084010-3205m403-1 Omim Verdelet Auma

RAAS LAFFAN C DESALINATION PLANT 084010
VERDELET CONTROL VALVES OPERATION MAINTENANCE INSTRUCTION MANUAL

Doc Nr 3205 M 403
Part 1 Part 2 Part 3
Equipment list Control valves sizing Dimensional drawings

3.1/ DxxTWL10AA071 3.2/ D00TXS19AA051 / D00TXS19AA052 3.3/ D00TXP71AA051
Part 4 Part 5
Instruction manual for control valves VERDELET Instruction manual for pneumatic actuators & accessories
5.1/ Actuators ROTORK 5.2/ Positioner ABB Operating instr. 5.3/ Positioner ABB Commissioning instr. 5.4/ Filter Regulator NORGREN 5.5/ Booster FAIRCHILD
Part 6
Instruction manual for electric actuators & accessories

6.1/ Multi-turn actuator AUMA 6.2/ Gearboxes AUMA 6.3/ Wiring diagrams
SUMMARY - PAGE- 2 -
1 EQUIPMENT LIST
EQUIPMENT LIST
Tag Nr Description Reference VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN700 (CS) VERDELET VALSTAR DN900 (SS) + remote installation VERDELET VALSTAR DN900 (SS) + remote installation
D11 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D12 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D13 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D21 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D22 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D31 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D32 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D33 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D41 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D42 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV D00 TXP71AA071 D00 TXS19AA051 D00 TXS19AA052 SEA WATER PUMPS MINI FLOW CTRL VALVE SEA WATER PUMPS MINI FLOW CTRL VALVE
PW TRANSFERT PPS RECYCLE FLOW CTRL VV VERDELET VALSTAR DN350 (SS)
1/1
2 SIZING CALCULATIONS
3 DIMENSIONAL DRAWINGS
1. 2. 3. DxxTWL10AA071 D00TXS19AA051 / D00TXS19AA052 D00TXP71AA051
4 INSTRUCTION MANUALS
- CONTROL VALVES -
- PNEUMATIC ACTUATOR & ACCESSORIES 1. 2. 3. 4. 5. Actuators ROTORK Positioner ABB - Operating Instruction Positioner ABB - Commissioning instructions Filter Regulator NORGREN Booster FAIRCHILD
CI/TZIDC/110/120_EN
TZIDC, TZIDC-110, TZIDC-120
Commissioning Instructions Electro-Pneumatic Positioner TZIDC, TZIDC-110, TZIDC-120
Neu
Electro-Pneumatic Positioner TZIDC, TZIDC-110, TZIDC-120
Commissioning Instruction - EN
CI/TZIDC/110/120-EN
06.2009
Manufacturer:
ABB Automation Products GmbH Schillerstrae 72 32425 Minden Germany Tel.: +49 551 905-534 Fax: +49 551 905-555 CCC-support.deapr@de.abb.com
Copyright 2009 by ABB Automation Products GmbH Subject to changes without notice This document is protected by copyright. It assists the user in safe and efficient operation of the device. The contents of this document, whether whole or in part, may not be copied or reproduced without prior approval by the copyright holder.
Contents
Contents
1 Safety ....................................................................................................................................................................4 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 3 General information and notes for the reader ................................................................................................4 Intended use...................................................................................................................................................4 Target groups and qualifications ....................................................................................................................5 Warranty provisions........................................................................................................................................5 Plates and symbols ........................................................................................................................................6 Safety/warning symbols, note symbols...................................................................................................6 Safety information for electrical installation....................................................................................................7 Operating safety information ..........................................................................................................................7
1.5.1
Ex relevant safety instructions ..........................................................................................................................7 Mounting ..............................................................................................................................................................8 3.1 3.2 Operating conditions at installation site..........................................................................................................8 Mechanical mount ..........................................................................................................................................8 General....................................................................................................................................................8 Mounting on linear actuators.................................................................................................................10 Mounting on rotary actuators ................................................................................................................14
3.2.1 3.2.2 3.2.3 4 4.1 4.2 4.3 5 6
Electrical connection ........................................................................................................................................17 Screw terminal assignments ........................................................................................................................18 Jumper configuration on mainboard (TZIDC-120 only)................................................................................19 Cable entry ...................................................................................................................................................20
Pneumatic connection ......................................................................................................................................21 Commissioning..................................................................................................................................................23 6.1 6.2 TZIDC ...........................................................................................................................................................23 Operating modes...................................................................................................................................24 Operating modes...................................................................................................................................26 TZIDC-110 / TZIDC-120...............................................................................................................................25 6.1.1 6.2.1
Ex relevant specifications ................................................................................................................................27 7.1 TZIDC ...........................................................................................................................................................27 ATEX .....................................................................................................................................................27 IECEx Issue No. 3.................................................................................................................................29 CSA International ..................................................................................................................................31 CSA Certification Record ......................................................................................................................33 EC-Type-Examination Test Certificate..................................................................................................34 IECEx Issue No. 3.................................................................................................................................35 CSA International ..................................................................................................................................37 CSA Certification Record ......................................................................................................................38 FM Approvals ........................................................................................................................................39 EC-Type-Examination Test Certificate..................................................................................................40 IECEx Issue No. 3.................................................................................................................................41 CSA International ..................................................................................................................................43 TZIDC, TZIDC-110, TZIDC-120 CI/TZIDC/110/120-EN 7.1.1 7.1.2 7.1.3 7.1.4 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.3 7.3.1 7.3.2 7.3.3
TZIDC-110....................................................................................................................................................34
TZIDC-120....................................................................................................................................................40
2 - EN
Contents
7.3.4 7.3.5 CSA Certification Record ......................................................................................................................44 FM Approvals ........................................................................................................................................45
CI/TZIDC/110/120-EN
EN - 3
Safety 1
1.1
Safety
General information and notes for the reader Read these instructions carefully prior to installing and commissioning the device. These instructions are an important part of the product and must be kept for later use. These instructions are intended as an overview and do not contain detailed information on all designs for this product or every possible aspect of installation, operation and maintenance. For additional information or in case specific problems occur that are not discussed in these instructions, contact the manufacturer. The content of these instructions is neither part of any previous or existing agreement, promise or legal relationship nor is it intended to change the same. This product is built based on state-of-the-art technology and is operationally safe. It has been tested and left the factory in a safe, maintenance-free state. The information in the manual must be observed and followed in order to maintain this state throughout the period of operation. Modifications and repairs to the product may only be performed if expressly permitted by these instructions. Only by observing all of the safety information and all safety/warning symbols in these instructions can optimum protection of both personnel and the environment, as well as safe and fault-free operation of the device, be ensured. Information and symbols directly on the product must be observed. They may not be removed and must be fully legible at all times.
1.2
Intended use TZIDC, TZIDC-110, TZIDC-120 positioners are electro-pneumatic positioning devices for use with pneumatically controlled actuators. The device may only be used for the applications listed in these operating instructions and in the data sheet. The maximum operating temperature must not be exceeded. The permissible operating temperature must not be exceeded. The housing protection type must be observed during operation.
4 - EN
CI/TZIDC/110/120-EN
Safety
1.3 Target groups and qualifications Installation, commissioning, and maintenance of the product may only be performed by trained specialist personnel who have been authorized by the plant operator to do so. The specialist personnel must have read and understood the manual and comply with its instructions. Prior to using corrosive and abrasive materials for measurement purposes, the operator must check the level of resistance of all parts coming into contact with the materials to be measured. ABB Automation Products GmbH will gladly support you in selecting the materials, but cannot accept any liability in doing so. The operators must strictly observe the applicable national regulations with regards to installation, function tests, repairs, and maintenance of electrical products.
1.4
Warranty provisions Using the device in a manner that does not fall within the scope of its intended use, disregarding this instruction, using underqualified personnel, or making unauthorized alterations releases the manufacturer from liability for any resulting damage. This renders the manufacturer's warranty null and void.
CI/TZIDC/110/120-EN
EN - 5
Safety
1.5 1.5.1 Plates and symbols Safety/warning symbols, note symbols DANGER <Serious damage to health / risk to life> This symbol in conjunction with the signal word "Danger" indicates an imminent danger. Failure to observe this safety information will result in death or severe injury. DANGER <Serious damage to health / risk to life> This symbol in conjunction with the signal word "Danger" indicates an imminent electrical hazard. Failure to observe this safety information will result in death or severe injury. WARNING <Bodily injury> This symbol in conjunction with the signal word Warning indicates a possibly dangerous situation. Failure to observe this safety information may result in death or severe injury. WARNING <Bodily injury> This symbol in conjunction with the signal word "Warning" indicates a potential electrical hazard. Failure to observe this safety information may result in death or severe injury. CAUTION <Minor injury> This symbol in conjunction with the signal word Caution indicates a possibly dangerous situation. Failure to observe this safety information may result in minor or moderate injury. This may also be used for property damage warnings. ATTENTION <Property damage>! The symbol indicates a potentially damaging situation. Failure to observe this safety information may result in damage to or destruction of the product and/or other system components. IMPORTANT (NOTICE) This symbol indicates operator tips, particularly useful information, or important information about the product or its further uses. It does not indicate a dangerous or damaging situation.
6 - EN
CI/TZIDC/110/120-EN
Ex relevant safety instructions

1.6 Safety information for electrical installation The electrical connections may only be performed by authorized specialist personnel according to the electrical plans. Comply with electrical connection information in the instruction. Otherwise, the electrical protection class can be affected. The secure separation of contact-dangerous electrical circuits is only ensured when the connected devices fulfil the requirements of the DIN EN 61140 (VDE 0140 Part 1) (basic requirements for secure separation). For secure separation, run the supply lines separated from contact-dangerous electrical circuits or additionally insulate them. 1.7 Operating safety information Before switching on the unit make sure that your installation complies with the environmental conditions listed in the chapter "Technical data" or in the data sheet. If there is a chance that safe operation is no longer possible, take the unit out of operation and secure against unintended startup. When mounting the unit in areas that may be accessed by unauthorized persons, take the required protective measures.
Ex relevant safety instructions

Depending on the type of explosion protection, an Ex label is attached to the left of the positioner beside the main name plate. It shows the explosion protection and the unit's relevant Ex certificate. Requirements / preconditions for safe operation of the positioner: Important Observe with the units relevant technical data and the special conditions in accordance with the relevant certificate. Manipulation of the device by users is not permitted. Modifications to the unit may only be performed by the manufacturer or an explosion protection specialist. The splash guard cap must be screwed in place to achieve IP 65 / NEMA 4x protection class. Operating the unit without splash guard cap is prohibited. The unit must be supplied with instrument air that is free of oil, water and dust. Do not use flammable gas nor oxygen or oxygen-enriched gas.
Important Use in areas with combustible dust To prevent loss of its ignition-proof classification, the housing may not be opened. Use only cable glands that conform to protection type IP 65. Avoid hazardous sliding brush discharges.
CI/TZIDC/110/120-EN
EN - 7
Mounting 3 Mounting
Caution - Risk of injury! Incorrect parameter values can cause the valve to move unexpectedly. This can lead to process failures and result in injuries. Before recommissioning a TZIDC, TZIDC-110, TZIDC-120 positioner that was used at another location, the device must always be reset to factory settings. Never start Autoadjust before restoring factory settings. 3.1 Operating conditions at installation site Important Before installation, check whether the TZIDC, TZIDC-110, TZIDC-120 positioner meets the control and safety requirements for the installation location (actuator or valve). See the Specifications chapter in the operating instructions or on the data sheet. 3.2 3.2.1 Mechanical mount General
Fig. 1: Operating range The arrow (1) on the positioner feedback shaft (and the lever) must move through the area marked by the arrows (2).
8 - EN
CI/TZIDC/110/120-EN
Mounting
1 +30 +100 +100 +60 2
VOITH
0 0 -30 -60 4 3
M00410
Fig. 2: Positioner range 1 Sensor range for linear actuators 2 Sensor range for rotary actuators
3 Operating range for linear actuators 4 Operating range for rotary actuators
Important During installation make sure that the actuator travel or rotation angle for position feedback is implemented correctly. The maximum rotation angle for position feedback is 60 when installed on linear actuators and 120 on rotary actuators. The minimum angle is always 25.
CI/TZIDC/110/120-EN
EN - 9
Mounting
3.2.2 Mounting on linear actuators For mounting on a linear actuator in accordance with DIN / IEC 534 (lateral mount per NAMUR) a complete mounting kit is available, and consists of the items in the following table:
Fig. 3: Mounting kit for linear actuators Lever (4) with follower pin, for stroke adjustment 10 ... 35 mm (0.39 ... 1.38 inch) or 20 ... 100 mm (0.79 ... 3.94 inch) Follower guide (13) with two screws (10), spring washers (11) and clamp plates (12) Mount bracket (3) with two screws (6) and two shims (5) Screw (1) and shim (2) for mounting to cast iron yoke Two U-bolts (7) with two shims (8) and two nuts (9) for mounting to columnar yoke
Required tools: Wrench, size 10 / 13 Allen key, size 4
10 - EN
CI/TZIDC/110/120-EN
Mounting
Procedure: 1. Attach follower guide to actuator
Fig. 4 Important Hand tighten the screws. Attach the follower guide (1) and clamp plates (2) with screws (4) and spring washers (3) to the actuator stem
2. Mount the lever and bracket on the positioner
Fig. 5 Attach the lever (6) to the feedback shaft (5) of the positioner (can only be mounted in one position due to the flat on the side of the shaft) Using the arrow marks (4) check whether the lever moves within the operating range (between the arrows) Hand-tighten the screw (7) on the lever Hold the prepared positioner with loose mount bracket (1) to the actuator so that the follower pin for the lever enters the follower guide to determine which holes on the positioner must be used for the mount bracket Attach the mount bracket (1) with screws (2) and shims (3) to the proper holes on the positioner housing. Tighten the screws as evenly as possible to ensure subsequent linearity. Align the mount bracket in the oblong hole to ensure that the operating range is symmetrical (lever moves between the arrows (4))
CI/TZIDC/110/120-EN
EN - 11
Mounting
3.a Mounting on cast iron yoke
Fig. 6 or 3.b Mounting on columnar yoke Attach the mount bracket (2) with screw (4) and shim (3) to the cast iron yoke (1)
Fig. 7 Hold the mount bracket (3) in the proper position on the columnar yoke (2) Insert the U-bolts (1) from the inside of the columnar yoke (2) through the holes for the mount bracket Add the washers (4) and nuts (5). Hand tighten the nuts
Important Adjust the height of the positioner on the cast iron yoke or columnar yoke until the lever is horizontal (based on visual check) at half stroke of the valve.
12 - EN
CI/TZIDC/110/120-EN
Mounting
Fig. 8: Linkage for positioner 1 larger 2 smaller The scale on the lever indicates the link point for the various stroke ranges of the valve. Move the bolt with the follower guide into the oblong hole of the lever to adjust the stroke range of the valve to the operating range for the position sensor. Moving the link point inward increases the rotation angle of the sensor. Moving the link point outward reduces the sensor's rotation angle. Adjust the actuator stroke to make use of as large an angle of rotation as possible (symmetrical around the center position). Recommended range for linear actuators: Minimum angle: between -28 ... 28 25
Important After mounting the unit check whether the positioner is operating within the sensor range.
CI/TZIDC/110/120-EN
EN - 13
Mounting
3.2.3 Mounting on rotary actuators For mounting on rotary actuators in accordance with VDI / VDE 3845, the following mounting kit is available:
Fig. 9 Adapter (1) with spring (5) each four screws M6 (4), spring washers (3) and shim (2) to attach the mounting bracket (6) on the positioner each four screws M5 (7), spring washers (8) and shim (9) to attach the mounting bracket on the actuator
Required tools: Wrench, size 10 / 13 Allen key, size 3
14 - EN
CI/TZIDC/110/120-EN
Mounting
Procedure: 1. Mounting the adapter on the positioner
Fig. 10 Determine the mounting position (parallel to actuator or at 90 angle) Calculate the rotational direction of the actuator (right or left) Move the rotary actuator into home position Based on the mounting position as well as the home position and rotational direction of the actuator, determine in which position the feedback shaft (1) for the positioner must be preadjusted and in which position the adapter (2) must be placed to enable the positioner to travel within the proper range (the arrow on the rear of the device must travel within the admissible range, see Fig. 1) Pre-adjust feedback shaft Place the adapter in the proper position on the feedback shaft and fasten with set screws (3). One of the set screws must be locked in place on the flat side of the feedback shaft
CI/TZIDC/110/120-EN
EN - 15
Mounting
2. Attach mounting bracket on the positioner
Fig. 11 1 Mounting bracket 3. Attach positioner to the actuator
Fig. 12 Important After mounting the unit check whether the operating range for the actuator matches the sensor range on the positioner.
16 - EN
CI/TZIDC/110/120-EN
Electrical connection 4 Electrical connection

Warning! Risk of explosion! (TZIDC only) It is prohibited to use the integrated communication interface (LKS) in an Ex area. Never use the integrated communication interface (LKS) on the mainboard with a positioner that is being used in an explosion risk area. 1. Strip the wire by approx. 6 mm (0.24 inch). 2. To connect the signal lines, the emergency shutdown module and the proximity switches or micro switches, insert the wire ends from the left into the respective screw terminals and hand-tighten the screws (access from above). To connect a plug-in module, insert the wire ends from above in the appropriate screw terminals and hand-tighten the screws (access from the side).
Fig. 13: Terminal connection diagram A Basic model B Options
1 2 3 4 5 6 7 8
Analog input / Bus connector Digital input 1) Digital output 1) Digital feedback 1) Analog feedback 1) Proximity switches Microswitches Emergency shutdown module
1) TZIDC only
Important Keep cable shields as short as possible and connect on both sides.
CI/TZIDC/110/120-EN
EN - 17
Electrical connection
4.1 Screw terminal assignments
Fig. 14 1 Module for analog position feedback 1) 2 Module for digital feedback 1) or service switch of emergency shutdown module 3 Module for digital position feedback 1) or terminals of the shutdown module 4 Installation kit for digital position feedback, either proximity switches or 24 V microswitches 5 Same as 4
1) TZIDC only
6 7 8 9
Digital output DO 1) Digital input DI 1) Signal 4 ... 20 mA / Bus connector Grounding screw
18 - EN
CI/TZIDC/110/120-EN
4.2 Jumper configuration on mainboard (TZIDC-120 only)
1 2
M00494
Fig. 15 1 Simulation 2 Write access There are two jumpers on the mainboard that can be used to activate or block simulation mode and write access. Set the jumpers as shown below:
1
M00495
Fig. 16 1 Block (Simulation blocked 1)) 2 Activate (Write access enabled 1))
1) Default setting (complies with Fieldbus Foundation standard)
CI/TZIDC/110/120-EN
EN - 19
4.3 Cable entry Important The cable terminals are delivered closed and must be unscrewed before inserting the cable. For the cable entry in the housing, there are two tap holes 1/2 - 14 NPT or M20 x 1.5 on the left side of the housing. One of these holes has a cable gland, the other a pipe plug.
Fig. 17: Cable entry 1 Pipe plug 2 Cable gland
20 - EN
CI/TZIDC/110/120-EN
Pneumatic connection 5 Pneumatic connection

Important The TZIDC, TZIDC-110, TZIDC-120 positioner must be supplied with instrument air that is free of oil, water and dust. The purity and oil content should meet the requirements of Class 3 according to DIN/ISO 8573-1. Notice - Potential damage to parts! Impurities on the pipe and positioner can damage components. The recommended pipe dimension is 6 x 1 mm. Dust, splinters or any other particles must be blown off the pipe before connecting. To connect the air pipes, G1/4 or 1/4-18 NPT tap holes are provided. We recommend that you use a line with the 6 x 1 mm dimensions. Notice - Potential damage to parts! Pressure above 6 bar (90 psi) can damage the positioner or actuator. Provisions should be made to ensure that in the event of an error the pressure does not rise above 6 bar (90 psi).
Fig. 18: Pneumatic connections 1 Pneumatic outputs 2 Supply air 3 Filter screw
CI/TZIDC/110/120-EN
EN - 21
Pneumatic connection
All pneumatic piping connections are located on the right side of the positioner. To connect the pneumatic pipes, G1/4 or 1/4-18 NPT tap holes are provided. The positioner is labeled according to the tap holes available. The corresponding pipe connections must be included. The level of supply pressure must be adjusted to the output pressure in the actuator required to provide increased actuating force. The operating range for the positioner is between 1.4 ... 6 bar (20 ... 90 psi). Arrange the connections according to their marks: Designation OUT1 OUT2 Pipe connection Air supply, pressure 1.4 ... 6 bar (20 ... 90 psi) Output pressure for actuator Output pressure for actuator (2nd connection with double-acting actuator)
22 - EN
CI/TZIDC/110/120-EN
Commissioning 6
6.1
bieten
Commissioning
TZIDC 1. Feed in pneumatic supply power 2. Feed in electrical supply power Feed in setpoint current 4 ... 20 mA (terminals +11 / -12) Press and hold. Additionally, press or until operating mode 1.3 (manual . adjustment within the sensor range) is displayed. Release Press or to move the actuator into the mechanical end position. Check the end positions. The rotation angle is displayed in degrees. For high speed mode, press and simultaneously Recommended range: between -28 ... 28 for linear actuators between -57 ... 57 for rotary actuators 3. Check mount:
Minimum angle: 25 4. Run Autoadjust Important Autoadjust is available for software version 2.XX and higher. For linear actuators 1): Press Press Release and hold until is displayed. Release the control button again and hold until the countdown ends . This starts the Autoadjust
For rotary actuators 1): Press Press Release and hold until is displayed. Release the control button and hold till the countdown ends . This starts the Autoadjust
With a successful Autoadjust, the parameters are stored automatically and the positioner returns to operating mode 1.1. If an error occurs during Autoadjust, the action is terminated with an error message. In this event, press and hold or for approximately three seconds. The unit switches to the operating level, mode 1.3 (manual adjustment within the sensor range). Check the mount and, if necessary, correct. Afterwards repeat the Autoadjust. 5. Set potential dead bands and tolerance bands. This step is only required for critical (e.g., very small) actuators. In a standard situation, it is not necessary.
1) The zero position is determined automatically and saved during Autoadjust (for linear actuators, counter-clockwise (CTCLOCKW), and for rotary actuators, clockwise (CLOCKW)).
CI/TZIDC/110/120-EN
EN - 23
Commissioning
6.1.1 Operating modes Selection from the operating level: Press Release The position is displayed in % or as a rotation angle Mode indicator
C % mA
and hold rapidly as often as required. The selected operating mode is displayed
Press and release
Operating mode 1.0 Control mode 1.1 Control mode 1.2 Manual adjustment Adjust via 1.3 Manual adjustment 2) in the sensor range. Adjust via or
3) 2) 1) 1)
Position indicator
C % mA
with adaptation (the control parameter)
conf
conf
C % mA
C % mA
without adaptation (the control parameter) in the operating range.
conf
conf
C % mA
C % mA
or
3)
conf
conf
C % mA
C % mA
conf
conf
1) Since self-optimization in operating mode 1.0 is subject to several factors during operation and mismatches could result over a longer period, we recommend that this operating mode only be activated over several hours and be followed by the mode 1.1 2) Position not active 3) For high speed mode: Press and simultaneously
24 - EN
CI/TZIDC/110/120-EN
Commissioning
6.2
bieten
TZIDC-110 / TZIDC-120 1. Feed in pneumatic auxiliary power 2. Connect the bus to the bus terminals with any polarity (or auxiliary power 9 ... 32 V DC),
C % mA
is displayed
3. Check mount: Press and hold down and release Press and hold down and . On completion of the countdown from 3 to 0, . The unit switches to the operating level, mode 1.x and
Additionally, press or until operating mode 1.3 (manual adjustment within the sensor range) is displayed. Release Press or to move the actuator into the mechanical end position. Check the end positions. The rotation angle is displayed in degrees. For high-speed mode, press and simultaneously. Recommended range: between -28 ... 28 for linear actuators between -57 ... 57 for rotary actuators
Minimum angle: 25 4. Go back to the bus level: Press and hold down and release
C % mA
and ,
. On completion of the countdown from 3 to 0,
is displayed.
5. Run Autoadjust. Check that the unit is on the bus level ("REMOTE")
For linear actuators 1): Press and hold down Press Release until is displayed. Release the control button again and hold down until the countdown ends . This starts Autoadjust
For rotary actuators 1): Press and hold down Press Release until is displayed. Release the control button again and hold down until the countdown ends . This starts Autoadjust
CI/TZIDC/110/120-EN
EN - 25
Commissioning
If Autoadjust is successful, the parameters will be stored automatically and the positioner will revert to operating mode 1.1. If an error occurs during Autoadjust, the process will be terminated with an error message. If this happens, press and hold down or for approximately three seconds. The unit will switch to the operating level, mode 1.3 (manual adjustment within the sensor range). Check the mount and correct if necessary. Then run Autoadjust again. 6. Set potential dead bands and tolerance bands. This step is only required for critical (e.g., very small) actuators. It is not necessary under normal circumstances.
1) The zero position is determined automatically and saved during Autoadjust (counter-clockwise (CTCLOCKW) for linear actuators and clockwise (CLOCKW) for rotary actuators).
6.2.1
Operating modes Selection from the operating level: Press and hold down Press and release Release The position is displayed in % or as a rotation angle Mode indicator
C % mA
as often as required to display the selected operating mode
Operating mode 1.1 Positioning with fixed setpoint Use 1.2 Manual adjustment Adjust with 1.3 Manual adjustment Adjust with or
1) 1)
Position indicator
C % mA
or
to adjust the setpoint in the operating range
conf
conf
C % mA
C % mA
or
2)
conf
conf
in the sensor range

conf
C % mA
C % mA
2)
conf
1) Positioning not active. 2) for high-speed mode: Press
and
simultaneously.
26 - EN
CI/TZIDC/110/120-EN
Ex relevant specifications 7 Ex relevant specifications

Important The values indicated here are taken from the respective certificates. Always observe the specifications and supplements in the explosion protection certificates. 7.1 7.1.1 TZIDC ATEX ATEX II 2G Ex ia IIC T6 II 2G Ex ib IIC T6 Type-Examination Test Certificate: Type: Device class: Standards: II 2G Ex iaD 21 T51 C TV 04 ATEX 2702 X Intrinsically safe equipment II 2G (EEx ia IIC) II 2G (Eex ib IIC) EN 60079-0:2006 EN 60079-11:2007 EN 61241-0:2006 EN 61241-11:2006 Ambient temperature range (II 2 G) -40 ... 85 C -40 ... 50 C -40 ... 40 C
Temperature class T4 T5 T6 1)
1) When using the plug-in module for "Digital Feedback" in temperature class T6, the maximum allowable ambient temperature range is -40 ... 35 C.
Housing surface temperature T81 C T61 C T51 C
Ambient temperature range (II 2 D) -40 ... 70 C -40 ... 50 C -40 ... 40 C
CI/TZIDC/110/120-EN
EN - 27
Ex relevant specifications
Electrical data In intrinsically safe explosion protection types Ex ib IIC / Ex ia IIC or Ex iaD, only for connection to a certified intrinsically safe circuit Signal circuit Maximum values: (Terminal +11 / -12) Ui = 30 V Ii = 320 mA Pi = 1.1 W Ci = 6.6 nF Li negligibly small Contact input Maximum values: (Terminal +81 / -82) Ui = 30 V Ii = 320 mA Pi = 1.1 W Ci = 4.2 nF Li negligibly small Contact output Maximum values: (Terminal +83 / -84) Ui = 30 V Ii = 320 mA Pi = 500 mW Ci = 4.2 nF Li negligibly small Mechanical digital feedback For max. values, see EC-type-examination test certificate (Terminals Limit1 +51 / -52 number PTB 00 ATEX 2049 X or Limit2 +41 / -42) Proximity switches manuf. by Pepperl & Fuchs Plug-in module for digital Maximum values: position feedback Ui = 30 V Ii = 320 mA (Terminal +51 / -52) or Pi = 500 mW +41 / -42) Ci = 3.7 nF Li negligibly small Plug-in module for analog Maximum values: position feedback Ui = 30 V Ii = 320 mA (Terminal +31 / -32) Pi = 1.1 W Ci = 6.6 nF Li negligibly small Plug-in module for shutdown Ui = 30 V contact input Ii = 320 mA Pi = 1.1 W (Terminal +51 / -52) or Ci = 3.7 nF +85 / -86) Li negligibly small Local communication Only for connection to a programmer outside the potentially interface (LKS) explosive area. Important The local communication interface (LKS) may only be operated at Um 30 V DC outside the potentially explosive area. The equipment may only be used as a II 2 D type device in areas where the level of mechanical hazard is "low".
28 - EN
CI/TZIDC/110/120-EN
Cable entries which meet the requirements of EN 61241-11 for category II 2 D as well as the ambient temperature range have to be used. Variants, which also comply with the type of protection "Flameproof Enclosure" according to a separate certificate, may not be operated in the type of protection "Intrinsically Safe" after use as apparatus in the type of protection "Flameproof Enclosure". 7.1.2 IECEx Issue No. 3 IECEx Ex ia IIC T6 Ex nA II T6 Certificate No.: Issue No.: Typ: Standards: Ex nL IIC T6 IECEx TUN 04.0015X 3 Intrinsic safety "i", Type of protection "n" IEC 60079-0:2000 IEC 60079-11:1999 IEC 60079-15:2001 IEC 60079-27:2005-04 TZIDC Ex ia IIC resp. Ex ib IIC Temperature Class T4 T5 T6 TZIDC Ex nA IIC resp. Ex nL IIC
Type and marking
Ambient temperature range -40 ... 85 C -40 ... 85 C -40 ... 50 C -40 ... 65 C -40 ... 40 C -40 ... 50 C
Electrical data for type TZIDC with marking Ex ia IIC resp. Ex ib IIC In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) only for the connection to a certified intrinsically safe circuit with the following maximum values: Signal circuit Ui = 30 V (Terminals +11 / -12) li = 320 mA Pi = 1.1 W effective internal capacitance: Ci = 6.6 nF The effective internal inductance is negligibly small. Switch input Ui = 30 V (Terminals +81 / -82) li = 320 mA Pi = 1.1 W effective internal capacitance: Ci = 4.2 nF The effective internal inductance is negligibly small. Switch output Ui = 30 V (Terminals +83 / -84) li = 320 mA Pi = 500 mW effective internal capacitance: Ci = 4.2 nF The effective internal inductance is negligibly small. Local interface for For the connection to a programmer outside of the explosiv communication (LKS) hazardous area only.
CI/TZIDC/110/120-EN
EN - 29
Optionally the following modules are allowed to be used: In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) only for the connection to a certified intrinsically safe circuit with the following maximum values: Plug-In module for digital Ui = 30 V feedback li = 320 mA Pi = 500 mW (Terminals +51 / -52 resp. effective internal capacitance: Ci = 3.7 nF +41 / -42) The effective internal inductance is negligibly small. Plug-In module for analogue Ui = 30 V feedback li = 320 mA Pi = 1.1 W (Terminals +31 / -32) effective internal capacitance: Ci = 6.6 nF The effective internal inductance is negligibly small. Plug-In module for Ui = 30 V shutdown-function li = 320 mA Pi = 1.1 W (Terminals +51 / -52 resp. effective internal capacitance: Ci = 3.7 nF +85 / -86) The effective internal inductance is negligibly small. Notice The intrinsically safe circuits are galvanically separated up to a voltage of 60 V. The local communication interface (LKS) is connected with the signal circuit.
Electrical data for type TZIDC with marking Ex nA IIC T6 Signal circuit U = 9.7 VDC; 4 ... 20 mA, max. 21.5 mA (Terminals +11 / -12) Switch input U = 12 ... 24 VDC; 4 mA (Terminals +81 / -82) Switch output U = 11 VDC (Terminals +83 / -84) Optionally the following modules are allowed to be used with type TZIDC Plug-In module for digital feedback U = 5 ... 11 VDC (Terminals +51 / -52 resp. +41 / -42) Plug-In module for analogue U = 10 ... 30 VDC; 4 ... 20 mA, max. 21.5 mA feedback (Terminals +31 / -32) Additionally the following modules are allowed to be used with all types marked Ex nA IIC T6 Plug-In module for shutdown-function U = 20 ... 30 VDC (Terminals +51 / -52 resp. +85, -86) Mechanical digital feedback U = 5 ... 11 VDC (Terminals Limit1 +51 / -52 resp. Limit2 +41 / -42)
30 - EN
CI/TZIDC/110/120-EN
7.1.3 CSA International Certificate: Class 2258 02 Class 2258 04 1052414 PROCESS CONTROL EQUIPMENT For Hazardous Locations PROCESS CONTROL EQUIPMENT Intrinsically Safe, Entity For Hazardous Locations
Class I, Div 2, Groups A, B, C and D; Class II, Div 2, Groups E, F, and G, Class III, Enclosure Type 4X: Model TZIDC, P/N V18345-x0x2x2xx0x Intelligent Positioner Input rated Max output pressure Max. ambient Class I, Div 1, Groups A, B, C and D; Class II, Div 1, Groups E, F and G Class III, Enclosure Type 4X: Model TZIDC, P/N V18345-x0x2x2xx0x Intelligent Positioner intrinsically safe with entity parameters of: Terminals 11 / 12 V max = 30 V I max = 104 mA Ci = 6.6 nF Li = 0 uH Terminals 81 / 82 V max = 30 V I max = 110 mA Ci = 4.2 nF Li = 0 uH Terminals 83 / 84 V max = 30 V I max = 90 mA Ci = 4.2 nF Li = 0 uH Terminals 31 / 32 V max = 30 V I max = 110 mA Ci = 6.6 nF Li = 0 uH Terminals 41 / 42 and V max = 30 V 51 / 52 I max = 96 mA Ci = 3.7 nF Li = 0 uH Terminals Limit2 41 / 42 and V max = 15.5 V Limit1 51 / 52 I max = 52 mA Ci = 20 nF Li = 30 uH 30 V DC; max. 4 ... 20 mA 90 psi 85 Deg C
CI/TZIDC/110/120-EN
EN - 31
When installed per installation Drawing No 901064 Temperature Code T4 Max. Ambient 85 Deg C Notice The "x" in P/N denotes minor mechanical variations or optional features. Do not use the local communication interface (LKS) in hazardous areas. Each pair of conductors for each intrinsic safety circuit must be shielded.
32 - EN
CI/TZIDC/110/120-EN
7.1.4 CSA Certification Record Certificate: Class 2258 04 1649904 (LR 20312) PROCESS CONTROL EQUIPMENT Intrinsically Safe, Entity For Hazardous Locations
Class I, Div 1, Groups A, B, C and D; Class II, Div 1, Groups E, F, and G, Class III, Div 1, Enclosure Type 4X: Model TZIDC, P/N V18345-x0x2x2xx0x Intelligent Positioner Input rated 30 V DC; max.4 20 mA Output pressure Max. 90 psi Intrinsically safe with entity parameters of: Terminals 11 / 12 V max = 30 V I max = 104 mA Ci = 6.6 nF Li = 0 uH Terminals 81 / 82 V max = 30 V I max = 110 mA Ci = 3.7 nF Li = 0 uH Terminals 83 / 84 V max = 30 V I max = 96 mA Ci = 3.7 nF Li = 0 uH Terminals 31 / 32 V max = 30 V I max = 110 mA Ci = 6.6 nF Li = 0 uH Terminals 41 / 42 and V max = 30 V 51 / 52 I max = 96 mA Ci = 3.7 nF Li = 0 uH Terminals Limit2 41 / 42 and V max = 15.5 V Limit1 51 / 52 I max = 52 mA Ci = 20 nF Li = 30 uH When installed per installation Drawing No 901064 Temperature Code T4 Max. Ambient 85 Deg C Notice The "x" in P/N denotes minor mechanical variations or optional features. Do not use the local communication interface (LKS) in hazardous areas. Each pair of conductors for each intrinsic safety circuit must be shielded.
CI/TZIDC/110/120-EN
EN - 33
7.2 7.2.1 TZIDC-110 EC-Type-Examination Test Certificate Designation: Type-Examination Test Certificate: Type: Standards: Temperature class T4 T5 T6 Electrical data Signal circuit (Terminal +11 / -12 or + / -) In intrinsically safe explosion protection types EEx ia IIC or EEx ib IIC, only for connection to a certified intrinsically safe circuit (e.g. FISCO supply unit) with max. values based on the following table: FISCO power supply ia/ib for Grp. IIB/IIC Barriers or power supply ia/ib for Grp. IIB/IIC 24 V 250 mA 1.2 W linear II 2 G EEx ia IIC T6 TV 02 ATEX 1831 X Intrinsically safe equipment EN 50014:1997 EN 50020:1994 Ambient temperature range -40 ... 85 C -40 ... 55 C -40 ... 40 C
FISCO power supply ia/ib for Grp. IIB/IIC Voltage Current Power Characteristic
17.5 V 17.5 V 380 mA 360 mA 5.32 W 2.52 W rectangular trapezoidal Li negligibly small Ci negligibly small
Shutdown contact input (Terminal +85 / -86)
Mechanical digital feedback (Terminals Limit1 +51 / -52 or Limit2 +41 / -42) Local communication Only for connection to a programmer or PC outside the interface (LKS) and program potentially explosive area. interface (X5) Important
In intrinsically safe explosion protection types EEx ia IIC or EEx ib IIC, only for connection to a certified intrinsically safe circuit with max. values Ui = 30 V Ci = 3.7 nF Li negligibly small For max. values, see EC-type-examination test certificate number PTB 00 ATEX 2049 X
The local communication interface (LKS) and program interface (X5) may only be operated outside the potentially explosive area.
34 - EN
CI/TZIDC/110/120-EN
7.2.2 IECEx Issue No. 3 IECEx Ex ia IIC T6 Ex nA II T6 Certificate No.: Issue No.: Typ: Standards: Ex nL IIC T6 IECEx TUN 04.0015X 3 Intrinsic safety "i", Type of protection "n" IEC 60079-0:2000 IEC 60079-11:1999 IEC 60079-15:2001 IEC 60079-27:2005-04 TZIDC-110 Ex ia IIC resp. Ex ib IIC Temperature Class T4 T5 T6 TZIDC-110 Ex nA IIC resp. Ex nL IIC
Type and marking
Ambient temperature range -40 ... 85 C -40 ... 85 C -40 ... 55 C -40 ... 65 C -40 ... 40 C -40 ... 50 C
Electrical data for type TZIDC-110 with marking Ex ia IIC T6 resp. Ex ib IIC T6 Input circuit In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) (terminals +11, -12 or +, -) only for the connection to a certified intrinsically safe circuit (e.g. FISCO power supply) with the following maximum values according to the following table: FISCO power supply Voltage Current Power Characteristic line Local interface for communication (LKS) and programming interface (X5) ia/ib for Grp. IIB/IIC Ui = 17.5 V li = 380 mA Pi = 5.32 W Barriers or power supply ia/ib for Grp. IIB/IIC Ui = 24 V li = 250 mA Pi = 1.2 W Linear
For the connection to a programmer resp. a PC outside of the explosive hazardous area only.
CI/TZIDC/110/120-EN
EN - 35
Optionally the following modules are allowed to be used: In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) only for the connection to a certified intrinsically safe circuit with the following maximum values: Plug-In module for Ui = 30 V shutdown-function li = 320 mA Pi = 1.1 W (terminals +51 / -52 resp. effective internal capacitance: Ci = 3.7 nF +85 / -86) The effective internal inductance is negligibly small. Notice The intrinsically safe circuits are galvanically separated up to a voltage of 60 V. The local communication interface (LKS) and program interface (X5) are connected with the signal circuit.
Electrical data for type TZIDC-110 with marking Ex nA IIC T6 Input circuit U = 9 ... 32 VDC; 10.5 mA (terminals +11 / -12) Additionally the following modules are allowed to be used with all types marked Ex nA IIC T6 Plug-In module for shutdown-function U = 20 ... 30 VDC (terminals +51 / -52 resp. +85 / -86) Mechanical digital feedback U = 5 ... 11 VDC (terminals Limit1 +51 / -52 resp. Limit2 +41 / -42) Electrical data for type TZIDC-110 with marking Ex nL IIC T6 Input circuit FNICO field device (terminals +11 / -12)
36 - EN
CI/TZIDC/110/120-EN
7.2.3 CSA International Certificate: Class 2258 04 Class 2258 02 Class I, Div 2, Groups A, B, C and D; Class II, Div 2, Groups E, F, and G, Class III, Enclosure Type 4X: Model TZIDC-110, P/N V18346-x032x2xx0x Intelligent Positioner Input rated Intrinsically safe with entity parameters of: Terminals 11 / 12 V max = 24 V I max = 250 mA Ci = 2.8 nF Li = 7.2 uH Terminals 85 / 86 U max = 30 V I max = 50 mA Ci = 3.8 nF Li = 0 uH Terminals 41 / 42 U max = 16 V I max = 20 mA Ci = 60 nF Li = 100 uH Terminals 51 / 52 U max = 16 V I max = 20 mA Ci = 60 nF Li = 100 uH When installed per installation Drawing No 901265 Temperature Code T4 Max. Ambient 85 Deg C Notice The "x" in P/N denotes minor mechanical variations or optional features. Do not use the local communication interface (LKS) in hazardous areas. Each pair of conductors for each intrinsic safety circuit must be shielded. 32 V DC; max.15 mA (powered by a SELV circuit) 1649904 (LR 20312) PROCESS CONTROL EQUIPMENT Intrinsically Safe, Entity For Hazardous Locations PROCESS CONTROL EQUIPMENT For Hazardous Locations
CI/TZIDC/110/120-EN
EN - 37
Class I, Div 1, Groups A, B, C and D; Class II, Div 1, Groups E, F, and G, Class III, Div 1, Enclosure Type 4X: Model TZIDC-110, P/N V18346-x032x2xx0x Intelligent Positioner Input rated 32 V DC; max. 15 mA (powered by a SELV Circuit) Intrinsically safe with entity parameters of: Terminals 11 / 12 V max = 24 V I max = 250 mA Ci = 2.8 nF Li = 7.2 uH Terminals 85 / 86 U max = 30 V I max = 50 mA Ci = 3.8 nF Li = 0 uH Terminals 41 / 42 U max = 16 V I max = 20 mA Ci = 60 nF Li = 100 uH When installed per installation Drawing No 901265 Temperature Code T4 Max. Ambient 85 Deg C Notice The "x" in P/N denotes minor mechanical variations or optional features. Do not use the local communication interface (LKS) in hazardous areas. Each pair of conductors for each intrinsic safety circuit must be shielded.
38 - EN
CI/TZIDC/110/120-EN
7.2.5 FM Approvals TZIDC-110 Positioner, Model V18346-a032b2cd0e IS/I,II,III/1/ABCDEFG/T6,T5,T4 Ta = 40 C, 55 C, 85 C-901265 Entity, FISCO Entity and FISCO Parameters Terminals +11 / -12 +11 / -12 +11 / -12 +51 / -52 +41 / -42 +85 / -86 Type Entity FISCO FISCO Entity Entity Entity Groups Vmax A-G A-G C-G A-G A-G A-G 24 V 17.5 V 17.5 V 16 V 16 V 30 V Imax 250 mA 360 mA 380 mA 20 mA 20 mA Parameters Pi 1.2 W 2.52 W 5.32 W Ci 2.8 nF 2.8 nF 2.8 nF 60 nF 60 nF 3.7 nF Li 7.2 uH 7.2 uH 7.2 uH 100 uH 100 uH < 1 uH
NI/I/2/ABCD/T6,T5,T4 Ta = 40 C, 55 C, 85 C S/II,III/2/EFG//T6,T5,T4 Ta = 40 C, 55 C, 85 C Enclosure type 4x a = Case/mounting 1, 2, 5 or 6 b = Output/safe protection 1, 2, 4 or 5 c = Option modules (shutdown) 0 or 4 d = Optional mechanical kit for digital position feedback 0, 1 or 3 e = Design (varnish/coding) 1 or E Equipment Ratings: TZIDC-110 Intrinsically safe, Entity and FISCO, for Class I, II and III, Division 1, Applicable Groups A, B, C, D, E, F, G; nonincendive for Class I, Division 2, Group E, F and G hazardous (classified) indoor and outdoort NEMA 4x locations. The following temperature code ratings were assigned for the equipment and protection methods described above: T6 in ambient temperatures of 40 C T5 in ambient temperatures of 55 C T4 in ambient temperatures of 85 C
CI/TZIDC/110/120-EN
EN - 39
7.3
cht
TZIDC-120 EC-Type-Examination Test Certificate Designation: Type-Examination Test Certificate: Type: Standards: Temperature class T4 T5 T6 Electrical data Signal circuit (Terminal +11 / -12 or + / -) In intrinsically safe explosion protection types EEx ia IIC or EEx ib IIC, only for connection to a certified intrinsically safe circuit (e.g. FISCO supply unit) with max. values based on the following table: FISCO power supply ia/ib for Grp. IIB/IIC Barriers or power supply ia/ib for Grp. IIB/IIC 24 V 250 mA 1.2 W Linear II 2 G EEx ia IIC T6 TV 02 ATEX 1834 X Intrinsically safe equipment EN 50014:1997 EN 50020:1994 Ambient temperature range -40 ... 85 C -40 ... 55 C -40 ... 40 C
7.3.1
FISCO power supply ia/ib for Grp. IIB/IIC Voltage Current Power Characteristic
17,5 V 17,5 V 380 mA 360 mA 5.32 W 2.52 W rectangular trapezoidal Li negligibly small Ci negligibly small
Shutdown contact input (Terminal +85 / -86)
Mechanical digital feedback (Terminals Limit1 +51 / -52 or Limit2 +41 / -42) Local communication Only for connection to a programmer or PC outside the interface (LKS) and program potentially explosive area. interface (X5) Important
In intrinsically safe explosion protection types EEx ia IIC or EEx ib IIC, only for connection to a certified intrinsically safe circuit with max. values Ui = 30 V Ci = 3.7 nF Li negligibly small For max. values, see EC-type-examination test certificate number PTB 00 ATEX 2049 X
The local communication interface (LKS) and program interface (X5) may only be operated outside the potentially explosive area.
40 - EN
CI/TZIDC/110/120-EN
7.3.2 IECEx Issue No. 3 IECEx Ex ia IIC T6 Ex nA II T6 Certificate No.: Issue No.: Typ: Standards: Ex nL IIC T6 IECEx TUN 04.0015X 3 Intrinsic safety "i", Type of protection "n" IEC 60079-0:2000 IEC 60079-11:1999 IEC 60079-15:2001 IEC 60079-27:2005-04 TZIDC-120 Ex ia IIC resp. Ex ib IIC Temperature Class T4 T5 T6 TZIDC-120 Ex nA IIC resp. Ex nL IIC
Type and marking
Ambient temperature range -40 85 C -40 85 C -40 55 C -40 65 C -40 40 C -40 50 C
Electrical data for type TZIDC-120 with marking Ex ia IIC T6 resp. Ex ib IIC T6 Input circuit In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) (terminals +11 / -12 or (+ / -) only for the connection to a certified intrinsically safe circuit (e.g. FISCO power supply) with the following maximum values according to the following table: FISCO power supply Voltage Current Power Characteristic line Local interface for communication (LKS) and programming interface (X5) ia/ib for Grp. IIB/IIC Ui = 17.5 V li = 380 mA Pi = 5.32 W Barriers or power supply ia/ib for Grp. IIB/IIC Ui = 24 V li = 250 mA Pi = 1.2 W Linear
For the connection to a programmer resp. a PC outside of the explosive hazardous area only.
CI/TZIDC/110/120-EN
EN - 41
Optionally the following modules are allowed to be used: In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) only for the connection to a certified intrinsically safe circuit with the following maximum values: Plug-In module for Ui = 30 V shutdown-function li = 320 mA Pi = 1.1 W (terminals +51 / -52 resp. effective internal capacitance: Ci = 3.7 nF +85 / -86) The effective internal inductance is negligibly small. Notice The intrinsically safe circuits are galvanically separated up to a voltage of 60 V. The local communication interface (LKS) and program interface (X5) are connected with the signal circuit.
Electrical data for type TZIDC-120 with marking Ex nA IIC T6 Input circuit U = 9 32 VDC; 11.5 mA (terminals +11 / -12) Additionally the following modules are allowed to be used with all types marked Ex nA IIC T6 Plug-In module for shutdown-function U = 20 30 VDC (terminals +51 / -52 resp. +85 / -86) Mechanical digital feedback U = 5 11 VDC (terminals Limit1 +51 / -52 resp. Limit2 +41 / -42) Electrical data for type TZIDC-120 with marking Ex nL IIC T6 Input circuit FNICO field device (terminals +11 / -12)
42 - EN
CI/TZIDC/110/120-EN
7.3.3 CSA International Certificate: Class 2258 04 Class 2258 02 Class I, Div 2, Groups A, B, C and D; Class II, Div 2, Groups E, F, and G, Class III, Enclosure Type 4X: Model TZIDC-120, P/N V18347-x042x2xx0x Intelligent Positioner Input rated 32 V DC; max.15 mA (powered by a SELV circuit) Intrinsically safe with entity parameters of: Terminals 11 / 12 V max = 24 V I max = 250 mA Ci = 2.8 nF Li = 7.2 uH Terminals 85 / 86 U max = 30 V I max = 50 mA Ci = 3.8 nF Li = 0 uH Terminals 41 / 42 U max = 16 V I max = 20 mA Ci = 60 nF Li = 100 uH Terminals 51 / 52 U max = 16 V I max = 20 mA Ci = 60 nF Li = 100 uH When installed per installation Drawing No 901265 Temperature Code T4 Max. Ambient 85 Deg C Notice The "x" in P/N denotes minor mechanical variations or optional features. Do not use the local communication interface (LKS) in hazardous areas. Each pair of conductors for each intrinsic safety circuit must be shielded. 1649904 (LR 20312) PROCESS CONTROL EQUIPMENT Intrinsically Safe, Entity For Hazardous Locations PROCESS CONTROL EQUIPMENT For Hazardous Locations
CI/TZIDC/110/120-EN
EN - 43
Class I, Div 1, Groups A, B, C and D; Class II, Div 1, Groups E, F, and G, Class III, Div 1, Enclosure Type 4X: Model TZIDC-120, P/N V18347-x042x2xx0x Intelligent Positioner Input rated 32 V DC; max. 15 mA (powered by a SELV Circuit) Intrinsically safe with entity parameters of: Terminals 11 / 12 V max = 24 V I max = 250 mA Ci = 2.8 nF Li = 7.2 uH Terminals 85 / 86 U max = 30 V I max = 50 mA Ci = 3.8 nF Li = 0 uH Terminals 41 / 42 U max = 16 V I max = 20 mA Ci = 60 nF Li = 100 uH When installed per installation Drawing No 901265 Temperature Code T4 Max. Ambient 85 Deg C Notice The "x" in P/N denotes minor mechanical variations or optional features. Do not use the local communication interface (LKS) in hazardous areas. Each pair of conductors for each intrinsic safety circuit must be shielded.
44 - EN
CI/TZIDC/110/120-EN
7.3.5 FM Approvals TZIDC-120 Positioner, Model V18347-a042b2cd0e IS/I,II,III/1/ABCDEFG/T6,T5,T4 Ta = 40 C, 55 C, 85 C-901265 Entity, FISCO Entity and FISCO Parameters Terminals +11 / -12 +11 / -12 +11 / -12 +51 / -52 +41 / -42 +85 / -86 Type Entity FISCO FISCO Entity Entity Entity Groups Vmax A-G A-G C-G A-G A-G A-G 24 V 17.5 V 17.5 V 16 V 16 V 30 V Imax 250 mA 360 mA 380 mA 20 mA 20 mA Parameters Pi 1.2 W 2.52 W 5.32 W Ci 2.8 nF 2.8 nF 2.8 nF 60 nF 60 nF 3.7 nF Li 7.2 uH 7.2 uH 7.2 uH 100 uH 100 uH < 1 uH
NI/I/2/ABCD/T6,T5,T4 Ta = 40 C, 55 C, 85 C S/II,III/2/EFG//T6,T5,T4 Ta = 40 C, 55 C, 85 C Enclosure type 4x a = Case/mounting 1, 2, 5 or 6 b = Output/safe protection 1, 2, 4 or 5 c = Option modules (shutdown) 0 or 4 d = Optional mechanical kit for digital position feedback 0, 1 or 3 e = Design (varnish/coding) 1 or E Equipment Ratings: TZIDC-120 Positioners Intrinsically safe, Entity and FISCO, for Class I, II and III, Division 1, Applicable Groups A, B, C, D, E, F, G; nonincendive for Class I, Division 2, Group E, F and G hazardous (classified) indoor and outdoort NEMA 4x locations. The following temperature code ratings were assigned for the equipment and protection methods described above: T6 in ambient temperatures of 40 C T5 in ambient temperatures of 55 C T4 in ambient temperatures of 85 C
CI/TZIDC/110/120-EN
EN - 45
46 - EN
CI/TZIDC/110/120-EN
ABB has Sales & Customer Support expertise in over 100 countries worldwide. www.abb.com/instrumentation
The Companys policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice. Printed in the Fed. Rep. of Germany (06.2009) CI/TZIDC/110/120-EN ABB 2009 3KXE341007R4401
ABB Limited Salterbeck Trading Estate Workington, Cumbria CA14 5DS UK Tel: +44 (0)1946 830 611 Fax: +44 (0)1946 832 661
ABB Inc. 125 E. County Line Road Warminster, PA 18974 USA Tel: +1 215 674 6000 Fax: +1 215 674 7183
ABB Automation Products GmbH Schillerstr. 72 32425 Minden Germany Tel: +49 551 905-534 Fax: +49 551 905-555 CCC-support.deapr@de.abb.com
B72G
Filter/Regulator B72G - ### - ### - ###
Port 2 ....1/4" 3 ....3/8"
Installation & Maintenance Instructions
Thread Form Bowl Element Adjustment Drain Diaphragm Spring (Outlet Pressure Range) * Gauge A....PTF A....Automatic D....Short metal with liquid level indicator 1 ....5 m N....Non-relieving C....0,3 to 2 bar (5 to 30 psig) K....Knob G....With B....ISO Rc taper T ....T-bar Q....Manual, 1/4 turn T ....Short transparent without guard 2 ....25 m R....Relieving F ....0,3 to 4 bar (5 to 60 psig) N....Without G....ISO G parallel S....Semi automatic L ....Long transparent without guard 3 ....40 m M...0,3 to 10 bar (5 to 150 psig) W...Long transparent with guard * Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges. 3. Push bowl, or bowl with guard, into body and turn fully clockwise before pressurizing. 4. Install a pressure gauge or plug gauge ports. Gauge ports can also be used as additional outlets for regulated air. 5. Plastic tube used on semi automatic drain is packed loose inside the shipping box. Push plastic tube over tip of semi automatic drain. ADJUSTMENT 1. Before applying inlet pressure to filter/regulator, turn adjustment (1 or 7) counterclockwise to remove all force on regulating spring (12). 2. Apply inlet pressure, then turn adjustment (1 or 7) clockwise to increase and counterclockwise to decrease pressure setting. 3. Always approach the desired pressure from a lower pressure. When reducing from a higher to a lower setting, first reduce to some pressure less than that desired, then bring up to the desired pressure. NOTE With non-relieving filter/regulators, make pressure reductions with some air flow in the system. If made under no flow (dead-end) conditions, the filter/regulator will trap the over-pressure in the downstream line. 4. KNOB ADJUSTMENT. Push knob down to lock pressure setting. Pull knob up to release. Install tamper resistant cover (see Replacement Items) to make setting tamper resistant. 5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock pressure setting. SERVICING 1. Open manual drain to expel accumulated liquids. Keep liquids below baffle (52). 2. Clean or replace filter element when dirty. DISASSEMBLY 1. Filter/regulator can be disassembled without removal from air line. 2. Shut off inlet pressure. Reduce pressure in inlet and outlet lines to zero. 3. Turn adjustment (1 or 7) fully counterclockwise. 4. Remove bowl - push into body and turn counterclockwise. 5. Disassemble in general accordance with the item numbers on exploded view. Do not remove the drains unless replacement is necessary. Remove and replace drains only if they malfunction. CLEANING 1. Clean plastic bowl (29, 38) with warm water only. Clean other parts with warm water and soap. 2. Rinse and dry parts. Blow out internal passages in body (16) with clean, dry compressed air. Blow air through filter element (53) from inside to outside to remove surface contaminants. 3. Inspect parts. Replace those found to be damaged. Replace plastic bowl with a metal bowl if plastic bowl shows signs of cracking or cloudiness. ASSEMBLY 1. Lubricate the following items with o-ring grease. 4 (Thrust washer) - outer circumference and both sides. 5, 7 (Adjusting screw) - threads and tip. 18, 31, 40 (Manual drain body) - the portion of the body that contacts the bowl, and the hole that accommodates the stem of drain valve (19, 32, 41). 54 (Center-post) - Bore for valve (57). 57 (Valve) - stem. 23, 28, 36, 37, 45, 50, 58, 59 - (O-rings) 2. Assemble the unit as shown on the exploded view. Push bowl, or bowl with guard, into body and turn fully clockwise. 3. Torque Table Item Torque in Nm (Inch-Pounds) 2, 9 (Screw) 2,3 to 2,8 (20 to 25) 22, 35, 44, 25, 36B (Nut) 2,3 to 2,8 (20 to 25) 46 (Screw) 1,9 to 2,5 (17 to 22) 52 (Baffle) 0,5 to 0,7 (4 to 6) 54 (Center-post) 0,7 to 0,9 (6 to 8)
6 7 1 8 2 59 9 10 11
TECHNICAL DATA Fluid: Compressed air Maximum pressure: Transparent bowl: 10 bar (150 psig) Metal bowl: 17 bar (250 psig) Operating temperature*: Transparent bowl: -20 to +50C (0 to +125F) Metal bowl: -20 to +65C (0 to +150F) * Air supply must be dry enough to avoid ice formation at temperatures below +2C (+35F). Particle removal: 5 m, 25 m, or 40 m filter element Air quality: Within ISO 8573-1, Class 3 and Class 5 (particulates) Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar (90 psig) set pressure and 1 bar (15 psig) droop from set: 38 dm3/s (80 scfm) Manual drain connection: 1/8" Semi automatic drain connection: Push on 8mm (5/16") ID tube Semi automatic drain operating conditions (pressure operated): Bowl pressure required to close drain: Greater than 0,1 bar (1.5 psig) Bowl pressure required to open drain: Less than 0,1 bar (1.5 psig) Minimum air flow required to close drain: 0,5 dm3/s (1 scfm) Manual operation: Lift stem to drain bowl Automatic drain connection: 1/8" Automatic drain operating conditions (float operated): Bowl pressure required to close drain: Greater than 0,3 bar (5 psig) Bowl pressure required to open drain: Less than 0,2 bar (3 psig) Minimum air flow required to close drain: 0,1 dm3/s (0.2 scfm) Manual operation: Depress pin inside drain outlet Nominal bowl size: Short bowl: 56 ml (1.9 fluid ounce) Long bowl: 65 ml (2.2 fluid ounce) Gauge ports: 18 PTF with PTF main ports Rc1/8 with ISO Rc and ISO G main ports Materials: Body: Zinc Bonnet: Acetal Valve: Brass Bowl: Transparent: Polycarbonate Transparent with guard: Polycarbonate, steel guard Metal: Zinc Metal bowl liquid level indicator lens: Transparent nylon Element: Sintered polypropylene Elastomers: Neoprene and nitrile REPLACEMENT ITEMS Service Kit (includes items circled on exploded view): Relieving.............................................................4383-500 Nonrelieving .......................................................4383-501 Liquid level lens kit (46, 48, 49, 50) ......................4380-030 Filter element, 5m (53) ..........................................5925-03 Filter element, 25m (53) ........................................5925-01 Filter element, 40m (53) ........................................5925-02 Manual drain (18,19,20) (31,32,33) (40,41,42).........619-50 Semiauto drain (21,22,23) (34,35,36) (43,44,45) ...5379-50 Auto drain (24,25,26) (36A,36B,36C)....................4000-50R Tamper resistant cover (knob adjustment only).......4255-51 PANEL MOUNTING DIMENSIONS Panel mounting hole diameter: 40 mm (1.57") Panel thickness: 2 to 4 mm (0.06" to 0.16") INSTALLATION 1. Shut off air pressure. Install filter/regulator in air line G vertically (bowl down), G with air flow in direction of arrow on body, G upstream of lubricators and cycling valves, G as close as possible to the device being serviced. 2. Connect piping to proper ports using pipe thread sealant on male threads only. Do not allow sealant to enter interior of unit.
Norgren 1998
3 4 5 12 13
57
58 56 55
16 54 14 15 53
52
18
21 29 28 23
24
17 27 20 19 22
26
25
31
36A 34 37
30 36 33 32 35 50 43 51 39 45 42 41 49 44 48 47 46 36B 38 36C
40
a subsidiary of IMI plc
IM-160.300.01 (4/98)
B72G
Installation & Maintenance Instructions
CAUTION Water vapor will pass through these units and could condense into liquid form downstream as air temperature drops. Install an air dryer if water condensation could have a detrimental effect on the application. WARNING These products are intended for use in industrial compressed air systems only. Do not use these products where pressures and temperatures can exceed those listed under Technical Data. Polycarbonate plastic bowls can be damaged and possibly burst if exposed to such substances as certain solvents, strong alkalies, compressor oils containing esterbased additives or synthetic oils. Fumes of these substances in contact with the polycarbonate bowl, externally or internally, can also result in damage. Clean with warm water only. Use metal bowl in applications where a plastic bowl might be exposed to substances that are incompatible with polycarbonate. If outlet pressure in excess of the filter/regulator pressure setting could cause downstream equipment to rupture or malfunction, install a pressure relief device downstream of the filter/regulator. The relief pressure and flow capacity of the relief device must satisfy system requirements. The accuracy of the indication of pressure gauges can change, both during shipment (despite care in packaging) and during the service life. If a pressure gauge is to be used with these products and if inaccurate indications may be hazardous to personnel or property, the gauge should be calibrated before initial installation and at regular intervals during use. Before using these products with fluids other than air, for non industrial applications, or for life-support systems consult Norgren.
Norgren 1998
a subsidiary of IMI plc
IM-160.300.02 (4/98)
- ELECTRIC ACTUATOR & ACCESSORIES 1. 2. 3. Multi-turn actuator AUMA Gearboxes AUMA Wiring diagram
Multi-turn actuator
SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive
with actuator controls

AUMATIC AC 01.1
Control:
Parallel Profibus DP Profibus DP with FO
Modbus
Modbus with FO DeviceNet Foundation Fieldbus
Operation instructions
Assembly, operation, commissioning
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus
Read the operation instructions first

Observe safety instructions. These operation instructions are part of the product. Store operation instructions during product life. Pass on instructions to any subsequent user or owner of the product.
Reference documents:
Manual (Operation and setting) AUMATIC AC 01.0/ACExC 01.1 Modbus. Manual (Fieldbus device integration) AUMATIC AC 01.0/ACExC 01.1 Modbus. Can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA (addresses from page 82). Page
. . . . . .
Table of contents 1.
1.1. 1.2. 1.3. 1.4. 1.5. General notes on safety Range of application Applications in Ex zone 22 (option) Warnings and notes Further references and symbols
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 6 7 8 8
2.
2.1. 2.2.
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Name plate Short description 9 11
3.
3.1. 3.2. 3.3.
Transport, storage and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Transport Storage Packaging 12 12 12
4.
4.1. 4.2. 4.2.1 4.2.2 4.3. 4.3.1 4.4.
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Handwheel fitting Multi-turn actuator mounting to valve/gearbox Output drive types B1, B2, B3, B4, B, and E Output drive type A Accessories (option) Protection tube for rising valve stem Mounting positions of the local controls 13 14 14 15 17 17 18
5.
5.1. 5.2. 5.3. 5.4. 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General notes Mains connection using AUMA plug/socket connector (SD) Bus connection using AUMA plug/socket connector (SD) Accessories for electrical connection (option) Controls mounted to wall bracket Parking frame Protection cover Double sealed intermediate frame Ground connection, external 19 21 24 29 29 30 30 30 30
6.
6.1. 6.2. 6.2.1 6.2.2 6.3. 6.3.1 6.3.2 6.4.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Manual operation Motor operation Local operation Operation from REMOTE Menu navigation via push buttons (for settings and indications) Short overview: functions of the push buttons Structural design and navigation Language change in the display 31 32 32 32 33 33 34 35
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus Page
7.
7.1. 7.1.1 7.2. 7.3.
Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Status indications in the display Status indication S0/S6 - operation Indication lights/LEDs Mechanical position indicator/running indication (option) 37 37 38 38
8.
8.1. 8.2. 8.3.
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Signals via fieldbus Feedback via output contacts (binary) - (option) Feedback signals (analogue) - (option) 39 39 39
9.
9.1. 9.2. 9.3. 9.4. 9.5. 9.6. 9.6.1 9.6.2 9.7. 9.7.1 9.7.2 9.8. 9.8.1 9.8.2 9.8.3 9.9. 9.10. 9.11. 9.12.
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Type of seating: check/edit for end positions Baudrate, parity and bus address (slaveaddress) setting Further parameters of the Modbus interface Switch compartment: open Torque switching: set Limit switching: set End position CLOSED (black section): set End position OPEN (white section): set Intermediate positions (option): set Running direction CLOSE (black section): set Running direction OPEN (white section): set Test run Rotational direction check Limit switching check Perform reference operation Potentiometer (option) setting Electronic position transmitter RWG setting (option) Mechanical position indicator setting (option) Switch compartment: close 41 44 46 47 48 49 49 49 50 50 50 51 51 52 52 53 54 55 56
10.
Corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
57 57 57 57 58 58 59 59 60 61 63 64 64 65
10.1. Faults during commissioning 10.1.1 Mechanical position indicator 10.1.2 Electronic position transmitter RWG 10.1.3 Limit and torque switches 10.1.4 Fault in end position (overrun not considered) 10.1.5 Push buttons do not react 10.2. Fault indications and warning indications 10.2.1 Status display S0 - faults and warnings 10.2.2 Status indication S1 - faults 10.2.3 Status indication S2 - warnings 10.2.4 Status indication S3 - causes for not ready remote 10.3. Fuses 10.3.1 Fuses within the actuator controls 10.3.2 Motor protection (thermal monitoring)
11.
11.1. 11.2. 11.3.
Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Preventive measures for servicing and safe operation Maintenance Disposal and recycling 66 67 67
Operation instructions Page
12.
12.1. 12.2.
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Controls AC 01.1 with AUMA plug/socket connector (SD) 68 70
13. 14.
14.1.
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Declaration of Conformity and Declaration of Incorporation 80
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.
1.1.
Safety instructions
General notes on safety Standards/directives AUMA products are designed and manufactured in compliance with recognised standards and directives. This is certified in a declaration of incorporation and a declaration of conformity. The end user or the contractor must ensure that all requirements with respect to assembly, electrical connection, and commissioning at the place of installation are met. They include among others: Applicable configuration directives for fieldbus applications. National regulations, laws, and prescriptions.
. .
Safety instructions/ warnings
All personnel working with this device must be familiar with the safety and warning instructions in this manual and observe the instructions given. Safety instructions and warning signs on the device must be observed to avoid personal injury or property damage. Assembly, electrical connection, commissioning, operation, and maintenance must be carried out exclusively by suitably qualified personnel having been authorised by the end user or contractor of the plant. Prior to working on this product, the staff must have thoroughly read and understood these instructions and, furthermore, know and observe officially recognised rules regarding occupational health and safety. Prior to commissioning, it is important to check that all settings are in compliance with the requirements of the application. Incorrect settings might present a danger to the application, e.g. cause damage to the valve or the installation. The manufacturer will not be held liable for any consequential damage. Such risk lies entirely with the user. Prerequisites for safe and smooth operation: Correct transport, proper storage, mounting and installation, as well as careful commissioning. Only operate the device if it is in perfect condition while observing these instructions. Immediately notify any faults and damage and allow for corrective measures. Observe recognised rules for occupational health and safety. Observe the national regulations. During operation, the housing warms up and surface temperatures > 60 C may occur. To prevent possible burns, we recommend to the check surface temperature with an appropriate thermometer prior to working with the device. The end user or the contractor are responsible for implementing required protective measures on site, such as enclosures, barriers, or personal safety equipment for the staff. To ensure safe device operation, the maintenance instructions included in this manual must be observed. Any device modification requires the consent of the manufacturer.
Qualification of staff
Commissioning
Operation
. . . . . .
Protective measures
Maintenance
1.2.
Range of application AUMA multi-turn actuators are designed for the operation of industrial valves, e.g. globe valves, gate valves, butterfly valves, and ball valves. Other applications require explicit (written) confirmation by the manufacturer.
. . . . . . . . . .
Information
The following applications are not permitted, e.g.: Industrial trucks according to EN ISO 3691 Lifting appliances according to EN 14502 Passenger lifts according to DIN 15306 and 15309 Service lifts according to EN 81-1/A1 Roller conveyors according to Standard EN 14673 (draft) Permanent operation Buried service Permanent submersion (observe enclosure protection) Potentially explosive areas, with the exception of zone 22 Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use. Observance of these operation instructions is considered as part of the devices designated use. These operation instructions are only valid for the clockwise closing standard version, i.e. driven shaft turns clockwise to close the valve. Separate instructions are available for the counterclockwise closing special version.
1.3.
Applications in Ex zone 22 (option) SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 actuators basically meet the requirements for applications in dust hazardous locations of ZONE 22, in compliance with the ATEX directive 94/9/EC. The actuators are designed to meet enclosure protection IP 67 or IP 68 and fulfil the requirements of EN 50281-1-1:1998 section 6 Electrical apparatus for use in presence of combustible dust hazards, requirements for category 3 electrical equipment protected by enclosures. To comply with all requirements of EN 50281-1-1: 1998, the following points must imperatively be observed:
. . . . . . . .
In compliance with the ATEX directive 94/9/EC, the actuators must be equipped with an additional identification II3D IP6X T150 C. The maximum surface temperature of the actuators, based on an ambient temperature of +40 C in accordance with EN 50281-1-1 section 10.4, is +150 C. In accordance with section 10.4, an increased dust deposit on the equipment was not considered for the determination of the max. surface temperature. The correct connection of the thermoswitches or the PTC thermistors as well as fulfilling the requirements of the duty type and the technical data are prerequisites for compliance with the maximum surface temperature of devices. The connection plug may only be plugged in or pulled out when device is disconnected from the mains. The cable glands used also have to meet the requirements of category II3 D and must at least comply with enclosure protection IP 67. The actuators must be connected by means of an external ground connection (accessory part) to the potential equaliser or integrated into a grounded piping system. The screw plug (part no. 511.0) or the stem protection tube with protection cap (part nos. 568.1 and 568.2) for sealing the hollow shaft must imperatively be mounted to guarantee the combustible dust hazard protection. As a general rule, the requirements of EN 50281-1-1 must be respected in dust hazardous locations. During commissioning, service, and maintenance, special care as well as qualified and trained personnel are required for the safe operation of actuators.
1.4.
Warnings and notes The following warnings draw special attention to safety-relevant procedures in these operation instructions, each marked by the appropriate signal word (DANGER, WARNING, CAUTION, NOTICE). DANGER WARNING CAUTION Indicates an imminently hazardous situation with a high level of risk. Failure to observe this warning will result in death or serious injury. Indicates a potentially hazardous situation with a medium level of risk. Failure to observe this warning could result in death or serious injury. Indicates a potentially hazardous situation with a low level of risk. Failure to observe this warning may result in minor or moderate injury. May also be used with property damage. Potentially hazardous situation. Failure to observe this warning may result in property damage. Is not used for personal injury. Arrangement and typographic structure of the warnings Safety alert symbol (warns of a potential personal injury hazard). Signal word (DANGER, WARNING, CAUTION, NOTE) DANGER Type of hazard and respective source! Possible consequence(s) in case of non-observance (option) Measures to avoid the danger Further measure(s)
NOTICE
1.5.
Further references and symbols The following references and symbols are used in these instructions:
Information
The term Information preceding the text indicates important notes and information.
Symbol for CLOSED.
Symbol for OPEN.
Via the menu to parameter Describes the path within the menu to the parameter. By using the push buttons of the local controls you may quickly find the desired parameter in the display. Description of the parameter settings/indications Describes the setting/viewing possibilities of a parameter. Step by step Provides a detailed description of each step for setting/viewing the parameter.
2.
2.1.
Identification
Name plate Each device (actuator, controls, motor) is equipped with a name plate. Figure 1 shows the arrangement of name plates on the device.
Figure 1
1 2
Actuator name plate Controls name plate
3 4
Motor name plate Additional plate, e.g. KKS plate
Identification data on the actuator name plate:

Figure 2
AUMA Riester GmbH&Co.KG D-79379 Mllheim SA 07.1-F10 Com No: 1309533 No : 3302MD 19302
1 2
1 2
Type and size of actuator Commission number
Identification data on the controls name plate:

Figure 3
1 2 3
Type and size of the controls Commission number Wiring diagram/control
auma
1 2
a CC
AC 01.1 P:1,5kW Com No: 1309595 No: 0902MA97286 KMS: TP180/001 ACP:11F1-2P0--K000 3 ~ 400V IP67 Control: RS 485
Type and size
These instructions apply to the following actuator controls combinations: Type: SA = multi-turn actuator for open-close duty Type: SAR = multi-turn actuator for modulating duty Size: 07.1 16.1 Type: AC = AUMATIC actuator controls Size: 01.1 An order-specific commission number is assigned to each device. You can use this commission number to download the wiring diagram, inspection records and further information for the device from the Internet (http://www.auma.com). Controlling the actuator controls is performed via a Modbus interface, if the 11th position in the ACP wiring diagram contains the letter K, L, J, N, H or V. Example: ACP 11F1-2P0K000.
Commission number
Wiring diagram/control
10
2.2.
Short description Multi-turn actuator Definition in compliance with EN ISO 5210: A multi-turn actuator is an actuator which transmits to the valve a torque for at least one full revolution. It is capable of withstanding thrust. AUMA multi-turn actuators are driven by an electric motor. A handwheel is provided for manual operation. Switching off in end positions may be either by limit or torque seating. Controls are required to operate or process the actuator signals. The AUMATIC actuator controls is used to operate AUMA actuators and is supplied ready for use. The controls can be mounted directly to the actuator but also separately on a wall bracket. The functions of the AUMATIC controls include standard valve control in OPEN - CLOSE duty, positioning, process control, logging of operating data, diagnosis functions right through control via fieldbus. Operation, setting, and display can be performed on site directly at the controls or alternatively from REMOTE via a fieldbus interface. On site it is possible to operate the actuator via the local controls (push buttons and display) and perform settings (contents of these instructions). read in or out data or modify and save settings via the COM-AC software (option), using a computer (laptop or PC). Depending on the version, the connection between computer and AUMATIC can be made with cable (infra-red interface) or without cable (Bluetooth interface) (Not included in these instructions.) Intrusive version: Limit and torque setting is performed via switches in the actuator. Non-Intrusive version: Limit and torque setting is performed via the controls, actuator and controls housings do not have to be opened. For this purpose, the actuator is equipped with an MWG (magnetic limit and torque transmitter), also supplying analogue torque feedback signals/torque indication.
Actuator controls
Local controls/ COM-AC/fieldbus
. . . .
Intrusive Non-intrusive
11
3.
3.1.
Transport, storage and packaging

Transport For transport to place of installation, use sturdy packaging. DANGER Hovering load! Death or serious injury possible. Do not place below hovering load. Attach ropes or hooks for the purpose of lifting by hoist only to housing and not to handwheel. Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting by hoist to valve and not to multi-turn actuator. Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting by hoist only to the gearbox using eyebolts and not to the actuator Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting by hoist only to actuator and not to controls.
3.2.
Storage
NOTICE
Danger of corrosion due to inappropriate storage! Store in a well-ventilated, dry room. Protect against floor dampness by storage on a shelf or on a wooden pallet. Cover to protect against dust and dirt. Apply suitable corrosion protection agent to uncoated surfaces. If the device must be stored for a long period (more than 6 months) the following points must be observed in addition: 1. Prior to storage: Protect uncoated surfaces, in particular the output drive parts and mounting surface, with long-term corrosion protection agent. 2. At an interval of approx. 6 months: Check for corrosion. If first signs of corrosion show, apply new corrosion protection.
Long-term storage:
3.3.
Packaging Our products are protected by special packaging for the transport ex works. The packaging consists of environmentally friendly materials which can easily be separated and recycled. We use the following packaging materials: wood, cardboard, paper, and PE foil. For the disposal of the packaging material, we recommend recycling and collection centres.
12
4.
4.1.
Assembly
Handwheel fitting Information For transport purposes, handwheels from a diameter of 400 mm are supplied separately. Damage at the change-over mechanism due to incorrect assembly! Only pivot the change-over lever manually. Using extensions as a lever for operation is not permitted. First engage manual operation correctly, then mount handwheel. 1. Manually lift the red change-over lever while slightly turning the shaft back and forth until manual operation engages. The manual operation is correctly engaged if the change-over lever can be lifted by approx. 85.
NOTICE
85
2. Attach handwheel over the red change-over lever then on to the shaft.
3. Secure handwheel using the circlip supplied.
13
4.2.
Multi-turn actuator mounting to valve/gearbox
4.2.1 Output drive types B1, B2, B3, B4, B, and E Application Design For rotating, non-rising valve stem. Output drive type bore with keyway: Type B1 B4 with bore according to ISO 5210. Type B and E with bore according to DIN 3210. Later change from B1 to B3, B4, or E is possible.
Figure 4
2 4
1 2
Output drive type B1/B2 and B Hollow shaft with keyway
3 4
Output drive B3/B4 and E Plug sleeve with bore and keyway
Information
Spigot at flanges should be loose fit. Mounting the multi-turn actuator 1. 2. 3. 4. 5. Check if mounting flanges fit together. Check whether bore and keyway match the input shaft. Thoroughly degrease mounting faces of the mounting flanges. Apply a small quantity of grease to the input shaft. Mount multi-turn actuator and ensure that the spigot mates uniformly in the recess and that the mounting faces are in complete contact. 6. Fasten multi-turn actuator with screws according to table 1. 7. Fasten screws crosswise with a torque according to table 1.
Table 1 Mounting flange F07 F10 F14 F16 Screws Thread M8 M10 M12 M16 Fastening torque TA [Nm] Strength class 8.8 25 51 87 214
NOTICE
Danger of corrosion due to damage to paint finish and condensation! Touch up damage to paint finish after working on the device. After mounting, connect the device immediately to electrical mains to ensure that heater reduces condensation.
14
Operation instructions 4.2.2 Output drive type A Application
. .
For rising, non-rotating valve stem. Capable of withstanding thrust
Design
Output drive type A as separate unit (figure 5):

Figure 5
1 2 3
1 2 Stem nut 3 Axial needle roller and cage assembly 4 Spigot ring Axial bearing washer
. .
The internal thread of the stem nut must match the thread of the valve stem. If not ordered explicitly with thread, the stem nut is supplied unbored or with a pilot bore.
Finish machining the stem nut Only required for stem nut if supplied unbored or with a pilot bore. 1. Remove spigot ring (3) from output drive type. 2. Take off stem nut (1) together with axial needle roller and cage assembly (2) and axial bearing washers (4). 3. Remove axial needle roller and cage assembly and axial bearing washers from stem nut. 4. Drill and bore stem nut and cut thread. When fixing in the chuck, make sure stem nut runs true! 5. Clean the machined stem nut. 6. Apply Lithium soap EP multi-purpose grease to axial needle roller and cage assembly and axial bearing washers, then place them on stem nut. 7. Re-insert stem nut with axial bearings into output drive type. Ensure that dogs or toothing are placed correctly in the slots of the hollow shaft. 8. Screw in spigot ring until it is firm against the shoulder. 9. Press in Lithium soap EP multi-purpose grease on mineral oil base at the grease nipple with a grease gun (for quantities, please refer to table 2). Grease quantities for bearing of output drive A:
Table 2 A 07.2 A 10.2 Output drive 1.5 g 2g Qty1) 1) For grease with density r = 0.9 kg/dm A 14.2 3g A 16.2 5g
15
Mounting the multi-turn actuator (with output drive A) to valve

Figure 6
1 2 3
Valve stem Output drive type A Screw to actuator
4 5
Valve flange Screws to output drive
1. Remove screws (3) and take off output drive type A (2) from multi-turn actuator. 2. Check if the flange of output drive type A matches the valve flange (4). 3. Thoroughly degrease mounting faces of the mounting flanges. 4. Apply a small quantity of grease to the valve stem (1). 5. Place output drive type A on valve stem and fasten until it is seated solidly on the valve flange. 6. Turn output drive type A until alignment of the fastening holes. 7. Screw in fastening screws (5), however do not completely fasten. 8. Fit multi-turn actuator on the valve stem so that the hollow shaft pinions engage into the stem nut. The flanges are flush with each other if properly engaged. 9. Turn multi-turn actuator until alignment of the fastening holes. 10 Fasten multi-turn actuator with screws (3) according to table 1, page 14. 11. Fasten screws crosswise with a torque according to table 1. 12. Engage manual operation at multi-turn actuator and turn handwheel in direction OPEN until valve flange and output drive type A are firmly placed together. 13. Tighten fastening screws (5) between valve and output drive type A crosswise with a torque according to table 1, page 14. NOTICE Danger of corrosion due to damage to paint finish and condensation! Touch up damage to paint finish after working on the device. After mounting, connect the device immediately to electrical mains to ensure that heater reduces condensation.
16
4.3.
Accessories (option)
4.3.1 Protection tube for rising valve stem

Figure 7
1 2 3
1 2
Cap for stem protection tube Stem protection tube
Sealing ring
1. 2. 3. 4.
Seal thread with hemp, Teflon tape, or thread sealing material. Screw protection tube (2) into thread and tighten it firmly. Push down the sealing ring (3) into the housing. Check whether cap (1) is available and in perfect condition.
17
4.4.
Mounting positions of the local controls The mounting position of the local controls is designed according to the order. If, after mounting the actuator to the valve or the gearbox on site, the local controls is in an unfavourable position, the mounting position can be changed at a later date. Four mounting positions are possible. Figure 8 shows mounting positions A and B:
Figure 8
Figure 9 shows mounting positions C and D:

Figure 9
Changing the mounting position DANGER Hazardous voltage! Electric shock possible. Disconnect device from the mains before opening. 1. Loosen bolts and remove the local controls. 2. Check whether O-ring is in good condition, correctly place O-ring. 3. Turn local controls into new position and re-place. NOTICE Cable damage due to twisting or squeezing! Functional failures possible. Turn local controls by a maximum of 180. Carefully assemble local controls to avoid pinching the cables. 4. Fasten bolts evenly crosswise.
18
5.
5.1.
General notes WARNING Danger due to incorrect electrical connection! Failure to observe this warning can result in death, serious injury, or property damage. The electrical connection must be carried out exclusively by suitably qualified personnel. Prior to connection, observe general references contained in this clause. After connection but prior to applying the voltage, observe the Commissioning and Test run clauses. The wiring diagram/terminal plan is attached to the device in a weather-proof bag, together with these operation instructions. It can also be obtained from AUMA (state commission no., refer to name plate) or downloaded directly from the Internet (www.auma.com). For short-circuit protection and for disconnecting the actuator from the mains, fuses and disconnect switches have to be provided by the customer. The current values for respective sizing can be derived from the current consumption of the motor plus the current consumption of the controls. Motor current consumption: Refer to name plate on motor (nominal current). Current consumption of the controls depending on the mains voltage: 100 to 120 V AC = max. 650 mA 208 to 240 V AC = max. 325 mA 380 to 500 V AC = max. 190 mA 24 V DC (+10 %/15 %) = max. 500 mA, filter capacitor 2200 F Current consumption for actuator with 1-ph DC motor: 24 V DC (+10 %/10 %) = max. 750 mA, filter capacitor 2200 F The maximum permissible fuse for controls with a rated power of 1.5 kW is 16 A (gL/gG); for controls with a rated power of 7.5 kW, the value amounts to 32 A (gL/gG). If the controls (electronics) are supplied externally with 24 V DC and DC motors (24 V DC, 48 V DC, 60 V DC, 110 V DC, 220 V DC) are used simultaneously, the 24 V DC voltage supply for the controls should be ensured via the XK25/26 terminals, separate from the power supply (U1, V1). In case of common supply using a single cable (links from U1, V1 with XK25/26, for 24 V DC only !!!), short-term excess or falling below the admissible voltage limits can be the consequence during switching (24 V DC +10 %/10 %). Any possibly incoming operation commands are not executed outside the admissible limit values. The controls briefly signal a fault condition.
Wiring diagram/terminal plan
Protection on site
Power supply for the controls (electronics)
Cable installation in accordance with EMC
Signal and bus cables are susceptible to interference.
. . . . .
Motor cables are interference sources. Lay cables being susceptible to interference or sources of interference at the highest possible distance from each other. The interference immunity of signal and bus cables increases if the cables are laid close to the ground potential. If possible, avoid laying long cables and make sure that they are installed in areas being subject to low interference. Avoid long parallel paths with cables being either susceptible to interference or interference sources. For the connection of remote position transmitters (potentiometer, RWG, MWG), screened cables must be used.
19
Bus cables
Only cables according to the recommendations of EIA 485 standard may be used for Modbus wiring. Cable recommendation: Impedance: Cable capacity: Core diameter Core cross section: Loop resistance: Screening: 135 to 165 Ohm, at a frequency of 3 to 20 MHz. < 30 pF per metre > 0.64 mm > 0.34 mm, corresponds to AWG 22 < 110 Ohm per km Copper shielding braid or shielding braid and shielding foil
. . . . .
Prior to installation, please note: Connect maximum 32 devices to one segment. If more devices are to be connected: Connect segments using repeaters. Respect a distance of minimum 20 cm between the bus cable and other cables. If possible, bus cables should be laid in a separate, conductive, and earthed cable tray. Make sure to avoid potential differences between the individual devices on the bus (perform a potential compensation)
20
5.2.
Mains connection using AUMA plug/socket connector (SD) Before mains connection Check whether type of current, supply voltage, and frequency comply with motor data (refer to name plate at motor).
VD00 63-4/45 Art No: Z006.413 3 ~ 400 V 50 Hz 0.090 kW Y 0.60 A
Opening the terminal compartment DANGER Hazardous voltage! Electric shock possible. Disconnect device from the mains before opening.
Figure 10
a CC
1 8 2 7 3 4 6 5
1 2 3 4
Connection housing Screws for connection housing O-ring Screws for socket carrier
5 6 7 8
Socket carrier Cable entry for mains Screw plug Cable gland (not included in delivery)
1. Loosen screws (2) and remove connection housing (1). 2. Loosen screws (4) and remove socket carrier (5) from connection housing (1). 3. Insert cable glands (8) suitable for connecting cables. The enclosure protection IP stated on the name plate is only ensured if suitable cable glands are used.
au
IP 67 1680 rpm Temp.Protection: Th Insulation Class: F
4. Seal cable entries (6) which are not used with suitable screw plugs (7). 5. Insert the wires into the cable glands (8).
21
Connecting the cables 1. Remove cable sheathing. 2. Strip wires. 3. For stranded wires: use end-sleeves according to DIN 46228. 4. Connect cables according to order-related wiring diagram. Cable cross sections: Power terminals (U1, V1, W1, U2, V2, W2) and protective earth connection (symbol: ) max. 6 mm flexible, max. 10 mm rigid Control contacts (1 to 50) = max. 2.5 mm Information For some special motors, the connection of the power terminals (U1, V1, W1, U2, V2, W2) is made via a terminal board at the motor. In case of failure: Hazardous voltage while protective conductor is not connected! Electric shock possible. Connect all protective conductors. Connect PE connection with external protective conductor of connecting cables. Start running the device only after having connected the protective conductor. 5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables) or loops (rigid cables) (symbol: ).
Figure 11
2 3 4 5 1 6
WARNING
1 2 3
Socket carrier Screw Washer
4 5 6
Spring lock washer Protective earth with ring lugs/loops PE connection
Connecting the heater The heater prevents condensation in the actuator. Unless ordered otherwise, the heater is internally supplied and does not require separate connection. NOTICE Danger of corrosion due to condensation! For version with external heater supply (option): Connect heater R1 according to terminal plan. For all versions: After mounting, immediately put device into operation.
Connecting the motor heater (option) Some actuators are equipped with an additional motor heater. The motor heater improves the start-up behaviour for extremely low temperatures. Connect motor heater R4, if available, according to wiring diagram.
22
Closing the terminal compartment Refer to figure 12. 1. Insert the socket carrier (5) into the connection housing (1) and fasten it with screws (4). 2. Clean sealing faces of connection housing and housing. 3. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces. 4. Check whether O-ring (3) is in good condition, correctly place O-ring. 5. Fit connection housing (1) and fasten bolts (2) evenly crosswise. 6. Fasten cable glands (8) applying the specified torque to ensure the required enclosure protection.
Figure 12
1 8 2 7 3 4 6 5
1 2 3 4
Connection housing Screws for connection housing O-ring Screws for socket carrier
5 6 7 8
Socket carrier Cable entry for mains Screw plug Cable gland (not included in delivery)
23
5.3.
Bus connection using AUMA plug/socket connector (SD) Opening the bus terminal compartment DANGER Hazardous voltage! Electric shock possible. Disconnect device from the mains before opening.
Figure 13: Bus connection

1 2 3 4/5
1 2
Cover Screws for cover
3 4 5
O-ring Cable entries for bus cables Screw plug
1. Loosen and remove plug cover (1). The connection board is located behind the plug cover. 2. Insert cable glands suitable for bus cables. The enclosure protection IP stated on the name plate is only ensured if suitable cable glands are used.
au
24
IP 67 1680 rpm Temp.Protection: Th Insulation Class: F
3. Seal cable entries (4) which are not used with suitable screw plugs (5). 4. Insert the wires into the cable glands.
Connecting bus cables 1. Connect bus cable (refer to figures 14 to 16). Table 4 indicates the fieldbus cable assignment:
Table 4 Fieldbus cable A B AUMA labelling at the connection N/A P/B SUB-D 9 plug pin (for other fieldbus devices) 8 3 Colour green red
2. If the actuator is the final device in the bus segment: Switching on the termination resistor for channel 1 using switch S1 (ON position). For component redundancy: Switching on the termination resistor for channel 2 using switch S2 (ON position). Both switches are supplied in position OFF. Information As soon as the termination resistors are switched on, the connection to the next Fieldbus device is automatically interrupted to avoid multiple terminations (not applicable for overvoltage protection). Table 3 describes the switch positions S1 S3:
Table 3 S1 S2 S3 ON OFF ON OFF 1SPC 2SPC Bus termination channel 1 ON Bus termination channel 1 OFF Bus termination channel 2 ON (option) Bus termination channel 2 OFF (option) one fieldbus board two fieldbus boards (redundancy, option)
3. Connect screen largely to the shielding clamp (X3). Figure14: Connection board (standard version).
Figure 14
S1
X1
N/A P/B
X2
N/A P/B
X3
S1 Bus termination channel 1
X1 Channel 1, from the previous device X2 Channel 1, to the next device X3 Shielding clamp
25
Figure 15: Connection board (version for overvoltage protection).

Figure 15
S1
S3
S2
X1
P N P N
X2
P N P N
S1 Bus termination channel 1 S2 Bus termination channel 2 S3 Redundancy
X1 Channel 1, from previous device Channel 1, to the next device X2 Channel 2, from the previous device Channel 2, to the next device
Figure 16: Connection board (version for redundancy).

Figure 16
S1
S3
S2
X1
N/A P/B
X2
N/A P/B
X3
N/A P/B
X4
N/A P/B
S1 Bus termination channel 1 S2 Bus termination channel 2 S3 Redundancy
X1 X2 X3 X4
Channel 1, from the previous device Channel 1, to the next device Channel 2, from the previous device Channel 2, to the next device
26
Special features for loop redundancy For loop redundancy, automatic termination is performed as soon as the AUMATIC is connected to the power supply. When interrupting the power supply, e.g. after removing the AUMA plug/socket connector, both RS-485 loop segments are automatically connected to each other. Figure 17: Connection board (version for loop redundancy).
Figure 17
X1
P/B N/A
X2
P/B
P/B
X1 Channel 1, from the previous device
X2 Channel 1, to the next device
Figure 18: Connection board (version for loop redundancy with overvoltage protection).
Figure 18
X1
N/A P/B
X2
N/A
X1 Channel 1, from the previous device
X2 Channel 1, to the next device
N/A
27
Closing the bus terminal compartment 1. Clean sealing faces of housing and cover. 2. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces. 3. Check whether O-ring (3) is in good condition, correctly place O-ring. 4. Fit cover (1) and fasten screws (2) evenly crosswise. 5. Fasten cable glands with the specified torque to ensure the required enclosure protection.
Figure 19
1 2 3 4/5
1 2
Cover Screws for cover
3 4 5
O-ring Cable entries for bus cables Screw plug
28
5.4.
Accessories for electrical connection (option)
5.4.1 Controls mounted to wall bracket The controls can also be mounted separately from the actuator on a wall bracket. Application
Design
. . .
If there is no proper access to the actuator/local controls In case of heavy vibration of the valve If the actuator is subjected to high temperatures
Figure 20
1 2 3
Wall bracket Connecting cables
Observe prior to connection
. . . . . .
3 4 5
Wall bracket terminals (XM) Actuator terminals (XA) Controls terminals (XK)
Permissible length of connecting cables: max. 100 m. If the actuator is equipped with a positioner (RWG): Connecting cables must be available as shielded version. Versions with potentiometer in the actuator are not suitable. We recommend: AUMA cable set LSW1. If the AUMA cable set is not used, suitable flexible and screened connecting cables are to be implemented. If connecting cables, e.g. of the heater or switch, are available requiring direct wiring from the actuator to the XK customer connector (XA-XM-XK, refer to wiring diagram), these connecting cables must be subject to an insulation test in compliance with EN 50178. Connecting cables of positioners (RWG, IWG, potentiometer) do not belong to this group. They may not be subject to an insulation test.
29
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus 5.4.2 Parking frame
Parking frame for safe storage of a disconnected plug. For protection against touching the bare contacts and against environmental influences.
Figure 23
5.4.3 Protection cover Protection cover for plug compartment when plug is removed. The open terminal compartment can be closed using a protective cover (not illustrated). 5.4.4 Double sealed intermediate frame When removing the electrical connection or due to leaky cable glands, ingress of dust and water into the housing is possible. This is prevented by inserting the double sealed intermediate frame (2) between the electrical connection (1) and actuator housing. The enclosure protection of the device, IP 67 or IP 68, will not be affected, even if the electrical connection is removed.
Figure 21
5.4.5 Ground connection, external As an option, an external ground connection (U-bracket) on the housing is available.
Figure 22
30
6.
6.1.
Operation
Manual operation In case of motor failure or power failure, the actuator may be operated manually for purposes of setting and commissioning. Manual operation is engaged by an internal change-over mechanism. Engaging manual operation NOTICE Damage at the change-over mechanism due to faulty operation! Engage manual operation only during motor standstill. Only pivot change-over lever manually. Using extensions as a lever for operation is not permitted. 1. Pivot change-over lever manually to approx. 85 while slightly turning the handwheel back and forth until manual operation engages.
2. Release change-over lever (should snap back into initial position by spring action), if necessary, push it back manually.
3. Turn handwheel into desired direction, in doing so the following applies: To close the valve, turn handwheel clockwise: Drive shaft (valve) turns clockwise in direction CLOSE.
Disengaging manual operation Manual operation is automatically disengaged when motor is started again. The handwheel does not rotate during motor operation.
31
6.2.
Motor operation Perform all commissioning settings prior to motor operation.
6.2.1 Local operation The local operation of the actuator is performed using the push buttons (figure 24).
Figure 24
1 2 STOP 3 4 Reset 5
1 2 3
Push button OPEN Push button STOP Push button CLOSE
4 5 6
Reset push button Selector switch Indication lights/LEDs
Set selector switch (5) to position Local control (LOCAL).
The actuator can now be operated using the push buttons (1 3). 1. Run actuator in direction OPEN: 2. Stop actuator: 3. Run actuator in direction CLOSE. Information Press push button (1). Press push button (2). Press push button (3).
The OPEN - CLOSE operation commands can be given either in push-to-run operation or in the self-retaining mode. For further information on this topic refer to Manual (Operation and setting) AUMATIC AC 01.1/ACExC 01.1 Modbus.
6.2.2 Operation from REMOTE Set selector switch to position Remote control (REMOTE).
I
0
Now, it is possible to operate the actuator by remote control via the fieldbus. Information Refer to the Manual (Operation and setting) AUMATIC AC 01.1/ ACExC 01.1 Modbus" to select between REMOTE MODE (open-close duty) and SETPOINT MODE (modulating duty).
32
6.3.
Menu navigation via push buttons (for settings and indications) The push buttons of the local controls (figure 25) are used to view, edit, and show various indications on the display.
Figure 25
1 6 2 3 4 5
p q
8
C
1 2 3
Push button p Push button q Push button 8
4 5 6
Push button C Selector switch Display
Set selector switch (5) to position 0 (OFF).
Now, settings and indications can be performed via the push buttons (1 4). 6.3.1 Short overview: functions of the push buttons
Table 5 Push Functions buttons Scrolling within a group (The triangles in the display show the direction of scrolling.) Change values Enter figures from 0 to 9
pq
Confirm the selection to go to a new menu/subgroup. Cancel process Return to previous display: press briefly
Change to another group (S, M, D) - press for approx. 3 seconds until group M0 is displayed. - hold down for more than 3 seconds until group D0 is displayed (thereby, group M is skipped).
33
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus 6.3.2 Structural design and navigation
. . .
The indications on the display are divided into 3 groups: Group S = status indications Group M = menu (settings) Group D = diagnostic indications The active group is displayed on the top right corner of the display.
M0 S0 100%
M0 OFF E2 OPEN POSITION
Change groups
Change from group S to group M: Press C push button and hold it down for approx. 3 seconds until group M0 appears. Change from group S to group D: Press C push button and hold it down until group D0 appears (group M is hereby skipped). Change from any group M or D back to group S: Briefly press C.
Scrolling
Press qp: The triangles in the top left corner of the display indicate the possible scrolling direction (within one group) of scrolling.
OFF E2 OPEN POSITION
S0 100%
Enter the password
In the menu (group M), the settings are protected by a password. To change the parameters, a password must first be entered. The following default password is set in the factory: 0000. After selecting EDIT, the following is displayed: ENTER PASSWORD 0 * * *
:EDIT
:OK C:ESC
1. 2. 3. 4. Information
Select figures 0 to 9: Press qp. Move to the next position: Press 8 . Repeat steps 1 and 2 for all four digits. To cancel a process: Press C.
If no input is received over a longer period of time (approx. 10 min), the controls automatically returns to the status indication S0.
34
6.4.
Language change in the display
Via the menu to parameter:
MAIN MENU (M0) LANGUAGE/CONTRAST (M00) VIEW (M00) EDIT (M01) LANGUAGE (M010) Default value: ENGLISH Setting range: GERMAN, PORTUGUESE, ITALIAN, SPANISH, FRENCH, ENGLISH, TUERKCE, POLSKI, MAGYAR
Step by step: 1. Set the selector switch to position 0 (OFF).
2. Press C and hold it down for approx. 3 seconds. Display indicates: MAIN MENU M0 LANGUAGE/CONTRAST SETTINGS OPERATIONAL DATA 3. Press 8 . Display indicates: LANGUAGE/CONTRAS VIEW EDIT 4. Press q. Display indicates: LANGUAGE/CONTRAS VIEW EDIT 5. Press 8 . Display indicates: ENTER PASSWORD 0 * * *
:EDIT
M00
M01
:OK C:ESC
6. Enter password: Press 8 4 times = 0000 (default factory password).
35
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus Display indicates: EDIT LANGUAGE LCD CONTRAST M010
7. Press 8 . Display shows the set value. EDIT M010 LANGUAGE ENGLISH :EDIT C:ESC 8. Press 8 again to enter the edit mode. Display indicates: EDIT M010 LANGUAGE ENGLISH :EDIT :OK C:ESC 9. Set new value: Press qp. 10. Accept value: Press 8 or cancel process without accepting the value: Press C.
36
7.
7.1.
Indications
Status indications in the display Status indications regarding faults and warnings, refer to page 59 et seqq.
7.1.1 Status indication S0/S6 - operation Information For actuators equipped with process controllers, status indication S6 is displayed instead of status indication S0.The description below applies to both indications (S0 and S6). Operation mode display Line 1 indicates the current operation mode (LOCAL MODE, OFF, SETPOINT MODE, )
LOCAL MODE
E2
100 % RUNNING OPEN
OPEN
S0
Operation command/ setpoint display
Line 2 indicates currently incoming operation commands (OPEN, STOP, CLOSE) or the setpoints E1 or E7 (for actuators equipped with positioner/process controller) in % of the total travel.
LOCAL MODE
E2
100 % RUNNING OPEN
OPEN
S0
Valve position display
Line 3 indicates the valve position in % of the travel. This indication is only available if the actuator is equipped with a position transmitter.
LOCAL MODE
E2
OPEN
S0 100%
RUNNING OPEN
End position/running indication
0 % = Actuator is in end position CLOSED 100 % = Actuator is in end position OPEN Line 4 indicates the current actuator status.
LOCAL MODE
E2
OPEN
S0 100%
RUNNING OPEN
Description of indications in line 4:
RUNNING OPEN
Actuator runs logically OPEN (remains set during operation pauses).
RUNNING CLOSE
Actuator runs logically CLOSE (remains set during operation pauses).
OPEN POSITION
End position OPEN reached.
CLOSED POSITION
End position CLOSED reached.
SETPOINT POSITION
Setpoint (modulating actuators only).
Description of the fault indications: See page 59.
37
7.2.
Indication lights/LEDs The indication lights/LEDs locally display the different operation states as optical signals. The assignment of signals is freely selectable. Figure 26 shows the indication lights/LEDs on the local controls:
Figure 26
Version (standard): LED marking with letters
Version (option): LED marking with figures
Table 6 describes the standard indication.

Table 6 LED 1 (left) ( symbol) LED 2 (T) LED 3 (Th) LED 4 (T) LED 5 (right) ( symbol) illuminated blinking illuminated illuminated illuminated illuminated blinking Actuator is in end position CLOSED Running indication: Actuator runs in direction CLOSE Torque fault CLOSE Motor protection tripped Torque fault OPEN Actuator is in end position OPEN Running indication: Actuator runs in direction OPEN
Information 7.3.
The behaviour (blinking/illuminated) can be changed via the BLINKER parameter.
Mechanical position indicator/running indication (option)
. . .
Mechanical position indicator continuously indicates the valve position (Indicator disc rotates approximately 180 to 230 at full travel from OPEN to CLOSED or vice versa.) indicates whether the actuator is running (running indication) indicates that the end positions (via indication mark) have been reached
Figure 27
auma
4 1 2 5
1 2 3
Cover Indicator disc Indicator mark
4 5
Symbol for position OPEN Symbol for position CLOSED
38
8.
8.1.
Signals
Signals via fieldbus Feedback signals via Modbus RTU can be read by using the respective Modbus function codes.
8.2.
Feedback via output contacts (binary) - (option) Feedback signals via output contacts are only available if a parallel interface is provided in addition to the fieldbus interface. The output contacts can be used to indicate operation modes of the actuator or the controls as binary signals. The signals can be freely assigned. Example: Output contact open = no thermal fault Output contact closed = thermal fault in actuator Fault signals can be issued via the ALARM CONTACT parameter, other signals via the OUTPUT CONTACTS 1 TO 5. Alarm contact default value: (Designation in the wiring diagram: NC fault/NO ready) FAULT GROUP 3 = fault signal (includes: Torque fault, thermal fault, phase failure, and internal faults) Standard values output contacts 1 to 5: (Designation in the wiring diagram: DOUT1 to DOUT5)
OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT
CONTACT CONTACT CONTACT CONTACT CONTACT
1 2 3 4 5
= = = = =
CLOSED POSITION OPEN POSITION REMOTE SW.POSITION TORQUE FAULT (CLOSE) TORQUE FAULT (OPEN)
For further information on this topic refer to Manual (Operation and setting) AUMATIC AC 01.1/ACExC 01.1 Modbus. 8.3. Feedback signals (analogue) - (option) Analogue feedback signals are only available if the following conditions are met: In addition to the fieldbus interface, the AUMATIC is equipped with a parallel interface. The actuator is equipped with a position transmitter (potentiometer or RWG). Valve position Signal: E2 = 0/4 20 mA (galvanically isolated) Designation in the wiring diagram: ANOUT1 (position) For further information on this topic refer to Manual (Operation and setting) AUMATIC AC 01.1/ACExC 01.1 Modbus.
. .
39
9.
Commissioning
Prior to any electrical operation (motor operation), ensure that all commissioning settings described in this clause have been performed. 1. Set the selector switch to position 0 (OFF).
Information
The selector switch is not a mains switch. The actuator control is disabled in 0 (OFF) position. The controls power supply is maintained. 2. Switch on the power supply. 3. Perform the settings described in this clause.
Low temperature version Heat-up time
Please note that for low temperature versions, the controls require a heat-up time. This heat-up time is applicable in case the actuator and the controls are not live and have cooled down to ambient temperature. Under these conditions, the following heat-up times have been met prior to commissioning after connection to the voltage supply: For 40 C = 30 min. For 50 C = 60 min. For 60 C = 100 min.
Figure 28: Sketch illustrating the heat-up time

Figure 28
t [min.]
100
60 50 30
10
20
30
40
50
60 J[C]
40
9.1.
Type of seating: check/edit for end positions
NOTICE
Valve damage due to incorrect setting! The type of seating must suit the valve. Only change the setting with the consent of the valve manufacturer. The limit switching is set in such a way that the actuator switches off at the desired switching points. The torque switching acts as an overload protection for the valve. The torque switching is set to the desired tripping torque. After reaching the tripping torque the actuator is turned off. The limit seating is used for signalling that the limit switching is tripped shortly before reaching the set tripping torque. If this is not the case, one of the following fault signals is displayed: TSO FAULTS or TSC FAULTS (menu S1). Via the menu to parameter:
Limit seating
Torque seating
MAIN MENU (M0) SETTINGS (M1) SEATING MODE (M11) VIEW (M110) EDIT (M111) OPEN POSITION (M11_0) CLOSED POSITION (M11_1) Default value: LIMIT
2. Press C and hold it down for approx. 3 seconds. Display indicates: MAIN MENU M0 LANGUAGE/CONTRAST SETTINGS OPERATIONAL DATA 3. Press q. Display indicates: MAIN MENU M1 LANGUAGE/CONTRAST SETTINGS OPERATIONAL DATA 4. Press 8 .
41
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus Display indicates: SETTINGS SEATING MODE TORQUE LOCAL CONTROLS 5. Press 8 . Display indicates: SEATING MODE VIEW EDIT M110 M11
6. Check settings (view): continue with 7. Change setting: continue with 10. Check settings (view) 7. Press 8 . Display indicates: VIEW M1100 OPEN POSITION CLOSED POSITION VIEW M1101 OPEN POSITION CLOSED POSITION
and CLOSED POSITION (right figure) displays. 8. Press 8 . Display indicates: VIEW OPEN POSITION LIMIT C:ESC
p q are used to change between the OPEN POSITION (left figure)
VIEW CLOSED POSITION LIMIT C:ESC
p q are also used here to change between the OPEN POSITION

(left figure) and CLOSED POSITION (right figure) displays. 9. Back to the VIEW/EDIT menu: Press C twice. Change setting Display indicates: SEATING MODE VIEW EDIT 10. Press q. Display indicates: SEATING MODE VIEW EDIT 11. Press 8 . M111 M110
42
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus Display indicates: ENTER PASSWORD 0 * * *
:EDIT
:OK C:ESC
12. Enter password: Press 8 4 times = 0000 (default factory password). Display indicates: EDIT M1110 OPEN POSITION CLOSED POSITION EDIT M1111 OPEN POSITION CLOSED POSITION
and CLOSED POSITION (right figure) displays. 13. Press 8 . Display shows the set value: EDIT M1110 OPEN POSITION LIMIT :EDIT C:ESC
p q are used to change between the OPEN POSITION (left figure)
EDIT M1111 CLOSED POSITION LIMIT :EDIT C:ESC
p q are also used here to change between the OPEN POSITION (left figure) and CLOSED POSITION (right figure) displays.
14. Press 8 again to enter the edit mode. Display indicates: EDIT M1110 OPEN POSITION LIMIT :EDIT :OK C:ESC EDIT M1111 CLOSED POSITION LIMIT :EDIT :OK C:ESC
15. Set new value: Press qp. 16. Accept value: Press 8 or cancel process without accepting the value: Press C. Display indicates: EDIT M1110 OPEN POSITION LIMIT :EDIT C:ESC EDIT M1111 CLOSED POSITION LIMIT :EDIT C:ESC
17. Return to status display: Press C several times until S0 is displayed.
43
9.2.
Baudrate, parity and bus address (slaveaddress) setting
Via the menu to parameter:
MAIN MENU (M0) SETTINGS (M1) MODBUS 1 (M1F) BAUDRATE (M1F11) PARITY (M1F12) SLAVEADDRESS(M1F14)
2. Press C and hold it down for approx. 3 seconds. Display indicates: MAIN MENU M0 LANGUAGE/CONTRAST SETTINGS OPERATIONAL DATA 3. Press q. Display indicates: MAIN MENU M1 LANGUAGE/CONTRAST SETTINGS OPERATIONAL DATA 4. Press 8 . Display indicates: SETTINGS M10 SET LIMIT SWITCHES SEATING MODE TORQUE 5. Select MODBUS 1 (M1F): Press q several times. Display indicates: SETTINGS POSITIONER CHANGE PASSWORD MODBUS 1 6. Press 8 . Display indicates: MODBUS 1 VIEW EDIT M1F0 M1F
7. Check setting (view): continue with 8. Change setting: continue with 11.
44
Check settings (view) 8. Press 8 . Display indicates: MODBUS 1 M1F01 BAUDRATE PARITY CONNECT-CONTROL TIME 9. Use p q to select BAUDRATE, PARITY or SLAVEADDRESS and press 8 to confirm selection. Display indicates. Example SLAVEADDRESS: VIEW SLAVEADDRESS 1 C:ESC
10. Back to the VIEW/EDIT menu: Press C twice. Change setting Display indicates: MODBUS 1 VIEW EDIT 11. Press q. Display indicates: MODBUS 1 VIEW EDIT 12. Press 8 . Display indicates: ENTER PASSWORD 0 * * *
:EDIT
M1F0
M1F1
:OK C:ESC
13. Enter password: Press 8 4 times = 0000 (default factory password). Display indicates: EDIT M1F11 BAUDRATE PARITY CONNECT-CONTROL TIME 14. Use p q to select BAUDRATE, PARITY or SLAVEADDRESS and press 8 to confirm selection.
45
Display shows the set value. Example SLAVEADDRESS: EDIT SLAVEADDRESS 1 :EDIT M1F14 C:ESC
15. Press 8 again to enter the edit mode. Display indicates: EDIT M1F14 SLAVEADDRESS 1 :EDIT :OK C:ESC 16. Set new value: Press qp. 17. Accept value: Press 8 or cancel process without accepting the value: Press C. Display indicates: EDIT SLAVEADDRESS 1 :EDIT M1F14 C:ESC
18. Press C several times until S0 is displayed to return to the status indication. Information Baudrate and Parity must correspond to the setting at the master. Setting range of the parameters: SLAVEADDRESS: 1 to 247 300 to 38 400 BAUD BAUDRATE:
PARITY:
EVEN, 1 STOPBIT ODD, 1 STOPBIT NO, 2 STOPBITS
Information
For component redundancy (option), the bus address for the 2nd fieldbus interface can be set in the same way as the 1st field interface. The menu for the second fieldbus interface has to be selected from the descriptions Via the menu to parameter, e.g. MODBUS 2 instead of MODBUS 1.
9.3.
Further parameters of the Modbus interface Connection control time Parameter: Default values:
CONNECT-CONTROL TIME (M1F_3) 3.0
This time should exceed the cycle time of the Modbus data transmission to all connected devices. If no valid Modbus telegram was received within this time, the DATA EX status is lost and the failure behaviour or the change-over of the communication channel is initiated, if enabled. Parameter for cable redundancy Parameter: Default values:
CABLE REDUNDANCY (M1F_5) CHANEL CHECK TIME (M1F_6) CABLE REDUNDANCY = OFF CHANEL CHECK TIME = 5,0 S
These parameters define the behaviour for cable redundancy. For further information on this topic refer to Manual (Operation and setting) AUMATIC AC 01.1/ACExC 01.1 Modbus.
46
9.4.
Switch compartment: open The switch compartment must be opened to perform the following settings. 1. Loosen screws (2) and remove cover (1) from the switch compartment.
2. If indicator disc (3) is available: Remove indicator disc (3) using a wrench (as lever).
47
9.5.
Torque switching: set
NOTICE
Valve damage due to excessive torque setting! The torque must suit the valve. Only change the setting with the consent of the valve manufacturer.
Figure 29
1 3
Switching head black for torque in direction CLOSE Lock screws
2 4
Switching head white for torque in direction OPEN Torque dial
Information
. .
1. Loosen both lock screws (3) at the indicator disc (figure 29). 2. Turn torque dial (4) for setting the required torque (1 da Nm = 10 Nm). Example: Figure 29 shows the following setting: 3.5 da Nm = 35 Nm for direction CLOSE 4.5 da Nm = 45 Nm for direction OPEN 3. Fasten lock screws (3) again. The torque switches setting is complete. The torque switches may also trip in manual operation. The torque switching acts as overload protection over full travel, also when stopping in the end positions by limit switching.
48
9.6.
Limit switching: set

Figure 30
1 2
Black section Setting spindle for end position CLOSED Pointer for end position CLOSED
4 5
White section Setting spindle for end position OPEN Pointer for end position OPEN
9.6.1 End position CLOSED (black section): set 1. Engage manual operation. 2. Turn handwheel clockwise until valve is closed. 3. Turn handwheel back by approximately half a turn (overrun). 4. Press down and turn setting spindle (1) (figure 30) using a screw driver in direction of the arrow, thereby observe pointer (2): While a ratchet is felt and heard, the pointer (2) moves 90 every time. 5. If the pointer (2) is 90 from mark (3): continue turning slowly. 6. If the pointer (2) moves to mark (3): stop turning and release setting spindle. The end position CLOSED setting is complete. 7. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped): continue turning the setting spindle in the same direction and repeat setting process. 9.6.2 End position OPEN (white section): set 1. Engage manual operation. 2. Turn handwheel counterclockwise until valve is open. 3. Turn handwheel back by approximately half a turn (overrun). 4. Press down and turn setting spindle (4) (figure 30) using a screw driver in direction of the arrow, thereby observe pointer (5): While a ratchet is felt and heard, the pointer (5) moves 90 every time. 5. When pointer (5) is 90 from mark (6): continue turning slowly. 6. When pointer (5) moves to mark (6): stop turning and release setting spindle. The end position OPEN setting is complete. 7. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped): continue turning the setting spindle in the same direction and repeat setting process.
49
9.7.
Intermediate positions (option): set Actuators equipped with DUO limit switching contain two intermediate position switches. One intermediate position may be set for each running direction.
Figure 31
1 2
Black section Setting spindle running direction CLOSE Pointer running direction CLOSE
4 5
White section Setting spindle running direction OPEN Pointer running direction OPEN
9.7.1 Running direction CLOSE (black section): set 1. Move valve in direction CLOSE until desired intermediate position. When overriding the desired point, turn valve back and approach again the intermediate position in direction CLOSE. (Always approach the intermediate position in the same direction as in later electrical operation). 2. Press down and turn setting spindle (1) (figure 31) using a screw driver in direction of the arrow, thereby observe pointer (2): While a ratchet is felt and heard, the pointer (2) moves 90 every time. 3. If the pointer (2) is 90 from mark (3): continue turning slowly. 4. If the pointer (2) moves to mark (3): stop turning and release setting spindle. The intermediate position setting in running direction CLOSE is complete. 5. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped): continue turning the setting spindle in the same direction and repeat setting process. 9.7.2 Running direction OPEN (white section): set 1. Move valve in OPEN direction until desired intermediate position. When overriding the desired point, turn valve back and approach again the intermediate position in OPEN direction. (Always approach the intermediate position in the same direction as in later electrical operation). 2. Press down and turn setting spindle (4) (figure 31) using a screw driver in direction of the arrow, thereby observe pointer (5): While a ratchet is felt and heard, the pointer (5) moves 90 every time. 3. If the pointer (5) is 90 from mark (6): continue turning slowly. 4. If the pointer (5) moves to mark (6): stop turning and release setting spindle: The intermediate position setting in running direction OPEN is complete. 5. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped): continue turning the setting spindle in the same direction and repeat setting process.
50
9.8.
Test run Perform test run only once all settings previously described in the Commissioning clause have been performed.
9.8.1 Rotational direction check NOTICE Valve damage due to incorrect direction of rotation! If the direction of rotation is wrong, switch off immediately (press STOP). Eliminate the cause, e.g. correct phase sequence for wall bracket cable set. Repeat test run.
1. Move actuator manually to intermediate position or to sufficient distance from end position. 2. Set selector switch to position Local control (LOCAL).
3. Operate push button CLOSE and observe the direction of rotation. 4. Switch off before reaching the end position. For actuators equipped with indicator disc Observe direction of rotation on the indicator disc. The direction of rotation is correct, if: The actuator moves in direction CLOSE while the indicator disc turns counterclockwise.
auma
51
For actuators without indicator disc Unscrew screw plug (1) and seal (2) or tube cap (4) and observe direction of rotation at hollow shaft (3) or the stem (5). The direction of rotation is correct, if: the actuator moves in direction CLOSE while the hollow shaft or the stem turn clockwise.
Figure 32
4 5 6
1 2 3
1 2 3
Screw plug Seal Hollow shaft
4 5 6
Cap for stem protection tube Stem Protection tube
9.8.2 Limit switching check 1. Set selector switch to position Local control (LOCAL).
2. Operate actuator using push buttons OPEN - STOP - CLOSE. The limit switching is set correctly if (standard indication): The yellow indication light/LED1 is illuminated in end position CLOSED The green indication light/LED5 is illuminated in end position OPEN The limit switching is set incorrectly, if: The actuator comes to a standstill before reaching the end position One of the red indication lights/LEDs is illuminated (torque fault), or the following fault signals are displayed: Status indication S0: FAULT. IND Status indication S1: TORQUE FAULT (CLOSE) or TORQUE FAULT
(OPEN)
3. If the end position setting is incorrect: Set limit switching again (page 49). 9.8.3 Perform reference operation
. .
52
For actuators with feedback signal (RWG, potentiometer), a reference operation has to be performed after the setting has been changed: Operate actuator electrically (via the push buttons OPEN and CLOSE of the local controls) once to the end position OPEN and once to the end position CLOSED. If no reference operation is performed after changing the limit switching, the feedback signal via the bus is not correct. The bus signals the missing reference operation as a warning.
9.9.
Potentiometer (option) setting The potentiometer as a travel monitor records the valve position. This setting is only required if the potentiometer is directly wired to the customer connection XK (refer to wiring diagram).
Figure 33
Potentiometer
1. Move valve to end position CLOSED. 2. Turn potentiometer (1) clockwise to the stop. End position CLOSED corresponds to 0 % End position OPEN corresponds to 100 %. 3. Turn potentiometer (1) slightly back. 4. Perform fine-tuning of the zero point at external setting potentiometer (for remote indication). Information Due to the ratio of the reduction gearing the complete resistance range/stroke is not always passed. Therefore, external adjustment (setting potentiometer) must be provided.
53
9.10. Electronic position transmitter RWG setting (option) The electronic position transmitter RWG records the valve position. On the basis of the nominal position value measured by the potentiometer (travel monitoring), it generates a current signal between 0 20 mA or 4 20 mA Technical data RWG 4020
Table 7 Terminal plan Output current Power supply max. current consumption Max. load Ia Uv I RB KMS TP_ _ 4 / _ _ _ 3-/4-wire system 0 20 mA, 4 20 mA 24 V DC, 15 % smoothed 24 mA For 20 mA output current 600 W
Figure 34
1 2 3
Potentiometer (travel monitor) Potentiometer min. (0/4 mA) Potentiometer max. (20 mA)
4 5
Measurement point (+) 0/4 20 mA Measurement point () 0/4 20 mA
1. 2. 3. 4. 5. 6. 7.
Connect voltage to electronic position transmitter. Move valve to end position CLOSED. Connect ammeter for 0 20 mA to measuring points (4 and 5). Turn potentiometer (1) clockwise to the stop. Turn potentiometer (1) slightly back. Turn potentiometer (2) clockwise until output current starts to increase. Turn potentiometer (2) back until the following value is reached: for 0 20 mA approx. 0.1 mA for 4 20 mA approx. 4.1 mA This ensures that the signal remains above the dead and live zero point. 8. Move valve to end position OPEN. 9. Set potentiometer max. (3) to end value 20 mA. 10. Approach end position CLOSED again and check minimum value (0.1 mA or 4.1 mA). If necessary, correct the setting. If the maximum value cannot be reached, check whether the appropriate reduction gearing has been selected. (The max. possible turns/stroke are indicated on the order-related technical data sheet for the actuator).
Information
54
9.11.
Mechanical position indicator setting (option) 1. Place indicator disc on shaft. 2. Move valve to end position CLOSED. 3. Turn lower indicator disc until symbol (CLOSED) is in alignment with the p mark on the cover.
4. Move actuator to end position OPEN. 5. Hold lower indicator disc CLOSED in position and turn upper disc with symbol (OPEN) until it is in alignment with the p mark on the cover.
6. Move valve to end position CLOSED again. 7. Check settings: If the symbol (CLOSED) is no longer in alignment with the p mark on the cover: Repeat setting procedure. Check whether the appropriate reduction gearing has been selected, if required. (The maximum possible turns/stroke are indicated on the order-related technical data sheet for the actuator).
55
9.12. Switch compartment: close 1. Clean sealing faces of housing and cover. 2. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces. 3. Check whether O-ring (3) is in good condition, insert O-ring correctly.
4. Place cover (1) on switch compartment. 5. Fasten screws (2) evenly crosswise. NOTICE Danger of corrosion due to damage to paint finish! Touch up damage to paint finish after work on the device.
56
10.
Corrective action
10.1. Faults during commissioning 10.1.1 Mechanical position indicator Fault description Possible cause Remedy Mechanical position indicator cannot be set. Actuator turns/stroke have been modified at a later date. Exchange reduction gearing.
10.1.2 Electronic position transmitter RWG Fault description Possible cause Remedy Measurement range 4 20 mA or maximum value 20 mA cannot be set. Wrong reduction gearing (turns/stroke). Check whether the appropriate reduction gearing has been selected. (The max. possible turns/stroke are indicated on the order-related technical data sheet for the actuator).
10.1.3 Limit and torque switches Fault description Possible cause Remedy Switch does not trip. Switch is defective or switch setting is incorrect. Check setting, if required, reset end position. Check switches and replace them, if required.
. .
Figure 35
Information
The red test buttons (1) and (2) are used for manual operation of the limit switches: Turn test button (1) in direction of the TSC arrow: Torque switch CLOSED trips. The indication light for torque fault CLOSE on the local controls is illuminated. Press push button OPEN to reset the fault (red indication light) by operating the device in the opposite direction. Turn test button (2) in direction of the TSO arrow: Torque switch OPEN trips. The indication light for torque fault OPEN) on the local controls is illuminated. Press push button CLOSE to reset the fault (red indication light) by operating the device in the opposite direction. If the actuator is equipped with a DUO limit switching (option), the intermediate position switches will be operated at the same time. Turn test button (1) in direction of the LSC arrow: Limit switch CLOSED trips. Turn test button (2) in direction of the LSO arrow: Limit switch OPEN trips.
57
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus 10.1.4 Fault in end position (overrun not considered) Fault description Possible cause
Actuator runs to end stop although the limit switches work properly. The overrun was not considered when setting the limit switching. The overrun is generated by the inertia of both the actuator and the valve and the delay time of the controls. 1. Determine overrun: Overrun = travel performed from switching off until complete standstill. 2. Set limit switching again (page 49) considering the overrun (turn handwheel back by the amount of the overrun).
Remedy
10.1.5 Push buttons do not react Fault description Push buttons do not react. The controls may not be operated via the local controls. Display indicates:
LOCAL RESTRICTED
S0 100%
E2
OPEN POSITION
EMERGENCY STOP
S0 100%
E2
OPEN POSITION
Possible cause
. .
RESTRICTED means that the local controls of the AUMATIC have not been released yet. EMERGENCY STOP signifies that the EMERGENCY STOP operation mode has been activated upon operating an EMERGENCY STOP button (option).
Remedy
For RESTRICTED: A release must be initiated externally via bus or input signal. See parameter ENABLE LOCAL MODE. For EMERGENCY STOP: EMERGENCY STOP button released.
58
10.2. Fault indications and warning indications Faults interrupt or prevent the electrical actuator operation. Warnings have no influence on the electrical actuator operation. They only serve for information purposes. Fault and warning indications are shown on the display. 10.2.1 Status display S0 - faults and warnings Line 4 of status indication S0 shows faults and warnings.
LOCAL MODE
E2
OPEN
S0 100%
FAULT IND.
Description of the fault indications:
FAULT IND.
A fault has occurred For further information, press qp and go to status indication S1.
WARNING IND.
A warning has occurred For further information, press qp and go to status indication S2.
FAULT + WARNING
Faults as well as warnings have occurred. For further information, press qp and go to status indications S1 (faults) or S2 (warnings).
NOT READY IND.

The actuator cannot be operated from REMOTE. The actuator can only be operated via the local controls. For further information, press qp and go to status indication S3 (cause for fault indications).
FLT + NR
Faults and the NOT READY IND. signal have occurred. For further information, press qp and go to status indications S1 or S3.
WRN + NR
Faults and the NOT READY IND. signal have occurred. For further information, press qp and go to status indications S2 or S3. Faults, warnings, and the NOT READY IND. signal have occurred. For further information, press qp and go to status indications S1 to S3.
FLT + WRN + NR
59
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus 10.2.2 Status indication S1 - faults Faults are indicated in this group:
FAULT IND.
NO FAULT
S1
NO FAULT
No fault has occurred.
INTERNAL FAULT
Internal fault has occurred. For further information: 1. Go to group D0: Press C and hold it down until diagnostic indication D0 is displayed. 2. Go to diagnostic indication D2: Press q twice.
TORQUE FAULT (CLOSE)

Torque fault in direction CLOSE. Operation command in direction OPEN, or Set selector switch to position Local control (LOCAL) and reset fault indication via Reset push button, or Issue reset command via fieldbus.
TORQUE FAULT (OPEN)

Torque fault in direction OPEN Operation command in direction CLOSE, or Set selector switch to position Local control (LOCAL) and reset fault indication via Reset push button, or Issue reset command via fieldbus.
LOSS OF PHASE
One phase is missing. Test/connect phases.
THERMAL FAULT
Motor protection tripped. Wait for cooling off. If the fault indication display persists after cooling off: Set selector switch to position Local control (LOCAL) and reset fault indication via Reset push button, or Issue reset command via fieldbus. Check fuse F4.
CONFIGURATION FAULT
The controls configuration is incorrect. For further information: 1. Go to group D0: Press C and hold it down until diagnostic indication D0 is displayed. 2. Go to diagnostic indication D4: Press q four times.
60
10.2.3 Status indication S2 - warnings Warnings are indicated at this position.

WARNING IND.
NO WARNING
S2
Description of the warnings:
NO WARNING
No warnings have occurred.
WARNING OPER.TIME
The preset running time for a travel between end position OPEN and end position CLOSED has been exceeded. Set the running time (MONITOR TRIGGERS parameter) in accordance with the actual running time. Check tripping behaviour of end position switches. Check actuator mechanics.
WARNING STARTS/RUN
The preset values for max. starts/h or max. running time/h have been exceeded. Check modulating behaviour. Increase dead time. Reduce number of nominal value changes.
INTERNAL FEEDBACK
Position transmitter is not standardised. Operate actuator into both end positions (OPEN and CLOSED).
INTERNAL WARNING
Internal warnings have occurred. For further information: 1. Go to group D0: Press C and hold it down until diagnostic indication D0 is displayed. 2. Go to diagnostic indication D3: Press q three times.
FEEDBACK E2 LOSS
Signal loss of position transmitter. Check position transmitter signal. 1. Go to group D0: Press C and hold it down until diagnostic indication D0 is displayed. 2. Go to diagnostic indication D7, D8, or D9: Press q either seven, eight, or nine times. Check position transmitter wiring. Check POSITION E2. The setting must correspond to the wiring diagram.
SETPOINT E1 LOSS
Signal loss of the set point. Check wiring.
TORQUE E6 LOSS
Signal loss of torque source. Check wiring.
I/O1 ANALOG IN1 LOSS

Loss of signal of the analogue input 1 of the parallel interface (only for fieldbus/standard interface combinations).
61
Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 Intrusive with actuator controls AUMATIC AC 01.1 Modbus Check wiring.
I/O1 ANALOG IN2 LOSS

Loss of signal of the analogue input 2 of the parallel interface (only for fieldbus/standard interface combinations). Check wiring.
P-FEEDBACK E4 LOSS
Signal loss of the actual process value E4 (only if PID controller is available and active). Check wiring.
FIBER OPTIC LOSS

Signal loss of FO cable (for bus with FO loop topology only). Check wiring.
ANALOG IN1 BUS1 LOSS

Signal loss of analogue input 1. Check wiring.
ANALOG IN2 BUS1 LOSS

Signal loss of analogue input 2. Check wiring.
62
10.2.4 Status indication S3 - causes for not ready remote The causes for the NOT READY IND. fault signals (status indication S0) are indicated within this group.
NOT READY IND.
READY
S3
READY
Actuator can be operated from REMOTE.
NOT REMOTE
Actuator cannot be operated from REMOTE because the selector switch is either in position LOCAL or OFF.
WRONG COMMAND
Indicates the fact that several operation commands were received simultaneously via Modbus (e.g. Remote OPEN and Remote CLOSE simultaneously or Remote CLOSE/Remote OPEN and Remote SETPOINT (nominal) simultaneously) or that the max. value for a nominal position has been exceeded.
EMERGENCY MODE
The EMERGENCY operation mode is active.
EXTERNAL CONTROLS
For combination fieldbus/standard interface function: Operation via parallel interface.
EMCY STOP ACTIVE

The EMERGENCY STOP button has been operated.
ACTUATOR LOCKED
Actuator locked (only set for special applications e.g. for by-pass function).
63
10.3. Fuses DANGER Hazardous voltage! Electric shock possible. Disconnect device from the mains before opening.
10.3.1 Fuses within the actuator controls Fuses F1 and F2 can be accessed after removing the cover (1) on the rear side. Fuses F3, F4, and F5 are located on the power supply unit and can be accessed after removing the electrical connection (2).
Figure 36
Rear cover
F1/F2
Primary fuses on power supply unit

Table 8 G fuses Size Reversing contactors Voltage supply 500 V Reversing contactors Voltage supply 500 V Thyristor units for motor power up to 1.5 kW Thyristor units for motor power up to 3.0 kW Thyristor units for motor power up to 5.5 kW F 1/F 2 6.3 x 32 mm 1 A T; 500 V 2 A FF; 660 V 15 A FF; 500 V 30 A FF; 500 V 1 A T; 500 V K002.277 K002.665 K001.189 K006.965 K002.277 AUMA Art. no.
F3 F4
. . .
Internal 24 V DC supply Internal 24 V AC supply (115 V AC) for: Heater, switch compartment, reversing contactors control, PTC tripping device for 115 V AC also control inputs OPEN - STOP - CLOSE
Table 9 G fuse according to IEC 60127-2/III Size Voltage output (power supply unit) = 24 V Voltage output (power supply unit) = 115 V F3 5 x 20 mm 1.0 A T; 250 V 1.0 A T; 250 V F4 5 x 20 mm 1.25 A T; 250 V 0.315 A T; 250 V
F5
Automatic reset fuse as short-circuit protection for external 24 V DC supply for customer (see wiring diagram) Screw cover back on again after fuse replacement.
64
10.3.2 Motor protection (thermal monitoring) In order to protect against overheating and impermissibly high temperatures at the actuator, PTC thermistors or thermoswitches are embedded in the motor winding. The thermoswitch is tripped as soon as the max. permissible winding temperature has been reached. The actuator is switched off and the following signals are given: LED 3 (thermal fault) on the local controls is illuminated. Status indication S0: operation mode OFF/LOCAL = FLT + NR Status indication S0/S6: operation mode REMOTE = FAULT IND. Status indication S1 in the display: THERMAL FAULT.
. . . . . .
The motor has to cool down before the operation can be resumed. Depending on the parameter setting, the fault signal is either automatically reset or the fault signal has to be acknowledged. The acknowledgement can either be made: via the Reset push button in selector switch position LOCAL. or with the reset command via the fieldbus.
For further information on this topic refer to Manual (Operation and setting) AUMATIC AC 01.1/ACExC 01.1 Modbus.
65
11.
Servicing and maintenance

Damage caused by inappropriate maintenance! Servicing and maintenance tasks must be carried out exclusively by suitably qualified personnel authorised by the end user or contractor of the plant only. Only perform servicing and maintenance tasks when the device is switched off. AUMA offers extensive service such as maintenance and inspection as well as customer product training. For the relevant contact addresses, please refer to page 82 et seqq. and on the Internet (www.auma.com).
CAUTION
Service
11.1. Preventive measures for servicing and safe operation
. . .
The following measures are required to ensure safe device operation:
Every 6 months after commissioning Carry out visual inspection: For electrical devices: cable entries, cable glands, screw plugs, etc. have to be checked for correct tightness and sealing. Consider torques according to manufacturers details. If rarely operated: perform test run. For devices with output drive A, press in Lithium soap EP multi-purpose grease on mineral oil base at the grease nipple with the grease gun (quantities see 15, table 2). This procedure does not grease the valve stem. Lubrication of the valve stem must be done separately.
Figure 37
Output drive type A
Grease nipple
6 months after commissioning and then once a year Check screws between multi-turn actuator and valve for tightness. If required, tighten by applying the torques given in table 1, page 14.
. .
For enclosure protection IP 68 (option) After submersion: Check multi-turn actuator. In case of ingress of water, dry device correctly and check for proper function.
66
11.2. Maintenance Maintenance intervals Lubricant change
. . . .
Refer to lubricant change. In the factory, the gear housing is filled with grease. Grease change is performed during maintenance. Generally after 4 to 6 years for modulating duty. Generally after 6 to 8 years if operated frequently (open-close duty). Generally after 10 to 12 years if operated rarely (open-close duty). No additional lubrication is required during operation.
11.3. Disposal and recycling AUMA devices have a long lifetime. However, they have to be replaced at one point in time. The devices have a modular design and may, therefore, easily be separated and sorted according to materials used, i.e.:
. . . . . . .
electronic scrap various metals plastics greases and oils
The following generally applies: Collect greases and oils during disassembly. Generally, these substances are hazardous to water and must not be released into the environment. Arrange for controlled waste disposal of the disassembled material or for separate recycling according to materials. Observe the national regulations for waste disposal.
67
12.
Spare parts list
12.1. Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1
68
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. 001.0 002.0 003.0 005.0 005.1 005.2 005.3 005.4 006.0 009.0 010.0 017.0 018.0 019.0 020.0 022.0 023.0 024.0 025.0 058.0 061.0 070.0 079.0 080.0 155.0 500.0 501.0 502.0 503.0 504.0 505.0 506.0 507.0 511.0 514.0 514.1 516.1 535.1 539.0 542.0 549.1 551.1 553.0 554.0 556.0 556.1 557.0 558.0 559.0-1 Designation Housing Bearing flange Hollow shaft without worm wheel Worm shaft Motor coupling Coupling pin Manual drive coupling Pull rod Worm wheel Planetary gear for manual drive Retaining flange Torque lever Gear segment Crown wheel Swing lever Drive pinion II for torque switching Output drive wheel for limit switching Intermediate wheel for limit switching Locking plate Wire for protective earth (pin) Torque switching head Motor (VD motor incl. no. 079.0) Planetary gear for motor drive (SA/SAR 07.1 14.1 for VD motor) Planetary gear for motor drive (SA/SAR 16.1 for AD90 motor) Reduction gearing Cover for switch compartment Socket carrier (complete with sockets) Pin carrier without pins Socket for controls Socket for motor Pin for controls Pin for motor Plug cover Screw plug Output drive form A (without stem nut) Axial needle roller bearing Output drive shaft D Snap ring Screw plug Handwheel with ball handle Output socket B3/B4/E Parallel key Mechanical position indicator Socket carrier with motor cable harness Potentiometer for position transmitter Potentiometer without slip clutch Heater Blinker transmitter including pins at wires (without impulse disc and insulation plate) Control unit without torque head, without switches Control unit with magnetic limit and torque transmitter (MWG) for Non-intrusive version in combination with AUMATIC integral controls Switch stack for OPEN direction Switch stack for CLOSE direction Switch for limit/torque switching Switch case Position transmitter RWG Potentiometer for RWG without slip clutch Type Sub-assembly Sub-assembly Sub-assembly Sub-assembly No. 566.2 566.3 567.1 568.1 568.2 568.3 569.0 569.1 569.2 574.1 575.1 S1 S2 Designation Electronic board RWG Wire harness for RWG Slip clutch for potentiometer/RWG Stem protection tube (without cap) Cap for stem protection tube V-seal Change-over lever assly. Change-over lever Notched pin Radial seal output drive A for ISO flange Stem nut type A Seal kit, small Seal kit, large Type Sub-assembly Sub-assembly Sub-assembly
Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly
Set Set
Sub-assembly
Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly
559.0-2 560.0-1 560.0-2 560.1 560.2 566.0 566.1
Sub-assembly Sub-assembly Sub-assembly
Sub-assembly Sub-assembly
69
12.2. Controls AC 01.1 with AUMA plug/socket connector (SD)
70
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. 001.0 002.0 002.3 006.0 008.1 009.0 011.1 050.1 500.0 501.0 502.0 503.0 504.0 505.0 506.0 507.0 507.1 508.0 509.1 510.0 S Designation Housing Local controls Local controls board Power supply Bus interface Logic board Relay board Bus connection board Cover Socket carrier (complete with sockets) Pin carrier without pins Socket for controls Socket for motor Pin for controls Pin for motor Electrical connection for bus without connection board (050.0) Frame Switchgear Padlock Fuse kit Seal kit Sub-assembly Sub-assembly Sub-assembly Sub-assembly Type
Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Set Set
71
13.
Technical data
Short time duty S2 - 15 min Intermittent duty S4 - 25 % Option: Short time duty S2 - 30 min Intermittent duty S4 - 50 % Intermittent duty S5 - 25 % Refer to actuator name plate Refer to actuator name plate Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34 Options: 1-ph AC motor, type IM B14 according to IEC 34 DC shunt motor, type IM B14 according to IEC 34 DC compound motor, type IM B14 according to IEC 34 Special motors Standard: F, tropicalized Option: H, tropicalized Standard: Thermoswitches (NC) Option: PTC thermistors (according to DIN 44082) Yes, for output speeds 4 to 90 Counter gear mechanism for end positions CLOSED and OPEN for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke) Standard: Single switch (1 NC and 1 NO) for each end position, not galvanically isolated Options: Tandem switches (2 NC and 2 NO) for each end position, switches galvanically isolated Triple switch (3 NC and 3 NO) for each end position, switches galvanically isolated Imax.: 5 A/30 250 V AC (cos phi = 0.8) Imax.: 2 A/30 V DC; 0.5 A/125 V DC; 0.4 A/250 V DC For gold plated contacts: min. 4 mA to max. 400 mA and min. 5 V to max. 50 V Torque switching for directions OPEN and CLOSE adjustable Standard: Single switch (1 NC and 1 NO) for each direction Options: Tandem switches (2 NC and 2 NO) for each direction, switches galvanically isolated Potentiometer or 0/4 20 mA (RWG) For further details see page 74 Continuous indication, adjustable indicator disc with OPEN and CLOSED symbols Resistance type heater with 5 W, 24 V DC (standard: internal supply) SA/SAR 07.1 10.1: 12.5 W SA/SAR 14.1 16.1: 25 W Manual drive for setting and emergency operation, handwheel does not rotate during electrical operation. Option: Handwheel lockable AUMA plug/socket connector with screw type connection A, B1, B2, B3, B4 according to EN ISO 5210 A, B, D, E according to DIN 3210 C according to DIN 3338 Special output drives: AF, AK, AG, IB1, IB3 SA SAR SA SAR
Features and functions of actuator Type of duty1) Standard:
Torque range Output speed Motors
Insulation class Motor protection Self-locking Limit switching
Torque switching
Position feedback, analogue (options) Mechanical position indicator (option) Heater in switch compartment Motor heater (option) Manual operation
Connection to controls Output drive types
Features and functions of controls Power supply For mains voltage and mains frequency, refer to name plates at the controls and the motor (for a description of the name plates, refer to page 9) Permissible variation of the nominal voltage: 10 % Permissible variation of the mains frequency: 5 % Motor current consumption: Refer to motor name plate Current consumption of the controls depending on the mains voltage: 100 to 120 V AC = max. 650 mA 208 to 240 V AC = max. 325 mA 380 to 500 V AC = max. 190 mA External supply of the electronics 24 V DC +20 %/15 %, (option) Current consumption: Basic version approx. 200 mA, with options up to 500 mA Rated power Refer to motor name plate The controls is designed for the rated power of the actuator. Overvoltage category Category III according to IEC 60 644-1
1) For nominal voltage and 20 C ambient temperature and at an average load with running torque or modulating torque according to Technical data SA or SAR
72
Switch gear Standard:
Reversing contactors2) (mechanically and electrically interlocked) for motor power up to 1.5 kW, nominal motor current up to 9 A (OPEN - CLOSE duty) or 5.2 A (modulating duty ) Option: Reversing contactors2) (mechanically and electrically interlocked) for motor power up to 7.5 kW, nominal motor current up to 20 A (OPEN - CLOSE duty) or 18 A (modulating duty ) Reversing contactors2) (mechanically and electrically interlocked) for actuators with DC motor 24 V, 48 V, 60 V, 110 V, 220 V (nominal current max. 25 A, starting current max. 70 A) Requires external supply of electronics with 24 V DC and thermal overload relay Thyristor unit (recommended for modulating actuators) For motor power up to 1.5 kW, 500 V AC with internal fuses For motor power up to 3.0 kW, 500 V AC, with internal fuses For motor power up to 5.5 kW, 500 V AC, external fuses required Via Modbus interface (page 75) Modbus interface with 4 free 24 V DC inputs (current consumption approx. 5mA/input) and 2 free 0/4 20 mA inputs3). Signal transmission via fieldbus interface. Modbus interface with 24 V DC control inputs OPEN - CLOSE - EMERGENCY, or alternatively OPEN - STOP - CLOSE (current consumption approx 5 mA/input), Control mode selection via 24 V DC input BUS/REMOTE. Modbus interface with 24 V DC control inputs OPEN - CLOSE (current consumption approx. 5 mA/input), and 0/4 20 mA input for nominal position value 4) (positioner). Selection of control mode via 24 V DC inputs BUS/REMOTE and MODE. Modbus interface with 24 V DC (optional 115 V AC) control inputs OPEN - STOP - CLOSE - EMERGENCY (current consumption approx. 10 mA/input, for 115 V AC approx. 15 mA/input) and 0/4 20 mA input for nominal position value4) (positioner). Selection of control mode via 24 V DC (optional 115 V AC) inputs BUS/REMOTE and MODE. Output signals via 6 programmable signal relays, position feedback 0/4 20 mA. Standard: Auxiliary voltage 24 V DC, max. 100 mA for supply of the control inputs, galvanically isolated from internal voltage supply Option: Auxiliary voltage 115 V AC, max. 30 mA for supply of the control inputs5), galvanically isolated from internal voltage supply AUMATIC is equipped with an additional redundant Modbus interface AUMATIC is equipped with an additional redundant Modbus interface to implement a redundant loop in combination with the SIMA Master Station. Max. number of AUMATIC actuators per redundant loop: 247 units. Max. possible cable length between the AUMATIC actuators without additional external repeaters: 1,200 m. Max. possible total cable length per redundant loop: approx. 290 km Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all three positions) Push buttons OPEN - STOP - CLOSE - RESET 5 indication lights: End position CLOSED and running indication CLOSE (yellow), torque fault CLOSED (red), motor protection tripped (red), torque fault OPEN (red) end position and running indication OPEN (green) LC display, illuminated Programming interface (infrared) Options: Bluetooth programming interface with Bluetooth class II chip with a range of up to 10m. Supports the Bluetooth profile SPP (Serial Port Profile). Release of the local controls with selector switch LOCAL - OFF - REMOTE: Operation of the actuator with the push buttons OPEN - STOP - CLOSE - RESET of the local controls can be disabled or released via Modbus. Special colours for the 5 indication lights: End position CLOSED and running indication CLOSE (green), torque fault CLOSED (blue), torque fault OPEN (yellow), motor protection tripped (white), end position and running indication OPEN (red) Protection cover, lockable Protection cover with indicator glass, lockable
Control and output signals Modbus RTU interface with additional inputs (options)
Voltage output
Component redundancy (option) Redundancy in loop structure (option)
Local controls
2) The reversing contactors are designed for a lifetime of 2 million starts. For applications requiring a high number of starts, we recommend the use of wearless thyristor units. 3) Only partly possible in connection with process controller PID, please contact AUMA. 4) Requires positioner in the actuator 5) Not possible in combination with PTC tripping device
73
Functions Standard:
Type of seating is programmable Limit or torque seating for end position OPEN and end position CLOSED Torque monitoring over the whole travel Torque-by-pass, adjustable to up to 5 seconds (no torque monitoring during this time) Phase failure monitoring6) with automatic phase correction Programmable behaviour in case of loss of bus connection Running indication via indication lights Positioner4): Nominal position value via Modbus interface Programmable behaviour on loss of signal Automatic adaptation of the dead band (adaptive behaviour selectable) Change-over between OPEN - CLOSE duty and modulating duty via Modbus Options: Process controller PID4): Nominal process value via Modbus interface Actual process value via 0/4 20 mA additional input Programmable behaviour on loss of signal Limitation of the control range Change-over between OPEN - CLOSE duty and modulating duty via Modbus Multiport valve function4) Direct approaching of up to 8 intermediate positions via Modbus and the local controls Monitoring functions Programmable monitoring of the max. number of starts, generates warning signal Reaction monitoring for operation command (programmable from 1 to 15 seconds), generates fault signal and results in switching off Operating time monitoring (programmable from 4 to 1,800 seconds), generates warning signal Electronic name plate Order data: AUMATIC commission number, actuator commission number, KKS number (definition system for power plants), valve number, plant number Order data: AUMATIC commission number, actuator commission number, KKS number (definition system for power plants), valve number, plant number Project data: Project name, 2 freely definable customer fields with a max. of 19 digits each Service data: Service telephone, Internet address, service text 1, service text 2 Logging of operating data A resettable counter and a lifetime counter for: Motor running time, number of starts, torque switch trippings in end position CLOSED, limit switch trippings in end position CLOSED, torque switch trippings in end position OPEN, limit switch trippings in end position OPEN, torque faults CLOSE, torque faults OPEN, motor protection trippings Motor protection evaluation Standard: Monitoring of the motor temperature in combination with thermoswitches in the motor Options: Additional thermal overload relay in the controls in combination with thermoswitches within the motor PTC tripping device in combination with PTC thermistors in the motor Electrical connection Standard: AUMA plug/socket connector with screw type connection Threads for cable glands: M-threads: 2 x M25 x 1.5; 4 x M20 x 1.5 Pg-threads: 2 x Pg21; 4 x Pg13.5 NPT-threads: 1 x NPT "; 4 x NPT " G-threads: 1 x G "; x G " Options: Special threads, other than standard mentioned above, possible Gold-plated control plug (pins and sockets) Parking frame for wall mounting of the disconnected plug Protection cover for plug compartment (when plus is removed) Overvoltage protection (option) Protection of the actuator and control electronics against overvoltages on the fieldbus cables of up to 4 kV Wiring diagram (basic version) ACP 11F1-2P0K000 KMS TP102/001 Additional features for version with potentiometer or RWG in the actuator Electronic timer Start and end of stepping mode as well as ON and OFF time (1 up to 300 seconds) can be programmed individually for the directions OPEN and CLOSE. Intermediate positions Any 8 intermediate positions between 0 and 100 % Reaction and signal behaviour programmable
4) Requires position transmitter in the actuator 6) During an adjustable period (factory setting 10 seconds), faults in the supply voltage (e.g. voltage drops) will not lead to a fault signal.
74
Setting/programming the Modbus interface Setting the Modbus interface Baud rate, parity and Modbus address are set via the display of the AUMATIC Commands and signals of the Modbus RTU interface Process representation output OPEN, STOP, CLOSE, nominal position value, RESET (command signals) Process representation input End position OPEN, CLOSE (feedback signals) Actuator position value Actual torque value Selector switch in position LOCAL/REMOTE Running indication (directional) Torque switch OPEN, CLOSED Limit switch OPEN, CLOSED Manual operation by handwheel or local controls Analogue (2) and digital (4) customer inputs Communication channel A or B (redundant channel) active Process representation input Motor protection tripped (fault signals) Torque switch tripped in mid-travel One phase missing
Loss of analogue customer inputs

Behaviour on loss of communication
The behaviour of the actuator is programmable:

- Stop in current position - Move to end position OPEN or CLOSED
- Move to any intermediate position

General data Modbus Communication protocol Network topology Modbus RTU Linear (BUS) structure. Active bus termination at both ends. Coupling and uncoupling of devices during operation without affecting other devices is possible. Twisted, screened copper cable according to IEC 61158 EIA-485 (RS485) Baud rate (bit/s) Max. cable length (segment length) without repeater 1,200 m Possible cable length with repeater (total network cable length) approx. 10 km
Transmission medium Modbus interface Transmission rate/cable length
300 38,400 Device types Number of devices Bus access Supported Modbus RTU functions (services)
Modbus RTU slave, e.g. devices with digital and/or analogue inputs/outputs such as actors, sensors) 32 devices in each segment without repeater, with repeaters expandable to 247 Polling between master and slaves (query response). 01 Read Coil Status 02 Read Input Status 03 Read Holding Registers 04 Read Input Registers 05 Force Single Coil 15 (0FHex) Force Multiple Coils 06 Preset Single Register 16 (10Hex) Preset Multiple Registers 07 Read Exception Status 17 (11Hex) Report Slave ID 08 Diagnostics: 00 00 Loopback 00 10 (0AHex) Clear Counters and Diagnostic Register 00 11 (0BHex) Return Bus Message Count 00 12 (0CHex) Return Bus Communication Error Count 00 13 (0DHex) Return Bus Exception Error Count 00 14 (0EHex) Return Slave Message Count 00 15 (0FHex) Return Slave No Response Count
75
Service conditions for actuator with controls Mounting position Any position Enclosure protection according Standard: IP 67 to EN 60 5299) Options: IP 68
Corrosion protection
Finish coating Colour Ambient temperature
Vibration resistance according to IEC 60 068
Lifetime
Weight Accessories Wall bracket11)
Max. 6 m head of water, duration of the flooding 72 hours max. Up to 10 operations during flooding Modulating duty is not possible during submersion IP 67 DS (Double Sealed) IP 68 DS (Double Sealed) (Double Sealed = Electrical connection compartment additionally sealed against interior) Standard: KN Suitable for installation in industrial units, in water or power plants with a low pollutant concentration Options: KS Suitable for installation in occasionally or permanently aggressive atmosphere with a moderate pollutant concentration (e.g. in wastewater treatment plants, chemical industry) KX Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant concentration KX-G Same as KX, however aluminium-free version (outer parts) Standard: Two-component iron-mica combination Option: Special primer/special finish coat (customers choice) Standard: AUMA silver-grey (similar to RAL 7037) Other colours are possible on request Standard: 25 C to +70 C Options: 40 C to +70 C, low temperature version incl. heating system 50 C to +70 C, extreme low temperature version incl. heating system Low temperature versions inc. heating system for connection to external power supply 230 V AC or 115 V AC. 1 g, for 10 to 200 Hz Resistant to vibrations during start-up or for failures of the plant. However, a fatigue strength may not be derived from this. Applies to actuator with actuator controls only, not valid in combination with gearboxes. Open-close duty: Operating cycles (OPEN - CLOSE - OPEN) SA 07.1 SA 10.1: 20,000 SA 14.1 SA 16.1: 15,000 Modulating duty:10) SAR 07.1 SAR 10.1: min. 5.0 million modulating steps SAR 14.1 SAR 14.5: min. 3.5 million modulating steps SAR 16.1: min. 3.5 million modulating steps Refer to separate Technical data SA/SAR/AC AUMATIC mounted separately from the actuator, including plug/socket connector. Connecting cables on request. Recommended for high ambient temperatures, difficult access, or in case of heavy vibrations during service. The control voltage of the reversing contactors is interrupted by operating the EMERGENCY STOP button. COM-AC. An interface cable is required for the standard infra-red programming interface Electromagnetic Compatibility (EMC): (2004/108/EC) Low Voltage Directive: (2006/95/EC) Machinery Directive: (98/37/EC)
EMERGENCY STOP button12) Programming software for PC Further information EU Directives
9) The enclosure protection according to name plate applies. Other enclosure protections apply to single phase AC motors, DC motors, or special motors (refer to separate technical data sheets). Enclosure protection IP 68 refers to the interior of the actuators (motor, gearing, switch compartment, and terminal compartment). For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended. Additionally, for enclosure protection IP 68, we recommend to use the double sealed terminal compartment DS. 10) he lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the longest possible maintenance and fault-free operating time, the number of starts per hour chosen should be as low as possible for the process. 11) Cable length between actuator and AUMATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an RWG has to be used. 12) Only in combination with reversing contactors and AUMATIC AC 01.1 in enclosure protection IP 67 or IP 68
76
Notes
77
Notes
78
Notes
79
14.
Certificates
14.1. Declaration of Conformity and Declaration of Incorporation
80
Index
A Accessories for mounting Assembly B Bus cables C Cable capacity Cable installation Cable installation in accordance with EMC Commission number Commissioning Connecting cables Connection control time Control Core cross section (bus cable) Core diameter (bus cable) Corrective action Corrosion protection Cross sections Current consumption D Declaration of Conformity Declaration of Incorporation Disconnect switches Disposal and recycling Double sealed intermediate frame DUO limit switching 17 13 20 20 19 19 9 40 29 46 10 20 20 57 12 22 19 80 80 19 67 30 50 I Impedance Indications Indicator disc Intermediate positions Internet Intrusive 20 37 47,55 50 10 11 35 49 12 20 40 67 21 67 31 55 22 32 65 14 18 11 R Rated power Reference documents Running indication S Safety instructions Screening (bus cable) Self-retaining mode Service Short-circuit protection Signals Size Spare parts list Controls Multi-turn actuator Status indication Stem nut Storage T Technical data Terminal plan Test run Thermoswitches Torque switching setting Transport Tripping torque Type V Valve position W Wall bracket Warnings Wiring diagram (name plate) Wiring diagram locating 72 2 38 5 20 32 66 19 39 10 68 70 68 37 15 12 72 19 51 65 48 12 48 10 37 29 59 10 19
L Language change in the display Limit switching Long-term storage Loop resistance Low temperature version Lubricant change M Mains connection Maintenance intervals Manual operation Mechanical position indicator Motor heater Motor operation Motor protection Mounting Mounting positions of the local controls N Non-Intrusive
E Electrical connection 19 Electronic position transmitter RWG 54 F Faults Faults at commissioning Fuses Fuses on site G Ground connection, external H Handwheel Handwheel fitting Heater Heat-up time 59 57 64 19 30 31 13 22 40
O Operation 31 Output drive type A 15 Output drive types B1, B2, B3, B4, B, and E 14 Overrun 58 P Packaging Parking frame Password entry Position indicator Position transmitter Position transmitter RWG Potentiometer Protection cover Protection on site Protection tube Protective earth PTC thermistors Push-to-run operation 12 30 34 55 19 54 53 30 19 17 22 65 32
81
AUMA worldwide
Europe
AUMA Riester GmbH & Co. KG
Plant Mllheim DE-79373 Mllheim Tel +49 7631 809 - 0 Fax +49 7631 809 - 1250 riester@auma.com www.auma.com Plant Ostfildern-Nellingen DE-73747 Ostfildern Tel +49 711 34803 - 0 Fax +49 711 34803 - 3034 riester@wof.auma.com Service Center Cologne DE-50858 Kln Tel +49 2234 2037 - 9000 Fax +49 2234 2037 - 9099 Service@sck.auma.com Service Center Magdeburg DE-39167 Niederndodeleben Tel +49 39204 759 - 0 Fax +49 39204 759 - 9429 Service@scm.auma.com Service Center Bavaria DE-85386 Eching Tel +49 81 65 9017- 0 Fax +49 81 65 9017- 2018 Riester@scb.auma.com AUMA Armaturenantriebe GmbH AT-2512 Tribuswinkel Tel +43 2252 82540 Fax +43 2252 8254050 office@auma.at www.auma.at AUMA (Schweiz) AG CH-8965 Berikon Tel +41 566 400945 Fax +41 566 400948 RettichP.ch@auma.com AUMA Servopohony spol. s.r.o. CZ-10200 Praha 10 Tel +420 272 700056 / 704125 Fax +420 272 704125 auma-s@auma.cz www.auma.cz OY AUMATOR AB FI-02230 Espoo Tel +358 9 5840 22 Fax +358 9 5840 2300 auma@aumator.fi www.aumator.fi AUMA France S.A.R.L. FR-95157 Taverny Cedex Tel +33 1 39327272 Fax +33 1 39321755 info@auma.fr www.auma.fr AUMA ACTUATORS Ltd. GB- Clevedon North Somerset BS21 6QH Tel +44 1275 871141 Fax +44 1275 875492 mail@auma.co.uk www.auma.co.uk AUMA ITALIANA S.r.l. a socio unico IT-20023 Cerro Maggiore (MI) Tel +39 0331 51351 Fax +39 0331 517606 info@auma.it www.auma.it AUMA BENELUX B.V. NL-2314 XT Leiden Tel +31 71 581 40 40 Fax +31 71 581 40 49 office@benelux.auma.com www.auma.nl
AUMA Polska Sp. z o.o. PL-41-310 Dabrowa Grnicza Tel +48 32 261 56 68 Fax +48 32 261 48 23 R.Ludzien@auma.com.pl www.auma.com.pl OOO Priwody AUMA RU-141400 Moscow region for mail: 124365 Moscow a/ya 11 Tel +7 495 221 64 28 Fax +7 495 221 64 38 aumarussia@auma.ru www.auma.ru ERICHS ARMATUR AB SE-20039 Malm Tel +46 40 311550 Fax +46 40 945515 info@erichsarmatur.se www.erichsarmatur.se GRNBECH & SNNER A/S DK-2450 Kbenhavn SV Tel +45 33 26 63 00 Fax +45 33 26 63 21 GS@g-s.dk www.g-s.dk IBEROPLAN S.A. ES-28027 Madrid Tel +34 91 3717130 Fax +34 91 7427126 iberoplan@iberoplan.com D. G. Bellos & Co. O.E. GR-13671 Acharnai Athens Tel +30 210 2409485 Fax +30 210 2409486 info@dgbellos.gr SIGURD SRUM A. S. NO-1300 Sandvika Tel +47 67572600 Fax +47 67572610 post@sigurd-sorum.no INDUSTRA PT-2710-297 Sintra Tel +351 2 1910 95 00 Fax +351 2 1910 95 99 industra@tyco-valves.com MEGA Endstri Kontrol Sistemieri Tic. Ltd. Sti. TR-06810 Ankara Tel +90 312 217 32 88 Fax +90 312 217 33 88 megaendustri@megaendustri.com.tr www.megaendustri.com.tr CTS Control Limited Liability Company UA-02099 Kiyiv Tel +38 044 566-9971, -8427 Fax +38 044 566-9384 v_polyakov@cts.com.ua
America
AUMA ACTUATORS INC. US-PA 15317 Canonsburg Tel +1 724-743-AUMA (2862) Fax +1 724-743-4711 mailbox@auma-usa.com www.auma-usa.com AUMA Chile Respresentative Office CL-9500414 Buin Tel +56 2 821 4108 Fax +56 2 281 9252 aumachile@adsl.tie.cl LOOP S. A. AR-C1140ABP Buenos Aires Tel +54 11 4307 2141 Fax +54 11 4307 8612 contacto@loopsa.com.ar Asvotec Termoindustrial Ltda. BR-13190-000 Monte Mor/ SP. Tel +55 19 3879 8735 Fax +55 19 3879 8738 atuador.auma@asvotec.com.br TROY-ONTOR Inc. CA-L4N 5E9 Barrie Ontario Tel +1 705 721-8246 Fax +1 705 721-5851 troy-ontor@troy-ontor.ca MAN Ferrostaal de Colombia Ltda. CO- Bogot D.C. Tel +57 1 401 1300 Fax +57 1 416 5489 dorian.hernandez@manferrostaal.com www.manferrostaal.com PROCONTIC Procesos y Control Automtico EC- Quito Tel +593 2 292 0431 Fax +593 2 292 2343 info@procontic.com.ec IESS de Mexico, S.A. de C.V. MX-C.P. 02900 Mexico D.F. Tel +52 55 55 56 1701 Fax +52 55 55 56 3337 informes@iess.com.mx Corsusa International S.A.C. PE- Miralflores - Lima Tel +511444-1200 / 0044 / 2321 Fax +511444-3664 corsusa@corsusa.com www.corsusa.com PASSCO Inc. PR-00936-4153 San Juan Tel +18 09 78 77 20 87 85 Fax +18 09 78 77 31 72 77 Passco@prtc.net Suplibarca VE- Maracaibo Estado, Zulia Tel +58 261 7 555 667 Fax +58 261 7 532 259 suplibarca@intercable.net.ve
Africa
AUMA South Africa (Pty) Ltd. ZA-1560 Springs Tel +27 11 3632880 Fax +27 11 8185248 aumasa@mweb.co.za A.T.E.C. EG- Cairo Tel +20 2 23599680 - 23590861 Fax +20 2 23586621 atec@intouch.com
Asia
AUMA Actuators (Tianjin) Co., Ltd. CN-300457 Tianjin Tel +86 22 6625 1310 Fax +86 22 6625 1320 mailbox@auma-china.com www.auma-china.com AUMA (INDIA) PRIVATE LIMITED IN-560 058 Bangalore Tel +91 80 2839 4655 Fax +91 80 2839 2809 info@auma.co.in www.auma.co.in
82
AUMA JAPAN Co., Ltd. JP-210-0848 Kawasaki-ku, Kawasaki-shi Kanagawa Tel +81 44 329 1061 Fax +81 44 366 2472 mailbox@auma.co.jp www.auma.co.jp AUMA ACTUATORS (Singapore) Pte Ltd. SG-569551 Singapore Tel +65 6 4818750 Fax +65 6 4818269 sales@auma.com.sg www.auma.com.sg Al Ayman Industrial. Eqpts AE- Dubai Tel +971 4 3682720 Fax +971 4 3682721 auma@emirates.net.ae PERFECT CONTROLS Ltd. HK- Tsuen Wan, Kowloon Tel +852 2493 7726 Fax +852 2416 3763 joeip@perfectcontrols.com.hk
DW Controls Co., Ltd. KR-153-803 Seoul Korea Tel +82 2 2113 1100 Fax +82 2 2113 1088/1089 sichoi@actuatorbank.com www.actuatorbank.com Al-Arfaj Engineering Co WLL KW-22004 Salmiyah Tel +965 481-7448 Fax +965 481-7442 info@arfajengg.com www.arfajengg.com Petrogulf W.L.L QA- Doha Tel +974 4350 151 Fax +974 4350 140 pgulf@qatar.net.qa Sunny Valves and Intertrade Corp. Ltd. TH-10120 Yannawa Bangkok Tel +66 2 2400656 Fax +66 2 2401095 sunnyvalves@inet.co.th www.sunnyvalves.co.th/
Top Advance Enterprises Ltd. TW- Jhonghe City Taipei Hsien (235) Tel +886 2 2225 1718 Fax +886 2 8228 1975 support@auma-taiwan.com.tw www.auma-taiwan.com.tw
Australia
BARRON GJM Pty. Ltd. AU-NSW 1570 Artarmon Tel +61 294361088 Fax +61 294393413 info@barron.com.au www.barron.com.au
2008-06-10
83
AUMA Riester GmbH & Co. KG P.O.Box 1362 D-79373 Mllheim Tel +49 7631 809 - 0 Fax+49 7631 809 - 1250 riester@auma.com www.auma.com
Certificate Registration No. 12 100/104 4269
Y004.639/003/en/1.08
For detailed information on AUMA products refer to the Internet:www.auma.com
Part-turn gearboxes
Worm gearboxes GS 50.3 GS 250.3
Worm gearboxes GS 50.3 GS 250.3 Scope of these instructions:
Operation instructions These operation instructions are valid for worm gearboxes of the type range GS 50.3 GS 125.3 with primary reduction gearings VZ 2.3 VZ 4.3. and GS 160.3 GS 250.3 with primary reduction gearings GZ 160.3 250.3.
Table of contents
1. Safety instructions 1.1 Range of application 1.2 Maintenance 1.3 Warnings and notes 2. Technical data 3. Transport, storage and packaging 3.1 Transport 3.2 Storage 3.3 Packaging 4. 5. 6. 7. Fitting of handwheel Mounting positions of the different versions Mounting of multi-turn actuators SA/SAR Mounting to valve
Page 3 3 3 3 4 7 7 7 7 7 8 9 11 12 12 13 13 13 14 16 16 17 18 19 19 20 20 20 21 21 21 22 22 23 23 24 26 28 30 31 32
8. Setting the end stops for manual operation 8.1 Worm gearboxes on butterfly valves 8.2 Worm gearboxes on ball valves 9. Setting the end stops with mounted multi-turn actuator 9.1 Worm gearboxes on butterfly valves 9.2 Worm gearboxes on ball valves 10. Changing the swing angle 10.1 Changing the swing angle for sizes GS 50.3 GS 125.3 (option) 10.2 Changing the swing angle for sizes GS 160.3 GS 250.3 11. Enclosure protection IP 68 12. Maintenance 12.1 General notes 12.2 Grease change for worm gearboxes GS 50.3 GS 125.3 and primary reduction gearing VZ 2.3 VZ 4.3 12.2.1 Worm gearboxes 12.2.2 Primary reduction gearing 12.3 Grease change for worm gearboxes GS 160.3 GS 250.3 and primary reduction gearing VZ 160.3 VZ 250.3 12.3.1 Worm gearboxes 12.3.2 Single-stage reductions gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1 and 8:1) 12.3.3 Double-stage primary reduction gearing GZ 200.3 GZ 250.3 (reduction ratio 16:1) 12.4 After maintenance 13. 14. 15. 16. 17. 18. Disposal and recycling Service Spare parts list worm gearboxes GS 50.3 GS 125.3 and reduction gearing VZ 2.3 VZ 4.3 Spare parts list worm gearboxes GS 160.3 GS 250.3 Spare parts list reduction gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) Declaration of Conformity and Declaration of Incorporation Index Addresses of AUMA offices and representatives
1.
1.1
Safety instructions
Range of application AUMA worm gearboxes GS 50.3 GS 250.3 are used for the operation of valves (e.g. butterfly valves and ball valves). They are designed for manual operation as well as motor operation in conjunction with electric actuators. For other applications, please consult us. The manufacturer is not liable for any possible damage resulting from use in other than the designated applications. Such risk lies entirely with the user. Observance of these operation instructions is considered as part of the gearboxes designated use. The maintenance instructions (refer to page 19) must be observed, otherwise a safe operation of the worm gearbox is no longer guaranteed. Non-observance of the warnings and notes may lead to serious injuries or damage. Qualified personnel must be thoroughly familiar with all warnings and notes in these operation instructions. Correct transport, proper storage, mounting and installation, as well as careful commissioning are essential to ensure a trouble-free and safe operation. The following references draw special attention to safety-relevant procedures in these operation instructions. Each is marked by the appropriate pictograph. This pictograph means: Note! Note marks activities or procedures which have major influence on the correct operation. Non-observance of these notes may lead to consequential damage. This pictograph means: Warning! Warning marks activities or procedures which, if not carried out correctly, can affect the safety of persons or material.
1.2 1.3
Maintenance Warnings and notes
2.
Technical data
Standard: clockwise rotation RR, counterclockwise rotation LL, option: RL or LR Standard: cast iron (GJL-250), Option: spheroidal cast iron (GJS-400-15) The gearboxes are self-locking when at stand-still under normal service conditions; strong vibrations may cancel the self-locking effect. While in motion, safe breaking is not guaranteed. If this is required, a separate brake must be used.
Type
100 % max. Nm 140 % max. Nm
Features and functions Version Housing material Self-locking Output torques
Output torques
175 %1) max. Nm
200 %1) max. Nm
Modulating torque2) max. Nm
GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3 GS 160.3 GS 200.3 GS 250.3
250 500 1,000 2,000 4,000 8,000 16,000 32,000
350 700 1,400 2,800 5,600 11,250 22,500 45,000
14,000 28,000 56,000
500 1,000 2,000 4,000 8,000
125 250 500 1,000 2,000 4,000 8,000 16,000
End stops Strength of end stop
Positive for both end positions by travelling nut, sensitive adjustment Guaranteed strength of end stop (in Nm) for input side operation
Type Reduction gearing Nm Type Reduction gearing Reduction ratio Nm 4:1 500 GS 50.3 250 GS 63.3 450 GS 160.3 GZ 160.3 8:1 450 4:1 GS 80.3 450 VZ 2.3 500 GS 200.3 GZ 200.3 8:1 500 16:1 4:1 GS 100.3 VZ 3.3 VZ 4.3 250 VZ 2.3 GS 125.3 VZ 3.3 500 GS 250.3 GZ 250.3 8:1 500 16:1 VZ 4.3 250
Swing angle GS 50.3 GS 125.3
Standard:
Swing angle GS 160.3 GS 250.3
Mechanical position indicator
Input shaft Operation Motor operation Type of duty Manual operation
Fixed swing angle up to max. 100; set in the factory to 92 unless ordered otherwise. Options: Adjustable in steps of: 10 35, 35 60, 60 80, 80 100, 100 125, 125 150, 150 170, 170 190 For version with worm wheel made of bronze: swing angle > 190, Multi-turn version without end stops, version GSD Standard: Adjustable 80 - 100; set in the factory to 92 unless ordered otherwise. Options: Adjustable in steps of: 20 40, 40 60, 60 80, 110 130, 130 150, 150 170, 170 190! For version with worm wheel made of bronze: swing angle > 100, Multi-turn version without end stops, version GSD Standard: Pointer cover for continuous position indication Options: Sealed pointer cover for horizontal outdoor installation3) Protection cover for buried service instead of pointer cover Cylindrical with parallel key according to DIN 6885.1 With electric multi-turn actuator, directly or through primary reduction gearing VZ/ GZ Flanges for mounting of actuator, refer also to separate Technical data sheets. According to actuator Via handwheel, directly or through primary reduction gearing VZ/ GZ Available handwheel diameters, selection according to the max. output torque:
Type Reduction gearing Handwheel mm GS 50.3 160 200 250 GS 63.3 250 315 GS 80.3 315 400 400 500 GS 100.3 VZ 2.3 VZ 3.3 VZ 4.3 315 400 315 400 250 315 500 630 800 GS 125.3 VZ 2.3 VZ 3.3 VZ 4.3 400 500 400 500 315 400
Type Reduction gearing Handwheel mm 630 800
GS 160.3 GZ 160.3 400 315
GS 200.3 GZ 200.3 500 630 400 315
GS 250.3 GZ 250.3 800 500 630 400
1) With worm wheel made of spheroidal cast iron 2) Requires worm wheel made of bronze 3) For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided
Primary reduction gearing Primary reduction gearing Valve attachment Valve attachment
Planetary gear with various reduction ratios for reducing the input torques Dimensions according to EN ISO 5211 Standard: GS 50.3 GS 125.3: without spigot GS 160.3 GS 250.3: with spigot Options: GS 50.3 GS 125.3: with spigot GS 160.3 GS 250.3: without spigot Standard: without bore or pilot bore from GS 160.3 Worm gearbox can be repositioned 4 x 90 on coupling Options: Machined with bore and keyway, square bore or bore with two-flats IP 68-3, dust and water tight up to max. 3 m head of water IP 68-6, dust and water tight up to max. 6 m head of water IP 68-10, dust and water tight up to max. 10 m head of water IP 68-20, dust and water tight up to max. 20 m head of water Standard: KN Suitable for installation in industrial units, in water or power plants with a low pollutant concentration Options: KS Suitable for installation in occasionally or permanently aggressive atmosphere with a moderate pollutant concentration (e.g. in wastewater treatment plants, chemical industry) KX Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant concentration Standard: GS 50.3 GS 125.3: Two-component iron-mica combination GS 160.3 GS 250.3: Primer coating Option: GS 160.3 GS 250.3: Two-component iron-mica combination Standard: AUMA silver-grey (similar to RAL 7037) Option: Other colours on request Standard: 25 C to + 80 C Options: 40 C to + 60 C (low temperature), version L 60 C to + 60 C (extreme low temperature), version EL 0 C to +120 C (high temperature), version H Open-close duty: The lifetime is based on a load profile typical for part-turn valves
Type Operating cycles (OPEN - CLOSE - OPEN) for swivel movements of 90 (max. 100) and a maximum output torque of 140 % 175 %6) 5 000 5 000 5 000 5 000 5 000 5 000 1 000 5 000 1 000 3 000 750
Splined coupling for connection to the valve shaft Service conditions Enclosure protection according to EN 60 5294)
Standard: Options5):
Corrosion protection
Paint Colour Ambient temperature
Lifetime
100 % 15 000 15 000 15 000 15 000 15 000 15 000 15 000 10 000
200 %6) 1 000 1 000 1 000 1 000 1 000
Modulating duty: min. 2.5 million operations7)
4) 5) 6) 7)
Refer to clause enclosure protection IP 68 Not available for GS 50.3 With worm wheel made of spheroidal cast iron The lifetime for modulating duty depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process

Accessories Valve position indicators
Valve position indicator WSG for the signalisation of intermediate and end positions for precise and low-backlash feedback for swing angles ranging from 82 98 (refer to separate data sheet) Valve position indicator WGD for signalisation of intermediate and end positions for swing angles > 180 (refer to separate data sheet) Limit switching Limit switching WSH for manually operated valves. For the signalisation of intermediate and end positions (refer to separate data sheet) Special features for use in potentially explosive atmospheres Explosion protection II2G c IIC T4 according to ATEX 94/9/EC Type of duty Short-time duty S2 - 15 min., max. 3 cycles (OPEN - CLOSE - OPEN) 90, then cool-down to ambient temperature Intermittent duty S4 - 25 % up to the maximum modulating torque Swing angle Swing angle > 90 on request Ambient temperature Standard: 20 C to +40 C Options: 40 C to +40 C (low temperature) 20 C to +60 C 40 C to +60 C (low temperature) 50 C to +60 C (extreme low temperature) 60 C to +60 C (extreme low temperature) Combinations with actuators SAExC/SARExC at ambient temperatures > 40 C with special sizing Further information Reference documents Product description Worm gearboxes GS 50.3 GS 250.3/GS 315 GS 500 Dimension sheets GS 50.3 GS 125.3, GS 160.3 GS 250.3 Technical data GS 50.3 GS 125.3, GS 160.3 GS 250.3 Technical data SA, SAR, WSG, WGD, WSH Lever gearboxes See separate documents
3.
3.1
Transport, storage and packaging

Transport
. . . . . . . .
Transport to place of installation in sturdy packing. If mounted together with actuator: Attach ropes or hooks for the purpose of lifting by hoist only to the gearbox and not to the actuator. Store in well-ventilated, dry room. Protect against floor dampness by storage on a shelf or on a wooden pallet. Cover to protect against dust and dirt. Apply suitable corrosion protection agent to bare surfaces.
3.2
Storage
In case worm gearboxes are to be stored for a long period (more than 6 months), the following points must be observed additionally: Prior to storage: Protect bare surfaces, in particular the output drive parts and mounting surface, with long-term corrosion protection agent. Check for corrosion approximately every 6 months. If first signs of corrosion show, apply new corrosion protection.
3.3
Packaging
Our products are protected by special packaging for the transport ex works. The packaging consists of environmentally friendly materials which can easily be separated and recycled. For the disposal of the packaging material, we recommend recycling and collection centres. We use the following packaging materials: Wooden material boards (OSB)/cardboard/paper/PE film For worm gearboxes designed for manual operation the handwheel is supplied separately. Fitting is done on site according to figure 1.
Figure 1: Handwheel Spacer (may be required) Circlip Ball handle (option) Spacer (may be required) Circlip
4.
Fitting the handwheel
Worm shaft gearbox
Handwheel
5.
RR
Mounting positions of the different versions

LL RL LR
Description of the 4 versions (viewed at the pointer cover): Code RR LL RL LR Direction of rotation at input shaft clockwise clockwise clockwise clockwise Position of worm shaft Right side Left side Right side Left side Direction of rotation at output drive clockwise counterclockwise counterclockwise clockwise
Mounting positions of AUMA multi-turn actuator with AUMA worm gearbox (please indicate when ordering) GS versions RR/RL
RR
RR
RR
RR
RL
RL
RL
RL
GS versions LL/LR
LL
LL
LL
LL
LR
LR
LR
LR
Mounting positions can easily be changed at a later date. Limitation: For SA/SAR 14.1/14.5 with GS 125.3, mounting position C in version RR/RL and A in version LL/LR is only possible for a handwheel diameter up to 315 mm. Up to size GS 125.3, the actuator-gearbox combination is delivered in the ordered mounting position. For packing reasons, actuator and gearbox will be delivered separately from size GS 160.3.
6.
Mounting multi-turn actuators SA/SAR

When gearboxes and multi-turn actuators are supplied together, the mounting has been done in the factory up to gearbox size GS 125.3. For sizes GS 160.3 and larger, the mounting of gearboxes is performed as follows. In case flange for actuator is not attached to gearbox or reduction gearing: Thoroughly degrease the mounting faces of the gearbox or reduction gearing as well as the flange for actuator. Fit flange for actuator and fasten with bolts and lock washers. Fasten bolts crosswise with a torque according to table 2.
Figure 2: Mounting multi-turn actuator to worm gearbox Flange for actuator
. . .
Bearing flange
Flange for actuator
Primary reduction gearing Bearing flange
Mounting the multi-turn actuator: Thoroughly degrease the faces of the flange for actuator at the gearbox or reduction gearing as well as the actuators bearing flange. Place the multi-turn actuator on the worm gearbox or reduction gearing. The multi-turn actuator can be mounted on the valve at every 90 (see page 8, mounting positions). Ensure that the spigot mates uniformly in the recess and that the mounting faces are in complete contact. Fasten actuator with bolts and lock washers (see table 1) at the flange of the worm gearbox. Fasten bolts crosswise with a torque according to table 2. Do not attach ropes or hooks for the purpose of lifting the actuator by hoist to the handwheel. If multi-turn actuator is mounted on gearbox, attach ropes or hooks for the purpose of lifting by hoist to gearbox and not to multi-turn actuator.
. . . . .
Table 1:
Bolts for mounting AUMA actuators to worm gearboxes/primary reduction gearing (strength class min. 8.8) SA/SAR 07.1-F07 Bolt M8 x 20 M8 x 20 Pcs. 4 4 SA/SAR 07.1-F10/G0 Bolt M10 x 25 M10 x 25 Pcs. 4 4 SA/SAR 07.5-F07 Bolt M8 x 20 M8 x 20 Pcs. 4 4 SA/SAR 07.5-F10/G0 Bolt M10 x 25 M10 x 25 M10 x 25 M10 x 25 M10 x 25 M10 x 25 SA/SAR 10.1-F10/G0 Bolt M10 x 25 M10 x 25 M10 x 25 M10 x 25 M10 x 25 M10 x 25 M10 x 25 M10 x 25 SA/SAR 25.1-F25 Bolt Pcs. Pcs. 4 4 4 4 4 4 4 4 SA/SAR 14.1-F14/G Bolt Pcs. SA/SAR 14.5-F14/G Bolt Pcs. Pcs. 4 4 4 4 4 4
Worm gearbox/ primary reduction gearing GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 100.3/VZ GS 125.3 GS 125.3/VZ GS 160.3 GS 160.3/GZ GS 200.3 GS 200.3/GZ Worm gearbox/ primary reduction gearing GS 63.3 GS 80.3 GS 100.3 GS 100.3/VZ GS 125.3 GS 125.3/VZ GS 160.3 GS 160.3/GZ GS 200.3 GS 200.3/GZ GS 250.3 GS 250.3/GZ Worm gearbox/ primary reduction gearing GS 160.3 GS 160.3/GZ GS 200.3 GS 200.3/GZ GS 250.3 GS 250.3/GZ
M10 x 25
SA/SAR 16.1-F16/G3 Bolt Pcs.
M16 x 40 M16 x 40 M16 x 40 M16 x 40 M16 x 40 M16 x 40
4 4 4 4 M20 x 50 4 4 M16 x 40 M16 x 40 4 4 M20 x 50 4 4 M16 x 40 M16 x 40 4 4 M20 x 50 4
SA/SAR 30.1-F30 Bolt Pcs.
M16 x 50 M16 x 50
8 8 M20 x 50 8
10
Worm gearboxes GS 50.3 GS 250.3 AUMA worm gearboxes GS and primary reduction gearings VZ/GZ can be operated in any mounting position. For butterfly valves, the recommended mounting position is end position CLOSED (Prior to mounting, bring the gearbox to the mechanical end stop CLOSED by turning the handwheel clockwise). For ball valves, the recommended mounting position is end position OPEN (Prior to mounting, bring the gearbox to the mechanical end stop OPEN by turning the handwheel counterclockwise).
7.
Mounting to valve
. . . . . . . .
Thoroughly degrease mounting faces of gearbox and valve. Place coupling sleeve onto valve shaft and secure (refer to figure 3, detail A or B), ensure that dimensions X, Y, and Z are observed (refer to table 2). Apply non-acidic grease at splines of coupling. Mount gearbox on valve. Ensure that the spigot (if provided) mates uniformly in the recess and that the mounting faces are in complete contact. Fasten gearbox with bolts (quality min. 8.8) and lock washers. Fasten bolts crosswise with a torque according to table 2.
A
Coupling Grub screw
Figure 3
Z Y
Valve
Table 2: Fastening torques for bolts with different strength classes Gearbox Flange type GS 50.3-F05 GS 50.3-F07 GS 50.3-F10 GS 63.3-F10 GS 63.3-F12 GS 80.3-F12 GS 80.3-F14 GS 100.3-F14 GS 100.3-F16 GS 125.3-F16 GS 125.3-F25 GS 160.3-F25 GS 160.3-F30 GS 200.3-F30 GS 200.3-F35 GS 250.3-F35 GS 250.3-F40 Dimensions X max Y max Z max 6 5 65 14 5 61 14 5 61 7 18 73 10 13 76 13 18 78 23 5 88 22 13 123 22 8 123 17 35 126 17 27 126 15 11 130 30 0 140 19 19 160 44 0 190 8 8 220 13 0 230 Bolts Qty. x threads 4xM 6 4xM 8 4 x M10 4 x M10 4 x M12 4 x M12 4 x M16 4 x M16 4 x M20 4 x M20 8 x M16 8 x M16 8 x M20 8 x M20 8 x M30 8 x M30 8 x M36 Strength class 8.8 11 25 51 51 87 87 214 214 431 431 214 214 431 431 (1489) (1489) (2594) Strength class Strength class A2-70/A4-70 A2-80/A4-80 Fastening torque TA [Nm] 8 10 18 24 36 48 36 48 61 82 61 82 150 200 150 200 294 392 294 392 150 200 150 200 294 392 294 392 564 564
Note: Experience showed that it is very difficult to fasten bolts or nuts of M30 or larger with the defined torques. The worm gearbox may be moved radially against the valve flange by accident. To improve adhesion between valve and gearbox, we recommend to apply Loctite 243 (or similar products) on mounting faces.
11
8.
Setting the end stops for manual operation

If worm gearboxes GS are supplied on a valve the end stops are already set.
8.1
Worm gearboxes on butterfly valves Setting end position CLOSED Remove all bolts (03) at limit stop housing (figures 4, 5). Turn valve manually to end position CLOSED. In case limit stop housing (10) has not yet rotated, turn it clockwise up to the stop. If the holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in the required position. Fasten bolts (03) with lock washers (04). Fasten bolts (see table 3) crosswise with a torque according to table 2.
Gearbox End stops fastened with bolts (03) M8 M8 M8 M12 M12 M10 M12 M16 Material protection cover fastened with bolts (054) Material
. . . . . .
Table 3:
A2-80 A2-80 A2-80 A2-80 A2-80 A2-80 A2-80 A2-80
M6 M6 M6
A2-80 A2-80 A2-80
Figure 4: End stop up to GS 125.3
Figure 5: End stop from GS 160.3
03/04
03/04
.
Setting end position OPEN
10
10
If the position of the pointer cover does not correspond to the symbol CLOSED, slightly loosen the screws of the pointer cover. Turn the pointer cover to the CLOSED symbol and fasten the screws again.
The end stop need not be set since the required swing angle has been set in the factory. If the swing angle does not match, refer to clause 10.
12
Operation instructions 8.2 Worm gearboxes on ball valves
Remove all bolts (03) at limit stop housing (10) (figures 4, 5). Turn valve manually to end position OPEN. In case limit stop housing (10) has not yet rotated, turn it counterclockwise up to the stop. If the holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in the required position. Fasten bolts (refer to table 3) crosswise with a torque according to table 2. Fasten bolts crosswise with a torque according to table 3. If the position of the pointer cover does not correspond to the symbol OPEN, slightly loosen the screws of the pointer cover. Turn the pointer cover to the OPEN symbol and fasten the screws again. Setting end position CLOSED The end stop need not be set since the required swing angle has been set in the factory. If the swing angle does not match, refer to clause 10.
. . . . . . .
In case end stops require adjustment, set end position OPEN first. If the exact end position of the valve cannot be seen through a position marking at the valve shaft, the setting may have to be done with the valve removed.
9.
Setting the end stops with mounted multi-turn actuator
. . .
9.1
Worm gearboxes on butterfly valves Determine the overrun of the multi-turn actuator for both directions, i. e. how much does the valve move after the motor has been switched off? Setting end position CLOSED Remove all bolts (03) at limit stop housing (figures 4, 5). Change actuator to manual drive and move the valve manually to end position CLOSED. In case limit stop housing (10) has not yet rotated, turn it clockwise up to the stop. Turn limit stop housing (10) back counterclockwise by turn. This ensures that the mechanical end stop is not reached in electric operation and thus the valve can close tightly, provided that torque seating has been specified. If the fixing holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in required position. Fasten bolts (03) with lock washers (04). Fasten bolts (refer to table 3) crosswise with a torque according to table 2. If the position of the pointer cover does not correspond to the symbol CLOSED, slightly loosen the screws of the pointer cover. Turn the pointer cover to the CLOSED symbol and fasten the screws again.
. . . . . . . . .
If worm gearboxes GS and multi-turn actuators are supplied on a valve, the end stops as well as limit and torque switching are already set. If the limit and torque switching have not yet been set, they have to be set according to the operation instructions SA/SAR and the specifications of the valve manufacturer. The valve manufacturer states whether the valve should be limit or torque seated.
13
. . . . . .
Limit seating in end position CLOSED Turn back the valve from the end position by an amount equal to the overrun. Set limit switching according to the operation instructions SA/SAR. Check torque switching for end position CLOSED according to the operation instructions SA/SAR, and, if necessary, set to the required value.
Torque seating in end position CLOSED Turn handwheel counterclockwise by approx. 4 6 turns. Set limit switching for the end position CLOSED according to the operation instructions SA/SAR (for signalisation). Check torque switching for end position CLOSED or set to the required value. The end stop need not be set since the required swing angle has been set in the factory. Move gearbox to the end stop in position OPEN. The last part of the travel has to be made manually.
. . .
To turn the valve back manually from the end position by an amount equal to the overrun, proceed as follows: For actuators mounted directly: by approx. 4 to 6 turns at the handwheel. With mounted primary reduction gearing VZ/GZ: by approx. 10 to 15 turns at the handwheel, according to the reduction ratio of the primary reduction gearing. Set limit switching in actuator for the end position OPEN according to the operation instructions SA/SAR. If the swing angle does not match, refer to clause 10.
03/04
03/04
10
10
9.2
Worm gearboxes on ball valves
In case end stops need to be adjusted, set end position OPEN first. If the exact end position of the valve cannot be seen through a position marking at the valve shaft, the setting may have to be done with the valve removed.
Determine overrun of the actuator for both directions, i. e. how much does the valve move after the motor has been switched off?
14
. . . . . . . . . . . . .
Remove all bolts (03) at limit stop housing (10) (figures 6, 7). Change to manual drive and move the valve manually to end position OPEN. In case limit stop housing (10) has not yet rotated, turn it counterclockwise up to the stop. Turn limit stop housing (10) back by turn clockwise. This ensures that the mechanical end stop is not reached in electric operation. If the holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in the required position. Fasten bolts (03) with lock washers (04). Fasten bolts (refer to table 3) crosswise with a torque according to table 2. If the position of the pointer cover does not correspond to the symbol OPEN, slightly loosen the screws of the pointer cover. Turn the pointer cover to the OPEN symbol and fasten the screws again. Turn back the valve from the end position by an amount equal to the overrun. Set limit switching according to the operation instructions SA/SAR.
Switching off in end position OPEN
Setting end position CLOSED The end stop need not be set since the required swing angle has been set in the factory. Move gearbox to the end stop in position CLOSED. The last part of the travel has to be made manually. To turn the valve back manually from the end position by an amount equal to the overrun, proceed as follows: For actuators mounted directly: by approx. 4 to 6 turns at the handwheel. With mounted primary reduction gearing VZ/GZ: by approx. 10 to 15 turns at the handwheel, according to the reduction ratio of the primary reduction gearing. Set limit switching in actuator for the end position CLOSED according to the operation instructions SA/SAR. If the swing angle does not match, refer to clause 10.
15
10. Changing the swing angle The adjustment is made in end position OPEN.
Optional for size GS 50.3 GS 125.3 Standard for size GS 160.3 GS 250.3 Accuracy: GS 50.3 GS 125.3: GS 160.3 GS 250.3: 0.6 0.11 to 0.14
10.1 Changing the swing angle for sizes GS 50.3 GS 125.3 (option) Unscrew protection cover (16) at limit stop housing (10) (figure 8). Remove roll pin (020) with appropriate tool (available from AUMA).
. . . . . . .
Increasing the swing angle Turn end stop nut (15) back counterclockwise. When turning back the end stop nut (015), make sure the roll pin (020) can still be tapped in within the oblong hole. Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7).
Reducing the swing angle Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). The end stop nut (15) must entirely cover the roll pin (020).
082/083 03/04 058
16 34 15
16 020 15 08 10
054 055
056 10
. . . .
Tap in roll pin (020) with tool. If slot in end stop nut (15) does not align with the hole in the worm shaft, turn end stop nut (15) slightly counterclockwise until it is in alignment, then tap in roll pin. Check O-ring (08) and replace, if damaged. Replace protection cover (16). If gearbox is mounted to a multi-turn actuator, set limit switching again for the end position OPEN according to the operation instructions SA/SAR. Allow for overrun.
16
Operation instructions 10.2 Changing the swing angle for sizes GS 160.3 GS 250.3
Increasing the swing angle Turn end stop nut (15) back counterclockwise. Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). Reducing the swing angle Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). Place setting ring (34), secure with washer (058) and screw (082). Check O-ring (056) and replace, if damaged. Place protection cover (16), fasten bolts (054) with lock washers (055). Fasten bolts (see table 3) crosswise with a torque according to table 2. If gearbox is mounted to a multi-turn actuator, set limit switching again for the end position OPEN according to the operation instructions SA/SAR. Allow for overrun.
. . . . . . . . . . . .
Remove all bolts (054) and pull off protection cover (16) (figure 9). Remove screw (082) with washer (058) and setting ring (34).
17
11. Enclosure protection IP 68

Definition According to EN 60 529, the conditions for meeting the requirements of enclosure protection IP 68 (requirements exceed those of IP 67) are to be agreed between manufacturer and user. AUMA worm gearboxes and primary reduction gearings in enclosure protection IP 68 meet the following requirements according to AUMA: IP 68-3, IP 68-6, IP 68-10, IP 68-20, submersible in water submersible in water submersible in water submersible in water up to up to up to up to 3 m head of water 6 m head of water 10 m head of water 20 m head of water
. . . .
Review
For size GS 50.3, only enclosure protection IP 68-3 is available. If submersed in other media, additional measures for corrosion protection may be necessary; please consult AUMA. Submersion in aggressive media, e.g. acids or alkaline solutions, is not permitted. Gearboxes in enclosure protection IP 68-3 were type tested in the factory. Gearboxes in enclosure protection IP 68-6, IP 68-10 and IP 68-20 undergo a routine testing for tightness in the factory.
Note:
. . . . . . . .
The enclosure protection IP 68 refers to the interior of the gearboxes, but not to the coupling compartment. If the gearboxes are likely to be repeatedly submersed, a higher corrosion protection KS or KX is required. For gearboxes intended for buried service we strongly recommend to use the higher corrosion protection KS or KX. For horizontal outdoor installation of the gearboxes, a sealed pointer cover should be used. For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided. In case of permanent submersion of the gearboxes or for buried service, a protection cover must be fitted instead of a pointer cover. This will be taken into account in the factory if indicated on the purchase order. Subsequent exchange of the pointer cover for the protection cover is possible. Use suitable sealing material between valve flange and gearbox. Water can enter into the coupling compartment along the valve shaft. This would lead to corrosion of hub and coupling. Therefore a suitable anticorrosive (or sticky grease) must be applied to the hub and coupling of the gearbox before mounting. With corrosion protection KX, the hub and coupling are provided with a high quality corrosion protection as standard.
18
12. Maintenance
12.1 General notes After commissioning, check worm gearbox for damage to paint finish. Do a thorough touch-up to prevent corrosion. Original paint in small quantities can be supplied by AUMA. AUMA worm gearboxes require only very little maintenance. To ensure that the worm gearbox is always ready to operate, we recommend for gearboxes operated less than 10 times per year, the following measures:
. . . . .
Approximately six months after commissioning and every year after, check bolts between multi-turn actuator, worm gearbox, and valve for tightness. If required, tighten applying the torques given in table 2 (page 11). Perform a test run every six months. Perform a visual inspection for grease leakage on each gearbox every 2 years. Carry out a detailed functional test for each gearbox every 5 years. Record the results for future reference. For gearboxes permanently exposed to ambient temperatures above 40 C, maintenance must be performed at shorter intervals.
Seals: Seals made of elastomer materials are subject to ageing. The theoretical usable lifetime of the seals made of NBR is 13.5 years from the date of manufacture. These figures are based on an average ambient temperature of 40 C. Seal kits may be obtained from AUMA. Grease: A grease and seal change is recommended after the following operation time: if operated seldom after 10 12 years if operated frequently, after 6 8 years in modulating duty after 4 6 years
. . .
. . .
Only original AUMA grease must be used. For the grease type, refer to the name plate. Lubricants should not be mixed.
Table 4: Grease quantities for worm gearboxes and primary reduction gearings GS Qty Weight1) Primary reduction gearing Quantity Weight1) dm kg dm kg 50.3 0.1 0.09 2.3 0.35 0.32 63.3 0.3 0.27 VZ 3.3 0.35 0.32 80.3 0.4 0.36 4.3 0.35 0.32 100.3 1.0 0.9 160.3 1.0 0.9 125.3 1.3 1.17 160.3 3.3 3.0 200.3 6.6 6.0 250.3 12.2 11.0
GZ 200.3 4:1/8:1 16:1 1.5 2.0 1.4 1.8
250.3 4:1/8:1 16:1 2.2 2.8 2.0 2.25
1) for = approx. 0.9 kg/dm3
The removed lubricant and the cleaning agent used must be disposed of according to the relevant regulations.
19
12.2 Grease change for worm gearboxes GS 50.3 GS 125.3 and primary reduction gearing VZ 2.3 VZ 4.3 For gearboxes with multi-turn actuator: Remove multi-turn actuator. Remove gearbox from the valve: During this time, the valve/pipeline must not be under pressure!
. . . . . . . . . . . .
12.2.1 Worm gearboxes
Refer to spare parts list GS 50.3 GS 125.3, page 24. Grease type, see name plate; grease quantities, see page 19, table 4. Mark position of the gearbox on the valve, loosen connecting bolts to the valve and remove the worm gearbox. Remove fastening bolts with lock washers from the housing cover (518.0) and take off housing cover. Remove bolts with lock washers from the bearing cover (522.0). Lift worm wheel carefully from the housing. For this, the worm shaft must be pulled from the bearings and tilted slightly in the worm channel. Remove old grease completely from the housing and the individual parts and clean gear housing. For this purpose, kerosene or a similar cleaning agent may be used. Clean mounting faces at housing and housing cover (518.0). Replace O-rings at the worm wheel [S1(010), S1(011)] by new ones. Re-insert worm wheel carefully and bring worm shaft into correct position, fasten bearing cover (522.0) at housing with bolts and lock washers. Fill with new grease. Place housing cover (518.0) on housing, while ensuring the proper position of the O-rings [S1(010), S1(011)] at the worm wheel. Place bolts with lock washers and fasten them evenly crosswise. Thoroughly degrease mounting faces at mounting flange. Apply non-acidic grease at splines of coupling Mount worm gearbox to valve, ensure correct position, observe mark Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts crosswise to the appropriate torque according to table 2, page 11. Gearbox without primary reduction gearing: Continue with clause After maintenance. Gearbox with reduction gearings VZ 2.3 VZ 4.3: Perform grease change at the reduction gearing according to the following subclause.
12.2.2 Primary reduction gearing
. . . . . . . .
20
Refer to spare parts list VZ 2.3 VZ 4.3., page 24. Grease type, see name plate; grease quantities, see page 19, table 4. Remove bolts with lock washers from housing cover (020.0) and pull off housing cover (020.0) with the complete drive shaft (021.0). Take off internal geared wheel (045.0) and planet carrier (022.0) with the planet wheels. Remove old grease completely from the housing and the individual parts and clean them. For this purpose, kerosene or a similar cleaning agent may be used. Clean mounting faces at housing (019.0), housing cover (020.0) and internal geared wheel (045.0). Replace O-rings by new ones. Insert planet carrier (022.0) with planet wheels. Fill with new grease. Place internal geared wheel (045.0) and insert the drive shaft (021.0) completely. Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. Continue with clause After maintenance, page 22.
12.3 Grease change for worm gearboxes GS 160.3 GS 250.3 and primary reduction gearing VZ 160.3 VZ 250.3
. .
For gearboxes with multi-turn actuator: Remove multi-turn actuator. Remove gearbox from the valve: During this time, the valve/pipeline must not be under pressure!
12.3.1 Worm gearboxes
Refer to spare parts list GS 160.3 GS 250.3, page 26. Grease type, see name plate; grease quantities, see page 19, table 4. Tools: Lock nut tool, can be obtained from AUMA.
. . . . . . . . . . . . . . . .
Mark position of the gearbox on the valve, loosen connecting bolts to the valve and remove the worm gearbox. Remove bolts with lock washers from the housing cover (518.0) and take off housing cover. Remove bolts with lock washers from the bearing cover (522.0). Take off bearing lock nut (537.0) by loosening the grub screw. Remove protection cover (536.0), pull off snap ring from end nut (526.0). Remove end stop (523.0). Lift worm wheel carefully from the housing. For this, the worm shaft must be pulled from the bearings and tilted slightly in the worm channel. Pull out worm shaft from housing in direction of the housing input. Remove old grease completely from the housing and the individual parts and clean gear-housing. For this purpose, kerosene or a similar cleaning agent may be used. Clean mounting faces at housing and housing cover (518.0). Replace O-rings at the worm wheel [S1(010), S1(011)] by new ones. Re-insert worm wheel carefully and bring worm shaft into correct position. Screw in bearing lock nut (537.0) and secure with grub screw. Fasten bearing cover (522.0) at the housing with bolts and lock nuts. Fill with new grease. Place housing cover (518.0) on housing, while ensuring the proper position of the O-rings [S1(010), S1(011)] at the worm wheel. Place bolts with lock washers and fasten them evenly crosswise. Thoroughly degrease mounting faces at mounting flange and valve. Apply non-acidic grease at splines of coupling. Mount worm gearbox to valve, ensure correct position, observe mark. Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts crosswise to the appropriate torque according to table 2, page 11. Gearbox without primary reduction gearing: Continue with clause After maintenance. Gearbox with reduction gearings GZ 160.3 GZ 250.3: Perform grease change at the reduction gearing according to the following clauses.
12.3.2 Single-stage reductions gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1 and 8:1) Refer to spare parts list GZ 160.3 GZ 250.3, page 28. Grease type, see name plate; grease quantities, see page 19, table 4. Remove bolts with lock washers at housing cover (002.0) and pull off housing cover (002.0) with the drive shaft (003.0) and the internal geared wheel). Remove screws from the internal geared wheel and separate the internal geared wheel from the drive shaft. Remove old grease completely from the housing and the individual parts and clean them. For this purpose, kerosene or a similar cleaning agent may be used. Clean mounting faces at housing (001.0), housing cover (002.0) and internal geared wheel. Replace O-rings by new ones. Fill housing cover (002.0) with new grease.
21
. . . . . . . . . . . . . . .
Operation instructions Fix internal geared wheel with screws at housing cover. Fill housing (001.0) with remaining grease and fit the complete housing cover with drive shaft (534.0). Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. Continue with clause After maintenance, page 22.
12.3.3 Double-stage primary reduction gearing GZ 200.3 GZ 250.3 (reduction ratio 16:1) Refer to spare parts list GZ 160.3 GZ 250.3, page 28. Grease type, see name plate; grease quantities, see page 19, table 4. Remove bolts with lock washers from housing cover (002.0) and pull off housing cover with the complete drive shaft (003.0). Take off screws with lock washers from housing frame (010.0) and remove housing frame with planet carrier and hollow wheel. Remove screws from the internal geared wheel and separate the internal geared wheel from the drive shaft (003.0). Remove screws from the second stage of the internal geared wheel and separate it from the pinion (011.1). Remove old grease completely from the housing and the individual parts and clean them. For this purpose, kerosene or a similar cleaning agent may be used. Clean mounting faces at housing (001.0), housing frame, housing cover (002.0) and hollow wheels. Replace O-rings by new ones. Fill housing (001.0) with new grease. Fix second stage of the internal geared wheel on housing frame (010.0). Replace complete housing frame. Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. Fill housing frame (010.0) and housing cover (002.0) with the remaining grease. Fix first stage of the internal geared wheel on the housing cover (002.0). Place complete housing cover with drive shaft onto housing frame. Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. If applicable, mount multi-turn actuator. Reset the end stops. For gearboxes with multi-turn actuator, check the setting of the limit switching according to the operation instructions for multi-turn actuators; if required, reset. Perform test run to ensure the proper function. Check worm gearbox for damage to paint finish. Do a thorough touch-up to prevent corrosion. Original paint in small quantities can be supplied by AUMA.
12.4 After maintenance
. . . . .
22
13. Disposal and recycling

AUMA gearboxes have an extremely long lifetime. However, they have to be replaced at one point in time. Our gearboxes have a modular design and may therefore easily be disassembled, separated and sorted according to materials, i.e.:
The following generally applies: Collect greases and oils during disassembly. As a rule, these substances are hazardous to water and must not be released into the environment. Arrange for controlled waste disposal of the disassembled material or for separate recycling according to materials. Observe the national regulations for waste disposal.
. . . . . .
various metals plastics greases and oils
14. Service
AUMA offers extensive services such as maintenance and inspection for gearboxes. Addresses of AUMA offices and representatives can be found on page 32 and on the Internet (www.auma.com).
23
15. Spare parts list worm gearboxes GS 50.3 GS 125.3 and reduction gearing VZ 2.3 VZ 4.3
24
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from liability. Delivered spare parts may slightly vary from the representation. No.
003.0 019.0 020.0 021.0 022.0 045.0 512.0 513.1 517.0 518.0 519.1 520.0 521.1 522.0 523.0 524.0 525.0 526.0 527.0 534.0 538.0 S1
Designation
Housing cover with drive shaft VZ Housing VZ Housing cover VZ Drive shaft VZ Planet carrier VZ Internal geared wheel VZ Flange for actuator Grub screw Housing Housing cover Worm wheel Worm shaft Travelling nut Bearing cover Limit stop housing Pointer cover Coupling End stop nut Protection cover Drive shaft Bearing cover with drive shaft Seal kit
Type
Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly
Sub-assembly
Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Set
25
16. Spare parts list worm gearboxes GS 160.3 GS 250.3
26
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from liability. Delivered spare parts may slightly vary from the representation. No.
512.0 513.1 517.0 518.0 519.1 520.0 521.1 522.0 523.0 524.0 525.0 526.0 527.0 534.0 536.0 537.0 538.0 S1
Designation
Flange for actuator Grub screw Housing Housing cover Worm wheel Worm shaft Travelling nut Bearing cover Limit stop housing Pointer cover Coupling End stop nut Protection cover Drive shaft Protection cover Lock nut Bearing cover with drive shaft Seal kit
Type
Sub-assembly
Sub-assembly
Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Set
27
17. Spare parts list reduction gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1)
GZ 160.1 GZ 250.1 4:1/8:1
GZ 200.1 GZ 250.1 16:1
28
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from liability. Delivered spare parts may slightly vary from the representation.
No. 001.0 002.0 003.0 006.0 007.0 008.0 010.0 011.1 512.0 513.1 534.0 S1 Housing Housing cover Housing cover with drive shaft Planetary gearing, first stage (GZ 160.3) Planetary gearing, first stage (GZ 200.3) Planetary gearing, first stage (GZ 250.3) Housing frame Pinion Flange for actuator Grub screw Drive shaft Seal kit Sub-assembly Set Sub-assembly Designation Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly
29
18. Declaration of Conformity and Declaration of Incorporation
30
Index
B Bolts for mounting actuators C Changing the swing angle Corrosion protection D Declaration of Conformity Declaration of Incorporation Disposal and recycling E Enclosure protection IP 68 F Fitting the handwheel H Handwheel 10 16 7 30 30 23 18 7 7 L Lubricant 20 S Safety instructions Service Setting the end stop with mounted multi-turn actuator Setting the end stops for manual operation Spare parts list GS 160.3 - GS 250.3 GS 50.3 - GS 125.3 GZ 160.3 - GZ 250.3 (4:1/8:1/16:1) Storage T Technical data Transport 3 23 13 12 26 24 28 7 4 7
M Maintenance 3,19 Manual operation 12 Motor operation 13 Mounting positions 8 Mounting the multi-turn actuators 9 Mounting to valve 11 P Packaging R Range of application 7 3
Information also available on the Internet:
Inspection records and further gearbox information can be downloaded directly from the Internet by entering the order no. or comm. no. (refer to name plate). Visit us at: http://www.auma.com
31
Europe
AUMA Riester GmbH & Co. KG Plant Mllheim DE-79373 Mllheim Tel +49 7631 809 - 0 Fax +49 7631 809 - 1250 riester@auma.com www.auma.com Plant Ostfildern-Nellingen DE-73747 Ostfildern Tel +49 711 34803 - 0 Fax +49 711 34803 - 3034 riester@wof.auma.com Service Center Cologne DE-50858 Kln Tel +49 2234 2037 - 9000 Fax +49 2234 2037 - 9099 Service@sck.auma.com Service Center Magdeburg DE-39167 Niederndodeleben Tel +49 39204 759 - 0 Fax +49 39204 759 - 9429 Service@scm.auma.com Service Center Bavaria DE-85386 Eching Tel +49 81 65 9017- 0 Fax +49 81 65 9017- 2018 Riester@scb.auma.com AUMA Armaturenantriebe GmbH AT-2512 Tribuswinkel Tel +43 2252 82540 Fax +43 2252 8254050 office@auma.at www.auma.at AUMA (Schweiz) AG CH-8965 Berikon Tel +41 566 400945 Fax +41 566 400948 RettichP.ch@auma.com AUMA Servopohony spol. s.r.o. CZ-10200 Praha 10 Tel +420 272 700056 / 704125 Fax +420 272 704125 auma-s@auma.cz www.auma.cz OY AUMATOR AB FI-02230 Espoo Tel +358 9 5840 22 Fax +358 9 5840 2300 auma@aumator.fi www.aumator.fi AUMA France S.A.R.L. FR-95157 Taverny Cedex Tel +33 1 39327272 Fax +33 1 39321755 info@auma.fr www.auma.fr AUMA ACTUATORS Ltd. GB- Clevedon Nort_inth Somerset BS21 6QH Tel +44 1275 871141 Fax +44 1275 875492 mail@auma.co.uk www.auma.co.uk AUMA ITALIANA S.r.l. a socio unico IT-20023 Cerro Maggiore (MI) Tel +39 0331 51351 Fax +39 0331 517606 info@auma.it www.auma.it AUMA BENELUX B.V. NL-2314 XT Leiden Tel +31 71 581 40 40 Fax +31 71 581 40 49 office@benelux.auma.com www.auma.nl
AUMA Polska Sp. z o.o. PL-41-310 Dabrowa Grnicza Tel +48 32 261 56 68 Fax +48 32 261 48 23 R.Ludzien@auma.com.pl www.auma.com.pl OOO Priwody AUMA RU-141400 Moscow region for mail: 124365 Moscow a/ya 11 Tel +7 495 221 64 28 Fax +7 495 221 64 38 aumarussia@auma.ru www.auma.ru ERICHS ARMATUR AB SE-20039 Malm Tel +46 40 311550 Fax +46 40 945515 info@erichsarmatur.se www.erichsarmatur.se GRNBECH & SNNER A/S DK-2450 Kbenhavn SV Tel +45 33 26 63 00 Fax +45 33 26 63 21 GS@g-s.dk www.g-s.dk IBEROPLAN S.A. ES-28027 Madrid Tel +34 91 3717130 Fax +34 91 7427126 iberoplan@iberoplan.com D. G. Bellos & Co. O.E. GR-13671 Acharnai Athens Tel +30 210 2409485 Fax +30 210 2409486 info@dgbellos.gr SIGURD SRUM A. S. NO-1300 Sandvika Tel +47 67572600 Fax +47 67572610 post@sigurd-sorum.no INDUSTRA PT-2710-297 Sintra Tel +351 2 1910 95 00 Fax +351 2 1910 95 99 industra@tyco-valves.com MEGA Endstri Kontrol Sistemieri Tic. Ltd. Sti. TR-06810 Ankara Tel +90 312 217 32 88 Fax +90 312 217 33 88 megaendustri@megaendustri.com.tr www.megaendustri.com.tr CTS Control Limited Liability Company UA-02099 Kiyiv Tel +38 044 566-9971, -8427 Fax +38 044 566-9384 v_polyakov@cts.com.ua
AUMA Chile Representative Office CL- La Reina Santiago de Chile Tel +56 22 77 71 51 Fax +56 22 77 84 78 aumachile@adsl.tie.cl LOOP S. A. AR-C1140ABP Buenos Aires Tel +54 11 4307 2141 Fax +54 11 4307 8612 contacto@loopsa.com.ar MAN Ferrostaal de Colombia Ltda. CO- Bogot D.C. Tel +57 1 401 1300 Fax +57 1 416 5489 dorian.hernandez@manferrostaal.com www.manferrostaal.com PROCONTIC Procesos y Control Automtico EC- Quito Tel +593 2 292 0431 Fax +593 2 292 2343 info@procontic.com.ec Corsusa International S.A.C. PE- Miralflores - Lima Tel +511444-1200 / 0044 / 2321 Fax +511444-3664 corsusa@corsusa.com www.corsusa.com PASSCO Inc. PR-00936-4153 San Juan Tel +18 09 78 77 20 87 85 Fax +18 09 78 77 31 72 77 Passco@prtc.net Suplibarca VE- Maracaibo Estado, Zulia Tel +58 261 7 555 667 Fax +58 261 7 532 259 suplibarca@intercable.net.ve
Sunny Valves and Intertrade Corp. Ltd. TH-10120 Yannawa Bangkok Tel +66 2 2400656 Fax +66 2 2401095 sunnyvalves@inet.co.th www.sunnyvalves.co.th/ Top Advance Enterprises Ltd. TW- Jhonghe City Taipei Hsien (235) Tel +886 2 2225 1718 Fax +886 2 8228 1975 support_int@auma-taiwan.com.tw www.auma-taiwan.com.tw
Australia
BARRON GJM Pty. Ltd. AU-NSW 1570 Artarmon Tel +61 294361088 Fax +61 294393413 info@barron.com.au www.barron.com.au
Asia
AUMA Actuators (Tianjin) Co., Ltd. CN-300457 Tianjin Tel +86 22 6625 1310 Fax +86 22 6625 1320 mailbox@auma-china.com www.auma-china.com AUMA (INDIA) PRIVATE LIMITED IN-560 058 Bangalore Tel +91 80 2839 4655 Fax +91 80 2839 2809 info@auma.co.in www.auma.co.in AUMA JAPAN Co., Ltd. JP-210-0848 Kawasaki-ku, Kawasaki-shi Kanagawa Tel +81 44 329 1061 Fax +81 44 366 2472 mailbox@auma.co.jp www.auma.co.jp AUMA ACTUATORS (Singapore) Pte Ltd. SG-569551 Singapore Tel +65 6 4818750 Fax +65 6 4818269 sales@auma.com.sg www.auma.com.sg AUMA Actuators Middle East W.L.L. AE- 15268 Salmabad 704 Tel +973 17877377 Naveen.Shetty@auma.com PERFECT CONTROLS Ltd. HK- Tsuen Wan, Kowloon Tel +852 2493 7726 Fax +852 2416 3763 joeip@perfectcontrols.com.hk DW Controls Co., Ltd. KR-153-803 Seoul Korea Tel +82 2 2113 1100 Fax +82 2 2113 1088/1089 sichoi@actuatorbank.com www.actuatorbank.com 2009-01-01
Africa
AUMA South Africa (Pty) Ltd. ZA-1560 Springs Tel +27 11 3632880 Fax +27 11 8185248 aumasa@mweb.co.za A.T.E.C. EG- Cairo Tel +20 2 23599680 - 23590861 Fax +20 2 23586621 atec@intouch.com
America
AUMA ACTUATORS INC. US-PA 15317 Canonsburg Tel +1 724-743-AUMA (2862) Fax +1 724-743-4711 mailbox@auma-usa.com www.auma-usa.com AUMA Automao do Brasil ltda. BR-Sao Paulo Tel +55 11 8114-6463 bitzco@uao.com.br
AUMA Riester GmbH & Co. KG P.O. Box 1362 79373 Mllheim, Germany Tel +49 7631 - 809-0 Fax +49 7631 - 809 1250 riester@auma.com www.auma.com
AUMA Riester GmbH & Co. KG P. O. Box 1151 D - 73747 Ostfildern Tel +49 711 - 34803 0 Fax +49 711 - 34803 34 riester@wof.auma.com www.auma.com
For detailed information on AUMA products, refer to the Internet
www.auma.com
Y003.822/003/en /2.09
AC01
13122204
F 98220770
AC01
13130176
F 98221102

084010-3205m403-1 Omim Verdelet Auma

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

084010-3205m403-1 Omim Verdelet Auma

Uploaded by

Copyright:

Available Formats

RAAS LAFFAN C DESALINATION PLANT 084010

VERDELET CONTROL VALVES OPERATION MAINTENANCE INSTRUCTION MANUAL

Part 1 Part 2 Part 3

Equipment list Control valves sizing Dimensional drawings

Instruction manual for electric actuators & accessories

PW TRANSFERT PPS RECYCLE FLOW CTRL VV VERDELET VALSTAR DN350 (SS)

TZIDC, TZIDC-110, TZIDC-120

Commissioning Instructions Electro-Pneumatic Positioner TZIDC, TZIDC-110, TZIDC-120

Electro-Pneumatic Positioner TZIDC, TZIDC-110, TZIDC-120

3.2.1 3.2.2 3.2.3 4 4.1 4.2 4.3 5 6

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Ex relevant safety instructions

Ex relevant safety instructions

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Required tools: Wrench, size 10 / 13 Allen key, size 4

TZIDC, TZIDC-110, TZIDC-120

2. Mount the lever and bracket on the positioner

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Required tools: Wrench, size 10 / 13 Allen key, size 3

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Fig. 11 1 Mounting bracket 3. Attach positioner to the actuator

TZIDC, TZIDC-110, TZIDC-120

Electrical connection 4 Electrical connection

Fig. 13: Terminal connection diagram A Basic model B Options

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Fig. 17: Cable entry 1 Pipe plug 2 Cable gland

TZIDC, TZIDC-110, TZIDC-120

Pneumatic connection 5 Pneumatic connection

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Press and release

with adaptation (the control parameter)

without adaptation (the control parameter) in the operating range.

TZIDC, TZIDC-110, TZIDC-120

. On completion of the countdown from 3 to 0,

TZIDC, TZIDC-110, TZIDC-120

as often as required to display the selected operating mode

to adjust the setpoint in the operating range

in the sensor range

1) Positioning not active. 2) for high-speed mode: Press

TZIDC, TZIDC-110, TZIDC-120

Ex relevant specifications 7 Ex relevant specifications

Housing surface temperature T81 C T61 C T51 C

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Type and marking

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

TZIDC, TZIDC-110, TZIDC-120

Shutdown contact input (Terminal +85 / -86)

TZIDC, TZIDC-110, TZIDC-120