available as accessories
• All-round complete service
The PROFIBUS interfacing is optional and is also supplied in a
redundant version in order to provide even more reliability. Due to
intensive tests, not least during certification by the PROFIBUS user
organization (PNO), perfect operation with other bus nodes is ensured.
V1 services for acyclical access
If a parameterizing and monitoring station is to be connected in
addition to cyclical data exchange with the process control system,
the station, as a "Class 2 master", can quickly obtain access to the
actuator data by means of the acyclical V1 services. As a standard
feature, the V1 services are supported by the SIPOS 5 Flash when
PROFIBUS interfacing is used.

PROFIBUS control via SIMATIC PCS7

 25

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

PROFIBUS communication with the SIPOS 5 Flash

Engineer´s console with STEP 7 Engineering Station ES

with SIMATIC PDM with STEP 7, Win CC etc.
with SIMATIC PDM

Plant bus

S7-400 S7-400

Field bus 45,45 kbit/s 1,5 Mbit/s

PROFIBUS-DP PROFIBUS-DP

DP/PA DP/PA
Coupler LINK

SITRANS T3K
SIPOS 5 Flash SIPOS 5 Flash

SITRANS P SIPART DR

SIPOS 5 Flash
PROFIBUS-PA

PROFIBUS-PA

SITRANS LR

SIPAN

possible connecting point

of a PC with SIMATIC PDM SIPOS 5 Flash SIPOS 5 Flash

Standardized interfaces
With the SIMATIC PCS7 family, function blocks and faceplates
SIMATIC PDM screen layout
(WinCC) are available for the SIPOS actuators. You can also use
these function blocks for control with the SIMATIC S7-300.
A SIPOS device description is available for integration in the
manufacturer-neutral configuration and parameterization tool
SIMATIC PDM (Process Device Manager). A function block for
SIPOS actuators is also available for the Siemens process control
system TELEPERM XP.
26

PROFIBUS DP
Function blocks

SIMATIC PCS7 Function block SIMATIC PCS7 Faceplate

SIPOS 5 Flash actuators communicate with the Siemens SIMATIC

PCS7 process control system via a function block. In the case of the
SIMATIC PCS7-400, a user-friendly interface (faceplate) for para-
meterization and hand-control is available.
 27

Complete solutions from a single source -

“Small” automation solutions
based on the PROFIBUS DP

Everyone knows the problem: a "small" installation with 10, 20 or

30 actuators is to be automated - as simply and reliably as possible.
You then have to go into the details of the usual field-bus and
automation systems, the actuators, other field devices, operator
terminals and so on - the list is never-ending. In practice, this means
a lot of work and not very much efficiency. Our counter-suggestion:
we supply you with a solution from a single source - based on
PROFIBUS DP with redundant control.
Extensive and detailed diagnostics enable rapid and precise
intervention in case of faults and also enable potential faults to be
detected at a very early stage.
Central data management makes it easy for you to maintain an
overview of your installation and, when necessary, allows fast
parameterization via the BUS.
Using PROFIBUS as the standardized field bus, additional field
devices are easy to integrate in the system.
Thanks to standard hardware (industrial PC) and a standard
operating system (Windows 2000/NT), all PC applications and
peripheral devices can be incorporated efficiently.
28

COM-SIPOS
PC-Parameterization program -
Functionality visualization made easy

The “more” in functionality and flexibility provided by an intelligent
SIPOS 5 Flash actuator is comfortably visualized and managed by
COM-SIPOS under Windows 9x, NT, 2000.
Display of actuator parameters
After the parameters have been downloaded from the actuator, they
are displayed in easy-to-understand menus.
Diagnosis of actuator and valve
With the SIPOS 5 Flash, the integrated microcontroller monitors and
stores all the important operating data. For preventive maintenance,
limits can be programmed so that, if they are exceeded, an alarm is
generated. Operating data and maintenance limits can be easily
displayed with COM-SIPOS.

The parameters can be changed with a click of the mouse - and then
easily uploaded to the actuator!
Installation documentation
One page per actuator – and all the settings are documented on
paper. One data file per actuator – and the data can be managed
centrally, sent by e-mail for remote diagnosis or uploaded into a
replacement unit.
Flexible interface to the control system
Whether rising or falling slopes, NC or NO signaling, tri-threshold
or 2-wire control - the flexibility of the interface to the control system
is almost without limits. COM-SIPOS provides a clear display of the
settings and possibilities.

Quick status check

A quick look into the "State of unit" window gives you a clear picture
of the status of actuator and valve.

Replacement local control panel

If an actuator used in the field is difficult to reach for commissioning
and diagnostic purposes, COM-SIPOS in local-control mode can even
replace the local control station.
 29

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

SIPOS 5 Flash is also easily

parameterized via PC
 30

SIPOS 5 Flash -
the clever way to go easy on your valve

Powerful but gentle at the same time Control via positioners

With powerful torque, valves are moved gently out of or into their
end position - without overtorque, even in the event of a blockage.
This difficult feat is achieved with the integrated frequency converter,
which automatically modulates frequency and amplitude in the end
positions and, as a result, operates with reduced motor speed.
optimizes the process and goes easy on the valve
The integrated positioner of the SIPOS 5 Flash PROFITRON is an
adaptive three-step controller, i.e. the dead zone is always adapted
to the quality of the setpoint signal and actual-value signal. This
ensures the greatest possible control accuracy with minimum
switching frequency, thus optimizing the process and protecting the
valve and pipeline from wear due to fewer switching cycles.

Output speed
Output speed range Output speed range Setpoint /
Positioner
feedback
value

n7 40 100%

n6 28 After-
running
Inner dead zone
n5 20
Starting point Setpoint feedback Stopping point
n4 14 value
n3 10
n2 7 Outer dead zone
n1 5

End position range End position range

Travel
0%
CLOSED OPEN t

Gentle movement out of or into the end positions of the valves shown with the example of a The positioner continuously detects and compares the setpoint and
selected speed range of 5 - 40 rpm with 14 rpm in the OPEN direction and 28 rpm in the CLOSE
direction. the actual value. If the control deviation is greater than the dead
zone, internal travel commands are generated.
With each SIPOS 5 Flash actuator, 7 adjustable output speeds are
available within selectable output speed ranges.

Analog output speed control

reduces the number of switching cycles
Since more accurate processes with improved control qualities are
increasingly in demand, an actuator must also react sensitively to
small changes reported by sensors. Slight deviations between the
actual value and setpoint can only be corrected with low motor
speeds.
With the help of the "External analog speed setpoint" function,
the SIPOS 5 Flash PROFITRON can be operated at different speeds
without changing parameters. The output speed is stipulated by a
0/4..20 mA signal at the second analog input of the actuator.
The result is greater control precision as well as additional advantages
such as the following:
Pressure surges in pipes when a valve is closed can be effectively
prevented with lower speed.
The danger of cavitation if the flow speed is increased due to pressure
can generally be avoided with maximum speed. Protection against
extreme stress and wear on the pipeline and valve can be provided
by SIPOS 5 Flash.
 31

Product range Mech. interface Converter (VSD) Electronics Details Commissioning Control Highlights

Use of simpler valves -

made possible by linearization of the valve characteristic
Where processes are complex, it is desirable to achieve propor-
tionality between valve travel and the flow-rate of the medium.
The SIPOS 5 Flash PROFITRON enables this by changing the speed
during movement from OPEN to CLOSE and vice versa. Depending
on the travel, different speeds are stipulated over a maximum of
10 interpolation points in the form of a characteristic curve.
The travel/speed interpolation points are set locally by means of
pushbuttons via the plain-text display or the PC-parameterization
program, COM-SIPOS.
This function is called the "travel-dependent output speed adjustment"
and is mainly used for linearizing valve characteristics.

Output speed setpoint curve realistic speed curve

Output Output speed

speed range
n5 40

n4 28

n3, n6 20
n2, n7 14
n1 10
Value pair 2 7
Linearization of valve characteristics 5
Due to the inertia of the actuator and the valve,
x1 x2 x3 x4 x5 x6 x7
the staggered travel/speed interpolation points
set output speed for OPEN and CLOSED
result in a smooth speed characteristic which Travel
can be further adapted by changing the ramp- 0% OPEN 100% CLOSED
up time parameter.

Keep a clear eye on valve status

Wear, deposits or corrosion make valves stiff or lead to complete
blockage.
Need-oriented instead of preventive maintenance is the most
economically efficient maintenance concept.
The SIPOS 5 Flash PROFITRON enables this in two ways. Firstly,
valve-specific and stress-dependent maintenance intervals - i.e.
maintenance limits for operating hours, torque-dependent cut-offs
and switching cycles - can be stipulated in advance which generate
a maintenance signal when the parameterizable maintenance limit
is reached.
Secondly, the status of your valve can be recorded and evaluated at
any time by recording the required valve torque levels. With sampling
rates of 1% increments of the travel, up to 3 speed curves can be
permanently stored . With COM-SIPOS, the data can be downloaded
and visualized via the serial interface. With SIMATIC PDM this can
be done via the PROFIBUS interface. Changes are immediately
detectable by comparing the data with reference records.

Curve No. 1

M [Nm] M [Nm]
12 12

10 10

8 8

6 6

4 4

2 2

0 0
[% OPEN] -5 0 10 20 30 40 50 60 70 80 90 100
105
100 90 80 70 60 50 40 30 20 10 0 -5 [% OPEN]
Torque curve of a valve
Torque-curve recording can be started via the
CLOSED Travel OPEN Travel CLOSED
actuator's local control station, COM-SIPOS or
PROFIBUS DP-V1 during acyclical operation.
 www.wildner-grafikdesign.de
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SIPOS Aktorik Germany

Sales headquarter and production
Tel. +49 (0) 911 / 632 84 - 0
Fax +49 (0) 911 / 632 84 - 111

E-mail info@sipos.de
www.sipos.de

MP 35 • 2004 >> edition 09/04 <<

SIPOS Aktorik GmbH Subject to changes without notice! Order no. E20185-P920-B500-X-7600
Electric actuators SIP-DO 00.01.001 GB 9.04
Dispostelle 34100
Donaustr. 36
AC012448 09.01/5.0
D-90451 Nuremberg www.sipos.de