Operating Manual Linear actuators with spring reset device

7 mm
Operating Manual
Linear actuators with
spring reset device
MC253SE/24 • MC253SE/230
March 2011 / 118362 / EN
General information
General information
Amendment
Copyright
Subject to alteration
Version
Date
Modifications
1.0
June 2010
Initial preparation
1.1
March 2011
Revision
The copyright for this operating manual as well as all rights in case of patent
awarding or registration of registered design remains with the manufacturer!
The regulations, directives, standards etc. are compliant with the current state of
information at the time of development and are not subject to modification service.
They must be applied by the operator at his own responsibility in their latest valid
version.
Concerning all data, information, and illustrations in this manual we reserve the
right of technical modifications and improvements. No claims can be considered
for alteration or rework of already delivered lift drives.
Manufacturer
HORA
Geschäftsbereich Flow Control
Holter Regelarmaturen GmbH & Co. KG
Helleforthstrasse 58–60
33758 Schloss Holte-Stukenbrock
Germany
phone: +49 (0) 5207/8903-0
mail: fc@hora.de
www.hora.de
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Operating Manual
Inhalt
Inhalt
1 Safety ......................................................................... 4
1.1 Proper use ............................................................... 4
1.2 Information for the operator ..................................... 4
1.3 Personnel................................................................. 5
1.4 Prior to starting work................................................ 5
1.5 During operation ...................................................... 5
1.6 Working environment............................................... 5
2 Product Specification ............................................... 6
2.1 Components ............................................................ 7
2.2 Accessories ............................................................. 8
2.3 Operating modes ..................................................... 8
2.3.1 Continuous mode ......................................... 8
2.3.2 Three-point mode ......................................... 9
2.4 Functions ................................................................. 9
2.4.1 Binary signal / Frost protection function ....... 9
2.4.2 Lock detection .............................................. 9
2.4.3 Internal temperature monitoring ................... 9
2.4.4 Open-circuit detection................................. 10
2.4.5 Set time ...................................................... 10
2.4.6 Hysteresis................................................... 10
2.4.7 Manual mode and feedback signal............. 10
2.4.8 Autotest ...................................................... 11
2.4.9 Autopause .................................................. 11
2.4.10 Potential-free way-switch (optional extra)... 11
2.5 Technical data ....................................................... 12
2.6 Type plate .............................................................. 13
3
Transportation & Storage ....................................... 13
4 Assembly..................................................................14
4.1 Checking the scope of delivery ..............................14
4.2 Preparing assembly ...............................................14
4.3 Mounting the linear actuator on the valve ..............15
4.4 Assembling/disassembling the cover .....................17
4.5 Electrical connection ..............................................18
4.5.1 Controller independent circuit .....................20
4.6 Optional extras installation .....................................21
4.6.1 Way-switch printed circuit board
installation...................................................21
4.6.2 Fit the printed circuit board for mA
output signal. ..............................................22
5 Commissioning........................................................24
5.1 Operating parameters and coding
switch positions ......................................................24
5.2 Set input signal.......................................................25
5.3 Set actuating time ..................................................25
5.4 Set hysteresis.........................................................26
5.5 Set actuating direction............................................26
5.6 Set Autotest and Autopause ..................................26
5.7 Set limit position .....................................................27
5.8 Set potential-free way-switch .................................27
5.9 Initialising the path measuring system ...................29
5.10 Commissioning.......................................................30
6 Operation..................................................................31
6.1 Changing between manual and automatic mode...31
6.2 LED display ............................................................32
7
Maintenance, Care and Repairs .............................32
8
Spare parts...............................................................32
9
Shutdown and Disposal..........................................33
10 Troubleshooting ......................................................33
10.1 Troubleshooting .....................................................33
10.2 Operating faults checklist .......................................34
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Operating Manual
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1 Safety
1 Safety
Read these Operating Instructions carefully particularly the following safety
instructions prior to installation and operation.
DANGER
Directly threatening hazard leading to death or serious physical injuries.
DANGER
WARNING
CAUTION
ATTENTION
Hint:
1.1
WARNING
Potentially hazardous situation which may lead to death or serious physical
injuries.
CAUTION
Potentially hazardous situation which could lead to minor physical injuries.
Indicates a hazard which may cause material damage.
ATTENTION
Potentially hazardous situation where the product or an object in its environment
may get damaged.
Utilisation instructions and other useful information.
Proper use
Linear actuator MC253SE/24, MC253SE/230 are controlled by three-point control
or constant control. Linear actuators in the series described in these Operating
Instructions are used for valve stroke adjustment.
Concurrence of the above type designation with the linear actuator rating plate
must be checked prior to starting any operations in order to guarantee utilisation
in accordance with specification. The data on the rating plate is decisive for linear
actuator technical data and mains power supply requirements.
Any utilisation for tasks other than the aforementioned usage in accordance with
specification and operating with mains power supply ratios other than those
permitted is not deemed to be utilisation in accordance with specification. The
operator bears sole liability for the risk to persons and machine and other assets
in the event of utilisation not in accordance with specification.
The intended use also includes the compliance with accident preventions, DIN
VDE regulations and safe working practices for all measures described in these
operating instructions in due consideration of prevailing rules.
1.2
Information for the operator
Always keep the Operating Instructions available at the linear actuator
deployment site.
Observe the current health and safety, accident prevention and DIN VDE
standards for installation, operation and maintenance.
Take into consideration any additional regional, local or in-house safety
regulations.
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Operating Manual
1 Safety
Ensure that every person entrusted with one of the tasks specified in these
Operating Instructions has read and understood these instructions.
1.3
Personnel
Only qualified personnel may work on these linear actuators or in their vicinity.
Qualified persons are those persons entrusted with installation, assembly,
commissioning and operation or maintenance of the linear actuators and
possessing the appropriate qualifications for their activity. The necessary and
prescribed qualifications include:
• Training / instruction or authorization to turn on /off circuits and appliances /
systems according to EN 60204 (DIN VDE 0100 / 0113) and the standards of
safety technology.
• Training or instruction according to the standards of the safety technology
concerning care and use of adequate safety and work protection equipment.
• First Aid training.
Work in a safe manner and refrain from any working practice which endangers the
safety of persons or damages the linear actuator or other assets in any way
whatsoever.
1.4
Prior to starting work
Prior to starting any work, check that the type designations specified here concur
with the data on the linear actuator rating plate.
Linear actuator MC253SE/24, MC253SE/230.
1.5
During operation
Safe operation is only possible if transportation, storage, installation, operation
and maintenance are carried out safely and materially and professionally
correctly.
Transportation,
installation and
assembly
Repairs and
maintenance
1.6
Observe the general set-up and safety regulations for heating, ventilation, airconditioning and pipework design. Use tools correctly. Wear the necessary
personal and other safety equipment.
Ensure that qualified personnel switch off the linear actuator prior to maintenance
or repair work in accordance with DIN VDE.
Working environment
Read the data concerning the working environment in the Technical Data.
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Operating Manual
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2 Product Specification
2 Product Specification
The linear actuator is used to actuate and adjust lift valves. The lifting movement
is generated by means of a spindle actuator coupled to a valve spindle comprising
a pivoted spindle and a spindle nut secured against skewing. The actuation of the
ball bearing mounted spindle is achieved by means of a stepper motor with
interconnected two-step planetary gear. The stepper motor receives the rotary
field required for operation from a micro controller based electric control.
The linear actuator comprises a spring reset device with an electro-hydraulically
blockable spring. On commissioning the spring is tensed inside the hydraulic unit
by the spindle actuator and blocked electro-hydraulically when reaching spring
limit position. During a cut of supply voltage this spring will be unlocked and the
clutch piece will move hydraulically dampened to the lower limit position –
actuator spindle.
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2 Product Specification
2.1
Components
201
201
107
107
34
34
230;
231
230;
231
7 mm
47
47
110
110
480
480
101
101
11
16
16
13
13
55
36
36
60
60
10
10
219
219
11
11
88
314
314
315
315
33
22
312
312
452
452
1
2
3
5
8
10
11
13
16
34
36
47
60
Actuator casing
Cross head
Coupling piece*
Spindle nut
Position display *
Protective tube
Spacer sleeve
Bridge
Gear casing
Knob
Hand wheel
Viewing window
Guide bush
diagram 1
*
101
107
110
201
219
230
231
312
314
315
452
480
Engine/ motor
Terminal board for 24 V or 230 V
Main board
Cover for 24 V or 230 V*
Hydraulic unit
Cable inlet M20 × 1.5*
Cable inlet M16 × 1.5*
Safety disk
Blank flange*
Bolt*
Hexagonal nut M10*
Type plate
Component drawings
This component is available as a spare part!
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2 Product Specification
2.2
Accessories
111
111
DIP
on
1 2 3 4 5 6 7 8 9 10
0 ... 20 mA mA
0...20
4...20
4 ... 20 mA mA
LED2
LED1
111 PCB for output signal X = 0/4 ... 20 mA
diagram 2
PCB for mA output signal in cover
106
LED1
LED2
LED1
LED2
106 PCB for path switch
diagram 3
2.3
Position switch PCB in cover
Operating modes
The linear actuator can be operated manually or automatically.
• In manual mode stroke is adjusted via the hand wheel.
• In automatic mode stroke is controlled electrically.
2.3.1
Continuous mode
In continuous mode the system control presets the position of the linear actuator
whilst inside the linear actuator the input signal (Y) of the system control is
continuously compared with the output signal (X) of the linear actuator. In doing
so the output signal depends on the position of the linear actuator (travel).
The linear actuator keeps moving until the input signal and the output signal
match.
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2 Product Specification
Input signal (Y)
The input signal (Y) from the system control specifies the reference position for
the linear actuator. It is an analogue signal on terminal Y.
The following input signals are possible:
• 0 … 10 V DC / 2 … 10 V DC
• 0 … 20 mA / 4 … 20 mA
Output signal (X)
The output signal (X) specifies the actual position of the linear actuator. It is an
analogue signal on terminal X.
0% to 100% valve lift is output as:
• 0 … 10 V DC
• 0 … 20 mA or 4 … 20 mA (Printed circuit board for output signal as optional
extra (111))
2.3.2
Three-point mode
The direction of movement is specified via a control voltage on terminal 2 and
terminal 3 on the motherboard:
• If the control voltage on terminal 2 is on, the spindle nut extends.
• If the control voltage on terminal 3 is on, the spindle nut retracts.
2.4
2.4.1
Functions
Binary signal / Frost protection function
Terminals B1 and B2 on the motherboard are bridged in Normal mode. If the
circuit between B1 and B2 is broken, the linear actuator stores the actual position
and then moves automatically to its limit position.
All other control signals are ignored during this process.
The linear actuator remains in the limit position until the circuit between B1 and
B2 is closed again.
• In Three-point mode the linear actuator then returns automatically to the
stored position.
• In Continuous mode the reference value of the input signal is again
approached.
2.4.2
Lock detection
If the linear actuator becomes mechanically locked, it returns briefly and tries
again to reach the required position. If this does not happen after a total of 7
attempts, the linear actuator is switched off to avoid damage to linear actuator and
actuator.
The lock detection is displayed via the green LED in the (60) viewing window.
 Table 7 on page 32
2.4.3
Internal temperature monitoring
The actuator has internal temperature monitoring.
Overheating protection
If the temperature in the actuator casing exceeds a limit value, the motor will be
switched off. Once the motor has cooled down, it is automatically switched on
again.
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2 Product Specification
Actuator heating
If the temperature in the actuator drops below 15 °C, the motor is switched to
heating in the operating pauses. The actuator heating switches off automatically
at a constant temperature of approx. 22 °C. The actuator heating does not affect
the functions of the actuator.
Heating capacity:
• 12.5 W at temperatures from approx. 8 °C to approx.15 °C
• 18 W at temperatures below 8 °C
The heating prevents the build-up of water condensation in the actuator and at the
same time guarantees the smooth running of the gears even at temperatures up
to approx. - 10°C.
Heating operation and motor switch-off are displayed via the LED in the (60)
viewing window.
 Table 8 Red LED display on page 32
2.4.4
Open-circuit detection
Open-circuit detection is only available in Continuous mode with an input signal
2 … 10 V DC and 4 … 20 mA.
If the input signal drops below 1 V or 2 mA in Continuous mode, the linear
actuator moves to the limit position set by coding switch S7.
Open-circuit detection is displayed via the green LED in the viewing window.
 Table 7 Green LED display on page 32
2.4.5
Set time
The time the spindle nut takes to travel a defined path, is called actuating time.
The actuating time is indicated in s/mm. The actuating time is set by coding switch
S5.
 5.3 Set actuating time on page 25
2.4.6
Hysteresis
The differential of the input signal (Y) required after a reversal of the signal
direction so that the spindle nut is moved, is called hysteresis.
It is used to avoid permanent oscillation of the actuator motor around a specific
lift position in the event of slight input signal changes.
 5.4 Set hysteresis on page 26
2.4.7
Manual mode and feedback signal
The lift can be manually changed in Manual mode without power supply.
• The electronic motor and control are switched off in Manual mode so that lift
movements by the control are not possible.
• As soon as the linear actuator is switched to Manual mode, the control
switches a signal to Terminal R, if the power supply is on.
 6.1 Changing between manual and automatic mode on page 31
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2 Product Specification
2.4.8
Autotest
If a valve is not actuated over a long period, the valve cone may seize. The
Autotest function prevents this. If the Autotest function of the linear actuator is
switched on, the linear actuator moves after approx.10 days without actuation
automatically in rapid traverse to the limit position set by coding switch S7 and
returns to the starting position.
 5.6 Set Autotest and Autopause on page 26
2.4.9
Autopause
The actuator uses this function to count the actuator commands which mean a
change in direction. In the event of more than 20 different directional actuator
commends per minute, a compulsory pause of 3 s is imposed.
 5.6 Set Autotest and Autopause on page 26
2.4.10
Potential-free way-switch (optional extra)
The optional way-switch printed circuit board (106) can be used to set two lift
positions at which a potential-free electrical contact is opened or closed.
 5.8 Set potential-free way-switch on page 27
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2 Product Specification
2.5
Technical data
Type
MC253SE/24
MC253SE/230
Supply voltage
24 V AC ± 10%
115 V AC ± 10%
230 V AC + 6% -10%
Power consumption
max. 50 VA
max. 80 VA
Weight
12 kg
12.5 kg
Dimensions
See technical data sheets (www.hora.de)
Stroke
max. 40 mm
max. 40 mm
Frequency
50/60 Hz ± 5%
50/60 Hz ± 5%
Ambient temperature
0 to +60°C
0 to +60°C
Enclosure protection
IP 54
IP 54
Suitable for use in the usual enviroment
Operating mode
S3-50% ED
S3-50% ED
Actuating time
2.5 or 5 s/mm
2.5 or 5 s/mm
Emergency actuating time 0.1 s/mm
0.1 s/mm
Actuating force
2.5 kN
2.5 kN
Recommended
T4 A
T1 A (115 V)
external protection
T800 mA (230 V)
Temperatur limits
transformer cover
T60 (EN60730 6.7; 14.5;
14.7; 17.3)
Surge voltage raiting
Overvoltage category 2 (EN60730 20.1.12; 20.1)
Ball pressure
Ball pressure test 1 test temperature 140°C
testing temperature
(EN60730 21.2.5)
Function
Control function according to EN 60730 = 1
Spring return function according to EN 60730 = 2
table 1
Technical data
0 … 10 V DC / 77 k
2 … 10 V DC / 77 k
0 … 20 mA / 510 
4 … 20 mA / 510 
Input signal Y/
Resistance of load
•
•
•
•
Output signal X/
Load rating
• 0 … 10 V DC / resistance of load 1200 , Imax. 8 mA
• 0 … 20 mA / resistance of load 500  with accessory PCB for output signal (111)
• 4 … 20 mA / resistance of load 500  with accessory PCB for output signal (111)
Response signal R/ load
rating
• 24 V DC / minimum impedance 480 Imax. 35 mA
Cable impedance between • max. 10 
B1 and B2
table 2
Technical data signals
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Operating Manual
3 Transportation & Storage
2.6
Type plate
The type plate is attached to the housing of the linear actuator.
It bears the type denomination, serial number (s/no) and date of manufacture (last
four digits).
 2.1 Components on page 7
MC253SE/230
F.-Nr.: 09200000/01/0310
Zertifikats-Nr.:
AC 50 Hz 230 V
80 VA
2,5
kN
Hub 40 mm
Y= 3-Punkt
IP 54
5
s/mm
Stellzeit
X= 0…10 V DC
S3-50% ED
0,1
s/mm
Rückstellzeit
diagram 4
T60
Example of type plate
3 Transportation & Storage
Non-compliance with safety regulations may result in injury!
• Wear the required personal and other safety equipment.
CAUTION
• Avoid impacts, blows, vibrations etc. to the linear actuator.
• Store the linear actuator (and, where appropriate, the entire controlling device)
in a dry place.
• Keep to the specified transport and storage temperatures between -20 to
+65°C.
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4 Assembly
4 Assembly
Prior to assembling the linear actuator:
 4.1 Checking the scope of delivery on page 14
 4.2 Preparing assembly on page 14
The following sequence of operations is part of the linear actuator assembly:
 4.3 Mounting the linear actuator on the valve on page 15
 4.4 Assembling/disassembling the cover on page 17
 4.5 Electrical connection on page 18
4.1
Checking the scope of delivery
1
Check the packaging for damage.
2
Dispose of packaging in an environmentally friendly manner.
3
Check the delivered items against the delivery note in order to see whether the
delivery is complete.
4
Report any missing or damaged products to the manufacturer.
4.2
ATTENTION
Preparing assembly
A non-attached valve causes damage!
If you operate the linear actuator without valve, the spindle nut may fall off due to
the missing stop.
• Always operate the linear actuator with a valve attached.
1
Allow for about 140 mm space above the cover at the site of installation.
2
Check the working environment before assembling and commissioning the linear
actuator:
3
Ensure that the valve is correctly fitted. For details please see assembly
instructions for valve.
4
Determine the assembly position of the linear actuator. Do not arrange linear
actuators in a hanging position.
M
M
M
M
M
M
A-B
A-B
7 mm
A
A
B
B
diagram 5
Assembly positions for linear actuator and valve
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Operating Manual
4 Assembly
4.3
Mounting the linear actuator on the valve
If the linear actuator and the valve are supplied separately you will have to mount
the linear actuator on the valve.
36
4
314
9
315
3
451
18
459
2
19
2
3
18
19
36
Cross head
Coupling piece
Valve stem
Valve neck
Hand wheel
diagram 6
314
315
451
459
Blank
Bolt
Hexagon nut M10
Hexagonal nut
Mounting the linear actuator on the valve

How to assemble linear actuator type MC253SE:
1
Pull off the blank (314).
 diagram 6 Mounting the linear actuator on the valve on page 15
2
Pull out the bolt (315) from the clutch piece (3) or drive it out.
3
Screw the hexagon locknut M10 (451) spanner width 17 onto the valve stem
(18).
4
Screw the clutch piece (3) onto the valve spindle (18). The area of the valve
stem (18) must be flush with the area of the clutch piece (3).
 diagram 6 Mounting the linear actuator on the valve on page 15 (Detail 4).
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4 Assembly
5
Put the actuator into upper limit position by means of the hand wheel (36) and
check whether it has reached the upper limit position.
6
Fit the actuator and crossbeam (2) and hexagon nut (459) on the valve neck
(19). Make sure that the valve spindle is in bottom position.
7
Fix the crossbeam (2) using the hexagon nut (459) hand tight.
8
Turn the clutch piece (3) until both borings are congruent.
 diagram 6 Mounting the linear actuator on the valve on page 15 (Detail 9).
9
Turn the clutch piece anti-clockwise by (3) one rotation (360°).
10
Loosen the hexagon nut (459) spanner width 50 and lift the actuator by c.
1.5 mm.
11
Insert the bolt (315) in the clutch piece (3) and secure it with a blank (314).
12
Tighten the hexagon nut (459) spanner width 50.
13
Fix the valve stem (18) by hexagon locknut M10 (451) spanner width 17 in order
to secure it against skewing.

How to disassemble the linear actuator
1
Move the linear actuator to the upper limit position (MAN / AUTO).
2
Turn the actuator by two rotations of the hand wheel away from the limit position.
3
Loosen the hexagon nut (459) spanner width 50.
4
Pull off the blank (314).
5
Pull out the bolt (315) from the clutch piece (3) or drive it out.
6
Remove the actuator.
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Operating Manual
4 Assembly
4.4
Assembling/disassembling the cover
The cover contains the terminals for electric connection.
Risk of injury from electric shock by live parts!
When the power supply is on there is a danger of electric shock due to live parts.
• Prior to commencing any work, ensure that the actuator is safely disconnected
from the power supply system.
WARNING
• Secure against unauthorised restarting.
• Remove the cover only momentarily.

How to remove the cover
1
Insert a screwdriver in the notch of the cover and lift the cover (201).
201
201
7 mm
7 mm
201 Cover
diagram 7
Removing the cover
Damaged cables result in damage to devices!
When lifting the cover you may tear off or damage the cabling inside the cover.
ATTENTION
• Carefully remove the cover.
2
Remove the cover (201) carefully.
3
Disconnect the plug-in connection between the main PCB and the (110) cover
(201).

How to attach the cover
1
Plug the previously pulled off cables back into the main PCB (110).
Pay attention to the notches on plug and socket.
Hint:
You can mount the cover (201) in four, different, positions each of which is
transposed by 90°. This allows the best possible laying of the connecting cable
for different installations of the linear actuator.
2
Place the cover (201) on top and push it down to make it fit by applying
moderate force.
3
Check the cover for correct fit to ensure air-tightness for the actuator housing.
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4 Assembly
4.5
Electrical connection
Danger of life caused by incompetent staff!
Electrical connections carried out by unqualified staff may result in death, severe
bodily injury or considerable material damage.
WARNING
• Make sure that such all work is carried out by qualified staff.
 1.3 Personnel on page 5
Risk of injury from electric shock by live parts!
When the supply voltage is turned on there is a risk of electric shock from live
parts.
WARNING
• Prior to commencing any work, ensure that the actuator is safely disconnected
from the power supply system.
• Secure against unauthorised restarting.

How to prepare the electric connection
1
Ensure that the supply voltage matches the specifications on the type place of
the linear actuator.
2
To avoid breakdown, construct the line diameter according to actuating
performance and required line length.
3
Lay the mains for a supply voltage of > 48 V separate from the signal and control
wires.
When laying cables in a joint cable duct, use shielded control wires.
4
Check the supply voltage.
If the required tolerance is not achieved by a power transformer you will have to
use an AC voltage stabilizer.
 2.5 Technical data on page 12
5
Secure the power cables (e.g. with cable-binders) in order to prevent the cable
sliding out from the connection terminal.
6
Ensure that there is fuse protection for the linear actuator.
 2.5 Technical data on page 12
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4 Assembly

How to establish electrical connection
1
Remove the cover (201).
 How to remove the cover on page 17
2
Run the cable through the screw joint in the cover to the terminal.
3
Connect the power supply according to the wiring diagram.
 diagram 8 on page 19
ATTENTION
Malfunctions caused by incorrect zero potential!
If the electric power supply for the linear actuator is fed by transducing sensors
with varying zero potentials this may result in incorrect automatic controller action.
• Ensure that the zero potential is properly applied.
 table 3 on page 20
4
Tighten the screw joints.
U
UB N1 2
3
R
T
B1 B2 N2 Y
X
WE1
WE1
WE2
WE2
20 21 22
23 24 25
GND
GND
230 VAC;
230
V AC;
24
24VAC;
V AC;
(GND)
NN(GND)
diagram 8
Circuit diagram
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4 Assembly
Terminal
Description
UB, N1
Supply voltage
2
Control voltage for downward movement during three-point mode
3
Control voltage for upward movement during three-point mode
R
Response signal during “manual” mode
• R= 24 V DC max. 35 mA
B1, B2
Binary input / frost protection function
N2
Zero potential of signals X, Y and R
• When the zero potentials of signals X, Y and R are identical to
the zero potential of the supply voltage it is possible to bridge
terminals N1 and N2.
• If you run the actuator in continuous mode at 230 V you will
have to connect N2.
• If you run the actuator in three-point mode at 230 V you will
have to connect N2 if you wish to use X or R at the same time.
Y
Input signal continuous mode
X
Output signal continuous mode
20, 21, 22
Terminals path switch unit PS1
23, 24, 25
Terminals path switch unit PS2
table 3
4.5.1
Key to wiring diagram
Controller independent circuit
When working with 24 V supply voltage and 0 … 10 V DC / 2 … 10 V DC input
signal you can switch the actuator controller-independently via a three-step
toggle switch in the control cabinet.

How to switch the actuator controller-independently
1
Run the supply voltage 24 V AC via a diode and a three-step toggle switch to
terminal Y.
z
Example: 1N4001;
1N4148
10 V Pos.
0 V Pos.
Closed-loop control
diagram 9
2
Controller independent circuit
Using the toggle you can move the linear actuator to the following positions:
• Closed-loop control by input signal Y (normal operation)
• 10 V-position
• 0 V-Position, the linear actuator can be moved to the position selected by
encoding switch S7 at 2 … 10 V DC.
 5.1 Operating parameters and coding switch positions on page 24
 5.7 Set limit position on page 27
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4 Assembly
4.6
Optional extras installation
Optional extras are only part of the scope of supply of the linear actuator if
expressly ordered! The linear actuators are prepared for retrofitting the following:
• Way-switch printed circuit board (106)
• Printed circuit board for output signal X=0/4 … 20 mA (111)
 2.2 Accessories on page 8
4.6.1
Way-switch printed circuit board installation
Electric shock due to live components!
If the power supply is switched off, there is danger of electric shock due to live
components.
WARNING
• Prior to starting work ensure that the actuator is disconnected safely from the
mains power supply.
• Secure against unauthorised switching-on.
1
Open the linear actuator (201) cover.
 4.4 Assembling/disassembling the cover on page 17
2
Press the way-switch printed circuit board (106) onto the terminal board (27)
using the (107) three spacers.
27
27
201
201
106
106
115
115
107
107
110
110
27 Spacers
106 Way-switch printed circuit board
107 Terminal board for 24 V or 230 V
diagram 10
3
115 Plug connector bush
110 Main board
201 Cover for 24 V or 230 V*
Installation of the way-switch printed circuit board in the cover
Place the plug connector bush (115) for the way-switch printed circuit board
(106) on the pin strip (123) on the (110) motherboard. Pay attention to the
grooves in the pin strip and plug connector bush.
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21
DIP
9 10
1
2
3
4
5
6
7
8
on
4 Assembly
123
LED2
116
LED1
123 Pin strip
diagram 11
4
Pin strip for way-switch printed circuit board on the motherboard
Adjust the way-switch.
 5.8 Set potential-free way-switch on page 27
4.6.2
Fit the printed circuit board for mA output signal.
Electric shock due to live components!
If the power supply is switched off, there is danger of electric shock due to live
components.
WARNING
• Prior to starting work ensure that the actuator is disconnected safely from the
mains power supply.
• Secure against unauthorised switching-on.
1
Open the cover (201) and remove the printed circuit board cover (Type plate).
 4.4 Assembling/disassembling the cover on page 17
 4.6 Optional extras installation on page 21
2
Remove the jumper (JP1) from the motherboard (110).
3
Put the jumper (JP1) onto the plug-in bridge (113) for the printed circuit board for
mA output signal.
4
Plug the printed circuit board for mA output signal (111) together with its pin strip
into the plug-in bridge (113) on the motherboard (110).
5
Lock the spacers (27) into the holes in the motherboard.
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4 Assembly
JP1
JP1
113
113
110
110
JP1
JP1
113
113
DIP
9 10
1
8
on
111
111
1
on
2
2
3
3
4
4
5
5
6
6
7
7
8
DIP
9 10
27
27
LED2
LED2
LED1
JP1 Jumper
27 Spacers
diagram 12
6
LED1
110 Main board
111 Printed circuit board for mA output
signal
113 Plug-in bridge
Installation of the printed circuit board for mA output signal
Select the output signal range with the jumper (JP1):
• Jumper right: 0 … 20 mA
• Jumper left: 4 … 20 mA
44 ... 20
20 mA
mA
0 ...
20mA
mA
... 20
JP1
JP1
JP1
JP1
111
111
DIP
9 10
1
2
3
4
5
6
7
8
on
110
110
LED2
diagram 13
LED1
Set signal range for mA output signal X
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5 Commissioning
5 Commissioning
WARNING
Electric shock due to live components!
If the power supply is switched off, there is danger of electric shock due to live
components.
• Prior to starting work ensure that the actuator is disconnected safely from the
mains power supply.
• Secure against unauthorised switching-on.
The operating parameters are set (116) on the coding switches. The coding
switches are located on the Main board (110).
DIP
9 10
1
2
3
4
5
6
7
8
on
 4.4 Assembling/disassembling the cover on page 17
 4.6 Optional extras installation on page 21
116
116
LED2
LED1
116 Coding switch
diagram 14
5.1
Printed circuit board cover and coding switches
Operating parameters and coding switch positions
The operating parameters must be set with the coding switches before the linear
actuator can be operated.
Malfunctions due to incorrect switch position S1
Switch S1 must always be at "on".
ATTENTION
• Ensure that switch S1 is at "on".
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5 Commissioning
Switch
on
off
S1
Ready for operation
-
S2
X characteristic Stroke
curve
X characteristic Stroke
curve
X
S3
Y characteristic Stroke
curve
X
Y characteristic Stroke
curve
Y
S4
Input signal (Y)
0 … 10 V DC or 0 … 20 mA
Input signal (Y)
2 … 10 V DC or 4 … 20 mA
S5
Actuating time 2.5 s/mm
Actuating time 5 s/mm
S6
Autotest and Autopause on
Autotest and Autopause off
S7
Limit position for actuator spindle
extended
Limit position for actuator spindle
retracted
S8, S9
The hysteresis (0.05 … 0.5 V) is set using S8 and S9.
S10
Input signal (Y) in mA
Table 4
5.2
Y
Input signal (Y) in V
Coding switch positions
Set input signal
0 ... 10 V
0 ... 20 mA
mA
2 ... 10 V
4 ... 20 mA
V
Diagram 15 Set input signal
 Further information: Input signal (Y) on page 9
5.3
Set actuating time
2.5 s/mm
5 s/mm
Diagram 16 Set actuating time
 Further information: 2.4.5 Set time on page 10
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5 Commissioning
5.4
Set hysteresis
0,15 V
0,05 V
0,3 V
0,5 V
Diagram 17 Set hysteresis
 For further information 2.4.6 Hysteresis on page 10
5.5
Set actuating direction
The actuating direction of the linear actuator can be reversed at the coding switch
(inverted operation).
Actuator position
Normal operation
5
Inverted operation (X and Y inverted)
Y = 10 V DC
Y = 0 V DC
Y = 20 mA
Y = 2 V DC
18
Y = 0 mA
Y = 4 mA
Y = 0 V DC
Y = 10 V DC
Y = 2 V DC
Y = 20 mA
5
18
Y = 0 mA
Y = 4 mA
Coding switch S2: X (output signal), coding switch S3: Y (input signal)
Table 5
Set actuating direction
5.6
Set Autotest and Autopause
If coding switch S6 is at ON, Autotest and Autopause are active.
Approaching the limit switch in rapid traverse is triggered approx. every 10 days
in Autotest. A new zero balance is carried out automatically.
A 3-second pause (2-minute measuring cycle) is carried out in Autopause after
more than 20 actuator commands in different directions per minute.
It is not possible to select these two functions separately.
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5.7
Set limit position
Select the limit position for the linear actuator using coding switch S7:
• S7 ON: Limit position with extended spindle nut
• S7 OFF: Limit position with retracted spindle nut
The limit position is approached in the following situations:
• In the event of open-circuit detection by the Y signal (only for 2 … 10 V DC or
4 … 20 mA),
• In the event of a binary signal (circuit is broken between terminals B1 and B2),
• in Autotest,
• upon disruption of the power supply (manual adjustment).
5.8
Set potential-free way-switch
Set the two way-switches via trimmer potentiometers P1/P2 independently from
one another. Carry out the specified working steps for each way-switch once.

Proceed as follows to set a way-switch:
1
Ensure that the linear actuator has been started up and initialised.
 5.10 Commissioning on page 30
 5.9 Initialising the path measuring system on page 29
ATTENTION
Malfunction due to inaccurately set way-switch!
If the actuator has been set to Manual mode (without power supply), the wayswitch can only be set inaccurately (Centre position of the arm corresponds to the
switching point for approx. 50% lift in this instance).
• Switch the actuator to Automatic mode in order to set the way-switch
accurately.
2
Move the actuator into a position where a switching event should be triggered.
The following working steps must be carried out with the power supply switched
on.
WARNING
Electric shock due to live components!
Once the power supply has been switched on, there is risk of electric shock due
to live components.
• Take care not to touch any live components.
• Take care not to cause a short circuit on a printed circuit board with the tool.
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5 Commissioning
3
Open the cover (201).
 4.4 Assembling/disassembling the cover on page 17
The way-switch printed circuit board is located in the cover (106).
4
Use a screwdriver to turn the trimmer potentiometer until the way-switch
switches. The associated LED goes on or off during this operation.
Use potentiometer P1 (105 P1) to set way-switch 1.
LED 1 indicates the switching status.
Use potentiometer P2 (105 P2) to set way-switch 2.
LED 2 indicates the switching status.
105
P1
106
LED1
LED2
105
P2
105 P1Trimmer potentiometer
diagram 18
5
105 P2Trimmer potentiometer
Way-switch printed circuit board in cover
Observe the permitted way-switch contact load:
Nominal load
8 A, 250 V AC
8 A, 30 V DC
Switching voltage
max. 400 V AC
max. 125 V DC
Table 6
Way-switch contact load
6
Switch off the power supply to the actuator and connect the way-switch contacts.
7
Close the linear actuator (201) cover
 How to attach the cover on page 17
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5.9
ATTENTION
Initialising the path measuring system
Linear actuator starts automatically!
The linear actuator starts immediately after being connected to the supply voltage
and automatically moves to a reference point of the path measuring system.
• Wait until this reference point has been reached and the linear actuator has
stopped.
The path measuring system has to be initialised after the following:
• At initial commissioning
• After repairs to the valve or actuator
• After a replacement of valve or actuator
Initialisation may be triggered in two different ways.

How to initialise via the initialising button
Risk of injury from electric shock by live parts!
When the supply voltage is turned on there is a risk of electric shock from live
parts.
WARNING
• Take care not to touch any live parts.
• Take care to apply the tool in a way that does not cause short-circuit.
1
Open the cover (201).
 4.4 Assembling/disassembling the cover on page 17
2
Ensure that supply voltage is applied.
3
After applying the supply voltage the emergency actuating unit (NE) will
automatically be tensed by the actuator. After tensing the actuator will remain in
bottom limit position.
4
After a waiting period of c. 25 seconds push and hold the initialising button (118)
for at least 2 seconds (stopping time). After the initialising cycle the actuator will
follow the actuating signal.
110
DIP
9 10
1
2
3
4
5
6
7
8
on
118
110 Main board
diagram 19
118 Initialising button
Initialising the path measuring system
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5 Commissioning

Proceed as follows to initialise via the connecting terminals
1
Connect the power supply simultaneously to terminals 2 and 3. Ensure that the
power supply remains on for at least 1 second.
 diagram 8 on page 19
5.10
1
Commissioning
Check that all installation and assembly tasks have been completed correctly.
 4 Assembly on page 14
2
Ensure that the electric actuation of the linear actuator is ensured without danger
to persons or equipment or the system.
3
Ensure that the linear actuator is correctly fixed and the linear actuator cover is
closed.
 4.4 Assembling/disassembling the cover on page 17
4
Ensure that the linear actuator is switched to Automatic mode.
 6.1 Changing between manual and automatic mode on page 31
5
Ensure that the operating parameters have been correctly set.
 5.1 Operating parameters and coding switch positions on page 24
6
Ensure that the path-measuring system has been initialised.
 5.9 Initialising the path measuring system on page 29
7
Connect the power supply. Then the linear actuator moves to the reference
point.
The linear actuator is ready for operation.
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6 Operation
6 Operation
Prior to commissioning the linear actuator you will have to initialise it and select
the operating mode.
 5 Commissioning on page 24
 5.9 Initialising the path measuring system on page 29
6.1
Changing between manual and automatic mode
It is possible to run the linear actuator in automatic mode or manual mode
(manual adjustment). During manual mode you will only be able to change the lift
when voltage is applied and the spring of the response unit is in a tensed state.
• In automatic mode the spindle nut moves to the position set by the controller.
• In manual mode it is possible to set the spindle manually, e. g.for control
purposes. Output signal (X) is not available in manual mode.
36
36
36
36
Automatic operation
36 Hand wheel
diagram 20
Manual operation
Selecting automatic mode

Proceed as follows to switch to Manual mode
1
Move the handwheel (36) into the manual mode position and rotate it until the
handwheel locks.
ATTENTION
Risk of damage to valve and actuator in Manual mode!
The valve can get damaged if it is pressed too firmly into its seat when closing in
Manual mode.
• Do not rotate the handwheel any further if the amount of effort needs to be
increased!
• Never use force.
2
Use the handwheel to rotate the spindle nut into the required position. Rotate the
handwheel until the rotational resistance increases. Do not use force!

Proceeds as follows to switch to Automatic mode
1
Move the handwheel (36) into the automatic mode position.
2
The linear actuator moves first of all into the position specified by coding switch
S7 and then into the position specified by the control.
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7 Maintenance, Care and Repairs
6.2
LED display
The LEDs in the viewing window (60) indicate operating states or faults.
 10.2 Operating faults checklist on page 34
Green LED
Operating status / fault
Normal operation, standby
The LED illuminates continuously, actuator awaits drive
command.
duration
Standard Operation
Actuator carries out drive command.
Open-circuit detection
Short - long rhythm
In operating modes 2 … 10 V DC or 4 … 20 mA, the input
signal has dropped below 1 V or below 2 mA.
 2.4.4 Open-circuit detection on page 10
Lock detection (only in Continuous mode)
The linear actuator is mechanically locked.
Long - long rhythm
 2.4.2 Lock detection on page 9
Continuous signal on terminals 2 and 3
Long - short rhythm
Table 7
An initialisation run starts in the event of simultaneous
control signal on terminals 2 and 3 (max. 4 attempts). The
linear actuator switches off automatically after 4 failed
attempts.
Green LED display
Red LED
Operating status / fault
Temperature within normal range
OFF
Heating operation
 Actuator heating on page 10
duration
Actuator overheats
 Overheating protection on page 9
Flashes regularly
Table 8
Red LED display
7 Maintenance, Care and Repairs
The linear actuator is low-maintenance. No routine or periodic maintenance is
required.
8 Spare parts
Check the data on the linear actuator rating plate when ordering optional extras
or spare parts. The data on the rating plate is decisive for linear actuator technical
data and mains power supply requirements.
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9 Shutdown and Disposal
ATTENTION
Equipment damage due to defective spare parts!
Spare parts must comply with the technical requirements specified by the
manufacturer.
• Use only original spare parts.
 2.1 Components on page 7
 2.2 Accessories on page 8
9 Shutdown and Disposal
Dispose of the linear actuator in accordance with national regulations and
legislation.
10 Troubleshooting
The path-measuring system needs to be re-initialised after troubleshooting.
 5.9 Initialising the path measuring system on page 29
10.1
Troubleshooting
If the linear actuator does not work perfectly, proceed as follows to eliminate the
fault:
1
Check that the linear actuator was installed correctly.
2
Check the linear actuator settings and the rating plate data.
3
Eliminate the faults using the checklist.
 10.2 Operating faults checklist on page 34
4
If this fault still cannot be eliminated, contact the manufacturer.
5
Please quote the following for all queries and returning goods to the
manufacturer:
• F-No. (Fabrication No. = Contract No.)
• Type designation
• Power supply and frequency
• Additional equipment
• Error report
6
If the fault cannot be eliminated by the inquiry, the equipment can be returned to
the manufacturer.
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10 Troubleshooting
10.2
Operating faults checklist
Fault
Cause/reason
Remedy
1. Linear actuator does not
work.
Handwheel (36) is in manual mode position  Switch handwheel to automatic mode
position.
Mains power failure
 Establish cause and eliminate.
Fuse defective. (in the electrical cabinet)
 Establish cause and eliminate, change
fuse.
Linear actuator incorrectly connected
 Rectify connection in accordance with
circuit diagram (on the cover).
Short circuit due to humidity
 Establish cause, dry the linear actuator,
change hood seal and screw
connections if necessary ad/or fit
protective hood.
Short circuit due to incorrect connection
 Rectify connection
Motor has coil damage (burnt out)
 Establish cause, measure current data
Compare with rating plate and table,
Remove linear actuator and return to
manufacturer for repair.
• e.g. due to too high voltage
• Electronic system defective
2. Linear actuator runs in an
Voltage drop due to too long connecting
unstable manner, i.e.
cables and/or too small cross-section.
switches between clockwise
and counter-clockwise
Mains power fluctuations greater than
rotation.
permissible tolerance
 Measure linear actuator current data,
recalculate and change connecting
cables if necessary.
 Improve mains power ratios
 2.5 Technical data on page 12
3. Linear actuator cuts out
from time to time or
initialises frequently.
Supply cable has loose contact
 Check and tighten connections (terminal
strips)
4. Linear actuator does not
Valve jams
move to the limit positions.
Too high system pressure
Valve does not close/open.
 Ensure smooth running valve
5. Linear actuator does not
move or does not move
correctly to the position
specified by input signal Y.
 Check input signal Y on linear actuator,
eliminate cause of fault
 Correct system pressure
Input signal Y faulty:
• Error signals
• Signal fluctuations
Motherboard faulty
 Change motherboard, remove linear
actuator and return to manufacturer for
repair if necessary.
6. Green LED flashes in long / Lock detection has responded
long rhythm
 Press INIT and observe actuator during
initialisation.
 Check valve for smooth running over
entire lift range.
7. Greed LED flashes in short / Open circuit detected
long rhythm
 Measure reference value voltage or
current on linear actuator.
8. Green LED flashes in long / Relay contact adherence
short rhythm
 Check control
9. Red LED flashes regularly
 Motor has switched off automatically.
Automatic start-up after cooling down
table 9
Actuator overheats
Operating faults checklist
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