ELWA OPERATING INSTRUCTIONS eden 8.96 in connection with the EVM-2 Viscosimeter “| for controlling a heat exchanger _— and an electric motor control valve TYPE: DUR 3.7-V_D-V_ SerialNo: _ - ELWA ELEKTRO-WARME-MUNCHEN A HILPOLTSTEINER GMBH & CO.KG 80674 MUNCHEN POSTFACH 210465 TELEFON ((89) $46778.0 TELEFAX (089) $546775-10 LANDSBERGER STRASSE 367.369 80687 MONCHEN.Page 2/13 | ELWA DESCRIPTION A24-10088-Ble VISCOSITY CONTROLLER "DUR" $8.96 Important hints on Safery! /Make sure to read and follow. It isa prerequisite for an impeccable and safe operation of the Viscosity Controller that it is correctly transported and stored, insalied and commissioned. adequately operated and carefully maintained. ]Only persons who are conversant with the installation, commissioning, operation and maintenance of similar equipment are allowed on the unit, who are suficiently qualified with regard to their activity. The following should be noted in particular: =the contents of the operating manuel, the safety regulations affixed on the unit itself the pertinent safety regularions for installation and operation of electrical plants, + the pertinent safety regulations for controllers duly authorise for technical use. ‘The regulations, standards and guidelines mentioned in this Instruction Manual re valid in the European Community If the unit is used in other countries, the national standards, or when used in ships the standards of the relative Classification Society should be observed. The Viscosity Controlier has been designed according to DIN VDE 0411, Part 1, the Low-Tension Guideline and the | EMVG Guideline, and has left our works in an irapeccable condition with regard to technical safety. In order to maintain this condition and ensure safe operation, the instructions contained in this manual should be heeded. ‘Otherwise, persons might be endangered and other units or equipment be damaged j [f the information contained in this manual is considered tobe insufficient, please contac the manufacturer's address. | Table of contents Description 2.3 Installation and connection 4.6 Operation 7.9 Error messages 10 Maintenance n Electrical diagram 13 Spare parts 14 Technical data Dimensions 144x192 mm Control range 5..30 mm/s Installation depth 230 mm Measuring range —_0...30 mm*/s Weight 2kg Value input 4...20 mA, Re=50 Q Protection IP 54, front Position feedback — 100...1000. 2 Fitting position any Relay output 1 center-zero relay, free from potemtial 250 V, 0.5 A, cos 2.0.7 Ambient temp 0...55°C Suppiy voltage BOVAC +10% Storage temp. -28..65°C 47.63 Hz rel. gir humidity —-<75% annual average 95% short-term Mech, load 30g/1 ims DIN IEC 68 EMV TEC 801/DIN VDE 0843 Electr. safety DIN/VDE 0411 prot, class 1Page 3/13 ELW A DESCRIPTION A24-10088-Ble VISCOSITY CONTROLLER "DUR" 8.96 The "Viscotronic" controller (I) serves to display and control the heavy oil viscosity in connection with a heat exchanger (4) heated by steam, hot water or thermal oil. The control system is supplied with current value data from a viscosimeter type EVM-2 (2) and then sends controlling instructions to an electrical two- or three-way control valve (3) The controller is installed in a built-in housing with a control pane] and should be electrically connected to the viscosimeter and the control valve without the need of any components. The control system is completely equipped with a digital controller, a digital display for process date, a switch system for manual and automatic operation, the error message for the motor of the viscosimeter, the min /max. viscosity alarm and the supply and protection of the viscosimeter. The following additional equipment is available: Temperature control with a Pt 100 feeler Analog value output ‘am of the controller 1) *Viscotronic" controller 2) Viscosimeter type EVM-2 3) Control valve 4) Heat exchangerPage 4/13 E LWA INSTALLATION AND CONNECTION A24-10088-Ble | VISCOSITY CONTROLLER "DUR" 8.96 Selection of the place of installation The place of installation should be so selected that the values stated in the Technical Data regarding the climatic and mechanical loads are not exceeded. Installation of the uni The controller can be fitted into a control panel. Protection class IP 54 is ensured by the housing. Push the unit from the front side into the cutout provided in the panel. (see dimensional diagram). ‘The unit is secured by means of mounting clamps to be fastened from the rear side. iemen = mw Serotttaieleussennitt Sulout for Ine maeroting pane Installation of the wiring Electrical connections for the unit to be made in accordance with the connection diagram. Make sure to to provide the connection between the ground wire (PE) and a suitable grounding prior to any other connection. Observe the pertinent regulations for making high-voltage installations with a rated voltage of up to 1000 V (DIN $7100 / VDE 0100) and corresponding local regulations, when selecting the wiring material and for the installation as such. Energy supply Connections for energy supply should conform to connection diagrams and terminal assignment patterns on the rear of the unit. For that purpose, observe the regulations for making high-voltage installations with a rated voltage of up to 1000 V and corresponding local regulations The supply voltage must agree with the values stated on the signplate. Please note: A suitable protective grounding or bonding will ensure faultless operation of the unit,f Page S/13 | ELVA | BSTALLATION ANDCONNECTION | a24.10086-B1¢ VISCOSITY CONTROLLER "DUR" a l Terminal diagram ¢ esos | Buia ose L tetosnaging | re 6 Rusgera [F Seley twig + ; oe 3 } fag vim tet / 3 Guia vise mDtor 3 WSL Reeisesgre 2 | — ICR Eras s $ oa Retoy ouibet 2 yt Oat gu : s ' g 2 Rt Resporg * as i 58 ' b ait: mea é abe | tonnes 2 | ms ; Bee eee serra PR EA6 | Ee Liens ai eins irgul t peat ieee out i a nha Sah Se Leet mains TBE Bie acer ‘VF i ‘ i 1 Raxinasilieg 1 areca Pe Relay output TF small inductive loads are switched, the quenching element installed will be sufficient. For higher inductivities, an RC quenching combination is recommended externally parallel to the load, to extend the service life of the relay switching contacts. 2.. 4 uFIA, electric strength >250V (effective), series resistor 100 © with adequate loadability. Analog signals Measuring lines and signal ines should be run separately from lines which might carry interference voltages (mains line, connection lines for contactors, motors, etc.). Lines twisted in pairs should be preferably used, taking into account separate running. Pairwise twisting will minimise the involvement and transmission of interferences. Running the there-wire separately from the back-wire of a signal circuit is inadmissible. Please note: In an environment where interferences prevail, use pairwise twisted and screened wiring, Connection of the cable screen The screening should be connected in the vicinity of cable ends with a low-impedance ground for high frequency (cubicle in the immediate vicinity of the unit). For that purpose, strip the insulation of the cable for the length of a metallic cable sleeve and connect the bare screening generously by means of the cable sleeve to the switch cabinet or # neighbouring metal surface, Any wire connection instead of the metallic cable sleeve should be avoided between the screening and HF-ground Resistor thermometer Line balancing occurs automatically with the four-conductor circuit. This circuit comprises a measuring and a wiring circuit. Please note: When making the installation, make sure that the wiring in the measuring circuit and in the wiring circuit are run symmetrically. Also, wiring material should be of same condition and idemtical cross-section.Page 6/13 E LWA | INSTALLATION AND CONNECTION, A24-10088-Ble VISCOSITY CONTROLLER "DUR" 8.96 Analog value output Connection for the electrically separated analog output has a max, load of 14 V DC. The burden resistance for the analog outpi must not exceed 700 O max. Connection diagram for vis Aree td OOM WOT Mem: scesmenetts 1) Ereigope Forserpunoe Enable Feeopurp Net ze rngeng wut Stet lentil Control valve ‘onnection diagram for viscosity and temperature control DUR 11.1 VID. Me Eb 505085 4. 20 ‘een 230y Severe ost wwe a Zorro! votePage 7/13 ELW A OPERATION A24-10088-Ble VISCOSITY CONTROLLER "DUR" 8.96 Display and operating elements on the front side: visc-retan A) ON/OFF switch B) _ Protective motor switch ©) Circuit breaker "Controller" D)___ Digital controller 1) Display change-over switch 2+3) —Plus/minus keys for set values and limit values Grenzwerte 4) Set value change-over switch viscos. temp. (additional equipment) 5) Upper display for actual value, pickup of variables, error message 6) Change-over switch manual-automatic 7+8) —Plus/minus keys for manual contro! 9) Lower display for set values and values of variables 10) _LED indicator for control output and alarm messages 11) _ Status display for major variables After switching the operating swich (A) on, the "Viscotronic” controller is ready for operation. The relative signal lamp lights up and the alarm message is activated. The protective switch (B) for the viscosity motor can always remain on. In case of cutout due to overload or short cicuit, the signal lamp extinguishes and the viscosity min. alarm is triggered. The circuit breaker ( C) serves to protect the digital controller (G).Page 8/13, E LW A OPERATION A24-10088-Ble VISCOSITY CONTROLLER "DUR" 8.95 Display and setting options ‘A number of process variables can be shown on the display and called with the display switch P; refer to the table below. a 2 n 4 1 Sore Display loop for Viscosity Key Display Setting at] Remark i 5 (top) 9 (bottom) i works > [Act valu 0,.30 mmils | Actual value -150.7200°C_] w | 12 mn% | Normal position™> = G_| Act value 0...30 mm/s Rated value 5...30_ mum*/s w_| 12 mm*s | Normal position TO [Act value 0...30 mm?/s Repetitive error % e = 710 TAct value 0..30 mm/s Valve position % y= FF [G11 max limit value 60.,.+60 mm/s [14 mms [G21 nin. limit value 60,60 mms = [Ho mms 70 |Pb Proportional range 0.1850 Ye 30% TO [m Resetting time 0...1999 % 120s 73 [ed Rate time 0.1999 % = [35s 5H Dead zone 0.5...10 % = 1% FF [ Ca Vaive zero point 199, +199 % =| 2% <8 | Bs Valve final value =199,..+199 % 87% Display loop for Temperature (additional equipment) Key Display ‘Sefting at] Remark 1 5 (09) 9 (bottom) 11_| works => DF __| Act value 0...200 mm*/s Actual value 5...30°C Ww = Normal position = [Act value 0.200 mm’/s | Rated value -150.+200°C | w_| = FO [Act value 0.200 mm/s Repetitive error % ea iemes TO [Act value 0,200 mists ‘Valve position % yt 11 |Pb1 Proportional range 0.1850 % = [| 0% t 5 [tnt Resetting time 0...1999 % = 120s FO ftdt Rate time, 0...1999 % = 255 5 [Hi Dead zone 0.3...10 % = 1% TICs Valve zero point 7199, #199 % = [24% “=F _[ Bs Valve final value 199.199 % = | 87% + only with additional equipment for Temp. ControlPage 9/13 OPERATION E LW. A VISCOSITY CONTROLLER "DUR" ee 3.95 The set value (w), both limit values G11 and G21, as well as control parameters Pb, tn and td can be adjusted with keys * and * Any violation of a limit value is shown on display 10. Set value justment After selecting the status "w" on the display, by actuating key P, the set value can be adjusted by means of keys * and ~ Key IE serves to switch to the temperature control channel. This change-over is only possible with additional equipment -VTD - An LED for E appears for the viscosity set value. An LED for I appears for the temperature set value. The change-over covers both the display field and the block of parameters. Change-over between the channels occurs smoothly in either direction ie. the control output is taken over. Display of the valve position Control display 10 is @ tendency display. if an accurate reading is required, the valve position can be set to display 9 by mans of key P. Status display *y” Adaptation to the setting range: Balancing to 0% and 100% is made after calling the variables e4 and bé on the display loop. At first, the control valve is set successively to both final positions and the value "y" read off the display for both positions. This permits to calculate c4 and b4 from the values thus obtained. 04 =-Yaines; b4 = 10000/Y ope ~ Yoint Mode of operation selector automatic/manual Selection of mods of operation is automatic and smoothly in both directions by actuating key HLA. ‘As soon as the relative LED for A or H stops flashing, the new mode is operative Manual mode . he output signal can always be reset, provided the unit is in the “manual” mode. By pressing the keys ¥ or “, the output signal for the setting valve changes in the direction of "cooling" or "heating". ‘The current valve position appears on display 9.Page 10/13 E LWA ERROR MESSAGE A24-10088-Ble VICOSITY-CONTROLLER "DUR" 8.96 Message from the self-monitoring svstem Er.AE Er.bA. Er.LP Er. Er.HP Er.00 Error Protected Configuration In case of a fault, the original setting is reloaded automaticaly, 1M The optical error message "ER.AE” on the display can be acknowledged by simultaneous actuation of keys Y + *. Keep keys depressed for approx. 3 s, to obtain an improved electromagnetic compatibility and a better protection from unauthorized intervention. Error Battery With this display, the unit remains operative, but the battery should be changed before a mains failure occurs. Error Low Power If the unit is supplied with undervoltage under the admis is stopped. le tolerance, the handling Error Hardware Monitoring Ifa serious error occurs in digital processing, the unit displays "Er.H_". A repair is required Error Auxiliary processor Errors of the auxiliary processor are displayed by the message "Er. HP" A repair is required, Error Software Monitoring Ifthe controller detects faulty handling for several times, it will first try to restart the program by reset. Ifit fails, the last input will be reloaded from the EPROM. The controller displays "Er.00" and tums to the "manual" mode This message is acknowledged with key P. Error Self-Parametrization ‘The message "Er. St" indicates that self-parametrization has been aborted without success, This message is acknowledged with key P.| Page 11/13 ELWA MAINTENANCE A24-10088-Ble VISCOSITY CONTROLLER "DUR" 8.96 General The unit requires no maintenance, except for a replacement of spent batteries. The relays are subject to wear, according to the magnitude of the switched load and the switching frequency. Battery change The module is to be removed from the housing for changing the buffer battery Bal Before opening the unit, it is required to switch the control system off; this also applies to the supply voltage for external users connected to the alarm systems. Loosen both screw plugs $1+S2 for opening the module housing, The module can be pulled out by means of screw plug S1 which also serves as a handle The spent battery Bal can be unsoldered and replaced by a new battery. It has 3 soldering connections serving as reverse protection Please note: As the circuits are provided with C-Mos components, the printed circuit boards should be protected from electrostatic charging when being handled. Spare battery (lithium) 3 - 170mAh Type Varta CR 2032 SLF Push the module with a soft pressure against the spring bar. Then secure it by means of both screw plugs $1+S2 Changing the battery causes the RAM to be erased. When the supply voltage has been switched on, an automatic reinitialization ocoursPage 12/13 ELW A MAINTENANCE A24-10088-Ble | VISCOSITY CONTROLLER "DUR" 8.96 | J Electrical diagramELWA SPARE PARTS VISCOSITY CONTROLLER "DUR" | Page 13/13 A24-10088-Ble 8.96 To enable us to supply correct.spare parts, please always state the serial number along with the accurate spare part designation. The serial number is located on the signplate of the machine ‘Viscosity Controller DUR 3.1-VOD-V 077998 [Digital controller Digitric P 61411-0-4699990 with input 4-20 mA BA 310/400 078099 [Input module current 4-20 mA 61419-4-0344051 078112 | Output module 2xcurrent 4-20 mA 61419-4-0344054 078111 [Relay board 4 relays general application |61419-4-0344032 088115 | Overload cutout switch "POWER" 3120-F351-P7T1-W19AL4-24 (088120 | Overload cutout switch "VISC-MOTOR" 3120-F3SF-P7T1-SGRXLA-0.5A 088110 | Overload cutout switch "FUSE 80mA* 105-P30-0.08 A. 103050 | Voltage supply 230 VAC / +12 VDC 24K 2574 (078618 | Spare battery Bal VARTA CR 2032 SLF ‘Viscosity/Temperature Controller DUR 11.1-VID-V. 077998 | Digital controller Digitric P 61411-0-4699990 with input 4-20 mA BA 310/400 078099 | Input module current 4-20 mA 61419-4-0344051 (078112 | Output module 2xcurrent 4-20 mA 61419-4-0344054 (078102 | Input module Pr 100, 4 wires 61419-4-0344238 078111 [Relay board 4 relays general application |61419-4-0344032 ‘088115 | Overload cutout switch "POWER" 3120-F351-P7T1-WI9AL42A, 088120 | Overload cutout switch "VISC-MOTOR™ 3120-F3SF-P7T1-SGRXL4-0.5A 088110 | Overioad cutout switch "FUSE 80mA" 105-P30-0,08 A 103050 | Voltage supply 230 VAC / #12 VDC 24 K 2374 078618 | Spare battery Bal VARTA CR 2032 SLF ‘Additional equipment for analog output Viscosity 078618 [DC buffer amplifier 0-20 mA / 0-20 mA 3829MH,<@> ARMATUREN Operating and Installation Instructions Straightway Control Valves BR440-446 ‘Contents 1.0 General Information on Operating Instructions..1 6.0 Notes on Dangers During Installation, Operation 2.0 Notes on Possible Dangers and Maintenance... 21. Significance of Symbols... 1 7.0 Putting the Valve into Operatior 22. Safety-Related Definitions ...unesmonsenne | 8.0 Care and Maintenance... 23, Qualified Personnel 8.1 Stem Packings / Assembly. 2 82. Packings with Chevron Types 2 83. Stuffing Box Packings.. 2 84 Bellows Seal... 8.5. Replacing the Plug, Stem and Seating... saved 9.0 Troubleshooting 2 10.0 Troubleshooting Table.. 3.3. Handling Before Installation. 4.0 Description 4.1 Scope of Applications. 4.2. Operating Principle 43° Diagram / Plug Designs... 5.0 Installation 5.1 General Notes on Installation... 5.2. Requirements at the Place of Instalatir 5.3. Installation instructions Concerning Actuators... 0040000053 0498 englischARMATUREN Operating and Installation Instructions Control Valves BR440-446 1.0 General Information on Operating Instructions ‘These operating instructions contain information necessary to install and operate the valve both safely and effectively. If problems arise which cannot be solved with the aid of these operating instructions, please contact the supplier/manufacturer for further information. These operating instructions comply with applicable EN safety standards as well as regulatiOns and codes of practice applicable in the Federal Republic of Germany. If the valve is used outside the Federal Republic of Germany, the operator or the person responsible for the system design must ensure that valid national codes of practice are complied with. ‘The manufacturer reserves all rights to implement technical modifications and improvements at any time. The use of these operating instructions assumes the user is qualified as described under Section 2.3, Qualified Personnel!’ ‘The operating personnel must be instructed in accordance with the operating instructions, 2.0 Notes on Possible Dangers 2.1 Significance of Symbols ZN ‘Warning of general danger 2.2 Safety-Related Definitions ‘The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating instructions as indications for particular hazards or for important information requiring special signs DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or considerable damage to property can occur. WARNING means that if the relevant information is disregarded, there is a danger of serious injury and / or damage to property can occur, CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or damage to property can occur. NOTE means that particular attention must be paid to certain technical aspects. All other information not specifically emphasised such as transport, installation, operating and maintenance instructions as well as technical data (in the operating instructions, product documentation and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to persons or damage to property. 2.3 Qualified Personnel The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-up, operation and maintenance of the product and have the qualifications corresponding to their responsibilities such as: Instruction and obligation to comply with all operational, regional and in-company regulations and requirements; ‘Training or instruction in accordance with safety technology standards with regard to the upkeep and use of appropriate safety and work protection equipment; First aid training, ete (see TRB 700). age | ‘0040000053 0498Uperaung anu snstauauon Lsirucuons Control Valves BR440-446 Apes ee CCE 3.0 Handling 3.1 Storage _ Storage temperature -20" to +65°C dry, free of dirt The painting is only a primer, intending to guard against rust during stock or transportation, Don't damage the paintwork. 5 - A desiccant or heating to prevent condensation is necessary in damp rooms. 3.2. Transport = Transport temperature -20° to +65°C. - Protect against extemal force (impact, vibration etc.). - Don't damage the paintwork. 3.3 Handling Before Installation If lange covers are fitted, remove shortly before maintenance! - Protect against atmospheric conditions e.g. wetness (applicate a desiccant). - Correct handling protects against damage. 4.0 Description 4.1 Scope of Applications These control valves are suitable for controlling the flow of liquids, gases and vapours in chemical and other processing plants and for plant engineering. ‘The materials have been selected and matched on the basis of current DIN, AD, TRD and UVV rules. ‘The mechanical and flow characteristics conform to standard DIN EN 60534. ‘The engineer planning a plant is responsible for selecting the correct valve for a given application. The special features of the valve concemed must be taken into account. 4.2 Operating Principles sRI control valves are especially suitable for actuation by pneumatic or electrical actuators. Three plug types are available to suit the various applications: parabolic plug (standard pattern) perforated plug : V-port plug The flow through control valves with parabolic and V-port plugs is always against the closing direction. In the case of control valves with perforated plugs, gases and vapours flow against the closing directions, but liquids flow through in the closing direction. If a pneumatic actuator is to be used on a straight-way valve with a perforated plug with the fluid moving in the closing direction, a higher closing force will be needed. This is f prevent vibration as the plug approaches the closed position. : : Pressure-balanced plugs can be provided if the actuator force is inadequate, ‘0040000053 0498 page 2Uper dung aHU dustanauUn Lust UeuUES Control Valves BR440-446 43 Diagram / Plug Designs al DLLITIT OIL Lb pe EV} i fig. L: Fig. ..440 standard design fig. 2: Fig. ..441 standard design fig. 3: Design with perforated plug fig. 4: Design with V-port plug page 3 0040000053 0498Man Angee A9LL Ue LULL Control Valves BR440-446 5.0 Installation 5,1 General Notes on Installation ‘The following points should be taken into account besides the general principles governing installation work: _ Remove flange covers if present. - There must be no foreign bodies inside the valve or piping. Pay attention to the direction of flow: see markings on the valve and refer to the operation and installation instructions (point 4.2). = Centre sealings between the flanges. = Connection flanges must mate exactly. « Ifthe valve is handling steam, the piping must be laid with a gradient to prevent water from accumulating in pockets. Condensation traps are needed to prevent water-hammer, - All parts must be free from stress after installation, - The valve must not serve as a fixed point. It must be carried by the piping. * protect the valve from dirt, especially during construction work. - Install compensators to compensate for thermal'expansion of the piping. - Keep the thread and shaft of the stem free from paint. 5.2 Requirements at the Place of Installation “ ~ The place of installation should be easily accessible and provide ample space for maintenance and removing the actuator. The valve should preferably installed vertically with the actuator atthe top. Inclined or horizontal installation without supports is permissible only with light actuators. Permissible servo weights for valves with unsupported horizontal stems: 20 kg for DN 15 - 32 25 kg for DN 40 - 65 35 kg for DN 80 - 100 ‘The pipes must be lagged to protect the actuators from excessive heat. Sufficient space must be left for the maintenance of the stem packing. To ensure that the control valves function correctly, the pipe run should be straight for atleast 2.x DN upstream and 6 x DN downstream of the valve 5.3 Installation Instructions Concerning Actuators Normally, control valves are supplied complete with actuator fired. It is not permitted to mantle / dismantle actuators with valves operating and service conditions (temperature and pressure) (see 2.3). The actuators must be assemble as describe in the operating instructions during conversion and maintenance. During assembly work, the plug is not be turned on its seating at closing pressure. When retrofitting actuators, the maximum permissible force for valve actuation must be taken into account. ~ ‘The maximum permissible actuation forces are: ‘ Fig. 440 / 445 Fig. 441/446 12 KN for DN 15 - 50 18 KN for DN 15 - 100 29 KN for DN 65 - 100 (0040000053 0498, page 4Control Valves BR440-446 0 Notes on Dangers During Installation, Operation and Maintenance ZXcasoen ! Operation can be completely safe only if the valve is properly installed, put into operation and maintained by trained personnel (cf. point 2.3 “Qualified personnel") paying full attention to the warnings in these operating instructions, In addition, the general installation and safety rules for piping and plant installation must be observed, and appropriate tools and safety equipment are to be used, Strict attention must be paid to the operating instructions during all work on the valve and when handling it. Injury or damage can be caused by ignoring them. 7.0 Putting the Valve into Operation ~ Before putting the valve into operation, check that the material, pressure, temperature and direction of flow are as specified with the plans of the piping system. - Regard the TRB 700. i - Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage. 7 DANGER ! Before putting a new plant into operation or restarting a plant after repairs or modification, always mi} sure that: Ee ~ all installation and assembly work has been completed! - only qualfied personnel (see point 2.3) are employed to start the plant! - the valve is in the correct position for its function! - existing guards have been attached and in good order. 8.0 Care and Maintenance Maintenance and maintenanceintervals have to be defined by the operator according to the service conditions (see TRB 700). 8.1 Stem Packings / Assembly fig. 5: Chevron type packing _fig. 6: Stuffing box sealing fig. 7: Bellows seal page 5 (0040000053 0498Sea 8.2 Packings with Chevron Types See Fig. 5 and 8 PTFE chevron type pack consisting of 1 backing ring 4 sealing rings | cover ring Owing to the installed compression'spring, this stem packing is self- adjusting. Ifthe stem starts leaking, the ring pack is worn out and must be replaced. Replacing PTFE chevron type packs: ‘Warning! See point 11.0 before dismantling the valve. - Remove the actuator (see operating instructions for actuator) ~ When replacing chevron type packs (12), make sure that the parts are installed in the correct order and positions (see Fig. on right) - Damaged stems must also be replaced (see point 8.5 for instructions) since a new ring pack will soon start leaking again with a damaged fl stem. - Attention! Gasket (17) must be replaced. 83 Stuffing Box Packings See Fig.6 and 10 fig. 8 ~ Stuffing box packings require maintenance. - If leaks develop, immediately tighten the sleeve screw (25) gradually ore until the packing stops leaking. nN on - The service life of stuffing box packings (24) can be increased by checking regularly leakage. ~ Hf leaks can no longer be stopped by tightening the nuts, a new packing ring must be inserted into the gland. Replacing a stuffing box packing: Warning! See point 11.0 before dismantling the valve. - Insert the new packing ring as shown in the Fig. on the right. fig. 9: Split packing ring “fig. 10 - Damaged stems must also be replaced (see point 8.5 for instructions) since a new ring pack will soon start leaking again with a damaged stem. (0040000053 0498 page 6Uperauny au we anauU 1124 UeuULD Control Valves BR440.446 8.4 Bellows Seal See Fig. 7 and 11 If the stem leaks, the bellows seal is defective. The leak can initially be stopped by tightening the sleeve screw (20.17). Replacing the bellows seal: Warning! See point 11.0 before dismantling the valve. - Remove the actuator (see operating instructions for actuator), - Slacken the sleeve screw (20.17) by about one tum. - Remove the bellows housing by unscrewing the nuts (11). - Remove the plug as described in point 8.5b. s - Detach the mounting bonnet (20.2) after unscrewing the nuts (20.8). - Extract the stem from the bellows housing. vacrzsz2 r PLLELIL: 1g. cu - Drill new stem with plug. - Replace 2 seals (20.6) and 1 seal (9). - When inserting the new bellows, make sure that the carrier is in the correct position. = Insert the grooved pin into the carrier, making sure that it runs with . Ss little friction. —_ ~ Assemble in the reverse order. Screw on the nuts (11, 20.8) | and tighten them crosswise (See page 9 for tightening torque‘s). oy (The stem can only be replaced complete with bellows.) A 85 Replacing the Plug, Stem and Seating aa ‘Warning! See point 11.0 before dismantling the valve. ~ Remove the actuator (see operating instructions for actuator) a) Control valves (cf, Fig, 1 and 12) - Detach the mounting bonnet (7). ~ Slacken sleeve screw (19) by about one turn. - Extract and replace the plug with stem, ~ Replace the gasket (9). - Set the mounting bonnet cover in place and secure it with nuts (11) tightened crosswise. (See page 9 for tightening torque‘s) (Plug and stem can only be replaced completely.) 7 0040000053 0498aa Control Valves BR440-446 b) Control Valves with Bellows Seal (cf. Fig, 2) - Unscrew the nuts (11) - Remove the bellows housing (20.1) with plug (2), Keep the stem pressed down, - Remove the clamping sleeve (4). - Unscrew the plug (2). - Fit the new plug in the reverse order. - Drill the plug and insert new pin. The stem can only be replaced complete with bellows (see point 8.4) c) Replacing the Seating Ring (only Fig. 55.445 and Fig. 55.446) ‘The seating ring is screwed into the valve body and can be unscrewed for replacement of remachining. ‘A special wrench is needed to remove the seating. It can be obtained from the manufacturer. When fitting a new or reconditioned seating, clean thread and sealing taper in body and apply suitable lubricant. See table below for seat ring tightening torque's. Tightening torque's DN 15/20 100 Nm rotated view = DN 25/32 150 Nm ere oo DN40/50 = 350.Nm \ ‘ “| DN 65 480 Nm PSH DN 80 660.Nm Hy ene i DN100 = 980 Nm fg. 13 (0040000053 0498 page 8<{> ARMATUREN Uperaung ana instauauen wnstrucuuas Control Valves BR440-446 4) = = Warning! See point 11.0 before dismantling the valve, - Detach valve top part and remove plug (replace if necessary) as described in point 8.5 a or b. ~ Prise wor piston seal (32) out of groove in plug with suitable tool (e.g. screwdriver), + Insert new piston seal, taking care that itis in the correct position (cf. Fig. 14). ~ Replace guide ring (31). fig. 14: Pressure-balanced plug ~ Clean sliding surface of guide bush (30); smooth with fine abrasive if necessary, - Before assembly, remember that two seals (9) must be replaced. - Set valve top part in place. - Tighten the hexagon nuts of the cover gradually crosswise. Tightening torque for hexagon nuts: Bolts Torque M10 20Nm Mi2 35.Nm M16 80 Nm erat for act wr install toi 9.0 Troubleshooting ) In the event of failures or malfunctions, check that the valve was assembled and installed as described ift these instructions. Regard the TRB 700. Compare the material, pressure, temperature and direction of flow with the information given in the plans of the piping system. Check also that the service conditions correspond to the data given on the data plate and the technical data. A DANGER ! It is essential that the safety regulations are observed when identifying faults! If malfunctions cannot be eliminate with the help of the followirtg troubleshooting table", the supplier ot manufacturer should be consulted. cage? 0040000053 0498Uperatng ana installation instructions Control Valves BR440-446 10.0 Troubleshooting Table Fault Possible cause Corrective measures No flow Valve closed (Open valve (using actuate, Flange covers not removed. Remove flange covers Tile How Valve not sufficiently open. ‘Open valve (using actuator. Dirt sieve clogged. Clean / replace sieve Relieve pressure firstt Piping system clogged. Check piping system, Valve plug slightly seized owing to solid din particles. Ks value of valve unsuitable it valve with higher Kvs value, Valve stem moves in jerks. | Stuffing box sealing too tight for valves __ | Slacken sleeve serew (25/20.17) slightly. with graphite packings). ‘Valve must nor star eakingt ‘Clean internals, smooth rough spots. See points 7.0 and 11.0! > Valve stem or plug eannor be moved. ‘Seating and plug clogged with dirt, expect ally with V-port and perforated plugs. (Clean seating and plug with suitable sol- vent. See points 7.0 and 11.0! Valve plug seized in seating or guide owing ‘0 deposits or dirt in medium. TReplace plug and seating; use paris made from different material if necessary. B Valve stem leaking. ‘Chevron type pack damaged or worn, Tn valves with packed stufing boxes, dghten sleeve nut (25). Replace ring pack - see point 82 See points 7.0 and 11.0! Tighten sleeve screw (25); replace packing if necessary. See point 8.3. See points 7.0 and 11.0! Bellows defective in valves with bellows seal Replace Gellows unit see point 84 See points 7.0 and 11.01 ‘Leakage too high when valve is closed. ‘Sealing surfaces of plug eroded or worn Replace plug - see point 85. See points 7.0 and 11.0! Preumatic actuator not completely vented, spring force not fully effective. "Actuator not powerful enough. ‘Sealing edge of seating damages or worn, | Replace seating (see point 8.5), (only Fig, ..445/446) See points 7.0 and 11.01 Piston sealing ring worn (pressure-balanced | Replace sealing ring valves). See points 7.0 and 11.01 ‘Seating andor plug diny. ‘Clean internals of valve. See points 7.0 and 11.0 ‘Vent actuator ar chamber completely. See points 7.0 and 11.01 Tnstall more powerful actuator. Check ser- vice data Caution: - Read point 11.0 prior to dismantling and repair work! - Read point 7.0 before restarting the plant! PRBBR PRD BD > ‘0040000053 0498 page 10ARMATUREN Operating and Installation Instructions Thrust Actuator ARI-PREMIO a2 TT) Contents 1.0 General Information on Operating 6.3.2 Mounting for valve lift over 30mm to 50mm, Instrwetions seme wl (Column Version) cannes HL 2.0 Notes on Possible Danger eunminennnnenmerl 64 Electrical Connection. aaa 644.1 Circuit Diagram 12 faba rrinhiere 6.4.2 Connection. B 2.2 Safety-Related Definitions: seer 2.3 Qualified Personnel...... 3.0 landing manne 3.1 Storage 3.2. Transport nnn 33 Handling Before lnstalation 4.0 Description... 4.1 Field of Application........ 65. Senings . 4 6.511 Torque ani Standard Feature... 6.5.2 Connection PC-Boards PA oF NA. ns 14 655.3 Stoke Switch. lS 653.1 Insulation of Additonal Suoke Switches.-15 653.2 Setng of Standard Soke Switch (S2).00017 65.3.3 Setting the additional stroke switches a (S485 and 524825) 14 18 6.5.4 Potentiometers a 18 ee ae 6.54.1 Installing the Potensiomeer 19 foetal Dalal 6.5.42 Setting the potentiometer. secon 44 Diagram... 65.5 Heating, 7 : 4S. Parts List 65.5.1 Installation of heating. 7 46 Dimensions . 6.5.6 Electronic Postion Indicator RI2i a) 65.7 Electronic Position Controller ESU woo 23 5.0 Notes on Dangers During Installation, Operation and Maintenance _u§ 7.0 Starting Up werner rg 80 Care and Maintenance enon 6.0 Installation. 6.1. General Installation Data... 3 9.0 Troubleshooting nuns 62. Manval Operation. 9 10.0 Troubleshooting table on 63 Insalation insructions for Mounting 11.0 Dismantlement of Thrust Actuator sone 25 0 Valves... v 10 12.0 Warranty anu eg bier rleitup on 19 13.0 EC declaration of conformity sunnene27 0040000107 3697 englischOperating and Installation Instructions Thrust actuator ARI-PREMIO 1.0 General Information on Operating Instructions ‘These operating instructions contain information necessary to install and operate the thrust actuator both safely and effectively. If problems arise which cannot be solved with the aid of these operating instructions, please contact the supplier/manufacturer for further information. These operating instructions comply with applicable EN safety standards as well as regulations and codes of practice applicable in the Federal Republic of Germany. If the electronic positioner is used outside the Federal Republic of Germany, the operator or the person responsible for the system design must ensure that valid national codes of practice are complied with. The manufacturer reserves all rights to implement technical modifications and improvements at any time. The use of these operating instructions assumes the user is qualified as described under Section 2.3 "Qualified Personnel". The operating personnel must be instructed in accordance with the operating instructions. 2.0 Notes on Possible Dangers 2.1 Significance of Symbols ZL waning of general danger Ay Warning of dangerous voltage Exposed to injury! Don't fouch the turning handwheel when the motor is running Exposed to injury! Don't put your hand into the up Gr downwards moving appliance Danger when not observing the operating and installation instructions! Before installing, operating, maintenance or dismantling read and observe the instructions Danger though voltage! Before dismantling the hood, switch of the electrical source and secure against tuning on again age | (0040000107 3697Operating and Installation Instructions Thrust actuator ARI-PREMIO 2.2 Safety-Related Definitions: ‘The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating instructions as indications for particular hazards or for important information requiring special signs. - DANGER means that if the relevant information is disregarded, there is 2 danger of fatal injury and / or considerable damage to property can occur. WARNING means that if the relevant information is disregarded, there is a danger of serious injury and / or damage to property can occur. CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or damage to property can occur. NOTE means that particular attention must be paid to certain technical aspects. Alll other information not specifically emphasised such as transport, installation, operating and maintenance instructions as well as technical data (in the operating instructions, product documentation and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to persons or damage to property. 2.3 Qualified Personnel ‘This refers to personnel possessing corresponding qualifications and familiar with the processes of installing and assembling the product as well as with putting the product into service and operating the same, ¢.g. - Training or instruction or authorisation to switch on and off electric circuits and equipment! systems and to disconnect, ground and identify the same in accordance with VDE 0100, the regulations stipulated by the local electricity generating boards as well as technical safety standards. ~ Instruction and obligation to comply with all regulations and requirements pertaining to use as well as regional and inhouse regulations and requirements, especially TRB 700. - Training or instruction in accordance with technical safety standards in the use and maintenance of pertinent safety equipment including job-safety equipment. ~ Training in first-aid, ete. 3.0 Handling 3.1 Storage - Storage temperature -20° to +70°C dry, free of dirt ~ Do not damage packing ~ A desiccant or heating to prevent condensation is necessary in damp rooms. 3.2 Transport ~ Transport temperature -20° to +70°C ~ Protect against external force (impact, vibration etc.).. ~ Do not damage packing 3.3 Handling Before Installation a - Protect against atmospheric conditions eg. wetness (applicate a desiccant). - Correct handling protects against damage. ~ Do not soil or damage type identification plate and wiring diagram on the controller. ‘0040000107 3697, page 2Operating and Installation Instructions D> ARMATUREN Thrust actuator ARI-PREMIO 4.0 Description 4,1 Field of Application ARI-PREMIO linear thrust actuators are employed to actuate control or shutoff valves requiring a nominal linear regulating distance of up to 50mm and thrust from 1.5KN to 5.0KN, The thrust actuators are set to the thrust forces specified in the technical data. If supplied with the valve, the lift of the thrust actuator will be set to the regulating distance of the valve Selection of the proper actuator version in alignment with the corresponding fitting as well as use of the thrust actuator in accordance with the specified technical data is the responsibility of the systems engineer. Any use of the thrust actuator beyond the specified technical data or improper use of the actuator is deemed to be not for the intended purpose. 4.2 Method of Functioning ‘The thrust acwator, fitted with a yoke or columns, is mounted to the valve. Transfer of force is effected via a coupling safeguarded against torsion. ‘The torsion safeguarding feature also serves as a lift indicator. ‘The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear clamps mounted to the column. The electrical components are accommodated separately from the gearbox underneath a sealed hood, thus being protected against operating and envinronmental effects. Following removal of the hood, easy access is provided to the switchgear and indicating feature, The rotary motion of the motor is transmitted to the spindle nut by means of spur gear. The drive spindle, which is safegarded against torsion, screws its way into the spindle nut and thus performs a pull or push motion depending on the sense of rotation, Inthe final positions of the valve, the spindle nut is pressed against a set of springs so as to produce closing force. The motor is switched off by means of two load-dependent switches and one stroke~dependent switch. The load-dependent switches will also switch off the motor if foreign bodies have lodged themselves between the valve seat and cone. ‘The load-dependent switches serve to protect the valve and thrust actuator against damage. page 3 0040000107 3697CVT 4.3 Technical Data Operating and Installation Instructions Thrust actuator ARI-PREMIO Type ARI- ARI- ARI-PREMIO PREMIO | PREMIO Thrust force i KN) Ls 22 5,0 [Regulating distance max. mm 30 Duty classification in accordance with S1 - 100 % duty cycle; $4 - 80% duty cycle 1200 c/h DIN VDE 0530 Control speed munvsec. 05 0,25 | 0.38 0.38 10 Motor voltage 230V - S0Hz | Power consumption WI 11,7 10,3 | 11,7 25,3 52,9 Torque switch 2 only, permanently wired, switching capacity 104, 250V- Stroke switch 1 only, permanently wired, switching capacity 10A, 250V~ ‘Type of enclosure DIN VDE 0470 P65 Max. ambient temperature 5 rC...+70°C Manual adjustment facilities Yes Mounting position ‘Any. Exception: motor must not be suspended downwards Gear lubricant Klidber Unigear LA02 Weight kg 34 34 6 65 Accessories ‘Additional limit switch 2 additional stroke switches, zero potential ‘Switching capacity 10A, 250V ~ Potentiometer max. 2 only ‘Obmage optional: 100, 200, 500, 1000, 2000, 5000, 10000 ohm; 1.5 watt Electronic position indicator RE 21 002)... 10V . 0(4)...20mA, Only 1 potentiometer possible Electronic position controller ES 11 002) .. OV. O(4)..20mA, Only 1 potentiometer possible Heating resistor | with automatic switching ) 230V-5OH2, 115V-S0Hz, 24V- 50H, 15 watt Other voltages/frequencies ‘24V-SOHz; 24V-60H2; 115V-50Hz; 115V-60H2; 230V-60H2 Low-voltage limit switch (electronic system) ‘Standard-voltage connection PC-board, PA 2 additional stroke switches, zero potential, ‘Switching capacity max. 0.1. 4-30 VDC 2 torque switches and I stroke switch, zero potential, ‘Switching capacity 10A, 250 ~ Low-voltage connection PC board (clectronie system), NA 2 torque switches and 1 stroke switch, Switching capacity max. O1A, 4-30 VDC (0040000107 3697 7 page 4Operating and Installation Instructions Thrust actuator ARI-PREMIO 4.4 Diagramm Yoke Version Column Version sao | 0s ase sgst sone fig.1 page 5 ‘0040000107 3697Operating and Installation instructions Thrust actuator ARI-PREMIO 4.5 Parts List Designation [Designation 150.1 Gearbox 50.41 head cap screw DIN 912-M4 [50.1.1 _|Gearbox cover plate [50.42 _[PC-board support [50.2 (Cable conduit fitting 2xPG11 150.43 ° [Standard PC-board [50.4 __|Sealing plug POT 150.45_|Shift lever 505 [Gasket [50.46 [Washer 150.6 [Hood 150.47 Circuit diagram sticker, standard 150.7 |Hood seal 50.48 [Connector, 3-pole (standard) 150.8 countersunk screw 30.50 [Trp side [DIN 7991-M5x20 [50.9 _|Sealing washer DIN 125-5,3 3051 _ [Setting spindle for switch S3 [50.10_|Colamo [50.52 [Setting spindle for switch S4 [50.12 _|Handwheei [50.53 _|Setting spindle for switch SS 50.14 | Yoke [50.54 {Trip cam 50.15 [Flange 50.55 [Lock washer DIN 6799-2,3 50.16 Spring washer DIN 128-A10 50.56 _|Spang PREMIO for trip slide 50.17 [Hexagon head screw [50.57 [head cap screw [DIN EN 24017-M10x30_ [DIN 912-M4x10 [50.18 [Hexagon head screw [50.58 Protective conductor terminal [DIN EN 24017-M10x45 50.19 |Thead bolt [5059 [Read cap screw DIN D12-Max6 DIN 261-M12x40 50.20 _| Washer DIN 125-13 [50.61 _|Stroke-switch PC-board 50.21 |Spring washer DIN 128-Al2 [50.62 Connector, 6-pole |(option: stroke switch) [50.22 [Hexagon nut 50.67 ytentiometer [DIN EN 24032-M12 5023 (Litt dial 50,68 [Connecting cable for loption: potentiometer [50.24 [Distance column [50.69 [Self-tapping screw [50.25 [Hexagon aut DIN 980-V-MI6 50,70 [Spiral spring (opin. potentiometer) 50.26 |2-ear clamp 50.71 _ [Slide block (option: potentiometer) [50.27 _ [Coupling 50.72 _|Set collar [50.30 [Driving spindle [50.73 [Pinion (option: potentiometer) 50.31 |Spindie safery feature [50.74 _|Connector, 3-pole |(option: potentiometer) 50.32 [Torsion safety feature [50.79 _ [Electronic position indicator RIZT [50.34 {Bellows [50.80 [Holding angie (option: ES1I/RI21) 150.36 _|Set collar [50.81 _ [head cap screw DIN 912-Max8 50.37 [Grub screw DIN 913-MaxS [50.82 _[Cheese-hd. screw DIN 913-Max12 50.38 [Guide spindle 50.87 _|Threaded bush [50.39 [Hexagon nut DIN EN 24034-M5 50.95 _|Spring washer [50.40 [Synchronous motor, compl. 5096 [O-ring (0010000107 3697 page 6Operating and Installation Instructions Ose GUL Thrust actuator ARI-PREMIO 4.6 Dimensions RLLLLLLLLILLM“{RML_L (LLLLLLLLLLLLSLLLLL LS Space requirements for aq Space requirements for removal of hood removal of hood a ARI-PREMIO 1.5 - 5.0kN ARI-PREMIO 1.5 - 5.0KN Nominal stroke max. 30mm Nomifial stroke >30mm - 50mm page 7 (0040000107 3697Operating and Installation Instructions Thrust actuator ARI-PREMIO 5.0 Notes on Dangers During Installation, Operation and Maintenance DANGER! : A Safe operation of the positioners only ensured if itis installed, put into operation and maintained by qualified personnel (refer to Point 2.3 "Qualified personnel"), while observing the warning notes provided in these operating instructions. In addition, care must be taken to ensure that the general equipment and safety regulations for electrical lines and installations are complied with and that tools and protection devices are used professionally. The operating instructions for the electronic positioner must be observed when carrying out all work on and when handling the electronic positioner. Disregard of these instructions can result in injury to persons or damage to property. 6.0 Installation 6.1 General Installation Data In addition to general installation guidelines, the following points are required to be observed: . - Existing operating instructions for valve. - Complete valve with crossarm. - Valve cone approximately in mid lift position - on no account supported inside a seat! ~ Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricity generating board. = Conductor cross-section selected to correspond to the given drive power and existing line length. - Mains fuse rating max. 6A. ~ Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the actuator. - Conformity of technical data on thrust actuator with field conditions. = Mains voltage in accordance with data specified on rating plate of thrust actuator. - Thrust actuator complete with yoke or distance columns and coupling parts intended for ‘mounting to the corresponding valve. ~ Qualified personnel possessing knowledge of the regulations pertaining to the erection of, power installations. - Ease of access to installation site. ~ Adequate clearance space above the thrust actuator for removing the hood (refer to section 4.4 Dimensions). - Thrust actuator mountable in any position except in downward suspended position. ‘0040000107 3697 age &Operating and Installation Instructions Thrust actuator ARI-PREMIO 6.2 Manual Operation With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the handwheel firmly meshed with the gear. Proceed as follows: - Swing out lever (50.12.1) from handwheel (50.12). = Turning in clockwise direction~> closes valve. A - Turing in counter-clockwise direction--> opens valve. CAUTION ! In the manual operating mode pay careful attention in the final positions that the handwheel is only turned to the point where the torque switch trips (audible click) as, otherwise damage will be caused to the thrust actuator! Since the handwheel always follows during motor-driven operation (running indication), never operate by hand while the motor is running - potential injury hazards!!! page? (0000001073697Uperaung and Instatlation Instructions Thrust actuator ARI-PREMIO 6.3 Installation instructions for Mounting to Valves 6.3.1 Mounting for valve-lift up to 30mm (yoke version) A BO c D E E fig. 4 To mount the thrust actuator to a vaive having a nominal lift of up to 30mm, proceed as follows: : ~ Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated) - Position valve cone approximately in mid lift position . Fig. A: - Tum flat hexagon nut if not present on valve spindle. Fig. A-B: - Slip coupling (50.27) over valve spindle. - Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (Y) and lock with hexagon nut. - Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm. Fig.C: - Place thrust actuator (50) on valve. - Mount thrust actuator (50) on fitting with two T-head bolts (50.19), two washers (50.20), two spring washers (50.21), two hexagon nuts (50.22). Fig. D/E: - Swing out handwheel lever (50.12.1) and use it to move out the thrust actuator until the driving spindle (50.30) comes to rest on the threaded bush (50.87). Fig. F: ~ Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure in place using grub screw M6 (50.35). ~ Run valve to lowest position. ~ Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is in alignment with tip of arrow mark on lift dial. - Run valve to both final positions and check to ensure that these are safely reached - Carry out electrical connection (refer to section 6.4.2). ~ Set stroke switch $3 (refer to section 6.5.3.2). (0040000107 3697 page 10Operating and Installation Instructions Thrust actuator ARI-PREMIO 6.3.2. Mounting for valve lift over 30mm to 50mm, (column version) A B c D E ¥ Si. ee fig. 5 ‘To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm, proceed as follows: ~ Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). - Position valve cone approximately in mid lift position . Fig A: -Tur flat hexagon nut if not present on valve spindle. Fig, A-B: - Slip coupling (50.27) over valve spindle. - Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (Y) and lock with hexagon nut. - Setting dimension (¥) for fitting-projection (X) 83mm = 102mm. - Setting dimension (¥) for fitting-projection (X) 98mm = 116mm. Bild C: Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly. - Screw distance column with 2-ear clamps on opposite side of handwheel into the flange in such a way that one of thé 2-ear clamps is situated above the torsion safety feature (50.32) and the other below. - Screw the other distance column into the flange likewise. ~ Place thrust actuator (50) with distance columns onto valve and fix into position with two self-locking hexagon nuts (50.25). Fig. D/E: - Swing out handwheel lever (50.12.1) and use it to move out the thrust actuator ‘until the driving spindle (50.30) comes to rest on the threaded bush (50.87). Fig. F: Screw coupling (50.27) firmly into torsion safery feature (50.32) and secure using grub screw M6 (50.35). - Run valve to lowest position. - Press on 2-ear clamps (50.26) corresponding to lift so as to be slip-resistant and in such a way that the lower one is situated in the lowest valve position directly below the torsion safety feature (50.32) and the upper one is located in the topmost valve position directly above the torsion safety feature. - Run valve to both final positions and check to ensure that these are safely reached - Carry out electrical connection (refer to sectiori-6.4.2). - Set stroke switch S3 (refer to section 6.5.3.2) page 11 (0040000107 3697‘Uperaumg anu 1ustauauon anstrucuens Thrust actuator ARI-PREMIO 6.4 Electrical Connection 6.4.1 Circuit Diagram tt a ny Path-governet switch in opening direction “ a Oe ‘Standard-voltage connection PC-board, zero potential Low-voltage connection PC-board, zero potential Potentiometer ‘Steoke-dependend switch, zero potential Electronic position indicator Heating resiston Torque switeh DE RDI ESI Ni PA por wi fig. 6 (0040000107 3697 page 12Operating and Installation Instructions Thrust actuator ARI-PREMIO DANGER !!! A™ proceeses of mains connection and putting the thrust actuator into service call for specialised knowledge of power installation erection (VDE 0100), knowledge of regulations for the prevention of accidents and the specific conditions for putting this, thrust actuator into service. Such work may only be carried out by suitably qualified personnel in accordance with section 2.3 "Qualified Personnel". The supply line for connecting up the thrust actuator must be in the dead state i.e. disconnected from the mains while connection work is being carried out. After being disconnected, the mains power must be prevented from being switched back on again accidentally. Failure to observe these instructions may lead to death, grievous bodily injury or substantial property damage! 6.4.2 Connection To connect the thrust actuator up to the electrical power supply, proceed as follows: = Run the thrust actuator a few mm out of the lower final position applying the manual mode. = Loosen countersunk screw in hood, carfeully remove hood in upward direction. = Screw out one of the two cable inlets and re-assemble in the same way without the supplied blank flange. = Insert the connection line through this cable inlet until sufficient conductor length is available up to the corresponding terminals; then tighten the cable inlet until the connecting cable is clamped in place inside it. - Strip connecting cable approx. 1-L.5em above cable inlet. - Strip the individual conductors approx. Smm away from the end and fit with conductor end sleeves. ~ Connect protective conductor of connecting cable up to protective conductor terminal of, thrust actuator. ~ Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator terminal strip. - Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator terminal strip. ~ Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal strip. - Place hood on carefully from above and mount firmly onto thrust actuator with countersunk serew and rubber gasket. ~ Connect supply line to mains and run thrust actuator to each of the final positions so as to check whether the final-position limit switches effect switching off, also checking to see whether the direction of movement on the thrust actuator corresponds to the desired direction. - If the directions of movement are contrary to those desired, the pulse lines governing the move-in and move-out connecting rod will need to be exchanged. page (3) ‘0040000107 3697Operating and Installation Instructions Thrust actuator ARI-PREMIO 6.5 Settings DANGER !! AN ‘The thrust actuator may énly be operated for a short time without the hood for unavoidable setting operations to the potentiometers, stroke switches and the electrical BD options. While these operations are in progress, the thrust actuator has hazardous, tive, uninsulated parts exposed as well as moving and rotating parts. Improper execution of the setting operations or lack of care may cause death, grievous bodily injury or substantial property damage. Only suitably qualified personnel must be allowed to perform these operations (refer to section 2.3 "Qualified Personnel") . Operation of the thrust actuator without the hood for any purpose other than that described above is strictly prohibited. 6.5.1 Torque and Stroke Switches - Standard Feature ‘The thrust actuators are equipped with a standard PC-board, this being one of the standard features. This contains a load-dependent limit switch for the closing direction ($1), a load- dependent limit switch for the opening direction (S2) and a stroke-dependent limit switch for ‘opening direction ($3). - ‘The load-dependent limit switches ($1, $3) switch off the motor as soon as the factory-set thrust force is attained. NOTE: The settings of the load-dependent limit switches must on no account whatsoever be changed! The stroke-dependent limit switch (S3) switches off the motor as soon as the lift or stroke is attained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent limit switch $3 is set in such a way that the motor of the thrust actuator is switched off as soon as the maximum valve-lift is atained. 1 the thrust actuator is supplied on a three-way valve, the trip cam belonging to limit switch S3 is set in the opening direction in the trip slide to such a downward extent that the upper final position of the valve is attained prior to limit switch $3 being reached, thus causing the load- dependent limit switch $2 to switch off the motor. For this function, all three switches reveal interiock-controlled circuitry on the PC-board, Ifthe standard limit switches are to be integrated directly into the facility control system, the standard PC-board can be replaced by optional PC-boards PA or NA. 6.5.2 Connection PC-Boards PA or NA ‘On connection PC-boards PA or NA, the standard limit switches $1 1/S21, $12/S22 and $13/ ‘S23 do not reveal interlock-controlled circuitry and can be integrated individually into the facility control system. ‘The 3 contacts on each of the switches $11/S21, $12/S22 and $13/S23, designed as double- throw contacts, are - in the case of these PC-boards - brought out on terminals 40-48 and can be freely connected. ‘The switches on the PA optional PC-board (standard-voltage connection PC board) are designed for switching capacities of up to 10, 250V AC ‘The switches on the NA optional PC-board (low-voltage connéction PC-board) are designed for switching capacities of up to 0.1, 4-30V (gold contacts). The optional PC-boards may only be installed at the factory due to the switching points of the load-dependent switches having to be reset following installation of these PC-boards! (0040000107 3697 page ItOperating and Installation Instructions Thrust actuator ARI-PREMIO CAUTION! ‘When using optional PC-boards PA or N, it must be warranted - due to the operator’s individual circuitry- that, when switching the load-dependent limit switches S11/21 and 12/822, the motor of the thrust actuator comes to a standstill without delay. This function is not provided for on the optional PC-boards PA and NA in the supplied state! 65.3 Stroke Switch The thrust actuators can be equipped with an additional stroke-switch PC-board containing wo stroke switches (double-throw contact S4 and $5). ‘These switches can be set on infinitely variable lines over the entire regulating distance in both lift directions and integrated at will into the facility control system (no interlock-controlled circuitry). ‘The maximum switching capacity of the switches (refer to section 4.3 Technical Data) must not be exceeded. For low voltage (refer to section 4.3 Technical Data), the additional stroke switches are supplied with gold contacts (option: low-voltage limit switch). 65.3.1 Installation of Additional Stroke Switches To install additional stroke switches, proceed as follows. ~ Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. = Loosen countersunk screw in hood, carefuily remove hood. = Disconnect motor plug and mains connection plug from PC-board. ~ Carefully ease open the lock washer (50.56) (open ends) with a screw driver while pulling the trip slide (50,50) upwards from the PC-board support. = Remove trip slide (50.50) from PC-board support by pulling upwards. + Loosen head cap serews (50.57) on PC-board support and remove this from gearbox (only necessary on SKN thrust actuator). ~ Insert stroke-switch PC-board (50.61) in PC-board support (50.42) and fix in place using the supplied screws (50.44). ~ Mount PC-board support loosely on gearbox cover plate with two head cap screws (50.57) (only necessary on SKN). = Push trip slide (50.50) back into PC-board support (50.42) from above and onto the guide spindle (50.38). - Align PC-board support (50.42) on gearbox cover plate in such a way that the guide spindle (30.38) is centrally situated in the borehole of the PC-board support (50.42); then screw down tightly on gearbox cover plate (only necessary on SKN). = Mount the trip slide (50.50) so that the spring (50.56) clips into the groove of the guide spindle (50.38). i ~ Insert 6-pole connector (50.62) in jack strip of stroke-switch PC-board. page 15 (0040000107 3697Operating and Installation Instructions Thrust actuator ARI-PREMIO - Proceed to strip the connecting cable that has been Jed in through the cable inlet and fastened, and connect the individual conductors to the terminal strip in accordance with the desired circuitry and the circuit diagram. - Set switch points on stroke switches in accordance with section 6.3.2. Setting the Stroke Switches + Insert motor connection plug in jack strip (50.43.3) provided for the purpose. ~ Insert mains connection plug in jack strip (50.43.3) provided for the purpose. ~ Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket and countersunk screw. i | ia fig. 7 [Designation Designation 3038 | Guide spindle 30.52 | Setting spindle for switch S¢ 3042 _[PC-board support 50.53 | Setting spindle for switch SS 5043.3 [Tack strip for mains connection | [50.54 [Tap cam 3043.4 [Jack strip for motor connection | [50.56 |Spring [5044 |SelFtapping screw [50.57 [head cap screws DIN 912-M4x10 30.50 _ | Trp slide 50.61 | Stroke-switch PC-board 3051 _ |Setting spindle for switch 83 30.62 | Connector, 6-pole (option: stroke switch) ‘0040000107 3697, page 16Operating and Installation Instructions EA Thrust actuator ARI-PREMIO 6.5.3.2 Setting of Standard Stroke Switch (S3): On delivery of the thrust actuator, the standard stroke switch (S3) is already set to the exisitng valve-lift and the setting spindle for the limit switch $3 (50.51) is sealed with screw glyptal. This setting needs no changing for normal operation. If reinstalling the thrust actuator on a straight-way valve, the stroke switch S3 needs to be set as follows: Move valve out of the lowest position so as to run valve-lift to up position. Using a screw driver, proceed to tum setting spindle for switch $3 (50.51) until the trip cam (50.54) arriving from below trips the switch (audible click). Run thrust actuator briefly in closing direction and then in opening direction once more, checking to see whether the thrust actuator is switched off at the desired point (nominal lift). If need be, correct the setting as described. If reinstalling the thrust actuator on a three-way valve, the stroke switch S3 needs to be set as follows: ~ Run valve in both final positions and check in each final position whether the valve switches off via the load-dependent switeh. ~ Camy out a check in the top final position the see whether, after switching off the thrust actuator, the trip cam (50.54) of the stroke switch S3 is situated below switch $3 and has not tripped the later. If the trip cam (50.54) is situated above the stroke switch $3 or trips the same, the setting spindle governing the stroke switch $3 (50.51) needs to be tuned until the trip cam is situated below stroke switch $3 without tripping it. ~ Run the thrust actuator in both final positions once more and check whether thrust actuator switches off in both final positions via the load-dependent switches. - If need be, comect the setting as described above. page 17 (00400001073697Operating and Installation Instructions Thrust actuator ARI-PREMIO <> ARMATUREN 6.5.3.3 Setting the additional stroke switches (S4/S5 and S24/S25) The two additional stroke switches can be freely set in both lift directions for indicating certain valve positions. ; To do this, proceed as follows: - Run valve to desired position due to be indicated by the corresponding switch. - Proceed to tum the setting spindle belonging to the appurtenant switch until the switch is tripped (audible click). ~ Run thrust actuator briefly in both directions, checking and, if need be, correcting the setting. ~ The actuating feature on the stroke switches is designed in such a way that both stroke switches can be overrun in both directions. - For that reason, care should be taken on additional stroke switches to see that the actuating state of the switches remains active only for a short time while the thrust actuator continues to run and that switching back takes place afterwards. - The actuating state of the stroke switches remains in force over a lift of 4mm. 6.5.4 Potentiometers ‘The potentiometers are used for electrical position acknowledgement on the facility control system or for the options - electronic position controller ES11 or electronic position indicator R21 A maximum of 2 potentiometers can be installed (= 1 double potentiometer). The potentiometers can be supplied with different resistance values (refer to section 4.3, Technical Data). For the electronic position controller ES11 and the electronic position indicator RI21 use must be made solely of 1000 ohm potentiometers. Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by means of transmission determined in respect of each valve-lift between the toothed rack on the tip slide and the pinion on the potentiometer shaft. Use must only be made of the pinion specified for the valve-lift. If the thrust actuatot is supplied with the valve and built-in potentiometer, the potentiometer is assembled and set ready for operation. (0040000107 3697 page 18Operating and Installation Instructions Thrust actuator ARI-PREMIO 6.5.4.1 Installing the Potentiometer If retrofitting the potentiometer, proceed as follows: - Switch off mains voitage and safeguard to prevent it from being switched back on again accidentally. - Loosen countersunk screw in hood, carefully remove hood. - Plug in the flat connectors on grey cables of potentiometer connecting cables into the middle connector pins and those of the yellow cables into the lower connector pins of the potentiometer (Fig. 8). - Slip washer (50,67.4) onto potentiometer (50.67.3) (Fig. 9). ~ Insert slide block (50.71) (inner surface of borehole direction circuit diagram) in PC-board support (50.42). - Insert potentiometer (50.67.3) with washer (50.67.4) from behind (surface of potentiometer direction circuit diagram) in slide block (50.71). - Tighten potentiometer (50.67.3) with tooth lock washer (50.67.2) and hexagon aut (50.67.1). - Slip pinion (50.73) (number of teeth corresponding to valve-lift) onto potentiometer shaft with toothed rim ahead. - Slip Spring washer (50.95) and set collar (50.72) onto potentiometer shaft. Press the set collar (50.72) against pinion (50.73) and fasten the grub screw with the aid of a screw driver, so that the pinion (50.73) can only be turned applying increase force to the potentiometer shaft (slip clutch). - Move potentiometer unit inside slide-block guide in such a way that pinion (50.73) meshes with toothed rack of trip slide. - Hook spiral spring (50.70) - on valve-lift up to 30mm - in the left-hand window inside the PC-board support above the potentiometer guide, insert in guide between slide block and potentiometer guide, and hook into recess below potentiometer. Ona valve-lift above 30mm to 50mm, the spiral spring (50.70) must be hooked into the right- hand window above the potentiometer guide. - Check to see whether pinion (50.73) is pressed into toothed rack by spiral spring ($0.70) and is positioned free from backlash. = If this is not the case, remove spiral spring (50.70), readjust by bending a little, and place back in position again. ~ Screw jack strip of connecting cable (50.68) to PC-board support (50.42) with two self- tapping screws (50.69) . ° - Insert additional 3-pole connector (50.74) in jack strip of connecting cable (50.68). - Set potentiometer (refer to section 6.4.2). - Place hood carefully onto thrust actuator and mount with rubber gasket and countersunk screw. r er tae Vibe (ee oF Ne retow yallow fig. 8 page 19) (0040000107 3697Operating and Installation Instructions Thrust actuator ARI-PREMIO wo— fig. 9 Designation [Designation 3042 [PC-board support 50.69 | Seif-tapping screw 50.47 |Circuit-diagram sticker [50.70 [Spiral spring _| option: potentiometer) '50.67.1 |Hexagon nut 50.71 Slide block (option: potentiometer) 30672 | Tooth lock washer 30.72__ [Set collar 30.673 | Potentiometer 50.73 [Pinion (selection depends on valve- lift 20, 30, 50mm) [50.674 _| Washer from PA [50.74 |Connector, 3-pole (option: potentiometer) 30.68 | Connecting cable for option: 50.95 | Spring washer potentiometer 65.4.2 Setting the potentiometer ‘To set the potentiometer, proceed as follows: - Move thrust actuator to closing position. - Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally, - Using a screw driver, turn slotted potentiometer shaft in counter-clockwise direction until reaching the limit stop. This places the potentiometer in the initial position (approx. 0 ohm). - For checking purposes, the resistance of the potentiometer needs to be measured using an ohmmeter. ~ Measure resistance on potentiometer I between terminals 25 and 26. ~ Measure resistance on potentiometer 2 between terminals 28 and 29. In this position of the actuator, the measured value should be approx. 0 ohm. ~ Run thrust actuator to upper final position and read off corresponding resistance value on ohmmeter. - The resistance values thus measured need to be taken into acount for the settings to the facility control system. (0040000107 3697 page 20Operating and Installation Instructions ‘Thrust actuator ARI-PREMIO EGG 65.5 Heating ‘A heating resistor can be fitted as a means of protection against the formation of condensation ‘water in cases involving widely varying ambient temperatures and high atmospheric humidity (outdoor use). The heating resistor is self-regulating so that a continuous supply of current merely needs to be connected up. 6.5.5.1 Installation of heating On principle, the heating can be combined with all options. Itis completely mounted on a holding angle. If simultaneous use is made of the electronic options ES11 or RI21, the holding angle supplied with the heating is-employed for mounting the electronics. ‘Where option ES11 or RI2I is already installed, the heating is screwed off the holding angle which is then removed. Afterwards the heating is installed and the electronics unit mounted (0 the holding angle. To install the heating proceed as follows: - Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. - Loosen countersunk screw in hood, carefully remove hood. - Using the supplied screws, mount complete heating (on holding angle) at the point on the ‘gearbox cover plate provided for the purpose. (Fig. 11). “Lead continuous-current cable (mains voltage = rated voltage of heating) through cable inlet into thrust actuator and fix in place with inlet. - Strip continuous-current cable approx. 1-1.Sem above cable inlet. - Strip individual conductors approx. Smm away from the end and provide with conductor end sleeves. - Lay the individual conductors in such a way that they do not come into contact with moving parts. = Connect the individual conductors up to the connection terminal block in accordance with the circuit diagram. page 21 ‘0040000107 3687Operating and Installation Instructions Thrust actuator ARI-PREMIO mening ne ns |Pa~ Mowing ee MO ferme ae S| etl ea beer TY moog sven ce / for opsons EST and R121 Mounting end m3 Ste | fig. 10 Designation 50.83.1 Holding angle 50.83.2 head cap screw DIN 84-M3x8 5083.3 Thermal circuit breaker 50.83.4 Jack stip 50.83.6 Connector, 2-pole 50.83.10 Heating resistor fig. 11 Designation 50.67 —_Potentiometer : 50.78/19 Option ES11 or R21 50.83 Heating (0040000107 3697 page 22Operating and Installation Instructions Thrust actuator ARI-PREMIO 6.5.6 Electronic Position Indicator RI21 The electronic position indicator RI21 converts the resistance of the 1000 ohm potentiometer corresponding to the lift into an optional output control signal 0(2) ..10V DC or 0(4) ..20mA DC. For installing and setting the electronic position indicator RI21 the ‘operating instructions applicable to this unit must be observed in the appropriate valid version. ‘The corresponding operating instructions are supplied with each unit. 6.5.7 Electronic Position Controller ES11 The electronic position controller converts continuous input control signals 0(2) ..10V DC or 0(4) ..20mA into a 3-point output signal for the motor, in which case interrogation of the valve position takes place via a 1000 ohm potentiometer. For installing and setting the electronic position controller ES11 the operating instructions applicable to this unit must be observed in the appropriate valid version, The corresponding operating instructions are supplied with each unit. 7.0 Starting Up A DANGER! Check the following before starting up a new system or restarting a system after repairs or conversion: - Correct completion of all installation/assembly work! ~ Circuits of the system in accordance with DIN VDE regulations and regulations of the relevant power supply company as well as compliance with all safety regulations, especially TRB 700. - hood of thrust actuator assembled, - Start up only by qualified personnel (see 2.3). While in operation, the thrust actuator has moving and rotating parts as well as being integrated in an electrical network system. Improper handling or failure to observe the operating instructions or the valid regulations may lead to death, grievous bodily injury or substantial property damage! ‘When piacing into service proceed as follows: = Using the handwheel, run the thrust actuator to approximately mid lift position. ~ Apply brief pulses to the thrust actuator for each direction of movement and check whether the directions of movement correspond to those desired. If this is not the case, the pulse lines governing the opening and closing action must be exchanged on the thrust actuator. - Run thrust actuator to the final position in each direction of movement and check whether it switches off automatically and whether all extemally moving parts are able to move freely. - If failing to function properly, check all installation and setting work previously carried out, correcting if necessary, and afterwards place into service once again. page 23 (0040000107 3697Operating and Installation Instructions Thrust actuator ARI-PREMIO <(> ARMATUREN 8.0 Care and Maintenance ‘The thrust actuator requires very little maintenance. Accordingly maintenance in specified intervals is not necessary. ° Depending on the conditions governing use, the maintanance and maintenance-intervals have to be defined by the operator (see TRB 700). ‘The thrust actuator must not be cleaned with high-pressure equipment or aggressive solvents or detergents injurious to health or highly inflammable. During and after cleaning, an inspection should-be carried out of the sealing points on the thrust actuator. If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements must. be repaired. 9.0 Troubleshooting In the event of malfunctions or disturbances in operation, first check whether the installation and adjustment work has been carried out and concluded in accordance with these operating instructions. Compare the data referring to operating voltage, actuating signal and temperature to the data specified on the layout drawing of the control system. Also check whether the given operating conditions comespond to those specified in the data sheet or to the technical data specified on the type identification plate. DANGER! All relevant safety regulations must be observed when carrying out the troubleshooting procedure, especially TRB 700. Contact the supplier/manufacturer if faults cannot be rectified on the basis of the following »sroubleshooting table“ (0040000107 3697 page 24