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Multi-turn actuator

SA 07.1 SA 16.1/SAR 07.1 SAR 16.1

Intrusive

with actuator controls

AUMATIC AC 01.1

Operation instructions Assembly, operation, commissioning

Control:

Parallel

Profibus DP

Profibus DP with FO

Modbus

Modbus with FO

DeviceNet

Foundation Fieldbus

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Table of contents Page

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

1.1. General notes on safety 5

1.2. Range of application 6

1.3. Applications in Ex zone 22 (option) 7

1.4. Warnings and notes 81.5. Further references and symbols 8

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

2.1. Name plate 9

2.2. Short description 11

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

3.1. Transport 12

3.2. Storage 12

3.3. Packaging 12

4. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.1. Handwheel fitting 13

4.2. Multi-turn actuator mounting to valve/gearbox 144.2.1 Output drive types B1, B2, B3, B4, B, and E 144.2.2 Output drive type A 15

4.3. Accessories (option) 174.3.1 Protection tube for rising valve stem 17

4.4. Mounting positions of the local controls 18

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

5.1. General notes 19

5.2. Mains connection using AUMA plug/socket connector (SD) 22

5.3. Bus connection using AUMA plug/socket connector (SD) 25

5.4. Accessories for electrical connection (option) 285.4.1 Controls mounted to wall bracket 285.4.2 Parking frame 295.4.3 Protection cover 295.4.4 Double sealed intermediate frame 295.4.5 Ground connection, external 29

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.1. Manual operation 30

6.2. Motor operation 316.2.1 Local operation 316.2.2 Operation from REMOTE 31

2

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

Read the operation instructions first. Observe safety instructions.. These operation instructions are part of the product.. Store operation instructions during product life.. Pass on instructions to any subsequent user or owner of the product.

Reference documents:

.

Manual (Operation and setting) AUMATIC AC 01.0/ACExC 01.1 Foundation Fieldbus.. Manual (Fieldbus device integration) AUMATIC AC 01.0/ACExC 01.1 Foundation Fieldbus.

Can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA (addresses from page 78).

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Page

6.3. Menu navigation via push buttons (for settings and indications) 326.3.1 Short overview: functions of the push buttons 326.3.2 Structural design and navigation 33

6.4. Language change in the display 34

7. Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.1. Status indications in the display 367.1.1 Status indication S0/S6 - operation 36

7.2. Indication lights/LEDs 38

7.3. Mechanical position indicator/running indication (option) 38

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

8.1. Signals via fieldbus 39

8.2. Feedback via output contacts (binary) - (option) 39

8.3. Feedback signals (analogue) - (option) 39

9. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409.1. Type of seating: check/edit for end positions 41

9.2. Switch compartment: open 44

9.3. Torque switching: set 45

9.4. Limit switching: set 469.4.1 End position CLOSED (black section): set 469.4.2 End position OPEN (white section): set 46

9.5. Intermediate positions (option): set 479.5.1 Running direction CLOSE (black section): set 479.5.2 Running direction OPEN (white section): set 47

9.6. Test run 489.6.1 Rotational direction check 48

9.6.2 Limit switching check 499.6.3 Perform reference operation 49

9.7. Potentiometer (option) setting 51

9.8. Electronic position transmitter RWG setting (option) 52

9.9. Mechanical position indicator setting (option) 53

9.10. Switch compartment: close 54

10. Corrective action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

10.1. Faults during commissioning 5510.1.1 Mechanical position indicator 5510.1.2 Position transmitter RWG 5510.1.3 Limit and torque switches 55

10.1.4 Fault in end position (overrun not considered) 5610.1.5 Push buttons do not react 56

10.2. Fault indications and warning indications 5710.2.1 Status display S0 - faults and warnings 5710.2.2 Status indication S1 - faults 5810.2.3 Status indication S2 - warnings 5910.2.4 Status indication S3 - causes for not ready remote 61

10.3. Fuses 6210.3.1 Fuses within the actuator controls 6210.3.2 Motor protection (thermal monitoring) 63

3

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

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Page

11. Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

11.1. Preventive measures for servicing and safe operation 64

11.2. Maintenance 65

11.3. Disposal and recycling 65

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

12.1. Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 68

12.2. Controls AC 01.1 with AUMA plug/socket connector (SD) 70

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

14. Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

14.1. Declaration of Conformity and Declaration of Incorporation 78

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4


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1. Safety instructions

1.1. General notes on safety

5


Standards/directives AUMA products are designed and manufactured in compliance with recog-

nised standards and directives. This is certified in a declaration of incorpora-tion and a declaration of conformity.The end user or the contractor must ensure that all requirements withrespect to assembly, electrical connection, and commissioning at the placeof installation are met. They include among others:. Applicable configuration directives for fieldbus applications.. National regulations, laws, and prescriptions.

Safety instructions/warnings

All personnel working with this device must be familiar with the safety andwarning instructions in this manual and observe the instructions given.Safety instructions and warning signs on the device must be observed toavoid personal injury or property damage.

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

Commissioning Prior to commissioning, it is important to check that all settings are in com-pliance with the requirements of the application. Incorrect settings mightpresent a danger to the application, e.g. cause damage to the valve or theinstallation.

The manufacturer will not be held liable for any consequential damage. Suchrisk lies entirely with the user.

Operation Prerequisites for safe and smooth operation:. Correct transport, proper storage, mounting and installation, as well as

careful commissioning.. Only operate the device if it is in perfect condition while observing these

instructions.. Immediately notify any faults and damage and allow for corrective mea-

sures.. Observe recognised rules for occupational health and safety.. Observe the national regulations..

During operation, the housing warms up and surface temperatures > 60 Cmay occur. To prevent possible burns, we recommend to the check surfacetemperature with an appropriate thermometer prior to working with the device.

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

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

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1.2. Range of application

6


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

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

The following applications are not permitted, e.g.:. Industrial trucks according to EN ISO 3691. Lifting appliances according to EN 14502. Passenger lifts according to DIN 15306 and 15309. Service lifts according to EN 81-1/A1. Roller conveyors according to Standard EN 14673 (draft). Permanent operation. Buried service. Permanent submersion (observe enclosure protection). Potentially explosive areas, with the exception of zone 22

.

Radiation exposed areas in nuclear power plants

No liability can be assumed for inappropriate or unintended use.

Observance of these operation instructions is considered as part of thedevices designated use.

Information These operation instructions are only valid for the clockwise closing stan-dard version, i.e. driven shaft turns clockwise to close the valve. Separateinstructions are available for the counterclockwise closing special version.

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1.4. Warnings and notes

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

Indicates an imminently hazardous situation with a high level of risk.Failure to observe this warning will result in death or serious injury.

Indicates a potentially hazardous situation with a medium level of risk.Failure to observe this warning could result in death or serious injury.

Indicates a potentially hazardous situation with a low level of risk.Failure to observe this warning may result in minor or moderate injury. Mayalso be used with property damage.

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

Arrangement and typographic structure of the warnings

Safety alert symbol (warns of a potential personal injury hazard).Signal word (DANGER, WARNING, CAUTION, NOTE)

1.5. Further references and symbols

The following references and symbols are used in these instructions:

Information The term Information preceding the text indicates important notes andinformation.

Symbol for CLOSED.

Symbol for OPEN.

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

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

Step by stepProvides a detailed description of each step for setting/viewing the parameter.

8


Type of hazard and respective source!

Possible consequence(s) in case of non-observance (option)

Measures to avoid the danger Further measure(s)

DANGER

CAUTION

WARNING

NOTICE

DANGER

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2. Identification

2.1. Name plate

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

Identification data on the actuator name plate:

Identification data on the controlsname plate:

9


Figure 1

1 Actuator name plate 3 Motor name plate

2 Controls name plate 4 Additional plate, e.g. KKS plate

1 Type and size of actuator

2 Commission number

1 Type and size of the controls

2 Commission number

3 Wiring diagram/control

a

CC

AUMA Riester GmbH&Co.KG

D-79379 Mllheim

No : 3302MD 19302

SA 07.1-

Com No: 1309533

F1012

Figure 2

auma

AC 01.1Com No: 1309595

ACP B:

P:1,5kW

No: 0902MA97286KMS:TP180/001

11F1-2 0-- 0003 ~ 400V IP67Control: RS 485

P

12

3

Figure 3

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2.2. Short description

Multi-turn actuator Definition in compliance with EN ISO 5210A multi-turn actuator is an actuator which transmits to the valve a torque forat least one full revolution. It is capable of withstanding thrustAUMA multi-turn actuators are driven by an electric motor. A handwheel isprovided for manual operation.Switching off in end positions may be either by limit or torque seating.Controls are required to operate or process the actuator signals.

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

Local controls/COM-AC/fieldbus

Operation, setting, and display can be performed on site directly at the con-trols or alternatively from REMOTE via a fieldbus interface.On site it is possible to. operate the actuator via the local controls (push buttons and display)

and perform settings (contents of these instructions).. read in or out data or modify and save settings via the COM-AC software

(option), using a computer (laptop or PC). Depending on the version, theconnection between computer and AUMATIC can be made with cable(infra-red interface) or without cable (Bluetooth interface). (Not includedin these instructions.)

Intrusive Non-Intrusive . Intrusive version:

Limit and torque setting is performed via switches in the actuator.

.

Non-Intrusive version:Limit and torque setting is performed via the controls, actuator and con-trols housings do not have to be opened.For this purpose, the actuator is equipped with an MWG (magnetic limitand torque transmitter), also supplying analogue torque feedback sig-nals/torque indication.

11


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3. Transport, storage and packaging

3.1. Transport

For transport to place of installation, use sturdy packaging.

3.2. Storage

Long-term storage: If the device must be stored for a long period (more than 6 months) the fol-lowing points must be observed in addition:1. Prior to storage: Protect uncoated surfaces, in particular the output drive parts and

mounting surface, with long-term corrosion protection agent.2. At an interval of approx. 6 months: Check for corrosion. If first signs of corrosion show, apply new corrosion

protection.

3.3. Packaging

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

12


Danger of corrosion due to inappropriate storage!

Store in a well-ventilated, dry room. Protect against floor dampness by storage on a shelf or on a wooden

pallet. Cover to protect against dust and dirt. Apply suitable corrosion protection agent to uncoated surfaces.

NOTICE

Hovering load!Death or serious injury possible.

Do not place below hovering load. Attach ropes or hooks for the purpose of lifting by hoist only to housing

and not to handwheel. Actuators mounted on valves:

Attach ropes or hooks for the purpose of lifting by hoist to valve and notto multi-turn actuator.

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

Actuators mounted to controls:

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

DANGER

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4. Assembly

4.1. Handwheel fitting

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

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

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

3. Secure handwheel using the circlip supplied.

13


85

Damage at the change-over mechanism due to incorrect assembly!

Only pivot the change-over lever manually. Using extensions as a lever for operation is not permitted. First engage manual operation correctly, then mount handwheel.

NOTICE

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4.2. Multi-turn actuator mounting to valve/gearbox

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

Application For rotating, non-rising valve stem.

Design Output drive type bore with keyway:Type B1 B4 with bore according to ISO 5210.Type B and E with bore according to DIN 3210.Later change from B1 to B3, B4, or E is possible.

Information Spigot at flanges should be loose fit.

Mounting the multi-turn actuator

1. Check if mounting flanges fit together.2. Check whether bore and keyway match the input shaft.3. Thoroughly degrease mounting faces of the mounting flanges.4. Apply a small quantity of grease to the input shaft.5. Mount multi-turn actuator and ensure that the spigot mates uniformly in

the recess and that the mounting faces are in complete contact.6. Fasten multi-turn actuator with screws according to table 2.7. Fasten screws crosswise with a torque according to table 2.

14


2

1 3

4

2

1 3

4

Figure 5

Danger of corrosion due to damage to paint finish and condensation!

Touch up damage to paint finish after working on the device.

After mounting, connect the device immediately to electrical mains toensure that heater reduces condensation.

NOTICE

1 Output drive type B1/B2 and B 3 Output drive B3/B4 and E

2 Hollow shaft with keyway 4 Plug sleeve

with bore and keyway

Mounting flange ScrewsThread

Fastening torque TA [Nm]Strength class 8.8

F07 M8 25

F10 M10 51

F14 M12 87

F16 M16 214

Table 3

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4.2.2 Output drive type A

Application . For rising, non-rotating valve stem.. Capable of withstanding thrust

Design Output drive type A as separate unit (figure 6):

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

. If not ordered explicitly with thread, the stem nut is supplied unbored orwith a pilot bore.

Finish machining the stem nut

Only required for stem nut if supplied unbored or with a pilot bore.

1. Remove spigot ring (3) from output drive type.2. Take off stem nut (1) together with axial needle roller and cage assembly

(2) and axial bearing washers (4).3. Remove axial needle roller and cage assembly and axial bearing wash-

ers from stem nut.4. Drill and bore stem nut and cut thread.

When fixing in the chuck, make sure stem nut runs true!5. Clean the machined stem nut.

6. Apply Lithium soap EP multi-purpose grease to axial needle roller andcage assembly and axial bearing washers, then place them on stem nut.

7. Re-insert stem nut with axial bearings into output drive type. Ensure thatdogs or toothing are placed correctly in the slots of the hollow shaft.

8. Screw in spigot ring until it is firm against the shoulder.9. Press in Lithium soap EP multi-purpose grease on mineral oil base at the

grease nipple with a grease gun (for quantities, please refer to table 4).

Grease quantities for bearing of output drive A:

15


1

3

2

2 4

4

Figure 6

1 Stem nut 3 Spigot ring

2 Axial needle roller and cage assembly 4 Axial bearing washer

Output drive A 07.2 A 10.2 A 14.2 A 16.2

Qty1)

1.5 g 2 g 3 g 5 g1) For grease with density = 0.9 kg/dm

Table 4

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

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

2. Check if the flange of output drive type A matches the valve flange (4).3. Thoroughly degrease mounting faces of the mounting flanges.

4. Apply a small quantity of grease to the valve stem (1).5. Place output drive type A on valve stem and fasten until it is seated sol-

idly on the valve flange.6. Turn output drive type A until alignment of the fastening holes.7. Screw in fastening screws (5), however do not completely fasten.8. Fit multi-turn actuator on the valve stem so that the hollow shaft pinions

engage into the stem nut. The flanges are flush with each other if prop-erly engaged.

9. Turn multi-turn actuator until alignment of the fastening holes.10 Fasten multi-turn actuator with screws (3) according to table 2, page 14.11. Fasten screws crosswise with a torque according to table 2.12. Engage manual operation at multi-turn actuator and turn handwheel in

direction OPEN until valve flange and output drive type A are firmlyplaced together.

13. Tighten fastening screws (5) between valve and output drive type Acrosswise with a torque according to table 2, page 14.

16


Figure 7

1 Valve stem 4 Valve flange

2 Output drive type A 5 Screws to output drive

3 Screw to actuator

Danger of corrosion due to damage to paint finish and condensation!

Touch up damage to paint finish after working on the device. After mounting, connect the device immediately to electrical mains to

ensure that heater reduces condensation.

NOTICE

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4.3. Accessories (option)

4.3.1 Protection tube for rising valve stem

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

17


3

2

1

Figure 8

1 Cap for stem protection tube 3 Sealing ring

2 Stem protection tube

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4.4. Mounting positions of the local controls

The mounting position of the local controls is designed according to theorder. If, after mounting the actuator to the valve or the gearbox on site, thelocal controls is in an unfavourable position, the mounting position can bechanged at a later date. Four mounting positions are possible.Figure 9 shows mounting positions A and B:

Figure 10 shows mounting positions C and D:

Changing the mounting position

1. Loosen bolts and remove the local controls.2. Check whether O-ring is in good condition, correctly place O-ring.3. Turn local controls into new position and re-place.

4. Fasten bolts evenly crosswise.

18


Figure 9

Figure 10

Hazardous voltage!Electric shock possible.

Disconnect device from the mains before opening.

Cable damage due to twisting or squeezing!

Functional failures possible.

Turn local controls by a maximum of 180. Carefully assemble local controls to avoid pinching the cables.

DANGER

NOTICE

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5. Electrical connection

5.1. General notes

19


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

Danger due to incorrect electrical connection!

Failure to observe this warning can result in death, serious injury, or prop-

erty damage. The electrical connection must be carried out exclusively by suitably

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

sioning and Test run clauses.

Protection on site For short-circuit protection and for disconnecting the actuator from themains, fuses and disconnect switches have to be provided by the customer.The current values for respective sizing can be derived from the currentconsumption of the motor plus the current consumption of the controls.Motor current consumption:Refer to name plate on motor (nominal current).Current consumption of the controls depending on the mains voltage:100 to 120 V AC = max. 650 mA208 to 240 V AC = max. 325 mA380 to 500 V AC = max. 190 mA24 V DC (+10 %/15 %) = max. 500 mA, filter capacitor 2200 F

Current consumption for actuator with 1-ph DC motor:24 V DC (+10 %/10 %) = max. 750 mA, filter capacitor 2200 FThe maximum permissible fuse for controls with a rated power of 1.5 kW is16 A (gL/gG); for controls with a rated power of 7.5 kW, the value amountsto 32 A (gL/gG).

WARNING

Cable installation in accordancewith EMC

Signal and bus cables are susceptible to interference.

Motor cables are interference sources.. Lay cables being susceptible to interference or sources of interference at

the highest possible distance from each other.. The interference immunity of signal and bus cables increases if the

cables are laid close to the ground potential.

.

If possible, avoid laying long cables and make sure that they areinstalled in areas being subject to low interference.

. Avoid long parallel paths with cables being either susceptible to interfer-ence or interference sources.

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Power supplyFoundation Fieldbus

Foundation Fieldbus requires an own power supply. Due to the specialrequirements regarding this power supply, appropriate power supply unitsmust be provided within the control station.The Foundation Fieldbus network design requires a power supply of 9 to 32 V DCfor each Foundation Fieldbus device.The typical Foundation Fieldbus current consumption of the AUMATIC is 11

mA.

Power supply for the controls(electronics)

If the controls (electronics) are supplied externally with 24 V DC and DCmotors (24 V DC, 48 V DC, 60 V DC, 110 V DC, 220 V DC) are used simul-taneously, the 24 V DC voltage supply for the controls should be ensuredvia the XK25/26 terminals, separate from the power supply (U1, V1). In caseof common supply using a single cable (links from U1, V1 with XK25/26, for

24 V DC only !!!), short-term excess or falling below the admissible voltagelimits can be the consequence during switching (24 V DC +10 %/10 %).Any possibly incoming operation commands are not executed outside theadmissible limit values. The controls briefly signal a fault condition.

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Bus cables Various types of fieldbus cables can be applied for Foundation Fieldbus. Thefollowing table lists the cable types specified by the IEC/ISA 61158-2, Physi-cal Layer Standard.The preferred fieldbus cable is type A cable. This cable should be used innew installations. However, other cable types may be used for the fieldbuswiring (e.g type B, C, and D).

Their disadvantage is the reduced cable length; for this reason their use isnot recommended.

Prior to installation, please note:

. Connect maximum 32 devices to one segment. Normally, maximum 10to 12 devices are connected within one network.

. Respect a distance of minimum 20 cm between the bus cable and othercables.

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

. Make sure to avoid potential differences between the individual devices

on the bus (perform a potential compensation).

.

When exceeding the maximum segment length, repeaters have to beused (up to four repeaters per network).

21


Type A(Refer-ence)

Type B Type C Type D

Cable designTwisted

conductorpair

One or multipletwisted

conductor pairs,overall shield

Multipletwisted pairs,not shielded

Multiplenon-twistedpairs, notshielded

Conductor cross-section(nominal)

0.8 mm(AWG 18)

0.32 mm(AWG 22)

0.13 mm(AWG 26)

1.25 mm(AWG 16)

Loop impedance

(DC current)

44 /km 112 /km 264 /km 40 /km

Wave resistance at31.25 kHz

100 20 %

100 30 %

not specified not specified

Wave attenuationat 39 kHz

3 dB/km 5 dB/km 8 dB/km 8 dB/km

Capacitve asymmetry 2 nF/km 2 nF/km not specified not specified

Group delay distortion(7.9 39 kHz)

1.7 s/km not specified not specified not specified

Degree of shieldcoverage

90 % not specified not specified not specified

Recommended networkexpansion (incl. spur line)

1,900 m 1,200 m 400 m 200 m

Table 5

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5.2. Mains connection using AUMA plug/socket connector (SD)

Before mains connection

Check whether type of current, supply voltage, and frequency complywith motor data (refer to name plate at motor).

Opening the terminal compartment

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

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

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

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

22


a

CC

VD00 63-4/45

Art No: Z006.413

0.090 kW

Y 0.60 A

~ 4 V 5 Hz

Hazardous voltage!

Electric shock possible.


au

IP 67

1680 rpm

Temp.Protection:Th

Insulation Class: F

1 Connection housing 5 Socket carrier

2 Screws for connection housing 6 Cable entry for mains

3 O-ring 7 Screw plug

4 Screws for socket carrier 8 Cable gland (not included in delivery)

3

1

2

7

4

8

5

6

Figure 11

DANGER

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Connecting the cables1. Remove cable sheathing.2. Strip wires.3. For stranded wires: use end-sleeves according to DIN 46228.

4. Connect cables according to order-related wiring diagram.Cable cross sections: Power terminals (U1, V1, W1, U2, V2, W2) and

protective earth connection (symbol: )max. 6 mm flexible, max. 10 mm rigid

Control contacts (1 to 50) = max. 2.5 mm

Information For some special motors, the connection of the power terminals (U1, V1,W1, U2, V2, W2) is made via a terminal board at the motor.

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

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

Connecting the motor heater (option)

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

23


1

2

3

4

5

6

Figure 12

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

Electric shock possible. Connect all protective conductors. Connect PE connection with external protective conductor of connecting

cables.

1 Socket carrier 4 Spring lock washer

2 Screw 5 Protective earth with ring lugs/loops

3 Washer 6 PE connection

Danger of corrosion due to condensation!

For version with external heater supply (option):Connect heater R1 according to terminal plan.

For all versions: After mounting, immediately put device into operation.

WARNING

NOTICE

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Closing the terminal compartmentRefer to figure 13.1. Insert the socket carrier (5) into the connection housing (1) and fasten it

with screws (4).2. Clean sealing faces of connection housing and housing.

3. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.4. Check whether O-ring (3) is in good condition, correctly place O-ring.5. Fit connection housing (1) and fasten bolts (2) evenly crosswise.6. Fasten cable glands (8) applying the specified torque to ensure the

required enclosure protection.

24


3

1

27

4

8

5

6

Figure 13

1 Connection housing 5 Socket carrier

2 Screws for connection housing 6 Cable entry for mains

3 O-ring 7 Screw plug

4 Screws for socket carrier 8 Cable gland (not included in delivery)

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

Opening the bus terminal compartment

1. Loosen and remove plug cover (1).The connection board is located behind the plug cover.

2. Insert cable glands suitable for bus cables.The enclosure protection IP stated on the name plate is only ensuredif suitable cable glands are used.

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

25


3

1

2

4/5

Figure 14: Bus connection

Hazardous voltage!Electric shock possible.


1 Cover 3 O-ring

2 Screws for cover 4 Cable entries for bus cables

5 Screw plug

au

IP 67

1680 rpm

Temp.Protection:Th

Insulation Class: F

DANGER

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Connecting the bus cables

1. Connect bus cable (refer to figure 15).

Information The max.current load of the pins for the Foundation Fieldbus cable in the elec-trical connection is 2.5 A.This has to be observed when planning the Founda-tion Fieldbus topology (location of the Foundation Fieldbus power supply andcurrent consumption of the connected Foundation Fieldbus devices).

2. If the actuator is the final device in the bus segment: The termination resistor for channel 1 has to be switched on using

switch S1 (ON position).The switch is supplied in OFF position.

Information As soon as the termination resistor is switched on, the connection to the nextFieldbus device is automatically interrupted to avoid multiple terminations.Table 6 describes the switch positions S1:

3. Connect X1 cable shield with Shield terminal.

Information The cable shield of Foundation Fieldbus cables may only be connected tothe ground potential at one single point.

Figure15: Connection board (standard version).

Information Although the AUMATIC is equipped with an automatic polarity detection andcorrection, it is recommended to connect the fieldbus cables according totheir polarity to generate a consistent wiring for all fieldbus devices.

26


Figure 15

S1 Bus termination channel 1 X1 Channel 1, from previous device

X4Shield connected/not connectedto earth

X2 Channel 1, to next device

S1ON Bus termination channel 1 ON

OFF Bus termination channel 1 OFF

Table 6

X4ON Shield connected to earth

OFF Shield isolated (default setting)

Table 7

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Closing the bus terminal compartment1. Clean sealing faces of housing and cover.2. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.3. Check whether O-ring (3) is in good condition, correctly place O-ring.

4. Fit cover (1) and fasten screws (2) evenly crosswise.5. Fasten cable glands with the specified torque to ensure the required

enclosure protection.

27


3

1

2

4/5

Figure 16

1 Cover 3 O-ring

2 Screws for cover 4 Cable entries for bus cables

5 Screw plug

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5.4. Accessories for electrical connection (option)

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

Application .

If there is no proper access to the actuator/local controls

.

In case of heavy vibration of the valve

.

If the actuator is subjected to high temperatures

Design

Observe prior to connection . Permissible length of connecting cables: max. 100 m. If the actuator is equipped with an position transmitter (RWG):

Connecting cables must be available as shielded version.. Versions with potentiometer in the actuator are not suitable.. We recommend: AUMA cable set LSW1.. If the AUMA cable set is not used, suitable flexible and screened con-

necting cables are to be implemented.. If connecting cables, e.g. of the heater, are available requiring direct wir-

ing from the actuator to the XK customer connector (XA-XM-XK, refer towiring diagram), these connecting cables must be subject to an insula-tion test in compliance with EN 50178.Connecting cables of position transmitters (RWG, potentiometer) do notbelong to this group. They may not be subject to an insulation test.

28


3

1

24

5

Figure 17

1 Wall bracket 3 Wall bracket terminals (XM)

2 Connecting cables

4

5

Actuator terminals (XA)

Controls terminals (XK)

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5.4.2 Parking frame

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

5.4.3 Protection cover

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

5.4.4 Double sealed intermediate frameWhen removing the electrical connection or due to leaky cable glands, ingressof dust and water into the housing is possible. This is prevented by inserting thedouble sealed intermediate frame (2) between the electrical connection (1) andactuator housing.The enclosure protection of the device, IP 67 or IP 68, will notbe affected, even if the electrical connection is removed.

5.4.5 Ground connection, externalAs an option, an external ground connection (clamping saddle) on the hous-

ing is available.

29


Figure 18

Figure 19

Figure 20

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6. Operation

6.1. Manual operation

In case of motor failure or power failure, the actuator may be operated man-ually for purposes of setting and commissioning.

Manual operation is engaged by an internal change-over mechanism.

Engaging manual operation

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

2. Release change-over lever (should snap back into initial position byspring action), if necessary, push it back manually.

3. Turn handwheel into desired direction, in doing so the following applies:To close the valve, turn handwheel clockwise:Drive shaft (valve) turns clockwise in direction CLOSE.

Disengaging manual operationManual operation is automatically disengaged when motor is started again.The handwheel does not rotate during motor operation.

30


Damage at the change-over mechanism due to faulty operation!

Engage manual operation only during motor standstill. Only pivot change-over lever manually. Using extensions as a lever for operation is not permitted.

NOTICE

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6.3. Menu navigation via push buttons (for settings and indications)

The push buttons of the local controls (figure 22) are used to view, edit, andshow various indications on the display.

Set selector switch (5) to position 0 (OFF).

Now, settings and indications can be performed via the push buttons (1 4).

6.3.1 Short overview: functions of the push buttons

32


1

6

1

2

3

4

5

C

Figure 22

1 Push button 4 Push buttonC

2 Push button 5 Selector switch

3 Push button 6 Display

0I

I

Pushbuttons

Functions

Scrolling within a group

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

Change values

Enter figures from 0 to 9

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

C

Cancel process

Return to previous display: press briefly

Change to another group (S, M, D)

- press for approx. 3 seconds until group M0 is displayed.

- hold down for more than 3 seconds until group D0 is displayed(thereby, group M is skipped).

Table 8

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6.3.2 Structural design and navigation

The indications on the display are divided into 3 groups:. GroupS = status indications. GroupM = menu (settings). GroupD = diagnostic indications

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

Change groups Change from groupS to groupM: PressC push button and hold it down for approx. 3 seconds until group

M0 appears.

Change from group S to group D: PressC push button and hold it down until groupD0 appears

(groupM is hereby skipped).

Change from any groupM or D back to group S: Briefly pressC.

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

Enter the password In the menu (groupM), the settings are protected by a password.To change the parameters, a password must first be entered.The following default password is set in the factory: 0000.

After selectingEDIT, the following is displayed:

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

Information If no input is received over a longer period of time (approx. 10 min), the con-trols automatically returns to the status indicationS0.

33


ENTER PASSWORD

0 * * *

:EDIT :OK C:ESC

OFF S0

OPEN POSITION

E2 100%

M0

M0

OFF S0

OPEN POSITION

E2 100%

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6.4. Language change in the display

Via the menu to parameter:MAIN MENU (M0)

LANGUAGE/CONTRAST (M00)

VIEW (M00)EDIT (M01)

LANGUAGE (M010)

Default value: ENGLISH

Setting range: GERMAN, PORTUGUESE, ITALIAN, SPANISH,FRENCH, ENGLISH, TUERKCE, POLSKI, MAGYAR

Step by step:1. Set the selector switch to position 0 (OFF).

2. PressC and hold it down for approx. 3 seconds.Display indicates:

3. Press .Display indicates:

4. Press.Display indicates:

5. Press .Display indicates:

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

34


LANGUAGE/CONTRAS M00

VIEW

EDIT

MAIN MENU M0

LANGUAGE/CONTRAST

SETTINGS

OPERATIONAL DATA

0I

I

LANGUAGE/CONTRAS M01

VIEW

EDIT

ENTER PASSWORD

0 * * *

:EDIT :OK C:ESC

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Display indicates:

7. Press .Display shows the set value.

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

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

PressC.

35


EDIT M010

LANGUAGE

ENGLISH

:EDIT C:ESC

EDIT M010

LANGUAGE

ENGLISH

:EDIT :OK C:ESC

EDIT M010

LANGUAGE

LCD CONTRAST

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7. Indications

7.1. Status indications in the display

Status indications regarding faults and warnings, refer to page 56 et seqq.

7.1.1 Status indication S0/S6 - operation

Information For actuators equipped with process controllers, status indicationS6 is dis-played instead of status indicationS0. The description below applies to bothindications (S0 undS6).

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

Operation command/setpoint dis-play

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

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

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

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

Description of indications in line 4:

RUNNING OPEN

Actuator runs logically OPEN (remains set during operation pauses).

RUNNING CLOSE

Actuator runs logically CLOSE (remains set during operation pauses).

OPEN POSITION

End position OPEN reached.

36


LOCAL MODE S0

OPEN

E2 100 %

RUNNING OPEN

LOCAL MODE S0

OPEN

E2 100 %

RUNNING OPEN

LOCAL MODE S0

OPEN

E2 100%

RUNNING OPEN

LOCAL MODE S0

OPEN

E2 100%

RUNNING OPEN

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CLOSED POSITION

End position CLOSED reached.

SETPOINT POSITION

Setpoint (modulating actuators only).

Description of the fault indications:See page 56.

37


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7.2. Indication lights/LEDs

The indication lights/LEDs locally display the different operation states asoptical signals. The signals can be freely assigned.Figure 23 shows the indication lights/LEDs on the local controls:

Table 9 describes the standard indication.

Information Thebehaviour (blinking/illuminated)can be changed via theBLINKER parameter.

7.3. Mechanical position indicator/running indication (option)

Mechanical position indicator. continuously indicates the valve position

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

. indicates whether the actuator is running (running indication)

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

38


LED 1 (left)( symbol)

illuminated Actuator is in end position CLOSED

blinkingRunning indication: Actuator runs in directionCLOSE

LED 2 (T) illuminated Torque fault CLOSE

LED 3 (Th) illuminated Motor protection tripped

LED 4 (T) illuminated Torque fault OPEN

LED 5 (right)( symbol)

illuminated Actuator is in end position OPEN

blinkingRunning indication: Actuator runs in directionOPEN

Table 9

Figure 23

auma

2

3

5

41

Figure 24

Version (standard): Version (option):

LED marking with letters LED marking with figures

1 Cover 4 Symbol for position OPEN2 Indicator disc 5 Symbol for position CLOSED

3 Indicator mark

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8. Signals

8.1. Signals via fieldbus

Feedback signals via Foundation Fieldbus can be configured.The configuration is only defined via the transducer blocks and/or the func-

tion blocks.

Information The DD (Device Description) can be downloaded from the Internet:www.auma.com

Please refer to the Manual (Device integration Fieldbus) AUMATIC AC01.1/ACExC 01.1 Foundation Fieldbus regarding the feedback signals viaFoundation Fieldbus and the parameter configuration via the fieldbusinterface.

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

Feedback signals via output contacts are only available if a parallel interface

is provided in addition to the fieldbus interfaceThe output contacts can be used to indicate operation modes of the actuatoror the controls as binary signals. The signals can be freely assigned. Exam-ple:Output contact open = no thermal faultOutput closes = thermal fault in actuator

Fault signals can be issued via theALARM CONTACT parameter, other sig-nals via theOUTPUT CONTACTS 1 to5.

Alarm contact default value:(Designation in the wiring diagram: NC fault/NO ready)FAULT GROUP 3 = fault signal (includes: Torque fault, thermal fault, phasefailure, and internal faults)

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

OUTPUT CONTACT 2 = OPEN POSITION

OUTPUT CONTACT 3 = REMOTE SW. POSITION

OUTPUT CONTACT 4 = TORQUE FAULT (CLOSE)

OUTPUT CONTACT 5 = TORQUE FAULT (OPEN)

For further information on this topic refer to Manual (Operation and setting)AUMATIC AC 01.1/ACExC 01.1.

8.3. Feedback signals (analogue) - (option)

Analogue feedback signals are only available if the following conditions aremet:. In addition to the fieldbus interface, the AUMATIC is equipped with a par-

allel interface.. The actuator is equipped with a position transmitter (potentiometer or

RWG).

Valve position Signal: E2 = 0/4 20 mA (galvanically isolated)Designation in the wiring diagram:ANOUT1 (position)

For further information on this topic refer to Manual (Operation and setting)AUMATIC AC 01.1/ACExC 01.1

39


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9. Commissioning

Prior to any electrical operation (motor operation), ensure that all commis-sioning settings described in this clause have been performed

1. Set the selector switch to position 0 (OFF).

Information The selector switch is not a mains switch. The actuator control is disabled in0 (OFF) position. The controls power supply is maintained.

2. Switch on the power supply.3. Perform the settings described in this clause.

Low temperature version Please note that for low temperature versions, the controls require a heat-uptime.

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

For 40 C = 30 min.For 50 C = 60 min.For 60 C = 100 min.

Figure 25: Sketch illustrating the heat-up time.

40


0

30

50

60

0 10 20 30 40 50

t [min.]

[C]

100

60

Figure 25

0I

I

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

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

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

(menuS1).

Via the menu to parameter:MAIN MENU (M0)

SETTINGS (M1)

SEATING MODE (M11)

VIEW (M110)

EDIT (M111)

OPEN POSITION (M11_0)

CLOSED POSITION (M11_1)

Default value: LIMIT

Step by step:1. Set the selector switch to position 0 (OFF).

2. PressC and hold it down for approx. 3 seconds.Display indicates:

3. Press.Display indicates:

4. Press .

41


Valve damage due to incorrect setting!

The type of seating must suit the valve.

Only change the setting with the consent of the valve manufacturer.

0I

I

MAIN MENU M0

LANGUAGE/CONTRAST

SETTINGS

OPERATIONAL DATA

MAIN MENU M1

LANGUAGE/CONTRAST

SETTINGS

OPERATIONAL DATA

NOTICE

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Display indicates:

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

are used to change between theOPEN POSITION (left figure)andCLOSED POSITION (right figure) displays.

13.Press .Display shows the set value:

are also used here to change between theOPEN POSITION (leftfigure) andCLOSED POSITION (right figure) displays.

14.Press again to enter the edit mode.Display indicates:

15. Set new value: Press.16. Accept value: Press or cancel process without accepting the value:

PressC.Display indicates:

17. Return to status display:PressC several times untilS0 is displayed.

43


EDIT M1111

OPEN POSITION

CLOSED POSITION

EDIT M1110

OPEN POSITION

CLOSED POSITION

EDIT M1111

CLOSED POSITION

LIMIT

:EDIT C:ESC

EDIT M1110

OPEN POSITION

LIMIT

:EDIT C:ESC

EDIT M1111

CLOSED POSITION

LIMIT

:EDIT :OK C:ESC

EDIT M1110

OPEN POSITION

LIMIT

:EDIT :OK C:ESC

EDIT M1111

CLOSED POSITIONLIMIT

:EDIT C:ESC

EDIT M1110

OPEN POSITIONLIMIT

:EDIT C:ESC

ENTER PASSWORD

0 * * *

:EDIT :OK C:ESC

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9.2. Switch compartment: open

The switch compartment must be opened to perform the following settings.

1. Loosen screws (2) and remove cover (1) from the switch compartment.

2. If indicator disc (3) is available: Remove indicator disc (3) using a wrench (as lever).

44


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9.3. Torque switching: set

1. Loosen both lock screws (3) at the indicator disc (figure 26).2. Turn torque dial (4) for setting the required torque (1 da Nm = 10 Nm).

Example:Figure 26 shows the following setting:3.5 da Nm = 35 Nm for direction CLOSE4.5 da Nm = 45 Nm for direction OPEN

3. Fasten lock screws (3) again.

The torque switches setting is complete.

Information . The torque switches may also trip in manual operation.. The torque switching acts as overload protection over full travel, also

when stopping in the end positions by limit switching.

45


Valve damage due to excessive torque setting!

The torque must suit the valve.

Only change the setting with the consent of the valve manufacturer.

Figure 26

1 Switching head black for 2 Switching head white for

torque in direction CLOSE torque in direction OPEN

3 Lock screws 4 Torque dial

NOTICE

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9.4. Limit switching: set

9.4.1 End position CLOSED (black section): set1. Engage manual operation.2. Turn handwheel clockwise until valve is closed.3. Turn handwheel back by approximately half a turn (overrun).4. Press down and turn setting spindle (1) (figure 27) using a screw driver

in direction of the arrow, thereby observe pointer (2):While a ratchet is felt and heard, the pointer (2) moves 90 every time.

5. If the pointer (2) is 90 from mark (3): continue turning slowly.6. If the pointer (2) moves to mark (3): stop turning and release setting

spindle.The end position CLOSED setting is complete.

7. If you override the tripping point inadvertently (ratchet is heard after thepointer has snapped): continue turning the setting spindle in the samedirection and repeat setting process.

9.4.2 End position OPEN (white section): set1. Engage manual operation.2. Turn handwheel counterclockwise until valve is open.3. Turn handwheel back by approximately half a turn (overrun).

4. Press down and turn setting spindle (4) (figure 27) using a screw driverin direction of the arrow, thereby observe pointer (5):While a ratchet is felt and heard, the pointer (5) moves 90 every time.

5. When pointer (5) is 90 from mark (6): continue turning slowly.6. When pointer (5) moves to mark (6): stop turning and release setting

spindle.The end position OPEN setting is complete.

7. If you override the tripping point inadvertently (ratchet is heard after thepointer has snapped): continue turning the setting spindle in the samedirection and repeat setting process.

46


Figure 27

Black section White section

1Setting spindle for end positionCLOSED

4Setting spindle for end positionOPEN

2 Pointer for end position CLOSED 5 Pointer for end position OPEN

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9.5. Intermediate positions (option): set

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

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

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


3. If the pointer (2) is 90 from mark (3): continue turning slowly.4. If the pointer (2) moves to mark (3): stop turning and release setting

spindle.The intermediate position setting in running direction CLOSE is com-plete.

5. If you override the tripping point inadvertently (ratchet is heard after the

pointer has snapped): continue turning the setting spindle in the samedirection and repeat setting process.

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

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


3. If the pointer (5) is 90 from mark (6): continue turning slowly.4. If the pointer (5) moves to mark (6): stop turning and release setting spindle:

The intermediate position setting in running direction OPEN is complete.5. If you override the tripping point inadvertently (ratchet is heard after the

pointer has snapped): continue turning the setting spindle in the samedirection and repeat setting process.

47


Figure 28

Black section White section

1Setting spindle running directionCLOSE

4Setting spindle running directionOPEN

2 Pointer running direction CLOSE 5 Pointer running direction OPEN

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

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

CLOSE while the hollow shaft or the stem turn clockwise.

9.6.2 Limit switching check

1. Set selector switch to position Local control (LOCAL).

2. Operate actuator using push buttons OPEN - STOP - CLOSE.The limit switching is set correctly if (standard indication): The yellow indication light/LED1 is illuminated in end position

CLOSED The green indication light/LED5 is illuminated in end position OPENThe limit switching is set incorrectly, if: The actuator comes to a standstill before reaching the end position One of the red indication lights/LEDs is illuminated (torque fault), or

the following fault signals are displayed:Status indication S0: FAULT IND.

Status indication S1: TORQUE FAULT (CLOSE) orTORQUE FAULT(OPEN)

3. If the end position setting is incorrect: Set limit switching again (page46).

9.6.3 Perform reference operation

For actuators with feedback signal (RWG, potentiometer), a reference oper-ation has to be performed after the setting has been changed:. Operate actuator electrically (via the push buttons OPEN and CLOSE of

the local controls) once to the end position OPEN and once to the endposition CLOSED.

.

If no reference operation is performed after changing the limit switching,the feedback signal via the bus is not correct. The bus signals the miss-ing reference operation as a warning.

49


1

2

3

4

5

6

Figure 29

1 Screw plug 4 Cap for stem protection tube

2 Seal 5 Stem

3 Hollow shaft 6 Protection tube

0I

I

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9.7. Potentiometer (option) setting

The potentiometer as a travel monitor records the valve position.

This setting is only required if the potentiometer is directly wired to the cus-tomer connection XK (refer to wiring diagram).

1. Move valve to end position CLOSED.2. Turn potentiometer (1) clockwise to the stop.

End position CLOSED corresponds to 0 %End position OPEN corresponds to 100 %.

3. Turn potentiometer (1) slightly back.4. Perform fine-tuning of the zero point at external setting potentiometer

(for remote indication).

Information Due to the ratio of the reduction gearing the complete resistancerange/stroke is not always passed. Therefore, external adjustment (settingpotentiometer) must be provided.

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Figure 30

1 Potentiometer

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9.8. Electronic position transmitter RWG setting (option)

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

Technical data RWG 4020

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

for 0 20 mA approx. 0.1 mA for 4 20 mA approx. 4.1 mAThis ensures that the signal remains above the dead and live zero point.

8. Move valve to end position OPEN.9. Set potentiometer max. (3) to end value 20 mA.10. Approach end position CLOSED again and check minimum value

(0.1 mA or 4.1 mA). If necessary, correct the setting.

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

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Terminal planKMS TP_ _ 4 / _ _ _

3-/4-wire system

Output current Ia 0 20 mA, 4 20 mA

Powersupply

Uv24 V DC, 15 %

smoothed

max.current consump-tion

I 24 mAFor 20 mA output current

Max. load RB 600

Table 10

Figure 31

1 Potentiometer (travel monitor) 4 Measurement point (+) 0/4 20 mA

2 Potentiometer min. (0/4 mA) 5 Measurement point () 0/4 20 mA

3 Potentiometer max. (20 mA)

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9.9. Mechanical position indicator setting (option)

1. Place indicator disc on shaft.2. Move valve to end position CLOSED.3. Turn lower indicator disc until symbol (CLOSED) is in alignment with

the mark on the cover.

4. Move actuator to end position OPEN.5. Hold lower indicator disc CLOSED in position and turn upper disc with

symbol (OPEN) until it is in alignment with the mark on the cover.

6. Move valve to end position CLOSED again.7. Check settings:

If the symbol (CLOSED) is no longer in alignment with themark on the cover:

Repeat setting procedure.

Check whether the appropriate reduction gearing has been selected, ifrequired.(The maximum possible turns/stroke are indicated on the order-relatedtechnical data sheet for the actuator).

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9.10. Switch compartment: close

1. Clean sealing faces of housing and cover.2. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.3. Check whether O-ring (3) is in good condition, insert O-ring correctly.

4. Place cover (1) on switch compartment.5. Fasten screws (2) evenly crosswise.

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Danger of corrosion due to damage to paint finish!

Touch up damage to paint finish after work on the device.

NOTICE

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10. Corrective action

10.1. Faults during commissioning

10.1.1 Mechanical position indicator

Fault description Mechanical position indicator cannot be set.

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

Remedy Replace reduction gearing.

10.1.2 Position transmitter RWG

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

Possible cause Incorrect reduction gearing (turns/stroke).

Remedy Check reduction gearing selected. (The max. possible turns/stroke are indi-

cated on the order-related technical data sheet for the actuator.)

10.1.3 Limit and torque switches

Fault description Switch does not trip.

Possible cause Switch is defective or switch setting is incorrect.

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

The red test buttons (1) and (2) are used for manual operation of the limitswitches: Turn test button (1) in direction of the TSC arrow:

Torque switch CLOSED trips.The indication light torque fault OPEN on the local controls is illumi-nated.

Press push button OPEN to reset the fault (red indication light) by oper-

ating the device in the opposite direction. Turn test button (2) in direction of the TSO arrow:

Torque switch OPEN trips.The indication light torque fault CLOSE on the local controls is illumi-nated.

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

Information If the actuator is equipped with a DUO limit switching (option), the intermedi-ate position switches will be operated at the same time. Turn test button (1) in direction of the LSC arrow:

Limit switch CLOSED trips. Turn test button (2) in direction of the LSO arrow:

Limit switch OPEN trips.

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Figure 32

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10.2. Fault indications and warning indications

Faults interrupt or prevent the electrical actuator operation.Warnings have no influence on the electrical actuator operation. They onlyserve for information purposes.

Fault and warning indications are shown on the display.

10.2.1 Status display S0 - faults and warnings

Line 4 of status indicationS0 shows faults and warnings.

Description of the fault indications:

FAULT IND.

A fault has occurred For further information, press and go to status indicationS1.

WARNING IND.

A warning has occurred For further information, press and go to status indicationS2.

FAULT + WARNING

Faults as well as warnings have occurred.

For further information, press

and go to status indicationsS1

(faults) orS2 (warnings).

NOT READY IND.

The actuator cannot be operated from REMOTE. The actuator can only beoperated via the local controls. For further information, press and go to status indicationS3

(cause for fault indications).

FLT + NR

Faults and theNOT READY IND. signal have occurred. For further information, press and go to status indications S1 or S3.

WRN + NR

Faults and theNOT READY IND. signal have occurred. For further information, press and go to status indications S2 or S3.

FLT + WRN + NR

Faults, warnings, and theNOT READY IND. signal have occurred. For further information, press and go to status indications S1 to S3.

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LOCAL MODE S0

OPEN

E2 100%

FAULT IND.

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


NO FAULT

No fault has occurred.

INTERNAL FAULT

Internal fault has occurred.For further information:1. Go to groupD0: Press C and hold it down until diagnostic indicationD0

is displayed.

2. Go to diagnostic indicationD2: Press twice.

TORQUE FAULT (CLOSE)

Torque fault in direction CLOSE. Operation command in direction OPEN, or Set selector switch to position Local control (LOCAL) and reset fault

indication via Reset push button, or Issue reset command via fieldbus.

TORQUE FAULT (OPEN)

Torque fault in direction OPEN Operation command in direction CLOSE, or Set selector switch to position Local control (LOCAL) and reset fault

indication via Reset push button, or Issue reset command via fieldbus.

LOSS OF PHASE

One phase is missing. Test/connect phases.

THERMAL FAULT

Motor protection tripped. Wait for cooling off.

If the fault indication display persists after cooling off:Set selector switch to position Local control (LOCAL) and reset faultindication via Reset push button, or

Issue reset command via fieldbus. Check fuse F4.

CONFIGURATION FAULT

The controls configuration is incorrect.For further information:1. Go to groupD0: Press C and hold it down until diagnostic indicationD0

is displayed.2. Go to diagnostic indicationD4: Press four times.

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FAULT IND. S1

NO FAULT

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

Description of the warnings:

NO WARNING

No warnings have occurred.

WARNING OPER.TIME

The preset running time for a travel between end position OPEN and endposition CLOSED has been exceeded. Set the running time (MONITOR TRIGGERS parameter) in accordance

with the actual running time.

Check tripping behaviour of end position switches. Check actuator mechanics.

WARNING STARTS/RUN

The preset values for max. starts/h or max. running time/h have beenexceeded. Check modulating behaviour. Increase dead time. Reduce number of nominal value changes.

INTERNAL FEEDBACK

Position transmitter is not standardised. Operate actuator into both end positions (OPEN and CLOSED).

INTERNAL WARNING

Internal warnings have occurred.For further information:1. Go to groupD0: PressC and hold it down until diagnostic indicationD0

is displayed.2. Go to diagnostic indicationD3: Press three times.

FEEDBACK E2 LOSS

Signal loss of position transmitter. Check position transmitter signal.1. Go to groupD0: PressC and hold it down until diagnostic indicationD0

is displayed.2. Go to diagnostic indicationD7,D8, orD9: Press either seven, eight,

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

gram.

SETPOINT E1 LOSS

Signal loss of the set point. Check wiring.

TORQUE E6 LOSS

Signal loss of torque source.

Check wiring.

I/O1 ANALOG IN1 LOSS

Loss of signal of the analogue input 1 of the parallel interface (only forfieldbus/standard interface combinations).

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WARNING IND. S2

NO WARNING

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Check wiring.

I/O1 ANALOG IN2 LOSS

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

P-FEEDBACK E4 LOSS

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

FIBER OPTIC LOSS

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

ANALOG IN1 BUS1 LOSS

Signal loss of analogue input 1. Check wiring.

ANALOG IN2 BUS1 LOSS

Signal loss of analogue input 2. Check wiring.

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10.2.4 Status indication S3 - causes for not ready remoteThe causes for theNOT READY IND. fault signals (status indicationS0)are indicated within this group.


READY

Actuator can be operated from REMOTE.

NOT REMOTE

Actuator cannot be operated from REMOTE as the selector switch is inposition LOCAL or OFF (0).

WRONG COMMANDIndicates that inadmissible operation commands have been received viaFoundation Fieldbus.

EMERGENCY MODE

The EMERGENCY operation mode is active.

EXTERNAL CONTROLS

For combination fieldbus/standard interface function:Operation via parallel interface.

EMCY STOP ACTIVE

The EMERGENCY STOP button has been operated.

ACTUATOR LOCKED

Actuator locked (only set for special applications e.g. for by-pass function).

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NOT READY IND. S3

READY

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10.3. Fuses

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

F1/F2 Primary fuses on power supply unit

F3 Internal 24 V DC supplyF4 Internal 24 V AC supply (115 V AC) for:

.

Heater, switch compartment, reversing contactors control,. PTC tripping device. for 115 V AC also control inputs OPEN - STOP - CLOSE

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

Screw cover back on again after fuse replacement.

61


Figure 33

Hazardous voltage!

Electric shock possible.


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

Size 6.3 x 32 mm

Reversing contactors

Voltage supply 500 V1 A T; 500 V K002.277

Reversing contactors

Voltage supply 500 V2 A FF; 660 V K002.665

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

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

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

Table 11

1 Rear cover 2 Electrical connection

DANGER

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

Size 5 x 20 mm 5 x 20 mm

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

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

Table 12

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11. Servicing and maintenance

Service AUMA offers extensive service such as maintenance and inspection as wellas customer product training. For the relevant contact addresses, pleaserefer to page 78 et seqq. and on the Internet (www.auma.com).

11.1. Preventive measures for servicing and safe operation

The following measures are required to ensure safe device operation:

Every 6 months after commissioning

.

Carry out visual inspection: For electrical devices: cable entries, cable glands, screw plugs, etc.

have to be checked for correct tightness and sealing.Consider torques according to manufacturers details.

. If rarely operated: perform test run.

. For devices with output drive A, press in Lithium soap EP multi-purposegrease on mineral oil base at the grease nipple with the grease gun(quantities see 15, table 4). This procedure does not grease the valvestem. Lubrication of the valve stem must be done separately.

6 months after commissioning and then once a yearCheck screws between multi-turn actuator and valve for tightness. Ifrequired, tighten by applying the torques given in table 2, page 14.

For enclosure protection IP 68 (option)After submersion:. Check multi-turn actuator.. In case of ingress of water, dry device correctly and check for proper

function.

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1 Output drive type A 2 Grease nipple

Figure 34

Damage caused by inappropriate maintenance!

Servicing and maintenance tasks must be carried out exclusively by suit-

ably qualified personnel authorised by the end user or contractor of theplant only. Only perform servicing and maintenance tasks when the device is

switched off.

CAUTION

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11.2. Maintenance

Maintenance intervals . Refer to lubricant change.

Lubricant change . In the factory, the gear housing is filled with

ba sar1!07!16 ac1 ffbus en

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