OM5510_04#C.

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ELECTRICAL ACTUATOR, TYPE PREMIO

Electrical actuator, type Premio

1 General
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 this operating instruction, please contact Alfa Laval for further infor-
mation.

1.1 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, e.g.

- Training, 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 per-
taining to use as well as regional and in-house regulations and requirements.
- Training or instruction in accordance with technical safety standards in the use and
maintenance of pertinent safety equipment including job-safety equipment.

1.2 Handling

Storage
• Storage temperature: -20ºC to +70ºC dry, free of dirt.
• Do not damage packing.
• A desiccant or heating to prevent condensation is necessary in damp rooms.
Transport
• Transport temperature: -20ºC to +70ºC.
• Protect against external force (impact, vibration, etc.).
• Do not damage packing.
Handling before installation
• Protect against atmospheric conditions e.g. wetness.
• Correct handling protects against damage.
• Do not soil or damage type identification plate and wiring diagram on the con-
troller.

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2 Description

2.1 Field of application

The PREMIO linear thrust actuators are employed to actuate control or shut-off valves
requiring anominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15
kN. 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 stroke distance
of the valve. Selection of the proper actuator version in alignment with the corre-
sponding fitting as well as use of the thrust actuator in accordance with the specified
technical data is the responsibility of the systems engineer.

Attention: 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.

The ambient conditions have to be conformed to the actual electromagnetic compati-

bility directives. Additional the compatibility to this directive has to be maintained in
case of expansion or other changing of the ambient conditions.

2.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve. Transfer
of force is affected 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 environmental effects. Fol-
lowing removal of the hood, easy access is provided to the switch gear 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 safeguarded against torsion, screws its way into the spindle
nut and thus performs a pull or push motion depending on the sense of rotation. In the
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 optional
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.

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2.3 Technical data

The technical date for the thrust actuators is appears from Table 1 and Table 2. Actuator
diagrams are illustrated in Figure 1 and Figure 2 and the part list is shown in Table 3.
Finally a dimension drawing can be found in Figure 3.

Technical data for Premio actuators

Type Actuator type
Thrust force [kN] 2.2 5.0 12.0 15.0
Travel distance max. [mm] 50 80
Duty classification according to
S3 80% 1200 c/h S3 – 50% 1200 c/h
EN 60034-1/A11
Control speed [mm/sec.] 0.38 0.38 1.0 0.79 0.38
Motor voltage 230 V – 50 Hz / 60 Hz 1) 230 V – 50 Hz
Power consumption [W] 11.7 25.3 52.9 109 96
Torque switch 2 pcs., permanently 2 pcs., permanently wired
wired, switching capacity 10A, 250V~ switching capacity 16 A, 250 V~
Travel switch 1 pcs., permanently wired, 1 pcs., permanently wired
switching capacity10 A, 250 V~ switching capacity 16 A, 250 V~
Enclosure IEC 60529 IP65
Max. permissible ambient temperature -20°C to +70°C
Hand wheel Yes (rotating during operation) Yes (engageable)
Mounting position Any. Exception: motor must not be suspended downwards
Gear lubricant Klüber Isoflex Topas NB 152 Molyduval Valenzia H2
Weight [kg] 5.4 6 6.5 10.5
1) Control speed and power consumption are 20% higher at frequency of 60 Hz

Table 1

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Accessories
Type Actuator type
Thrust force [kN] 2.2 5.0 12.0 15.0
Trip slide for travel switch S3 for actuating travel switch S3 / retracting spindle
(the travel switch S3 exists in the standard version)
Additional travel switches S4, S52) 2 additional travel switches, zero potential, switching capacity 10 A, 250 V~
Additional intermediate position 2 additional intermediate position switches, zero potential, with gold contacts for low
switches for low-voltage / electronic switching capacities and at aggressive atmosphere,
system S4, S5 2) switching capacity max. 0.1 A, 4-30 V
Potentiometer 2) Max. 2 only. Ohmage optional: 100, 200, 500, 1000, 1000 ohm; 1.5 W;
TÜV-approved potentiometer2) max. 2 only - Ohmage 5000
or optional: 100, 200, 500, 1000 Ohm; 1.5 W
Not compatible for use with the heating resistor or RI21!
No retrofitting possible!
Electronic position indicator RI 212) 0 (2) -10 V, 0 (4) – 20 mA – only 1 potentiometer possible.
Using the temperature controller, installation is only possible in the control cabinet.
Electronic position indicator RI322) 2... 10V; 4... 20 mA Only 1 potentiometer possible.
Electronic position controller ES 11 2) 0 (2) -10 V, 0 (4) – 20 mA – only 1 potentiometer possible.
Not compatible for use with the temperature controller.
Heating resistor (with automatic switching) 230 V – 50 Hz, 115 V – 50 Hz, 24 V – 50 Hz, 15 W
Additional voltages / frequencies 24 V - 50/60 Hz 1) 24V,50Hz 24 V – 50/601) Hz
1) 1)
24V, 60 Hz 1)
115 V - 50/60 Hz 115 V – 50/601) Hz
115V, 50 Hz 230V - 601) Hz
115V, 60 Hz 1)
3~400 V – 50 Hz
230V, 60 Hz 1) 3~400 V – 601) Hz
Standard-voltage connection board PA 2 torque switches and 1 travel switch, zero Possible with standard version
potential, for free wiring,
switching capacity 10 A, 250 V ~
Low-voltage connection board (elec- 2 torque switches and 1 travel switch, for free wiring, with gold contacts, for low
tronic system), NA switching capacities and at aggressive atmosphere.
Switching capacity max. 01A, 4-30V
Integrated temperature-controller Three-step temperature-controller in microprocessor-technology.
dTRON 316 Control range: -200°C to 850°C (resistance thermometer)
Voltage: 24V, 115V or 230V 50/60Hz
Compatible with resistance thermometers and thermocouples (provided by customer),
or standardized active current or voltage signals.
Not compatible for use with the ES11!
Integrated reversing contactor -- Actuator with 400 V – 50 Hz and
440 V – 60 Hz.
Only 1 electronic module possible.
Phase control relay -- Only in addition with integrated revers-
ing contactor
DC-Module To control PREMIO 230V-50Hz with
3-step converter 24VDC. Not compatible for use with the
temperature controller!
1)Control speed and power consumption are 20% higher at frequency of 60 Hz

2) Option trip slide necessary

Table 2

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Diagram for actuators 2.2 - 5.0

Figure 1 om5510_04_1x0609320en.jpg

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Diagram for actuators type 12.0 - 15.0 kN

Figure 2 om5510_04_2x0609330en.jpg

Part list
Pos. Designation Pos. Designation Pos. Designation

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Part list
Head cap screw DIN EN ISO
50.1 Gearbox Hexagon head screw DIN EN 50.41
50.18 4762-M4 - 18
24017-M10x55
50.1.1 Gearbox cover plate 50.42 Board support
50.19 T-head bolt DIN 261-M12x40 50.43 Standard board
Cable conduit fitting
50.43. Directional switch (valve – up)
2.2–5.0 kN: 2 x M16 x 1.5 50.20 Washer DIN EN ISO 7089
50.2 1 S3
12–15 kN: 2 x M16 x 1.5 /
50.43.
1 x M20 x 1.5 50.21 Spring washer DIN 128-A12 Torque switch
2
Hexagon nut DIN EN ISO
50.4 Sealing plug 1 x M16 x 1.5 50.22 50.45 Shift lever
4032-M12
50.6 Hood 50.23 Lift dial 50.46 Washer
50.7 Hood seal 50.24 Distance column 50.47 Wiring diagram sticker, std.
Counter-sunk screw DIN EN
50.8 50.25 Hexagon nut DIN 980-V-M16 50.48 Connector, 3-pole (standard)
ISO 10642 - M5x20
Head cap screw DIN EN ISO
Sealing washer DIN EN ISO 50.26 2-ear clamp (stroke indicator) 50.57
50.9 4762-M4x10
7089
50.27 Coupling 50.58 Protective conductor terminal
Head cap screw DIN EN ISO
50.10 Column 50.30 Driving spindle 50.59
4762-M4x6
50.11 Conical spring washer 50.31 Spindle safety feature 50.87 Threaded bush
50.12 Hand wheel 50.32 Torsion safety feature 50.96 O-ring DIN 3771 – 4 x 1.8
50.12. 50.10
Turning handle of hand wheel 50.34 Bellow Connector, 8-pole
1 1
50.14 Yoke 50.35 Grub screw DIN ISO 4766 - M6 50.11
Gear cap
50.15 Flange 50.36 Set collar 0
50.11
50.16 Spring washer DIN 128-A10 50.37 Grub screw DIN 913-M3x5 O-ring DIN 3771 - 52x2.5
5
50.11
50.40 Synchronous motor, complete Fan wheel
Hexagon head screw DIN EN 9
50.17
ISO 4017-M10x40 50.40.
Motor capacitor
3

Table 3

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Dimensions diagram

Figure 3 om5510_04_3x0729030en.wmf

3 Installation

Note: Safe operation of the actuator is only ensured if it is installed, put into
operation, and maintained by qualified personnel. 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 pro-
tection devices are used professionally. The operating instructions for the
electronic actuator must be observed when carrying out all work on and
when handling the electronic actuator. Disregard of these instructions can
result in injury to persons or damage to property.

3.1 General installation data

In addition to general installation guidelines, the following points are required to be

observed:

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- Existing operating instructions for valve.

- Complete valve with cross-arm.
- Valve cone approximately in mid lift position -on no account supported inside a
seat.
- Electrical installation in accordance with current regional regulations.
- Conductor cross-section selected to correspond to the given drive power and ex-
isting line length.
- Mains fuse rating max. 6 A.
- Circuit breakers 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 inten-
ded 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 and adequate clearance space above the thrust
actuator for removing the hood – refer to dimensions diagram, Fig. 3.
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must be between -20°C and +70ºC.
- In case of widely fluctuating ambient temperatures and high atmospheric humidity,
user is recommended to install a heating resistor to minimise condensation build-
up in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
- If installed with a horizontal connecting rod, the thrust actuator must be mounted
so that both legs of the yoke or columns are on top of one another in the vertical
plane.

3.2 Manual operation

For actuators type 2.2 -5.0 kN

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:

Step A: Swing out lever (50.12.1) from handwheel (50.12), see Figure 4.
- Turning in clockwise direction --> closes valve.
- Turning in counter-clockwise direction --> opens valve.

Hand wheel operation (actuator type 2.2 - 5.0 kN)

Figure 4 om5510_04_premiox0053410en.wmf

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In the manual operating mode pay careful attention in the final positions that the hand-
wheel is only turned to the point where the torque switch trips (audible click) as oth-
erwise damage will be caused to the thrust actuator. Since the handwheel always fol-
lows during motor-driven operation (running indication), never operate by hand while
the motor is running –potential injury hazards.

For actuators type 12.0 -15.0 kN

With the motor in the stationary state, the thrust actuator can be run in the open and
closed state with the engage able hand wheel. Proceed as follows:

Step A: Fold the turning handle out of the hand wheel (A), see Figure 5.
Step B: Turn the hand wheel slightly and push in the engaging button for manual
mode (B) --> the button engages.
- Turning in clockwise direction --> closes valve.
- Turning in counter-clockwise direction --> opens valve.
The motor is no longer in mesh when the hand wheel is engaged. The hand wheel is
automatically disengaged when the motor starts and the hand wheel is once more in
mesh.

Hand wheel operation (actuator type 12.0 - 15.0 kN)

Figure 5 om5510_04_5x0729040en.wmf

In the manual operating mode pay careful attention in the final positions that the hand
wheel is only turned to the point where the torque switch trips (audible click) as oth-
erwise damage will be caused to the thrust actuator.

3.3 Installation instructions for mounting to valves

3.3.1 Mounting for valve-lift up to 30 mm (yoke version)

To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed
as follows (Fig. and position numbers refer to Figure 6):

Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actua-
tor(not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Turn flat hexagon nut if not present on valve spindle (Figure 6 A).
Step D: Slip coupling (50.27) over valve spindle (Figure 6 A-B).
Step E: 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.

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Step F: Place thrust actuator (50) on valve (Figure 6 C).Mount thrust actuator on
fitting with two T-head bolts (50.19), two washers(50.20), two spring wash-
ers (50.21), and two hexagon nuts (50.22).
Step G: Swing out handwheel lever (50.12.1) and use it to move out the thrust ac-
tuator until the driving spindle (50.30) comes to rest on the threaded bush
(50.87), (Figure 6 D-E).
Step H: Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and
secure in-place using grub screw M6 (50.35), (Figure 6 F).
Step I: Run valve to lowest position.
Step J: 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.
Step K: Run valve to both final positions and check to ensure that these are safely
reached.
Step L: Carry out electrical connection (see section 3.4) and set optional travel
switch S3 (see section 4.3).

Mounting for valve-lift up to 30 mm (yoke version)

Figure 6 om5510_04_premiox0053435en.wmf

3.3.2 Mounting for valve-lift over 30 mm to 80 mm (column version)

To mount the thrust actuator to a valve having a nominal lift of over 30mm to 80 mm,
proceed as follows (Fig. and position numbers refer to Figure 7):

Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator
(not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Turn flat hexagon nut if not present on valve spindle (Figure 7 A).
Step D: Slip coupling (50.27) over valve spindle (Figure 7 A-B).
Step E: 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) 83mm = 102mm or fitting- projec-
tion (X) 98 mm = 116 mm.
Step F: Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly
(Figure 7 C).

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Step G: Screw distance column with 2-ear clamps on opposite side of handwheel
into the flange in such a way that one of the 2-ear clamps is situated above
the torsion safety feature(50.32) and the other below.
Step H: Screw the other distance column into the flange likewise.
Step I: Place thrust actuator (50) with distance columns onto valve and fix into
position with two self-locking hexagon nuts (50.25).
Step J: Fold out turning handle of handwheel (50.12.1), slightly turn the handwheel
and press in the engaging button for manual mode (only 12- 15 kN) (button
engages). Having done this, move out the thrust actuator until driving spindle
(50.30) comes into contact with threaded bush (50.87), (Figure 7 D-E).
Step K: Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure
using grubscrew M6 (50.35), (Figure 7 F).
Step L: Move the valve to the lowest position.
Step M: Press 2-ear clamps (50.26) into position according to the stroke so they can-
not slip, with the bottom clamp in the lowest valve position located directly
below torsion safety feature (50.32) and the top clamp in the highest valve
position located directly above the torsion safety feature.
Step N: Move the valve to both travel positions and check that it reaches them reli-
ably. Fold turning handle of handwheel (50.12.1) back in.
Step O: Make the electrical connection (see section 3.4). The engaging button for
manual mode (only 12- 15 kN) disengages when the motor starts up.
Step P: Set optional travel switch S3 (see section 4.3).

Mounting for valve-lift over 30 mm to 80 mm (column version)

Figure 7 om5510_04_premiox0053443en.wmf

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3.4 Electrical connection

Figure 8 and Figure 9 illustrate the wiring diagrams for actuators type 2.2 – 5.0 kN and
actuators type 12.0 – 15.0 kN respectively. To connect the thrust actuator up to the
electrical power supply, proceed as follows:

Step A: Run the thrust actuator a few mm out of the lower final position applying
the manual mode.
Step B: Loosen countersunk screw in hood, carefully remove hood in upward di-
rection.
Step C: Remove blind plug from the cable gland.
Step D: Insert the connection cable through this cable gland until sufficient conduc-
tor length is available up to the corresponding terminals. Then tighten the
cable gland until the connecting cable is clamped in place inside it.
Step E: Strip connecting cable approx. 1 – 1.5 cm above cable inlet.
Step F: Strip the individual conductors approx. 5 mm away from the end and fit with
terminal lugs.
Step G: Connect protective conductor of connecting cable up to protective conductor
terminal of thrust actuator.
Step H: Connect neutral N/MP conductor of connecting cable up to terminal 1/N of
thrust -actuator terminal strip.
Step I: Connect pulse line for move-out connecting rod up to terminal 11 of thrust-
actuator terminal strip.
Step J: Connect pulse line for move-in connecting rod up to terminal 14 of thrust-
actuator terminal strip.
Step K: Place hood on carefully from above and mount firmly onto thrust actuator
with countersunk screw and rubber gasket.
Step L: Connect supply line to mains and run thrust actuator to each of the final
positions, also checking to see whether the direction of movement on the
thrust actuator corresponds to the desired direction.
Step M: 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 swob-
bed.

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Wiring diagram for actuators type 2.2 - 5.0 kN

Trip sllide optional

Figure 8 om5510_04_8x0609340en.1.wmf

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Wiring diagram for actuators type 12.0 - 15.0 kN

Trip sllide optional

Figure 9 om5510_04_92x0729720en.wmf

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4 Settings

4.1 Torque switches -standard feature

Thrust actuators are as standard equipped with a load-dependent travel switch for the
closing direction (S1), and a load-dependent travel switch for the opening direction
(S2). The load-dependent travel switches (S1, S2) switch off the motor as soon as the
factory-set thrust force is attained.

Note: The settings of the load-dependent travel switches must on no account

whatsoever be changed.

4.2 Setting of optional travel switch (S3)

4.2.1 2-way valve

The stroke-dependent travel switch (S3) is activated by an optional trip slide. It
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 travel switch S3 is set in such
a way that the motor of the thrust actuator is switched off as soon as the maximum
valve-lift is attained. If the thrust actuator is supplied on a three-way valve, the trip
cam belonging to travel switch S3 is set in the opening direction in the optional trip
slide to such a downward extent that the upper final position of the valve is attained
prior to travel switch S3 being reached, thus causing the load-dependent travel switch
S2 to switch off the motor. For this function, all three switches reveal interlock-con-
trolled circuitry on the board. If the standard travel switches are to be integrated directly
into the facility control system, the standard board can be replaced by optional boards
PA or NA (only 2.2 – 5.0 kN)

On delivery of the thrust actuator, the optional travel switch (S3) is already set to the
existing valve-lift and the setting spindle for the travel switch (S3) is sealed with screw
glyptic. This setting needs no changing for normal operation.

If reinstalling the thrust actuator on a straight-way valve, the travel switch (S3) needs
to be set as follows:

Step A: Move valve out of the lowest position so as to run valve-lift to up position.
Step B: Using a screw driver, proceed to turn setting spindle for switch (S3) until
the trip cam arriving from below trips the switch (audible click).
Step C: 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).
Step D: If needed, correct the setting as described.

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4.2.2 3-way valve

• Step A: If reinstalling the thrust actuator on a three-way valve, the travel switch
(S3) needs to be set as follows:
Step B: Run valve in both final positions and check in each final position wheth-
er the valve switches off via the load-dependent switches.
Step C: Carry out a check in the top final position the see whether, after switch-
ing off the thrust actuator, the trip cam of the travel switch (S3) is situated
below switch (S3) and has not tripped the latter. If the trip cam is situated
above the travel switch (S3) or trips the same, the setting spindle gov-
erning the travel switch (S3) needs to be turned until the trip cam is
situated below travel switch (S3) without tripping it.
Step D: 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.
Step E: f needed, correct the setting as described above.

4.3 Potentiometers

An optional trip slide is required to install 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 RI21. A maximum of 2 potentiometers can be installed (= 1 double
potentiometer). The potentiometers can be supplied with different resistance values.

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 deter-
mined in respect of each valve-lift between the toothed rack on the trip slide and the
pinion on the potentiometer shaft. Use must only be made of the pinion specified for
the valve-lift.

If the thrust actuator is supplied with the valve and built-in potentiometer, the poten-
tiometer is assembled and set ready for operation. To achieve optimal electromagnetic
compatibility it is recommended to use shielded cables for connecting potentiometers
or standardized active current or voltage signals.

4.3.1 Installing the potentiometer

If retrofitting the potentiometer, proceed as follows:

Step A: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.
Step B: Loosen countersunk screw in hood, carefully remove hood.
Step C: Plug in the flat connectors on grey potentiometer cables onto the middle
connector pins, those of the red cables onto the upper connector pins and
those of the yellow cables onto the lower connector pins of the potentiometer
(see Figure 10, Figure 11, and Table 4).
Step D: Insert the potentiometer into the guide in the way that the pinion (50.73) of
the potentiometer meshes with the gear stick of the trip slide.

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Step E: With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand
window of board support (50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook into
the cut-out below the potentiometer.
Step F: With a valve lift between 30 mm and 50mm, hook spiral spring (50.70) into
the right-hand window (for 12.0 – 15.0 kN middle window) above the po-
tentiometer guide, insert into the guide between the slide block and the po-
tentiometer guide and hook into the cut-out below the potentiometer.
Step G: With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70) into
the middle window in board support (50.42) above the potentiometer guide,
insert into the guide between the slide block and the potentiometer guide
and hook into the cut-out below the potentiometer.
Step H: Check to see whether pinion (50.73) is pressed into toothed rack by spiral
spring (50.70) and is positioned free from backlash.
Step I: If this is not the case, remove spiral spring (50.70), readjust by bending a
little, and place back in position again.
Step J: Screw jack strip of connecting cable (50.68) to board support (50.42) with
two self-tapping screws (50.69), (single potentiometer connectors 25-27).
Step K: Insert additional 3-pole connector (50.74) in jack strip of connecting cable
(50.68).
Step L: Set potentiometer.
Step M: Place hood carefully onto thrust actuator and fasten it on the actuator with
rubber gasket and countersunk screw.

Installation of potentiometer

Figure 10 om5510_04_10x0621140en.jpg

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Potentiometer connection cable

Figure 11 premio_11x0291060en.tif

Part list for potentiometer PREMIO 2.2 - 5.0 kN

Pos. Designation Pos. Designation Pos. Designation
50.4 Board support 50.6 Potentiometer 50.71 Slide block (potenti-
2 7.3 ometer)
50.4 Washer
6
50.4 Circuit-diagram sticker Connecting cable for Pinion (selection de-
50.6
7 option: pends on
8
potentiometer 50.73 valve lift 20, 30, 50, 65,
50.6 Hexagon nut 50.6 Self-tapping screw 80)
7.1 9
50.6 Tooth lock washer 50.7 Spiral spring (option: Connector, 3-pole
50.74
7.2 0 potentiometer) (option: potentiometer)

Table 4

4.3.2 Setting the potentiometer

To set the potentiometer, proceed as follows:

Step A: Move thrust actuator to closing position.

Step B: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.
Step C: Using a screw driver, turn slotted potentiometer shaft in counter-clockwise
direction until reaching the travel stop. This places the potentiometer in the
initial position (approx. 0 ohm).
Step D: For checking purposes, the resistance of the potentiometer needs to be
measured using an ohmmeter.
Step E: Measure the resistance on potentiometer 1 between terminals 25 and 26.
Step F: Measure the resistance on potentiometer 2 between terminals 28 and 29.
Step G: In this position of the actuator, the measured value should be approx. 0 ohm.
Step H: Run thrust actuator to upper final position and read corresponding resistance
value on ohmmeter.
Step I: The resistance values thus measured need to be taken into account for the
settings to the facility control system.

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4.4 Electronic position controller ES11 (option)

The electronic position controller ES11 converts continuous input control signals
0(2) .. 10 VDC or 0(4) .. 20 mA into a 3-point output signal for the motor, in which
case interrogation of the valve 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 op-
erating instructions are supplied with each unit.

Installing RI21 / ES11 / heating 2.2 - 5 kN

Figure 12 om5510_04_11x0621150en.jpg

Part list for position controller

Pos. Designation Pos. Designation
50.78/79 Option ES11 50.81 Head cap screw DIN EN ISO 4762 - M4x8
50.80 Holding bracket 50.82 Head cap screw DIN EN ISO 4762 - M4x12

Table 5

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5 Starting up
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 reg-
ulations.
• Hood of thrust actuator assembled.
• Start up only by qualified personnel.

Warning: 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 placing into service proceed as follows:

Step A: Use the handwheel, to run the thrust actuator to approximately mid lift po-
sition.
Step B: 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 swopped on the thrust actuator.
Step C: Run thrust actuator to the final position in each direction of movement and
check whether it switches off automatically and whether all externally mov-
ing parts are able to move freely.
Step D: If failing to function properly, check all installation and setting work previ-
ously carried out, correcting if necessary, and afterwards place into service
once again.

6 Care and maintenance

The thrust actuator requires very little maintenance. Accordingly maintenance in
specified intervals is not necessary. 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.

7 Dismantlement of the thrust actuator

In addition to general installation guidelines, the following points are required to be
observed:

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• Dismantlement of the thrust actuator from the fitting must only to be carried out
by suitably qualified personnel.
• The supply line for connecting up the thrust actuator must be in the dead state i.e.
disconnected while dismantlement work is being carried out. After being discon-
nected, the mains power must be prevented from being switched back on again
accidentally.
• The system must be run down (depressurised state) as the valve cone is not held
without the thrust actuator and would thus be conducted by the system pressure.
• Valve cone approximately in mid lift position -on no account supported inside a
seat.
To dismantle the thrust actuator proceeds as follows:

Step A: Loosen counter-sunk screw in hood, carefully remove hood.

Step B: Disconnect all cables led into thrust actuator from outside and remove from
thrust actuator.
Step C: Place hood on carefully from above and fix in place with counter-sunk screw
and rubber gasket.
Step D: Loosen grub screw inside torsion safety feature; screw coupling out of tor-
sion safety feature.
Step E: Loosen clamping bolts connecting the thrust actuator to the fitting.
Step F: Remove thrust actuator from valve.

8 Troubleshooting
In the event of malfunctions or disturbances in operation, first check whether the in-
stallation 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 correspond to those specified on
the type identification plate.

Warning: All relevant safety regulations must be observed when carrying out the
troubleshooting procedure.

Contact Alfa Laval faults cannot be rectified on the basis of the following trouble-
shooting table:

Troubleshooting table
Fault Possible causes Remedy
Power failure Ascertain and eliminate cause
Fuse has blown Replace fuse
Rectify connection on thrust actuator in
Thrust actuator not properly connected
accordance with wiring diagram
Thrust actuator fails to move
Short circuit due to: Ascertain exact cause,
-moisture Dry the thrust actuator and eliminate leak-
age
-wrong connection

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Thrust actuator alternates between clock-
wise and counter-clockwise rotation
Thrust actuator fails to run to final posi-
tions and also produces chatter
Periodic failure on thrust actuator
Thrust actuator is switched off in opening
direction prior to load-dependent switch
(three-way valve)
Table 6
Language UK
Troubleshooting table
-motor has burned out
Connector contacts not plugged in/ not
properly plugged into jack strip
(Only for 12.0 – 15.0 kN)
Hand wheel is still engaged and does not
disengage when the motor starts up
Motor operating capacitor defective
Load-dependent travel switches out of ad-
justment / defective
Voltage drop due to excessively long con-
necting cables or inadequate conductor
cross-section
Mains fluctuations beyond permissible
tolerance travels
System pressure too high
Loose connection on feed line
Travel switch (S3) not set corresponding
to use
Rectify connection on thrust actuator in
accordance with wiring diagram
Check whether the mains voltage agrees
with the voltage specified on the rating
plate. Have motor changed.
Insert connector firmly in jack strip thus
affected
Unscrew the motor mounting screw clos-
est to the cable feed-through. (Manual re-
lease of the hand wheel disengagement
mechanism)
Have motor operating capacitor replaced
Remove thrust actuator and send to for
repair
Lay connecting cables in accordance with
requisite output
Arrange for "clean" mains system within
requisite tolerances
Reduce system pressure
Tighten connections on terminal strips
Set travel switch (S3) in accordance with
operating instructions
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