084010-3205m403-1 Omim Verdelet Auma

RAAS LAFFAN C DESALINATION PLANT

084010

SUMMARY - PAGE- 2 -

VERDELET

CONTROL VALVES

OPERATION MAINTENANCE INSTRUCTION MANUAL

Doc Nr 3205 M 403

Part 1 Equipment list

Part 2 Control valves sizing

Part 3 Dimensional drawings

3.1/ DxxTWL10AA071

3.2/ D00TXS19AA051 / D00TXS19AA052

3.3/ D00TXP71AA051

Part 4 Instruction manual for control valves VERDELET

Part 5 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

1

EQUIPMENT

LIST

EQUIPMENT LIST

Description Reference

D11 TWL10AA071 LP STM TO LP ST PRESSURE CTRL VV VERDELET VALSTAR DN700 (CS)










D00 TXP71AA071 PW TRANSFERT PPS RECYCLE FLOW CTRL VV VERDELET VALSTAR DN350 (SS)

D00 TXS19AA051 SEA WATER PUMPS MINI FLOW CTRL VALVE VERDELET VALSTAR DN900 (SS) + remote installation

D00 TXS19AA052 SEA WATER PUMPS MINI FLOW CTRL VALVE VERDELET VALSTAR DN900 (SS) + remote installation

Tag Nr

1 / 1

2

SIZING

CALCULATIONS

3

DIMENSIONAL

DRAWINGS

1. DxxTWL10AA071

2. D00TXS19AA051 / D00TXS19AA052

3. D00TXP71AA051

4

INSTRUCTION

MANUALS

- CONTROL VALVES -

5

INSTRUCTION

MANUALS

- PNEUMATIC ACTUATOR &

ACCESSORIES -

1. Actuators ROTORK 2. Positioner ABB - Operating Instruction 3. Positioner ABB - Commissioning instructions

4. Filter Regulator NORGREN 5. 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 Schillerstraße 72 32425 Minden Germany Tel.: +49 551 905-534 Fax: +49 551 905-555 [email protected]

© 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.

Content

s

mailto:[email protected]

Contents

2 - EN TZIDC, TZIDC-110, TZIDC-120 CI/TZIDC/110/120-EN

1 Safety....................................................................................................................................................................4 1.1 General information and notes for the reader ................................................................................................4 1.2 Intended use...................................................................................................................................................4 1.3 Target groups and qualifications ....................................................................................................................5 1.4 Warranty provisions........................................................................................................................................5 1.5 Plates and symbols ........................................................................................................................................6

1.5.1 Safety/warning symbols, note symbols...................................................................................................6 1.6 Safety information for electrical installation....................................................................................................7 1.7 Operating safety information ..........................................................................................................................7

2 Ex relevant safety instructions ..........................................................................................................................7 3 Mounting ..............................................................................................................................................................8

3.1 Operating conditions at installation site..........................................................................................................8 3.2 Mechanical mount ..........................................................................................................................................8

3.2.1 General....................................................................................................................................................8 3.2.2 Mounting on linear actuators.................................................................................................................10 3.2.3 Mounting on rotary actuators ................................................................................................................14

4 Electrical connection ........................................................................................................................................17 4.1 Screw terminal assignments ........................................................................................................................18 4.2 Jumper configuration on mainboard (TZIDC-120 only)................................................................................19 4.3 Cable entry ...................................................................................................................................................20

5 Pneumatic connection ......................................................................................................................................21 6 Commissioning..................................................................................................................................................23

6.1 TZIDC...........................................................................................................................................................23 6.1.1 Operating modes...................................................................................................................................24

6.2 TZIDC-110 / TZIDC-120...............................................................................................................................25 6.2.1 Operating modes...................................................................................................................................26

7 Ex relevant specifications ................................................................................................................................27 7.1 TZIDC...........................................................................................................................................................27

7.1.1 ATEX.....................................................................................................................................................27 7.1.2 IECEx Issue No. 3.................................................................................................................................29 7.1.3 CSA International ..................................................................................................................................31 7.1.4 CSA Certification Record ......................................................................................................................33

7.2 TZIDC-110....................................................................................................................................................34 7.2.1 EC-Type-Examination Test Certificate..................................................................................................34 7.2.2 IECEx Issue No. 3.................................................................................................................................35 7.2.3 CSA International ..................................................................................................................................37 7.2.4 CSA Certification Record ......................................................................................................................38 7.2.5 FM Approvals ........................................................................................................................................39

7.3 TZIDC-120....................................................................................................................................................40 7.3.1 EC-Type-Examination Test Certificate..................................................................................................40 7.3.2 IECEx Issue No. 3.................................................................................................................................41 7.3.3 CSA International ..................................................................................................................................43

Contents

CI/TZIDC/110/120-EN TZIDC, TZIDC-110, TZIDC-120 EN - 3

7.3.4 CSA Certification Record ......................................................................................................................44 7.3.5 FM Approvals ........................................................................................................................................45

Safety


1 Safety

1.1 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.

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.

Safety

1.5 Plates and symbols

1.5.1 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.


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.

2 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 unit’s 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.


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 Mechanical mount

3.2.1 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).


Mounting

M00410

1 2

34

+30° +60°

-60°-30°

+100°

+100°

0°

0°

VOITH

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°.


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


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))


Mounting

3.a Mounting on cast iron yoke

Fig. 6

• Attach the mount bracket (2) with screw (4) and shim (3) to the cast iron yoke (1)

or

3.b Mounting on columnar yoke

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.


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: between -28 ... 28°

Minimum angle: 25°

Important After mounting the unit check whether the positioner is operating within the sensor range.


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


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 pre-adjusted 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


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.


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 Analog input / Bus connector 2 Digital input 1) 3 Digital output 1) 4 Digital feedback 1) 5 Analog feedback 1) 6 Proximity switches 7 Microswitches 8 Emergency shutdown module

1) TZIDC only

Important Keep cable shields as short as possible and connect on both sides.



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

6 Digital output DO 1) 7 Digital input DI 1) 8 Signal 4 ... 20 mA / Bus connector 9 Grounding screw

1) TZIDC only



4.2 Jumper configuration on mainboard (TZIDC-120 only)

M00494

1

2

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:

M00495

1

2

Fig. 16 1 Block (Simulation blocked 1)) 2 Activate (Write access enabled 1))

1) Default setting (complies with Fieldbus Foundation standard)



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


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


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 Pipe connection

- Air supply, pressure 1.4 ... 6 bar (20 ... 90 psi)

OUT1 Output pressure for actuator

OUT2 Output pressure for actuator (2nd connection with double-acting actuator)

Commissioning

6 Commissioning

6.1 TZIDC bieten

1. Feed in pneumatic supply power

2. Feed in electrical supply power

• Feed in setpoint current 4 ... 20 mA (terminals +11 / -12)

3. Check mount:

• 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

Minimum angle: 25°

4. Run Autoadjust

Important Autoadjust is available for software version 2.XX and higher.

For linear actuators 1):

• Press and hold until is displayed. Release the control button

• Press again and hold until the countdown ends

• Release . This starts the Autoadjust

For rotary actuators 1):

• Press and hold until is displayed. Release the control button

• Press and hold till the countdown ends

• Release . 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)).


Commissioning

6.1.1 Operating modes

Selection from the operating level:

• Press and hold

• Press and release rapidly as often as required. The selected operating mode is displayed

• Release

• The position is displayed in % or as a rotation angle

Operating mode Mode indicator Position indicator

1.0

Control mode 1)

with adaptation (the control parameter) conf

mA%

C°

conf

mA%

C°

1.1

Control mode 1)

without adaptation (the control parameter) conf

mA%

C°

conf

mA%

C°

1.2

Manual adjustment 2) in the operating range.

Adjust via or 3) conf

mA%

C°

conf

mA%

C°

1.3

Manual adjustment 2) in the sensor range.

Adjust via or 3) conf

mA%

C°

conf

mA%

C°

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


Commissioning

6.2 TZIDC-110 / TZIDC-120 bieten

1. Feed in pneumatic auxiliary power

2. Connect the bus to the bus terminals with any polarity (or auxiliary power 9 ... 32 V DC),

mA%

C°

is displayed

3. Check mount:

• Press and hold down and . On completion of the countdown from 3 to 0, release and . The unit switches to the operating level, mode 1.x

• Press and hold down 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 . On completion of the countdown from 3 to 0, release and ,

mA%

C°

is displayed.

5. Run Autoadjust.

• Check that the unit is on the bus level ("REMOTE")

For linear actuators 1):

• Press and hold down until is displayed. Release the control button

• Press again and hold down until the countdown ends

• Release . This starts Autoadjust

For rotary actuators 1):

• Press and hold down until is displayed. Release the control button

• Press again and hold down until the countdown ends

• Release . This starts Autoadjust


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 as often as required to display the selected operating mode

• Release

• The position is displayed in % or as a rotation angle

Operating mode Mode indicator Position indicator

1.1

Positioning with fixed setpoint

Use or to adjust the setpoint conf

mA%

C°

conf

mA%

C°

1.2

Manual adjustment 1) in the operating range

Adjust with or 2) conf

mA%

C°

conf

mA%

C°

1.3

Manual adjustment 1) in the sensor range

Adjust with or 2) conf

mA%

C°

conf

mA%

C°

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


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 TZIDC

7.1.1 ATEX

ATEX II 2G Ex ia IIC T6

II 2G Ex ib IIC T6

II 2G Ex iaD 21 T51 °C Type-Examination Test Certificate: TÜV 04 ATEX 2702 X Type: Intrinsically safe equipment Device class: II 2G (EEx ia IIC)

II 2G (Eex ib IIC) Standards: EN 60079-0:2006

EN 60079-11:2007 EN 61241-0:2006 EN 61241-11:2006

Temperature class Ambient temperature range (II 2 G) T4 -40 ... 85 °C T5 -40 ... 50 °C

T6 1) -40 ... 40 °C 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 Ambient temperature range (II 2 D) T81 °C -40 ... 70 °C T61 °C -40 ... 50 °C T51 °C -40 ... 40 °C



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 (Terminal +11 / -12)

Maximum values: Ui = 30 V Ii = 320 mA Pi = 1.1 W Ci = 6.6 nF Li negligibly small

Contact input (Terminal +81 / -82)


Contact output (Terminal +83 / -84)

Maximum values: Ui = 30 V Ii = 320 mA Pi = 500 mW Ci = 4.2 nF Li negligibly small

Mechanical digital feedback (Terminals Limit1 +51 / -52 or Limit2 +41 / -42)

For max. values, see EC-type-examination test certificate number PTB 00 ATEX 2049 X Proximity switches manuf. by Pepperl & Fuchs

Plug-in module for digital position feedback (Terminal +51 / -52) or +41 / -42)

Maximum values: Ui = 30 V Ii = 320 mA Pi = 500 mW Ci = 3.7 nF Li negligibly small

Plug-in module for analog position feedback (Terminal +31 / -32)


Plug-in module for shutdown contact input (Terminal +51 / -52) or +85 / -86)

Ui = 30 V Ii = 320 mA Pi = 1.1 W Ci = 3.7 nF Li negligibly small

Local communication interface (LKS)

Only for connection to a programmer outside the potentially 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".




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

Ex nL IIC T6 Certificate No.: IECEx TUN 04.0015X Issue No.: 3 Typ: Intrinsic safety "i", Type of protection "n" Standards: IEC 60079-0:2000

IEC 60079-11:1999 IEC 60079-15:2001 IEC 60079-27:2005-04

Type and marking TZIDC

Ex ia IIC resp. Ex ib IIC

TZIDC

Ex nA IIC resp. Ex nL IIC

Temperature Class Ambient temperature range T4 -40 ... 85 °C -40 ... 85 °C T5 -40 ... 50 °C -40 ... 65 °C T6 -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 (Terminals +11 / -12)

Ui = 30 V li = 320 mA Pi = 1.1 W effective internal capacitance: Ci = 6.6 nF The effective internal inductance is negligibly small.

Switch input (Terminals +81 / -82)


Switch output (Terminals +83 / -84)

Ui = 30 V li = 320 mA Pi = 500 mW effective internal capacitance: Ci = 4.2 nF The effective internal inductance is negligibly small.

Local interface for communication (LKS)

For the connection to a programmer outside of the explosiv hazardous area only.


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 feedback (Terminals +51 / -52 resp. +41 / -42)

Ui = 30 V li = 320 mA Pi = 500 mW effective internal capacitance: Ci = 3.7 nF The effective internal inductance is negligibly small.

Plug-In module for analogue feedback (Terminals +31 / -32)


Plug-In module for shutdown-function (Terminals +51 / -52 resp. +85 / -86)


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 (Terminals +11 / -12) U = 9.7 VDC; 4 ... 20 mA, max. 21.5 mA

Switch input (Terminals +81 / -82) U = 12 ... 24 VDC; 4 mA

Switch output (Terminals +83 / -84) U = 11 VDC

Optionally the following modules are allowed to be used with type TZIDC Plug-In module for digital feedback (Terminals +51 / -52 resp. +41 / -42)

U = 5 ... 11 VDC

Plug-In module for analogue feedback (Terminals +31 / -32)

U = 10 ... 30 VDC; 4 ... 20 mA, max. 21.5 mA

Additionally the following modules are allowed to be used with all types marked Ex nA IIC T6 Plug-In module for shutdown-function (Terminals +51 / -52 resp. +85, -86)

U = 20 ... 30 VDC

Mechanical digital feedback (Terminals Limit1 +51 / -52 resp. Limit2 +41 / -42)

U = 5 ... 11 VDC




7.1.3 CSA International

Certificate: 1052414 Class 2258 02 PROCESS CONTROL EQUIPMENT –For

Hazardous Locations Class 2258 04 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 30 V DC; max. 4 ... 20 mA

Max output pressure 90 psi

Max. ambient 85 Deg C


Class II, Div 1, Groups E, F and G


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 41 / 42 and 51 / 52

V max = 30 V I max = 96 mA Ci = 3.7 nF Li = 0 uH

Terminals Limit2 41 / 42 and Limit1 51 / 52

V max = 15.5 V 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.



7.1.4 CSA Certification Record

Certificate: 1649904 (LR 20312) Class 2258 04 PROCESS CONTROL EQUIPMENT –




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 41 / 42 and 51 / 52

V max = 30 V I max = 96 mA Ci = 3.7 nF Li = 0 uH

Terminals Limit2 41 / 42 and Limit1 51 / 52

V max = 15.5 V I max = 52 mA Ci = 20 nF Li = 30 uH


Notice






7.2 TZIDC-110

7.2.1 EC-Type-Examination Test Certificate

Designation: II 2 G EEx ia IIC T6 Type-Examination Test Certificate: TÜV 02 ATEX 1831 X Type: Intrinsically safe equipment Standards: EN 50014:1997

EN 50020:1994

Temperature class Ambient temperature range T4 -40 ... 85 °C T5 -40 ... 55 °C T6 -40 ... 40 °C

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

FISCO power supply


Barriers or power supply

ia/ib for Grp. IIB/IIC Voltage 17.5 V 17.5 V 24 V Current 380 mA 360 mA 250 mA Power 5.32 W 2.52 W 1.2 W Characteristic rectangular trapezoidal linear Li negligibly small

Ci negligibly small

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

Shutdown contact input (Terminal +85 / -86)

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

Local communication interface (LKS) and program interface (X5)

Only for connection to a programmer or PC outside the potentially explosive area.

Important

• The local communication interface (LKS) and program interface (X5) may only be operated outside the potentially explosive area.





IECEx Ex ia IIC T6

Ex nA II T6


IEC 60079-11:1999 IEC 60079-15:2001 IEC 60079-27:2005-04

Type and marking TZIDC-110


TZIDC-110


Temperature Class Ambient temperature range T4 -40 ... 85 °C -40 ... 85 °C T5 -40 ... 55 °C -40 ... 65 °C T6 -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 (terminals +11, -12 or +, -)

In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) 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



ia/ib for Grp. IIB/IIC Voltage Ui = 17.5 V Ui = 24 V Current li = 380 mA li = 250 mA Power Pi = 5.32 W Pi = 1.2 W Characteristic line

Linear

Local interface for communication (LKS) and programming interface (X5)

For the connection to a programmer resp. a PC outside of the explosive hazardous area only.




Plug-In module for shutdown-function (terminals +51 / -52 resp. +85 / -86)


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 (terminals +11 / -12) U = 9 ... 32 VDC; 10.5 mA

Additionally the following modules are allowed to be used with all types marked Ex nA IIC T6 Plug-In module for shutdown-function (terminals +51 / -52 resp. +85 / -86)

U = 20 ... 30 VDC

Mechanical digital feedback (terminals Limit1 +51 / -52 resp. Limit2 +41 / -42)

U = 5 ... 11 VDC

Electrical data for type TZIDC-110 with marking Ex nL IIC T6 Input circuit (terminals +11 / -12) FNICO field device






Class 2258 02 PROCESS CONTROL EQUIPMENT – For Hazardous Locations




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



Notice












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




Notice







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

Parameters Terminals Type Groups

Vmax Imax Pi Ci Li

+11 / -12 Entity A-G 24 V 250 mA 1.2 W 2.8 nF 7.2 uH

+11 / -12 FISCO A-G 17.5 V 360 mA 2.52 W 2.8 nF 7.2 uH

+11 / -12 FISCO C-G 17.5 V 380 mA 5.32 W 2.8 nF 7.2 uH

+51 / -52 Entity A-G 16 V 20 mA - 60 nF 100 uH


+85 / -86 Entity A-G 30 V - - 3.7 nF < 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




7.3 TZIDC-120 ht c

7.3.1 EC-Type-Examination Test Certificate

Designation: II 2 G EEx ia IIC T6 Type-Examination Test Certificate: TÜV 02 ATEX 1834 X Type: Intrinsically safe equipment Standards: EN 50014:1997

EN 50020:1994

Temperature class Ambient temperature range T4 -40 ... 85 °C T5 -40 ... 55 °C T6 -40 ... 40 °C

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


FISCO power supply



ia/ib for Grp. IIB/IIC Voltage 17,5 V 17,5 V 24 V Current 380 mA 360 mA 250 mA Power 5.32 W 2.52 W 1.2 W Characteristic rectangular trapezoidal Linear Li negligibly small

Ci negligibly small

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

Shutdown contact input (Terminal +85 / -86)

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

Local communication interface (LKS) and program interface (X5)

Only for connection to a programmer or PC outside the potentially explosive area.

Important

• The local communication interface (LKS) and program interface (X5) may only be operated outside the potentially explosive area.





IECEx Ex ia IIC T6

Ex nA II T6


IEC 60079-11:1999 IEC 60079-15:2001 IEC 60079-27:2005-04

Type and marking TZIDC-120


TZIDC-120


Temperature Class Ambient temperature range T4 -40 … 85 °C -40 … 85 °C T5 -40 … 55 °C -40 … 65 °C T6 -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 (terminals +11 / -12 or (+ / -)

In type of protection "Intrinsic Safety" (Ex ia IIC resp. Ex ib IIC) 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



ia/ib for Grp. IIB/IIC Voltage Ui = 17.5 V Ui = 24 V Current li = 380 mA li = 250 mA Power Pi = 5.32 W Pi = 1.2 W Characteristic line

Linear

Local interface for communication (LKS) and programming interface (X5)

For the connection to a programmer resp. a PC outside of the explosive hazardous area only.




Plug-In module for shutdown-function (terminals +51 / -52 resp. +85 / -86)


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 (terminals +11 / -12) U = 9 … 32 VDC; 11.5 mA

Additionally the following modules are allowed to be used with all types marked Ex nA IIC T6 Plug-In module for shutdown-function (terminals +51 / -52 resp. +85 / -86)

U = 20 … 30 VDC

Mechanical digital feedback (terminals Limit1 +51 / -52 resp. Limit2 +41 / -42)

U = 5 … 11 VDC

Electrical data for type TZIDC-120 with marking Ex nL IIC T6 Input circuit (terminals +11 / -12) FNICO field device






Class 2258 02 PROCESS CONTROL EQUIPMENT – For Hazardous Locations




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





Notice












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




Notice







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

Parameters Terminals Type Groups

Vmax Imax Pi Ci Li

+11 / -12 Entity A-G 24 V 250 mA 1.2 W 2.8 nF 7.2 uH

+11 / -12 FISCO A-G 17.5 V 360 mA 2.52 W 2.8 nF 7.2 uH

+11 / -12 FISCO C-G 17.5 V 380 mA 5.32 W 2.8 nF 7.2 uH



+85 / -86 Entity A-G 30 V - - 3.7 nF < 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:






n

ABB has Sales & Customer Support expertise in over 100 countries worldwide. www.abb.com/instrumentation

The Company’s 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)

© ABB 2009

3KXE341007R4401

CI/T

ZID

C/1

10/1

20-E

N

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 [email protected]

B72GInstallation & Maintenance

InstructionsFilter/RegulatorB72G - ★★★ - ★★★ - ★★★

Thread FormA....PTFB....ISO Rc taperG....ISO G parallel

3. Push bowl, or bowl with guard, into body and turn fullyclockwise before pressurizing.

4. Install a pressure gauge or plug gauge ports. Gaugeports can also be used as additional outlets for regulatedair.

5. Plastic tube used on semi automatic drain is packedloose inside the shipping box. Push plastic tube over tipof semi automatic drain.

ADJUSTMENT1. Before applying inlet pressure to filter/regulator, turn

adjustment (1 or 7) counterclockwise to remove all forceon regulating spring (12).

2. Apply inlet pressure, then turn adjustment (1 or 7)clockwise to increase and counterclockwise to decreasepressure setting.

3. Always approach the desired pressure from a lowerpressure. When reducing from a higher to a lowersetting, first reduce to some pressure less than thatdesired, then bring up to the desired pressure.

NOTEWith non-relieving filter/regulators, make pressurereductions with some air flow in the system. Ifmade under no flow (dead-end) conditions, thefilter/regulator will trap the over-pressure in thedownstream line.

4. KNOB ADJUSTMENT. Push knob down to lock pressuresetting. Pull knob up to release. Install tamper resistantcover (see Replacement Items) to make setting tamperresistant.

5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lockpressure setting.

SERVICING1. Open manual drain to expel accumulated liquids. Keep

liquids below baffle (52).2. Clean or replace filter element when dirty.DISASSEMBLY1. 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 drainsunless replacement is necessary. Remove and replacedrains only if they malfunction.

CLEANING1. 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 throughfilter element (53) from inside to outside to removesurface contaminants.

3. Inspect parts. Replace those found to be damaged.Replace plastic bowl with a metal bowl if plastic bowlshows signs of cracking or cloudiness.

ASSEMBLY1. 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. Pushbowl, or bowl with guard, into body and turn fullyclockwise.

3. Torque TableItem 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)

TECHNICAL DATAFluid: Compressed airMaximum pressure:

Transparent bowl: 10 bar (150 psig)Metal bowl: 17 bar (250 psig)

Operating temperature*: Transparent bowl: -20° to +50°C (0° to +125°F)Metal bowl: -20° to +65°C (0° to +150°F)

* Air supply must be dry enough to avoid ice formation attemperatures below +2°C (+35°F).

Particle removal: 5 µm, 25 µm, or 40 µm filter elementAir 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 tubeSemi 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 outletNominal bowl size:

Short bowl: 56 ml (1.9 fluid ounce)Long bowl: 65 ml (2.2 fluid ounce)

Gauge ports: 1⁄8 PTF with PTF main portsRc1/8 with ISO Rc and ISO G main ports

Materials:Body: ZincBonnet: AcetalValve: BrassBowl:

Transparent: PolycarbonateTransparent with guard: Polycarbonate, steel guardMetal: ZincMetal bowl liquid level indicator lens: Transparent

nylon Element: Sintered polypropyleneElastomers: Neoprene and nitrile

REPLACEMENT ITEMSService Kit (includes items circled on exploded view):

Relieving.............................................................4383-500Nonrelieving .......................................................4383-501

Liquid level lens kit (46, 48, 49, 50) ......................4380-030Filter element, 5µm (53) ..........................................5925-03Filter element, 25µm (53) ........................................5925-01Filter element, 40µm (53) ........................................5925-02Manual drain (18,19,20) (31,32,33) (40,41,42).........619-50Semiauto drain (21,22,23) (34,35,36) (43,44,45) ...5379-50Auto drain (24,25,26) (36A,36B,36C)....................4000-50RTamper resistant cover (knob adjustment only).......4255-51PANEL MOUNTING DIMENSIONSPanel mounting hole diameter: 40 mm (1.57")Panel thickness: 2 to 4 mm (0.06" to 0.16")INSTALLATION1. Shut off air pressure. Install filter/regulator in air line -

● vertically (bowl down),● with air flow in direction of arrow on body,● upstream of lubricators and cycling valves,● as close as possible to the device being serviced.

2. Connect piping to proper ports using pipe thread sealanton male threads only. Do not allow sealant to enterinterior of unit.

IM-160.300.01 (4/98)a subsidiary of IMI plc

© Norgren 1998

Port2 ....1/4"3 ....3/8"

* 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.

Spring (Outlet Pressure Range) *C....0,3 to 2 bar (5 to 30 psig)F ....0,3 to 4 bar (5 to 60 psig)M...0,3 to 10 bar (5 to 150 psig)

GaugeG....WithN....Without

DiaphragmN....Non-relievingR....Relieving

AdjustmentK....KnobT ....T-bar

DrainA....AutomaticQ....Manual, 1/4 turnS....Semi automatic

BowlD....Short metal with liquid level indicator T ....Short transparent without guardL ....Long transparent without guardW...Long transparent with guard

Element1 ....5 µm2 ....25 µm3....40 µm

50

47

4649

17

18

27

20

19

31

33

32

40

42

41

51

48

30

39

21

23

22

34

35

43

45

44

28

29

25

24

26

38

37

36B

36A

36C36

1

3

4

5

2

12

13

16

14

15

11

7

8

9

10

6

58

56

55

54

53

52

59

57

CAUTIONWater vapor will pass through these units and couldcondense into liquid form downstream as air temperaturedrops. Install an air dryer if water condensation could havea detrimental effect on the application.

WARNINGThese products are intended for use in industrial

compressed air systems only. Do not use these productswhere pressures and temperatures can exceed those listedunder Technical Data.

Polycarbonate plastic bowls can be damaged andpossibly burst if exposed to such substances as certainsolvents, strong alkalies, compressor oils containing ester-based additives or synthetic oils. Fumes of thesesubstances in contact with the polycarbonate bowl,externally or internally, can also result in damage. Cleanwith warm water only.

Use metal bowl in applications where a plastic bowlmight be exposed to substances that are incompatible withpolycarbonate.

If outlet pressure in excess of the filter/regulatorpressure setting could cause downstream equipment torupture or malfunction, install a pressure relief devicedownstream of the filter/regulator. The relief pressure andflow capacity of the relief device must satisfy systemrequirements.

The accuracy of the indication of pressure gauges canchange, both during shipment (despite care in packaging)and during the service life. If a pressure gauge is to beused with these products and if inaccurate indications maybe hazardous to personnel or property, the gauge should becalibrated before initial installation and at regular intervalsduring use.

Before using these products with fluids other than air,for non industrial applications, or for life-support systemsconsult Norgren.

IM-160.300.02 (4/98)a subsidiary of IMI plc

© Norgren 1998

B72GInstallation & Maintenance

Instructions

6

INSTRUCTION

MANUALS

- ELECTRIC ACTUATOR &

ACCESSORIES -

1. Multi-turn actuator AUMA 2. Gearboxes AUMA 3. 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

Operation instructions Assembly, operation, commissioning

Control:

Parallel

Profibus DP

Profibus DP with FO

� Modbus

Modbus with FO

DeviceNet

Foundation Fieldbus

Table of contents Page

1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1. General notes on safety 51.2. Range of application 61.3. Applications in Ex zone 22 (option) 71.4. Warnings and notes 81.5. Further references and symbols 8

2. Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1. Name plate 92.2. Short description 11

3. Transport, storage and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1. Transport 123.2. Storage 123.3. Packaging 12

4. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1. Handwheel fitting 134.2. Multi-turn actuator mounting to valve/gearbox 144.2.1 Output drive types B1, B2, B3, B4, B, and E 144.2.2 Output drive type A 154.3. Accessories (option) 174.3.1 Protection tube for rising valve stem 174.4. Mounting positions of the local controls 18

5. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1. General notes 195.2. Mains connection using AUMA plug/socket connector (SD) 215.3. Bus connection using AUMA plug/socket connector (SD) 245.4. Accessories for electrical connection (option) 295.4.1 Controls mounted to wall bracket 295.4.2 Parking frame 305.4.3 Protection cover 305.4.4 Double sealed intermediate frame 305.4.5 Ground connection, external 30

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.1. Manual operation 316.2. Motor operation 326.2.1 Local operation 326.2.2 Operation from REMOTE 326.3. Menu navigation via push buttons (for settings and indications) 336.3.1 Short overview: functions of the push buttons 336.3.2 Structural design and navigation 346.4. Language change in the display 35

2

Multi-turn actuator SA 07.1 – SA 16.1/SAR 07.1 – SAR 16.1 Intrusivewith actuator controls AUMATIC AC 01.1 Modbus Operation instructions

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

7. Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1. Status indications in the display 377.1.1 Status indication S0/S6 - operation 377.2. Indication lights/LEDs 387.3. Mechanical position indicator/running indication (option) 38

8. Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8.1. Signals via fieldbus 398.2. Feedback via output contacts (binary) - (option) 398.3. Feedback signals (analogue) - (option) 39

9. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.1. Type of seating: check/edit for end positions 419.2. Baudrate, parity and bus address (slaveaddress) setting 449.3. Further parameters of the Modbus interface 469.4. Switch compartment: open 479.5. Torque switching: set 489.6. Limit switching: set 499.6.1 End position CLOSED (black section): set 499.6.2 End position OPEN (white section): set 499.7. Intermediate positions (option): set 509.7.1 Running direction CLOSE (black section): set 509.7.2 Running direction OPEN (white section): set 509.8. Test run 519.8.1 Rotational direction check 519.8.2 Limit switching check 529.8.3 Perform reference operation 529.9. Potentiometer (option) setting 539.10. Electronic position transmitter RWG setting (option) 549.11. Mechanical position indicator setting (option) 559.12. Switch compartment: close 56

10. Corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

10.1. Faults during commissioning 5710.1.1 Mechanical position indicator 5710.1.2 Electronic position transmitter RWG 5710.1.3 Limit and torque switches 5710.1.4 Fault in end position (overrun not considered) 5810.1.5 Push buttons do not react 5810.2. Fault indications and warning indications 5910.2.1 Status display S0 - faults and warnings 5910.2.2 Status indication S1 - faults 6010.2.3 Status indication S2 - warnings 6110.2.4 Status indication S3 - causes for not ready remote 6310.3. Fuses 6410.3.1 Fuses within the actuator controls 6410.3.2 Motor protection (thermal monitoring) 65

11. Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

11.1. Preventive measures for servicing and safe operation 6611.2. Maintenance 6711.3. Disposal and recycling 67

3

Multi-turn actuator SA 07.1 – SA 16.1/SAR 07.1 – SAR 16.1 IntrusiveOperation instructions with actuator controls AUMATIC AC 01.1 Modbus

Page

12. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

12.1. Multi-turn actuator SA 07.1 – SA 16.1/SAR 07.1 – SAR 16.1 6812.2. Controls AC 01.1 with AUMA plug/socket connector (SD) 70

13. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

14. Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

14.1. Declaration of Conformity and Declaration of Incorporation 80

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4


1. Safety instructions

1.1. General notes on safety

5


Standards/directives AUMA products are designed and manufactured in compliance with recog-nised standards and directives. This is certified in a declaration of incorpora-tion and a declaration of conformity.The end user or the contractor must ensure that all requirements withrespect to assembly, electrical connection, and commissioning at the placeof 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 andwarning instructions in this manual and observe the instructions given.Safety instructions and warning signs on the device must be observed toavoid personal injury or property damage.

Qualification of staff Assembly, electrical connection, commissioning, operation, and mainte-nance must be carried out exclusively by suitably qualified personnel havingbeen authorised by the end user or contractor of the plant.Prior to working on this product, the staff must have thoroughly read andunderstood these instructions and, furthermore, know and observe officiallyrecognised rules regarding occupational health and safety.

Commissioning Prior to commissioning, it is important to check that all settings are in com-pliance with the requirements of the application. Incorrect settings mightpresent a danger to the application, e.g. cause damage to the valve or theinstallation.The manufacturer will not be held liable for any consequential damage. Suchrisk lies entirely with the user.

Operation 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 mea-

sures.. 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 surfacetemperature with an appropriate thermometer prior to working with the device.

Protective measures The end user or the contractor are responsible for implementing requiredprotective measures on site, such as enclosures, barriers, or personalsafety equipment for the staff.

Maintenance To ensure safe device operation, the maintenance instructions included inthis manual must be observed.Any device modification requires the consent of the manufacturer.

1.2. Range of application

6


AUMA multi-turn actuators are designed for the operation of industrialvalves, e.g. globe valves, gate valves, butterfly valves, and ball valves.

Other applications require explicit (written) confirmation by the manufacturer.

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 thedevice’s designated use.

Information These operation instructions are only valid for the “clockwise closing” stan-dard version, i.e. driven shaft turns clockwise to close the valve. Separateinstructions 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 therequirements for applications in dust hazardous locations of ZONE 22, incompliance with the ATEX directive 94/9/EC.

The actuators are designed to meet enclosure protection IP 67 or IP 68 andfulfil the requirements of EN 50281-1-1:1998 section 6 – Electrical appara-tus for use in presence of combustible dust hazards, requirements for cate-gory 3 electrical equipment – protected by enclosures.To comply with all requirements of EN 50281-1-1: 1998, the following pointsmust imperatively be observed:

. In compliance with the ATEX directive 94/9/EC, the actuators must beequipped with an additional identification – II3D IP6X T150 °C.

. The maximum surface temperature of the actuators, based on an ambi-ent temperature of +40 °C in accordance with EN 50281-1-1 section10.4, is +150 °C. In accordance with section 10.4, an increased dustdeposit on the equipment was not considered for the determination ofthe max. surface temperature.

. The correct connection of the thermoswitches or the PTC thermistors aswell as fulfilling the requirements of the duty type and the technical dataare prerequisites for compliance with the maximum surface temperatureof devices.

. The connection plug may only be plugged in or pulled out when device isdisconnected from the mains.

. The cable glands used also have to meet the requirements of categoryII3 D and must at least comply with enclosure protection IP 67.

. The actuators must be connected by means of an external ground con-nection (accessory part) to the potential equaliser or integrated into agrounded piping system.

. The screw plug (part no. 511.0) or the stem protection tube with protec-tion cap (part nos. 568.1 and 568.2) for sealing the hollow shaft mustimperatively be mounted to guarantee the combustible dust hazardprotection.

. As a general rule, the requirements of EN 50281-1-1 must be respectedin dust hazardous locations. During commissioning, service, and mainte-nance, special care as well as qualified and trained personnel arerequired for the safe operation of actuators.

7


1.4. Warnings and notes

The following warnings draw special attention to safety-relevant proceduresin these operation instructions, each marked by the appropriate signal word(DANGER, WARNING, CAUTION, NOTICE).

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. Mayalso be used with property damage.

Potentially hazardous situation.Failure to observe this warning may result in property damage. Is not usedfor 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)

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 andinformation.

Symbol for CLOSED.

Symbol for OPEN.

� Via the menu to parameterDescribes the path within the menu to the parameter. By using the push but-tons of the local controls you may quickly find the desired parameter in thedisplay.

� Description of the parameter settings/indicationsDescribes the setting/viewing possibilities of a parameter.

� Step by stepProvides a detailed description of each step for setting/viewing the parame-ter.

8


Type of hazard and respective source!Possible consequence(s) in case of non-observance (option)

� Measures to avoid the danger� Further measure(s)

DANGER

CAUTION

WARNING

NOTICE

DANGER

2. Identification

2.1. Name plate

Each device (actuator, controls, motor) is equipped with a name plate.Figure 1 shows the arrangement of name plates on the device.

Identification data on the actuator name plate:

Identification data on the controls’ name plate:

9


Figure 1

1 Actuator name plate 3 Motor name plate2 Controls name plate 4 Additional plate, e.g. KKS plate

1 Type and size of actuator2 Commission number

1 Type and size of the controls2 Commission number3 Wiring diagram/control

aC

C

AUMA Riester GmbH&Co.KGD-79379 Müllheim

No : 3302MD 19302

SA 07.1-Com No: 1309533

F1012

Figure 2

aum

a

AC 01.1Com No: 1309595

ACP K:

P:1,5kW

No: 0902MA97286KMS: TP180/001

11F1-2P0-- 0003 ~ 400V IP67Control: RS 485

12

3

Figure 3

Type and size These instructions apply to the following actuator controls combinations:Type: SA = multi-turn actuator for open-close dutyType: SAR = multi-turn actuator for modulating dutySize: 07.1 – 16.1Type: AC = AUMATIC actuator controlsSize: 01.1

Commission number An order-specific commission number is assigned to each device. You canuse this commission number to download the wiring diagram, inspectionrecords and further information for the device from the Internet(http://www.auma.com).

Wiring diagram/control Controlling the actuator controls is performed via a Modbus interface, ifthe 11th position in the ACP wiring diagram contains the letter K, L, J, N, Hor V. Example: ACP 11F1-2P0—K000.

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 forat least one full revolution. It is capable of withstanding thrust.AUMA multi-turn actuators are driven by an electric motor. A handwheel isprovided 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.

Actuator controls The AUMATIC actuator controls is used to operate AUMA actuators and issupplied ready for use.The controls can be mounted directly to the actuator but also separately ona wall bracket.The functions of the AUMATIC controls include standard valve control inOPEN - CLOSE duty, positioning, process control, logging of operating data,diagnosis functions right through control via fieldbus.

Local controls/COM-AC/fieldbus

Operation, setting, and display can be performed on site directly at the con-trols 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, theconnection between computer and AUMATIC can be made with cable(infra-red interface) or without cable (Bluetooth interface) (Not includedin these instructions.)

Intrusive – Non-intrusive . 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 con-trols housings do not have to be opened.For this purpose, the actuator is equipped with an MWG (magnetic limitand torque transmitter), also supplying analogue torque feedback sig-nals/torque indication.

11


3. Transport, storage and packaging

3.1. Transport

� For transport to place of installation, use sturdy packaging.

3.2. Storage

Long-term storage: If the device must be stored for a long period (more than 6 months) the fol-lowing 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.

3.3. Packaging

Our products are protected by special packaging for the transport ex works.The packaging consists of environmentally friendly materials which can eas-ily be separated and recycled.We use the following packaging materials: wood, cardboard, paper, and PEfoil. For the disposal of the packaging material, we recommend recyclingand collection centres.

12


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.

NOTICE

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 notto multi-turn actuator.

� Actuators mounted to gearboxes:Attach ropes or hooks for the purpose of lifting by hoist only to the gear-box using eyebolts and not to the actuator

� Actuators mounted to controls:Attach ropes or hooks for the purpose of lifting by hoist only to actuatorand not to controls.

DANGER

4. Assembly

4.1. Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are sup-plied separately.

1. Manually lift the red change-over lever while slightly turning the shaftback and forth until manual operation engages.The manual operation is correctly engaged if the change-over lever canbe lifted by approx. 85°.

2. Attach handwheel over the red change-over lever then on to the shaft.

3. Secure handwheel using the circlip supplied.

13


85°

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.

NOTICE

4.2. Multi-turn actuator mounting to valve/gearbox

4.2.1 Output drive types B1, B2, B3, B4, B, and E

Application For rotating, non-rising valve stem.

Design 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.

Information Spigot at flanges should be loose fit.

Mounting the multi-turn actuator

1. Check if mounting flanges fit together.2. Check whether bore and keyway match the input shaft.3. Thoroughly degrease mounting faces of the mounting flanges.4. Apply a small quantity of grease to the input shaft.5. 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.

14


2

1 3

4

Figure 4

1 Output drive type B1/B2 and B 3 Output drive B3/B4 and E2 Hollow shaft with keyway 4 Plug sleeve

with bore and keyway

Mounting flange ScrewsThread

Fastening torque TA [Nm]

Strength class 8.8

F07 M8 25F10 M10 51F14 M12 87F16 M16 214

Table 1

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.

NOTICE

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):

. The internal thread of the stem nut must match the thread of the valvestem.

. If not ordered explicitly with thread, the stem nut is supplied unbored orwith 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 wash-

ers 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:

15


1

3

2

2 4

4

Figure 5

1 Stem nut 3 Spigot ring2 Axial needle roller and cage assembly 4 Axial bearing washer

Output drive A 07.2 A 10.2 A 14.2 A 16.2

Qty1) 1.5 g 2 g 3 g 5 g

1) For grease with density � = 0.9 kg/dm³

Table 2

Mounting the multi-turn actuator (with output drive A) to valve

1. Remove screws (3) and take off output drive type A (2) from multi-turnactuator.

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 sol-

idly 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 prop-erly 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 firmlyplaced together.

13. Tighten fastening screws (5) between valve and output drive type Acrosswise with a torque according to table 1, page 14.

16


Figure 6

1 Valve stem 4 Valve flange2 Output drive type A 5 Screws to output drive3 Screw to actuator

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.

NOTICE

4.3. Accessories (option)

4.3.1 Protection tube for rising valve stem

1. Seal thread with hemp, Teflon tape, or thread sealing material.2. Screw protection tube (2) into thread and tighten it firmly.3. Push down the sealing ring (3) into the housing.4. Check whether cap (1) is available and in perfect condition.

17


3

2

1

Figure 7

1 Cap for stem protection tube 3 Sealing ring2 Stem protection tube

4.4. Mounting positions of the local controls

The mounting position of the local controls is designed according to theorder. If, after mounting the actuator to the valve or the gearbox on site, thelocal controls is in an unfavourable position, the mounting position can bechanged at a later date. Four mounting positions are possible.Figure 8 shows mounting positions A and B:

Figure 9 shows mounting positions C and D:

Changing the mounting position

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.

4. Fasten bolts evenly crosswise.

18


Figure 8

Figure 9

Hazardous voltage!Electric shock possible.

� Disconnect device from the mains before opening.

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.

DANGER

NOTICE

5. Electrical connection

5.1. General notes

19


Wiring diagram/terminal plan The wiring diagram/terminal plan is attached to the device in aweather-proof bag, together with these operation instructions. It can also beobtained from AUMA (state commission no., refer to name plate) or down-loaded directly from the Internet (www.auma.com).

Danger due to incorrect electrical connection!Failure to observe this warning can result in death, serious injury, or prop-erty damage.

� The electrical connection must be carried out exclusively by suitablyqualified personnel.

� Prior to connection, observe general references contained in this clause.� After connection but prior to applying the voltage, observe the Commis-

sioning and Test run clauses.

Protection on site For short-circuit protection and for disconnecting the actuator from themains, fuses and disconnect switches have to be provided by the customer.The current values for respective sizing can be derived from the currentconsumption 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 mA208 to 240 V AC = max. 325 mA380 to 500 V AC = max. 190 mA24 V DC (+10 %/–15 %) = max. 500 mA, filter capacitor 2200 μFCurrent consumption for actuator with 1-ph DC motor:24 V DC (+10 %/–10 %) = max. 750 mA, filter capacitor 2200 μFThe maximum permissible fuse for controls with a rated power of 1.5 kW is16 A (gL/gG); for controls with a rated power of 7.5 kW, the value amountsto 32 A (gL/gG).

WARNING

Cable installation in accordancewith 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 interfer-

ence or interference sources.. For the connection of remote position transmitters (potentiometer, RWG,

MWG), screened cables must be used.

Power supply for the controls(electronics)

If the controls (electronics) are supplied externally with 24 V DC and DCmotors (24 V DC, 48 V DC, 60 V DC, 110 V DC, 220 V DC) are used simul-taneously, the 24 V DC voltage supply for the controls should be ensuredvia the XK25/26 terminals, separate from the power supply (U1, V1). In caseof common supply using a single cable (links from U1, V1 with XK25/26, for24 V DC only !!!), short-term excess or falling below the admissible voltagelimits can be the consequence during switching (24 V DC +10 %/–10 %).Any possibly incoming operation commands are not executed outside theadmissible limit values. The controls briefly signal a fault condition.

Bus cables Only cables according to the recommendations of EIA 485 standard may beused for Modbus wiring.

Cable recommendation:

Impedance: 135 to 165 Ohm, at a frequencyof 3 to 20 MHz.

Cable capacity: < 30 pF per metreCore diameter > 0.64 mmCore cross section: > 0.34 mm², corresponds to AWG 22Loop resistance: < 110 Ohm per kmScreening: 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 othercables.

. If possible, bus cables should be laid in a separate, conductive, andearthed cable tray.

. Make sure to avoid potential differences between the individual deviceson 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).

Opening the terminal compartment

1. Loosen screws (2) and remove connection housing (1).2. Loosen screws (4) and remove socket carrier (5) from connection hous-

ing (1).3. Insert cable glands (8) suitable for connecting cables.

The enclosure protection IP… stated on the name plate is only ensuredif suitable cable glands are used.

4. Seal cable entries (6) which are not used with suitable screw plugs (7).5. Insert the wires into the cable glands (8).

21


aC

C

VD00 63-4/45Art No: Z006.413

0.090 kWY 0.60 A

3 ~ 400 V 50 Hz



au IP 67 1680 rpm

Temp.Protection: ThInsulation Class: F

1 Connection housing 5 Socket carrier2 Screws for connection housing 6 Cable entry for mains3 O-ring 7 Screw plug4 Screws for socket carrier 8 Cable gland (not included in delivery)

3

1

27

4

8

5

6

Figure 10

DANGER

Connecting the cables1. 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 mm² flexible, max. 10 mm² rigid

– Control contacts (1 to 50) = max. 2.5 mm²

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.

5. Tighten PE conductors firmly to PE connection using ring lugs (flexiblecables) or loops (rigid cables) (symbol: ).

Connecting the heaterThe heater prevents condensation in the actuator. Unless ordered other-wise, the heater is internally supplied and does not require separate con-nection.

Connecting the motor heater (option)Some actuators are equipped with an additional motor heater. The motorheater improves the start-up behaviour for extremely low temperatures.� Connect motor heater R4, if available, according to wiring diagram.

22


1

2

3

4

5

6

Figure 11

In case of failure: Hazardous voltage while protective conductor is notconnected!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.

1 Socket carrier 4 Spring lock washer2 Screw 5 Protective earth with ring lugs/loops3 Washer 6 PE connection

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.

WARNING

NOTICE

Closing the terminal compartmentRefer 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.

23


3

1

27

4

8

5

6

Figure 12

1 Connection housing 5 Socket carrier2 Screws for connection housing 6 Cable entry for mains3 O-ring 7 Screw plug4 Screws for socket carrier 8 Cable gland (not included in delivery)

5.3. Bus connection using AUMA plug/socket connector (SD)

Opening the bus terminal compartment

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 ensuredif suitable cable glands are used.

3. Seal cable entries (4) which are not used with suitable screw plugs (5).4. Insert the wires into the cable glands.

24


3

1

2

4/5

Figure 13: Bus connection



1 Cover 3 O-ring2 Screws for cover 4 Cable entries for bus cables

5 Screw plug

au IP 67 1680 rpm

Temp.Protection: ThInsulation Class: F

DANGER

Connecting bus cables

1. Connect bus cable (refer to figures 14 to 16).Table 4 indicates the fieldbus cable assignment:

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 thenext Fieldbus device is automatically interrupted to avoid multiple termina-tions (not applicable for overvoltage protection).Table 3 describes the switch positions S1 – S3:

3. Connect screen largely to the shielding clamp (X3).Figure14: Connection board (standard version).

25


S1

X1

X3

P/B

X2

P/B

N/A

N/A

Figure 14

S1 Bus termination channel 1 X1 Channel 1, � from the previous deviceX2X3

Channel 1, � to the next deviceShielding clamp

S1ON Bus termination channel 1 ONOFF Bus termination channel 1 OFF

S2ON Bus termination channel 2 ON (option)OFF Bus termination channel 2 OFF (option)

S31SPC one fieldbus board2SPC two fieldbus boards (redundancy, option)

Table 3

Fieldbuscable

AUMAlabelling at the

connection

SUB-D 9 plug pin(for other

fieldbus devices)Colour

A N/A 8 greenB P/B 3 red

Table 4

Figure 15: Connection board (version for overvoltage protection).

Figure 16: Connection board (version for redundancy).

26


S1 Bus termination channel 1 X1 Channel 1, � from the previous deviceS2 Bus termination channel 2 X2 Channel 1, � to the next deviceS3 Redundancy X3 Channel 2, � from the previous device

X4 Channel 2, � to the next device

S1 Bus termination channel 1 X1 Channel 1, � from previous deviceS2 Bus termination channel 2 Channel 1, � to the next deviceS3 Redundancy X2 Channel 2, � from the previous device

Channel 2, � to the next device

X1

P

S1 S3

X2

S2

N P N P N P N

Figure 15

S1 S3 S2

X1

P/B

X2 X3 X4

P/B

P/B

P/B

N/A

N/A

N/A

N/A

Figure 16

Special features for loop redundancyFor loop redundancy, automatic termination is performed as soon as theAUMATIC is connected to the power supply.When interrupting the power supply, e.g. after removing the AUMAplug/socket connector, both RS-485 loop segments are automatically con-nected to each other.

Figure 17: Connection board (version for loop redundancy).

Figure 18: Connection board (version for loop redundancy with overvoltageprotection).

27


X1

P/B

X2

P/B

N/A

N/A

Figure 17

X1 Channel 1, � from the previous device X2 Channel 1, � to the next device

X1

P/B

X2

P/B

N/A

N/A

Figure 18

X1 Channel 1, � from the previous device X2 Channel 1, � to the next device

Closing the bus terminal compartment1. 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.

28


3

1

2

4/5

Figure 19

1 Cover 3 O-ring2 Screws for cover 4 Cable entries for bus cables

5 Screw plug

5.4. Accessories for electrical connection (option)

5.4.1 Controls mounted to wall bracketThe controls can also be mounted separately from the actuator on a wallbracket.

Application . 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

Design

Observe prior to connection . 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 con-

necting 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 besubject to an insulation test in compliance with EN 50178.Connecting cables of positioners (RWG, IWG, potentiometer) do notbelong to this group. They may not be subject to an insulation test.

29


3

1

24

5

Figure 20

1 Wall bracket 3 Wall bracket terminals (XM)

2 Connecting cables45

Actuator terminals (XA)Controls terminals (XK)

5.4.2 Parking frame

Parking frame for safe storage of a disconnected plug.For protection against touching the bare contacts and against environmentalinfluences.

5.4.3 Protection coverProtection cover for plug compartment when plug is removed.The open terminal compartment can be closed using a protective cover (notillustrated).

5.4.4 Double sealed intermediate frameWhen removing the electrical connection or due to leaky cable glands,ingress of dust and water into the housing is possible. This is prevented byinserting the double sealed intermediate frame (2) between the electricalconnection (1) and actuator housing. The enclosure protection of the device,IP 67 or IP 68, will not be affected, even if the electrical connection isremoved.

5.4.5 Ground connection, externalAs an option, an external ground connection (U-bracket) on the housing isavailable.

30


Figure 21

Figure 22

Figure 23

6. Operation

6.1. Manual operation

In case of motor failure or power failure, the actuator may be operated man-ually for purposes of setting and commissioning.Manual operation is engaged by an internal change-over mechanism.

Engaging manual operation

1. Pivot change-over lever manually to approx. 85° while slightly turning thehandwheel back and forth until manual operation engages.

2. Release change-over lever (should snap back into initial position byspring 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 operationManual operation is automatically disengaged when motor is started again.The handwheel does not rotate during motor operation.

31


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.

NOTICE

6.2. Motor operation

Perform all commissioning settings prior to motor operation.

6.2.1 Local operationThe local operation of the actuator is performed using the push buttons(figure 24).

� 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: Press push button (1).2. Stop actuator: Press push button (2).3. Run actuator in direction CLOSE. Press push button (3).

Information The OPEN - CLOSE operation commands can be given either inpush-to-run operation or in the self-retaining mode. For further informationon 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).

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


1 Push button OPEN 4 Reset push button2 Push button STOP 5 Selector switch3 Push button CLOSE 6 Indication lights/LEDs

0

II

0

II

16 1

2

3

4

5

STOP

Reset

Figure 24

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, andshow various indications on the 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

33


1

6

1

2

3

4

5

�

�

�

C

Figure 25

1 Push button� 4 Push button C2 Push button� 5 Selector switch

3 Push button � 6 Display

0

II

Pushbuttons

Functions

��

Scrolling within a group

(The triangles� in the display show the direction of scrolling.)

Change values

Enter figures from 0 to 9

� Confirm the selection to go to a new menu/subgroup.

C

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).

Table 5

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 indicationsThe active group is displayed on the top right corner of the display.

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��:The triangles� in the top left corner of the display indicate the possiblescrolling direction (within one group) of scrolling.

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:

1. Select figures 0 to 9: Press��.2. Move to the next position: Press � .3. Repeat steps 1 and 2 for all four digits.4. To cancel a process: Press C.

Information If no input is received over a longer period of time (approx. 10 min), the con-trols automatically returns to the status indication S0.

34


ENTER PASSWORD

0 * * *

� :EDIT �:OK C:ESC

OFF S0

OPEN POSITION

E2 100%

M0

M0

OFF S0

OPEN POSITION

E2 100%

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:

3. Press � .Display indicates:

4. Press�.Display indicates:


6. Enter password:Press � 4 times = 0000 (default factory password).

35


LANGUAGE/CONTRAS M00

VIEW

EDIT

MAIN MENU M0

LANGUAGE/CONTRAST

SETTINGS

OPERATIONAL DATA

0II

LANGUAGE/CONTRAS M01

VIEW

�EDIT

ENTER PASSWORD

0 * * *


Display indicates:

7. Press � .Display shows the set value.

8. Press � again to enter the edit mode.Display indicates:

9. Set new value: Press��.10. Accept value: Press � or cancel process without accepting the value:

Press C.

36


EDIT M010

LANGUAGE

ENGLISH

�:EDIT C:ESC

EDIT M010

LANGUAGE

ENGLISH


EDIT M010

LANGUAGE

LCD CONTRAST

7. Indications

7.1. Status indications in the display

Status indications regarding faults and warnings, refer to page 59 et seqq.

7.1.1 Status indication S0/S6 - operationInformation For actuators equipped with process controllers, status indication S6 is dis-

played instead of status indication S0.The description below applies to bothindications (S0 and S6).

Operation mode display Line 1 indicates the current operation mode(LOCAL MODE, OFF, SETPOINT MODE, …)

Operation command/setpoint display

Line 2 indicates currently incoming operation commands(OPEN, STOP, CLOSE) or the setpoints E1 or E7 (for actuators equippedwith positioner/process controller) in % of the total travel.

Valve position display Line 3 indicates the valve position in % of the travel. This indication is onlyavailable if the actuator is equipped with a position transmitter.

0 % = Actuator is in end position CLOSED100 % = Actuator is in end position OPEN

End position/running indication Line 4 indicates the current actuator status.

� 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


�LOCAL MODE S0

OPEN

E2 100 %

RUNNING OPEN

�LOCAL MODE S0

OPEN

E2 100 %

RUNNING OPEN

�LOCAL MODE S0

OPEN

E2 100%

RUNNING OPEN

�LOCAL MODE S0

OPEN

E2 100%

RUNNING OPEN

7.2. Indication lights/LEDs

The indication lights/LEDs locally display the different operation states asoptical signals. The assignment of signals is freely selectable.Figure 26 shows the indication lights/LEDs on the local controls:

Table 6 describes the standard indication.

Information The behaviour (blinking/illuminated) can be changed via the BLINKERparameter.

7.3. Mechanical position indicator/running indication (option)

Mechanical position indicator. continuously indicates the valve position

(Indicator disc rotates approximately 180° to 230° at full travel fromOPEN to CLOSED or vice versa.)

. indicates whether the actuator is running (running indication)

. indicates that the end positions (via indication mark) have been reached

38


LED 1 (left)( symbol)

illuminated Actuator is in end position CLOSED

blinking Running indication: Actuator runs in directionCLOSE

LED 2 (T) illuminated Torque fault CLOSE

LED 3 (Th) illuminated Motor protection tripped

LED 4 (T) illuminated Torque fault OPEN

LED 5 (right)( symbol)

illuminated Actuator is in end position OPEN

blinking Running indication: Actuator runs in directionOPEN

Table 6

Figure 26

auma

2

3

5

41

Figure 27

Version (standard): Version (option):LED marking with letters LED marking with figures

1 Cover 4 Symbol for position OPEN2 Indicator disc 5 Symbol for position CLOSED3 Indicator mark

8. Signals

8.1. Signals via fieldbus

Feedback signals via Modbus RTU can be read by using the respectiveModbus function codes.

8.2. Feedback via output contacts (binary) - (option)

Feedback signals via output contacts are only available if a parallel interfaceis provided in addition to the fieldbus interface.The output contacts can be used to indicate operation modes of the actuatoror the controls as binary signals. The signals can be freely assigned. Exam-ple:Output contact open = no thermal faultOutput contact closed = thermal fault in actuator

Fault signals can be issued via the ALARM CONTACT parameter, other sig-nals 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, phasefailure, and internal faults)

Standard values output contacts 1 to 5:(Designation in the wiring diagram: DOUT1 to DOUT5)OUTPUT CONTACT 1 = CLOSED POSITION

OUTPUT CONTACT 2 = OPEN POSITION

OUTPUT CONTACT 3 = REMOTE SW.POSITION

OUTPUT CONTACT 4 = TORQUE FAULT (CLOSE)

OUTPUT CONTACT 5 = 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 aremet:. In addition to the fieldbus interface, the AUMATIC is equipped with a par-

allel 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)


39


9. Commissioning

Prior to any electrical operation (motor operation), ensure that all commis-sioning 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 in0 (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 Please note that for low temperature versions, the controls require a heat-uptime.

Heat-up time This heat-up time is applicable in case the actuator and the controls are notlive and have cooled down to ambient temperature. Under these conditions,the following heat-up times have been met prior to commissioning after con-nection 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

40


0

30

50

60

0 – 10 – 20 – 30 – 40 – 50

t [min.]

�[°C]

100

– 60

Figure 28

0

II

9.1. Type of seating: check/edit for end positions

Limit seating The limit switching is set in such a way that the actuator switches off at thedesired switching points. The torque switching acts as an overload protec-tion for the valve.

Torque seating The torque switching is set to the desired tripping torque. After reaching thetripping torque the actuator is turned off.The limit seating is used for signalling that the limit switching is trippedshortly before reaching the set tripping torque. If this is not the case, one ofthe following fault signals is displayed: TSO FAULTS or TSC FAULTS

(menu S1).


SETTINGS (M1)

SEATING MODE (M11)

VIEW (M110)

EDIT (M111)

OPEN POSITION (M11_0)

CLOSED POSITION (M11_1)

Default value: LIMIT




4. Press � .

41


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.

0

II

MAIN MENU M0

LANGUAGE/CONTRAST

SETTINGS

OPERATIONAL DATA

MAIN MENU M1

LANGUAGE/CONTRAST

�SETTINGS

OPERATIONAL DATA

NOTICE

Display indicates:


6. Check settings (view): continue with 7.Change setting: continue with 10.

Check settings (view)7. Press � .

Display indicates:

�� are used to change between the OPEN POSITION (left figure)and CLOSED POSITION (right figure) displays.


�� 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 settingDisplay indicates:


11. Press � .

42


SEATING MODE M110

VIEW

EDIT

VIEW M1101

OPEN POSITION

�CLOSED POSITION

VIEW

CLOSED POSITION

LIMIT

C:ESC

SEATING MODE M110

VIEW

EDIT

VIEW M1100

OPEN POSITION

CLOSED POSITION

VIEW

OPEN POSITION

LIMIT

C:ESC

SEATING MODE M111

VIEW

�EDIT

SETTINGS M11

SEATING MODE

TORQUE

LOCAL CONTROLS

Display indicates:

12. Enter password:Press � 4 times = 0000 (default factory password).Display indicates:

�� are used to change between the OPEN POSITION (left figure)and CLOSED POSITION (right figure) displays.

13. Press � .Display shows the set value:

�� are also used here to change between the OPEN POSITION (leftfigure) and CLOSED POSITION (right figure) displays.



Press C.Display indicates:

17. Return to status display:Press C several times until S0 is displayed.

43


EDIT M1111

OPEN POSITION

�CLOSED POSITION

EDIT M1110

OPEN POSITION

CLOSED POSITION

EDIT M1111

�CLOSED POSITION

LIMIT

�:EDIT C:ESC

EDIT M1110

OPEN POSITION

LIMIT

�:EDIT C:ESC

EDIT M1111

CLOSED POSITION

LIMIT


EDIT M1110

OPEN POSITION

LIMIT


EDIT M1111

�CLOSED POSITION

LIMIT

�:EDIT C:ESC

EDIT M1110

OPEN POSITION

LIMIT

�:EDIT C:ESC

ENTER PASSWORD

0 * * *


9.2. Baudrate, parity and bus address (slaveaddress) setting


SETTINGS (M1)

MODBUS 1 (M1F)

BAUDRATE (M1F11)

PARITY (M1F12)

SLAVEADDRESS(M1F14)





5. Select MODBUS 1 (M1F): Press� several times.Display indicates:


7. Check setting (view): continue with 8.Change setting: continue with 11.

44


0

II

MAIN MENU M0

LANGUAGE/CONTRAST

SETTINGS

OPERATIONAL DATA

MAIN MENU M1

LANGUAGE/CONTRAST

�SETTINGS

OPERATIONAL DATA

SETTINGS M10

SET LIMIT SWITCHES

SEATING MODE

TORQUE

SETTINGS M1F

POSITIONER

CHANGE PASSWORD

�MODBUS 1

MODBUS 1 M1F0

VIEW

EDIT

Check settings (view)8. Press � .

Display indicates:

9. Use�� to select BAUDRATE, PARITY or SLAVEADDRESS andpress � to confirm selection.Display indicates. Example SLAVEADDRESS:

10. Back to the VIEW/EDIT menu:Press C twice.

Change settingDisplay indicates:



13. Enter password:Press � 4 times = 0000 (default factory password).Display indicates:

14. Use�� to select BAUDRATE, PARITY or SLAVEADDRESS andpress � to confirm selection.

45


MODBUS 1 M1F1

VIEW

�EDIT

MODBUS 1 M1F01

BAUDRATE

PARITY

CONNECT-CONTROL TIME

VIEW

SLAVEADDRESS

1

C:ESC

MODBUS 1 M1F0

VIEW

EDIT

ENTER PASSWORD

0 * * *


EDIT M1F11

BAUDRATE

PARITY

CONNECT-CONTROL TIME

Display shows the set value. Example SLAVEADDRESS:



Press C.Display indicates:

18. Press C several times until S0 is displayed to return to the status indica-tion.

Information Baudrate and Parity must correspond to the setting at the master.Setting range of the parameters:SLAVEADDRESS: 1 to 247BAUDRATE: 300 to 38 400 BAUD

PARITY: EVEN, 1 STOPBIT

ODD, 1 STOPBIT

NO, 2 STOPBITS

Information For component redundancy (option), the bus address for the 2nd fieldbusinterface can be set in the same way as the 1st field interface.The menu for the second fieldbus interface has to be selected from thedescriptions Via the menu to parameter, e.g. MODBUS 2 instead ofMODBUS 1.

9.3. Further parameters of the Modbus interface

Connection control time Parameter: CONNECT-CONTROL TIME (M1F_3)

Default values: 3.0

This time should exceed the cycle time of the Modbus data transmission toall connected devices. If no valid Modbus telegram was received within thistime, the “DATA EX” status is lost and the failure behaviour or thechange-over of the communication channel is initiated, if enabled.

Parameter forcable redundancy

Parameter: CABLE REDUNDANCY (M1F_5)

CHANEL CHECK TIME (M1F_6)

Default values: 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


EDIT M1F14

SLAVEADDRESS

1


EDIT M1F14

SLAVEADDRESS

1

�:EDIT C:ESC

EDIT M1F14

SLAVEADDRESS

1

�:EDIT C:ESC

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

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 CLOSE4.5 da Nm = 45 Nm for direction OPEN

3. Fasten lock screws (3) again.The torque switches setting is complete.

Information . 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


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 Switching head black for 2 Switching head white fortorque in direction CLOSE torque in direction OPEN

3 Lock screws 4 Torque dial

NOTICE

9.6. Limit switching: set

9.6.1 End position CLOSED (black section): set1. 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 thepointer has snapped): continue turning the setting spindle in the samedirection and repeat setting process.

9.6.2 End position OPEN (white section): set1. 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.


49


Figure 30

Black section White section

1 Setting spindle for end positionCLOSED 4 Setting spindle for end position

OPEN2 Pointer for end position CLOSED 5 Pointer for end position OPEN

9.7. Intermediate positions (option): set

Actuators equipped with DUO limit switching contain two intermediate posi-tion switches. One intermediate position may be set for each running direc-tion.

9.7.1 Running direction CLOSE (black section): set1. Move valve in direction CLOSE until desired intermediate position.

When overriding the desired point, turn valve back and approach againthe intermediate position in direction CLOSE. (Always approach theintermediate position in the same direction as in later electricaloperation).

2. Press down and turn setting spindle (1) (figure 31) using a screw driverin 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 com-plete.


9.7.2 Running direction OPEN (white section): set1. Move valve in OPEN direction until desired intermediate position.

When overriding the desired point, turn valve back and approach againthe intermediate position in OPEN direction. (Always approach the inter-mediate position in the same direction as in later electrical operation).

2. Press down and turn setting spindle (4) (figure 31) using a screw driverin 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 samedirection and repeat setting process.

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Figure 31

Black section White section

1 Setting spindle running directionCLOSE 4 Setting spindle running direction

OPEN2 Pointer running direction CLOSE 5 Pointer running direction OPEN

9.8. Test run

Perform test run only once all settings previously described in the Commis-sioning clause have been performed.

9.8.1 Rotational direction check

1. Move actuator manually to intermediate position or to sufficient distancefrom 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 directionCLOSE while the indicator disc turns counterclockwise.

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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.

0

II

auma

NOTICE

For actuators without indicator disc� Unscrew screw plug (1) and seal (2) or tube cap (4) and observe direc-

tion of rotation at hollow shaft (3) or the stem (5).The direction of rotation is correct, if: the actuator moves in directionCLOSE while the hollow shaft or the stem turn clockwise.

9.8.2 Limit switching check1. 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 OPENThe 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

For actuators with feedback signal (RWG, potentiometer), a reference oper-ation 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 endposition 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 miss-ing reference operation as a warning.

52


1

2

3

4

5

6

Figure 32

1 Screw plug 4 Cap for stem protection tube2 Seal 5 Stem3 Hollow shaft 6 Protection tube

0

II

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 cus-tomer connection XK (refer to wiring diagram).

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 resistancerange/stroke is not always passed. Therefore, external adjustment (settingpotentiometer) must be provided.

53


Figure 33

1 Potentiometer

9.10. Electronic position transmitter RWG setting (option)

The electronic position transmitter RWG records the valve position. On thebasis of the nominal position value measured by the potentiometer (travelmonitoring), it generates a current signal between 0 – 20 mA or 4 – 20 mA

Technical data RWG 4020

1. Connect voltage to electronic position transmitter.2. Move valve to end position CLOSED.3. Connect ammeter for 0 – 20 mA to measuring points (4 and 5).4. Turn potentiometer (1) clockwise to the stop.5. Turn potentiometer (1) slightly back.6. Turn potentiometer (2) clockwise until output current starts to increase.7. 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 mAThis 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.

Information If the maximum value cannot be reached, check whether the appropriatereduction gearing has been selected. (The max. possible turns/stroke areindicated on the order-related technical data sheet for the actuator).

54


Terminal plan KMS TP_ _ 4 / _ _ _3-/4-wire system

Output current Ia 0 – 20 mA, 4 – 20 mAPowersupply

Uv24 V DC, ± 15 %

smoothedmax.current consump-tion

I 24 mAFor 20 mA output current

Max. load RB 600 �

Table 7

Figure 34

1 Potentiometer (travel monitor) 4 Measurement point (+) 0/4 – 20 mA2 Potentiometer min. (0/4 mA) 5 Measurement point (–) 0/4 – 20 mA3 Potentiometer max. (20 mA)

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� 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� 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�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-relatedtechnical 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.

56


Danger of corrosion due to damage to paint finish!� Touch up damage to paint finish after work on the device.

NOTICE

10. Corrective action

10.1. Faults during commissioning

10.1.1 Mechanical position indicator

Fault description Mechanical position indicator cannot be set.

Possible cause Actuator turns/stroke have been modified at a later date.

Remedy Exchange reduction gearing.

10.1.2 Electronic position transmitter RWG

Fault description Measurement range 4 – 20 mA or maximum value 20 mA cannot be set.

Possible cause Wrong reduction gearing (turns/stroke).

Remedy Check whether the appropriate reduction gearing has been selected. (Themax. possible turns/stroke are indicated on the order-related technical datasheet for the actuator).

10.1.3 Limit and torque switches

Fault description Switch does not trip.

Possible cause Switch is defective or switch setting is incorrect.

Remedy . Check setting, if required, reset end position.. Check switches and replace them, if required.

The red test buttons (1) and (2) are used for manual operation of the limitswitches:� 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 illumi-nated.

� Press push button OPEN to reset the fault (red indication light) by oper-ating 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 illumi-nated.

� Press push button CLOSE to reset the fault (red indication light) by oper-ating the device in the opposite direction.

Information If the actuator is equipped with a DUO limit switching (option), the intermedi-ate 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


Figure 35

10.1.4 Fault in end position (overrun not considered)

Fault description Actuator runs to end stop although the limit switches work properly.

Possible cause The overrun was not considered when setting the limit switching.The overrun is generated by the inertia of both the actuator and the valveand the delay time of the controls.

Remedy 1. Determine overrun:Overrun = travel performed from switching off until complete standstill.

2. Set limit switching again (page 49) considering the overrun (turnhandwheel back by the amount of the overrun).

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:

Possible cause . RESTRICTED means that the local controls of the AUMATIC have notbeen released yet.

. EMERGENCY STOP signifies that the EMERGENCY STOP operationmode 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 param-

eter ENABLE LOCAL MODE.For EMERGENCY STOP:� EMERGENCY STOP button released.

58


�LOCAL RESTRICTED S0

E2 100%

OPEN POSITION

��EMERGENCY STOP S0

E2 100%

OPEN POSITION

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 onlyserve 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.

� Description of the fault indications:

FAULT IND.

A fault has occurred� For further information, press�� and go to status indication S1.

WARNING IND.

A warning has occurred� For further information, press�� and go to status indication S2.

FAULT + WARNING

Faults as well as warnings have occurred.� For further information, press�� and go to status indications S1

(faults) or S2 (warnings).

NOT READY IND.

The actuator cannot be operated from REMOTE. The actuator can only beoperated via the local controls.� For further information, press�� 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�� and go to status indications S1 or S3.

WRN + NR

Faults and the NOT READY IND. signal have occurred.� For further information, press�� and go to status indications S2 or S3.

FLT + WRN + NR

Faults, warnings, and the NOT READY IND. signal have occurred.� For further information, press�� and go to status indications S1 to S3.

59


�LOCAL MODE S0

OPEN

E2 100%

FAULT IND.

10.2.2 Status indication S1 - faultsFaults are indicated in this group:


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� 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 faultindication 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� four times.

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�FAULT IND. S1

NO FAULT

10.2.3 Status indication S2 - warningsWarnings are indicated at this position.

� 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 endposition 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 beenexceeded.� 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� 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� either seven, eight,

or nine times.� Check position transmitter wiring.� Check POSITION E2. The setting must correspond to the wiring dia-

gram.

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 forfieldbus/standard interface combinations).

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�WARNING IND. S2

NO WARNING

� Check wiring.

I/O1 ANALOG IN2 LOSS

Loss of signal of the analogue input 2 of the parallel interface (only forfieldbus/standard interface combinations).� Check wiring.

P-FEEDBACK E4 LOSS

Signal loss of the actual process value E4 (only if PID controller is availableand 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.

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10.2.4 Status indication S3 - causes for not ready remoteThe causes for the NOT READY IND. fault signals (status indication S0)are indicated within this group.


READY

Actuator can be operated from REMOTE.

NOT REMOTE

Actuator cannot be operated from REMOTE because the selector switch iseither in position LOCAL or OFF.

WRONG COMMAND

Indicates the fact that several operation commands were received simulta-neously via Modbus (e.g. Remote OPEN and Remote CLOSE simulta-neously or Remote CLOSE/Remote OPEN and Remote SETPOINT (nomi-nal) simultaneously) or that the max. value for a nominal position has beenexceeded.

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).

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�NOT READY IND. S3

READY

10.3. Fuses

10.3.1 Fuses within the actuator controlsFuses F1 and F2 can be accessed after removing the cover (1) on the rearside.Fuses F3, F4, and F5 are located on the power supply unit and can beaccessed after removing the electrical connection (2).

F1/F2 Primary fuses on power supply unit

F3 Internal 24 V DC supplyF4 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

F5 Automatic reset fuse as short-circuit protection for external 24 V DC supplyfor customer (see wiring diagram)

� Screw cover back on again after fuse replacement.

64


Figure 36



G fuses F 1/F 2 AUMA Art. no.

Size 6.3 x 32 mm

Reversing contactorsVoltage supply � 500 V

1 A T; 500 V K002.277

Reversing contactorsVoltage supply 500 V

2 A FF; 660 V K002.665

Thyristor units for motor power up to 1.5 kW 15 A FF; 500 V K001.189

Thyristor units for motor power up to 3.0 kW 30 A FF; 500 V K006.965

Thyristor units for motor power up to 5.5 kW 1 A T; 500 V K002.277

Table 8

1 Rear cover 2 Electrical connection

DANGER

G fuse according to IEC 60127-2/III F3 F4

Size 5 x 20 mm 5 x 20 mm

Voltage output (power supply unit) = 24 V 1.0 A T; 250 V 1.25 A T; 250 V

Voltage output (power supply unit) = 115 V 1.0 A T; 250 V 0.315 A T; 250 V

Table 9

10.3.2 Motor protection (thermal monitoring)In order to protect against overheating and impermissibly high temperaturesat the actuator, PTC thermistors or thermoswitches are embedded in themotor winding. The thermoswitch is tripped as soon as the max. permissiblewinding 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 automaticallyreset 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.


65


11. Servicing and maintenance

Service AUMA offers extensive service such as maintenance and inspection as wellas customer product training. For the relevant contact addresses, pleaserefer to page 82 et seqq. and on the Internet (www.auma.com).

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 manufacturer’s details.

. If rarely operated: perform test run.

. For devices with output drive A, press in Lithium soap EP multi-purposegrease on mineral oil base at the grease nipple with the grease gun(quantities see 15, table 2). This procedure does not grease the valvestem. Lubrication of the valve stem must be done separately.

6 months after commissioning and then once a yearCheck screws between multi-turn actuator and valve for tightness. Ifrequired, 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


1 Output drive type A 2 Grease nipple

Figure 37

Damage caused by inappropriate maintenance!� Servicing and maintenance tasks must be carried out exclusively by suit-

ably qualified personnel authorised by the end user or contractor of theplant only.

� Only perform servicing and maintenance tasks when the device isswitched off.

CAUTION

11.2. Maintenance

Maintenance intervals . Refer to lubricant change.

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 atone point in time.The devices have a modular design and may, therefore, easily be separatedand 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 sub-stances are hazardous to water and must not be released into the envi-ronment.

. Arrange for controlled waste disposal of the disassembled material or forseparate 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


001.0 Housing Sub-assembly002.0 Bearing flange Sub-assembly003.0 Hollow shaft without worm wheel Sub-assembly005.0 Worm shaft Sub-assembly005.1 Motor coupling005.2 Coupling pin005.3 Manual drive coupling005.4 Pull rod006.0 Worm wheel009.0 Planetary gear for manual drive Sub-assembly010.0 Retaining flange Sub-assembly017.0 Torque lever Sub-assembly018.0 Gear segment019.0 Crown wheel Sub-assembly020.0 Swing lever Sub-assembly022.0 Drive pinion II for torque switching Sub-assembly023.0 Output drive wheel for limit switching Sub-assembly024.0 Intermediate wheel for limit switching Sub-assembly025.0 Locking plate Sub-assembly058.0 Wire for protective earth (pin) Sub-assembly061.0 Torque switching head Sub-assembly070.0 Motor (VD motor incl. no. 079.0) Sub-assembly

079.0 Planetary gear for motor drive (SA/SAR07.1 – 14.1 for VD motor) Sub-assembly

080.0 Planetary gear for motor drive (SA/SAR16.1 for AD90 motor) Sub-assembly

155.0 Reduction gearing Sub-assembly500.0 Cover for switch compartment Sub-assembly501.0 Socket carrier (complete with sockets) Sub-assembly502.0 Pin carrier without pins Sub-assembly503.0 Socket for controls Sub-assembly504.0 Socket for motor Sub-assembly505.0 Pin for controls Sub-assembly506.0 Pin for motor Sub-assembly507.0 Plug cover Sub-assembly511.0 Screw plug Sub-assembly514.0 Output drive form A (without stem nut) Sub-assembly

514.1 Axial needle roller bearing Sub-assembly

516.1 Output drive shaft D535.1 Snap ring539.0 Screw plug542.0 Handwheel with ball handle Sub-assembly549.1 Output socket B3/B4/E551.1 Parallel key553.0 Mechanical position indicator Sub-assembly554.0 Socket carrier with motor cable harness Sub-assembly556.0 Potentiometer for position transmitter Sub-assembly556.1 Potentiometer without slip clutch Sub-assembly557.0 Heater Sub-assembly

558.0 Blinker transmitter including pins at wires(without impulse disc and insulation plate) Sub-assembly

559.0-1 Control unit without torque head, withoutswitches Sub-assembly

559.0-2

Control unit with magnetic limit and torquetransmitter (MWG) for Non-intrusive ver-sion in combination with AUMATIC inte-gral controls

Sub-assembly

560.0-1 Switch stack for OPEN direction Sub-assembly560.0-2 Switch stack for CLOSE direction Sub-assembly560.1 Switch for limit/torque switching560.2 Switch case566.0 Position transmitter RWG Sub-assembly566.1 Potentiometer for RWG without slip clutch Sub-assembly

566.2 Electronic board RWG Sub-assembly566.3 Wire harness for RWG Sub-assembly567.1 Slip clutch for potentiometer/RWG Sub-assembly

568.1 Stem protection tube(without cap)

568.2 Cap for stem protection tube568.3 V-seal569.0 Change-over lever assly.569.1 Change-over lever569.2 Notched pin574.1 Radial seal output drive A for ISO flange575.1 Stem nut type AS1 Seal kit, small SetS2 Seal kit, large Set

69


Note:Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMAspare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any lia-bility. Delivered spare parts may slightly vary from the representation.

No. Designation Type No. Designation Type

12.2. Controls AC 01.1 with AUMA plug/socket connector (SD)

70


001.0 Housing Sub-assembly

002.0 Local controls Sub-assembly

002.3 Local controls board

006.0 Power supply Sub-assembly

008.1 Bus interface

009.0 Logic board Sub-assembly

011.1 Relay board

050.1 Bus connection board

500.0 Cover Sub-assembly

501.0 Socket carrier (complete with sockets) Sub-assembly

502.0 Pin carrier without pins Sub-assembly

503.0 Socket for controls Sub-assembly

504.0 Socket for motor Sub-assembly

505.0 Pin for controls Sub-assembly

506.0 Pin for motor Sub-assembly

507.0 Electrical connection for bus without connection board (050.0) Sub-assembly

507.1 Frame Sub-assembly

508.0 Switchgear Sub-assembly

509.1 Padlock

510.0 Fuse kit Set

S Seal kit Set

71


Note:Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMAspare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any lia-bility. Delivered spare parts may slightly vary from the representation.

No. Designation Type

13. Technical data

Features and functions of actuatorType of duty1) Standard: SA Short time duty S2 - 15 min

SAR Intermittent duty S4 - 25 %Option: SA Short time duty S2 - 30 min

SAR Intermittent duty S4 - 50 %Intermittent duty S5 - 25 %

Torque range Refer to actuator name plateOutput speed Refer to actuator name plateMotors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34

Options: 1-ph AC motor, type IM B14 according to IEC 34DC shunt motor, type IM B14 according to IEC 34DC compound motor, type IM B14 according to IEC 34Special motors

Insulation class Standard: F, tropicalizedOption: H, tropicalized

Motor protection Standard: Thermoswitches (NC)Option: PTC thermistors (according to DIN 44082)

Self-locking Yes, for output speeds 4 to 90Limit switching 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 isolatedOptions: 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 isolatedImax.: 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 DCFor gold plated contacts: min. 4 mA to max. 400 mA and min. 5 V to max. 50 V

Torque switching Torque switching for directions OPEN and CLOSE adjustableStandard: Single switch (1 NC and 1 NO) for each directionOptions: Tandem switches (2 NC and 2 NO) for each direction, switches galvanically isolated

Position feedback, analogue(options)

Potentiometer or 0/4 – 20 mA (RWG)For further details see page 74

Mechanical position indicator(option)

Continuous indication, adjustable indicator disc with OPEN and CLOSED symbols

Heater in switch compartment Resistance type heater with 5 W, 24 V DC (standard: internal supply)Motor heater (option) SA/SAR 07.1 – 10.1: 12.5 W

SA/SAR 14.1 – 16.1: 25 WManual operation Manual drive for setting and emergency operation, handwheel does not rotate during

electrical operation.Option: Handwheel lockable

Connection to controls AUMA plug/socket connector with screw type connectionOutput drive types A, B1, B2, B3, B4 according to EN ISO 5210

A, B, D, E according to DIN 3210C according to DIN 3338Special output drives: AF, AK, AG, IB1, IB3

Features and functions of controlsPower 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 plateCurrent consumption of the controls depending on the mains voltage:100 to 120 V AC = max. 650 mA208 to 240 V AC = max. 325 mA380 to 500 V AC = max. 190 mA

External supply of the electronics(option)

24 V DC +20 %/–15 %,Current consumption: Basic version approx. 200 mA, with options up to 500 mA

Rated power Refer to motor name plateThe 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 thermaloverload relayThyristor unit (recommended for modulating actuators)For motor power up to 1.5 kW, 500 V AC with internal fusesFor motor power up to 3.0 kW, 500 V AC, with internal fusesFor motor power up to 5.5 kW, 500 V AC, external fuses required

Control and output signals Via Modbus interface (page 75)Modbus RTU interface withadditional inputs (options)

Modbus interface with 4 free 24 V DC inputs (current consumption approx. 5mA/input) and2 free 0/4 – 20 mA inputs3). Signal transmission via fieldbus interface.Modbus interface with 24 V DC control inputs OPEN - CLOSE - EMERGENCY, oralternatively OPEN - STOP - CLOSE (current consumption approx 5 mA/input), Control modeselection via 24 V DC input BUS/REMOTE.Modbus interface with 24 V DC control inputs OPEN - CLOSE (current consumptionapprox. 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. 15mA/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.

Voltage output 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

Component redundancy (option) AUMATIC is equipped with an additional redundant Modbus interfaceRedundancy in loop structure(option)

AUMATIC is equipped with an additional redundant Modbus interface to implement aredundant loop in combination with the SIMA Master Station. Max. number of AUMATICactuators per redundant loop: 247 units. Max. possible cable length between the AUMATICactuators without additional external repeaters: 1,200 m.Max. possible total cable length per redundant loop: approx. 290 km

Local controls Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)Push buttons OPEN - STOP - CLOSE - RESET5 indication lights:End position CLOSED and running indication CLOSE (yellow), torque faultCLOSED (red), motor protection tripped (red), torque fault OPEN (red)end position and running indication OPEN (green)LC display, illuminatedProgramming interface (infrared)

Options: Bluetooth programming interface with Bluetooth class II chip with a range ofup 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 - RESETof 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 faultCLOSED (blue), torque fault OPEN (yellow), motor protection tripped (white),end position and running indication OPEN (red)Protection cover, lockableProtection cover with indicator glass, lockable

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 wearlessthyristor units.

3) Only partly possible in connection with process controller PID, please contact AUMA.4) Requires positioner in the actuator5) Not possible in combination with PTC tripping device

73


Functions Standard: Type of seating is programmableLimit or torque seating for end position OPEN and end position CLOSEDTorque monitoring over the whole travelTorque-by-pass, adjustable to up to 5 seconds (no torque monitoring during this time)Phase failure monitoring6) with automatic phase correctionProgrammable behaviour in case of loss of bus connectionRunning indication via indication lightsPositioner4):

Nominal position value via Modbus interfaceProgrammable behaviour on loss of signalAutomatic 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 interfaceActual process value via 0/4 – 20 mA additional inputProgrammable behaviour on loss of signalLimitation of the control rangeChange-over between OPEN - CLOSE duty and modulating duty via Modbus

Multiport valve function4)

Direct approachingof up to8 intermediate positions viaModbus and the local controlsMonitoring 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 offOperating time monitoring (programmable from 4 to 1,800 seconds), generates warningsignal

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 eachService 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, limitswitch trippings in end position CLOSED, torque switch trippings in end position OPEN, limitswitch trippings in end position OPEN, torque faults CLOSE, torque faults OPEN, motorprotection trippings

Motor protection evaluation Standard: Monitoring of the motor temperature in combination with thermoswitchesin the motor

Options: Additional thermal overload relay in the controls in combination withthermoswitches within the motorPTC tripping device in combination with PTC thermistors in the motor

Electrical connection Standard: AUMA plug/socket connector with screw type connectionThreads for cable glands:M-threads: 2 x M25 x 1.5; 4 x M20 x 1.5Pg-threads: 2 x Pg21; 4 x Pg13.5NPT-threads: 1 x NPT ½"; 4 x NPT ¾"G-threads: 1 x G ½"; x G ¾"

Options: Special threads, other than standard mentioned above, possibleGold-plated control plug (pins and sockets)Parking frame for wall mounting of the disconnected plugProtection cover for plug compartment (when plus is removed)

Overvoltage protection (option) Protection of the actuator and control electronics against overvoltages on the fieldbuscables of up to 4 kV

Wiring diagram (basic version) ACP 11F1-2P0—K000 KMS TP102/001Additional features for version with potentiometer or RWG in the actuatorElectronic 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 actuator6) 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 interfaceSetting the Modbus interface Baud rate, parity and Modbus address are set via the display of the AUMATICCommands and signals of the Modbus RTU interfaceProcess representation output(command signals)

OPEN, STOP, CLOSE, nominal position value, RESET

Process representation input(feedback signals)

End position OPEN, CLOSEActuator position valueActual torque valueSelector switch in position LOCAL/REMOTERunning indication (directional)Torque switch OPEN, CLOSEDLimit switch OPEN, CLOSEDManual operation by handwheel or local controlsAnalogue (2) and digital (4) customer inputsCommunication channel A or B (redundant channel) active

Process representation input(fault signals)

Motor protection tripped

Torque switch tripped in mid-travelOne phase missingLoss of analogue customer inputs

Behaviour on loss ofcommunication

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 ModbusCommunication protocol Modbus RTUNetwork topology Linear (BUS) structure. Active bus termination at both ends.

Coupling and uncoupling of devices during operation without affecting other devices is pos-sible.

Transmission medium Twisted, screened copper cable according to IEC 61158Modbus interface EIA-485 (RS485)Transmission rate/cable length

Device types Modbus RTU slave, e.g. devices with digital and/or analogue inputs/outputs such as actors, sensors)Number of devices 32 devices in each segment without repeater, with repeaters expandable to 247Bus access Polling between master and slaves (query response).Supported Modbus RTUfunctions (services)

01 Read Coil Status02 Read Input Status03 Read Holding Registers04 Read Input Registers05 Force Single Coil15 (0FHex) Force Multiple Coils06 Preset Single Register16 (10Hex) Preset Multiple Registers07 Read Exception Status17 (11Hex) Report Slave ID08 Diagnostics:

00 00 Loopback00 10 (0AHex) Clear Counters and Diagnostic Register00 11 (0BHex) Return Bus Message Count00 12 (0CHex) Return Bus Communication Error Count00 13 (0DHex) Return Bus Exception Error Count00 14 (0EHex) Return Slave Message Count00 15 (0FHex) Return Slave No Response Count

75


Baud rate (bit/s) Max. cable length(segment length) without

repeater

Possible cable lengthwith repeater

(total network cable length)

300 – 38,400 1,200 m approx. 10 km

Service conditions for actuator with controlsMounting position Any positionEnclosure protection accordingto EN 60 5299)

Standard: IP 67Options: IP 68 Max. 6 m head of water, duration of the flooding 72 hours max.

Up to 10 operations during floodingModulating duty is not possible during submersion

IP 67 DS (Double Sealed)IP 68 DS (Double Sealed)(Double Sealed = Electrical connection compartment additionally sealedagainst interior)

Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plantswith a low pollutant concentration

Options: KS Suitable for installation in occasionally or permanently aggressiveatmosphere with a moderate pollutant concentration (e.g. inwastewater treatment plants, chemical industry)

KX Suitable for installation in extremely aggressive atmosphere with highhumidity and high pollutant concentration

KX-G Same as KX, however aluminium-free version (outer parts)Finish coating Standard: Two-component iron-mica combination

Option: Special primer/special finish coat (customer’s choice)Colour Standard: AUMA silver-grey (similar to RAL 7037)

Other colours are possible on requestAmbient temperature 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 supply230 V AC or 115 V AC.

Vibration resistance according toIEC 60 068

1 g, for 10 to 200 HzResistant to vibrations during start-up or for failures of the plant. However, a fatiguestrength may not be derived from this.Applies to actuator with actuator controls only, not valid in combination with gearboxes.

Lifetime Open-close duty: Operating cycles (OPEN - CLOSE - OPEN)SA 07.1 – SA 10.1: 20,000SA 14.1 – SA 16.1: 15,000Modulating duty:10)

SAR 07.1 – SAR 10.1: min. 5.0 million modulating stepsSAR 14.1 – SAR 14.5: min. 3.5 million modulating stepsSAR 16.1: min. 3.5 million modulating steps

Weight Refer to separate Technical data SA/SAR/ACAccessoriesWall bracket11) 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 heavyvibrations during service.

EMERGENCY STOP button12) The control voltage of the reversing contactors is interrupted by operating theEMERGENCY STOP button.

Programming software for PC COM-AC. An interface cable is required for the standard infra-red programming interfaceFurther informationEU Directives Electromagnetic Compatibility (EMC): (2004/108/EC)

Low Voltage Directive: (2006/95/EC)Machinery Directive: (98/37/EC)

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 enclosureprotection 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 possiblemaintenance 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 hasto 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


IndexAAccessories for mounting 17Assembly 13

BBus cables 20

CCable capacity 20Cable installation 19Cable installation inaccordance with EMC 19

Commission number 9Commissioning 40Connecting cables 29Connection control time 46Control 10Core cross section (bus cable) 20Core diameter (bus cable) 20Corrective action 57Corrosion protection 12Cross sections 22Current consumption 19

DDeclaration of Conformity 80Declaration of Incorporation 80Disconnect switches 19Disposal and recycling 67Double sealed intermediateframe 30

DUO limit switching 50

EElectrical connection 19Electronic position transmitter RWG54

FFaults 59Faults at commissioning 57Fuses 64Fuses on site 19

GGround connection, external 30

HHandwheel 31Handwheel fitting 13Heater 22Heat-up time 40

IImpedance 20Indications 37Indicator disc 47,55Intermediate positions 50Internet 10Intrusive 11

LLanguage change in the display 35Limit switching 49Long-term storage 12Loop resistance 20Low temperature version 40Lubricant change 67

MMains connection 21Maintenance intervals 67Manual operation 31Mechanical position indicator 55Motor heater 22Motor operation 32Motor protection 65Mounting 14Mounting positions of the localcontrols 18

NNon-Intrusive 11

OOperation 31Output drive type A 15Output drive types B1, B2, B3, B4,B, and E 14Overrun 58

PPackaging 12Parking frame 30Password entry 34Position indicator 55Position transmitter 19Position transmitter RWG 54Potentiometer 53Protection cover 30Protection on site 19Protection tube 17Protective earth 22PTC thermistors 65Push-to-run operation 32

RRated power 72Reference documents 2Running indication 38

SSafety instructions 5Screening (bus cable) 20Self-retaining mode 32Service 66Short-circuit protection 19Signals 39Size 10Spare parts list 68

Controls 70Multi-turn actuator 68

Status indication 37Stem nut 15Storage 12

TTechnical data 72Terminal plan 19Test run 51Thermoswitches 65Torque switching setting 48Transport 12Tripping torque 48Type 10

VValve position 37

WWall bracket 29Warnings 59Wiring diagram (name plate) 10Wiring diagram locating 19

81


EuropeAUMA Riester GmbH & Co. KGPlant MüllheimDE-79373 MüllheimTel +49 7631 809 - 0Fax +49 7631 809 - [email protected]

Plant Ostfildern-NellingenDE-73747 OstfildernTel +49 711 34803 - 0Fax +49 711 34803 - [email protected]

Service Center CologneDE-50858 KölnTel +49 2234 2037 - 9000Fax +49 2234 2037 - [email protected]

Service Center MagdeburgDE-39167 NiederndodelebenTel +49 39204 759 - 0Fax +49 39204 759 - [email protected]

Service Center BavariaDE-85386 EchingTel +49 81 65 9017- 0Fax +49 81 65 9017- [email protected]

AUMA Armaturenantriebe GmbHAT-2512 TribuswinkelTel +43 2252 82540Fax +43 2252 [email protected]

AUMA (Schweiz) AGCH-8965 BerikonTel +41 566 400945Fax +41 566 [email protected]

AUMA Servopohony spol. s.r.o.CZ-10200 Praha 10Tel +420 272 700056 / 704125Fax +420 272 [email protected]

OY AUMATOR ABFI-02230 EspooTel +358 9 5840 22Fax +358 9 5840 [email protected]

AUMA France S.A.R.L.FR-95157 Taverny CedexTel +33 1 39327272Fax +33 1 [email protected]

AUMA ACTUATORS Ltd.GB- Clevedon North Somerset BS21 6QHTel +44 1275 871141Fax +44 1275 [email protected]

AUMA ITALIANA S.r.l. a socio unicoIT-20023 Cerro Maggiore (MI)Tel +39 0331 51351Fax +39 0331 [email protected]

AUMA BENELUX B.V.NL-2314 XT LeidenTel +31 71 581 40 40Fax +31 71 581 40 [email protected]

AUMA Polska Sp. z o.o.PL-41-310 Dabrowa GórniczaTel +48 32 261 56 68Fax +48 32 261 48 [email protected]

OOO Priwody AUMARU-141400 Moscow region for mail:124365 Moscow a/ya 11Tel +7 495 221 64 28Fax +7 495 221 64 [email protected]

ERICHS ARMATUR ABSE-20039 MalmöTel +46 40 311550Fax +46 40 [email protected]

GRØNBECH & SØNNER A/SDK-2450 København SVTel +45 33 26 63 00Fax +45 33 26 63 [email protected]

IBEROPLAN S.A.ES-28027 MadridTel +34 91 3717130Fax +34 91 [email protected]

D. G. Bellos & Co. O.E.GR-13671 Acharnai AthensTel +30 210 2409485Fax +30 210 [email protected]

SIGURD SØRUM A. S.NO-1300 SandvikaTel +47 67572600Fax +47 [email protected]

INDUSTRAPT-2710-297 SintraTel +351 2 1910 95 00Fax +351 2 1910 95 [email protected]

MEGA Endüstri Kontrol Sistemieri Tic. Ltd.Sti.TR-06810 AnkaraTel +90 312 217 32 88Fax +90 312 217 33 [email protected]

CTS Control Limited Liability CompanyUA-02099 KiyivTel +38 044 566-9971, -8427Fax +38 044 [email protected]

AfricaAUMA South Africa (Pty) Ltd.ZA-1560 SpringsTel +27 11 3632880Fax +27 11 [email protected]

A.T.E.C.EG- CairoTel +20 2 23599680 - 23590861Fax +20 2 [email protected]

AmericaAUMA ACTUATORS INC.US-PA 15317 CanonsburgTel +1 724-743-AUMA (2862)Fax +1 [email protected]

AUMA Chile Respresentative OfficeCL-9500414 BuinTel +56 2 821 4108Fax +56 2 281 [email protected]

LOOP S. A.AR-C1140ABP Buenos AiresTel +54 11 4307 2141Fax +54 11 4307 [email protected]

Asvotec Termoindustrial Ltda.BR-13190-000 Monte Mor/ SP.Tel +55 19 3879 8735Fax +55 19 3879 [email protected]

TROY-ONTOR Inc.CA-L4N 5E9 Barrie OntarioTel +1 705 721-8246Fax +1 705 [email protected]

MAN Ferrostaal de Colombia Ltda.CO- Bogotá D.C.Tel +57 1 401 1300Fax +57 1 416 [email protected]

PROCONTIC Procesos y Control AutomáticoEC- QuitoTel +593 2 292 0431Fax +593 2 292 [email protected]

IESS de Mexico, S.A. de C.V.MX-C.P. 02900 Mexico D.F.Tel +52 55 55 56 1701Fax +52 55 55 56 [email protected]

Corsusa International S.A.C.PE- Miralflores - LimaTel +511444-1200 / 0044 / 2321Fax [email protected]

PASSCO Inc.PR-00936-4153 San JuanTel +18 09 78 77 20 87 85Fax +18 09 78 77 31 72 [email protected]

SuplibarcaVE- Maracaibo Estado, ZuliaTel +58 261 7 555 667Fax +58 261 7 532 [email protected]

AsiaAUMA Actuators (Tianjin) Co., Ltd.CN-300457 TianjinTel +86 22 6625 1310Fax +86 22 6625 [email protected]

AUMA (INDIA) PRIVATE LIMITEDIN-560 058 BangaloreTel +91 80 2839 4655Fax +91 80 2839 [email protected]

82

AUMA worldwide

AUMA JAPAN Co., Ltd.JP-210-0848 Kawasaki-ku, Kawasaki-shiKanagawaTel +81 44 329 1061Fax +81 44 366 [email protected]

AUMA ACTUATORS (Singapore) Pte Ltd.SG-569551 SingaporeTel +65 6 4818750Fax +65 6 [email protected]

Al Ayman Industrial. EqptsAE- DubaiTel +971 4 3682720Fax +971 4 [email protected]

PERFECT CONTROLS Ltd.HK- Tsuen Wan, KowloonTel +852 2493 7726Fax +852 2416 [email protected]

DW Controls Co., Ltd.KR-153-803 Seoul KoreaTel +82 2 2113 1100Fax +82 2 2113 1088/[email protected]

Al-Arfaj Engineering Co WLLKW-22004 SalmiyahTel +965 481-7448Fax +965 [email protected]

Petrogulf W.L.LQA- DohaTel +974 4350 151Fax +974 4350 [email protected]

Sunny Valves and Intertrade Corp. Ltd.TH-10120 Yannawa BangkokTel +66 2 2400656Fax +66 2 [email protected]/

Top Advance Enterprises Ltd.TW- Jhonghe City Taipei Hsien (235)Tel +886 2 2225 1718Fax +886 2 8228 [email protected]

AustraliaBARRON GJM Pty. Ltd.AU-NSW 1570 ArtarmonTel +61 294361088Fax +61 [email protected]

2008-06-10

83

Certificate Registration No.12 100/104 4269

AUMA Riester GmbH & Co. KGP.O.Box 1362D-79373 MüllheimTel +49 7631 809 - 0Fax+49 7631 809 - [email protected]

For detailed information on AUMA products refer to the Internet:www.auma.com

Y004.639/003/en/1.08


Part-turn gearboxes

Operation instructions

Worm gearboxesGS 50.3 – GS 250.3

2

Worm gearboxes GS 50.3 – GS 250.3 Operation instructions

Table of contents Page

1. Safety instructions 31.1 Range of application 31.2 Maintenance 31.3 Warnings and notes 3

2. Technical data 4

3. Transport, storage and packaging 73.1 Transport 73.2 Storage 73.3 Packaging 7

4. Fitting of handwheel 7

5. Mounting positions of the different versions 8

6. Mounting of multi-turn actuators SA/SAR 9

7. Mounting to valve 11

8. Setting the end stops for manual operation 128.1 Worm gearboxes on butterfly valves 128.2 Worm gearboxes on ball valves 13

9. Setting the end stops with mounted multi-turn actuator 139.1 Worm gearboxes on butterfly valves 139.2 Worm gearboxes on ball valves 14

10. Changing the swing angle 1610.1 Changing the swing angle for sizes GS 50.3 – GS 125.3 (option) 1610.2 Changing the swing angle for sizes GS 160.3 – GS 250.3 17

11. Enclosure protection IP 68 18

12. Maintenance 1912.1 General notes 1912.2 Grease change for worm gearboxes GS 50.3 – GS 125.3 and primary reduction gearing

VZ 2.3 – VZ 4.3 2012.2.1 Worm gearboxes 2012.2.2 Primary reduction gearing 2012.3 Grease change for worm gearboxes GS 160.3 – GS 250.3 and primary reduction gearing

VZ 160.3 – VZ 250.3 2112.3.1 Worm gearboxes 2112.3.2 Single-stage reductions gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1 and 8:1) 2112.3.3 Double-stage primary reduction gearing GZ 200.3 – GZ 250.3 (reduction ratio 16:1) 2212.4 After maintenance 22

13. Disposal and recycling 23

14. Service 23

15. Spare parts list worm gearboxes GS 50.3 – GS 125.3 and reduction gearing VZ 2.3 – VZ 4.3 24

16. Spare parts list worm gearboxes GS 160.3 – GS 250.3 26

17. Spare parts list reduction gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) 28

18. Declaration of Conformity and Declaration of Incorporation 30

Index 31

Addresses of AUMA offices and representatives 32

Scope of these instructions: These operation instructions are valid for worm gearboxes of the type rangeGS 50.3 – GS 125.3 with primary reduction gearings VZ 2.3 – VZ 4.3. andGS 160.3 – GS 250.3 with primary reduction gearings GZ 160.3 – 250.3.

1. Safety instructions1.1 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 inconjunction with electric actuators.For other applications, please consult us. The manufacturer is not liable forany possible damage resulting from use in other than the designated appli-cations. Such risk lies entirely with the user.Observance of these operation instructions is considered as part of thegearboxes’ designated use.

1.2 Maintenance The maintenance instructions (refer to page 19) must be observed, other-wise a safe operation of the worm gearbox is no longer guaranteed.

1.3 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries ordamage. Qualified personnel must be thoroughly familiar with all warningsand notes in these operation instructions.Correct transport, proper storage, mounting and installation, as well ascareful commissioning are essential to ensure a trouble-free and safe oper-ation.The following references draw special attention to safety-relevant proce-dures in these operation instructions. Each is marked by the appropriatepictograph.

This pictograph means: Note!“Note” marks activities or procedures which have major influence on thecorrect operation. Non-observance of these notes may lead to consequen-tial damage.

This pictograph means: Warning!“Warning” marks activities or procedures which, if not carried out correctly,can affect the safety of persons or material.

3

Operation instructions Worm gearboxes GS 50.3 – GS 250.3

2. Technical data

Features and functionsVersion Standard: clockwise rotation RR, counterclockwise rotation LL, option: RL or LRHousing material Standard: cast iron (GJL-250), Option: spheroidal cast iron (GJS-400-15)Self-locking 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 notguaranteed. If this is required, a separate brake must be used.

Output torques

End stops Positive for both end positions by travelling nut, sensitive adjustmentStrength of end stop Guaranteed strength of end stop (in Nm) for input side operation

Swing angleGS 50.3 – GS 125.3

Standard: Fixed swing angle up to max. 100°; set in the factory to 92° unless orderedotherwise.

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

Swing angleGS 160.3 – GS 250.3

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 GSDMechanical position indicator Standard: Pointer cover for continuous position indication

Options: Sealed pointer cover for horizontal outdoor installation3)

Protection cover for buried service instead of pointer coverInput shaft Cylindrical with parallel key according to DIN 6885.1OperationMotor operation 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.Type of duty According to actuatorManual operation Via handwheel, directly or through primary reduction gearing VZ/ GZ

Available handwheel diameters, selection according to the max. output torque:

1) With worm wheel made of spheroidal cast iron2) Requires worm wheel made of bronze3) 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

4


Type Output torques100 % 140 % 175 %1) 200 %1) Modulating torque2)

max. Nm max. Nm max. Nm max. Nm max. Nm

GS 50.3 250 350 – 500 125

GS 63.3 500 700 – 1,000 250

GS 80.3 1,000 1,400 – 2,000 500

GS 100.3 2,000 2,800 – 4,000 1,000

GS 125.3 4,000 5,600 – 8,000 2,000

GS 160.3 8,000 11,250 14,000 – 4,000

GS 200.3 16,000 22,500 28,000 – 8,000

GS 250.3 32,000 45,000 56,000 – 16,000

Type GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3

Reduction gearing – – – – VZ 2.3 VZ 3.3 VZ 4.3 – VZ 2.3 VZ 3.3 VZ 4.3

Handwheel Ømm

160200250

250315

315400

400500

315400

315400

250315

500630800

400500

400500

315400

Type GS 160.3 GS 200.3 GS 250.3

Reduction gearing – GZ 160.3 – GZ 200.3 – GZ 250.3

Handwheel Ømm

630800

400 315 – 500630

400 315 – 800 500630

400

Type GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3

Reduction gearing – – – VZ 2.3 VZ 3.3 VZ 4.3 VZ 2.3 VZ 3.3 VZ 4.3

Nm 250 450 450 500 250 500 250

Type GS 160.3 GS 200.3 GS 250.3

Reduction gearing GZ 160.3 GZ 200.3 GZ 250.3

Reduction ratio 4:1 8:1 4:1 8:1 16:1 4:1 8:1 16:1

Nm 500 450 500 500

Primary reduction gearingPrimary reduction gearing Planetary gear with various reduction ratios for reducing the input torquesValve attachmentValve attachment Dimensions according to EN ISO 5211

Standard: GS 50.3 – GS 125.3: without spigotGS 160.3 – GS 250.3: with spigot

Options: GS 50.3 – GS 125.3: with spigotGS 160.3 – GS 250.3: without spigot

Splined coupling for connectionto the valve shaft

Standard: without bore or pilot bore from GS 160.3Worm gearbox can be repositioned 4 x 90° on coupling

Options: Machined with bore and keyway, square bore or bore with two-flatsService conditionsEnclosure protection accordingto EN 60 5294)

Standard: IP 68-3, dust and water tight up to max. 3 m head of waterOptions5): 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 waterIP 68-20, dust and water tight up to max. 20 m head of water

Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plantswith a low pollutant concentration

Options: KS Suitable for installation in occasionally or permanently aggressiveatmosphere with a moderate pollutant concentration(e.g. in wastewater treatment plants, chemical industry)

KX Suitable for installation in extremely aggressive atmospherewith high humidity and high pollutant concentration

Paint Standard: GS 50.3 – GS 125.3: Two-component iron-mica combinationGS 160.3 – GS 250.3: Primer coating

Option: GS 160.3 – GS 250.3: Two-component iron-mica combinationColour Standard: AUMA silver-grey (similar to RAL 7037)

Option: Other colours on requestAmbient temperature 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

Lifetime Open-close duty: The lifetime is based on a load profile typical for part-turn valves

Modulating duty: min. 2.5 million operations7)

4) Refer to clause enclosure protection IP 685) Not available for GS 50.36) With worm wheel made of spheroidal cast iron7) 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

5


Type Operating cycles (OPEN - CLOSE - OPEN)for swivel movements of 90° (max. 100°)

and a maximum output torque of100 % 140 % 175 %6) 200 %6)

GS 50.3 15 000 5 000 – 1 000GS 63.3 15 000 5 000 – 1 000GS 80.3 15 000 5 000 – 1 000GS 100.3 15 000 5 000 – 1 000GS 125.3 15 000 5 000 – 1 000GS 160.3 15 000 5 000 1 000 –GS 200.3 15 000 5 000 1 000 –GS 250.3 10 000 3 000 750 –

AccessoriesValve 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 swingangles > 180° (refer to separate data sheet)

Limit switching Limit switching WSH for manually operated valves. For the signalisation of intermediate andend positions (refer to separate data sheet)

Special features for use in potentially explosive atmospheresExplosion protection II2G c IIC T4 according to ATEX 94/9/ECType of duty Short-time duty S2 - 15 min., max. 3 cycles (OPEN - CLOSE - OPEN) 90°, then cool-down

to ambient temperatureIntermittent duty S4 - 25 % up to the maximum modulating torque

Swing angle Swing angle > 90° on requestAmbient 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 specialsizing

Further informationReference 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 250.3Technical data GS 50.3 – GS 125.3, GS 160.3 – GS 250.3Technical data SA, SAR, WSG, WGD, WSH

Lever gearboxes See separate documents

6


3. Transport, storage and packaging

3.1 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 thegearbox and not to the actuator.

3.2 Storage .Store in well-ventilated, dry room..Protect against floor dampness by storage on a shelf or on awooden pallet..Cover to protect against dust and dirt..Apply suitable corrosion protection agent to bare surfaces.

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 corro-sion 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 caneasily be separated and recycled.For the disposal of the packaging material, we recommend recycling andcollection centres.We use the following packaging materials:Wooden material boards (OSB)/cardboard/paper/PE film

4. Fitting the handwheel For worm gearboxes designed for manual operation the handwheel issupplied separately. Fitting is done on site according to figure 1.

7


Figure 1: HandwheelBall handle(option)

Spacer(may be required)

Circlip

HandwheelWorm shaft gearbox

Circlip

Spacer(may be required)

5. Mounting positions of the different versions

8


C

RR

RL

B

RR

RL

D

RR

RL

B C

LL

LR

D

LL

LR

A

LL

LR

A

RR

RL

GS versions LL/LR

Description of the 4 versions (viewed at the pointer cover):

LL

LR

RR LL RL LR

Mounting positions of AUMA multi-turn actuator with AUMA worm gearbox (please indicate when ordering)GS versions RR/RL

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 isonly 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 packingreasons, actuator and gearbox will be delivered separately from size GS 160.3.

Code Direction of rotation at input shaft Position of worm shaft Direction of rotation at output driveRR clockwise Right side clockwiseLL clockwise Left side counterclockwiseRL clockwise Right side counterclockwiseLR clockwise Left side clockwise

6. Mounting multi-turn actuators SA/SAR

When gearboxes and multi-turn actuators are supplied together, themounting has been done in the factory up to gearbox size GS 125.3. Forsizes GS 160.3 and larger, the mounting of gearboxes is performed asfollows.

In case flange for actuator is not attached to gearbox orreduction 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.

Mounting the multi-turn actuator:.Thoroughly degrease the faces of the flange for actuator at the gearbox orreduction gearing as well as the actuator’s 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 themounting faces are in complete contact..Fasten actuator with bolts and lock washers (see table 1) at the flange ofthe worm gearbox..Fasten bolts crosswise with a torque according to table 2.

Do not attach ropes or hooks for the purpose of lifting theactuator by hoist to the handwheel. If multi-turn actuator ismounted on gearbox, attach ropes or hooks for the purposeof lifting by hoist to gearbox and not to multi-turn actuator.

9


Figure 2: Mounting multi-turn actuator to worm gearbox

Flange for actuator

Flange for actuator

Primary reductiongearing

Bearing flange

Bearing flange

10


Worm gearbox/primary

reduction gearing

SA/SAR 07.1-F07 SA/SAR 07.1-F10/G0 SA/SAR 07.5-F07 SA/SAR 07.5-F10/G0

Bolt Pcs. Bolt Pcs. Bolt Pcs. Bolt Pcs.

GS 50.3 M8 x 20 4 M10 x 25 4

GS 63.3 M8 x 20 4 M10 x 25 4 M8 x 20 4 M10 x 25 4

GS 80.3 M8 x 20 4 M10 x 25 4

GS 100.3

GS 100.3/VZ M10 x 25 4 M10 x 25 4

GS 125.3

GS 125.3/VZ M10 x 25 4

GS 160.3

GS 160.3/GZ M10 x 25 4

GS 200.3

GS 200.3/GZ M10 x 25 4


reduction gearing

SA/SAR 10.1-F10/G0 SA/SAR 14.1-F14/G½ SA/SAR 14.5-F14/G½ SA/SAR 16.1-F16/G3

Bolt Pcs. Bolt Pcs. Bolt Pcs. Bolt Pcs.

GS 63.3 M10 x 25 4

GS 80.3 M10 x 25 4

GS 100.3 M10 x 25 4 M16 x 40 4

GS 100.3/VZ M10 x 25 4

GS 125.3 M16 x 40 4 M16 x 40 4

GS 125.3/VZ M10 x 25 4 M16 x 40 4

GS 160.3 M16 x 40 4 M20 x 50 4

GS 160.3/GZ M10 x 25 4 M16 x 40 4

GS 200.3 M20 x 50 4

GS 200.3/GZ M10 x 25 4 M16 x 40 4 M16 x 40 4

GS 250.3

GS 250.3/GZ M10 x 25 4 M16 x 40 4 M16 x 40 4 M20 x 50 4


reduction gearing

SA/SAR 25.1-F25 SA/SAR 30.1-F30

Bolt Pcs. Bolt Pcs.

GS 160.3

GS 160.3/GZ

GS 200.3 M16 x 50 8

GS 200.3/GZ

GS 250.3 M16 x 50 8 M20 x 50 8

GS 250.3/GZ

Table 1: Bolts for mounting AUMA actuators to worm gearboxes/primary reduction gearing(strength class min. 8.8)

7. Mounting to valve AUMA worm gearboxes GS and primary reduction gearings VZ/GZ can beoperated 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 stopCLOSED by turning the handwheel clockwise)..For ball valves, the recommended mounting position is end positionOPEN(Prior to mounting, bring the gearbox to the mechanical end stop OPENby turning the handwheel counterclockwise)..Thoroughly degrease mounting faces of gearbox and valve..Place coupling sleeve onto valve shaft and secure (refer to figure 3, detail Aor 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) matesuniformly 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.

Note:Experience showed that it is very difficult to fasten bolts or nuts of M30 orlarger with the defined torques. The worm gearbox may be moved radiallyagainst the valve flange by accident.To improve adhesion between valve and gearbox, we recommend to applyLoctite 243 (or similar products) on mounting faces.

11


A

X

B

Z

Y

Figure 3

Coupling

Valve

Grub screw

Gearbox Dimensions Bolts Strength class8.8

Strength classA2-70/A4-70

Strength classA2-80/A4-80

Flange type X max Y max Z max Qty. x threads Fastening torque TA [Nm]GS 50.3-F05 6 5 65 4 x M 6 11 8 10GS 50.3-F07 14 5 61 4 x M 8 25 18 24GS 50.3-F10 14 5 61 4 x M10 51 36 48GS 63.3-F10 7 18 73 4 x M10 51 36 48GS 63.3-F12 10 13 76 4 x M12 87 61 82GS 80.3-F12 13 18 78 4 x M12 87 61 82GS 80.3-F14 23 5 88 4 x M16 214 150 200GS 100.3-F14 22 13 123 4 x M16 214 150 200GS 100.3-F16 22 8 123 4 x M20 431 294 392GS 125.3-F16 17 35 126 4 x M20 431 294 392GS 125.3-F25 17 27 126 8 x M16 214 150 200GS 160.3-F25 15 11 130 8 x M16 214 150 200GS 160.3-F30 30 0 140 8 x M20 431 294 392GS 200.3-F30 19 19 160 8 x M20 431 294 392GS 200.3-F35 44 0 190 8 x M30 (1489) 564 –GS 250.3-F35 8 8 220 8 x M30 (1489) 564 –GS 250.3-F40 13 0 230 8 x M36 (2594) – –

Table 2: Fastening torques for bolts with different strength classes

8. Setting the end stops for manual operation

If worm gearboxes GS are supplied on a valve the end stopsare 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 tothe stop.. If the holes of limit stop housing (10) do not align with the threads of thehousing (1), take off the limit stop housing (10) and replace it in therequired position..Fasten bolts (03) with lock washers (04)..Fasten bolts (see table 3) crosswise with a torque according to table 2.

. If the position of the pointer cover does not correspond to the symbolCLOSED, slightly loosen the screws of the pointer cover. Turn the pointercover to the CLOSED symbol and fasten the screws again.

Setting end position OPEN The end stop need not be set since the required swing angle has been setin the factory.If the swing angle does not match, refer to clause 10.


12

Gearbox End stops fastenedwith

bolts (03)

Material protection cover fas-tened withbolts (054)

Material

GS 50.3 M8 A2-80GS 63.3 M8 A2-80GS 80.3 M8 A2-80GS 100.3 M12 A2-80GS 125.3 M12 A2-80GS 160.3 M10 A2-80 M6 A2-80GS 200.3 M12 A2-80 M6 A2-80GS 250.3 M16 A2-80 M6 A2-80

Table 3:

03/04

10 1

Figure 4: End stop up to GS 125.3

03/04

10 1

Figure 5: End stop from GS 160.3

8.2 Worm gearboxes on ball valves

In case end stops require adjustment, set end positionOPEN first. If the exact end position of the valve cannot beseen through a position marking at the valve shaft, thesetting may have to be done with the valve removed.

Setting end position OPEN .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 counterclockwiseup to the stop.. If the holes of limit stop housing (10) do not align with the threads of thehousing (1), take off the limit stop housing (10) and replace it in therequired 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 symbolOPEN, slightly loosen the screws of the pointer cover. Turn the pointercover 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 setin the factory.If the swing angle does not match, refer to clause 10.

9. Setting the end stops with mounted multi-turn actuator

. If worm gearboxes GS and multi-turn actuators are sup-plied on a valve, the end stops as well as limit and torqueswitching are already set.. If the limit and torque switching have not yet been set, theyhave to be set according to the operation instructionsSA/SAR and the specifications of the valve manufacturer..The valve manufacturer states whether the valve shouldbe limit or torque seated.

9.1 Worm gearboxes on butterfly valves.Determine the overrun of the multi-turn actuator for both directions, i. e. howmuch 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 endposition CLOSED.. In case limit stop housing (10) has not yet rotated, turn it clockwise up tothe stop..Turn limit stop housing (10) back counterclockwise by ½ turn. Thisensures that the mechanical end stop is not reached in electric operationand thus the valve can close tightly, provided that torque seating has beenspecified.. If the fixing holes of limit stop housing (10) do not align with the threads ofthe housing (1), take off the limit stop housing (10) and replace it inrequired 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 symbolCLOSED, slightly loosen the screws of the pointer cover. Turn the pointercover to the CLOSED symbol and fasten the screws again.

13


Limit seating in end position CLOSED.Turn back the valve from the end position by an amount equal to theoverrun..Set limit switching according to the operation instructions SA/SAR..Check torque switching for end position CLOSED according to the opera-tion 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 operationinstructions SA/SAR (for signalisation)..Check torque switching for end position CLOSED or set to the requiredvalue.

Setting end position OPEN The end stop need not be set since the required swing angle has been setin 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 equalto 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 reductionratio of the primary reduction gearing..Set limit switching in actuator for the end position OPEN according to theoperation instructions SA/SAR.If the swing angle does not match, refer to clause 10.

9.2 Worm gearboxes on ball valves In case end stops need to be adjusted, set end positionOPEN first. If the exact end position of the valve cannot beseen through a position marking at the valve shaft, thesetting may have to be done with the valve removed.

.Determine overrun of the actuator for both directions, i. e. how much does thevalve move after the motor has been switched off?

14


03/04

10 1


03/04

10 1


Setting end position OPEN .Remove all bolts (03) at limit stop housing (10) (figures 6, 7)..Change to manual drive and move the valve manually to end positionOPEN.. In case limit stop housing (10) has not yet rotated, turn it counterclockwiseup to the stop..Turn limit stop housing (10) back by ½ turn clockwise. This ensures thatthe mechanical end stop is not reached in electric operation.. If the holes of limit stop housing (10) do not align with the threads of thehousing (1), take off the limit stop housing (10) and replace it in therequired 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 symbolOPEN, slightly loosen the screws of the pointer cover. Turn the pointercover to the OPEN symbol and fasten the screws again.

Switching off in end positionOPEN

.Turn back the valve from the end position by an amount equal to theoverrun..Set limit switching according to the operation instructions SA/SAR.

Setting end position CLOSED The end stop need not be set since the required swing angle has been setin 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 equalto 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 reductionratio of the primary reduction gearing..Set limit switching in actuator for the end position CLOSED according tothe 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 125.3Standard for size GS 160.3 – GS 250.3

Accuracy:GS 50.3 – GS 125.3: 0.6°GS 160.3 – GS 250.3: 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 rollpin (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).

.Tap in roll pin (020) with tool. If slot in end stop nut (15) does not align withthe hole in the worm shaft, turn end stop nut (15) slightly counterclockwiseuntil 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 forthe end position OPEN according to the operation instructions SA/SAR.Allow for overrun.


16

020 15 10 716 08


03/04082/083058

10 7056054055

34 1516


10.2 Changing the swing angle for sizes GS 160.3 – GS 250.3.Remove all bolts (054) and pull off protection cover (16)(figure 9)..Remove screw (082) with washer (058) and setting ring (34).

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 forthe end position OPEN according to the operation instructions SA/SAR.Allow for overrun.


17

11. Enclosure protection IP 68

Definition According to EN 60 529, the conditions for meeting the requirements ofenclosure protection IP 68 (requirements exceed those of IP 67) are to beagreed between manufacturer and user. AUMA worm gearboxes andprimary reduction gearings in enclosure protection IP 68 meet the followingrequirements according to AUMA:. IP 68-3, submersible in water up to 3 m head of water. IP 68-6, submersible in water up to 6 m head of water. IP 68-10, submersible in water up to 10 m head of water. IP 68-20, submersible in water up to 20 m head of water

For size GS 50.3, only enclosure protection IP 68-3 is available.

If submersed in other media, additional measures for corrosion protectionmay be necessary; please consult AUMA. Submersion in aggressive media,e.g. acids or alkaline solutions, is not permitted.

Review 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 undergoa routine testing for tightness in the factory.

Note: .The enclosure protection IP 68 refers to the interior of the gearboxes, butnot to the coupling compartment.. If the gearboxes are likely to be repeatedly submersed, a higher corrosionprotection KS or KX is required..For gearboxes intended for buried service we strongly recommend to usethe higher corrosion protection KS or KX..For horizontal outdoor installation of the gearboxes, a sealed pointer covershould be used.For gas applications with sealed pointer cover, an air vent in the pointercover or venting grooves in the valve mounting flange must be provided.. In case of permanent submersion of the gearboxes or for buried service, aprotection cover must be fitted instead of a pointer cover. This will be takeninto account in the factory if indicated on the purchase order. Subsequentexchange 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. Thiswould lead to corrosion of hub and coupling. Therefore a suitableanticorrosive (or sticky grease) must be applied to the hub and coupling ofthe gearbox before mounting..With corrosion protection KX, the hub and coupling are provided with ahigh quality corrosion protection as standard.


18

12. Maintenance12.1 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 recom-mend for gearboxes operated less than 10 times per year, the followingmeasures:.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 every2 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 above40 °C, maintenance must be performed at shorter intervals.

Seals:Seals made of elastomer materials are subject to ageing. The theoreticalusable lifetime of the seals made of NBR is 13.5 years from the date ofmanufacture. These figures are based on an average ambient temperatureof 40 °C. Seal kits may be obtained from AUMA.

Grease:A grease and seal change is recommended after the following operationtime:. 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.

The removed lubricant and the cleaning agent used must bedisposed of according to the relevant regulations.


19

GS 50.3 63.3 80.3 100.3 125.3 160.3 200.3 250.3

Qty dm³ 0.1 0.3 0.4 1.0 1.3 3.3 6.6 12.2

Weight1) kg 0.09 0.27 0.36 0.9 1.17 3.0 6.0 11.0

Primaryreductiongearing

VZ GZ

2.3 3.3 4.3 160.3 200.3 250.34:1/8:1 16:1 4:1/8:1 16:1

Quantity dm² 0.35 0.35 0.35 1.0 1.5 2.0 2.2 2.8

Weight1) kg 0.32 0.32 0.32 0.9 1.4 1.8 2.0 2.25

1) for ρ = approx. 0.9 kg/dm3

Table 4: Grease quantities for worm gearboxes and primary reduction gearings

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 pres-sure!

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 wormwheel carefully from the housing. For this, the worm shaft must be pulledfrom the bearings and tilted slightly in the worm channel..Remove old grease completely from the housing and the individual partsand clean gear housing. For this purpose, kerosene or a similar cleaningagent may be used..Clean mounting faces at housing and housing cover (518.0). ReplaceO-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 posi-tion of the O-rings [S1(010), S1(011)] at the worm wheel. Place bolts withlock 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 boltscrosswise to the appropriate torque according to table 2, page 11..Gearbox without primary reduction gearing: Continue with clause “Aftermaintenance”..Gearbox with reduction gearings VZ 2.3 – VZ 4.3: Perform grease changeat the reduction gearing according to the following subclause.

12.2.2 Primary reduction gearing 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 theplanet wheels..Remove old grease completely from the housing and the individual partsand clean them. For this purpose, kerosene or a similar cleaning agentmay be used..Clean mounting faces at housing (019.0), housing cover (020.0) andinternal 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 cross-wise to the appropriate torque according to table 2, page 11..Continue with clause “After maintenance”, page 22.


20

12.3 Grease change for worm gearboxes GS 160.3 – GS 250.3 and primary reduction gearingVZ 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 pres-sure!

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 takeoff housing cover..Remove bolts with lock washers from the bearing cover (522.0). Take offbearing lock nut (537.0) by loosening the grub screw. Remove protectioncover (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 wormshaft must be pulled from the bearings and tilted slightly in the wormchannel.Pull out worm shaft from housing in direction of the housing input..Remove old grease completely from the housing and the individual partsand clean gear-housing. For this purpose, kerosene or a similar cleaningagent may be used..Clean mounting faces at housing and housing cover (518.0). ReplaceO-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. Fastenbearing 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 posi-tion of the O-rings [S1(010), S1(011)] at the worm wheel. Place bolts withlock 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, fastenbolts crosswise to the appropriate torque according to table 2, page 11..Gearbox without primary reduction gearing: Continue with clause “Aftermaintenance”..Gearbox with reduction gearings GZ 160.3 – GZ 250.3: Perform greasechange 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 gearedwheel)..Remove screws from the internal geared wheel and separate the internalgeared wheel from the drive shaft..Remove old grease completely from the housing and the individual partsand 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) andinternal geared wheel. Replace O-rings by new ones..Fill housing cover (002.0) with new grease.


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.Fix internal geared wheel with screws at housing cover..Fill housing (001.0) with remaining grease and fit the complete housingcover with drive shaft (534.0). Screw in bolts with lock washers and fastenthem 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 removehousing frame with planet carrier and hollow wheel..Remove screws from the internal geared wheel and separate the internalgeared wheel from the drive shaft (003.0)..Remove screws from the second stage of the internal geared wheel andseparate it from the pinion (011.1)..Remove old grease completely from the housing and the individual partsand clean them. For this purpose, kerosene or a similar cleaning agentmay 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 andfasten them evenly crosswise to the appropriate torque according to table2, page 11..Fill housing frame (010.0) and housing cover (002.0) with the remaininggrease..Fix first stage of the internal geared wheel on the housing cover (002.0)..Place complete housing cover with drive shaft onto housing frame. Screwin bolts with lock washers and fasten them evenly crosswise to the appro-priate torque according to table 2, page 11.

12.4 After maintenance . If applicable, mount multi-turn actuator..Reset the end stops..For gearboxes with multi-turn actuator, check the setting of the limitswitching according to the operation instructions for multi-turn actuators; ifrequired, reset..Perform test run to ensure the proper function..Check worm gearbox for damage to paint finish. Do a thorough touch-upto prevent corrosion. Original paint in small quantities can be supplied byAUMA.


22

13. Disposal and recyclingAUMA gearboxes have an extremely long lifetime. However, they have to bereplaced at one point in time.Our gearboxes have a modular design and may therefore easily be disas-sembled, separated and sorted according to materials, i.e.:.various metals.plastics.greases and oils

The following generally applies:.Collect greases and oils during disassembly. As a rule, these substancesare hazardous to water and must not be released into the environment..Arrange for controlled waste disposal of the disassembled material or forseparate recycling according to materials..Observe the national regulations for waste disposal.

14. Service AUMA offers extensive services such as maintenance and inspection forgearboxes. Addresses of AUMA offices and representatives can be found onpage 32 and on the Internet (www.auma.com).


23

15. Spare parts list worm gearboxes GS 50.3 – GS 125.3 and reduction gearingVZ 2.3 – VZ 4.3

24


Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only originalAUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA fromliability. Delivered spare parts may slightly vary from the representation.

25



003.0 Housing cover with drive shaft VZ Sub-assembly

019.0 Housing VZ Sub-assembly

020.0 Housing cover VZ Sub-assembly

021.0 Drive shaft VZ Sub-assembly

022.0 Planet carrier VZ Sub-assembly

045.0 Internal geared wheel VZ Sub-assembly

512.0 Flange for actuator Sub-assembly

513.1 Grub screw


518.0 Housing cover Sub-assembly

519.1 Worm wheel

520.0 Worm shaft Sub-assembly

521.1 Travelling nut

522.0 Bearing cover Sub-assembly

523.0 Limit stop housing Sub-assembly

524.0 Pointer cover Sub-assembly

525.0 Coupling Sub-assembly

526.0 End stop nut Sub-assembly

527.0 Protection cover Sub-assembly

534.0 Drive shaft Sub-assembly

538.0 Bearing cover with drive shaft Sub-assembly

S1 Seal kit Set

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 originalAUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA fromliability. Delivered spare parts may slightly vary from the representation.

27




513.1 Grub screw



519.1 Worm wheel

520.0 Worm shaft Sub-assembly

521.1 Travelling nut

522.0 Bearing cover Sub-assembly

523.0 Limit stop housing Sub-assembly

524.0 Pointer cover Sub-assembly

525.0 Coupling Sub-assembly

526.0 End stop nut Sub-assembly




537.0 Lock nut Sub-assembly

538.0 Bearing cover with drive shaft Sub-assembly

S1 Seal kit Set

17. Spare parts list reduction gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1)

28


GZ 200.1 – GZ 250.116:1

GZ 160.1 – GZ 250.14:1/8:1

Note:Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMAspare 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.

29


No. Designation



003.0 Housing cover with drive shaft Sub-assembly

006.0 Planetary gearing, first stage (GZ 160.3) Sub-assembly



010.0 Housing frame Sub-assembly

011.1 Pinion


513.1 Grub screw


S1 Seal kit Set

18. Declaration of Conformity and Declaration of Incorporation

30


RiestererB

ze_ei_ko_gs3_gs0_gf3_gk2_gst1_en

31


IndexBBolts for mounting actuators 10

CChanging the swing angle 16Corrosion protection 7

DDeclaration of Conformity 30Declaration of Incorporation 30Disposal and recycling 23

EEnclosure protection IP 68 18

FFitting the handwheel 7

HHandwheel 7

LLubricant 20

MMaintenance 3,19Manual operation 12Motor operation 13Mounting positions 8Mounting the multi-turn actuators 9Mounting to valve 11

PPackaging 7

RRange of application 3

SSafety instructions 3Service 23Setting the end stop

with mountedmulti-turn actuator 13

Setting the end stopsfor manual operation 12

Spare parts listGS 160.3 - GS 250.3 26GS 50.3 - GS 125.3 24GZ 160.3 - GZ 250.3(4:1/8:1/16:1) 28

Storage 7

TTechnical data 4Transport 7

Information also availableon the Internet:

Inspection records and further gearbox information can be downloadeddirectly from the Internet by entering the order no. or comm. no.(refer to name plate).Visit us at: http://www.auma.com


www.auma.com

AUMA Riester GmbH & Co. KGP.O. Box 136279373 Müllheim, [email protected]

+49 7631 - 809-0+49 7631 - 809 1250

+49 711 - 34803 0+49 711 - 34803 34

AUMA Riester GmbH & Co. KGP. O. Box 1151D - 73747 [email protected]

For detailed information on AUMA products, refer to the InternetY003.822/003/en /2.09

EuropeAUMA Riester GmbH & Co. KGPlant MüllheimDE-79373 MüllheimTel +49 7631 809 - 0Fax +49 7631 809 - [email protected] Ostfildern-NellingenDE-73747 OstfildernTel +49 711 34803 - 0Fax +49 711 34803 - [email protected] Center CologneDE-50858 KölnTel +49 2234 2037 - 9000Fax +49 2234 2037 - [email protected] Center MagdeburgDE-39167 NiederndodelebenTel +49 39204 759 - 0Fax +49 39204 759 - [email protected] Center BavariaDE-85386 EchingTel +49 81 65 9017- 0Fax +49 81 65 9017- [email protected] Armaturenantriebe GmbHAT-2512 TribuswinkelTel +43 2252 82540Fax +43 2252 [email protected] (Schweiz) AGCH-8965 BerikonTel +41 566 400945Fax +41 566 [email protected] Servopohony spol. s.r.o.CZ-10200 Praha 10Tel +420 272 700056 / 704125Fax +420 272 [email protected] AUMATOR ABFI-02230 EspooTel +358 9 5840 22Fax +358 9 5840 [email protected] France S.A.R.L.FR-95157 Taverny CedexTel +33 1 39327272Fax +33 1 [email protected] ACTUATORS Ltd.GB- Clevedon Nort_inth Somerset BS216QHTel +44 1275 871141Fax +44 1275 [email protected] ITALIANA S.r.l. a socio unicoIT-20023 Cerro Maggiore (MI)Tel +39 0331 51351Fax +39 0331 [email protected] BENELUX B.V.NL-2314 XT LeidenTel +31 71 581 40 40Fax +31 71 581 40 [email protected]

AUMA Polska Sp. z o.o.PL-41-310 Dabrowa GórniczaTel +48 32 261 56 68Fax +48 32 261 48 [email protected] Priwody AUMARU-141400 Moscow region for mail: 124365Moscow a/ya 11Tel +7 495 221 64 28Fax +7 495 221 64 [email protected] ARMATUR ABSE-20039 MalmöTel +46 40 311550Fax +46 40 [email protected]ØNBECH & SØNNER A/SDK-2450 København SVTel +45 33 26 63 00Fax +45 33 26 63 [email protected] S.A.ES-28027 MadridTel +34 91 3717130Fax +34 91 [email protected]. G. Bellos & Co. O.E.GR-13671 Acharnai AthensTel +30 210 2409485Fax +30 210 [email protected] SØRUM A. S.NO-1300 SandvikaTel +47 67572600Fax +47 [email protected] SintraTel +351 2 1910 95 00Fax +351 2 1910 95 [email protected] Endüstri Kontrol Sistemieri Tic. Ltd. Sti.TR-06810 AnkaraTel +90 312 217 32 88Fax +90 312 217 33 [email protected] Control Limited Liability CompanyUA-02099 KiyivTel +38 044 566-9971, -8427Fax +38 044 [email protected]

AfricaAUMA South Africa (Pty) Ltd.ZA-1560 SpringsTel +27 11 3632880Fax +27 11 [email protected] CairoTel +20 2 23599680 - 23590861Fax +20 2 [email protected]

AmericaAUMA ACTUATORS INC.US-PA 15317 CanonsburgTel +1 724-743-AUMA (2862)Fax +1 [email protected] Automação do Brasil ltda.BR-Sao PauloTel +55 11 [email protected]

AUMA Chile Representative OfficeCL- La Reina Santiago de ChileTel +56 22 77 71 51Fax +56 22 77 84 [email protected] S. A.AR-C1140ABP Buenos AiresTel +54 11 4307 2141Fax +54 11 4307 [email protected] Ferrostaal de Colombia Ltda.CO- Bogotá D.C.Tel +57 1 401 1300Fax +57 1 416 5489dorian.hernandez@manferrostaal.comwww.manferrostaal.comPROCONTIC Procesos y Control AutomáticoEC- QuitoTel +593 2 292 0431Fax +593 2 292 [email protected] International S.A.C.PE- Miralflores - LimaTel +511444-1200 / 0044 / 2321Fax [email protected] Inc.PR-00936-4153 San JuanTel +18 09 78 77 20 87 85Fax +18 09 78 77 31 72 [email protected] Maracaibo Estado, ZuliaTel +58 261 7 555 667Fax +58 261 7 532 [email protected]

AsiaAUMA Actuators (Tianjin) Co., Ltd.CN-300457 TianjinTel +86 22 6625 1310Fax +86 22 6625 [email protected] (INDIA) PRIVATE LIMITEDIN-560 058 BangaloreTel +91 80 2839 4655Fax +91 80 2839 [email protected] JAPAN Co., Ltd.JP-210-0848 Kawasaki-ku, Kawasaki-shiKanagawaTel +81 44 329 1061Fax +81 44 366 [email protected] ACTUATORS (Singapore) Pte Ltd.SG-569551 SingaporeTel +65 6 4818750Fax +65 6 [email protected] Actuators Middle East W.L.L.AE- 15268 Salmabad 704Tel +973 [email protected] CONTROLS Ltd.HK- Tsuen Wan, KowloonTel +852 2493 7726Fax +852 2416 [email protected] Controls Co., Ltd.KR-153-803 Seoul KoreaTel +82 2 2113 1100Fax +82 2 2113 1088/[email protected]

Sunny Valves and Intertrade Corp. Ltd.TH-10120 Yannawa BangkokTel +66 2 2400656Fax +66 2 [email protected]/Top Advance Enterprises Ltd.TW- Jhonghe City Taipei Hsien (235)Tel +886 2 2225 1718Fax +886 2 8228 [email protected]

AustraliaBARRON GJM Pty. Ltd.AU-NSW 1570 ArtarmonTel +61 294361088Fax +61 [email protected]

2009-01-01

AC01 13122204

F 98220770

AC01 13130176

F 98221102

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