AUMA SQREx 14.2 Operation Instructions Manual

AUMA SQREx 14.2 is a part-turn actuator designed for modulating duty, offering precise control and reliable operation of industrial valves. This model is suitable for demanding applications in various industries and is engineered to meet rigorous safety standards. It features a robust design, integrated handwheel for manual operation, and advanced capabilities for electrical connection and commissioning. The SQREx 14.2 is highly customizable and can be equipped with optional features, ensuring optimal performance and flexibility for diverse operating environments.
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Part-turn actuators
SQEx 05.2 – SQEx 14.2
SQREx 07.2 – SQREx 14.2
AUMA NORM actuator (without controls)
Operation instructions
Assembly and commissioning
Table of contents
Target group:
This document contains information for assembly, commissioning and maintenance staff.
Read operation instructions first.
•
Heed 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.
Table of contents
1 Safety instructions ...........................................................................................................................................
4
1.1 Prerequisites for the safe handling of the product......................................................................................
4
1.2 Range of application ..................................................................................................................................
5
1.3 Warnings and notes ...................................................................................................................................
6
1.4 References and symbols............................................................................................................................
6
2 Short description..............................................................................................................................................
7
3 Name plate ........................................................................................................................................................
8
4 Transport and storage ..................................................................................................................................... 11
4.1 Transport.................................................................................................................................................... 11
4.2 Storage....................................................................................................................................................... 12
5 Assembly .......................................................................................................................................................... 13
5.1 Mounting position ....................................................................................................................................... 13
5.2 Fit handwheel............................................................................................................................................. 13
5.3 Mount actuator to valve.............................................................................................................................. 13
5.3.1 Overview on coupling variants ........................................................................................................ 14
6 Electrical connection ....................................................................................................................................... 17
6.1 Basic information........................................................................................................................................ 17
6.2 Overview of AUMA electrical connections ................................................................................................. 18
6.3 KT/KM electrical connection.......................................................................................................................
6.3.1 Open terminal compartment ...........................................................................................................
6.3.2 Cable connection ............................................................................................................................
6.3.3 Close terminal compartment ...........................................................................................................
19
20
21
23
6.4 KES electrical connection ..........................................................................................................................
6.4.1 Open terminal compartment ...........................................................................................................
6.4.2 Cable connection ............................................................................................................................
6.4.3 Close terminal compartment ...........................................................................................................
24
25
26
27
6.5 External earth connection .......................................................................................................................... 28
6.6 Accessories for electrical connection (option)............................................................................................ 28
6.6.1 Parking frame.................................................................................................................................. 28
7 Operation .......................................................................................................................................................... 29
7.1 Manual operation ....................................................................................................................................... 29
7.1.1 Manual valve operation................................................................................................................... 29
7.2 Motor operation .......................................................................................................................................... 29
8 Indications (option) .......................................................................................................................................... 30
8.1 Mechanical position indication via indicator mark ...................................................................................... 30
9 Signals (output signals)................................................................................................................................... 31
2
Table of contents
9.1 Feedback signals from actuator ................................................................................................................. 31
10 Commissioning (basic settings) ..................................................................................................................... 32
10.1 End stops in part-turn actuator................................................................................................................... 32
10.1.1 Set end stop CLOSED .................................................................................................................... 33
10.1.2 Set end stop OPEN......................................................................................................................... 33
10.2 Open switch compartment ......................................................................................................................... 33
10.3 Set torque switching................................................................................................................................... 34
10.4 Set limit switching....................................................................................................................................... 35
10.4.1 Set end position CLOSED (black section) ...................................................................................... 35
10.4.2 Set end position OPEN (white section)........................................................................................... 36
10.5 Test run ...................................................................................................................................................... 36
10.5.1 Check direction of rotation at mechanical position indicator ........................................................... 36
10.5.2 Check limit switching....................................................................................................................... 37
10.6 Set mechanical position indicator............................................................................................................... 37
10.7 Close switch compartment ......................................................................................................................... 38
11 Commissioning (optional equipment settings) ............................................................................................. 39
11.1 Potentiometer............................................................................................................................................. 39
11.1.1 Potentiometer setting ...................................................................................................................... 39
11.2 RWG electronic position transmitter........................................................................................................... 39
11.2.1 Set measuring range....................................................................................................................... 40
11.3 EWG 01.1 electronic position transmitter...................................................................................................
11.3.1 Set measuring range.......................................................................................................................
11.3.2 Adjust current values ......................................................................................................................
11.3.3 Switch on/off LED end position signalling .......................................................................................
40
41
42
43
11.4 Set intermediate positions.......................................................................................................................... 43
11.4.1 Set running direction CLOSE (black section).................................................................................. 43
11.4.2 Set running direction OPEN (white section).................................................................................... 44
12 Corrective actions ............................................................................................................................................ 45
12.1 Faults during operation/commissioning...................................................................................................... 45
12.2 Motor protection (thermal monitoring) ........................................................................................................ 46
13 Servicing and maintenance............................................................................................................................. 47
13.1 Preventive measures for servicing and safe operation .............................................................................. 47
13.2 Disconnection from the mains.................................................................................................................... 47
13.2.1 Disconnection from the mains with KT/KM electrical connection.................................................... 48
13.2.2 Mains disconnection with KES electrical connection ...................................................................... 49
13.3 Maintenance............................................................................................................................................... 49
13.4 Disposal and recycling ............................................................................................................................... 50
14 Technical data .................................................................................................................................................. 52
14.1 Technical data Part-turn actuator............................................................................................................... 52
14.2 Tightening torques for screws .................................................................................................................... 54
15 Spare parts list ................................................................................................................................................. 55
15.1 Part-turn actuators SQEx 05.2 – SQEx 14.2 KT/KM / SQREx 05.2 – SQREx 14.2 KT/KM....................... 55
Index .................................................................................................................................................................. 57
3
Safety instructions
1 Safety instructions
1.1 Prerequisites for the safe handling of the product
Standards/directives
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly, electrical connection, commissioning and operation are met at the place of installation.
Depending on the device version, this includes:
•
Standards and directives such as IEC 60079:
Part 14: Electrical installations design, selection and erection.
Part 17: Electrical installations inspection and maintenance.
•
Configuration guidelines for the respective fieldbus or network applications.
Safety instructions/warn- All personnel working with this device must be familiar with the safety and warning inings structions in this manual and heed the instructions given. Safety instructions and
warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must be
carried out by suitably qualified personnel authorised by the end user or contractor of
the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules regarding occupational health and safety.
Work performed in potentially explosive atmospheres is subject to special regulations
which have to be observed. The end user or contractor of the plant is responsible for
respect and control of these regulations, standards, and laws.
Electrostatic charging Highly efficient charge generating processes (processes more efficient than manual
friction) on the device surface must be excluded at any time. Highly efficient charge
generating processes will lead to propagating brush discharges and therefore to ignition of a potentially explosive atmosphere. This safety instruction also applies to fireproof coatings or covers available as an option.
When using a stem protection tube, any type of charge generating processes must be
excluded at its protective cap as well as the V-seal (e.g. only wipe with a damp cloth).
Otherwise, ignitable electrostatic discharges might occur.
Ignition hazards Gearings were subjected to an ignition hazard assessment in compliance with the currently applicable standard according to ISO 80079-36/ -37. Hot surfaces, mechanically
generated sparks as well as static electricity and stray electric currents were identified
and assessed as major potential ignition sources. Protective measures to prevent the
likelihood that ignition sources arise were applied to the gearboxes. This includes in
particular lubrication of the gearbox, the protection level of enclosure protection and
the warnings and notes contained in these operation instructions.
Commissioning Prior to commissioning, imperatively check that all settings meet the requirements of
the application. Incorrect settings might present a danger to the application, e.g. cause
damage to the valve or the installation. The manufacturer will not be held liable for any
consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:
4
•
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 report any faults and damage and allow for corrective measures.
•
Heed recognised rules for occupational health and safety.
•
Heed national regulations.
Safety instructions
•
During operation, the housing warms up and surface temperatures &gt; 60 &deg;C may
occur. To prevent possible burns, we recommend checking the surface temperature using an appropriate thermometer and wearing protective gloves, prior to
working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment for
the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior written consent of the manufacturer.
1.2 Range of application
AUMA part-turn actuators SQEx/SQREx are designed for the operation of industrial
valves, e.g. butterfly valves and ball valves.
The devices described below are approved for use in the potentially explosive atmospheres of zones 1, 2, 21, and 22.
If temperatures &gt; 40 &deg;C are to be expected at the valve flange or the valve stem (e.g.
due to hot media), please consult AUMA.
Temperatures &gt; 40 &deg;C are not considered with regards to the non-electrical explosion
protection.
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
•
Escalators
•
Continuous duty
•
Buried service
•
Continuous underwater use (observe enclosure protection)
•
Potentially explosive areas of zones 0 and 20
•
Potentially explosive areas of group I (mining)
•
Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's designated use.
These operation instructions are only valid for the “clockwise closing” standard version, i.e. driven shaft turns clockwise to close the valve. For “counterclockwise closing”
version, a supplement must be observed in addition to these operation instructions.
Particular conditions of use
The particular conditions of use are listed on the certificates supplied. Among others,
this includes the following conditions:
•
For further references to minimise the risk of electrostatic charging within a potentially explosive atmosphere, refer to Prerequisites for the safe handling of the
product [} 4].
•
For information regarding the dimensions of the flameproof joints, contact the
manufacturer.
•
Special fasteners according to IEC 60079-0 to seal flameproof enclosures must
have the following strength classes:
5
Safety instructions
•
–
Minimum A*-70 for all special fasteners, excluding screws for fixing motors of
VKX type
–
Minimum A*-80 for screws for fixing motors of VKX type
For tightening the screws, refer to Tightening torques for screws [} 54].
1.3 Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these
operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
DANGER
Indicates an imminently hazardous situation with a high level of risk.
Failure to observe this warning results in death or serious injury.
WARNING
Indicates a potentially hazardous situation with a medium level of risk.
Failure to observe this warning could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation with a low level of risk. Failure to observe this warning could result in minor or moderate injury. May
also be used with property damage.
NOTICE
Potentially hazardous situation. Failure to observe this warning could
result in property damage. Is not used for personal injury.
The
safety symbol warns of a potential personal injury hazard.
The signal word (here: DANGER) indicates the level of hazard.
1.4 References and symbols
The following references and symbols are used in these instructions:
The term Information preceding the text indicates important notes and information.
Information The term Information is part of an instruction and gives important notes and information with regard to an action step.
Symbol for CLOSED (valve closed)
Symbol for OPEN (valve open)
Result of a process step
Describes the result of a preceding process step.
Action step
Describes one single action step.
Reference to the page number
Refers to the page number for further information. To return from the target to the previous view, it is possible to jump back to the previous view within PDF documents:
When using Adobe Acrobat via Menu &gt; Previous view, or using the key combination
Alt + left.
6
Short description
2 Short description
Part-turn actuator Definition according to ISO 22153:
A part-turn actuators is an actuator which transmits torque to the valve for less than
one revolution, and does not need to be capable of withstanding operational thrust.
AUMA part-turn actuator Figure 1: AUMA SQEx 10.2 part-turn actuator
[2]
[3]
[1]
[5]
[4]
[1]
[3]
[5]
Motor
Handwheel
Mechanical position indicator
[2]
[4]
Electrical connection
Valve attachment
AUMA part-turn actuators SQEx/SQREx are driven by an electric motor. A handwheel
is available for setting and emergency operation.
Actuator controls are required to operate or process the actuator signals.
Actuators without controls can be equipped with AUMA actuator controls at a later
date. For any queries, please state our order number. The order number is available
on the name plate. (Refer to Actuator name plate [} 8].)
Switching off in end positions may be either by limit or torque seating.
7
Name plate
3 Name plate
Figure 2: Arrangement of name plates
[1]
[2] [3][4]
[1]
[3]
Motor name plate
Additional plate, e.g. KKS plate (Power
Plant Classification System)
[2]
[4]
Actuator name plate
Explosion protection approval plate
Actuator name plate
Figure 3: Actuator name plate (example)
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[1]
[3]
[5]
[7]
[9]
[11]
[13]
8
[13]
[12]
Name of manufacturer
Type designation
Serial number
Torque range in direction CLOSE
Type of lubricant
Can be assigned as an option upon
customer request
Data Matrix code
[2]
[4]
[6]
[8]
[10]
[12]
Address of manufacturer
Order number
Operating time
Torque range in direction OPEN
Permissible ambient temperature
Enclosure protection
Name plate
Motor name plate
Figure 4: Motor name plate (example)
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[14]
[13]
[12]
[11]
[1]
[3]
[5]
[7]
[9]
Motor type
Serial number
Nominal power
Type of duty
Motor protection (temperature protection)
Speed
Mains frequency
[11]
[13]
[2]
[4]
[6]
[8]
[10]
Motor article number
Current type, mains voltage
Nominal current
Enclosure protection
Insulation class
[12]
[14]
Power factor cos phi
Data Matrix code
Approval plate in explosion-proof version
Figure 5: Approval plates in explosion-proof version (examples)
ATEX
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[1]
[2]
[3]
[4]
[6]
[7]
[1]
Ex symbol, CE mark, number of test
authority
Classification for electrical gas explosion protection
Classification for non-electrical explosion protection
Not used
[3]
[5]
[7]
IECEx
IECEx DEK 12.0080X
Ex db eb IIC T4 Gb
Ex tb IIIC T130&deg;C Db
M20 + M25 + M32
[2]
Ex certificate (number)
[4]
Classification for electrical dust explosion protection
Threads for cable entries at electrical
connection
[6]
Descriptions referring to name plate indications
Type designation Table 1: Description of type designation with the example of SQEx 07.2-F10
SQEx
07.2
-F10
Type SQEx = Part-turn actuators for open-close duty
Type SQREx = Part-turn actuators for modulating duty
SQEx
Size
These instructions apply to sizes 05.2, 07.2, 10.2, 12.2, 14.2
07.2
F10
Flange size
Ex marking Table 2: Description of the Ex marking with the example of /-a3b1
–
a
3
–
Not used
b
1
9
Name plate
–
a
3
a
Motor type
a = ADX or VDX: 3-phase AC motor
b = AEX, ACX, VEX, VCX: 1-phase AC motor
3
b
1
Protection type of electrical connection
3 = Terminal compartment Ex e increased safety
4 = Terminal compartment Ex d flameproof enclosure
Protection type of position transmitter
a = Without intrinsically safe electric circuit
b = Electric circuit Ex i Intrinsic safety (RWG 5020.2Ex)
b
1
Protection type of fieldbus
1 = without intrinsically safe Ex ic fieldbus connection
3 = Ex ic intrinsically safe fieldbus connection
Order number The product can be identified using this number and the technical data as well as order-related data pertaining to the device can be requested.
Please always state this number for any product inquiries.
On our website at http://www.auma.com, via Service &amp; Support| myAUMA, we offer a service allowing authorised users to download order-related documents such as
wiring diagrams and technical data (both in German and English), inspection certificate and the operation instructions when entering the order number.
Actuator serial number Table 3: Serial number until 2023, description with the example of 0523NS12345
05
23
05
Positions 1+2: Assembly in week = week 05
23
NS12345
Positions 3+4: Year of manufacture = 2023
NS12345
Internal number for unambiguous product identification
Table 4: Serial number as from 2024, description with the example 0000-00101-2024
00000-00101
– 2024
Serial number of sales article
11-digit, internal number for unambiguous product identification
00000-00101
2024
Year of manufacture = 2024
Data Matrix code When registered as authorised user, you may use our AUMA Assistant App to scan
the Data Matrix code and directly access the order-related product documents without
having to enter order number or serial number.
Figure 6: Link to AUMA Assistant App
For further Service &amp; Support, Software/Apps/..., refer to www.auma.com.
10
Transport and storage
4 Transport and storage
4.1 Transport
Actuator For transport to place of installation, use sturdy packaging.
DANGER
Suspended load!
Death or serious injury.
&agrave; Do NOT stand below suspended load.
&agrave; Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT
to handwheel.
&agrave; Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting by
hoist to valve and NOT to actuator.
&agrave; Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
&agrave; Respect total weight of combination (actuator, gearbox, valve)
&agrave; Secure load against falling down, sliding or tilting.
&agrave; Perform lift trial at low height to eliminate any potential danger e.g. by tilting.
Figure 7: Example: Lifting the actuator
Weights Table 5: Weights for SQEx/SQREx part-turn actuators with 3-phase AC motors
Type designation
Actuator
Weight 1)
Weight with base and lever 2)
approx. [kg]
approx. [kg]
SQEx 05.2/
SQREx 05.2
29
34
SQEx 07.2/
SQREx 07.2
29
34
SQEx 10.2/
SQREx 10.2
34
38
SQEx 12.2/
SQREx 12.2
42
50
SQEx 14.2/
SQREx 14.2
51
62
1)
Indicated weight includes AUMA NORM part-turn actuator with 3-phase AC motor, electrical connection in standard version, unbored coupling and handwheel For other output drive types, consider additional weights.
2)
Indicated weight includes AUMA NORM part-turn actuator with 3-phase AC motor, electrical connection in standard version, and handwheel, including base and lever For other output drive types, consider additional weights.
11
Transport and storage
Table 6: Weights for SQEx/SQREx part-turn actuators with 1-phase AC motors
Type designation
Actuator
Weight 1)
Weight with base and lever 2)
approx. [kg]
approx. [kg]
SQEx 05.2/
SQREx 05.2
33
39
SQEx 07.2/
SQREx 07.2
33
39
SQEx 10.2/
SQREx 10.2
39
43
SQEx 12.2/
SQREx 12.2
47
55
SQEx 14.2/
SQREx 14.2
56
67
1)
Indicated weight includes part-turn actuator AUMA NORM with 1-phase AC motor, electrical connection in standard version, unbored coupling and handwheel For other output drive types, consider additional weights.
2)
Indicated weight includes AUMA NORM part-turn actuator with 1-phase AC motor, electrical connection in standard version, and handwheel, including base and lever For other output drive types, consider additional weights.
4.2 Storage
NOTICE
Danger of corrosion due to inappropriate storage!
&agrave; Store in a well-ventilated, dry room.
&agrave; Protect against floor dampness by storage on a shelf or on a wooden pallet.
&agrave; Cover to protect against dust and dirt.
&agrave; Apply suitable corrosion protection agent to uncoated surfaces.
Long-term storage For long-term storage (more than 6 months), observe the following points:
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.
12
Assembly
5 Assembly
5.1 Mounting position
When using grease as lubricant, the product described herein can be operated in any
mounting position.
When using oil instead of grease within the actuator gear housing, perpendicular
mounting position is specified whereby the flange is pointing downward. The type of
lubricant used is indicated on the actuator name plate (short designation F...= grease;
O...= oil).
5.2 Fit handwheel
Figure 8: Handwheel
[2]
[3]
[1]
[4]
[1]
[3]
Spacer
Handwheel
[2]
[4]
Input shaft
Retaining ring
How to proceed 1. If required, fit spacer [1] on input shaft [2].
2. Slip handwheel [3] onto input shaft.
3. Secure handwheel [3] with retaining ring [4].
Information: The retaining ring [4] (together with these operation instructions) is
stored in a weatherproof bag, which is attached to the device prior to delivery.
5.3 Mount actuator to valve
NOTICE
Corrosion due to damage to paint finish and condensation!
&agrave; Touch up damage to paint finish after work on the device.
&agrave; After mounting, connect the device immediately to electrical mains to ensure that
heater minimises condensation.
The actuator is mounted to the valve using a coupling (standard) or via lever. Separate instructions are available for actuator mounting to the valve when equipped with
base and lever.
13
Assembly
5.3.1 Overview on coupling variants
Set-up Figure 9: Valve attachment via coupling
[1]
[1]
[3]
Application •
•
[2]
Bore with keyway
Bore with two-flats
[3]
[2]
Square bore
For valve attachments according to EN ISO 5211
For rotating, non-rising valve stem
5.3.1.1 Actuator (with coupling): mount
Unbored couplings or couplings with pilot bore must be machined to match the valve
shaft prior to mounting the actuator to the valve (e.g. with bore and keyway, two-flat or
square bore).
Assemble valve and actuator in the same end position. As standard, the actuator is supplied in end position CLOSED.
a) Recommended mounting position for butterfly valves: End position CLOSED.
b) Recommended mounting position for ball valves: End position OPEN.
We recommend applying liquid thread sealing material to the screws to avoid
contact corrosion.
Assembly steps 1. If required, move actuator in same end position as valve using the handwheel.
2. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
3. Apply a small quantity of grease to the valve shaft [2].
4. Place coupling [1] onto valve shaft [2] and secure against axial slipping by using a
grub screw [3] or a clamping washer and a screw with curved spring lock washer
[4]. Observe dimensions X, Y or L. Refer to following picture and table Mounting
positions for coupling.
14
Assembly
Figure 10: Examples: Fit coupling
[4]
[3]
[1]
[1]
[2]
[1]
[3]
[2]
Coupling
Grub screw
[2]
[4]
Valve shaft
Clamping washer and screw with
curved spring lock washer
Figure 11: Mounting positions for coupling
L
X
Y
Table 7: Mounting position of the coupling within fitting dimensions according to AUMA definition
Dimensions [mm]
SQEx 05.2
SQEx 07.2
SQEx 10.2
SQEx 12.2
SQEx 14.2
EN ISO 5211
F05
F07
F05
F07
F10
F10
F12
F12
F14
F14
F16
X max.
3
3
3
3
3
4
4
5
5
8
8
Y max.
2
2
2
2
2
5
5
10
10
10
10
L max.
40
40
40
40
66
50
82
61
101
75
125
5. Apply non-acidic grease at splines of coupling (e.g. Gleitmo by Fuchs).
6. Fit actuator. If required, slightly turn actuator until splines of coupling engage.
15
Assembly
Figure 12: Fit actuator
&eth; Information: Ensure that the spigot (if provided) fits uniformly in the recess
and that the flanges are in complete contact.
7. If flange bores do not match thread: Slightly rotate handwheel until bores line up.
8. If the bores do not align even after rotating the handwheel, shift the actuator by
one tooth on the coupling, if required.
9. Fasten actuator with screws.
10. Tighten screws crosswise with a torque according to the table in chapter Tightening torques for screws [} 54].
16
Electrical connection
6 Electrical connection
6.1 Basic information
WARNING
Electric shock due to presence of hazardous voltage!
Failure to observe this warning could result in death, serious injury, or property damage.
&agrave; The electrical connection must be carried out exclusively by suitably qualified personnel.
&agrave; Prior to connection, heed basic information contained in this chapter.
Wiring diagram/terminal The pertaining wiring diagram/terminal plan (in German or English) is attached to the
plan device in a weather-proof bag, together with these operation instructions. It can also
be requested from AUMA when indicating the order number (refer to name plate) or
downloaded directly from our Website (http://www.auma.com).
NOTICE
Valve damage when connecting to actuator controls!
&agrave; NORM actuators require actuator controls: Connect motor via actuator controls
only (reversing contactor circuit).
&agrave; Respect the type of seating specified by the valve manufacturer.
&agrave; The torque switches also serve the purpose of valve overload protection and must,
therefore, also be connected for limit seating.
&agrave; Heed wiring diagram.
Delay time The delay time is the time from the tripping of the limit or torque switches to the motor
power being switched off. To protect the valve and the actuator, we recommend a
delay time &lt; 50 ms. Longer delay times are possible provided operating time, output
drive type, valve type, and type of installation are considered. We recommend switching off the corresponding contactor directly by limit or torque switch.
Limit and torque switches Limit and torque switches can be provided as single, tandem, or triple switches. Only
the same potential can be switched on the two circuits (NC/NO contact) of each single
switch. If different potentials are to be switched simultaneously, tandem switches or
triple switches are required. When using tandem/triple switches:
•
For signalling use the leading contacts DSR1/TSC1, DOEL1/TSO1, WSR1/LSC1,
WOEL1/LSO1.
•
For switching off use the lagging contacts DSR/TSC, DOEL/TSO, WSR/LSC,
WOEL/LSO.
Current type, mains Type of current, mains voltage and mains frequency must match the data on the motor
voltage, mains frequency name plate. Refer to Motor name plate [} 9].
Figure 13: Motor name plate (example)
[1]
[1]
[3]
[2]
[3]
Type of current
Mains frequency
[2]
Mains voltage
Protection and sizing on For short-circuit protection and for disconnecting the actuator from the mains, fuses
site and disconnect switches or circuit breakers have to be provided by the customer.
17
Electrical connection
The current value for sizing the protection is derived from the current consumption of
the motor (refer to Motor name plate [} 9]).
We recommend adapting the switchgear sizing to the max. current (Imax) and selecting
and setting the overcurrent protection device in compliance with the indications in the
electrical data sheet.
Protection via thermal mo- Version with thermoswitch or PTC thermistor as motor protection permissible.
tor protection
CAUTION
Without motor protection, impermissibly high temperatures at the actuator may occur: Ignition hazard, risk of explosion!
Risk of death, serious injury or motor damage. Our warranty for the motor will lapse if
the motor protection is not connected.
&agrave; According to EN 60079-14/VDE 0165, a thermal overcurrent protection device
(e.g. Motor protection switch) must be installed for explosion-proof actuator versions with thermoswitches, in addition to the thermoswitches.
&agrave; For versions with PTC thermistor:s, an additional suitable tripping device must be
integrated into the controls.
Safety standards Safety measures and safety equipment must comply with the respectively valid national on site specifications. All externally connected devices shall comply with the relevant safety standards applicable for the place of installation.
Connecting cables, cable •
glands, reducers, blanking
plugs
•
We recommend using connecting cables and connecting terminals according to
nominal current (IN). (Refer to Motor name plate [} 9] or electrical data sheet.)
For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
•
Use connecting cables, cable glands, reducers, blanking plugs with a minimum
temperature range of +80 &deg;C.
•
To avoid contact corrosion, we recommend the use of sealing agents for cable
glands and blanking plugs made of metal.
•
For connecting cables exposed to UV radiation (outdoor installation), use UV resistant cables.
•
For connecting position transmitters, only use screened cables.
6.2 Overview of AUMA electrical connections
The section below provides an overview of the different electrical connections described in the chapters to follow.
Table 8: Versions of the AUMA plug/socket connector
Electrical connection
18
Figure
Properties
For description and assembly refer to
chapter
KT
Plug-in integral terminal
connection with enlarged
terminal compartment
KT/KM electrical connection [} 19]
KES
Plug-in terminal connecKES electrical connection [} 24]
tion with enlarged terminal
compartment
Electrical connection
6.3 KT/KM electrical connection
Figure 14: Electrical connection for KT/KM (figure shows KT version)
KT-Ex d
KT-Ex e
Ex d
[1]
Ex e
[1]
[2]
[2]
Ex d
Ex d
[1]
Terminal carrier with screw-type/spring
clamp terminals
[2]
Connection frame
Short description KT plug-in electrical connection with screw-type terminals for power connection and
spring clamp terminals for control contacts.
KM version with additional support terminals (terminal blocks) via terminal carrier.
Both versions (KT and KM) are available with terminal compartment in protection type
Ex e (increased safety) as well as in protection type Ex d.
The protection type is indicated on the name plate by means of the Ex marking. Refer
to Actuator name plate [} 8].
Plug-in connection is made via the connection frame. Removing the cover is sufficient
for connecting the cables. Thereby, the connection frame with the cable entries remains at the device. The flameproof interior of the connected devices remains sealed.
Technical data Table 9: KT/KM electrical connection
Power contacts
Control contacts
No. of contacts max.
6 + PE conductor 1)
50
Designations
U1, V1, W1, U2, V2, W2,
1 to 36, 37 to 50
Support terminals max.
3
12
Connection voltage max.
1,000 V
250 V
Nominal current max.
25 A
5 A2)
Type of customer connection
Screw connection
PE = Ring lug/U-bracket
Spring clamp terminals
Connection diameter max.
10 mm2
2.5 mm2
1)
Four protective earth connections within frame
2)
The sum of the currents of all control contacts must not exceed 50 A.
19
Electrical connection
6.3.1 Open terminal compartment
Figure 15: Open terminal compartment
[1]
[2]
[3]
Ex e
[6]
[5]
[1]
[3]
[5]
DANGER
[4]
Cover (illustration shows KT version in
type of protection Ex e)
O-ring
Cable gland (example)
[2]
Screws for cover
[4]
[6]
Blanking plug
Connection frame (in our example KTEx e)
Electric shock due to presence of hazardous voltage!
Death or serious injury.
&agrave; Disconnect device from the mains before opening.
WARNING
Risk of explosion in case of non-respect of the protection type!
Risk of death or serious injury!
&agrave; During commissioning, replace supplied blanking plugs with cable glands or blanking plugs with Ex approval, suitable for the type of protection. Thread types and
thread sizes are specified on the approval plate.
NOTICE
Corrosion by ingress of humidity when using unsuitable cable glands!
&agrave; Use suitable cable glands according to the IP enclosure protection specified on
the name plate.
Figure 16: Name plate, example with enclosure protection IP68
For shielded cables: Use EMC cable glands.
How to proceed 1. Loosen screws [2] and remove cover [1].
2. Insert cable glands suitable for connecting cables.
3. Seal unused cable entries with approved plugs suitable for the required protection
type.
20
Electrical connection
6.3.2 Cable connection
Table 10: Customising the cables
Terminal designation
Power contacts
(U1, V1, W1, U2, V2, W2)
PE connection
control contacts
(1 to 36, 37 to 50)
Protective earth connections within frame (customer connection)
WARNING
Wires per
terminal
Terminal cross sections Dismantling length3)
solid
1
flexible
Type
Without wire
end sleeve
With wire end sleeve
according to DIN
46228; length of wire
end sleeve insulated
(without insulation)
0.25 – 10.0 mm2
12 mm
Not permissible
1
up to 2.5 mm2
up to 4 mm2
up to 10 mm2
not permissible
8 (8) mm
10 (10) mm
12 (12) mm
flexible
25)
0.25 – 6 mm2
Not permissible
12 (12) mm
solid
1
0.25 – 2.5 mm2
10 mm
Not permissible
flexible
1
0.25 – 1.0 mm2
up to 1.5 mm2
up to 2.5 mm2
10 mm
10 (6) mm
10 (7) mm
10 (10) mm
flexible
25)
0.25 – 0.75 mm2
Not permissible
10 (10) mm
solid
2
1.5 mm2 – 10 mm2
10 mm
Not permissible
not permissible
10 (10) mm
with M6 ring lug as an
alternative3)
flexible
2
2
1.5 mm – 10 mm
2
Type of connection
and (tightening torque)
Screw-type terminals4)
(M = 1.2 – 1.5 Nm)
Spring clamp
terminals6)
U-bracket
(M = 3 – 4 Nm)
In case of a fault: Hazardous voltage while protective earth conductor is
NOT connected!
Risk of electric shock
&agrave; Connect all protective earth conductors.
&agrave; Connect PE connection to external protective earth conductor of connection cable.
&agrave; Power the device only once the protective earth conductor has been connected.
CAUTION
Without motor protection, impermissibly high temperatures at the actuator may occur: Ignition hazard, risk of explosion!
Risk of death, serious injury or motor damage. Our warranty for the motor will lapse if
the motor protection is not connected.
&agrave; Connect PTC thermistors or thermoswitches to actuator controls.
How to proceed 1. Remove cable sheathing in a length of 250 – 300 mm.
2. Insert the wires into the cable glands.
3. Fasten cable glands with the specified torque to ensure required enclosure protection.
Information: For shielded cables: Link the cable shield end via the cable gland to
the housing (earthing).
4. Strip wires.
For dismantling length, refer to Cable connection [} 21].
5. Connect cables according to order-related wiring diagram.
Information: Each spring clamp terminal is equipped with a test contact for service purpose which is located above the numbering.
Information: For flexible cables: for screw-type terminals, use wire end sleeves
according to DIN 46228. For spring clamp terminals, connection is possible
without wire end sleeves.
3)
For dismantling length, refer to manufacturer's specifications for wire end sleeve or ring lug
4)
Flexible cables for screw-type terminals with wire end sleeves
5)
For two wires per terminal, a twin wire end sleeve must be used
6)
Flexible cables for spring clamp terminals permissible even without wire end sleeves. Dismantling: 10 mm
21
Electrical connection
Figure 17: Connect cables to terminal carrier.
[1]
[1]
Fitting control cables into spring clamp
terminals
[2]
[2]
Tightening power terminals
6. Firmly tighten protective earth to PE connection (M6 ).
WARNING! In case of fault: Hazardous voltage while protective earth conductor is NOT connected!
Figure 18: Protective earth connections within connection frame
M4
M6
M6
M4
M6
Customer protective earth connection for M6 ring lug or with U-bracket for up to two wires.
M4
Internal protective earth connections via M4 ring lug (to cover and terminal carrier) connected in
the factory
Protective earth connection to terminal carrier (power terminals); connected in the factory.
22
Electrical connection
6.3.3 Close terminal compartment
Figure 19: Close terminal compartment
[1]
[2]
[3]
[6]
[5]
[4]
[1]
[3]
[5]
Cover (illustration shows KT version in
type of protection Ex e)
O-ring
Cable gland (example)
[2]
Screws for cover
[4]
[6]
Blanking plug
Connection frame (KT-Ex e)
For version in flameproof enclosure (Ex d), heed the following:
WARNING
Risk of explosion in case of damage to flameproof enclosure!
Risk of death or serious injury!
&agrave; Handle cover and housing parts with care.
&agrave; Flameproof joints must neither be damaged nor soiled in any way.
&agrave; Do not jam cover during fitting.
How to proceed 1. Clean sealing faces of cover [1] and connection frame [6].
2. For design in flameproof enclosure (Ex d): Preserve joint surfaces with an acidfree corrosion protection agent.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and insert
it correctly.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
WARNING! Risk of explosion in case of damage to flameproof enclosure!
23
Electrical connection
6.4 KES electrical connection
Figure 20: KES electrical connection
KES
KES-Ex d
Ex d
Ex e
[1]
[1]
[2]
[2]
Ex d
[1]
Ex d
Terminal blocks
[2]
Connection frame
Short description KES plug-in electrical connection with terminal blocks for power and control contacts.
The KES electrical connection is available with terminal compartment in protection
type Ex e (increased safety) as well as in protection type Ex d (flameproof enclosure).
The protection type is indicated on the name plate by means of the Ex marking. Refer
to Actuator name plate [} 8].
Plug-in connection is made via the connection frame. Removing the cover is sufficient
for connecting the cables. Thereby, the connection frame with the cable entries remains at the device. The flameproof interior of the connected devices remains sealed.
Technical data Table 11: KES electrical connection
24
Power contacts
Control contacts
No. of contacts max.
3 + protective earth connection at
frame
50
Designations
U, V, W, (PE)
1 to 50
Connection voltage max.
750 V
250 V
Nominal current max.
25 A
10 A
Type of customer connection
Screw connection
PE = Ring lug/U-bracket
Cage clamp,
screw-type connection as an option
Connection diameter max.
6 mm2/10 mm2
2.5 mm2 flexible, 4 mm2 solid
Electrical connection
6.4.1 Open terminal compartment
Figure 21: Open terminal compartment
[2]
[1]
[3]
[6]
[5]
[4]
[1]
[3]
[5]
DANGER
Cover (illustration shows type of protec- [2]
tion Ex e)
O-ring
[4]
Cable gland
[6]
Screws for cover
Blanking plug
Connection frame
Electric shock due to presence of hazardous voltage!
Death or serious injury.
&agrave; Disconnect device from the mains before opening.
WARNING
Risk of explosion in case of non-respect of the protection type!
Risk of death or serious injury!
&agrave; During commissioning, replace supplied blanking plugs with cable glands or blanking plugs with Ex approval, suitable for the type of protection. Thread types and
thread sizes are specified on the approval plate.
NOTICE
Corrosion by ingress of humidity when using unsuitable cable glands!
&agrave; Use suitable cable glands according to the IP enclosure protection specified on
the name plate.
Figure 22: Name plate, example with enclosure protection IP68
For shielded cables: Use EMC cable glands.
How to proceed 1. Loosen screws [2] and remove cover [1].
2. Insert cable glands suitable for connecting cables.
25
Electrical connection
3. Seal unused cable entries with approved plugs suitable for the required protection
type.
6.4.2 Cable connection
Table 12: Terminal cross sections and terminal tightening torques
WARNING
Designation
Terminal cross sections
Tightening torques
Power contacts (U, V, W)
max. 10 mm&sup2; (flexible or solid)
1.5 – 1.8 Nm
PE connection
max. 10 mm&sup2; (flexible or solid)
3.0 – 4.0 Nm
Control contacts (1 to 50)
max. 2.5 mm&sup2; (flexible) or
max. 4 mm&sup2; solid
0.6 – 0.8 Nm
In case of a fault: Hazardous voltage while protective earth conductor is
NOT connected!
Risk of electric shock
&agrave; Connect all protective earth conductors.
&agrave; Connect PE connection to external protective earth conductor of connection cable.
&agrave; Power the device only once the protective earth conductor has been connected.
CAUTION
Without motor protection, impermissibly high temperatures at the actuator may occur: Ignition hazard, risk of explosion!
Risk of death, serious injury or motor damage. Our warranty for the motor will lapse if
the motor protection is not connected.
&agrave; Connect PTC thermistors or thermoswitches to actuator controls.
How to proceed 1. Remove cable sheathing and insert the wires into the cable glands.
2. Fasten cable glands with the specified torque to ensure required enclosure protection. For shielded cables: Link the cable shield end via the cable gland to the
housing (earthing).
3. Strip wires.
4. For flexible cables: Use wire end sleeves according to DIN 46228.
5. Connect cables according to order-related wiring diagram.
6. Firmly tighten protective earth to PE connection (symbol ).
WARNING! In case of fault: Hazardous voltage while protective earth conductor is NOT connected!
Figure 23: PE connection
[1]
[1]
26
U-bracket for PE connection
Electrical connection
6.4.3 Close terminal compartment
Figure 24: Close terminal compartment
[1]
[2]
[3]
[5]
[6]
[1]
[3]
[5]
[4]
Cover (illustration shows type of protec- [2]
tion Ex e)
O-ring
[4]
Cable gland
[6]
Screws for cover
Blanking plug
Connection frame
For version in flameproof enclosure (Ex d), heed the following:
WARNING
Risk of explosion in case of damage to flameproof enclosure!
Risk of death or serious injury!
&agrave; Handle cover and housing parts with care.
&agrave; Flameproof joints must neither be damaged nor soiled in any way.
&agrave; Do not jam cover during fitting.
How to proceed 1. Clean sealing faces of cover [1] and connection frame [6].
2. For design in flameproof enclosure (Ex d): Preserve joint surfaces with an acidfree corrosion protection agent.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and insert
it correctly.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
WARNING! Risk of explosion in case of damage to flameproof enclosure!
27
Electrical connection
6.5 External earth connection
Figure 25: Earth connection for part-turn actuator
Application External earth connection (U-bracket) for connection to equipotential compensation.
Table 13: Terminal cross sections and earth connection tightening torques
Conductor type
Terminal cross sections
Tightening torques
Solid wire and stranded
2.5 mm&sup2; to 6 mm&sup2;
3 – 4 Nm
Fine stranded
1.5 mm&sup2; to 4 mm&sup2;
3 – 4 Nm
For fine stranded (flexible) wires, connection is made via cable lugs/ring terminals. When connecting two
individual wires with a U-bracket, cross sections have to be identical.
6.6 Accessories for electrical connection (option)
6.6.1 Parking frame
Figure 26: PAFEx 01.1 parking frame
Application Parking frame for safe storage of a disconnected plug or cover.
For protection against touching the bare contacts and against environmental influences.
WARNING
Explosion hazard!
Risk of death or serious injury.
&agrave; Prior to opening the device (removing the plug) ensure that the device is free of
gas and voltage!
&agrave; Do NOT switch on voltage in potentially explosive atmospheres.
For PAFEx 01.1, separate operation instructions are available.
28
Operation
7 Operation
7.1 Manual operation
For purposes of setting and commissioning, in case of motor or power failure, the actuator may be operated manually. Manual operation is engaged by an internal changeover mechanism.
Manual operation is automatically disengaged when motor is started again. The handwheel does not rotate during motor operation.
7.1.1 Manual valve operation
CAUTION
Damage at the manual change-over mechanism/motor coupling due to
faulty operation!
&agrave; Engage manual operation only during motor standstill.
&agrave; Do NOT use extensions as lever for operation.
How to proceed 1. Press push button.
2. Turn handwheel in desired direction.
Figure 27: Engage manual operation
&eth; The closing direction is marked on the handwheel:
Table 14: Handwheel marking (examples)
→ For valve closing, turn handwheel in direction of the arrowhead.
Clockwise closing
Counterclockwise closing
Drive shaft (valve) turns clockwise in direction
CLOSE.
Drive shaft (valve) turns counterclockwise in direction CLOSE.
7.2 Motor operation
NOTICE
Valve damage due to incorrect setting!
&agrave; Perform all commissioning settings and the test run prior to motor operation.
Actuator controls are required to operate an actuator during motor operation. An additional local control unit must be provided if local actuator operation is required.
How to proceed 1. Switch on the power supply.
2. To close the valve, switch on motor operation in direction CLOSE.
&eth; Valve shaft turns counterclockwise in direction CLOSE.
29
Indications (option)
8 Indications (option)
8.1 Mechanical position indication via indicator mark
Figure 28: Mechanical position indicator
[1]
[2]
[3]
[1]
[3]
Properties •
•
End position OPEN reached
Indicator mark at cover
[2]
Independent of power supply
Used as running indication: Indicator disc rotates during actuator operation and
continuously indicates the valve position
(For “clockwise closing” version, the symbols
ection for operations in direction CLOSE)
•
/
rotate in counterclockwise dir-
Indicates that end positions (OPEN/CLOSED) have been reached
(Symbols
30
End position CLOSED reached
(OPEN)/
(CLOSED) point to the indicator mark
at cover)
Signals (output signals)
9 Signals (output signals)
9.1 Feedback signals from actuator
The switches can be provided as single switches (1 NC and 1 NO), as tandem
switches (2 NC and 2 NO) or as triple switches (3 NC and 3 NO). The precise
version is indicated in the terminal plan or on the order-related technical data
sheet.
Table 15: Feedback signals from actuator
Feedback signal
End position OPEN/CLOSED
reached
Intermediate position reached (option)
Type and designation in wiring diagram
Setting via limit switching
Switches: 1 NC and 1 NO (standard)
WSR/LSC
Limit switch, closing, clockwise rotation
WOEL/LSO
Limit switch, opening, counterclockwise rotation
Setting via DUO limit switching
Switches: 1 NC and 1 NO (standard)
WDR/LSA
DUO limit switch, clockwise rotation
WDL/LSB
DUO limit switch, counterclockwise rotation
Setting via torque switching
Switches: 1 NC and 1 NO (standard)
Torque OPEN/CLOSED reached
DSR/TSC
Torque switch, closing, clockwise rotation
DOEL/TSO
Torque switch, opening, counterclockwise rotation
Also thermoswitches or PTC thermistors, depending on the version
Motor protection tripped
Running indication (option)
F1, Th
Thermoswitch
R3
PTC thermistor
Switches: 1 NC (standard)
S5, BL
Blinker transmitter
Depending on version either with potentiometer or electronic position transmitter EWG/RWG
Position feedback signal (option)
Manual operation engaged (option)
R2
Potentiometer
R2/2
Potentiometer in tandem arrangement (option)
B1/B2, EWG/
RWG
3-wire or 4-wire system (0/4– 20 mA)
B3/B4, EWG/
RWG
2-wire system (4 – 20 mA)
Switches
31
Commissioning (basic settings)
10 Commissioning (basic settings)
10.1 End stops in part-turn actuator
The internal end stops limit the swing angle. They protect the valve in case of limit
switching failure during motor operation and serve the purpose as limitation for manual
operation via handwheel. They may not be used for torque tripping in end positions
during standard operation.
End stop setting is generally performed by the valve manufacturer prior to installing
the valve into the pipework.
CAUTION
Exposed, rotating parts (discs/balls) at the valve!
Pinching and damage by valve or actuator.
&agrave; End stops should be set by suitably qualified personnel only.
&agrave; Never completely remove the setting screws [2] and [4] to avoid grease leakage.
&agrave; Observe dimension Tmin.
The swing angle set in the factory is indicated on the name plate:
Figure 29: Example of swing angle on name plate
The setting sequence depends on the valve:
•
Recommendation for butterfly valves: Set end stop CLOSED first.
•
Recommendation for ball valves: Set end stop OPEN first.
Figure 30: End stop
[2]
[4]
[1]
[3]
[1]
T T min.
[3]
[1]
[3]
Screw plug for end stop OPEN
Screw plug for end stop CLOSED
[2]
[4]
Setting screw for end stop OPEN
Setting screw for end stop CLOSED
Table 16: Dimensions/size (mm)
32
Dimensions/size (mm)
05.2
07.2
10.2
12.2
14.2
T (for 90&deg;)
17
17
20
23
23
Tmin.
11
11
12
13
12
Commissioning (basic settings)
10.1.1 Set end stop CLOSED
How to proceed 1. Remove screw plug [3]
2. Move valve to end position CLOSED with handwheel.
3. If the valve end position is not reached: Slightly turn setting screw counterclockwise until valve end position CLOSED can be correctly set.
Turning the setting screw [4] clockwise decreases the swing angle.
Turning the setting screw [4] counterclockwise increases the swing angle.
Figure 31: Setting screws
4. Turn setting screw [4] clockwise to the stop.
&eth; This completes the setting of end stop CLOSED.
5. Check O-ring of screw plug for seat and condition, replace if damaged.
6. Fasten and tighten screw plug [1].
Having completed this procedure, the end position detection CLOSED can be set immediately.
10.1.2 Set end stop OPEN
In general, the end stop OPEN does not have to be set.
How to proceed 1. Remove screw plug [1].
2. Move valve to end position OPEN with handwheel.
3. If the valve end position is not reached: Slightly turn setting screw [2] counterclockwise until valve end position OPEN can be correctly set.
Turning the setting screw [2] clockwise decreases the swing angle.
Turning the setting screw [2] counterclockwise increases the swing angle.
Figure 32: Direction of rotation of setting screws
4. Turn setting screw [2] clockwise to the stop.
&eth; This completes the setting of end stop OPEN.
5. Check O-ring of screw plug for seat and condition, replace if damaged.
6. Fasten and tighten screw plug [1].
After this procedure, the end position detection OPEN can be set immediately.
10.2 Open switch compartment
The switch compartment must be opened to perform the following settings.
WARNING
Ignition of potentially explosive atmospheres caused by sparks.
Risk of death or serious injury
&agrave; Before opening the flameproof enclosure, ensure absence of gas and voltage.
&agrave; Handle cover and housing parts with care.
&agrave; Flameproof joints must neither be damaged nor soiled in any way.
&agrave; Do not jam cover during fitting.
How to proceed 1. Loosen screws [2] and remove cover [1] from the switch compartment.
33
Commissioning (basic settings)
Figure 33: Open switch compartment
[1]
[3]
[2]
[1]
[3]
Cover
Indicator disc
[2]
Screws for cover
2. If indicator disc [3] is available: Remove indicator disc [3] using a spanner (as a
lever).
Information: To avoid damage to the paintwork, place a soft object, e.g. a cloth,
under the spanner.
Figure 34: Pull off indicator disc
10.3 Set torque switching
Once the set tripping torque is reached, the torque switches are tripped (overload protection of the valve).
NOTICE
Valve damage due to excessive tripping torque limit setting!
&agrave; The tripping torque must suit the valve.
&agrave; Only change the setting with prior consent of the valve manufacturer.
The torque switches may also trip during manual operation.
34
Commissioning (basic settings)
Figure 35: Torque switching heads
[3]
[3]
[1]
[2]
[4]
[4]
[1]
[3]
Torque switching head black in direction CLOSE
Lock screws
[2]
[4]
Torque switching head white in direction OPEN
Torque dials
How to proceed 1. Loosen both lock screws [3] at the indicator disc.
2. Turn torque dial [4] to set the required torque (1 da Nm = 10 Nm). Example:
&eth; Black torque switching head set to approx. 25 da Nm ≙ 250 Nm for direction
CLOSE.
&eth; White torque switching head set to approx. 20 da Nm ≙ 200 Nm for direction
OPEN
3. Fasten lock screws [3] again.
Information: Maximum tightening torque: 0.3 – 0.4 Nm
&eth; The torque switch setting is complete.
10.4 Set limit switching
The limit switching records the travel. When reaching the preset position, switches are
operated.
Figure 36: Setting elements for limit switching
[1]
[4]
[2]
[5]
[3]
[6]
[1]
[3]
[5]
Setting spindle: End position CLOSED [2]
(black section)
Mark: End position CLOSED set (black [4]
section)
Pointer: End position OPEN (white sec- [6]
tion)
Pointer: End position CLOSED (black
section)
Setting spindle: End position OPEN
(white section)
Mark: End position OPEN set (white
section)
10.4.1 Set end position CLOSED (black section)
How to proceed 1. Engage manual operation.
2. Turn handwheel clockwise until valve is closed.
3. Press down and turn setting spindle [1] with screwdriver in direction of the arrow
and observe the pointer [2]: While a ratchet click is felt and heard, the pointer [2]
moves 90&deg; every time.
35
Commissioning (basic settings)
4. As soon as the pointer [2] is 90&deg; from mark [3]: Continue turning slowly.
5. As soon as the pointer [2] moves to mark [3]: Stop turning and release setting
spindle.
&eth; The end position CLOSED setting is complete.
6. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
10.4.2 Set end position OPEN (white section)
How to proceed 1. Engage manual operation.
2. Turn handwheel counterclockwise until valve is open.
3. Press down and turn setting spindle [4] with screwdriver in direction of the arrow
and observe the pointer [5]: While a ratchet click is felt and heard, the pointer [5]
moves 90&deg; every time.
4. As soon as the pointer [5] is 90&deg; from mark [6]: Continue turning slowly.
5. As soon as the pointer [5] moves to mark [6]: Stop turning and release setting
spindle.
&eth; The end position OPEN setting is complete.
6. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
10.5 Test run
Perform test run only once all settings previously described have been performed.
10.5.1 Check direction of rotation at mechanical position indicator
NOTICE
Valve damage due to incorrect direction of rotation!
&agrave; If the direction of rotation is incorrect, switch off immediately.
&agrave; Correct phase sequence.
&agrave; Repeat test run.
Switch off before reaching the end position.
How to proceed 1. Move actuator manually to intermediate position or to sufficient distance from end
position.
2. Switch on actuator in direction CLOSE and observe the direction of rotation on the
mechanical position indication:
•
36
For mechanical position indication via indicator mark:
The direction of rotation is correct if the actuator operates in direction CLOSE
and the symbols ( / ) turn counterclockwise:
Commissioning (basic settings)
Figure 37: Direction of rotation
/
(for “clockwise closing” version)
10.5.2 Check limit switching
How to proceed 1. Manually operate actuator into both valve end positions.
2. The limit switching is set correctly if:
&eth; WSR/LSC contact trips in end position CLOSED
WOEL/LSO contact trips in end position OPEN
&eth; the switches release the contacts after turning back the handwheel
3. If the end position setting is incorrect: Reset limit switching.
10.6 Set mechanical position indicator
How to proceed &uuml; If options (such as potentiometer, position transmitter) are available: Only set
mechanical position indication once all optional equipment has been successfully
set.
1. Fit indicator disc onto shaft.
2. Move valve to end position CLOSED.
3. Turn lower indicator disc until symbol
mark on the cover.
(CLOSED) is in alignment with the
Figure 38: Indication CLOSED
4. Operate actuator to end position OPEN.
5. Hold lower indicator disc in position and turn upper disc with symbol
until it is in alignment with the
mark on the cover.
(OPEN)
Figure 39: Indication OPEN
6. Move valve to end position CLOSED again.
37
Commissioning (basic settings)
7. Check settings: If the symbol
on the cover:
(CLOSED) is no longer in alignment with
mark
7.1 Repeat setting.
10.7 Close switch compartment
If options (such as potentiometer, position transmitter) are available: Only close switch
compartment once all optional equipment has been successfully set.
WARNING
Risk of explosion in case of damage to flameproof enclosure!
Risk of death or serious injury!
&agrave; Handle cover and housing parts with care.
&agrave; Flameproof joints must neither be damaged nor soiled in any way.
&agrave; Do not jam cover during fitting.
NOTICE
Corrosion due to damage to paint finish!
&agrave; Touch up damage to paint finish after work on the device.
How to proceed 1. Clean sealing faces of housing and cover.
2. Preserve joint surfaces with an acid-free corrosion protection agent.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and insert
it correctly.
Figure 40: Close switch compartment
5. Place cover [1] on switch compartment.
WARNING! Risk of explosion in case of damage to flameproof enclosure!
6. Fasten screws [2] evenly crosswise.
38
Commissioning (optional equipment settings)
11 Commissioning (optional equipment settings)
11.1 Potentiometer
The potentiometer is used as travel sensor and records the valve position.
Setting elements The potentiometer is housed in the actuator switch compartment. The switch compartment must be opened to perform any settings. Refer to Open switch compartment
[} 33].
Setting is made via potentiometer [1].
Figure 41: View of control unit
[1]
[1]
Potentiometer
11.1.1 Potentiometer setting
Due to the ratio of the reduction gearing, the complete resistance range/stroke
is not always covered. Therefore, external adjustment (setting potentiometer)
must be provided.
How to proceed 1. Move valve to end position CLOSED.
2. Turn potentiometer [1] clockwise to the stop.
&eth; End position OPEN corresponds to 0 %.
&eth; End position OPEN corresponds to 100 %.
3. Turn potentiometer [1] slightly in opposite direction.
4. Perform fine-tuning of the zero point at external setting potentiometer (for remote
indication).
11.2 RWG electronic position transmitter
RWG electronic position transmitter records the valve position. On the basis of the actual position value measured by the potentiometer (travel sensor), it generates a current signal between 0 – 20 mA or 4 – 20 mA.
Technical data Table 17: RWG 4020
Data
3-wire and 4-wire systems
2-wire system
Output current Ia
0 – 20 mA, 4 – 20 mA
4 – 20 mA
Power supply UV 1)
24 V DC (18 – 32 V)
14 V DC + (I x RB), max. 30 V
Max. current consumption
24 mA at 20 mA output current
20 mA
Max. load RB
600 Ω
(UV – 14 V)/20 mA
Impact of power supply
0.1 %/V
0.1 %/V
Load influence
0.1 %/(0 – 600 Ω)
Temperature impact
Ambient temperature 2)
Transmitter potentiometer
0.1 %/100 Ω
&lt; 0.3 ‰/K
–60 &deg;C to +80 &deg;C
5 kΩ
39
Commissioning (optional equipment settings)
1)
Power supply possible via: AC, AM actuator controls or external power supply
2)
Depending on temperature range of the actuator: refer to name plate
Setting elements The RWG is housed in the actuator switch compartment. The switch compartment
must be opened to perform any settings. Refer to Open switch compartment [} 33].
Setting is made via three potentiometers [1], [2] and [3].
Figure 42: View on control unit when switch compartment is open
[3]
[2]
[1]
[4]
[5]
[1]
[3]
[5]
Potentiometer (travel sensor)
Potentiometer max. (20 mA)
Measuring point (–) 0/4 – 20 mA
[2]
[4]
Potentiometer min. (0/4 mA)
Measuring point (+) 0/4 – 20 mA
The output current (measuring range 0 – 20 mA) can be checked at measuring points
[4] and [5].
11.2.1 Set measuring range
For setting, voltage must be applied at the position transmitter.
How to proceed 1. Move valve to end position CLOSED.
2. Connect measuring equipment for 0 – 20 mA to measuring points [4] and ]5]. If no
value can be measured:
Check whether external load is connected to customer connection XK (for standard wiring: terminals 23/24). Consider maximum load RB.
Or connect link across customer connection XK (for standard wiring: terminals
23/24).
3. Turn potentiometer [1] clockwise to the stop.
4. Turn potentiometer [1] slightly in opposite direction.
5. Turn potentiometer [2] clockwise until output current starts to increase.
6. Turn potentiometer [2] in opposite direction until the following value is reached:
at 0 – 20 mA approx. 0.1 mA
at 4 – 20 mA approx. 4.1 mA
&eth; This ensures that the signal remains above the dead and live zero point.
7. Move valve to end position OPEN.
8. Set potentiometer [3] to end value 20 mA.
9. Approach end position CLOSED anew and check minimum value (0.1 mA or 4.1
mA). Correct if required.
11.3 EWG 01.1 electronic position transmitter
EWG 01.1 electronic position transmitter signals the remote position or the valve position. On the basis of the actual valve position sensed by hall sensor, a current signal
between 0 – 20 mA or 4 – 20 mA is generated.
Technical data Table 18: EWG 01.1
40
Data
3-wire and 4-wire systems
2-wire system
Output current Ia
0 – 20 mA, 4 – 20 mA
4 – 20 mA
Commissioning (optional equipment settings)
Data
3-wire and 4-wire systems
2-wire system
Power supply UV 1)
24 V DC (18 – 32 V)
24 V DC (18 – 32 V)
Max. current consumption
LED off = 26 mA,
LED on = 27 mA
20 mA
Max. load RB
600 Ω
(UV – 12 V)/20 mA
Impact of power supply
0.1 %
Load influence
0.1 %
Temperature impact
&lt; 0.1 ‰/K
Ambient temperature 2)
–60 &deg;C to +80 &deg;C
1)
Power supply possible via: AC, AM actuator controls or external power supply
2)
Depending on temperature range of the actuator: refer to name plate
Setting elements The EWG is housed in the actuator switch compartment. The switch compartment
must be opened to perform any settings. Refer to Open switch compartment [} 33].
All settings are made via the two push buttons [S1] and [S2].
Figure 43: View on control unit when switch compartment is open
[S1]
[S2]
LED
[1]
[S1]
LED
[2]
[2]
Push button: Set 0/4 mA
Optical aid for setting
Measuring point (–) 0/4 – 20 mA
[S2]
[1]
Push button: Set 20 mA
Measuring point (+) 0/4 – 20 mA
The output current (measuring range 0 – 20 mA) can be checked at measuring points
[1] and [2].
Table 19: Short overview on push button functions
Push buttons
Function
[S1] + [S2]
→ press simultaneously for 5 s: Activate setting mode
[S1]
→ press in setting mode for 3 s: Set 4 mA
→ press in setting mode for 6 s: Set 0 mA (only possible for 3-/4-wire version)
→ press in operation for 3 s: Switch on/off LED end position signalling
→ touch in end position: Reduce current value by 0.02 mA
[S2]
→ press in setting mode for 3 s: Set 20 mA
→ press in operation for 3 s: Switch on/off LED end position signalling
→ touch in end position: Increase current value by 0.02 mA
11.3.1 Set measuring range
For setting, voltage must be applied at the electronic position transmitter.
For output current verification, connect a test device for 0 – 20 mA to measurement
points (+/–) (for 2-wire systems, connecting a test device is imperatively required).
41
Commissioning (optional equipment settings)
a) Measuring range 0/4 – 20 mA as well as measuring range 20 – 0/4 mA (inverse
operation) can be set.
During setting process, the measuring range (normal or inverse operation) is assigned to the end positions by push button S1/S2 assignment.
b) For 2-wire systems, switch off LED end position signalling prior to setting the
measuring range. Refer to Switch on/off LED end position signalling [} 43].
c) Setting mode activation clears the settings in both end positions and sets the output current to a value of 3.5 mA. After activation, both end values (0/4 mA and 20
mA) need to be reset.
d) In case of inadvertent incorrect adjustment, the settings can always be reset by
renewed activation of the setting mode (simultaneous pressing of [S1] and [S2]).
For 2-wire systems read current values at test device.
Activate setting mode 1. Press both push buttons [S1] and [S2] and hold down for 5 seconds:
&eth; By pulsing double flashes, the LED indicates that the setting mode is correctly
activated:
LED
&eth; For any other LED flash sequence (single/triple flashing): refer to Faults during
operation/commissioning [} 45].
Set measuring range 2. Operate valve in one of the end positions (OPEN/CLOSED).
3. Set desired output current (0/4 mA or 20 mA):
&eth; for 4 mA: Hold down [S1] for approx. 3 seconds,
.
until LED is blinking slowly
&eth; for 0 mA: Hold down [S1] for approx. 6 seconds (only possible for 3-/4-wire
version)
.
until LED is blinking fast
&eth; for 20 mA: Hold down [S2] for approx. 3 seconds
until LED is illuminated
.
4. Operate valve into opposite end position.
&eth; The value set in end position (0/4 mA or 20 mA) does not change during travel
in setting mode.
5. Perform setting in the second end position following the same steps.
6. Approach both end positions again to check the setting.
&eth; If the measuring range cannot be set: refer to Faults during operation/commissioning [} 45].
&eth; If the current values (0/4/20 mA) are incorrect: refer to Adjust current values
[} 42].
&eth; If the current value fluctuates (e.g. between 4.0 – 4.2 mA): Switch off LED end
position signalling. Refer to Switch on/off LED end position signalling [} 43].
11.3.2 Adjust current values
The current values (0/4/20 mA) set in end positions can be adjusted at any time. Typical values are 0.1 mA (instead of 0 mA) or 4.1 mA (instead 4 mA).
42
Commissioning (optional equipment settings)
If the current value fluctuates (e.g. between 4.0 – 4.2mA), the Switch on/off
LED end position signalling [} 43] must be switched off for current adjustment.
How to proceed 1. Operate valve in desired end position (OPEN/CLOSED).
2. Reduce current value: Press push button [S1].
(The current is reduced by 0.02 mA every time the push button is pressed.)
3. Increase current value: Press push button [S2].
(The current is increased by 0.02 mA every time the push button is pressed.)
11.3.3 Switch on/off LED end position signalling
The LED behaviour for end position reached can be set as follows: blinking/continuous
illumination or no illumination. During setting mode, end position signalling is switched
on.
How to proceed 1. Operate valve in one of the end positions (OPEN/CLOSED).
2. Hold down push buttons [S1] or [S2] for approx. 3 seconds.
&eth; End position signalling is switched on or off.
Table 20: LED behaviour when end position signalling is switched on
Set output current
LED behaviour in end position
4 mA
LED is blinking slowly
0 mA
LED is blinking fast
20 mA
LED is illuminated
11.4 Set intermediate positions
Actuators equipped with DUO limit switching are equipped with two intermediate position switches. One intermediate position may be set for each running direction.
Figure 44: Setting elements for limit switching
[3]
[2]
[6]
[5]
[1]
[4]
[1]
[3]
[5]
Setting spindle: Running direction
[2]
CLOSE (black section)
Mark: Intermediate position CLOSED
[4]
set (black section)
Pointer: Running direction OPEN (white [6]
section)
Pointer: Running direction CLOSE
(black section)
Setting spindle: Running direction
OPEN (white section)
Mark: Intermediate position OPEN set
(white section)
11.4.1 Set running direction CLOSE (black section)
How to proceed 1. Move valve in direction CLOSE to desired intermediate position.
43
Commissioning (optional equipment settings)
2. If you override the tripping point inadvertently: Move valve in opposite direction
and approach intermediate position again in direction CLOSE (always approach
the intermediate position in the same direction as in later electrical operation).
3. Press down and turn setting spindle [1] with screwdriver in direction of the arrow
and observe the pointer [2]: While a ratchet click is felt and heard, the pointer [2]
moves 90&deg; every time.
4. As soon as the pointer [2] is 90&deg; from mark [3]: Continue turning slowly.
5. As soon as the pointer [2] moves to mark [3]: Stop turning and release setting
spindle.
&eth; The intermediate position setting in running direction CLOSE is complete.
6. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
11.4.2 Set running direction OPEN (white section)
How to proceed 1. Move valve in direction OPEN to desired intermediate position.
2. If you override the tripping point inadvertently: Move valve in opposite direction
and approach intermediate position again in direction OPEN (always approach the
intermediate position in the same direction as in later electrical operation).
3. Press down and turn setting spindle [4] with screwdriver in direction of the arrow
and observe the pointer [5]: While a ratchet click is felt and heard, the pointer [5]
moves 90&deg; every time.
4. As soon as the pointer [5] is 90&deg; from mark [6]: Continue turning slowly.
5. As soon as the pointer [5] moves to mark [6]: Stop turning and release setting
spindle.
&eth; The intermediate position setting in running direction OPEN is complete.
6. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
44
Corrective actions
12 Corrective actions
12.1 Faults during operation/commissioning
Table 21: Faults during operation and commissioning
Faults
Description/cause
Remedy
Mechanical position indicator cannot
be set.
Reduction gearing is not suitable for actuator
swing angle.
Exchange reduction gearing.
In spite of correct setting of mechanThe overrun was not considered when setting the •
ical limit switching, actuator operates limit switching.
into the valve or actuator end position. The overrun is generated by the inertia of both the
•
actuator and the valve and the delay time of the
actuator controls.
Determine overrun: Overrun = travel covered
from switching off until complete standstill.
No value can be measured at measur- The current loop across the RWG is open.
ing points of the RWG.
(Position feedback 0/4 – 20 mA is only possible if
the current loop is closed across the RWG.)
•
Connect link across RWG to XK (terminals
23/24).
•
Connect external load to XK, e.g. remote indication.
•
Observe maximum load RB.
Set limit switching again considering the overrun. (Turn handwheel back by the amount of
the overrun)
Measuring range 0/4 – 20 mA or max- Reduction gearing is not suitable for actuator
imum value 20 mA at position transswing angle.
mitter cannot be set or supplies an incorrect value.
Exchange reduction gearing.
the measuring range 0/4 – 20 mA at
EWG position transmitter cannot be
set.
Request AUMA Service.
The LED on the EWG either flashes in setting
mode a) single flash or b) triple flash:
a) EWG is not calibrated.
b) Magnet positions of EWG are not aligned.
Check setting, if required, reset end positions.
Limit and/or torque switches do not
trip.
Handwheel rotates on the shaft
without transmitting torque.
Switch is defective or switch setting is incorrect.
Refer to Switch check [} 45], or replace switches,
if required.
Actuator in version with overload protection for
manual operation: Shear pin rupture due to excessive torque at handwheel.
Dismount handwheel. Replace overload protection
and remount handwheel.
Switch check
The red test buttons [1] and [2] are used for manual operation of the switches:
Figure 45: Test buttons
[1]
[2]
1. Turn test button [1] in direction of the DSR/TSC arrow (clockwise closing): Torque
switch CLOSE trips.
2. Turn test button [2] in direction of the D&Ouml;L/TSO arrow (counterclockwise opening):
Torque switch OPEN trips.
If the actuator is equipped with DUO limit switching (option), the intermediate position
switches WDR/LSA and WDL/LSB will be operated at the same time as the torque
switches.
1. Turn test button [1] in direction of the WSL/LSC arrow (clockwise closing): Limit
switch CLOSED trips.
2. Turn test button [2] in direction of the W&Ouml;L/LSO arrow: Limit switch OPEN trips.
45
Corrective actions
12.2 Motor protection (thermal monitoring)
PTC thermistors or thermoswitches are provided in the motor winding to monitor the
motor winding temperature. Motor protection trips as soon as the max. permissible
winding temperature has been reached.
Possible causes Overload, running time exceeded, max. number of starts exceeded, max. ambient
temperature exceeded.
46
Servicing and maintenance
13 Servicing and maintenance
CAUTION
Damage caused by inappropriate maintenance!
&agrave; Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
We recommend contacting our service for any interventions.
&agrave; Only perform servicing and maintenance tasks when the device is switched off.
Service &amp; Support AUMA offers extensive service such as servicing and maintenance as well as customer product training. Contact addresses are indicated on our website
(www.auma.com).
13.1 Preventive measures for servicing and safe operation
The following actions are required to ensure safe device function during operation:
6 months after commissioning and then once a year
•
Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing. If required, tighten cable glands and blanking plugs with
torque in compliance with the manufacturer's specifications.
Check actuator for damage as well as for grease or oil leakage.
•
When deployed in areas where dust formation represents a potential explosion
hazard, perform visual inspection for deposit of dirt or dust on a regular basis.
Clean devices if required.
•
Check fastening screws between actuator and gearbox/valve for tightness. If required, fasten screws while applying the tightening torques as indicated in Tightening torques for screws [} 54] chapter.
•
When rarely operated: Perform test run.
For enclosure protection IP68
After immersion:
•
Check actuator.
•
In case of ingress of water, locate leaks and repair. Dry device correctly and check
for proper function.
13.2 Disconnection from the mains
If the device must be dismantled, for service purposes, it can be isolated from the
mains without having to remove the wiring at the electrical connection.
47
Servicing and maintenance
13.2.1 Disconnection from the mains with KT/KM electrical connection
Figure 46: KT/KM electrical connection
[2]
[1]
[2]
[1]
[3]
[6]
[4]
[3]
Ex d
Ex e
[4]
[5]
[5]
[3]
[3]
Ex d
WARNING
Ex d
[1]
[3]
Cover
O-ring
[2]
[4]
[5]
Connection frame
[6]
Screws for cover
Screws (with gaskets) within connection frame
Grub screws within connection frame
Ignition of potentially explosive atmospheres caused by sparks.
Risk of death or serious injury
&agrave; Before opening the flameproof enclosure, ensure absence of gas and voltage.
&agrave; Handle cover and housing parts with care.
&agrave; Flameproof joints must neither be damaged nor soiled in any way.
&agrave; Do not jam cover during fitting.
Removing the plug 1. Loosen the screws [2].
2. Remove cover [1].
3. For versions with terminal compartment in Ex d (flameproof enclosure): Remove
grub screws [6] inside the connection frame.
4. Loosen screws [4] inside the connection frame.
5. Remove electrical connection.
Fitting the plug 6. Clean sealing faces of plug/socket connector, cover and housing.
7. Preserve joint surfaces with an acid-free corrosion protection agent.
8. Check whether O-rings [3] are in good condition, replace if damaged.
9. Slightly grease the O-rings with acid-free grease (e.g. petroleum jelly) and insert
them correctly.
10. Fit electrical connection (connection frame) and fasten screws [4] (with gaskets)
evenly crosswise.
11. For versions with terminal compartment in Ex d (flameproof enclosure): Fasten
grub screws [6] (tightening torque approx. 10 Nm).
Information: The flameproof enclosure is only guaranteed provided the grub
screws are fastened [6].
12. Fit cover [1] and fasten screws [2] evenly crosswise.
48
Servicing and maintenance
13.2.2 Mains disconnection with KES electrical connection
Figure 47: KES Ex e electrical connection
[1]
[4]
[2]
[3]
[1]
[3]
WARNING
Cover
O-ring
[2]
[4]
Screws for housing
Connection frame
Ignition of potentially explosive atmospheres caused by sparks.
Risk of death or serious injury
&agrave; Before opening the flameproof enclosure, ensure absence of gas and voltage.
&agrave; Handle cover and housing parts with care.
&agrave; Flameproof joints must neither be damaged nor soiled in any way.
&agrave; Do not jam cover during fitting.
Removing the plug 1. Loosen the screws [2].
2. Remove electrical connection.
&eth; Cover [1] and plug-in type frame [4] or connection frame [5] remain together.
3. Seal open plug/socket connection, e.g. using AUMA protection cover and parking
frame.
Fitting the plug 4. Clean sealing faces of plug/socket connector and housing.
5. Preserve joint surfaces with an acid-free corrosion protection agent.
6. Check whether O-ring [3] is in good condition, replace if damaged.
7. Slightly grease the O-ring with acid-free grease (e.g. petroleum jelly) and insert
them correctly.
8. Replace electrical connection and fasten screws evenly crosswise.
13.3 Maintenance
Maintenance intervals In compliance with EN 60079-17, Ex certified products either require repeated testing
at an interval of 3 years or continuous monitoring by trained personnel.
Manual operation During maintenance, the mechanical parts of the handwheel activation, in particular
motor coupling, must be checked. Replace the parts in case of visible wear.
Lubrication •
In the factory, the gear housing is filled with grease.
•
Additional lubrication of the gear housing is not required during operation.
•
Grease change is performed during maintenance
–
Generally after 4 to 6 years for modulating duty.
49
Servicing and maintenance
•
Notes relating to mainten- •
ance
–
Generally after 6 to 8 years if operated frequently (open-close duty).
–
Generally after 10 to 12 years if operated infrequently (open-close duty).
We recommend replacing the seals when changing the grease.
Perform visual inspection of actuator and mounted accessories. Ensure that no
outside damage, changes or leakage of grease and oil are visible.
•
Check actuator for unusual running or grinding noise or vibration which might be
an indication of bearing or gear damage.
•
Electrical connection cables must be placed properly and in perfect condition.
•
Thoroughly touch up any possible damage to painting to prevent corrosion. Original paint in small quantities can be supplied by AUMA.
•
Check whether Ex connections are fastened correctly.
•
Take care of possible discolouration of the terminals and wires. This would indicate an increased temperature.
•
For Ex housings, pay special attention to a possible collection of water. This may
originate from “breathing” due to severe temperature variations (e.g. change of
night and day), from damaged seals etc. Remove any water immediately.
•
The process temperature range must be within the range of the specified ambient
temperature.
•
Check the flame path gaps of flameproof enclosures for dirt and corrosion.
•
Since the dimensions of all flameproof joints are strictly defined and inspected, no
mechanical work (such as grinding) shall be performed on them. The joint surfaces have to be cleaned chemically (e.g. with Esso-Varsol).
•
Consult manufacturer for indications regarding flameproof joints.
•
Repair interventions on flameproof joints is not permitted.
•
Prior to fitting, preserve joint surfaces with an acid-free corrosion protection agent
(e.g. Esso Rust-BAN 397).
•
Thoroughly handle all housing covers and check sealing elements.
•
All cable and motor protection components have to be checked.
•
If defects impairing the safety are detected during maintenance, repair measures
have to be initiated without delay.
•
Any kind of surface coating for the joint surfaces is not permitted.
•
When replacing parts, sealing elements, etc. only original spare parts shall be
used.
•
Cables and wire entries, blanking plug, cable glands, plugs etc. have to be
checked for correct tightness and sealing. Consider torques according to manufacturer's details. If required, replace the components. Only use components with appropriate Ex approval.
13.4 Disposal and recycling
Our devices have a long service life. However, they have to be replaced at one point
in time. The devices have a modular design and may therefore easily be disassembled, separated, and sorted according to materials, i.e.:
•
Electronic scrap
•
Various metals
•
Plastic materials
•
Greases and oils
The following generally applies:
•
50
Generally, greases and oils are hazardous to water and must not be released into
the environment.
Servicing and maintenance
•
Arrange for controlled waste disposal of the disassembled material or for separate
recycling according to materials.
•
Heed the national regulations for waste disposal.
51
Technical data
14 Technical data
The following tables include standard and optional features. For detailed information on the customer-specific version, refer to the order-related data
sheet. The technical data sheet can be downloaded from our website at http://
www.auma.com in both German and English (please state the order number).
14.1 Technical data Part-turn actuator
Features and functions
Explosion protection
Refer to name plate
Certificates and standards
Certificates are attached to the device. All standards applied and their respective issues are indicated on
these certificates.
Type of duty
(Part-turn actuators for open-close
duty)
Type of duty
(Part-turn actuators for modulating
duty)
With 3-phase AC motor: Short-time duty S2 - 15 min, classes A and B according to EN ISO 22153
With 1-phase AC motor: Short-time duty S2 - 10 min, classes A and B according to EN ISO 22153
For nominal voltage and +40 &deg;C ambient temperature and at run torque load.
Standard:
With 3-phase AC motor: Intermittent duty S4 − 25 %, class C according to EN ISO 22153
With 1-phase AC motor: Intermittent duty S4 − 20 %, class C according to EN ISO 22153
Option:
With 3-phase AC motor: Intermittent duty S4 − 50 %, class C according to EN ISO 22153
For nominal voltage and +40 &deg;C ambient temperature and at modulating torque load.
Motors
Standard:
3-phase AC asynchronous squirrel-cage motor, type IM B9 according to IEC 60034-7,
IC410 cooling procedure according to IEC 60034-6
Option:
1-phase AC motor with permanent split capacitor (PSC),
type IM B9 according to IEC 60034-7, IC410 cooling procedure according to IEC 60034-6
Mains voltage, mains frequency
Refer to motor name plate
Permissible variation of mains voltage: &plusmn;10 %
Permissible variation of mains frequency: &plusmn;5 % (for 3-phase and 1-phase AC current)
Overvoltage category
Category III according to IEC 60364-4-44
Insulation class
Standard:
F, tropicalized
Option:
H, tropicalized (with 3-phase or 1-phase AC motor)
Standard:
PTC thermistors (according to DIN 44082)
PTC thermistors additionally require a suitable tripping device in the actuator controls
Option:
Thermoswitches (NC)
According to EN 60079-14, a thermal overcurrent protection device (e.g. motor protection
switch) must be installed for explosion-proof actuators in addition to the thermoswitches.
Motor protection
Self-locking
Yes (actuator are self-locking if the valve position cannot be changed from standstill while torque acts
upon the output drive.)
Motor heater (option)
Voltages:
110 – 120 V AC, 220 – 240 V AC or 380 – 480 V AC
Power depending on the size 12.5 W
Swing angle
Manual operation
Standard:
Adjustable between 75&deg; and &lt; 105&deg;
Options:
15&deg; to &lt; 45&deg;, 45&deg; to &lt; 75&deg;, 105&deg; to &lt; 135&deg;, 135&deg; to &lt; 165&deg;, 165&deg; to &lt; 195&deg;, 195&deg; to &lt; 225&deg;
Manual drive for setting and emergency operation, handwheel does not rotate during electrical operation.
Options:
Handwheel lockable
Handwheel stem extension
Power tool for emergency operation with square 30 mm or 50 mm
Indication for manual operation (opIndication whether manual operation is active/not active via single switch (1 change-over contact)
tion)
Electrical connection
Threads for cable entries
Standard:
AUMA Ex plug/socket connector (KT); screw-type motor terminals;
control terminals in spring clamp terminal technology
Option:
AUMA Ex plug/socket connector with terminal blocks (KES)
Standard:
Metric threads
Option:
Pg threads, NPT threads, G threads
Terminal plan
Terminal plan according to order number enclosed with delivery
Splined coupling for connection to
the valve shaft
Standard:
Coupling without bore
Options:
Machined coupling with bore and keyway, square bore or bore with two-flats according to
EN ISO 5211
Valve attachment
Dimensions according to EN ISO 5211 without spigot
52
Technical data
With base and lever (option)
Swing lever
Made of spheroidal cast iron with two or three bores for fixing a lever arrangement. Considering the installation conditions, the lever may be mounted to the output shaft in any desired position.
Ball joints (option)
Two ball joints matching the lever, including lock nuts and two welding nuts, suitable for pipe according to
dimension sheet.
Fixing
Base and four holes for fastening screws
Electromechanical control unit
Limit switching
Torque switching
Switch contact materials
Position feedback signal, analogue
(options)
Counter gear mechanism for end positions OPEN and CLOSED
Turns per stroke: 2 to 500 (standard) or 2 to 5,000 (option)
Standard:
Single switch (1 NC and 1 NO) for each end position, not galvanically isolated
Options:
Tandem switch (2 NC and 2 NO) for each end position, switch galvanically isolated
Triple switch (3 NC and 3 NO) for each end position, switch galvanically isolated
Intermediate position switches (DUO limit switching), adjustable for each direction of operation
Torque switching adjustable for directions OPEN and CLOSE
Standard:
Single switch (1 NC and 1 NO) for each direction, not galvanically isolated
Option:
Tandem switch (2 NC and 2 NO) for each direction, switch galvanically isolated
Standard:
Silver (Ag)
Option:
Gold (Au), recommended for low voltage actuator controls
Potentiometer or 0/4 – 20mA (electronic position transmitter)
Mechanical position indicator
(option)
Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
Running indication
Blinker transmitter (option for modulating actuators)
Heater in switch compartment
Standard:
Self-regulating PTC heater, 5 – 20 W, 110 – 250 V AC/DC
Options:
24 – 48 V AC/DC or 380 – 400 V AC
A resistance type heater of 5 W, 24 V AC is installed in the actuator in combination with AM or AC actuator controls.
Technical data for limit and torque switches
Mechanical lifetime
2 x 106 starts
Silver plated contacts:
U min.
24 V AC/DC
U max.
250 V AC/DC
I min.
20 mA
I max. AC current
5 A at 250 V (resistive load)
3 A at 250 V (inductive load, cos phi = 0.6)
I max. DC current
0.4 A at 250 V (resistive load)
0.03 A at 250 V (inductive load, L/R = 3 &micro;s)
5 A at 30 V (resistive load)
5 A at 30 V (inductive load, L/R = 3 &micro;s)
Gold plated contacts:
U min.
5V
U max.
50 V
I min.
4 mA
I max.
400 mA
Technical data for blinker transmitter
Mechanical lifetime
107 starts
Silver plated contacts:
U min.
10 V AC/DC
U max.
250 V AC/DC
I max. AC current
3 A at 250 V (resistive load)
2 A at 250 V (inductive load, cos phi ≈ 0.8)
I max. DC current
0.25 A at 250 V (resistive load)
Technical data for handwheel activation switches
Mechanical lifetime
106 starts
Silver plated contacts:
53
Technical data
Technical data for handwheel activation switches
U min.
12 V DC
U max.
250 V AC
I max. AC current
3 A at 250 V (inductive load, cos phi ≈ 0.8)
I max. DC current
3 A at 12 V (resistive load)
Service conditions
Use
Indoor and outdoor use permissible
Mounting position
As required for grease use as lubricant (standard). When using oil instead of grease within the actuator
gear housing, perpendicular mounting position is specified whereby the flange is pointing downward.
Installation altitude
≤ 2,000 m above sea level
&gt; 2,000 m above sea level on request
Ambient temperature
Refer to actuator name plate
Humidity
Up to 100 % relative humidity across the entire permissible temperature range
Enclosure protection in accordance
For exact version, refer to actuator controls name plate.
with IEC 60529
Pollution degree according to
IEC 60664-1
Pollution degree 4 (when closed), pollution degree 2 (internal)
Vibration resistance according to
IEC 60068-2-6
2 g, 10 to 200 Hz (AUMA NORM), 1 g, 10 to 200 Hz (for actuators with actuator controls)AM oder AC)
Resistant to vibration during start-up or for failures of the plant. Valid for part-turn actuators in version
AUMA NORM and in version with actuator controls, each with AUMA plug/socket connector. Not valid in
combination with gearboxes.
Corrosion protection
Standard:
KS: Suitable for use in areas with high salinity, almost permanent condensation, and high
pollution.
Options:
KX: Suitable for use in areas with extremely high salinity, permanent condensation, and
high pollution.
KX-G: Same as KX, however aluminium-free version (outer parts)
Coating
Double layer powder coating
Colour
Standard:
AUMA silver-grey (similar to RAL 7037)
Option:
Available colours on request
Lifetime
AUMA part-turn actuators meet or exceed the lifetime requirements of EN ISO 22153. Detailed information can be provided on request.
Sound pressure level
&lt; 72 dB (A)
Further information
EU Directives
ATEX Directive 2014/34/EU
Machinery Directive 2006/42/EC
Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU
14.2 Tightening torques for screws
Table 22: Tightening torques for screws
Threads
Tightening torque [Nm]
Strength class
A2-70/A4-70
A2-80/A4-80
M6
7.4
10
M8
18
24
M10
36
48
M12
61
82
M16
150
200
M20
294
392
M30
1,015
1,057
M36
1,769
2,121
54
Spare parts list
15 Spare parts list
15.1 Part-turn actuators SQEx 05.2 – SQEx 14.2 KT/KM / SQREx 05.2 – SQREx 14.2 KT/KM
55
Spare parts list
Please state device type and our order number (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Representation of spare parts may slightly vary from actual delivery.
Ref. No.
Designation
Type
005.0
Drive shaft
Sub-assembly
Ref. No.
Designation
Type
558.0
Blinker transmitter including pins at wires
(without impulse disc and insulation plate)
005.1
Motor coupling
Sub-assembly
Sub-assembly
005.3
Manual drive coupling
Sub-assembly
559.0-1
Electromechanical control unit with
Sub-assembly
switches, including torque switching heads
009.0
Manual gearing
Sub-assembly
019.0
Crown wheel
Sub-assembly
559.0-2
Electronic control unit with magnetic limit
and torque transmitter (MWG)
Sub-assembly
023.0
024.0
Output drive wheel for limit switching
Sub-assembly
560.0-1
Switch stack for direction OPEN
Sub-assembly
Drive wheel for limit switching
Sub-assembly
560.0-2
Switch stack for direction CLOSE
Sub-assembly
025.0
Locking plate
Sub-assembly
560.1
Switch for limit/torque
Sub-assembly
058.0
Cable for protective earth
Sub-assembly
560.2-1
Switch case for direction OPEN
–
070.0
Motor (incl. ref. no. 079.0)
Sub-assembly
560.2-2
Switch case for direction CLOSE
–
079.0
Planetary gearing for motor drive
Sub-assembly
566.0
RWG position transmitter
Sub-assembly
155.0
Reduction gearing
Sub-assembly
566.1
Potentiometer for RWG without slip clutch
Sub-assembly
500.0
Cover
Sub-assembly
566.2
Position transmitter board for RWG
Sub-assembly
502.0
Pin carrier without pins
Sub-assembly
566.3
Cable set for RWG
Set
505.0
Pin for controls
Sub-assembly
567.1
Slip clutch for potentiometer
Sub-assembly
506.0
Pin for motor
Sub-assembly
583.0
Motor coupling on motor shaft
Sub-assembly
525.0
Coupling
Sub-assembly
596.0
Output drive flange with end stop
Sub-assembly
539.0
Screw plug
Sub-assembly
612.0
Screw plug for end stop
Sub-assembly
541.0
Earth connection
Sub-assembly
614.0
EWG position transmitter
Sub-assembly
553.0
Mechanical position indicator
Sub-assembly
627.0
MWG 05.03 cover
–
554.0
Socket carrier for motor plug/socket connector with cable harness
–
628.0
Ex plug/socket connector with terminal car–
rier (KT)
556.0
Potentiometer as position transmitter
Sub-assembly
629.0
Pinion shaft
Sub-assembly
556.1
Potentiometer without slip clutch
Sub-assembly
S1
Seal kit, small
Set
557.0
Heater
Sub-assembly
S2
Seal kit, large
Set
56
Index
Index
A
Ambient temperature
Applications
Approval plate
Assembly
AUMA Assistant App
I
8, 54
5
9
13
10
B
Blanking plug
18
C
Cable glands
Cables
Commissioning
Basic settings
Optional equipment
Connecting cables
Corrective actions
Corrosion protection
Coupling
Current consumption
18
18
4
32
39
18
45
12, 54
14
18
D
Data Matrix code
Delay time
Direction of rotation
Directives
Disposal
DUO limit switching
10
17
36
4
50
43
E
EC type test certificate
Electrical connection
Electrical connections
Electronic position transmitter
Enclosure protection
End position signalling
End stops
EWG
EWG position transmitter
Ex certificate
Explosion protection
Explosion protection marking
9
17
18
39, 40
8, 9, 54
43
32
40
40
9
9
9
F
Faults
Features and functions
Flange size
45
52, 53, 54
9
13
4
37
10
9
43
42
L
LED end position signalling
Lifetime
Limit switches
Limit switching
Lubrication
43
54
17
35, 37
49
M
Mains connection
Mains frequency
Mains voltage
Maintenance
Marking for explosion protection
Mechanical position indicator
Motor heater
Motor operation
Motor protection
Motor type
17
9, 17
9, 17
5, 49
9
37
52
29
9, 46, 52
9
N
Name plate
Nominal current
Nominal power
8, 17
9
9
O
Operation
Order number
4, 29
8, 10
P
Parking frame
Position indicator
Position transmitter EWG
Potentiometer
Power factor
Protection (motor protection)
Protection on site
Protective measures
PTC thermistor
28
37
40
39
9
18
17
5, 18
46
Q
Qualification of staff
H
Handwheel
Ignition hazards
Indicator disc
Inspection certificate
Insulation class
Intermediate positions
Inverse operation (0/20 – 4 mA)
4
R
Range of application
5
57
Index
Recycling
Reductions
RWG
RWG position transmitter
50
18
39
39
S
Safety instructions
Safety instructions/warnings
Safety standards
Screw plugs
Serial number
Service
Service conditions
Short-circuit protection
Size
Spare parts list
Speed
Standards
Storage
Support
Switch check
Switches
4
4
18
18
8, 10
47
54
17
9
55
8, 9
4
12
47
45
17
T
Tandem switches
Technical data
Temperature protection
Terminal plan
Test run
Thermal monitoring
Thermoswitch
Torque range
Torque switches
Torque switching
Transport
Type
Type designation
Type of current
Type of duty
Type of lubricant
17
52
9
17
36
46
46
8
17
34
11
9
8, 9
9, 17
9, 52
8
V
Valve attachment
52
W
Wiring diagram
10, 17
Y
Year of production
58
10
59
AUMA Riester GmbH &amp; Co. KG
Location Muellheim
PO Box 1362
79373 Muellheim, Germany
Tel +49 7631 809 - 0
Fax +49 7631 8091250
[email protected]
www.auma.com
Y005.953/003/en/1.23
For detailed information on AUMA products, refer to the Internet: www.auma.com
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Key features

Modulating duty
Robust design
Integrated handwheel
Electrical connection options
Commissioning features
Optional equipment
Frequently asked questions

It is designed for operating industrial valves, specifically butterfly and ball valves. The manual provides additional information on specific applications.
The manual details the procedures for setting end stops, including both 'CLOSED' and 'OPEN' positions. Refer to section 10.1 for detailed instructions.
The SQREx 14.2 offers various electrical connection options, such as KT/KM and KES. The manual provides detailed guidelines for each connection type, including cable connections and terminal compartments. Refer to sections 6.3 and 6.4 for specifics.
What type of valves can the AUMA SQREx 14.2 operate?

How do I set the end stops for the actuator?

What are the different electrical connection options available?

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