AUMA SQ 05.2, SQ 14.2 Operating Instructions Manual
AUMA SQ 05.2 part-turn actuators are designed to operate industrial valves like butterfly and ball valves. They are driven by an electric motor and incorporate a handwheel for manual operation and emergency use. The SQ 05.2 can be equipped with AUMA actuator controls at a later stage, allowing for greater control and customization.
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Part-turn actuators SQ 05.2 – SQ 14.2 SQR 07.2 – SQR 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 .................................................................................................................................. 4 1.3 Warnings and notes ................................................................................................................................... 5 1.4 References and symbols............................................................................................................................ 5 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 S/SH electrical connection (AUMA plug/socket connector) ....................................................................... 6.2.1 Open terminal compartment ........................................................................................................... 6.2.2 Cable connection ............................................................................................................................ 6.2.3 Close terminal compartment ........................................................................................................... 18 19 19 21 6.3 Accessories for electrical connection (option)............................................................................................ 6.3.1 Parking frame.................................................................................................................................. 6.3.2 DS intermediate frame for double sealing....................................................................................... 6.3.3 External earth connection ............................................................................................................... 22 22 22 23 7 Operation .......................................................................................................................................................... 24 7.1 Manual operation ....................................................................................................................................... 24 7.1.1 Manual valve operation................................................................................................................... 24 7.2 Motor operation .......................................................................................................................................... 24 8 Indications (option) .......................................................................................................................................... 25 8.1 Mechanical position indication via indicator mark ...................................................................................... 25 9 Signals (output signals)................................................................................................................................... 26 9.1 Feedback signals from actuator ................................................................................................................. 26 10 Commissioning (basic settings) ..................................................................................................................... 27 10.1 End stops in part-turn actuator................................................................................................................... 27 10.1.1 Set end stop CLOSED .................................................................................................................... 28 2 Table of contents 10.1.2 Set end stop OPEN......................................................................................................................... 28 10.2 Open switch compartment ......................................................................................................................... 28 10.3 Set torque switching................................................................................................................................... 29 10.4 Set limit switching....................................................................................................................................... 30 10.4.1 Set end position CLOSED (black section) ...................................................................................... 30 10.4.2 Set end position OPEN (white section)........................................................................................... 31 10.5 Test run ...................................................................................................................................................... 31 10.5.1 Check direction of rotation at mechanical position indicator ........................................................... 31 10.5.2 Check limit switching....................................................................................................................... 32 10.6 Set mechanical position indicator............................................................................................................... 32 10.7 Close switch compartment ......................................................................................................................... 33 11 Commissioning (optional equipment settings) ............................................................................................. 34 11.1 Potentiometer............................................................................................................................................. 34 11.1.1 Potentiometer setting ...................................................................................................................... 34 11.2 RWG electronic position transmitter........................................................................................................... 34 11.2.1 Set measuring range....................................................................................................................... 35 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 ....................................................................................... 35 36 37 38 11.4 Set intermediate positions.......................................................................................................................... 38 11.4.1 Set running direction CLOSE (black section).................................................................................. 38 11.4.2 Set running direction OPEN (white section).................................................................................... 39 12 Corrective actions ............................................................................................................................................ 40 12.1 Faults during operation/commissioning...................................................................................................... 40 12.2 Motor protection (thermal monitoring) ........................................................................................................ 41 13 Servicing and maintenance............................................................................................................................. 42 13.1 Preventive measures for servicing and safe operation .............................................................................. 42 13.2 Maintenance............................................................................................................................................... 42 13.3 Disposal and recycling ............................................................................................................................... 42 14 Technical data .................................................................................................................................................. 44 14.1 Technical data Part-turn actuator............................................................................................................... 44 14.2 Tightening torques for screws .................................................................................................................... 46 15 Spare parts list ................................................................................................................................................. 47 15.1 Part-turn actuators SQ 05.2 – SQ 14.2 S / SQR 05.2 – SQR 14.2 S......................................................... 47 Index .................................................................................................................................................................. 49 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: • 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. 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: • 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. • During operation, the housing warms up and surface temperatures > 60 °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 SQ/SQREx are designed for the operation of industrial valves, e.g. butterfly valves and ball valves. Other applications require explicit (written) confirmation by the manufacturer. The following applications are not permitted, e.g.: 4 • 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 Safety instructions • Continuous duty • Buried service • Continuous underwater use (observe enclosure protection) • Potentially explosive atmospheres • 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. 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 5 Safety instructions 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 > 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 SQ 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 SQ/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] [1] [3] Motor name plate Additional plate, e.g. KKS plate (Power Plant Classification System) [2] Actuator name 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] [1] [3] [5] [7] [9] [11] [13] [11] [12] [13] [14] Motor type Serial number Nominal power Type of duty Motor protection (temperature protection) Data Matrix code Power factor cos phi [2] [4] [6] [8] [10] Motor article number Current type, mains voltage Nominal current Enclosure protection Insulation class [12] [14] Mains frequency Speed Descriptions referring to name plate indications Type designation Table 1: Description of type designation with the example of SQ 07.2-F10 SQ 07.2 -F10 Type SQ = Part-turn actuators for open-close duty Type SQREx = Part-turn actuators for modulating duty SQ Size These instructions apply to sizes 05.2, 07.2, 10.2, 12.2, 14.2 07.2 F10 Flange size 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 & 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 2: 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 3: 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. 9 Name plate Figure 5: Link to AUMA Assistant App For further Service & 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. à Do NOT stand below suspended load. à Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT to handwheel. à Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting by hoist to valve and NOT to actuator. à 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. à Respect total weight of combination (actuator, gearbox, valve) à Secure load against falling down, sliding or tilting. à Perform lift trial at low height to eliminate any potential danger e.g. by tilting. Figure 6: Example: Lifting the actuator Weights Table 4: Weights for SQ/SQR part-turn actuators with 3-phase motors Type designation Actuator Weight 1) Weight with base and lever 2) approx. [kg] approx. [kg] SQ 05.2/ SQR 05.2 21 27 SQ 07.2/ SQR 07.2 21 27 SQ 10.2/ SQR 10.2 26 31 SQ 12.2/ SQR 12.2 35 43 SQ 14.2/ SQR 14.2 44 55 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 5: Weights for SQ/SQR part-turn actuators with 1-phase AC motors Type designation Actuator Weight 1) Weight with base and lever 2) approx. [kg] approx. [kg] SQ 05.2/ SQR 05.2 23 29 SQ 07.2/ SQR 07.2 23 29 SQ 10.2/ SQR 10.2 28 32 SQ 12.2/ SQR 12.2 37 45 SQ 14.2/ SQR 14.2 46 57 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! à Store in a well-ventilated, dry room. à Protect against floor dampness by storage on a shelf or on a wooden pallet. à Cover to protect against dust and dirt. à 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 7: 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! à Touch up damage to paint finish after work on the device. à 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 8: 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 9: 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 10: Mounting positions for coupling L X Y Table 6: Mounting position of the coupling within fitting dimensions according to AUMA definition Dimensions [mm] SQ 05.2 EN ISO 5211 F05 F07 SQ 07.2 F05 F07 F10 SQ 10.2 F10 F12 SQ 12.2 F12 F14 SQ 14.2 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 11: Fit actuator ð 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 [} 46]. 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. à The electrical connection must be carried out exclusively by suitably qualified personnel. à 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! à NORM actuators require actuator controls: Connect motor via actuator controls only (reversing contactor circuit). à Respect the type of seating specified by the valve manufacturer. à The torque switches also serve the purpose of valve overload protection and must, therefore, also be connected for limit seating. à 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 < 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 12: 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. 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. • To avoid contact corrosion, we recommend the use of sealing agents for cable glands and blanking plugs made of metal. • Use connecting cable with appropriate minimum rated temperature. • For connecting cables exposed to UV radiation (outdoor installation), use UV resistant cables. • For connecting position transmitters, only use screened cables. 6.2 S/SH electrical connection (AUMA plug/socket connector) Figure 13: S and SH electrical connection SH S [1] [1] [2] [2] [3] [3] [1] Cover [2] [3] Actuator housing with pin carrier Socket carrier with screw-type terminals, with crimp connection as an option Short description Plug-in electrical connection with screw-type terminals for pins for motors and pins for controls. Control contacts also available as crimp-type connection as an option. S version (standard) with three cable entries. SH version (enlarged) with additional cable entries. For cable connection, remove the AUMA plug/socket connector and the socket carrier from cover. Technical data Table 7: Electrical connection via AUMA plug/socket connector 18 Power contacts Control contacts No. of contacts max. 6 (3 equipped) + protective earth conductor (PE) 50 pins/sockets Designations U1, V1, W1, U2, V2, W2, PE 1 to 50 Connection voltage max. 750 V 250 V Nominal current max. 25 A 16 A Type of customer connection Screw connection Screw connection, crimp-type (option) Connection diameter max. 6 mm2 (flexible) 10 mm2 (solid) 2.5 mm2 (Flexible or solid) Electrical connection 6.2.1 Open terminal compartment Figure 14: Open terminal compartment [1] [2] [8] [7] [3] [6] [5] [4] [1] [3] [5] [7] DANGER Cover (figure shows S version) O-ring Socket carrier Blanking plug [2] [4] [6] [8] Screws for cover Screws for socket carrier Cable entry Cable gland (not included in scope of delivery) Electric shock due to presence of hazardous voltage! Death or serious injury. à Disconnect device from the mains before opening. NOTICE Corrosion by ingress of humidity when using unsuitable cable glands! à Use suitable cable glands according to the IP enclosure protection specified on the name plate. Figure 15: Example: Name plate for enclosure protection IP68 How to proceed 1. Loosen screws [2] and remove cover [1]. 2. Loosen screws [4] and remove socket carrier [5] from cover [1]. 3. Insert cable glands [8] suitable for connecting cables. 4. Seal unused cable entries [6] with suitable blanking plugs [7]. 6.2.2 Cable connection Table 8: Terminal cross sections and terminal tightening torques Designation Terminal cross sections Tightening torques Power contacts (U1, V1, W1, U2, V2, W2) 1.0 – 6 mm² (flexible) 1.5 –10 mm² (solid) 1.2 – 1.5 Nm PE connection 1.0 – 6 mm² (flexible) with ring lugs 1.5 – 10 mm² (rigid) with loops 1.2 – 2.2 Nm Control contacts (1 to 50) 0.25 – 2.5 mm² (flexible) 0.34 – 2.5 mm² (rigid) 0.5 – 0.7 Nm 19 Electrical connection WARNING In case of a fault: Hazardous voltage while protective earth conductor is NOT connected! Risk of electric shock à Connect all protective earth conductors. à Connect PE connection to external protective earth conductor of connection cable. à Power the device only once the protective earth conductor has been connected. NOTICE Risk of motor damage if PTC thermistors or thermoswitches are not connected! Our warranty for the motor will lapse if the motor protection is not connected. à Connect PTC thermistors or thermoswitches to external controls. How to proceed 1. Remove cable sheathing. 2. Insert the wires into the cable glands. 3. Fasten cable glands with the specified torque to ensure required enclosure protection. 4. Strip wires: Controls approx. 6 mm, motor approx. 10 mm. 5. For flexible cables: Use wire end sleeves according to DIN 46228. 6. Connect cables according to order-related wiring diagram. 7. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables) or loops (solid cables). Figure 16: Protective earth connection [2] [3] [4] [1] [5] [6] [1] [3] [5] Socket carrier Washer PE conduction with ring lugs/loops [2] [4] [6] Screw Lock washer Protective earth connection 8. For shielded cables: Link the cable shield end via the cable gland to the housing (earthing). 20 Electrical connection 6.2.3 Close terminal compartment Figure 17: Close terminal compartment [1] [6] [7] [2] [3] [5] [4] [1] [3] [5] [7] WARNING Cover (figure shows S version) O-ring Socket carrier Cable gland (not included in scope of delivery) [2] [4] [6] Screws for cover Screws for socket carrier Blanking plug Short-circuit due to pinching of cables! Risk of electric shock and functional failures. à Carefully fit socket carrier to avoid pinching the cables. How to proceed 1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4]. 2. Clean sealing faces of cover [1] and housing. 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. 6. Fasten cable glands and blanking plugs applying the specified torque to ensure the required enclosure protection. 21 Electrical connection 6.3 Accessories for electrical connection (option) 6.3.1 Parking frame Figure 18: Parking frame, example with S plug/socket connector and cover Application Parking frame for safe storage of a disconnected plug or cover. For protection against touching the bare contacts and against environmental influences. 6.3.2 DS intermediate frame for double sealing Figure 19: Electrical connection with DS intermediate frame [1] [2] [3] [1] [3] Electrical connection Actuator housing [2] DS intermediate frame Application When removing the electrical connection or due to leaky cable glands, there is a potential risk for ingress of dust and water into the housing. This is prevented effectively by inserting the double sealed intermediate frame [2] between the plug/socket connector [1] and the housing of the device. The enclosure protection of the device (IP68) will not be affected, even if the electrical connection [1] is removed. 22 Electrical connection 6.3.3 External earth connection Figure 20: Earth connection for part-turn actuator Application External earth connection (U-bracket) for connection to equipotential compensation. Table 9: Terminal cross sections and earth connection tightening torques Conductor type Terminal cross sections Tightening torques Solid wire and stranded 2.5 mm² to 6 mm² 3 – 4 Nm Fine stranded 1.5 mm² to 4 mm² 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. 23 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! à Engage manual operation only during motor standstill. à Do NOT use extensions as lever for operation. How to proceed 1. Press push button. 2. Turn handwheel in desired direction. Figure 21: Operate handwheel ð The closing direction is marked on the handwheel: Table 10: 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! à 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. ð Valve shaft turns counterclockwise in direction CLOSE. 24 Indications (option) 8 Indications (option) 8.1 Mechanical position indication via indicator mark Figure 22: 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) • End position CLOSED reached / rotate in counterclockwise dir- Indicates that end positions (OPEN/CLOSED) have been reached (Symbols (OPEN)/ (CLOSED) point to the indicator mark at cover) 25 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 11: 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) 26 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 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. à End stops should be set by suitably qualified personnel only. à Never completely remove the setting screws [2] and [4] to avoid grease leakage. à Observe dimension Tmin. The swing angle set in the factory is indicated on the name plate: Figure 23: 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 24: 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 12: Dimensions/size (mm) Dimensions/size (mm) 05.2 07.2 10.2 12.2 14.2 T (for 90°) 17 17 20 23 23 Tmin. 11 11 12 13 12 27 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 25: Setting screws 4. Turn setting screw [4] clockwise to the stop. ð 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 26: Direction of rotation of setting screws 4. Turn setting screw [2] clockwise to the stop. ð 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. How to proceed 1. Loosen screws [2] and remove cover [1] from the switch compartment. 28 Commissioning (basic settings) Figure 27: Open switch compartment [3] [1] [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 28: 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! à The tripping torque must suit the valve. à Only change the setting with prior consent of the valve manufacturer. The torque switches may also trip during manual operation. 29 Commissioning (basic settings) Figure 29: 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: ð Black torque switching head set to approx. 25 da Nm ≙ 250 Nm for direction CLOSE. ð 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 ð 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 30: 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° every time. 30 Commissioning (basic settings) 4. As soon as the pointer [2] is 90° from mark [3]: Continue turning slowly. 5. As soon as the pointer [2] moves to mark [3]: Stop turning and release setting spindle. ð 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° every time. 4. As soon as the pointer [5] is 90° from mark [6]: Continue turning slowly. 5. As soon as the pointer [5] moves to mark [6]: Stop turning and release setting spindle. ð 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! à If the direction of rotation is incorrect, switch off immediately. à Correct phase sequence. à 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: • 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: 31 Commissioning (basic settings) Figure 31: 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: ð WSR/LSC contact trips in end position CLOSED WOEL/LSO contact trips in end position OPEN ð 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 ü 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 32: 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. Figure 33: Indication OPEN 6. Move valve to end position CLOSED again. 32 (OPEN) 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. NOTICE Corrosion due to damage to paint finish! à Touch up damage to paint finish after work on the device. How to proceed 1. Clean sealing faces of housing and cover. 2. Check whether O-ring [3] is in good condition, replace if damaged. 3. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and insert it correctly. Figure 34: Close switch compartment 4. Place cover [1] on switch compartment. 5. Fasten screws [2] evenly crosswise. 33 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 [} 28]. Setting is made via potentiometer [1]. Figure 35: 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. ð End position OPEN corresponds to 0 %. ð 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 13: 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 34 0.1 %/100 Ω < 0.3 ‰/K –60 °C to +80 °C 5 kΩ 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 [} 28]. Setting is made via three potentiometers [1], [2] and [3]. Figure 36: 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 ð 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 14: EWG 01.1 Data 3-wire and 4-wire systems 2-wire system Output current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA 35 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 < 0.1 ‰/K Ambient temperature 2) –60 °C to +80 °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 [} 28]. All settings are made via the two push buttons [S1] and [S2]. Figure 37: 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 15: 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). 36 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 [} 38]. 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: ð By pulsing double flashes, the LED indicates that the setting mode is correctly activated: LED ð For any other LED flash sequence (single/triple flashing): refer to Faults during operation/commissioning [} 40]. 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): ð for 4 mA: Hold down [S1] for approx. 3 seconds, until LED is blinking slowly . ð for 0 mA: Hold down [S1] for approx. 6 seconds (only possible for 3-/4-wire version) until LED is blinking fast . ð for 20 mA: Hold down [S2] for approx. 3 seconds until LED is illuminated . 4. Operate valve into opposite end position. ð 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. ð If the measuring range cannot be set: refer to Faults during operation/commissioning [} 40]. ð If the current values (0/4/20 mA) are incorrect: refer to Adjust current values [} 37]. ð 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 [} 38]. 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). 37 Commissioning (optional equipment settings) If the current value fluctuates (e.g. between 4.0 – 4.2mA), the Switch on/off LED end position signalling [} 38] 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. ð End position signalling is switched on or off. Table 16: 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 38: 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. 38 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° every time. 4. As soon as the pointer [2] is 90° from mark [3]: Continue turning slowly. 5. As soon as the pointer [2] moves to mark [3]: Stop turning and release setting spindle. ð 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° every time. 4. As soon as the pointer [5] is 90° from mark [6]: Continue turning slowly. 5. As soon as the pointer [5] moves to mark [6]: Stop turning and release setting spindle. ð 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. 39 Corrective actions 12 Corrective actions 12.1 Faults during operation/commissioning Table 17: 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 [} 40], 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 39: 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 DÖL/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 WÖL/LSO arrow: Limit switch OPEN trips. 40 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. 41 Servicing and maintenance 13 Servicing and maintenance CAUTION Damage caused by inappropriate maintenance! à 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. à Only perform servicing and maintenance tasks when the device is switched off. Service & 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 [} 46] 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 Maintenance 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. – 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. 13.3 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.: 42 Servicing and maintenance • Electronic scrap • Various metals • Plastic materials • Greases and oils The following generally applies: • Generally, greases and oils are hazardous to water and must not be released into the environment. • Arrange for controlled waste disposal of the disassembled material or for separate recycling according to materials. • Heed the national regulations for waste disposal. 43 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 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) 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 Type of duty (Multi-turn actuators for modulating duty) Standard: Intermittent duty S4 - 25 %, class C according to EN ISO 22153 Option: Intermittent duty S4 - 50 %, class C according to EN ISO 22153 Intermittent duty S5 - 25 % (insulation class H required), class C according to EN ISO 22153 For nominal voltage and +40 °C ambient temperature and at run torque load. For nominal voltage and +40 °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: ±10 % Permissible variation of mains frequency: ±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° and < 105° Options: 15° to < 45°, 45° to < 75°, 105° to < 135°, 135° to < 165°, 165° to < 195°, 195° to < 225° 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 plug/socket connector with screw-type connection Options: Terminals or crimp-type connection Gold-plated control plug (sockets and pins) 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 44 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 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 Position feedback signal, analogue (options) Potentiometer or 0/4 – 20mA (electronic position transmitter) Mechanical position indication 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 or 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 µs) 5 A at 30 V (resistive load) 5 A at 30 V (inductive load, L/R = 3 µs) 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: U min. 12 V DC 45 Technical data Technical data for handwheel activation switches 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 > 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) oder ) 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 < 72 dB (A) Further information EU Directives 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 18: 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 46 Spare parts list 15 Spare parts list 15.1 Part-turn actuators SQ 05.2 – SQ 14.2 S / SQR 05.2 – SQR 14.2 S 47 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 Ref. No. Designation Type 001.0 Housing Sub-assembly 556.0 Potentiometer as position transmitter Sub-assembly 005.0 Drive shaft Sub-assembly 556.1 Potentiometer without slip clutch Sub-assembly 005.1 Motor coupling Sub-assembly 557.0 Heater Sub-assembly 005.3 Manual drive coupling – 558.0 Sub-assembly 006.0 Worm wheel Sub-assembly Blinker transmitter including pins at wires (without impulse disc and insulation plate) 009.0 Manual gearing Sub-assembly 559.0-1 017.0 Torque lever – Electromechanical control unit with Sub-assembly switches, including torque switching heads 018.0 Gear segment Sub-assembly 559.0-2 Electronic control unit with magnetic limit and torque transmitter (MWG) Sub-assembly 019.0 Crown wheel – 560.0-1 Switch stack for direction OPEN Sub-assembly 023.0 Output drive wheel for limit switching Sub-assembly 560.0-2 Switch stack for direction CLOSE Sub-assembly 024.0 Drive wheel for limit switching Sub-assembly 560.1 Switch for limit/torque Sub-assembly 025.0 Locking plate Sub-assembly 560.2-1 Switch case for direction OPEN – 058.0 Cable for protective earth Sub-assembly 560.2-2 Switch case for direction CLOSE – 070.0 Motor (incl. ref. no. 079.0) Sub-assembly 566.0 RWG position transmitter Sub-assembly 079.0 Planetary gearing for motor drive Sub-assembly 566.1 Potentiometer for RWG without slip clutch Sub-assembly 155.0 Reduction gearing Sub-assembly 566.2 Position transmitter board for RWG Sub-assembly 500.0 Cover Sub-assembly 566.3 Cable set for RWG Sub-assembly 501.0 Socket carrier (complete with sockets) Sub-assembly 567.1 Slip clutch for potentiometer Sub-assembly 502.0 Pin carrier without pins Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly 503.0 Socket for controls Sub-assembly 583.1 Pin for motor coupling Sub-assembly 504.0 Socket for motor – 584.0 Retaining spring for motor coupling – 505.0 Pin for controls Sub-assembly 596.0 Output drive flange with end stop Sub-assembly 506.0 Pin for motor Sub-assembly 612.0 Screw plug for end stop Sub-assembly 507.0 Cover for electrical connection Sub-assembly 614.0 EWG position transmitter Sub-assembly 525.0 Coupling Sub-assembly 627.0 MWG 05.03 cover – 539.0 Screw plug Sub-assembly 629.0 Pinion shaft Sub-assembly 542.0 Handwheel with ball handle – S1 Seal kit, small Set 553.0 Mechanical position indicator Sub-assembly S2 Seal kit, large Set 554.0 Socket carrier for motor plug/socket connector with cable harness Sub-assembly 48 Index Index A Ambient temperature Applications Approval plate Assembly AUMA Assistant App 8, 46 4 9 13 9 B Blanking plug 18 Inspection certificate Insulation class Intermediate positions Inverse operation (0/20 – 4 mA) 9 9 38 37 L LED end position signalling Lifetime Limit switches Limit switching Lubrication 38 46 17 30, 32 42 C Cable glands Cables Commissioning Basic settings Optional equipment Connecting cables Corrective actions Corrosion protection Coupling Current consumption 18 18 4 27 34 18 40 12, 46 14 18 D Data Matrix code Delay time Direction of rotation Directives Disposal DUO limit switching 9 17 34, 35 8, 9, 46 38 27 35 35 9 9 13 I Indicator disc 17 9, 17 9, 17 4, 42 32 44 24 9, 41, 44 9 8, 17 9 9 O 4, 24 8, 9 P Parking frame Position indicator Position transmitter EWG Potentiometer Power factor Protection on site Protective measures PTC thermistor 22 32 35 34 9 17 4, 18 41 Q 40 44, 45, 46 9 H Handwheel Name plate Nominal current Nominal power Operation Order number F Faults Features and functions Flange size Mains connection Mains frequency Mains voltage Maintenance Mechanical position indicator Motor heater Motor operation Motor protection Motor type N 9 17 31 4 42 38 E EC type test certificate Electrical connection Electronic position transmitter Enclosure protection End position signalling End stops EWG EWG position transmitter Ex certificate Explosion protection M Qualification of staff 4 R Range of application Recycling Reductions RWG RWG position transmitter 4 42 18 34 34 32 49 Index 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, 9 42 46 17 9 47 8, 9 4 12 42 40 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 44 9 17 31 41 41 8 17 29 11 9 8, 9 9, 17 9, 44 8 V Valve attachment 44 W Wiring diagram 9, 17 Y Year of production 50 9 51 AUMA Riester GmbH & Co. KG Location Muellheim PO Box 1362 79373 Muellheim, Germany Tel +49 7631 809 - 0 Fax +49 7631 8091250 [email protected] www.auma.com Y0005.559/003/en/1.23 For detailed information on AUMA products, refer to the Internet: www.auma.com ">
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Key features
- Electric motor driven
- Handwheel for manual operation
- Part-turn for valve operation
- Compatible with AUMA controls
- Valve overload protection
- Modular design
Frequently asked questions
The AUMA SQ 05.2 is designed for the operation of industrial valves, primarily butterfly and ball valves.
It is driven by an electric motor, and features a handwheel for manual operation.
The manual states it is designed for butterfly valves and ball valves, but other applications may require confirmation from the manufacturer.
Yes, the AUMA SQ 05.2 can be equipped with AUMA actuator controls at a later date.
They serve the purpose of valve overload protection and are also used for limit seating.