Orton GS Series Valve Manual

Centred Rubber Seated Valves
DS SERIES
USER GUIDE
CENTRED RUBBER SEATED VALVES USER GUIDE
DS SERIES
INDEX
SECTION 1 PRECOMMISSIONING & COMMISSIONING ……………………………….. Pag.1
SECTION 2 VALVE HANDLING & ERECTION ……………………….……………………. Pag.5
SECTION 3 STORAGE ……………………………………….……………………………….. Pag.7
SECTION 4 MAINTENANCE ………………………………………………………………... Pag.9
SECTION 5 VALVE SERVICE CONDITION …………………………...……………………………….. Pag.15
SECTION 6 P.E.D. OPERATING & SAFETY INSTRUCTION …………………...…………………………… Pag.17
SECTION 7 ATEX OPERATING & SAFETY INSTRUCTION ………………...……………………………….. Pag.20
SECTION 8 OPERATIONAL TESTS ………………...……………………………….. Pag.26

DS SERIES
SECTION 1
PRECOMMISSIONING &
COMMISSIONING
CENTRED RUBBER SEATED VALVES 1 USER GUIDE
DS SERIES
SECTION 1 PRECOMMISSIONING & COMMISSIONING

1.1 Inspection
 Remove the valve from the shipping package, taking care to avoid any damage to the valve and/or actuator
 Remove the flange protectors and clean carefully
 Clean the internal part of the valve with an air line, ensuring the absence of solid objects coming from the package,
plastic coatings etc.
 Check the integrity of the seat ring
 Check that the materials listed on the valve label are appropriate for the service intended and that they are as specified
1.2 Installation
General information for installation on site
 The valve can be installed in the pipeline in any position

 Before installing the valve, the pipeline must be cleaned from dirt and welding residues, otherwise seat may be damaged
 Pipe must be free of tension
 Series DS butterfly valves shall be installed directly in between flanges without
interposing any gasket.
Installation in line related to wafer butterfly valve series DS (on the existing pipe)
 Verify the distance between two flanges to be equal to face to face valve dimension
 In order to facilitate installation of the valve, allow with adequate tools a sufficient room in between flanges
 Insert in the lower part of flanges at least two flange-bolts
 Close valve disc partially so that the disc edge is at least 10 mm within the body
 Insert the valve in between flanges. Valve will be held by the two flange-bolts previously fitted in the lower part of flanges
 Insert the flange bolts through centring lugs of valve
 Insert all the remaining flange-bolts aligning the valve with the flanges and tightening flange-bolts manually
 Maintain the valve aligned, remove gradually flange spreaders and tighten bolts partially
 Control open and close operation of valve to be easy and smooth
 Open the valve and complete cross tighten the bolts to adequate torque
 Installation of lug type butterfly valves has same procedure of wafer type using studs instead of bolts and nuts
Installation in line related to wafer butterfly valve series DS (in the new pipeline)
 Shut partially valve disc until disc profile is at least 10 mm within the body
 Centre the two flanges with the valve body
 Span the body with some flange-bolts and tighten the bolts partially. Finish tightening by uniform cross bolting
 Use the flange-valve-flange unit to fit up and pipe centring
 Tack weld the flanges to the pipe
 Remove the bolting and the valve from the flanges. Important: do not complete flanges welding procedure when the
valve is inserted as high heat temperature can damage valve seat
 Weld flanges to the pipe and wait until complete cooled
 Install the valve following the installation instructions on existing pipeline
Important
 Before shipment seat surface and stems are lubricated with a mixture of silicon grease. If same is considered not
necessary, it can be removed with solvent. In case the valve is for oxygen, hydrogen and chlorine service, the valve is
perfectly cleaned and degreased.
 ORTON Butterfly with disc and stems in stainless steel and with the seat duty selected, when cleaned and degreased,
can be used with food products.
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1.3 Correct Installing Procedure
 Spread flanges to facilitate valve insertion with disc in semi-closed position

 This avoids disc edge to be damaged during installation and reduce interference; moreover reduces initial torque
 Disc has to be completely open after having aligned valve in between flanges before tightening all bolts
1.4 Uncorrect Installing Procedure
 A pipe flange not spread enough can tear rubber. Open disc when installing the valve, may hit against pipe flanges and may
cause damage to disc profile
 Valve installation with totally closed disc can distort seat during bolt tightening and may increase initial torque
 Do not use gaskets between valve and flanges
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1.5 Functional Test
 Stroke the valve to its “full open” and “full closed” positions to check the valve operates correctly
Important
If the piping is under pressure with water for testing and if it is shut down after testing for a long time it is essential to either:
 Use corrosion inhibitor in the water to pressurise the pipe
 Depressurise the pipe and completely drain the test water after testing
 Manoeuvre the valve through a complete opening / closing cycle and leave the disc in half-open position.
Warning - Safety rules for operation
As the media can be corrosive, toxic, inflammable or contaminating, the following safety precautions must be taken before
disassembling the valve from the pipeline:
a) Check if there's upstream and downstream pressure in the pipe and in the valve; it's suggested to close the upstream and
the downstream valve.
b) Furthermore:
- always wear protective glasses
- always wear gloves and overalls
- always wear protective shoes
- make sure there is always running water available close to you
- make sure there is always a fire extinguisher, if the fluid is inflammable
TROUBLE-SHOOTER TABLE
Symptom Cause Resolution

Valve does not rotate 1. Actuator has failed 1. Replace or repair
2. Valve packed with debris 2. Flush or clean the valve
3. Stem key has sheared (over 12”) 3. Find cause of shearing and correctly replace stem key
Bottom flange gasket leaking 1. Bottom flange bolting loose 1. Tighten bottom flange bolting
2. Seat o’rings damage 2. Replace seat o’rings
3. Plug / Bottom flange gasket damage 2. Check and replace gasket
Valve leaking 1. Valve not fully closed 1. Close the valve
2. Debris trapped in valve 2. Cycle and flush (with valve open) to remove debris
3. Actuator mechanical stop improperly set 3. Remove the stop for closure and reset properly
4. Seat ring damaged 4. Replace seat ring
Jerky operation 1. Air supply is inadequate 1. Check for correct pressure and increase air supply
B pressure and/or volume if appropriate
2. Actuator / stem adapter misaligned 2. Remove actuator mounting and realign
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SECTION 2
VALVE HANDLING & ERECTION
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SECTION 2 VALVE HANDLING & ERECTION

Applicability
2.1 Packaging for shipment

 Pack the valves with the disc in slightly open position; protect the protruding rubber seat with Silicon grease and fix
plastic or wooden flange protectors with straps on the flange faces
 In case of bare shaft valves, cover the shaft ends with plastic tubes
 If a “fail open” hydraulic or pneumatic actuator is mounted to the valve, use the manual override to lock the disc in
the closed position; if a manual override is not included, construct a proper protective box
 The packing method is to be defined in the Customer’s order and it must be able to ensure safe transportation and
eventual storage
2.2 Handling
 Crate: handle the packed valves by means of fork lift truck
 Case: use the proper lifting points
 Unpacked valves: the handling must be carried out on pallets, paying attention to the machined surfaces or, in case of large
size using appropriate tools, i.e. brackets, hooks, fasteners, slings, etc. (see Figs. 1, 2, 3)
Caution
 For valve handling and/or lifting, size and select the equipment considering the valve weight indicated in the packing
list and/or delivery note.
 Take care to avoid damaging to the most delicate parts of actuators (see actuator manual)
 During handling, pay attention to avoid impacting and / or dropping the equipment. Respect and adhere to all local safety
regulations.
Fig.1 - Bare shaft valve or with manual gear Fig.2 - Valves with pneumatic or hydraulic actuator Fig.3 - Valves with electric actuator
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SECTION 3
STORAGE
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SECTION 3 STORAGE PROCEDURE
Applicability
Orton DS Series entire range: double flanged u-section, wafer, lugged standard versions
3.1 PRESERVATION PROCEDURE AND STORAGE ACTIVITIES
For a correct valve preservation & storage ORTON suggests to store the valves in a closed area to avoid contact with earth, sand
and other solids that could damage the rubber seat and the most delicate parts of the manual actuators.
 The suggested environmental conditions for the storage are:

- Temperature not higher than 50° C.
- Relative humidity less than 65%.
- Direct exposure to sunlight should be avoided
- Clean environment
 During the valves handling caution must be taken to avoid impact between them or with resistant solid bodies, particularly for
rubber seats and actuators.
We suggest to make sure that the valves discs are slightly opened and that they do not stick out from
valves face to face.
 If the valve is stored for long periods is suggested to operate it at least once a month for n°5 open/close complete cycles,
without a complete closing of the disc.
 Carry out periodical checks in the storage area to be sure of the continued above mentioned conditions
Note
Only if the valves have a proper packing, i.e. cases lined with tarred paper and contents well protected with barrier sacks,
the storage in an open area can be considered.
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SECTION 4
MAINTENANCE
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SECTION 4 MAINTENANCE
4.1 Use
The best result and a long lasting performance with ORTON butterfly valves is obtained when valve is used according to
relevant working conditions and in accordance with ORTON guideline tables as to pressure, temperature and media
indications contained in main ORTON catalogue for butterfly valves
Manual Operation
 Open and close operations are obtained with a quarter turn by handlever (90°) or gear operator with handwheel.
Handlever is supplied in ductile iron epoxy coated; on demand can be supplied in aluminium or in ductile iron rilsan
coated. Rilsan coating protection can stand a maximum temperature of 120°C. When watching to the lever position,
easy is to identify whether the valve is open or closed.
 The valve is in open position when the lever is in line with the pipe (i.e. when transversal to the valve).
 The valve is in closed position when the lever is transversal to the pipe (i.e. in line to the body valve).
4.2 Maintenance
Note:
If the valve is installed on the line and kept closed for long periods, we suggest to operate it at least once a month for 3 complete
open/close cycles.
 Series Ds butterfly valve do not require maintenance or periodical lubrication.

 Valve series DS is shop lubricated in rotating points with a mixture of silicon grease in proper stem grooves thus
remaining permanently active.
 Valve series DS in addition to normal lubrication is equipped with bronze bushings to ensure long lasting life and easy
operation. After some years service following possible leakage may occur
 Line leakage or stem leakage: control perfect line closing. In this case leakage is due to seat damaged or to
damaged disc edge. It will be then necessary to disassemble the valve and replace damaged parts
 Precautions before disassembling the valve from the line:
 Fluid flowing in a pipe could be corrosive, toxic, flammable or contaminating
 Before removing valve, inspect that no pressure is present in line, either upstream or downstream of the valve.
Suggestion is made as to close valves upstream and downstream to isolate the valve to be repaired.
 Following safety precautions are recommended when repairing the valve:
 Always wear protective glasses or eye shields
 Always wear gloves and overalls
 Wear protective footwear
 Ensure easy availability of running water
 Have ready an adequate fire extinguisher if media is flammable
 Shut almost completely the disc, remove all nuts and after all bolts with the exception of the two lowest sustaining the
valve
 Spread the flanges with proper tools and remove valve to substitute seat and disc (do not use the valve to spread
flanges, because seat damage might be the result).
 Open the valve
 Remove connecting screws between valve and gear operator
 Remove gear operator and pay attention for valve keys, that may fall out (over 12” diameter)
At this point maintenance changes depending on valve diameter.
4.3 A: for DS series from 1” ½ to 12”
4.3 B: for DS series from 14” to 24”
4.3 C: for DS series over 24”
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4.3 A
Valve disassembly from 1” ½ to 12” FIG.1 VALVE DISASSMBLY FROM 1” ½ TO 12”
1- Remove the seeger (9) from upper shaft (4)

2- Unloose anti blow out screws (12) and remove the
anti blow out (11)
3- Remove O’ring (8.1) from upper bearing (8)
4- Pull out upper shaft (4), and remove upper bearing
(8)
5- Unloose plug (6) and remove plug washer (10)
6- Pull out lower shaft (3)
7- Remove disc (2) pushing and turning it out from the
seat (7)
8- Remove seat (7) from valve body applying pressure
or by light wooden hammer blow or by using soft
tools
9- Remove O’ring (5) from the seat
10- Inspect all parts and replace when necessary
Valve assembly from 1” ½ to 12”
1- Apply silicon grease on body internal diameter (1)

2- Insert O’rings (5) on seat (7) and lubricate
3- Insert seat (7) in the valve body (1)
4- Match perfectly seat holes (7) with body holes (1)
using a round bar with a conical end
5- Apply silicon grease on internal seat surface (7) in
contact with disc edge
6- Insert disc (2) pushing and rotating it towards the
seat locating (7) the square connection aligned to the
valve neck
7- Insert grease lubricated lower shaft (3) in the body
(1)
8- Loose plug (6) with relevant washer (10)
9- Insert the upper bearing (8)
10-Insert grease lubricated upper shaft (4) in the body
(1)
11- Insert upper bearing O’ring (8.1)
12- Insert anti blow out (11) and loose anti blow out
screws (12)
13- Insert seeger (9) on upper shaft (4)
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4.3 B
Valve disassembly from 14” to 24” FIG.2 VALVE FROM 14” TO 24”
1- Unloose anti blow out screws (12.2) and remove

the anti blow out (12)
2- Remove seeger (12.1) from upper shaft (4)
3- Pull out upper shaft (4)
4- Remove upper bearing (11) with relevant O’rings
(11.1 e 11.2)
5- Remove spacer (10) and bearing (9)
6- Unloose bottom flange screws (6.2) and remove in
sequence: washer (6.3), bottom flange (6) and
relevant gasket (6.1)
7- Remove lower shaft pin (3.1) and lower shaft (3)
seat (7) and after remove disc bearing (8)
9- Remove seat (7) from valve body applying
pressure or by light wooden hammer blow or by
using soft tools
10-Remove O’rings (5) from the seat
Valve assembly from 14” to 24”
1- Insert bearing (9) in the upper body hub (1)

4- Insert seat (7) in the body (1)
7- Insert disc bearing (8) in the disc, after Insert disc
(2) pushing and rotating it towards the seat
locating (7) the square connection aligned to the
valve neck
8- Insert grease lubricated lower shaft (3) and lower
shaft pin (3.1) in the body (1)
9- Assembly bottom flange (6) with relevant gasket
(6.1), loosening bottom flange screws (6.2) with
relevant washer (6.3)
10-Insert bearing (9) and spacer (10)
11-Insert upper bearing (11) with relevant O’rings
(11.1 e 11.2)
12- Insert grease lubricated upper shaft (4) in the
body (1)
13-Insert seeger (12.1) on upper shaft (4)
screws (12.2)
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4.3 C
Valve disassembly over 24” FIG.3 VALVE OVER 24”

1- Unloose bottom flange screws (6.2) with relevant
washer (6.3) and remove bottom flange (6) with
relevant gasket (6.1)
2- Unloose thrust bearing nut (6.4) and remove thrust
bearing (6.5), after unloose thrust bearing stud bolt
nut (6.6) and remove thrust bearing stud bolt (3.1)
3- Unloose anti blow out screws (10.2), remove the
anti blow out (10) and seeger (10.1) from upper
shaft
4- Unloose pin nuts (4.3) and remove pins (4.1) with
relevant O’rings (4.2)
5- Remove in sequence upper shaft (4) and upper
bearing (9) with relevant O’rings (9.1 e 9.2) from
the valve body
6- Pull out lower shaft (3)
seat (7)
8- Remove the seat (7) from valve body applying
pressure or by light wooden hammer blow or by
using soft tools
9- Remove O’rings (5) from the seat and remove
bearings (8) from body hubs
Valve assembly over 24”

1- Insert bearings (8) in the body hubs
4- Insert seat (7) in the body (1)
7- Insert pins (4.1) to verify disc-shafts coupling
8- Insert disc (2) in the seat (7)
9- Insert grease lubricated lower shaft (3) in the body
(1)
10- Insert upper bearing (9) with relevant O’rings (9.1 e
9.2)
11- Insert grease lubricated upper shaft (4) in the body
(1)
12- Insert pins (4.1) with relevant O’rings (4.2) and
loose the pin nut (4.3)
13- Insert seeger (10.1) on the upper shaft (4)
screws (10.2)
15- Loose thrust bearing stud bolt (3.1) in the lower
shaft (3) anti loose thrust bearing stud bolt nut (6.6)
16- Insert the thrust bearing (6.5) and loose the thrust
bearing nut (6.4)
17- Verify when the bottom flange (6) is in contact with
the body (1), no space remain between nut (6.4)
and bottom flange
18- Insert bottom flange O’ring (6.1) and loose bottom
flange screws(6.2) with relevant washer (6.3)
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Table 2
Tightening Torque for Bolt & Screws
Bolt Dim. Torque Value
mm Nm
8 20
10 45
12 70
14 110
16 175
18 235
20 340
22 370
24 450
27 600
30 750
33 780
36 1020
39 1310
42 1630
45 2030
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SECTION 5
VALVE SERVICE CONDITION
NOTE : If the valve is supplied with P.E.D. certification

(Pressure Equipment Directive 97/23/CE) refer to Section 6
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SECTION 5 VALVE SERVICE CONDITION
LABEL
DS-DL SERIES VALVES MUST BE USED IN STRICT ACCORDANCE WITH THE

SERVICE FOR WHICH THEY WERE PURCHASED.
ABRASIVE APPLICATIONS
PERIODIC INSPECTION IS HIGHLY RECOMMENDED. CONSULT ORTON.
RESPONSIBILITY
FCx ORTON DECLINES ANY RESPONSIBILITY IN CASE OF APPLICATIONS

OVER THE LIMITS INDICATED IN THE LABEL
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SECTION 6
P.E.D. OPERATING & SAFETY INSTRUCTION
NOTE : Refer to this section if the valve is supplied with P.E.D. certification
(Pressure Equipment Directive 97/23/CE)
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SECTION 6 P.E.D. OPERATING & SAFETY INSTRUCTION
IMPORTANT:
This document is an integral part of valve Maintenance and Operating manual.
Valve must be strictly used in accordance with the “Essential Safety Requirements” stated below.
Orton is not liable for any misuse of valve outside the limits imposed by the “Essential Safety
requirements”.
According to directive 97/23/EC valves installed in the European Community

are provided, if applicable, with the following CE label:
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ESSENTIAL SAFETY REQUIREMENTS (to be followed by the end user)
Valves must not be used outside the relevant values of working temperature ( min/max WT ).
The pressure values to which the valve can be used, with disk opened, must be evaluated in
relationship to the maximum body design pressure at room temperature and in relationship to the
actual working temperature in accordance with the standard ASME B16.34.
Such standard defines a decreasing of the maximum working pressure of a material with
increasing temperature.
In every case with disk closed the pressure value at which the valve sealing has been tested must
not be overcome.
Classification of the valve according to the directive is performed considering the process fluid the
valve shall operate with, specified in the offer/order phase.
Any use of valves with fluids different from the one specified must be previously evaluated and
accepted by Orton.
In order to maintain a good performance of the valve, spare parts must be substituted before they
could lead to a leakage, in line or to the external, greater than the maximum allowable leakage
accepted by the end user.
The period after which spare parts shall be substituted depend greatly on the fluid process and on
the operating conditions (pressure/temperature).
A periodical check of the seal conditions may be done by the end user or during plant shut-off
phases.
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SECTION 7
ATEX OPERATING & SAFETY INSTRUCTION
NOTE : Refer to this section if the valve is supplied with ATEX certification
(ATEX Directive 94/9/CE)
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SECTION 7 ATEX OPERATING & SAFETY INSTRUCTION
IMPORTANT:
requirements”.
According to ATEX directive 94/9/CE valves installed in the European

Community are provided, in case required by the end user, with the following
CE label:
where each item has the following meaning:
1 – Valve series according to Orton std

2 – Nominal diameter of the valve (mm)
3 – Rating of valve body end connection (i.e. Cl.150, Cl. 300, 150 psi, …)
4 – Valve serial number
5 – Year of construction
6 – User Valve TAG code
7 – Reference to Orton Technical File produced in accordance with Directive 94/9/EC att. VIII
8 – CE mark
9 – Ex mark
10 – Orton valve classification as explained below
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II 2 GD c II Tx min/max WT (*) Tech.File: ST 04-215
II 2 = Group II (surface), category 2

G = Explosive Atmosphere with gases, vapours, mists or air/dust mixtures presence
D = Explosive Atmosphere with dust presence
II = Gas group
c = Protection mode for non electrical equipment “constructional safety”
TX = Max Surface temperature
The valve is classified TX, since the temperature depends from the process media passing through the valve.
min / max WT (*) = min / max working temperature : -196°C / + 550°C
The min / max working temperatures are listed in the valve main name plate.
Tech.File: ST 04-215 = reference of Technical File deposited to Notified Body (DNV ITALIA)
Correspondence between hazardous areas, substances and categories
Zona pericolosa Categories in accordance with Directive

94/9/CE
Gases, vapours or mists Zone 0 1G
Gases, vapours or mists Zone 1 2G or 1G
Gases, vapours or mists Zone 2 3G, 2G or 1G
Dusts Zone 20 1D
Dusts Zone 21 2D or 1D
Dust Zone 22 3D, 2D or 1D
 SCOPE
The aim of this instruction is to inform the final user about the necessary info to correctly and safely use Orton valve in order to
prevent the creation of potentially presence of explosive atmosphere or the ignition of explosion in case the valve is used in
explosive atmosphere.
 ADDITIONAL INFORMATION
In case of actuated valve, all the equipments and electrical components installed on it, shall be covered with a separated
certification in accordance with ATEX 94/9/CE.
All the components shall be suitable for use in classified zones with presence of Gas of group II and/or with presence of dust (group
III).
Orton butterfly valves shall be installed and maintained in accordance with the International standards relevant to installation in
hazardous area with risk of explosion in presence of gases / dusts (i.e. EN 60079-14, EN 60079-17)
In case of combustible dusts, regular clearing shall be performed in order to avoid dusts deposit.
All the maintenance operations shall be performed as explained in the maintenance manual and by qualified personnel only.
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 PREVENTION OF POTENTIAL IGNITION SOURCES
HOT SURFACE:
The valve surface temperature can reach the process design maximum temperature. The final user has to verify that the
temperature:
- can’t trigger the potential explosive atmosphere that could be present outside of the valve;
- can’t burn the dust present in the area where the valve is installed. Dust could deposit on the external valve surface. The
fire of that dusts may trigger a potential explosive atmosphere that can be present outside of the valve.
- Due to solar radiation, the external valve surface can reach temperature higher then dust ignition point. The dust fire could
ignite a potential explosive atmosphere that can be present outside of the valve.
Orton valve are designed to withstand the maximum temperature that the valve could reach due to an external fire in accordance
with ISO 10497 (as indicated on tag plate). It is recommended that final user acknowledge with the limits indicated in the applicable
Fire Safe standard.
The temperature classes and/or the maximum components temperature shall be suitable for the temperature limit of the installation
area.
The min / max working temperature WT are indicated on the valve name plate.
TX: the valve is classified TX because the temperature depends from the process media passing through the valve.
Base on the safety limits indicated in the standard EN 1127-1, it is final user responsibility to limit the external valve surface
temperature under the ignition point of some substances (i.e. gases, dust, liquid, mixture) present in the hazardous areas (refer to
areas classification)
In case of temperature higher than 440°C, the valve surface temperature shall be consider a remaining hazard of explosion. This
hazard shall be evaluated by the final user in accordance with the Directive ATEX 99/92/EC (Equipment and protective systems for
potentially explosive) or with other national standards.
FLAMES AND HOT GASES:
It is prohibited to use, near the valve during normal operation, flames and/or sparks (i.e. grinding) and/or electric arcs( i.e. any kind
of welding). In case some of the above potential sources is used, it is required to ensure that every possible potential explosive
atmospheres, inside and outside of the valve, are completely removed.
Orton valve are designed to withstand the maximum temperature that the valve could reach due to an external fire in accordance
with ISO 10497 (as indicated on tag plate). It is recommended that final user acknowledge with the limits indicated in the applicable
Fire Safe standard.
ELECTRICAL COMPONENTS
Ensure that the Ground Connection is directly connected with plant structures.
The valve doesn’t contain any electrical components. The only electrical components, if present, are installed on the actuator.
All the electrical components are purchased with ATEX marking and certification in accordance with Customer request and/or with
valve marking and certification. Please refer to dedicated Maintenance manual of each components for any additional info.
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STRAY ELECTRICAL CURRENT AND PROTECTION AGAINST CATHODIC CORROSION
Orton valve design guarantees the electrical continuity between every single components.
It is final user responsibility to ensure the equipotentiality between all the plant components directly connected to the valve.
STATIC ELECTRICITY
PAINTING
The glitters prevention on non-conductive surface is ensure for group IIG using gases and vapours by group IIA and IIB with a
minimum painting thickness ≤ 2mm. In case of group IIC, the minimum painting thickness shall be ≤ 0,2 mm
THUNDERBOLT
It is final user responsibility to protect the valve installed using appropriated protection against thunderbolt.
The thunderbolt protection shall not compromised the corrosion cathodic protection.
ELECTROMAGNETIC WAVES, IONIC RADIATION, ULTRASUONDS, ADIABATIC COMPRESSION AND SHOCK WAVE
It is final user responsibility to verify that no source of electromagnetic waves, ionic radiation, ultrasounds, adiabatic compression
and shock waves are present as indicated in the standard EN 1127-1
EXOTHERMIC REACTION (INCLUDED DUST IGNITION)
The valve materials are in accordance with Customer request and verified with process data supplied.
In case final user decides to use the valve with different fluid, not indicated in the process data previously supplied, it is final user
responsibility to verify the valve material compatibility.
 PREVENTION OF POTENTIAL EXPLOSIVE ATMOSPHERE CREATION
FIRE EXPOSURE
The valves are designed to withstand the maximum temperature that the valve could reach due to an external fire in accordance
with ISO 10497 (as indicated on tag plate). It is recommended that final user acknowledge the limits indicated in the applicable Fire
Safe standard.
After Fire event, the valve shall be completely verified (metallic and non metallic components) before placing it again in service
EXPOSURE BELOW 0°C
When the valve is exposure at a temperature below 0°C, the process media passing through the valve can solidify increasing it is
volume. The volume increase can compromise the valve sealing. In this case, a valve pressurisation with potential explosive fluid
could generate an external leaking and consequently a creation of potential explosive atmosphere, with a possible propagation of
explosion inside of the valve.
It is final user responsibility to verify that the fluid, during testing, normal o malfunction operation, shouldn’t solidify due to a
temperature reduction.
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RATING OVERPRESSURE EXPOSURE
On the valve name plate it is clearly indicated which are the pressure and temperature limits for a correct and safety valve use.
The Rating overpressure exposure can damage the valve body and compromise the sealing capability.
MECHANICAL EXTERNAL STRESSES
Orton valve body is different from other type of valve, for example ball or gate valve. The valve body is similar to the pipeline but it
has an higher thickness that allows Orton valve to withstand the pipeline stresses without compromising the valve performance.
In case the valve is stressed during operation, the weakest point are the connecting flanges. As a matter of fact, connecting flanges
have always a thickness higher than the pipeline on which the valve is connected / installed.
FABRICATION AND SEALING MATERIAL SELECTION
The fabrication and sealing valve material are in accordance with Customer request, verified with process data supplied.
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

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SECTION 8
OPERATIONAL TESTS
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26
DS SERIES
Full Stroke Test
The “Full Stroke Test” (“On/Off line”) must be executed to satisfy PFD (probably of failure on
demand) values reported in SIL Certification Documents.
 Test Interval = 8760 h/ year

 Procedure:
o the valves should be operated for n.° 2 open/close complete cycles without complete
closing the valve (to verify the Failure to deliver a full stroke)
o the valves should be operated for n.° 2 open/close complete cycles closing under
complete torque the valve (to verify the Failure to leak tight shut-off (TSO))
o See provided Orton Facility Test Certificates in terms of :
 Required Open – Closure Times
 Allowable Leakage
 Allowable Pressure Drop across valve trim.



Partial Stroke Test (when requested)
When a restricted rotation successfully carried out it becomes highly likely that the remaining
rotation will be carried out as well. A typical partial stroke value can be 20 degrees
There is no risk of seat seals coming loose with slow partial stroke at high differential pressure or
with assuming the partial opening position for some time
Summarising it is stated that Orton MV Series Valves successfully delivers on demand a partial
stroke, then it is highly likely that the valve is capable to make the full quarter turn.
The “Partial Stroke Test” (“On line”) must be executed to satisfy PFD (probably of failure on
demand) values reported in SIL Certification document.
 Test Interval = at least 4380 h/year

 Procedure: the valves should be operated for n.° 4 open/close cycles till 20 degrees min.
27
Triple Eccentric Metal Seated Valves
MV SERIES
USER GUIDE
Triple Eccentric USER GUIDE
Metal Seated Valves
MV Series
INDEX
SECTION 1 PRECOMMISSIONING & COMMISSIONING ………………………….. Pag.1
SECTION 2 VALVE HANDLING & ERECTION …………………….………………………. Pag.4
SECTION 3 STORAGE ……………………………………….………………………. Pag.6
SECTION 4 MAINTENANCE ……………………………………………………... Pag.8
SECTION 5 VALVE SERVICE CONDITION …………………...……………………… Pag.14
SECTION 6 P.E.D. OPERATING & SAFETY INSTRUCTION …………...………………………………. Pag.16
SECTION 7 ATEX OPERATING & SAFETY INSTRUCTION …………………………………. Pag.19
SECTION 8 OPERATIONAL TEST ………………...……………………………………………. Pag.25

Metal Seated Valves
MV Series
SECTION 1
PRECOMMISSIONING &
COMMISSIONING
1
Metal Seated Valves
MV Series
SECTION 1 PRECOMMISSIONING & COMMISSIONING

1.1 Inspection
 Remove the valve from the shipping package, taking care to avoid any damage to the valve and/or actuator
 Remove the flange protectors and clean carefully, then remove the protective oil from both machined surfaces
with a solvent
 Clean the internal part of the valve with an air line, ensuring the absence of solid objects coming from the package,
plastic coatings etc.
 Check the integrity of the seal ring, especially in case of “fail-open” actuator presence
 Check that the materials listed on the valve label are appropriate for the service intended and that they are as specified
 Define the preferred mounting orientation with respect to the system pressure. Please remember that the valve is
properly installed when the high pressure acts on the shaft side of the disc (refer to the arrow label)
1.2 Installation
 The valve should be installed with shaft in horizontal position, or off of vertical in order to minimise any problem associated
with solid particles present in the media that, otherwise, could deposit in the lower bearing area.
 It is suggested to install the valve at least 5 times the pipe ND from any curve
 Unless otherwise specified, the disc should be in the slightly open position to ensure that the seal ring cannot be damaged
during installation. Particular care should be taken with valves equipped with “fail-open” actuators: if there is no manual
override, connect the actuator to the supply media, to close the disc prior to installation (especially for wafer and lug body
styles)
 The valve should be fitted between the pipe flanges inserting two gaskets to guarantee the seal to atmosphere
 Valve body thermal insulation is suggested for operating temperatures over 200°C
 The use of hexagonal head bolts or shorter studs is recommended when the valve has threaded tapped holes in the neck
areas; tighten with a load adequate to the chosen gaskets
 Follow the criteria and instructions of section 2 for handling and lifting of the valves during the installation.
Caution
Perform piping flushing before installation; if not possible, keep the disc in fully open position before starting with flushing.
When the pipe is lined, pay attention that the disc does not come in contact with the lining during its stroke, especially with wafer
and lug bodies.
1.3 Functional Test

 Valve packing has been already pre settled in ORTON before shipping; if during normal operation a leakage is detected
from packing, tighten the packing just to prevent stem leakage.
Over-tightening increases the operating torque and decreases the packing life (see Table 1).
 Stroke the valve to its “full open” and “full closed” positions to check the valve operates correctly
 To verify the valve orientation, the disc position indicator mark on the shaft should rotate between the cast bosses on the
upper flange of the valve body for valves with top circular flanges. The disc rotates clockwise to close.
Important
If the piping is under pressure with water for testing and if it is shut down after testing for a long time it is essential to either:
 Use corrosion inhibitor in the water to pressurise the pipe
 Depressurise the pipe and completely drain the test water after testing
 Manoeuvre the valve through a complete opening / closing cycle and leave the disc in half-open position.
Warning - Safety rules for operation
As the media can be corrosive, toxic, inflammable or contaminating, the following safety precautions must be taken before
disassembling the valve from the pipeline:
a) Check if there's upstream and downstream pressure in the pipe and in the valve; it's suggested to close the upstream and the
downstream valve.
b) Furthermore:
- always wear protective glasses
- always wear gloves and overalls
- always wear protective shoes
- make sure there is always running water available close to you
- make sure there is always a fire extinguisher, if the fluid is inflammable

Metal Seated Valves 2
MV Series
TROUBLE-SHOOTER TABLE
Symptom Symptom Resolution

Valve does not rotate 1. The packing is too tight 1. Loosen gland nuts
2. Actuator has failed 2. Replace or repair
3. Valve packed with debris 3. Flush or clean the valve
4. Stem key has sheared 4. Find cause of shearing and correctly replace stem key
5. Fluid solidification between bearings and shaft 5. Flush bearings using flushing taps (if present)
Stem packing leaking 1. Gland flange nuts too loose 1. Tighten gland flange nuts - See Table 1
2. Packing damaged 2. Replace packing - See paragraph 4.1
Bottom flange gasket leaking 1. Bottom flange bolting loose 1. Tighten bottom flange bolting
2. Check the spiral groove on the body and replace gasket -
2. Spiral wound gasket damage
b See paragraph 4.3
Valve leaking 1. Valve not fully closed 1. Close the valve
2. Debris trapped in valve 2. Cycle and flush (with valve open) to remove debris
3. Actuator mechanical stop improperly set 3. Remove the stop for closure and reset properly
4. Seal ring damaged 4. Replace seal ring - See paragraph 4.2
Jerky operation 1. Packing is too tight 1. Loosen gland nuts, cycle valve, retighten - See Table 1
2. Check for correct pressure and increase air supply
2. Air supply is inadequate
B pressure and/or volume if appropriate
3. Actuator / stem adapter misaligned 3. Remove actuator mounting and realign
Table 1
USE
Torque Values for Gland Flange Nuts
ND Cl.125 Cl.150 Cl.300 Cl.600 Cl.900
General use
in. mm Nm Nm Nm Nm Nm
The MV Series valves are torque seated, so for: 3 80 5,0 5,0 5,0 6,0 -
4 100 5,0 5,0 5,0 11,0 -
 Manual operated valves 6 150 6,0 6,0 6,0 20,0 -
8 200 6,0 6,0 12,0 26,0 81,0
Operate the valve applying the required torque; 10 250 12,0 12,0 14,0 54,0 115,5
do not force with added levers. 12 300 14,0 14,0 15,0 59,0 129,0
To close, rotate the hand-wheel clockwise. 14 350 16,0 16,0 30,0 63,0 129,0
16 400 30,0 30,0 32,0 89,0 285,0
 Pneumatically actuated valves 18 450 32,0 32,0 41,0 104,0 327,0
20 500 41,0 41,0 47,0 174,0 493,5
Be sure of the correct pressure level of the supply media. 24 600 47,0 47,0 72,0 233,0 406,5
If the manual gear has been used, take care 28 700 72,0 72,0 111,0 297,0 450,0
to disconnect it (after the use). 30 750 101,0 101,0 111,0 297,0 552,0
In case micro switches are used, take particular 32 800 101,0 101,0 111,0 336,0 552,0
care in connecting all the components in the correct way 36 900 111,0 111,0 129,0 305,0 711,0
(e.g. in a such way not to exchange "open" with "closed") 40 1000 120,0 120,0 173,0 336,0 -
to obtain the correct signalling. 42 1050 120,0 120,0 173,0 336,0 -
44 1100 150,0 150,0 195,0 370,0 -
 Electrically operated valves 48 1200 173,0 173,0 218,0 - -
52 1300 187,0 195,0 - - -
Be sure of the correct electrical
56 1400 187,0 195,0 - - -
power requirements (Volts)
60 1500 187,0 235,0 - - -
64 1600 187,0 235,0 - - -
68 1700 220,0 235,0 - - -
72 1800 220,0 290,0 - - -
76 1900 255,0 290,0 - - -
Metal Seated Valves
MV Series
3
SECTION 2
VALVE HANDLING & ERECTION
4
Metal Seated Valves
MV Series
SECTION 2 VALVE HANDLING & ERECTION

Applicability
2.1 Packaging for shipment

 Pack the valves with the disc in slightly open position; protect the raised faces with protective oil (i.e. Valvoline oil Tectyl 846 )
and fix plastic or wooden flange protectors with straps on the flange faces
 In case of bare shaft valves, cover the shaft ends with plastic tubes
 If a “fail open” hydraulic or pneumatic actuator is mounted to the valve, use the manual override to lock the disc in
the closed position; if a manual override is not included, construct a proper protective box
 The packing method is to be defined in the Customer’s order and it must be able to ensure safe transportation and
eventual storage
2.2 Handling
 Crate: handle the packed valves by means of fork lift truck
 Case: use the proper lifting points
 Unpacked valves: the handling must be carried out on pallets, paying attention to the machined surfaces or, in case of large
size using appropriate tools, i.e. brackets, hooks, fasteners, slings, etc. (see Figs. 1, 2, 3)
Caution
 For valve handling and/or lifting, size and select the equipment considering the valve weight indicated in the packing
list and/or delivery note.
 Take care to avoid damaging to the most delicate parts of actuators (see actuator manual)
 During handling, pay attention to avoid impacting and / or dropping the equipment. Respect and adhere to all local safety
regulations.
Fig.1 - Bare shaft valve or with manual gear Fig.2 - Valves with pneumatic or hydraulic actuator
Fig.3 - Valves with electric actuator
5
Metal Seated Valves
MV Series
SECTION 3
STORAGE
6
Metal Seated Valves
MV Series
SECTION 3 STORAGE
Applicability
Orton MV Series entire range: double flanged, gate, wafer, lugged standard versions
3.1 PRESERVATION PROCEDURE AND STORAGE ACTIVITIES
For a correct valve preservation & storage ORTON suggests to store the valves in a closed area to avoid contact with earth,
sand and other solids that could damage the metal seal and the most delicate parts of the manual actuators.
 The suggested environmental conditions for the storage are:

- Temperature not higher than 50° C.
- Relative humidity less than 65%.
- Direct exposure to sunlight should be avoided
- Clean environment
 During the valves handling caution must be taken to avoid impact between them or with resistant solid bodies, particularly for
metal seals and actuators.
We suggest to make sure that the valves discs are slightly opened and that they do not stick out from
valves face to face.
 In case the valve will be in storage for a period longer than 6 months, Orton recommends to perform a functional test,
with a minimum of 5 open/close complete cycles, to check valve and actuator performances before installation.
 Carry out periodical checks in the storage area to be sure of the continued above mentioned conditions
Note
Only if the valves have a proper packing, i.e. cases lined with tarred paper and contents well protected with barrier sacks,
the storage in an open area can be considered.
7
Metal Seated Valves
MV Series
SECTION 4
MAINTENANCE
8
Metal Seated Valves
MV Series
SECTION 4 MAINTENANCE
4.1 Packing
If shaft leakage occurs through the packing, tighten the gland nuts slowly and evenly until the leakage stops (see Table 1).
Proceed as follows:
Caution
When tightening the gland nuts, use half-turn increments until leakage has stopped.
 Remove the gear / actuator and relevant connecting keys (2)

 Remove gland nuts (9). If present, remove belleville springs, paying attention to note their assembly configuration
in order to reassemble them correctly.
 Remove packing gland flange (6), anti blow-out ring (5) (if present) and packing follower (4).
 Remove old packing (3); if the packing flush option is present, remove lantern ring too (7).
 Clean packing cavity and shaft and apply a film of lubricant on internal body surface see (Tab.3).
 Insert new packing rings (and the lantern ring if present) in the same sequence as the one followed during disassembly;
 Reassemble packing follower, anti blow-out if present and gland flange; if applicable, assemble the belleville springs,
as noted in the relative previous point, then assembly the gland nuts and tighten with torque as per table 1
 Reassemble keys on the upper stem end
 Reassemble the gear / actuator and close the valve (make sure that both the valve and gear are in the open position when
mounting the gear).
Caution
Do not force actuator on the stem. This should be a free moving fit!
4.1.1 Packing Test After Maintenance

 Cycle the valve
 Re-pressurise the line
 If a leakage is detected, tighten the gland nuts slowly and evenly until the leakage stops (do not exceed values in Table1).
9
Metal Seated Valves
MV Series
4.2 Sealing Elements Maintenance

Proceed as follows:
Warning
Depressurise the line before starting any maintenance. Otherwise, serious personal injury and/or equipment damage may occur.
 Remove the valve from the line with the disc in closed position. If piping is large enough, the maintenance can be done
inside the line without removing the valve from the line
 Slightly open the valve
 Loosen the seal retaining flange screws (13)
 Completely open the valve
 Remove the retainer flange screws
 Remove retainer flange (10); take extra precautions to prevent damaging the body seat with retainer during removal
 Remove the seal ring (11) and the spiral wound gasket (12)
 If necessary, clean the body seat with solvent and then with fine abrasive cloth (n°600 or finer)
 Carefully clean the disc seal ring area and the spiral wound gasket groove in order to avoid foreign particles presence
 Apply a film of lubricant (in accordance with Tab.3) on the disc upper face (9), where the seal ring (11) and the gasket (10)
will be re-fixed
 Assemble the new spiral wound gasket (12) without forcing or damaging
 Replace the seal ring (11), aligning the reference mark (A) and (D) (details (X) and (Y))
10
Metal Seated Valves
MV Series
Caution
Do not use excessive amounts of lubricant.
 Assemble the seal retainer flange (10), aligning the locating hole (B) in the seal retainer flange with the relevant mark
on the seal ring (A) and on the disc (D) (see detail (Y))
 Carefully clean the bottom of the disc threaded holes with solvent, then apply Loctite 270 or equivalent
 Slightly tighten all the fastening screws and then verify that the seal ring can be moved freely by hand without rotating it
Note
If the valve has a solid seal ring, apply a film of lubricant (according to Table 3) on the body seat and on the sealing conical
surface of the seal ring
 Seat and unseat the valve twice
 Keep the disc in the closed position. Tighten the retaining screws with the crossover method to avoid any seal ring movement.
Do not exceed the torque values in Table 2.
4.2.1 Sealing Elements Test After Maintenance
Test on sealing elements might be performed only if a direct investigation of downstream side of the valve is possible
If possible, sealing test should be performed according to test pressures and fluid media as indicated the relevant ITP applied during
shop test.
Please contact ORTON for any clarification, for reference please communicate valve serial number
(as indicated in valve label at position 7 – See section 5 & 6)
4.3 Bottom Flange Gasket Maintenance
Proceed as follows:
 Remove the bottom flange (6)
 Remove the spiral wound gasket (13)
 Inspect and clean the groove of the spiral wound gasket in the body and in the bottom flange
 Apply a film of lubricant (according to Table 3) on the bottom spiral wound gasket, then insert it in the bottom
flange, centring and positioning all on the body bore; centre the holes with the threaded holes on the body
Apply a film of lubricant (according to Table 3) on the threads of the screws, then introduce and tighten them using
a torque value from Table 2.
4.3.1
Bottom Flange Test After Maintenance
Pressurize the valve

Check for any leakage around the bottom flange area
If leakage defected re-tighten the screws
If leakage persist, remove the bottom flange and check for any improper gasket installation or damage.
11
Metal Seated Valves
MV Series
4.4 Bolted seat Elements Maintenance
Proceed as follows:
Caution
Depressurise the line before starting any maintenance. Otherwise, serious personal injury and/or equipment damage may occur.
 Fully open the valve

 Remove all threaded dowel jam screws (1,5)
 Loosen the threaded dowels (1,6) from the seat retainer (1,2) but do not remove at this time
 Remove the reaction clip from the body (1,3)
 Remove the seat retainer (1,2) from the valve body
 Remove the seat (1,1) from the body; take extra precaution to prevent damage to the seat by other valve components
 Remove the body seat gasket (1,4) and discard
 Carefully clean and dry the body in the seat and gasket area to remove any foreign particles; take extra precaution not to
scratch or otherwise damage the machined surfaces
 Insert the new gasket (1,4) into the seat groove; do not force the gasket as damage may occur
 Carefully insert the seat ring (1,1) into the body. The seat is provided with two recesses that allow to install the seat in only
one position inside the body, by aligning these recesses with the shaft
 Place the seat retainer flange (1,2) into the body
 Screw all the threaded dowels (1,6) until they make contact with the seat
 Insert the retaining clip (1,3) into the body. The retaining clip may have some deformation due to the disassembly phase
and may not easily remain in the groove. While screwing in the threaded dowels (and the subsequent rise of retaining
flange) firmly insert the clip into its groove
 Screw each of the dowels (1,6) EVENLY into the retaining flange until the seat retainer rises up and reacts against the
retaining clip.
 Use Table 2 for maximum dowel torque allowable values
 Close the valve disc
 Visually check the seal ring and seat alignment
 At this point it is possible to pressurise the valve shaft side to check for any leakage
 If a leakage is occurs depressurise the valve, unloose the dowels (2,5) and adjust the seat position
 Screw again the dowels (1,6) and re-check seat position
 Insert threaded jam dowels (1,5) into each hole and firmly tighten (see Table 2 for maximum allowable torque values)
12
Metal Seated Valves
MV Series
Ta ble 1
Torqu e V a lue s for G la nd F lan ge Nu ts
Table 2
ND C l .12 5 C l .15 0 Cl .3 00 C l .60 0 C l. 900 Tightening Torque for Bolt & Screws
in. mm Nm Nm Nm Nm Nm
3 80 5, 0 5, 0 5 ,0 6 ,0 -
Bolt Dim. Torque Value
4 10 0 5,0 5, 0 5 ,0 11 ,0 - mm Nm
6 15 0 6,0 6, 0 6 ,0 20 ,0 - 6 17
8 20 0 6,0 6, 0 1 2,0 26 ,0 81 ,0
10 25 0 12 ,0 12 ,0 1 4,0 54 ,0 1 15 ,5 8 20
12 30 0 14 ,0 14 ,0 1 5,0 59 ,0 1 29 ,0 10 45
14 35 0 16 ,0 16 ,0 3 0,0 63 ,0 1 29 ,0
16 40 0 30 ,0 30 ,0 3 2,0 8 9,0 2 85 ,0 12 70
18 45 0 32 ,0 32 ,0 4 1,0 10 4, 0 3 27 ,0 14 110
50 0 41 ,0 41 ,0 4 7,0 17 4, 0 4 93 ,5
20
24 60 0 47 ,0 47 ,0 7 2,0 23 3, 0 4 06 ,5
16 175
28 70 0 72 ,0 72 ,0 1 11, 0 29 7, 0 45 0,0 18 235
10 1, 0
30 75 0
10 1, 0
10 1,0 1 11, 0 29 7, 0 55 2,0
20 340
32 80 0 10 1,0 1 11, 0 33 6, 0 55 2,0
36 90 0 11 1, 0 11 1,0 1 29, 0 30 5, 0 71 1,0 22 370
40 1 00 0 12 0, 0 12 0,0 17 3, 0 3 36 ,0 - 24 450
42 1 05 0 12 0, 0 12 0,0 17 3, 0 3 36 ,0 -
44 11 00 15 0,0 15 0,0 19 5,0 37 0, 0 - 27 600
48 1 20 0 17 3, 0 17 3,0 21 8, 0 - - 30 750
1 30 0 19 5, 0 - - -
52
56 14 00
1 87 ,0
18 7, 0 1 95 ,0 - - -
33 780
60 15 00 18 7, 0 2 35 ,0 - - - 36 1020
64 16 00 18 7, 0 2 35 ,0 - - -
39 1310
68 17 00 22 0, 0 2 35 ,0 - - -
72 18 00 2 20 ,0 2 90 ,0 - - - 42 1630
76 19 00 2 55 ,0 2 90 ,0 - - - 45 2030
13
Metal Seated Valves
MV Series
SECTION 5
VALVE SERVICE CONDITION
NOTE : If the valve is supplied with P.E.D. certification

(Pressure Equipment Directive 97/23/CE) refer to Section 6
14
Metal Seated Valves
MV Series
SECTION 5 VALVE SERVICE CONDITION
LABEL
MV SERIES VALVES MUST BE USED IN STRICT ACCORDANCE WITH THE

SERVICE FOR WHICH THEY WERE PURCHASED.
ABRASIVE APPLICATIONS
PERIODIC INSPECTION IS HIGHLY RECOMMENDED. CONSULT ORTON.
RESPONSIBILITY
ORTON S.r.l. DECLINES ANY RESPONSIBILITY IN CASE OF APPLICATIONS

OVER THE LIMITS INDICATED IN THE LABEL
15
Metal Seated Valves
MV Series
SECTION 6
P.E.D. OPERATING & SAFETY INSTRUCTION
NOTE : Refer to this section if the valve is supplied with P.E.D. certification
(Pressure Equipment Directive 97/23/CE)
16
Metal Seated Valves
MV Series
IMPORTANT:

requirements”.
According to directive 97/23/EC valves installed in the European Community

are provided, if applicable, with the following CE label:
17
Metal Seated Valves
MV Series
ESSENTIAL SAFETY REQUIREMENTS (to be followed by the end user)
Valves must not be used outside the relevant values of working temperature ( min/max WT).
The pressure values to which the valve can be used, with disk opened, must be evaluated in
relationship to the maximum body design pressure at room temperature and in relationship to the
actual working temperature in accordance with the standard ASME B16.34.
Such standard defines a decreasing of the maximum working pressure of a material with increasing
temperature.
In every case with disk closed the pressure value at which the valve sealing has been tested must
not be overcome.
Classification of the valve according to the directive is performed considering the process fluid the
valve shall operate with, specified in the offer/order phase.
Any use of valves with fluids different from the one specified must be previously evaluated and
accepted by Orton.
In order to maintain a good performance of the valve, spare parts must be substituted before they
could lead to a leakage, in line or to the external, greater than the maximum allowable leakage
accepted by the end user.
The period after which spare parts shall be substituted depend greatly on the fluid process and on
the operating conditions (pressure/temperature).
A periodical check of the seal conditions may be done by the end user or during plant shut-off
phases.
18
Metal Seated Valves
MV Series
SECTION 7
ATEX OPERATING & SAFETY INSTRUCTION
NOTE : Refer to this section if the valve is supplied with ATEX certification
(ATEX Directive 94/9/CE)
19
Metal Seated Valves
MV Series
IMPORTANT:
requirements”.
According to ATEX directive 94/9/CE valves installed in the European

Community are provided, in case required by the end user, with the following
CE label:
where each item has the following meaning:
1 – Valve series according to Orton std

2 – Nominal diameter of the valve (mm)
3 – Rating of valve body end connection (i.e. Cl.150, Cl. 300, 150 psi, …)
4 – Valve serial number
5 – Year of construction
6 – User Valve TAG code
7 – Reference to Orton Technical File produced in accordance with Directive 94/9/EC att. VIII
8 – CE mark
9 – Ex mark
10 – Orton valve classification as explained below
20
Metal Seated Valves
MV Series
II 2 GD c II Tx min/max WT (*) Tech.File: ST 04-215
II 2 = Group II (surface), category 2

G = Explosive Atmosphere with gases, vapours, mists or air/dust mixtures presence
D = Explosive Atmosphere with dust presence
II = Gas group
c = Protection mode for non electrical equipment “constructional safety”
TX = Max Surface temperature
The valve is classified TX, since the temperature depends from the process media passing through the valve.
min / max WT (*) = min / max working temperature : -196°C / + 550°C
The min / max working temperatures are listed in the valve main name plate.
Tech.File: ST 04-215 = reference of Technical File deposited to Notified Body (DNV ITALIA)
Correspondence between hazardous areas, substances and categories
Zona pericolosa Categories in accordance with Directive 94/9/CE

Gases, vapours or mists Zone 0 1G
Gases, vapours or mists Zone 1 2G or 1G
Gases, vapours or mists Zone 2 3G, 2G or 1G
Dusts Zone 20 1D
Dusts Zone 21 2D or 1D
Dust Zone 22 3D, 2D or 1D
 SCOPE
The aim of this instruction is to inform the final user about the necessary info to correctly and safely use Orton valve in order to
prevent the creation of potentially presence of explosive atmosphere or the ignition of explosion in case the valve is used in explosive
atmosphere.
 ADDITIONAL INFORMATION
In case of actuated valve, all the equipments and electrical components installed on it, shall be covered with a separated certification
in accordance with ATEX 94/9/CE.
All the components shall be suitable for use in classified zones with presence of Gas of group II and/or with presence of dust (group
III).
Orton butterfly valves shall be installed and maintained in accordance with the International standards relevant to installation in
hazardous area with risk of explosion in presence of gases / dusts (i.e. EN 60079-14, EN 60079-17)
In case of combustible dusts, regular clearing shall be performed in order to avoid dusts deposit.
All the maintenance operations shall be performed as explained in the maintenance manual and by qualified personnel only.
21
Metal Seated Valves
MV Series
 PREVENTION OF POTENTIAL IGNITION SOURCES
HOT SURFACE:
The valve surface temperature can reach the process design maximum temperature. The final user has to verify that the temperature:
- can’t trigger the potential explosive atmosphere that could be present outside of the valve;
- can’t burn the dust present in the area where the valve is installed. Dust could deposit on the external valve surface. The fire
of that dusts may trigger a potential explosive atmosphere that can be present outside of the valve.
- Due to solar radiation, the external valve surface can reach temperature higher then dust ignition point. The dust fire could
ignite a potential explosive atmosphere that can be present outside of the valve.
Orton valve are designed to withstand the maximum temperature that the valve could reach due to an external fire in accordance with
ISO 10497 (as indicated on tag plate). It is recommended that final user acknowledge with the limits indicated in the applicable Fire
Safe standard.
The temperature classes and/or the maximum components temperature shall be suitable for the temperature limit of the installation
area.
The min / max working temperature WT are indicated on the valve name plate.
TX: the valve is classified TX because the temperature depends from the process media passing through the valve.
Base on the safety limits indicated in the standard EN 1127-1, it is final user responsibility to limit the external valve surface
temperature under the ignition point of some substances (i.e. gases, dust, liquid, mixture) present in the hazardous areas (refer to
areas classification)
In case of temperature higher than 440°C, the valve surface temperature shall be consider a remaining hazard of explosion. This
hazard shall be evaluated by the final user in accordance with the Directive ATEX 99/92/EC (Equipment and protective systems for
potentially explosive) or with other national standards.
FLAMES AND HOT GASES:
It is prohibited to use, near the valve during normal operation, flames and/or sparks (i.e. grinding) and/or electric arcs( i.e. any kind of
welding). In case some of the above potential sources is used, it is required to ensure that every possible potential explosive
atmospheres, inside and outside of the valve, are completely removed.
Orton valve are designed to withstand the maximum temperature that the valve could reach due to an external fire in accordance with
ISO 10497 (as indicated on tag plate). It is recommended that final user acknowledge with the limits indicated in the applicable Fire
Safe standard.
ELECTRICAL COMPONENTS
Ensure that the Ground Connection is directly connected with plant structures.
The valve doesn’t contain any electrical components. The only electrical components, if present, are installed on the actuator.
All the electrical components are purchased with ATEX marking and certification in accordance with Customer request and/or with
valve marking and certification. Please refer to dedicated Maintenance manual of each components for any additional info.
22
Metal Seated Valves
MV Series
STRAY ELECTRICAL CURRENT AND PROTECTION AGAINST CATHODIC CORROSION
It is final user responsibility to ensure the equipotentiality between all the plant components directly connected to the valve.
STATIC ELECTRICITY
PAINTING
The glitters prevention on non-conductive surface is ensure for group IIG using gases and vapours by group IIA and IIB with a
minimum painting thickness ≤ 2mm. In case of group IIC, the minimum painting thickness shall be ≤ 0,2 mm
THUNDERBOLT
It is final user responsibility to protect the valve installed using appropriated protection against thunderbolt.
The thunderbolt protection shall not compromised the corrosion cathodic protection.
ELECTROMAGNETIC WAVES, IONIC RADIATION, ULTRASUONDS, ADIABATIC COMPRESSION AND SHOCK WAVE
It is final user responsibility to verify that no source of electromagnetic waves, ionic radiation, ultrasounds, adiabatic compression and
shock waves are present as indicated in the standard EN 1127-1
EXOTHERMIC REACTION (INCLUDED DUST IGNITION)
The valve materials are in accordance with Customer request and verified with process data supplied.
 PREVENTION OF POTENTIAL EXPLOSIVE ATMOSPHERE CREATION
FIRE EXPOSURE
The valves are designed to withstand the maximum temperature that the valve could reach due to an external fire in accordance with
ISO 10497 (as indicated on tag plate). It is recommended that final user acknowledge the limits indicated in the applicable Fire Safe
standard.
After Fire event, the valve shall be completely verified (metallic and non metallic components) before placing it again in service
EXPOSURE BELOW 0°C
When the valve is exposure at a temperature below 0°C, the process media passing through the valve can solidify increasing it is
volume. The volume increase can compromise the valve sealing. In this case, a valve pressurisation with potential explosive fluid
could generate an external leaking and consequently a creation of potential explosive atmosphere, with a possible propagation of
explosion inside of the valve.
It is final user responsibility to verify that the fluid, during testing, normal o malfunction operation, shouldn’t solidify due to a
temperature reduction.
23
Metal Seated Valves
MV Series
RATING OVERPRESSURE EXPOSURE
On the valve name plate it is clearly indicated which are the pressure and temperature limits for a correct and safety valve use.
The Rating overpressure exposure can damage the valve body and compromise the sealing capability.
MECHANICAL EXTERNAL STRESSES
Orton valve body is different from other type of valve, for example ball or gate valve. The valve body is similar to the pipeline but it
has an higher thickness that allows Orton valve to withstand the pipeline stresses without compromising the valve performance.
In case the valve is stressed during operation, the weakest point are the connecting flanges. As a matter of fact, connecting flanges
have always a thickness higher than the pipeline on which the valve is connected / installed.
FABRICATION AND SEALING MATERIAL SELECTION
The fabrication and sealing valve material are in accordance with Customer request, verified with process data supplied.
24
Metal Seated Valves
MV Series
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



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



SECTION 8
OPERATIONAL TESTS


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25
Metal Seated Valves
MV Series
Full Stroke Test
The “Full Stroke Test” (“On/Off line”) must be executed to satisfy PFD (probably of failure on
demand) values reported in SIL Certification Documents.
 Test Interval = 8760 h/ year

 Procedure:
o the valves should be operated for n.° 2 open/close complete cycles without complete
closing the valve (to verify the Failure to deliver a full stroke)
o the valves should be operated for n.° 2 open/close complete cycles closing under
complete torque the valve (to verify the Failure to leak tight shut-off (TSO))
o See provided Orton Facility Test Certificates in terms of :
 Required Open – Closure Times
 Allowable Leakage
 Allowable Pressure Drop across valve trim.



Partial Stroke Test (when requested)
When a restricted rotation successfully carried out it becomes highly likely that the remaining
rotation will be carried out as well. A typical partial stroke value can be 20 degrees
There is no risk of seat seals coming loose with slow partial stroke at high differential pressure or
with assuming the partial opening position for some time
Summarising it is stated that Orton MV Series Valves successfully delivers on demand a partial
stroke, then it is highly likely that the valve is capable to make the full quarter turn.
The “Partial Stroke Test” (“On line”) must be executed to satisfy PFD (probably of failure on
demand) values reported in SIL Certification document.
 Test Interval = at least 4380 h/year

 Procedure: the valves should be operated for n.° 4 open/close cycles till 20 degrees min.
26
Part-turn actuators
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Control unit: electronic (MWG)
with actuator controls
AUMATIC AC 01.2 Non-Intrusive
Control
→ Parallel
Profibus DP
Modbus
Foundation Fieldbus
Operation instructions Assembly, operation, commissioning

SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2 Control unit: electronic (MWG)
Table of contents AC 01.2 Non-Intrusive
Read operation instructions first.

●
Observe safety instructions.
●
These operation instructions are part of the product.
●
Retain operation instructions during product life.
●
Pass on instructions to any subsequent user or owner of the product.
Purpose of the document:

This document contains information for installation, commissioning, operation and maintenance staff. It is intended
to support device installation and commissioning.
Reference documents:
●
Manual (Operation and setting) AUMATIC AC 01.2 Parallel
Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(refer to <Addresses>).
Table of contents Page

1. Safety instructions................................................................................................................. 5
1.1. Basic information on safety 5
1.2. Range of application 5
1.3. Applications in Ex zone 22 (option) 6
1.4. Warnings and notes 6
1.5. References and symbols 7
2. Identification........................................................................................................................... 8
2.1. Name plate 8
2.2. Short description 9
3. Transport, storage and packaging........................................................................................ 11
3.1. Transport 11
3.2. Storage 11
3.3. Packaging 11
4. Assembly................................................................................................................................ 12
4.1. Mounting position 12
4.2. Handwheel fitting 12
4.3. Actuator: mount to valve 12
4.4. Mounting positions of local controls 14
4.4.1. Mounting positions: modify 14
5. Electrical connection............................................................................................................. 16
5.1. Basic information 16
5.2. Connection with AUMA plug/socket connector 17
5.2.1. Terminal compartment: open 18
5.2.2. Cable connection 18
5.2.3. Terminal compartment: close 20
5.3. Accessories for electrical connection 20
5.3.1. Controls mounted to wall bracket 20
5.3.2. Parking frame 21
5.3.3. Protection cover 22
5.3.4. Double sealed intermediate frame 22
5.3.5. Earth connection, external 22
2
AC 01.2 Non-Intrusive Table of contents
6. Operation................................................................................................................................ 23
6.1. Manual operation 23
6.1.1. Manual operation: engage 23
6.1.2. Manual operation: disengage 23
6.2. Motor operation 23
6.2.1. Local actuator operation 23
6.2.2. Actuator operation from remote 24
6.3. Menu navigation via push buttons (for settings and indications) 24
6.3.1. Menu layout and navigation 25
6.4. User level, password 26
6.4.1. Password entry 27
6.4.2. Password change 27
6.5. Language in the display 28
6.5.1. Language change 28
7. Indications.............................................................................................................................. 30
7.1. Indications during commissioning 30
7.2. Indications in the display 30
7.2.1. Feedback indications from actuator and valve 31
7.2.2. Status indications according to AUMA classification 34
7.2.3. Status indications according to NAMUR recommendation 35
7.3. Mechanical position indicator/running indication 36
7.4. Indication lights 37
8. Signals..................................................................................................................................... 38
8.1. Status signals via output contacts (digital outputs) 38
8.1.1. Assignment of outputs 38
8.1.2. Encoding of outputs 38
8.2. Analogue signals 38
9. Commissioning (basic settings)........................................................................................... 39
9.1. End stops in part-turn actuator 39
9.1.1. End stop CLOSED: set 40
9.1.2. End stop OPEN: set 40
9.2. Type of seating: set 41
9.3. Torque switching: set 42
9.4. Limit switching: set 44
9.5. Test run 45
9.5.1. Direction of rotation: check 46
9.5.2. Limit switching: check 46
9.6. Switch compartment: open 46
9.7. Mechanical position indicator: set 47
9.8. Switch compartment: close 47
10. Corrective action.................................................................................................................... 49
10.1. Faults during commissioning 49
10.2. Fault indications and warning indications 49
10.3. Fuses 52
10.3.1. Fuses within the actuator controls 52
10.3.2. Motor protection (thermal monitoring) 53
11. Servicing and maintenance................................................................................................... 55
11.1. Preventive measures for servicing and safe operation 55
3
11.2. Maintenance 55
11.3. Disposal and recycling 55
12. Technical data......................................................................................................................... 57
12.1. Features and functions of actuator 57
12.2. Features and functions of actuator controls 58
12.3. Service conditions 61
12.4. Accessories 62
12.5. Further information 62
13. Spare parts............................................................................................................................. 63
13.1. Part-turn actuators SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2 63
13.2. Actuator controls AUMATIC AC 01.2 65
14. Certificates.............................................................................................................................. 67
14.1. Declaration of Incorporation and EC Declaration of Conformity 67
Index........................................................................................................................................ 68
Addresses............................................................................................................................... 70
4
AC 01.2 Non-Intrusive Safety instructions
1. Safety instructions
1.1. Basic information on safety
Standards/directives AUMA products are designed and manufactured in compliance with recognised
standards and directives. This is certified in a Declaration of Incorporation and an
EC Declaration of Conformity.
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly,
electrical connection, commissioning and operation are met at the place of installation.
Safety instructions/warn- All personnel working with this device must be familiar with the safety and warning
ings instructions in this manual and observe the instructions given. Safety instructions
and warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must
be carried out exclusively by suitably qualified personnel having been authorised by
the end user or contractor of the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules
regarding occupational health and safety.
Commissioning Prior to commissioning, it is important to check that all settings meet the requirements
of the application. Incorrect settings might present a danger to the application, e.g.
cause damage to the valve or the installation. The manufacturer will not be held
liable for any consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:

● Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
● Only operate the device if it is in perfect condition while observing these instruc-
tions.
● Immediately report any faults and damage and allow for corrective measures.
● Observe recognised rules for occupational health and safety.
● Observe the national regulations.
● During operation, the housing warms up and surface temperatures > 60 °C may
occur. To prevent possible burns, we recommend checking the surface temper-
ature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior consent of the manufacturer.
1.2. Range of application
AUMA part-turn actuators are designed for the operation of industrial valves, e.g.
butterfly valves and ball valves.
Other applications require explicit (written) confirmation by the manufacturer.
The following applications are not permitted, e.g.:

● Industrial trucks according to EN ISO 3691
● Lifting appliances according to EN 14502
● Passenger lifts according to DIN 15306 and 15309
● Service lifts according to EN 81-1/A1
5
Safety instructions AC 01.2 Non-Intrusive
● Escalators
● Continuous duty
● Buried service
● Permanent submersion (observe enclosure protection)
● Potentially explosive areas, with the exception of zone 22
● Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's
designated use.
Information These operation instructions are only valid for the "clockwise closing" standard
version, i.e. driven shaft turns clockwise to close the valve.
1.3. Applications in Ex zone 22 (option)
Actuators of the indicated series basically meet the requirements for applications in
dust hazardous locations of ZONE 22 in compliance with the ATEX directive 94/9/EC.
The actuators are designed to meet enclosure protection IP68 and fulfil the
requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for use in
presence of combustible dust, requirements for category 3 electrical equipment -
protected by enclosures.
To comply with all requirements of EN 50281-1-1:1998, it is imperative that the
following points are observed:
● In compliance with the ATEX directive 94/9/EC, the actuators must be equipped
with an additional identification – II3D IP6X T150 °C.
● The maximum surface temperature of the actuators, based on an ambient
temperature of +40 °C in accordance with EN 50281-1-1 section 10.4, is +150
°C. In accordance with section 10.4, an increased dust deposit on the equipment
was not considered for the determination of the maximum surface temperature.
● The correct connection of the thermoswitches or the PTC thermistors as well
as fulfilling the requirements of the duty type and the technical data are pre-
requisites for compliance with the maximum surface temperature of devices.
● The connection plug may only be plugged in or pulled out when device is dis-
connected from the mains.
● The cable glands used also have to meet the requirements of category II3 D
and must at least comply with enclosure protection IP68.
● The actuators must be connected by means of an external ground connection
(accessory part) to the potential compensation or integrated into an earthed
piping system.
● As a general rule, the requirements of EN 50281-1-1 must be respected in dust
hazardous locations. During commissioning, service, and maintenance, special
care as well as qualified and trained personnel are required for the safe operation
of actuators.
1.4. Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these

operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure

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

6
Indicates a potentially hazardous situation with a low level of risk. Failure to

observe this warning may result in minor or moderate injury. May also be used
with property damage.
Potentially hazardous situation. Failure to observe this warning may result in

property damage. Is not used for personal injury.
Arrangement and typographic structure of the warnings
Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)
→ Measures to avoid the danger
→ Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.

The signal word (here: DANGER) indicates the level of hazard.
1.5. References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)

Symbol for OPEN (valve open)
Important information before the next step. This symbol indicates what is required
for the next step or what has to be prepared or observed.
Via the menu to parameter
Describes the path within the menu to the parameter. By using the push buttons of
the local controls you may quickly find the desired parameter in the display.
<> Reference to other sections
Terms in brackets shown above refer to other sections of the document which provide
further information on this topic. These terms are either listed in the index, a heading
or in the table of contents and may quickly be found.
7
Identification AC 01.2 Non-Intrusive
2. Identification
2.1. Name plate
Each device component (actuator, controls, motor) is equipped with a name plate.
Figure 1: Arrangement of name plates
[1] Actuator name plate

[2] Controls name plate
[3] Motor name plate
[4] Additional plate, e.g. KKS plate (Power Plant Classification System)
Description of actuator name plate

Figure 2: Actuator name plate (example)
[1] Name of manufacturer

[2] Address of manufacturer
[3] Type designation (see explanation below)
[4] Commission number (see explanation below)
[5] Actuator serial number
[6] Operating time in [s] for a part-turn movement of 90°
[7] Torque range in direction CLOSE
[8] Torque range in direction OPEN
[9] Lubricant type – [10] enclosure protection
[11] Permissible ambient temperature
[12] Can be assigned as an option upon customer request
[13] Can be assigned as an option upon customer request
8
AC 01.2 Non-Intrusive Identification
Type designation Figure 3: Type designation (example)
1. Type and size of actuator

2. Flange size
Type and size
These instructions apply to the following devices types and sizes:
Part-turn actuators for open-close duty: SQ 05.2, 07.2, 10.2, 12.2, 14.2
Part-turn actuators for modulating duty: SQR 05.2, 07.2, 10.2, 12.2, 14.2
Commission number An order-relevant commission number (order number) is assigned to each device.
This commission number can be used to directly download the wiring diagram (in
German and English language), inspection records and further information regarding
the device from the Internet: http://www.auma.com. For some details, the customer
number might be required.
Actuator serial number

Table 1: Description of serial number (with example)
05 12 N S 12345
st nd
1 + 2 position: Assembly in week
05 In our example: Week 05
rd th
3 + 4 position: Year of manufacture
12 In our example: Year of manufacture: 2012
All other positions
N S 12345 Internal works number for unambiguous product identification
Description of controls name plate

Figure 4: Controls name plate
[1] Type designation

[2] Commission number
[3] Wiring diagram
[4] Control
Type designation AC 01.2 = actuator controls AUMATIC

th
Wiring diagram 9 position in the TPA wiring diagram: Position transmitter (actuator):
Electronic control unit:
I, Q = MWG (Magnetic limit and torque transmitter)
Control 24 V DC = Control via parallel interface at 24 V DC control voltage

115 V AC = Control via parallel interface at 115 V AC control voltage
0/4 – 20 mA = Control via parallel interface via analogue input 0/4 – 20 mA
2.2. Short description
Part-turn actuator Definition in compliance with EN ISO 5211:

A part-turn actuator is an actuator which transmits a torque to the valve for less than
one full revolution. It need not be capable of withstanding thrust.
9
AUMA part-turn actuators are driven by an electric motor. A handwheel is provided

for manual operation. Switching off in end positions may be either by limit or torque
seating. Controls are required to operate or process the actuator signals.
Actuator controls The AUMATIC actuator controls are used to operate AUMA actuators and are supplied
ready for use. The controls may be mounted directly to the actuator or separately
on a wall bracket.
The functions of the AUMATIC controls include standard valve control in OPEN -
CLOSE duty, positioning, process control, logging of operating data right through to
diagnostic functions.
Local controls/AUMA Operation, setting, and display can be performed on site directly at the controls.
CDT When set to local control, it is possible to
● operate the actuator via the local controls (push buttons and display) and perform
settings (contents of these instructions).
● read in or out data or modify and save settings via the AUMA CDT software
(option), using a computer (laptop or PC). The connection between computer
and AUMATIC is wireless via Bluetooth interface (not included in these instruc-
tions).
Intrusive - Non-Intrusive ● Intrusive version (control unit: electromechanical):
Limit and torque setting is performed via switches in the actuator.
● Non-Intrusive version (control unit: electronic):
Limit and torque setting is performed via the controls, actuator and controls
housings do not have to be opened. For this purpose, the actuator is equipped
with an MWG (magnetic limit and torque transmitter), also supplying analogue
torque feedback signals/torque indication and analogue position feedback sig-
nals/position indication.
10
AC 01.2 Non-Intrusive Transport, storage and packaging
3. Transport, storage and packaging

3.1. Transport
For transport to place of installation, use sturdy packaging.
Hovering load!
Risk of death or serious injury.
→ Do NOT stand below hovering load.
→ Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT
to handwheel.
→ Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting
by hoist to valve and NOT to actuator.
→ Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
→ Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting
by hoist only to the actuator and NOT to the controls.
3.2. Storage
Danger of corrosion due to inappropriate storage!

→ Store in a well-ventilated, dry room.
→ Protect against floor dampness by storage on a shelf or on a wooden pallet.
→ Cover to protect against dust and dirt.
→ Apply suitable corrosion protection agent to uncoated surfaces.
Damage on display caused by temperatures below permissible level!

→ The AUMATIC actuator controls must NOT be stored below –30 °C.
Long-term storage If the device must be stored for a long period (more than 6 months) the following
points must be observed in addition:
1. Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting
surface, with long-term corrosion protection agent.
2. At an interval of approx. 6 months:
Check for corrosion. If first signs of corrosion show, apply new corrosion protec-
tion.
3.3. Packaging
Our products are protected by special packaging for transport when leaving the
factory. The packaging consists of environmentally friendly materials which can easily
be separated and recycled. We use the following packaging materials: wood,
cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.
11
Assembly AC 01.2 Non-Intrusive
4. Assembly
4.1. Mounting position
AUMA actuators and actuator controls can be operated without restriction in any
mounting position.
4.2. Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are supplied separ-
ately.
Figure 5: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
1. If required, fit spacer [1] onto input shaft [2].

2. Slip handwheel [3] onto input shaft.
3. Secure handwheel [3] using the circlip [4] supplied.
4.3. Actuator: mount to valve
Danger of corrosion due to damage to paint finish and condensation!

→ Touch up damage to paint finish after work on the device.
→ After mounting, connect the device immediately to electrical mains to ensure
that heater minimises condensation.
The actuator is mounted to the valve using a coupling.
12
AC 01.2 Non-Intrusive Assembly
Figure 6: Coupling fitting dimensions
[1] Coupling
[2] Valve shaft
[3] Grub screw
[4] Screw
Table 2: Coupling fitting dimensions

Type, size - output mounting flange X max [mm] Y max [mm] Z max [mm]
SQ/SQR 05.2-F05 3 2 40
SQ/SQR 05.2-F07 3 2 40
SQ/SQR 07.2-F07 3 2 40
SQ/SQR 07.2-F10 3 2 66
SQ/SQR 10.2-F10 4 5 50
SQ/SQR 10.2-F12 4 5 82
SQ/SQR 12.2-F12 5 10 62
SQ/SQR 12.2-F14 5 10 102
SQ/SQR 14.2-F14 8 10 77
SQ/SQR 14.2-F16 8 10 127
1. Use handwheel to run actuator to mechanical end stop.

Information: Assemble valve and actuator in the same end position.
- For butterfly valves: Recommended mounting position is end position
CLOSED.
- For ball valves: Recommended mounting position is end position OPEN.
2. Thoroughly degrease mounting faces of the output mounting flanges.
3. Apply a small quantity of grease to the valve shaft [2].
4. Place coupling [1] onto valve shaft [2] and secure against axial slipping by using
a grub screw, a circlip or a screw. Thereby, ensure that dimensions X, Y or Z
are observed (refer to figure and table <Coupling fitting dimensions>).
5. Apply non-acidic grease at splines of coupling.
6. Fit actuator.
Information: Ensure that the spigot (if provided) fits uniformly in the recess
and that the flanges are in complete contact.
7. If flange bores do not match thread:
7.1 Slightly rotate handwheel until bores line up.
7.2 If required, shift actuator position by one tooth on the coupling.
13
8. Fasten actuator with screws [4].

Information: We recommend applying liquid thread sealing material to the
screws to avoid contact corrosion.
→ Fasten screws [4] crosswise with a torque according to table.
Table 3: Tightening torques for screws

Screws Tightening torque TA [Nm]
Threads Strength class 8.8
M6 11
M8 25
M10 51
M12 87
M16 211
4.4. Mounting positions of local controls
The mounting position of the local controls is selected according to the order. If, after
mounting the actuator to the valve or the gearbox on site, the local controls are in
an unfavourable position, the mounting position can be changed at a later date. Four
mounting positions are possible.
Figure 7: Mounting positions A and B
Figure 8: Mounting positions C and D
4.4.1. Mounting positions: modify
Hazardous voltage!
Risk of electric shock.
→ Disconnect device from the mains before opening.
14
Electrostatic discharge ESD!

Risk of damage to electronic components.
→ Earth both operators and devices.
1. Loosen screws and remove the local controls.

2. Check whether O-ring is in good condition, correctly insert O-ring.
3. Turn local controls into new position and re-place.
Cable damage due to twisting or pinching!

Risk of functional failures.
→ Turn local controls by a maximum of 180°.
→ Carefully assemble local controls to avoid pinching the cables.
4. Fasten screws evenly crosswise.
15
Electrical connection AC 01.2 Non-Intrusive
5. Electrical connection
5.1. Basic information
Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury, or property damage.
→ The electrical connection must be carried out exclusively by suitably qualified
personnel.
→ Prior to connection, observe basic information contained in this chapter.
→ After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
Wiring diagram/terminal
The pertaining wiring diagram/terminal plan (in German and English language) is
plan attached to the device in a weather-proof bag, together with these operation
instructions. It can also be obtained from AUMA (state commission no., refer to name
plate) or downloaded directly from the Internet (www.auma.com).
Permissible networks
The controls (actuators) are suitable for for use in TN and TT networks with directly
(supply networks) earthed star point and a maximum voltage of 690 V AC. Use in IT networks is
permitted while observing the respective <Protection on site> for for maiximum supply
voltages of 600 V AC.
Protection on site
For short-circuit protection and for disconnecting the actuator from the mains, fuses
and disconnect switches have to be provided by the customer.
The current values for respective sizing is derived from the current consumption of
the motor (refer to electrical data sheet) plus the current consumption of the controls.
Table 4: Current consumption controls

Mains voltage Max. current consumption
Permissible variation of the mains voltage ±10 % –30 %
100 to 120 V AC 750 mA 1,200 mA
208 to 240 V AC 400 mA 750 mA
380 to 500 V AC 250 mA 400 mA
515 to 690 V AC 200 mA 400 mA
Table 5: Maximum permissible protection

Switchgear Rated power Max. protection
Reversing contactor A1 up to 1.5 kW 16 A (gL/gG)
Thyristor B1 up to 1.5 kW 16 A (g/R) I²t<1,500A²s
If controls are mounted separately from actuator (controls on wall bracket): Consider
length and cross section of connecting cable when defining the protection required.
Use appropriate insulation monitors when working in power installations, for example
an insulation monitor measuring the pulse code.
Power supply for the
In case of external supply of the controls (electronics): The external power supply
controls (electronics) must have a reinforced insulation against the mains voltage in accordance with IEC
61010-1 and may only be supplied by a circuit limited to 150 VA in accordance with
IEC 61010-1.
Potential of customer All input signals (control) must be supplied with the same potential.
connections All output signals (status signals) must be supplied with the same potential.
Safety standards All externally connected devices shall comply with the relevant safety standards.
Cable installation in ac-
Signal and bus cables are susceptible to interference.
cordance with EMC
Motor cables are interference sources.
16
AC 01.2 Non-Intrusive Electrical connection
● Lay cables being susceptible to interference or sources of interference at the

highest possible distance from each other.
● The interference immunity of signal and bus cables increases if the cables are
laid close to the earth potential.
● If possible, avoid laying long cables and make sure that they are installed in
areas being subject to low interference.
● Avoid long parallel paths with cables being either susceptible to interference or
interference sources.
● For the connection of remote position transmitters, screened cables must be
used.
Type of current, mains Type of current, mains voltage and mains frequency must match the data on the
voltage and mains fre- motor name plate.
quency
Figure 9: Motor name plate (example)
[1] Type of current

[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ● For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
● Use connecting cable with appropriate minimum rated temperature.
● For connecting cables exposed to UV radiation (outdoor installation), use UV
resistant cables.
5.2. Connection with AUMA plug/socket connector
Cross sections AUMA plug/socket connector:
● Power terminals (U1, V1, W1, U2, V2, W2): max. 6 mm² flexible/10 mm² solid
●
PE connection : max. 6 mm² flexible/10 mm² solid
● Control contacts (1 to 50): max. 2.5 mm²
17
5.2.1. Terminal compartment: open
Figure 10: Connection AUMA plug/socket connector, version S
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Screws for socket carrier
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
[8] Cable gland (not included in delivery)
Hazardous voltage!
1. Loosen screws [2] and remove cover [1].

2. Loosen screws [4] and remove socket carrier [5] from cover [1].
3. Insert cable glands [8] suitable for connecting cables.
➥ The enclosure protection IP... stated on the name plate is only ensured if suitable
cable glands are used.
Figure 11: Example: Name plate shows enclosure protection IP68
4. Seal unused cable entries [6] with suitable blanking plugs [7].
5. Insert the cables into the cable glands [8].
5.2.2. Cable connection
✔ Observe permissible cross sections.
Danger of corrosion: Damage due to condensation!

→ After mounting, commission the device immediately to ensure that heater min-
imises condensation.
18
1. Remove cable sheathing.

2. Strip wires.
3. For flexible cables: Use end sleeves according to DIN 46228.
4. Connect cables according to order-related wiring diagram.
In case of a fault: Hazardous voltage while protective earth conductor is NOT

connected!
→ Connect all protective earth conductors.
→ Connect PE connection to external protective earth conductor of connecting
cables.
→ Start running the device only after having connected the protective earth con-
ductor.
5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables)

or loops (rigid cables).
Figure 12: PE connection
[1] Socket carrier

[2] Screw
[3] Washer
[4] Lock washer
[5] Protective earth with ring lugs/loops
[6] PE connection, symbol:
Information Some actuators are equipped with an additional motor heater. The motor heater
minimises condensation within the motor and improves the start-up behaviour for
extremely low temperatures.
19
5.2.3. Terminal compartment: close
Figure 13: Example: Version S
[1] Cover
[3] O-ring
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
Short-circuit due to pinching of cables!

Risk of electric shock and functional failures.
→ Carefully fit socket carrier to avoid pinching the cables.
1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4].
2. Clean sealing faces of cover [1] and housing.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and
insert it correctly.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
6. Fasten cable glands [8] applying the specified torque to ensure the required
enclosure protection.
5.3. Accessories for electrical connection
— Option —
5.3.1. Controls mounted to wall bracket
The wall bracket allows separate mounting of controls and actuator.
Application ● If the actuator cannot be accessed.
● If the actuator is subjected to high temperatures.
● In case of heavy vibration of the valve.
20
Design Figure 14: Design principle with wall bracket
[1] Wall bracket

[2] Connecting cables
[3] Electrical connection of wall bracket (XM)
[4] Electrical connection of actuator (XA)
[5] Electrical connection of controls (XK) – customer connector
Observe prior to connec- ● Permissible length of connecting cables: max. 100 m.
tion ● We recommend: AUMA cable set LSW20.
● If the AUMA cable set is not used:
- Use suitable flexible and screened connecting cables.
- Use separate, CAN bus data cable for MWG of 120 Ohm character imped-
ance (e.g. UNITRONIC BUS-FD P CAN UL/CSA - 2 x 2 x 0.5 mm², man-
ufacturer: Lapp).
- Data cable connection: XM2-XA2 = CAN L, XM3-XA3 = CAN H.
- Voltage supply MWG: XM6-XA6 = GND, XM7-XA7 = + 24 V DC (refer to
wiring diagram).
- For the electrical connection at wall bracket [3], the terminals are made
as crimp connections.
- Use a suitable four indent crimp tool for crimping.
- Cross sections for flexible wires:
- Control cables: max. 0.75 to 1.5 mm²
- Mains connection: max. 2.5 to 4 mm²
● When using connecting cables, e.g. of the heater, requiring direct wiring from
the actuator to the XK customer connector (XA-XM-XK, refer to wiring diagram),
these connecting cables must be subject to an insulation test in compliance
with EN 50178. Connecting cables for MWG do not belong to this group. They
may not be subject to an insulation test.
5.3.2. Parking frame
Application Parking frame for safe storage of a disconnected plug.
For protection against touching the bare contacts and against environmental
influences.
21
Figure 15: Parking frame
5.3.3. Protection cover

Protection cover for plug compartment when plug is removed.
The open terminal compartment can be closed using a protective cover (not
illustrated).
5.3.4. Double sealed intermediate frame
When removing the electrical connection or due to leaky cable glands, ingress of
dust and water into the housing may occur. This is prevented effectively by inserting
the double sealed intermediate frame [2] between the plug/socket connector [1] and
the housing of the device. The enclosure protection of the device (IP68) will not be
affected, even if the electrical connection [1] is removed.
Figure 16: Electrical connection with double sealed intermediate frame
[1] Electrical connection

[2] Double sealed intermediate frame
5.3.5. Earth connection, external

As an option, the housing is equipped with an external earth connection (U-bracket)
to connect the device to the equipotential earth bonding.
Figure 17: Earth connection
22
AC 01.2 Non-Intrusive Operation
6. Operation
Valve damage due to incorrect basic setting!

→ Prior to electrical operation of the actuator, the basic settings i.e. type of seating,
torque and limit switching have to be completed.
6.1. Manual operation

For purposes of setting and commissioning, in case of motor or power failure, the
actuator may be operated manually. Manual operation is engaged by an internal
change-over mechanism.
6.1.1. Manual operation: engage
Damage at the motor coupling due to faulty operation!

→ Engage manual operation only during motor standstill.
1. Press push button.
2. Turn handwheel in desired direction.

→ To close the valve, turn handwheel clockwise:
➥ Drive shaft (valve) turns clockwise in direction CLOSE.
6.1.2. Manual operation: disengage
Manual operation is automatically disengaged when motor is started again. The

handwheel does not rotate during motor operation.
6.2. Motor operation
✔ Perform all commissioning settings and the test run prior to motor operation.
6.2.1. Local actuator operation

Local actuator operation is performed using the push buttons of the local controls of
the AC.
23
Operation AC 01.2 Non-Intrusive
Figure 18: Local controls
[1] Push button for operation command in direction OPEN

[2] Push button STOP
[3] Push button for operation command in direction CLOSE
[4] Push button RESET
[5] Selector switch
Hot surfaces, e.g. possibly caused by high ambient temperatures or strong

direct sunlight!
Danger of burns
→ Check surface temperature and wear protective gloves, if required.
→ Set selector switch [5] to position Local control (LOCAL).
➥ The actuator can now be operated using the push buttons [1 – 3].
- Run actuator in direction OPEN: Press push button [1] .
- Stop actuator: Press push button STOP [2].
- Run actuator in direction CLOSE: Press push button [3] .
6.2.2. Actuator operation from remote
→ Set selector switch to position Remote control (REMOTE).
➥ Now, it is possible to operate the actuator via remote control, via operation
commands (OPEN, STOP, CLOSE) or analogue setpoints (e.g. 0 – 20 mA).
6.3. Menu navigation via push buttons (for settings and indications)
Menu navigation for display and setting is made via the push buttons [1 – 4] of the
local controls.
Set the selector switch [5] to position 0 (OFF) when navigating through the menu.
24
The bottom row of the display [6] serves as navigation support and explains which
push buttons [1 – 4] are used for menu navigation.
Figure 19:
[1–4] Push buttons or navigation support

[5] Selector switch
[6] Display
Table 6: Important push button functions for menu navigation

Push buttons Navigation sup- Functions
port on display
[1] Up ▲ Change screen/selection
Change values
Enter figures from 0 to 9
[2] Down ▼ Change screen/selection
Change values
[3] Ok Confirm selection
Save Save
Edit Enter <Edit> menu
Details Display more details
[4] C Setup Enter Main menu
Esc Cancel process
Return to previous display
Backlight ● The display is illuminated in white during normal operation. The backlight turns
to red under fault conditions.
● The screen illumination is brighter when operating a push button. If no push
button is operated for 60 seconds, the display will become dim again.
6.3.1. Menu layout and navigation
Groups The indications on the display are divided into 3 groups:

Figure 20: Groups
[1] Startup menu

[2] Status menu
[3] Main menu
ID Status menu and main menu are marked with an ID.
25
Figure 21: Marking with ID
S ID starts with S = status menu

M ID starts with M = main menu
Group selection It is possible to select between status menu S and main menu M:
For this, set selector switch to 0 (OFF), hold down push button C for approx. 2
seconds until a screen containing the ID M... appears.
Figure 22: Select menu groups
You return to the status menu if:

● the push buttons on the local controls have not been operated within 10 minutes
● or by briefly pressing C
Direct display via ID When entering the ID within the main menu, screens can be displayed directly (without
clicking through).
Figure 23: Direct display (example)
Display indicates in the bottom row: Go to

1. Press push button Go to.
Display indicates: Go to menu M0000
2. Use push buttons Up ▲ Down ▼ to select figures 0 to 9.
3. Press push button Ok to confirm first digit.
4. Repeat steps 2 and 3 for all further digits.
5. To cancel the process: Press C Esc.
6.4. User level, password
User level The user level defines which menu items or parameters can be displayed or modified
by the active user.
There are 6 different user levels. The user level is indicated in the top row:
Figure 24: User level display (example)
Password A password must be entered to allow parameter modification. The display indicates:
Password 0***
A specific password is assigned to each user level and permits different actions.
26
Table 7: User levels and authorisations

Designation (user level) Authorisation/password
Observer (1) Verify settings
No password required
Operator (2) Change settings
Default factory password: 0000
Maintenance (3) Reserved for future extensions
Specialist (4) Change device configuration
e.g. type of seating, assignment of output
contacts
Service (5) Service staff
Change configuration settings
AUMA (6) AUMA administrator
6.4.1. Password entry
1. Select desired menu and hold down push button for approx. 3 seconds.
➥ Display indicates the set user level, e.g Observer (1)
2. Press Up ▲to select a higher user level and press Ok to confirm.
➥ Display shows: Password 0***
4. Confirm first digit of password via push button Ok.
➥ Having confirmed the last digit with Ok, access to all parameters within one
user level is possible if the password entry is correct.
6.4.2. Password change

Only the passwords of same or lower user level may be changed.
Example: The user is signed in as Specialist (4). This authorises him or her to modify
the passwords between user levels (1) to (4).
Device configuration M0053
Service functions M0222
Change passwords M0229
Menu point Service functions M0222 is only visible if user level has been set to
Specialist (4) or higher.
Select main menu 1. Set selector switch to position 0 (OFF).
2. Press push button C Setup and hold it down for approx. 3 seconds.
➥ Display goes to main menu and indicates: ▶ Display...
27
Change passwords 3. Select parameter Change passwords either:

→ click via the menu to parameter, or
→ via direct display: press and enter ID M0229
- Display indicates: ▶ Change passwords
- The user level is indicated in the top row (1 – 6), e.g.:
- For user level 1 (view only), passwords cannot be changed. To change pass-
words, you must change to a higher user level. For this, enter a password via
a parameter.
4. For a user level between 2 and 6: Press push button Ok.
➥ The display indicates the highest user level, e.g.: For user 4
5. Select user level via push buttons Up ▲ Down ▼ and confirm with Ok.
➥ Display indicates: ▶ Change passwords Password 0***
6. Enter current password (→ enter password).
➥ Display indicates: ▶ Change passwords Password (new) 0***
7. Enter new password (→ enter password).
➥ Display indicates: ▶ Change passwords For user 4 (example)
8. Select next user level via push buttons Up ▲ Down ▼ or cancel the process
via Esc.
6.5. Language in the display
The AUMATIC display is multilingual.
6.5.1. Language change
Display... M0009
Language M0049
Change language 3. Press Ok.
➥ Display indicates: ▶ Language
4. Press Ok.
➥ Display indicates the selected language, e.g.: ▶ Deutsch
5. The bottom row of the display indicates:
→ Save → continue with step 10
→ Edit → continue with step 6
6. Press Edit.
➥ Display indicates: ▶ Observer (1)
7. Select user level via Up ▲ Down ▼ resulting in the following significations:
→ black triangle: ▶ = current setting
→ white triangle: ▷ = selection (not saved yet)
8. Press Ok.
➥ Display indicates: Password 0***
28
9. Enter password (→ enter password).

➥ Display indicates: ▶ Language and Save (bottom row)
Language selection 10. Select new language via Up ▲ Down ▼ resulting in the following significa-
tions:
11. Confirm selection via Save.
➥ The display changes to the new language.The new language selection is saved.
29
Indications AC 01.2 Non-Intrusive
7. Indications
7.1. Indications during commissioning
LED test When switching on the power supply, all LEDs on the local controls illuminate for
approx. 1 second. This optical feedback indicates that the voltage supply is connected
to the controls and all LEDs are operable.
Figure 25: LED test
Language selection During the self-test, the language selection can be activated so that the selected
language is immediately indicated in the display. For this, set selector switch [5] to
position 0 (OFF).
Activate language selection:
1. Display indicates in the bottom row: Language selection menu? 'Reset'
2. Press push button RESET and hold it down until the following text is displayed
in the bottom line: Language menu loading, please wait.
Figure 26: Self-test
The language selection menu follows the startup menu.

Startup menu The current firmware version is displayed during the startup procedure:
Figure 27: Startup menu with firmware version: 04.00.00–xxxx
If the language selection feature has been activated during the self-test, the menu
for selecting the display language will now be indicated. For further information on
language setting, please refer to chapter <Language in the display>.
Figure 28: Language selection
If no entry is made over a longer period of time (approx. 1 minute), the display
automatically returns to the first status indication.
7.2. Indications in the display
Status bar
The status bar (first row in the display) indicates the operation mode [1], the presence
of an error [2] and the ID number [3] of the current display indication.
30
AC 01.2 Non-Intrusive Indications
Figure 29: Information in the status bar (top)
[1] Operation mode

[2] Error symbol (only for faults and warnings)
[3] ID number: S = Status page
Navigation support If further details or information are available with reference to the display, the following
indications Details or More appear in the navigation support (bottom display row).
Then, further information can be displayed via the push button.
Figure 30: Navigation support (bottom)
[1] shows list with detailed indications

[2] shows further available information
The navigation support (bottom row) is faded out after approx. 3 seconds. Press any
push button (selector switch in position 0 (OFF)) to fade in the navigation support.
7.2.1. Feedback indications from actuator and valve
Display indications depend on the actuator version.

Valve position (S0001)
This indication is only available if a position transmitter (potentiometer, RWG or
MWG) is installed in the actuator.
● S0001 on the display indicates the valve position in % of the travel.
● The bargraph display appears after approx. 3 seconds.
● When issuing an operation command, an arrow indicates the direction
(OPEN/CLOSE).
Figure 31: Valve position and direction of operation
Reaching the preset end positions is additionally indicated via symbols (CLOSED)
and (OPEN).
Figure 32: End position CLOSED/OPEN reached
0% Actuator is in end position CLOSED

100% Actuator is in end position OPEN
31
Torque (S0002)
The indication is only available if the actuator is equipped with an MWG (magnetic
limit and torque transmitter).
● S0002 on the display indicates the torque applied at the actuator output.
Figure 33: Torque
Select unit The push button allows to select the unit displayed (percent %, Newton metre Nm
or "foot-pound" ft-lb
Figure 34: Units of torque
Display in percent 100 % indication equals the max. torque indicated on the name plate of the actuator.
Example: SA 07.5 with 20 – 60 Nm.
● 100 % corresponds to 60 Nm of nominal torque.
Operation commands (S0003)
The display S0003 indicates:
● active operation commands, like e.g.: Operation in direction CLOSE or in direc-
tion OPEN
● the actual value E2 as bargraph indication and as value between 0 and 100 %.
● for setpoint control (positioner): setpoint E1
● for stepping mode or for intermediate positions with operation profile: pivot
points and operation behaviour of pivot points
The navigation support (bottom row) is faded out after approx. 3 seconds and the
axis/axes for pivot point display are shown.
OPEN - CLOSE control Active operation commands (OPEN, CLOSE, ...) are shown above the bargraph
display. The figure below shows the operation command in direction CLOSE.
Figure 35: Display for OPEN - CLOSE control
E2 Actual position value
32
Setpoint control If the positioner is enabled and activated, the bargraph indication for E1 (position
setpoint) is displayed.
The direction of the operation command is displayed by an arrow above the bargraph
indication. The figure below shows the operation command in direction CLOSE.
Figure 36: Display for setpoint control (positioner)
E1 Position setpoint
Pivot point axis The pivot points and their operation behaviour (operation profile) are shown on the
pivot point axis by means of symbols.
The symbols are only displayed if at least one of the following functions is activated:
Operation profile M0294
Timer CLOSE M0156
Timer OPEN M0206
Figure 37: Examples: on the left pivot points (intermediate positions); on the right
stepping mode
Table 8: Symbols along the pivot point axis

Symbol Pivot point (intermediate position) Stepping mode
with operation profile
| Pivot point without reaction End of stepping mode
Stop during operation in direction Start of stepping mode in direction
CLOSE CLOSE
OPEN OPEN
Stop during operation in directions –
OPEN and CLOSE
Pause for operation in direction CLOSE –
Pause for operation in direction OPEN –
Pause for operation in directions OPEN –
and CLOSE
Multiport valve positions (S0017)

In case of active multiport valve function, the display S0017 indicates a second
bargraph display with set positions (valve connections) above the actual position
value E2. Positions (P1, P2, ...) are displayed with a black triangle . Push buttons
are used to select positions. Both positions and the actual position value E2 are
displayed in degrees.
33
Figure 38: Status indication for multiport valve (example P4 = 180°)
P (P1, P2, ...) selected position (1, 2, ...)

(– –) no position selected
7.2.2. Status indications according to AUMA classification
These indications are available, if the parameter Diagnostic classific. M0539 is set
to AUMA.
Warnings (S0005)
If a warning has occurred, the display shows S0005:
● the number of warnings occurred
● a blinking question mark after approx. 3 seconds
Figure 39: Warnings
For further information, please also refer to <Corrective action>.

Not ready REMOTE (S0006)
The S0006 display shows indications of the Not ready REMOTE group.
If such an indication has occurred, the display shows S0006:
● the number of indications occurred
● a blinking crossbar after approx. 3 seconds
Figure 40: Not ready REMOTE indications

Fault (S0007)
If a fault has occurred, the display shows S0007:
● the number of faults occurred
● a blinking exclamation mark after approx. 3 seconds
34
Figure 41: Fault

7.2.3. Status indications according to NAMUR recommendation
These indications are available, if the parameter Diagnostic classific. M0539 is set
to NAMUR.
Out of Specification (S0008)
The S0008 indication shows out of specification indications according to NAMUR
recommendation NE 107.
● a blinking triangle with question mark after approx. 3 seconds
Figure 42: Out of specification

Function check (S0009)
The S0009 indication shows function check indications according to NAMUR
If an indication has occurred via the function check, the display shows S0009:
● a blinking triangle with a spanner after approx. 3 seconds
Figure 43: Function check

Maintenance required (S0010)
The S0010 indication shows maintenance indications according to NAMUR
● a blinking square with an oil can after approx. 3 seconds
35
Figure 44: Maintenance required

Failure (S0011)
The S0011 indication shows the causes of the failure indication according to NAMUR
● a blinking circle with a cross after approx. 3 seconds
Figure 45: Failure

7.3. Mechanical position indicator/running indication
Mechanical position indicator:
● Continuously indicates the valve position
(For a swing angle of 90°, the indicator disc [2] rotates by approximately 180°.)
● Indicates whether the actuator is running (running indication)
● Indicates that the end positions are reached (via indicator mark [3])
Figure 46: Mechanical position indicator
[1] Cover
[2] Indicator disc
[3] Mark
[4] Symbol for position OPEN
[5] Symbol for position CLOSED
36
7.4. Indication lights

Figure 47: Arrangement and signification of indication lights
[1] Marking with symbols (standard)

[2] Marking with figures 1 – 6 (option)
1 End position CLOSED reached (blinking: for operation in direction CLOSE)
2 Tc Torque fault CLOSE
3 Motor protection tripped
4 To Torque fault OPEN
5 End position OPEN reached (blinking: for operation in direction OPEN)
6 Bluetooth connection
Modify indication light assignment (indications)
Different indications can be assigned to LEDs 1 – 5.

Local controls M0159
Indication light 1 (left) M0093
Indication light 2 M0094
Indicat. light 5 (right) M0097
Signal interm. pos. M0167
Defaut values (Europe):
Indication light 1 (left) = End p. CLOSED, blink
Indication light 2 = Torque fault CLOSE
Indication light 3 = Thermal fault
Indication light 4 = Torque fault OPEN
Indicat. light 5 (right) = End p. OPEN, blink
Signal interm. pos. = OPEN/CLOSED = Off
37
Signals AC 01.2 Non-Intrusive
8. Signals
8.1. Status signals via output contacts (digital outputs)
Characteristics Output contacts are used to send status signals (e.g. reaching the end positions,
selector switch position, faults...) as binary signals to the control room.
Status signals only have two states: active or inactive. Active means that the
conditions for the signal are fulfilled.
8.1.1. Assignment of outputs
The output contacts (outputs DOUT 1 – 12) can be assigned to various signals.
Required user level: Specialist (4) or higher.
I/O interface M0139
Digital outputs M0110
Signal DOUT 1 M0109
Default values:
Signal DOUT 1 = Fault
Signal DOUT 2 = End position CLOSED
Signal DOUT 3 = End position OPEN
Signal DOUT 4 = Selector sw. REMOTE
Signal DOUT 5 = Torque fault CLOSE
Signal DOUT 6 = Torque fault OPEN
8.1.2. Encoding of outputs
The output signals DOUT 1 – 12 can be set either to high active or low active.
● High active = output contact closed = signal active
● Low active = output contact open = signal active
I/O interface M0139
Coding DOUT 1 M0102
Default values for DOUT 1 – 12: High active
8.2. Analogue signals
Valve position Signal: E2 = 0/4 – 20 mA (galvanically isolated)
Designation in the wiring diagram:
ANOUT1 (position)
Torque feedback Signal: E6 = 0/4 – 20 mA (galvanically isolated)
ANOUT2 (torque)
For further information on this topic, please refer to Manual (Operation and setting).
38
AC 01.2 Non-Intrusive Commissioning (basic settings)
9. Commissioning (basic settings)

1. Set selector switch to position 0 (OFF).
Information: The selector switch is not a mains switch. When positioned to 0

(OFF), the actuator cannot be operated. The controls' power supply is
maintained.
2. Switch on the power supply.
Information: Please consider the heat-up time for ambient temperatures below
–20 °C.
3. Perform basic settings.
9.1. End stops in part-turn actuator
The internal end stops limit the swing angle. They protect the valve in the event of
limit switching failure.
End stop setting is generally performed by the valve manufacturer prior to installing
the valve into the pipework.
Exposed, rotating parts (discs/balls) at the valve!

Pinching and damage by valve or actuator.
→ End stops should be set by suitably qualified personnel only.
→ Never completely remove the setting screws [2] and [4] to avoid grease leakage.
→ Observe dimension Tmin.
Information ● The swing angle set in the factory is indicated on the name plate:
● The setting sequence depends on the valve:

- Recommendation for butterfly valves: Set end stop CLOSED first.
- Recommendation for ball valves: Set end stop OPEN first.
39
Commissioning (basic settings) AC 01.2 Non-Intrusive
Figure 48: End stop
[1] Screw plug for end stop OPEN

[2] Setting screw for end stop OPEN
[3] Screw plug for end stop CLOSED
[4] Setting screw for end stop CLOSED
Dimensions/sizes 05.2 07.2 10.2 12.2 14.2

T (for 90°) 17 17 20 23 23
Tmin. 11 11 12 13 12
9.1.1. End stop CLOSED: set
1. Remove screw plug [3].

2. Move valve to end position CLOSED with handwheel.
3. If the valve end position is not reached:
→ Slightly turn setting screw [4] counterclockwise until valve end position
CLOSED can be safely set.
➥ Turning the setting screw [4] clockwise results in a smaller swing angle.
➥ Turning the setting screw [4] counterclockwise results in a larger swing
angle.
4. Turn setting screw [4] clockwise to the stop.

➥ This completes the setting of end stop CLOSED.
5. Check O-ring in screw plug and replace if damaged.
6. Fasten and tighten screw plug [3].
Having completed this procedure, the end position detection CLOSED can be set
immediately.
9.1.2. End stop OPEN: set
Information In general, the end stop OPEN does not have to be set.
1. Remove screw plug [1].
2. Move valve to end position OPEN with handwheel.
40
3. If the valve end position is not reached:

→ Slightly turn setting screw [2] counterclockwise until valve end position
OPEN can be safely set.
➥ Turning the setting screw [2] clockwise results in a smaller swing angle.
➥ Turning the setting screw [2] counterclockwise results in a larger swing
angle.
4. Turn setting screw [2] clockwise to the stop.

➥ This completes the setting of end stop OPEN.
5. Check O-ring in screw plug and replace if damaged.
6. Fasten and tighten screw plug [1].
Having completed this procedure, the end position detection OPEN can be set
immediately.
9.2. Type of seating: set
Valve damage due to incorrect setting!

→ The type of seating must suit the valve.
→ Only change the setting with the consent of the valve manufacturer.
Customer settings M0041

Type of seating M0012
End position CLOSED M0086
End position OPEN M0087
Default value: Limit
Setting values:
Limit Seating in end positions via limit switching.
Torque Seating in end positions via torque switching.
Select parameter 3. Select parameter either:
→ via direct display: press and enter ID M0086 or M0087
➥ Display indicates: End position CLOSED
CLOSE or OPEN 4. Use Up ▲ Down ▼ to select:
→ ▶ End position CLOSED
→ ▶ End position OPEN
➥ The black triangle ▶ indicates the current selection.
41
5. Press Ok.
➥ Display indicates the current setting: Limit or Torque
➥ The bottom row of the display indicates either:
- Edit → continue with step 6
- Save → continue with step 10
6. Press Edit.
➥ Display indicates: ▶ Specialist (4)
Log on user 7. Use Up ▲ Down ▼ to select user:
Information: Required user level: Specialist (4) or higher
➥ The symbols have the following meaning:
- black triangle: ▶ = current setting
- white triangle: ▷ = selection (not saved yet)
8. Press Ok.
➥ The screen indicates the pre-set type of seating (▶ Limit or ▶ Torque) by means
of a black triangle ▶.
Change settings 10. Select new setting Up ▲ Down ▼ resulting in the following significations:
➥ The setting for the type of seating is complete.
12. Back to step 4 (CLOSED or OPEN): Press Esc .
9.3. Torque switching: set
Once the set torque is reached, the torque switches will be tripped (overload protection
of the valve).
Information The torque switches may also trip during manual operation.
Valve damage due to excessive tripping torque limit setting!

→ The tripping torque must suit the valve.

Torque switching M0013
Trip torque CLOSE M0088
Trip torque OPEN M0089
Default value: According to order data
Setting range: Torque range according to actuator name plate
42

→ via direct display: press and enter ID M0088.
➥ Display indicates: Trip torque CLOSE
CLOSE or OPEN 4. Select via Up ▲ Down ▼:
→ ▶ Trip torque CLOSE
→ ▶ Trip torque OPEN
5. Press Ok.
➥ Display shows the set value.
➥ The bottom row indicates: Edit Esc
6. Press Edit.
➥ Display indicates:
- Specialist (4) → continue with step 7
- in bottom row Up ▲ Down ▼ Esc → continue with step 11
➥ The symbols have the following meanings:
8. Press Ok.
10. Press Edit.
Change value 11. Enter new value for tripping torque via Up ▲ Down ▼.
Information: The adjustable torque range is shown in round brackets
12. Save new value via Save.
➥ The tripping torque is set.
13. Back to step 4 (CLOSED or OPEN): Press Esc.
Information The following fault signals are sent if the set torque is reached in mid-travel:
● Status indication S0007 Fault = Torque fault OPEN or Torque fault CLOSE
The fault has to be acknowledged before the operation can be resumed. The
acknowledgement is made:
1. either by an operation command in the opposite direction.
- For Torque fault OPEN : Operation command in direction OPEN
- For Torque fault CLOSE : Operation command in direction CLOSE
2. or, in case the torque applied is lower than the preset tripping torque:
- via the push button RESET in selector switch position Local control
(LOCAL).
43
9.4. Limit switching: set
Valve damage at valve/gearbox due to incorrect setting!

→ When setting with motor operation: Stop actuator before reaching end of travel
(press push button STOP).
→ Allow for overrun when selecting limit seating.

Limit switching M0010
Set end pos.CLOSED? M0084
Set end pos. OPEN? M0085
2. Press push button C and hold it down for approx. 3 seconds.

➥ Display indicates: Set end pos.CLOSED?
CLOSED or OPEN 4. Use Up ▲ Down ▼ to select:
→ ▶ Set end pos.CLOSED? M0084
→ ▶ Set end pos. OPEN? M0085
5. Press Ok.
➥ The display indicates either:
- Set end pos.CLOSED? CMD0009 → continue with step 9
- Set end pos. OPEN? CMD0010 → continue with step 14
Log on user 6. Use Up ▲ Down ▼to select a user:
7. Press Ok to confirm selected user level.
44
Set end position 9. Re-set end position CLOSED:

CLOSED CMD0009 9.1 For large strokes: Set selector switch in position Local control (LOCAL)
and operate actuator in motor operation via push button (CLOSED) in
direction of the end position.
Information: Stop actuator before reaching end of travel (press push
button STOP) to avoid damage.
9.2 Engage manual operation.
9.3 Turn handwheel until valve is closed.
9.4 Set selector switch to position 0 (OFF).
➥ Display indicates: Set end pos.CLOSED? Yes No
10. Press Yes to accept new end position setting.
➥ Display indicates: End pos. CLOSED set!
➥ The left LED is illuminated (standard version) and thus indicates that the end
position CLOSED setting is complete.
11. Make selection:

→ Edit → back to step 9: Set end position CLOSED "once again"
→ Esc → back to step 4; either set end position OPEN or exit the menu.
Set end position OPEN 12. Re-set end position OPEN:
CMD0010 12.1 For large strokes: Set selector switch in position Local control (LOCAL)
and operate actuator in motor operation via push button (OPEN) in
12.3 Turn handwheel until valve is open.
➥ Display indicates: Set end pos. OPEN? Yes No
➥ Display indicates: End pos. OPEN set!
➥ The right LED is illuminated (standard version) and thus indicates that the end
position setting is complete.
14. Make selection:

→ Edit → back to step 9: Set end position OPEN "once again"
→ Esc → back to step 4; either set end position CLOSED or exit the menu.
Information If an end position cannot be set: Check the type of control unit in actuator.
9.5. Test run

Perform test run only once all settings previously described have been performed.
45
9.5.1. Direction of rotation: check
1. Move actuator manually to intermediate position or to sufficient distance from

end position.
2. Switch on actuator in direction CLOSE and observe the direction of rotation on
the indicator disc.
→ Switch off before reaching the end position.
➥ The direction of rotation is correct if actuator runs in direction CLOSE and
indicator disc turns counterclockwise.
9.5.2. Limit switching: check
1. Set selector switch to position Local control (LOCAL).
2. Operate actuator using push buttons OPEN, STOP, CLOSE.

➥ The limit switching is set correctly if (default indication):
- the yellow indication light/LED1 is illuminated in end position CLOSED
- the green indication light/LED5 is illuminated in end position OPEN
- the indication lights go out after travelling into opposite direction.
➥ The limit switching is set incorrectly if:
- the actuator comes to a standstill before reaching the end position
- one of the red indication lights/LEDs is illuminated (torque fault)
- the status indication S0007 in the display signals a fault.
3. If the end position setting is incorrect: Reset limit switching.
9.6. Switch compartment: open
The switch compartment must be opened to perform the following settings (options).
46
→ Loosen screws [2] and remove cover [1] from the switch compartment.
9.7. Mechanical position indicator: set
1. Move valve to end position CLOSED.

2. Turn lower indicator disc until symbol (CLOSED) is in alignment with the
mark on the cover.
3. Move actuator to end position OPEN.

4. Hold lower indicator disc in position and turn upper disc with symbol (OPEN)
until it is in alignment with the mark on the cover.
5. Move valve to end position CLOSED again.

6. Check settings:
If the symbol (CLOSED) is no longer in alignment with mark on the cover:
→ Repeat setting procedure.
9.8. Switch compartment: close
Danger of corrosion due to damage to paint finish!

1. Clean sealing faces of housing and cover.

47
4. Place cover [1] on switch compartment.

5. Fasten screws [2] evenly crosswise.
48
AC 01.2 Non-Intrusive Corrective action
10. Corrective action
10.1. Faults during commissioning
Table 9: Faults during commissioning

Fault description Possible causes Remedy
Mechanical position indicator Reduction gearing is not suitable for Set gear stage of the reduction gearing.
cannot be set. turns/stroke of the actuator. The control unit might have to be exchanged.
Fault in end position The overrun was not considered when setting Determine overrun: Overrun = travel covered
Actuator runs to end stop al- the limit switching. from switching off until complete standstill.
though the limit switches work The overrun is generated by the inertia of Set limit switching again considering the
properly. both the actuator and the valve and the delay overrun (turn handwheel back by the amount
time of the controls. of the overrun).
10.2. Fault indications and warning indications
Faults interrupt or prevent the electrical actuator operation. In the event of a fault,
the display backlight is red.
Warnings have no influence on the electrical actuator operation. They only serve
for information purposes.
Collective signals include further indications which can be displayed via the
Details push button.
Table 10: Faults and warnings via status indications in the display
Indication on display Description/cause For indicated value > 0:
Warnings S0005 Collective signal 02: Press push button Details.
Indicates the number of active warnings. For details, refer to <Warnings and Out of
specification> table.
Not ready REMOTE S0006 Collective signal 04: Press push button Details.
Indicates the number of active signals. For details, refer to <Not ready REMOTE and
Function check> table.
Fault S0007 Collective signal 03: Press push button Details to display a list
Indicates the number of active faults. of detailed indications.
The actuator cannot be operated. For details, refer to <Faults and Failure> table.
Out of specification S0008 Collective signal 07: Press push button Details.
Indication according to NAMUR recommenda- For details refer to <Warnings and Out of
tion NE 107 specification> table.
Actuator is operated outside the normal oper-
ation conditions.
Function check S0009 Collective signal 08: Press push button Details.
Indication according to NAMUR recommenda- For details, refer to <Not ready REMOTE and
tion NE 107 Function check> table.
The actuator is being worked on; output sig-
nals are temporarily invalid.
Maintenance required S0010 Collective signal 09: Press push button Details to display a list
Indication according to NAMUR recommenda- of detailed indications.
tion NE 107
Recommendation to perform maintenance.
Failure S0011 Collective signal 10: Press push button Details to display a list
tion NE 107 For details, refer to <Faults and Failure> table.
Actuator function failure, output signals are
invalid
Table 11: Warnings and Out of specification

Indication on display Description/cause Remedy
Config. warning Collective signal 06: Press push button Details to display a list
Possible cause: of individual indications.
Configuration setting is incorrect.
The device can still be operated with restric-
tions.
49
Corrective action AC 01.2 Non-Intrusive

Internal warning Collective signal 15: Press push button Details to display a list
Device warnings of individual indications.
The device can still be operated with restric-
tions.
24 V DC external The external 24 V DC voltage supply of the Check 24 V DC voltage supply.
controls has exceeded the power supply limits.
Wrn on time running Warning on time max. running time/h ex- ● Check modulating behaviour of actuator.
ceeded ● Check parameter Perm. running time/h
M0356, re-set if required.
Wrn on time starts Warning on time max. number of motor starts ● Check modulating behaviour of actuator.
(starts) exceeded ● Check parameter Permissible starts/h
M0357, re-set if required.
Failure behav. active The failure behaviour is active since all re- Verify signals:
quired setpoints and actual values are incor- ● Setpoint E1
rect. ● Actual value E2
● Actual process value E4
Wrn input AIN 1 Warning: Loss of signal analogue input 1 Check wiring.
Wrn setpoint position Warning: Loss of signal of actuator setpoint Check setpoint signal.
position
Possible causes:
Input signal for setpoint = 0 (signal loss)
Op. time warning The set time (parameter Perm.op. time, The warning indications are automatically
manual M0570) has been exceeded. The cleared once a new operation command is
preset operating time is exceeded for a com- executed.
plete travel from end position OPEN to end ● Check valve.
position CLOSED. ● Check parameter Perm.op. time, manual
M0570.
Wrn controls temp. Temperature within controls housing too high Measure/reduce ambient temperature.
Wrn motor temp. Temperature within motor winding too high Check actuator sizing, correct accordingly.
Wrn gearbox temp. Temperature within actuator gear housing too Check actuator sizing, correct accordingly.
high
RTC not set Real time clock has not yet been set. Set time.
RTC button cell Voltage of the RTC button cell is too low. Replace button cell.
PVST fault Partial Valve Stroke Test (PVST) could not be Check actuator (PVST settings).
successfully completed.
PVST abort Partial Valve Stroke Test (PVST) was aborted Perform RESET or restart PVST.
or could not be started.
Wrn no reaction No actuator reaction to operation commands ● Check movement at actuator.
within the set reaction time. ● Check parameter Reaction time M0634.
Wrn FOC Optical receiving signal (channel 1) incorrect Check/repair FO cables.
(no or insufficient Rx receive level) or RS-485
format error (incorrect bit(s))
Wrn FO cable budget Warning: FO cable system reserve reached Check/repair FO cables.
(critical or permissible Rx receive level)
Wrn FOC connection Warning FO cable connection is not available. Fit FO cable connection.
Torque wrn OPEN Limit value for torque warning in direction Check parameter Wrn torque OPEN M0768,
OPEN exceeded. re-set if required.
Torque wrn CLOSE Limit value for torque warning in direction Check parameter Wrn torque CLOSE M0769,
CLOSE exceeded. re-set if required.
Table 12: Faults and Failure

Configuration error Collective signal 11: Press push button Details to display a list
Configuration error has occurred. of individual indications.
50

Config. error REMOTE Collective signal 22: Press push button Details to display a list
Internal error Collective signal 14: AUMA service
Internal error has occurred. Press push button Details to display a list
of individual indications.
Torque fault CLOSE Torque fault in direction CLOSE Perform one of the following measures:
● Issue operation command in direction
OPEN.
● Set selector switch to position Local con-
trol (LOCAL) and reset fault indication via
push button RESET.
Torque fault OPEN Torque fault in direction OPEN Perform one of the following measures:
CLOSE.
push button RESET.
Phase fault ● When connecting to a 3-ph AC system and Test/connect phases.
with internal 24 V DC supply of the elec-
tronics: Phase 2 is missing.
● When connecting to a 3-ph or 1-ph AC
system and with external 24 V DC supply
of the electronics: One of the phases L1,
L2 or L3 is missing.
Incorrect phase seq The phase conductors L1, L2 and L3 are Correct the sequence of the phase conductors
connected in the wrong sequence. L1, L2 and L3 by exchanging two phases.
Only applicable if connected to a 3-ph AC
system.
Mains quality Due to insufficient mains quality, the controls ● Check mains voltage.
cannot detect the phase sequence (sequence ●
Check parameter Tripping time M0172,
of phase conductors L1, L2 and L3) within the
pre-set time frame provided for monitoring. extend time frame if required.
Thermal fault Motor protection tripped ● Cool down, wait.
● If the fault indication display persists after
cooling down:
- Set selector switch to position Local
control (LOCAL) and reset fault indic-
ation via push button RESET.
● Check fuses.
Fault no reaction No actuator reaction to operation commands Check movement at actuator.
within the set reaction time.
Table 13: Not ready REMOTE and Function check (collective signal 04)
Wrong oper. cmd Collective signal 13: ● Check operation commands (send one
Possible causes: operation command only).
● Several operation commands (e.g. OPEN
● Set parameter Positioner to Function act-
and CLOSE simultaneously, or OPEN and
ive.
SETPOINT operation simultaneously)
● Check setpoint.
● A setpoint is present and the positioner is
Press push button Details to display a list
not active
● For fieldbus: Setpoint exceeds 100.0 %
Sel. sw. not REMOTE Selector switch is not in position REMOTE. Set selector switch to position REMOTE.
Service active Operation via service interface (Bluetooth) and Exit service software.
service software AUMA CDT.
Disabled Actuator is in operation mode Disabled. Check setting and status of function <Local
controls enable>.
51

EMCY stop active The EMERGENCY stop switch has been op- ● Enable EMERGENCY stop switch.
erated. The motor control power supply (con- ●
Reset EMERGENCY stop state by means
tactors or thyristors) is disconnected.
of Reset command.
EMCY behav. active Operation mode EMERGENCY is active ● Detect cause for EMERGENCY signal.
(EMERGENCY signal was sent). ● Verify failure source.
0 V are applied at the EMERGENCY input.
● Apply +24 V DC at EMERGENCY input.
I/O interface The actuator is controlled via the I/O interface Check I/O interface.
(parallel).
Handwheel active Manual operation is activated. Start motor operation.
Interlock An interlock is active. Check interlock signal.
Interlock by-pass By-pass function is interlocked. Check states of main and by-pass valve.
PVST active Partial Valve Stroke Test (PVST) is active. Wait until PVST function is complete.
10.3. Fuses
10.3.1. Fuses within the actuator controls
Fuses used
F1/F2 Primary fuses on power supply unit
G fuse F1/F2 AUMA art. no.

Size 6.3 x 32 mm
Reversing contactors 1 A T; 500 V K002.277
Power supply ≤ 500 V
Reversing contactors 2 A FF; 690 V K002.665
Power supply > 500 V
Thyristor units for motor power up to 1.5 kW 1 A T; 500 V K002.277
Thyristor units for motor power up to 3.0 kW
F3 Internal 24 V DC supply
G fuse according to IEC 60127-2/III F3 AUMA art. no.

Size 5 x 20 mm
Voltage output (power supply unit) = 24 V 2.0 A T; 250 V K006.106
F4 Internal 24 V AC supply (115 V AC) for:

● Heater, switch compartment, reversing contactors control
● PTC tripping device
● for 115 V AC also control inputs OPEN - STOP - CLOSE
G-fuse according to IEC 60127-2/III F4 AUMA art. no.

Size 5 x 20 mm
Voltage output (power supply unit) = 115 V — —
F5 Automatic reset fuse as short-circuit protection for external 24 V DC supply for

customer (see wiring diagram)
Replace fuses F1/F2
Hazardous voltage!
52
1. Loosen screws [1] and remove plug/socket connector [2].
2. Pull fuse holder [3] out of pin carrier, open fuse cover and replace old fuses by
new ones.
Fuses F3/F4: test/replace
1. Loosen screws [1] and remove cover [2] on the rear of the actuator controls.
The power supply unit has measurement points (solder pins) allowing to perform
a resistance (continuity) measurement:
Verifying Measuring points
F3 MTP5 – MTP6
F4 MTP7 – MTP8
2. To replace defective fuses:. Carefully loosen power supply unit [3] and pull out.
(The fuses are on the equipped part of the power supply board).
Cable damage due to pinching!

→ Carefully assemble power supply unit to avoid pinching the cables.
10.3.2. Motor protection (thermal monitoring)
In order to protect against overheating and impermissibly high surface temperatures

at the actuator, PTC thermistors or thermoswitches are embedded in the motor
winding. The thermoswitch is tripped as soon as the max. permissible winding
temperature has been reached.
The actuator is switched off and the following signals are given:
● LED 3 (thermal fault) on the local controls is illuminated.
53
● Status indication S0007 displays a fault. The fault Thermoswitch is displayed

when selecting Details.
The motor has to cool down before the operation can be resumed. Depending on
the parameter setting, the fault signal is either automatically reset or the fault signal
has to be reset using the push button Reset in selector switch position LOCAL.
For further information to this topic, please refer to Manual (Operation and setting).
54
AC 01.2 Non-Intrusive Servicing and maintenance
11. Servicing and maintenance
Damage caused by inappropriate maintenance!

→ Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
Therefore, we recommend contacting our service.
→ Only perform servicing and maintenance tasks when the device is switched off.
AUMA
AUMA offer extensive service such as servicing and maintenance as well as customer
Service & Support product training. For the relevant contact addresses, please refer to <Addresses>
in this document or to the Internet (www.auma.com).
11.1. Preventive measures for servicing and safe operation
The following measures are required to ensure safe device operation:

6 months after commissioning and then every year
● Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing.
Respect torques according to manufacturer's details.
● Check fastening screws between actuator and gearbox/valve for tightness. If
required, fasten screws while applying the tightening torques as indicated in
chapter <Assembly>.
● When rarely operated: Perform test run.
For enclosure protection IP68
After continuous immersion:

● Check actuator.
● In case of ingress of water, locate leaks and repair, dry device correctly and
check for proper function.
11.2. Maintenance
Lubrication ● In the factory, the gear housing is filled with grease.

● Grease change is performed during maintenance
- Generally after 4 to 6 years for modulating duty.
- Generally after 6 to 8 years if operated frequently (open-close duty).
- Generally after 10 to 12 years if operated rarely (open-close duty).
● We recommend exchanging the seals when changing the grease.
● No additional lubrication of the gear housing is required during operation.
11.3. Disposal and recycling
Our devices have a long lifetime. However, they have to be replaced at one point in
time. The devices have a modular design and may, therefore, easily be separated
and sorted according to materials used, i.e.:
● electronic scrap
● various metals
● plastics
● greases and oils
The following generally applies:
● Greases and oils are hazardous to water and must not be released into the
environment.
● Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
55
Servicing and maintenance AC 01.2 Non-Intrusive
● Observe the national regulations for waste disposal.
56
AC 01.2 Non-Intrusive Technical data
12. Technical data

Information The following technical data includes standard and optional features. For detailed
information on the customer-specific version, refer to the order-relevant data sheet.
This data sheet can be downloaded from the Internet at http://www.auma.com in
German and English (indication of commission number required).
12.1. Features and functions of actuator
Type of duty1) Standard:

● SQ: Short-time duty S2 - 15 min
● SQR: Intermittent duty S4 - 25 %
Options:
● SQ: Short-time duty S2 - 30 min
Torque range Refer to actuator name plate
Operating time for 90° Refer to actuator name plate
Motor Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC/EN 60034 Part 1
Motor voltage and frequency Refer to motor name plate
Permissible variation of mains voltage: ±10 %
Permissible variation of mains frequency: ±5 %
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Motor heater (option) Voltages: 110 – 120 V AC, 220 – 240 V AC or 400 V AC (externally supplied)
Power depending on the size 12.5 – 25 W
Swing angle Standard: Adjustable between 75° and < 105°
Options: 15° to < 45°, 45° to < 75°, 105° to < 135°
Self-locking Self-locking
Part-turn actuators are self-locking, if the valve position cannot be changed from standstill
while torque acts upon the output drive.
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during elec-
trical operation.
Option: Handwheel lockable
Indication for manual operation Indication whether manual operation is active/not active via switch (1 change-over contact)
(option)
Connection to controls AUMA plug/socket connector with screw-type connection
Coupling Standard: Coupling without bore
Options: Machined coupling with bore and keyway, square bore or bore with two-flats accord-
ing to EN ISO 5211
Valve attachment Dimensions according to EN ISO 5211
Electronic control unit
Limit switching Magnetic limit and torque transmitter MWG for 1 to 500 turns per stroke or 10 to 5,000 turns
per stroke
Torque switching Via MWG (like limit switching)
Position feedback signal, ana- Via MWG
logue (option)
Torque feedback signal, ana- Via MWG
logue (option)
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
Heater in switch compartment Standard: Resistance type heater, 5 W, 24 V AC, (internal supply)
Temperature for motor (option) Temperature sensor PT 100
Temperature for gear housing Temperature sensor PT 100
(option)
57
Technical data AC 01.2 Non-Intrusive
1) For nominal voltage and 40 °C ambient temperature and an average load with 35 % of the maximum torque according to separate
technical data. The type of duty must not be exceeded.
Technical data for handwheel activation switches

6
Mechanical lifetime 10 starts
Silver plated contacts:
U min. 12 V DC
U max. 250 V AC
I max. AC current 3 A at 250 V (inductive load, cos phi = 0.8)
I max. DC current 3 A at 12 V (resistive load)
12.2. Features and functions of actuator controls
Power supply For mains voltage and mains frequency, refer to name plates at the controls and the motor
Mains frequency Permissible variation of the mains voltage: ±10 %
Permissible variation of the mains frequency: ±5 %
Option: Permissible variation of the mains voltage: ±30 %
External supply of the electron- 24 V DC +20 % / –15 %
ics (option) Current consumption: Basic version approx. 250 mA, with options up to 500 mA
The external power supply must have a reinforced insulation against the mains voltage in
accordance with IEC 61010-1 and may only be supplied by a circuit limited to 150 VA in ac-
cordance with IEC 61010-1.
Current consumption Current consumption of the controls depending on the mains voltage:
For permissible variation of mains voltage by ±10 %:
● 100 to 120 V AC = max. 740 mA
● 208 to 240 V AC = max. 400 mA
● 380 to 500 V AC = max. 250 mA
● 515 to 690 V AC = max. 200 mA
● 100 to 120 V AC = max. 1,200 mA
● 208 to 240 V AC = max. 750 mA
● 380 to 500 V AC = max. 400 mA
● 515 to 690 V AC = max. 400 mA
Motor current consumption: Refer to motor name plate
Overvoltage category Category III according to IEC 60364-4-443
Rated power The controls are designed for the rated motor power, refer to motor name plate
Switchgear1) 2) Standard:
Reversing contactors (mechanically and electrically interlocked) for motor power up to power
class A1
Options:
● Thyristor unit for mains voltage up to 500 V AC (recommended for modulating actuators)
for AUMA power class B1
Control Standard:
Via digital inputs OPEN, STOP, CLOSE, EMERGENCY (via opto-isolator, OPEN, STOP,
CLOSE with one common), respect minimum pulse duration for modulating actuators
Option:
Additional enable inputs for directions OPEN and CLOSE
Voltage and current values for Standard:
control inputs3) 24 V DC, current consumption: approx. 10 mA per input
Options:
48 V DC, current consumption: approx. 7 mA per input
115 V AC, current consumption: approx. 15 mA per input
58
Status signals Standard:

6 programmable output contacts:
● 5 potential-free NO contacts with one common, max. 250 V AC, 1 A (resistive load)
- Default configuration: End position CLOSED, end position OPEN, selector switch in
REMOTE, torque fault CLOSE, torque fault OPEN
● 1 potential-free change-over contact, max. 250 V AC, 5 A (resistive load)
- Default configuration: Collective fault signal (torque fault, phase failure, motor protection
tripped)
Options:
● 5 change-over contacts with one common, max. 250 V AC, 5 A (resistive load)
12 programmable output contacts:4)
● 10 potential-free NO contacts, one common for respectively 5 contacts, max. 250 V AC,
1 A (resistive load)
● 2 potential-free change-over contacts, max. 250 V AC, 5 A (resistive load)
● 6 potential-free change-over contacts without one common, per contact max. 250 V AC,
10 programmable output contacts:4)
● 10 potential-free change-over contacts without one common, per contact max. 250 V
AC, 5 A (resistive load)
All output signals must be supplied with the same potential.
Position feedback signal Galvanically isolated analogue output E2 = 0/4 – 20 mA (load max. 500 Ω)
Voltage output Standard:
Auxiliary voltage 24 V DC, max. 100 mA for supply of the control inputs, galvanically isolated
from internal voltage supply
Option:
Auxiliary voltage 115 V AC, max. 30 mA to supply the control inputs5), galvanically isolated
Local controls Standard:
● Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
● Push buttons OPEN, STOP, CLOSE, RESET
● 6 indication lights:
- End position CLOSED (yellow), torque fault CLOSE (red), motor protection tripped
(red), torque fault OPEN (red), end position and running indication OPEN (green),
Bluetooth (blue)
● Graphic LC display, illuminated
Options:
● Special colours for the 5 indication lights:
- End position CLOSED (green), torque fault CLOSE (blue), torque fault OPEN (yellow),
motor protection tripped (white), end position OPEN (red)
Bluetooth Bluetooth class II chip, version 2.0 with a range up to 10 m in industrial environments. Supports
Communication interface the SPP Bluetooth profile (Serial Port Profile).
Programming software:
AUMA CDT, commissioning and diagnostic tool for windows based PCs, PDAs and smart
phones
59
Application functions Standard:

● Switch-off mode adjustable
- Limit or torque seating for end position OPEN and end position CLOSED
● Torque by-pass, adjustable up to 5 seconds (no torque monitoring during this time)
● Start and end of stepping mode as well as ON and OFF time (1 up to 1,800 seconds)
can be programmed individually for directions OPEN and CLOSE.
● Any 8 intermediate positions between 0 and 100 %, reaction and signal behaviour pro-
grammable
Options:
● Positioner
- Position setpoint via analogue input E1 = 0/4 – 20 mA
- Automatic adaptation of the dead band (adaptive behaviour can be selected)
- Split Range operation
- MODE input for selecting between OPEN - CLOSE duty and modulating duty
Failure functions Standard:
● EMERGENCY operation, behaviour programmable
- Digital input low active, reaction can be selected: Stop, move to end position CLOSED,
move to end position OPEN, move to intermediate position
- Torque monitoring can be by-passed during EMERGENCY operation.
- Thermal protection can be by-passed during EMERGENCY operation (only in com-
bination with thermoswitch in the actuator, not with PTC thermistor).
Options:
● Enabling local controls via digital input Enable LOCAL. Thus, the actuator operation can
be enabled or disabled via push buttons on the local controls.
● Local Stop
- The actuator can be stopped via push button Stop of local controls if the selector
switch is in position REMOTE. Not activated when leaving the factory.
● EMERGENCY stop button (latching) interrupts electrical operation irrespective of the
selector switch position.
● Interlock, enabling the operation commands OPEN or CLOSE via digital inputs Interlock
OPEN or Interlock CLOSE
Monitoring functions Standard:
● Valve overload protection (adjustable), results in switching off and generates fault indic-
ation
● Motor temperature monitoring (thermal monitoring), results in switching off and generates
fault indication
● Monitoring the heater within the actuator, generates warning signal
● Monitoring of permissible on-time and number of starts (adjustable), generates warning
signal
● Operation time monitoring (adjustable), generates warning signal
● Phase failure monitoring, results in switching off and generates fault indication
● Automatic correction of the direction of rotation upon wrong phase sequence (3-phase
AC currrent)
60
Diagnostic functions ● Electronic device ID with order and product data

● Logging of operating data: A resettable counter and a lifetime counter each for:
- Motor running time, number of starts, torque switch trippings in end positions CLOSED,
limit switch trippings in end position CLOSED, torque switch trippings in end position
OPEN, limit switch trippings in end position OPEN, torque faults CLOSE, torque faults
OPEN, motor protection trippings
● Time-stamped event report with setting, operation and fault history:
- Status signals in compliance with NAMUR recommendation NE 107: "Failure",
”Function check", "Out of specification", "Maintenance required"
● Torque characteristics
- 3 torque characteristics (torque-travel characteristic) for opening and closing directions,
can be saved separately. Torque characteristics stored can be shown on the display.
Electrical connection Standard:
AUMA plug/socket connector (S) with screw-type connection and M-threads
Options:
● Pg-threads, NPT-threads, G-threads, special threads
● Gold-plated control contacts (pins and sockets)
● Parking frame for wall mounting of the disconnected plug
● Protection cover for plug compartment (when plug is removed)
Wiring diagram Refer to name plate
1) The reversing contactors are designed for a lifetime of 2 million starts.
2) For the assignment of AUMA power classes, please refer to electrical data on actuator.
3) All input signals must be supplied with the same potential.
4) Not possible for low temperature versions with heating system
5) Not possible in combination with PTC tripping device
Further options for Non-intrusive version with MWG in the actuator

Setting limit and torque switching via the controls’ local controls
Torque feedback signal Galvanically isolated analogue output E6 = 0/4 – 20 mA (max. load 500 Ω), only possible in
combination with output contacts
12.3. Service conditions
Use Indoor and outdoor use permissible

Mounting position Any position
Installation altitude ≤ 2,000 m above sea level
for > 2,000 m above sea level, please contact AUMA
Humidity Up to 100 % relative humidity over the entire permissible temperature range
Ambient temperature Standard:
● Open-close duty: –25 °C to +70 °C
Modulating duty: –25 °C to +60 °C
●
For actual version, refer to actuator/controls name plate.

Enclosure protection according Standard: IP68 with AUMA 3-phase AC motor/1-phase AC motor
to EN 60529 According to AUMA definition, enclosure protection IP68 meets the following requirements:
● Depth of water: maximum 8 m head of water
● Duration of continuous immersion in water: Max. 96 hours
● Up to 10 operations during continuous immersion
Modulating duty is not possible during continuous immersion.
●

Pollution degree Pollution degree 4 (when closed) according to EN 50178
Vibration resistance according 1 g, from 10 to 200 Hz
to IEC 60068–2–6 Resistant to vibration during start-up or for failures of the plant. However, a fatigue strength
may not be derived from this.
61
Corrosion protection Standard:

● KS: Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration as well as for installation in occasionally or permanently aggressive atmo-
sphere with a moderate pollutant concentration (e.g. wastewater treatments plants,
chemical industry)
Options:
● KX: Suitable for installation in extremely aggressive atmospheres with high humidity and
high pollutant concentration
● KX-G : same as KX, however aluminium-free version (outer parts)
Finish coating Powder coating
Colour Standard: AUMA silver-grey (similar to RAL 7037)
Lifetime AUMA part-turn actuators meet or even exceed the lifetime requirements of EN 15714-2.
Detailed information can be provided on request.
Weight Refer to separate technical data
12.4. Accessories
Wall bracket1) AUMATIC mounted separately from the actuator, including plug/socket connector. Connecting
cables on request. Recommended for high ambient temperatures, difficult access, or in case
of heavy vibration during service
Programming software for PC AUMA CDT
1) Cable distance between actuator and AUMATIC max. 100 m. Requires separate data cable for MWG. If actuator and AUMATIC are
separated at a later date, the max. cable length is 10 m.
12.5. Further information
EU Directives ● Electromagnetic Compatibility (EMC): (2004/108/EC)

● Low Voltage Directive: (2006/95/EC)
● Machinery Directive: (2006/42/EC)
62
AC 01.2 Non-Intrusive Spare parts
13. Spare parts

13.1. Part-turn actuators SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
63
Spare parts AC 01.2 Non-Intrusive
Information: Please state type and commission no. of the device (see name plate) when ordering spare parts.
Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation in these instructions.
No. Designation Type No. Designation Type
001.0 Housing Sub-assembly 553.0 Mechanical position indicator Sub-assembly
003.0 Hollow shaft with worm wheel Sub-assembly 554.0 Socket carrier with motor cable har- Sub-assembly
ness
005.0 Drive shaft Sub-assembly 556.0 Potentiometer for position transmitter Sub-assembly
005.1 Motor coupling on output drive shaft 556.1 Potentiometer without slip clutch Sub-assembly
005.3 Manual drive coupling 557.0 Heater Sub-assembly
006.0 Worm wheel 558.0 Blinker transmitter including pins at Sub-assembly
wires (without impulse disc and insula-
tion plate)
009.0 Planetary gearing for manual drive Sub-assembly 559.0–1 Control unit with torque switching Sub-assembly
heads and switches
017.0 Torque lever Sub-assembly 559.0–2 Control unit with magnetic limit and Sub-assembly
torque transmitter (MWG) for Non-in-
trusive version in combination with
AUMATIC integral controls
018.0 Gear segment 560.0–1 Switch stack for direction OPEN Sub-assembly
019.0 Crown wheel 560.0–2 Switch stack for direction CLOSE Sub-assembly
022.0 Drive pinion II for torque switching Sub-assembly 560.1 Switch for limit/torque Sub-assembly
023.0 Output drive wheel for limit switching Sub-assembly 560.2 Switch case
024.0 Drive wheel for limit switching Sub-assembly 566.0 Position transmitter RWG Sub-assembly
025.0 Locking plate Sub-assembly 566.1 Potentiometer for RWG without slip Sub-assembly
clutch
058.0 Wire for protective earth (pin) Sub-assembly 566.2 Electronic board RWG Sub-assembly
070.0 Motor (VD motor incl. no. 079.0) Sub-assembly 566.3 Wire harness for RWG Sub-assembly
079.0 Planetary gearing for motor drive Sub-assembly 567.1 Slip clutch for potentiometer/RWG Sub-assembly
(SQ/SQR 05.2 – 14.2 for VD motor)
155.0 Reduction gearing Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly
500.0 Cover for switch compartment Sub-assembly 583.1 Pin for motor coupling
501.0 Socket carrier (complete with sockets) Sub-assembly 584.0 Retaining spring for motor coupling Sub-assembly
502.0 Pin carrier without pins Sub-assembly 596.0 Output drive flange with end stop Sub-assembly
503.0 Socket for control Sub-assembly S1 Seal kit, small Set
504.0 Socket for motor Sub-assembly S2 Seal kit, large Set
505.0 Pin for controls Sub-assembly
506.0 Pin for motor Sub-assembly
507.0 Plug cover Sub-assembly
525.0 Coupling Sub-assembly
539.0 Screw plug Sub-assembly
542.0 Handwheel with ball handle Sub-assembly
64
13.2. Actuator controls AUMATIC AC 01.2
65
AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. Designation Type
001.0 Housing Sub-assembly
002.0 Local controls Sub-assembly
002.3 Local controls board Sub-assembly
002.4 Display faceplate Sub-assembly
006.0 Power supply Sub-assembly
008.1–1 I/O board Sub-assembly
009.0 Logic board Sub-assembly
011.1 Relay board Sub-assembly
012.0 Option board Sub-assembly
500.0 Cover Sub-assembly
501.0 Socket carrier complete with sockets Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
508.0 Switchgear Sub-assembly
509.1 Padlock
510.0 Fuse kit Sub-assembly
S Seal kit Set
66
AC 01.2 Non-Intrusive Certificates
14. Certificates
14.1. Declaration of Incorporation and EC Declaration of Conformity
67
Index AC 01.2 Non-Intrusive
I
Index Identification 8
Indication lights 37
A Indications 30
Accessories (electrical con- 20 Indications on display 30
nection) Indicator disc 36 , 47
Actual value - indication on 32 Inspection record 9
display Intermediate frame 22
Actuator operation at the local 23 Intermediate position indica- 37
controls tion via LEDs
Actuator operation from re- 24 Intrusive 10
mote
Ambient temperature 8 , 61 L
Analogue signals 38 Language in the display 28
Applications 5 LEDs (indication lights) 37
Assembly 12 Local actuator operation 23
Local control 23
C Local controls 23
Cable set 20 Local setting 24
Certificates 67 Lubrication 55
Commissioning 5
Commissioning (indications 30 M
on display) Main menu 25
Commission number 8, 9 Mains frequency 17
Connecting cable 20 Mains voltage 17
Control 9, 9 Maintenance 5 , 55 , 55
Corrective action 49 Maintenance required - indic- 35
Corrosion protection 11 , 62 ation on display
Cross sections 17 Manual operation 23
Current consumption 16 Mechanical position indicator 36 , 47
Menu navigation 24
D Motor heater 19
Declaration of Incorporation 67 Motor operation 23
Device type 9, 9 Multiport valve - Indications 33
Digital outputs 38 on display
Direct display via ID 26
Direction of rotation 46 N
Directives 5 Name plate 8 , 17
Display (indications) 30 Network types 16
Disposal 55 Non-Intrusive 10
Double sealed 22 Not ready REMOTE - indica- 34
tion on display
E
Earth connection 22 O
EC Declaration of Conformity 67 Operating time 8
Electrical connection 16 Operation 5 , 23
EMC 16 Operation commands - indic- 32
Enclosure protection 8 , 61 ations on display
End stops 39 Order number 8, 9
Error - indication on display 30 Out of specification - indica- 35
tion on display
F Output contacts 38
Failure - indication on display 36
Fault - indication on display 34
Flange size 9
Function check - indication on 35
display
Fuses 52
H
Handwheel 12
68
AC 01.2 Non-Intrusive Index
P V
Packaging 11 Valve position - indication on 31
Parking frame 21 display
Password 26
Password change 27 W
Password entry 27 Wall bracket 20
Positioner - indication on dis- 33 Warnings - indication on dis- 34
play play
Position indicator 47 Wiring diagram 9 , 9 , 16
Power supply 16 , 17 Works number 9
Protection cover 22
Y
Protection on site 16
Year of manufacture 9
Protective measures 5
Year of production 9
Q
Qualification of staff 5
R
Range of application 5
Recycling 55
Remote actuator operation 24
Running indication 36
S
Safety instructions 5
Safety instructions/warnings 5
Serial number 8, 9
Service 55
Service conditions 61
Servicing 55
Setpoint - indication on dis- 33
play
Short-circuit protection 16
Signals 38
Signals (analogue) 38
Size 9, 9
Spare parts 63
Standards 5
Status menu 25
Status signals 38
Storage 11
Supply networks 16
Support 55
T
Technical data 57
Terminal plan 16
Test run 45
Torque - indication on display 32
Torque range 8
Torque switching 42
Transport 11
Type (device type) 9, 9
Type designation 8
Type of current 17
Type of lubricant 8
U
User level 26
69
AUMA worldwide
Europe IBEROPLAN S.A. AUMA Polska Sp. z o.o.

ES 28027 Madrid PL 41-219 Sosnowiec
AUMA Riester GmbH & Co. KG Tel +34 91 3717130 Tel +48 32 783 52 00
iberoplan@iberoplan.com biuro@auma.com.pl
Plant Müllheim www.auma.com.pl
DE 79373 Müllheim AUMA Finland Oy
Tel +49 7631 809 - 0 FI 02230 Espoo AUMA-LUSA Representative Office, Lda.
riester@auma.com Tel +358 9 5840 22 PT 2730-033 Barcarena
www.auma.com auma@auma.fi Tel +351 211 307 100
www.auma.fi geral@aumalusa.pt
Plant Ostfildern-Nellingen
DE 73747 Ostfildern AUMA France S.A.R.L. SAUTECH
Tel +49 711 34803 - 0 FR 95157 Taverny Cedex RO 011783 Bucuresti
riester@wof.auma.com Tel +33 1 39327272 Tel +40 372 303982
info@auma.fr office@sautech.ro
Service-Center Bayern www.auma.fr
DE 85386 Eching OOO PRIWODY AUMA
Tel +49 81 65 9017- 0 AUMA ACTUATORS Ltd. RU 141402 Khimki, Moscow region
Riester@scb.auma.com GB Clevedon, North Somerset BS21 6TH Tel +7 495 221 64 28
Tel +44 1275 871141 aumarussia@auma.ru
Service-Center Köln mail@auma.co.uk www.auma.ru
DE 50858 Köln www.auma.co.uk
Tel +49 2234 2037 - 900 OOO PRIWODY AUMA
Service@sck.auma.com D. G. Bellos & Co. O.E. RU 125362 Moscow
GR 13673 Acharnai, Athens Tel +7 495 787 78 21
Service-Center Magdeburg Tel +30 210 2409485 aumarussia@auma.ru
DE 39167 Niederndodeleben info@dgbellos.gr www.auma.ru
Tel +49 39204 759 - 0
Service@scm.auma.com APIS CENTAR d. o. o. ERICHS ARMATUR AB
HR 10437 Bestovje SE 20039 Malmö
AUMA-Armaturenantriebe Ges.m.b.H. Tel +385 1 6531 485 Tel +46 40 311550
AT 2512 Tribuswinkel auma@apis-centar.com info@erichsarmatur.se
Tel +43 2252 82540 www.apis-centar.com www.erichsarmatur.se
office@auma.at
www.auma.at Fabo Kereskedelmi és Szolgáltató Kft. ELSO-b, s.r.o.
HU 8800 Nagykanizsa SK 94901 Nitra
AUMA BENELUX B.V. B. A. Tel +36 93/324-666 Tel +421 905/336-926
BE 8800 Roeselare auma@fabo.hu elsob@stonline.sk
Tel +32 51 24 24 80 www.fabo.hu www.elsob.sk
office@auma.be
www.auma.nl Falkinn HF Auma Endüstri Kontrol Sistemleri Limited
IS 108 Reykjavik Sirketi
ProStream Group Ltd. Tel +00354 540 7000 TR 06810 Ankara
BG 1632 Sofia os@falkinn.is Tel +90 312 217 32 88
Tel +359 2 9179-337 www.falkinn.is info@auma.com.tr
valtchev@prostream.bg
www.prostream.bg AUMA ITALIANA S.r.l. a socio unico AUMA Technology Automations Ltd
IT 20023 Cerro Maggiore (MI) UA 02099 Kiev
OOO “Dunkan-Privod” Tel +39 0331 51351 Tel +38 044 586-53-03
BY 220004 Minsk info@auma.it auma-tech@aumatech.com.ua
Tel +375 29 6945574 www.auma.it
belarus@auma.ru Africa
www.zatvor.by AUMA BENELUX B.V.
LU Leiden (NL) Solution Technique Contrôle Commande
AUMA (Schweiz) AG Tel +31 71 581 40 40 DZ Bir Mourad Rais, Algiers
CH 8965 Berikon office@auma.nl Tel +213 21 56 42 09/18
Tel +41 566 400945 stcco@wissal.dz
RettichP.ch@auma.com NB Engineering Services
MT ZBR 08 Zabbar A.T.E.C.
AUMA Servopohony spol. s.r.o. Tel + 356 2169 2647 EG Cairo
CZ 250 01 Brandýs n.L.-St.Boleslav nikibel@onvol.net Tel +20 2 23599680 - 23590861
Tel +420 326 396 993 contactus@atec-eg.com
auma-s@auma.cz AUMA BENELUX B.V.
www.auma.cz NL 2314 XT Leiden SAMIREG
Tel +31 71 581 40 40 MA 203000 Casablanca
GRØNBECH & SØNNER A/S office@auma.nl Tel +212 5 22 40 09 65
DK 2450 København SV www.auma.nl samireg@menara.ma
Tel +45 33 26 63 00
GS@g-s.dk SIGUM A. S. MANZ INCORPORATED LTD.
www.g-s.dk NO 1338 Sandvika NG Port Harcourt
Tel +47 67572600 Tel +234-84-462741
post@sigum.no mail@manzincorporated.com
www.manzincorporated.com
70
AUMA worldwide
AUMA South Africa (Pty) Ltd. AUMA Actuators Middle East AUMA Malaysia Office
ZA 1560 Springs BH 152 68 Salmabad MY 70300 Seremban, Negeri Sembilan
Tel +27 11 3632880 Tel +97 3 17896585 Tel +606 633 1988
aumasa@mweb.co.za salesme@auma.com sales@auma.com.my
America Mikuni (B) Sdn. Bhd. Mustafa Sultan Science & Industry Co LLC
BN KA1189 Kuala Belait OM Ruwi
AUMA Argentina Rep.Office Tel + 673 3331269 / 3331272 Tel +968 24 636036
AR Buenos Aires mikuni@brunet.bn r-negi@mustafasultan.com
Tel +54 11 4737 9026
contacto@aumaargentina.com.ar AUMA Actuators (Tianjin) Co., Ltd. Beijing FLOWTORK TECHNOLOGIES
Branch CORPORATION
AUMA Automação do Brazil ltda. CN 100020 Beijing PH 1550 Mandaluyong City
BR Sao Paulo Tel +86 10 8225 3933 Tel +63 2 532 4058
Tel +55 11 4612-3477 mailbox@auma-china.com flowtork@pldtdsl.net
contato@auma-br.com cn.auma.com
M & C Group of Companies
TROY-ONTOR Inc. PERFECT CONTROLS Ltd. PK 54000 Cavalry Ground, Lahore Cantt
CA L4N 8X1 Barrie, Ontario HK Tsuen Wan, Kowloon Tel +92 42 3665 0542, +92 42 3668 0118
Tel +1 705 721-8246 Tel +852 2493 7726 sales@mcss.com.pk
troy-ontor@troy-ontor.ca joeip@perfectcontrols.com.hk www.mcss.com.pk
AUMA Chile Representative Office PT. Carakamas Inti Alam Petrogulf W.L.L
CL 9500414 Buin ID 11460 Jakarta QA Doha
Tel +56 2 821 4108 Tel +62 215607952-55 Tel +974 44350151
aumachile@auma-chile.cl auma-jkt@indo.net.id pgulf@qatar.net.qa
Ferrostaal de Colombia Ltda. AUMA INDIA PRIVATE LIMITED. AUMA Saudi Arabia Support Office
CO Bogotá D.C. IN 560 058 Bangalore SA 31952 Al Khobar
Tel +57 1 401 1300 Tel +91 80 2839 4656 Tel + 966 5 5359 6025
dorian.hernandez@ferrostaal.com info@auma.co.in Vinod.Fernandes@auma.com
www.ferrostaal.com www.auma.co.in
AUMA ACTUATORS (Singapore) Pte Ltd.
Transcontinental Trading Overseas SA. ITG - Iranians Torque Generator SG 569551 Singapore
CU Ciudad Habana IR 13998-34411 Teheran Tel +65 6 4818750
Tel +53 7 208 9603 / 208 7729 +982144545654 sales@auma.com.sg
tto@ttoweb.com info@itg-co.ir www.auma.com.sg
AUMA Región Andina & Centroamérica Trans-Jordan Electro Mechanical Supplies NETWORK ENGINEERING
EC Quito JO 11133 Amman SY Homs
Tel +593 2 245 4614 Tel +962 - 6 - 5332020 +963 31 231 571
auma@auma-ac.com Info@transjordan.net eyad3@scs-net.org
www.auma.com
AUMA JAPAN Co., Ltd. Sunny Valves and Intertrade Corp. Ltd.
Corsusa International S.A.C. JP 211-0016 Kawasaki-shi, Kanagawa TH 10120 Yannawa, Bangkok
PE Miraflores - Lima Tel +81-(0)44-863-8371 Tel +66 2 2400656
Tel +511444-1200 / 0044 / 2321 mailbox@auma.co.jp mainbox@sunnyvalves.co.th
corsusa@corsusa.com www.auma.co.jp www.sunnyvalves.co.th
www.corsusa.com
DW Controls Co., Ltd. Top Advance Enterprises Ltd.
Control Technologies Limited KR 153-702 Gasan-dong, GeumChun-Gu,, TW Jhonghe City, Taipei Hsien (235)
TT Marabella, Trinidad, W.I. Seoul Tel +886 2 2225 1718
Tel + 1 868 658 1744/5011 Tel +82 2 2624 3400 support@auma-taiwan.com.tw
www.ctltech.com import@actuatorbank.com www.auma-taiwan.com.tw
www.actuatorbank.com
AUMA ACTUATORS INC. AUMA Vietnam Hanoi RO
US PA 15317 Canonsburg Al-Arfaj Engineering Co WLL VN Hanoi
Tel +1 724-743-AUMA (2862) KW 22004 Salmiyah +84 4 37822115
mailbox@auma-usa.com Tel +965-24817448 chiennguyen@auma.com.vn
www.auma-usa.com info@arfajengg.com
www.arfajengg.com Australia
Suplibarca
VE Maracaibo, Estado, Zulia TOO “Armaturny Center” BARRON GJM Pty. Ltd.
Tel +58 261 7 555 667 KZ 060005 Atyrau AU NSW 1570 Artarmon
suplibarca@intercable.net.ve Tel +7 7122 454 602 Tel +61 2 8437 4300
armacentre@bk.ru info@barron.com.au
Asia www.barron.com.au
Network Engineering
AUMA Actuators UAE Support Office LB 4501 7401 JBEIL, Beirut
AE 287 Abu Dhabi Tel +961 9 944080
Tel +971 26338688 nabil.ibrahim@networkenglb.com
Nagaraj.Shetty@auma.com www.networkenglb.com
71
AUMA Riester GmbH & Co. KG
P.O.Box 1362
DE 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
Y005.955/003/en/3.13
For detailed information on AUMA products refer to the Internet: www.auma.com

Multi-turn actuators
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Control unit: electronic (MWG)
with actuator controls
AUMATIC AC 01.2 Non-Intrusive
Control
→ Parallel
Profibus DP
Modbus

SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2 Control unit: electronic (MWG)

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

● Manual (Operation and setting) AUMATIC AC 01.2 Parallel
Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(refer to <Addresses>).

1.3. Applications in Ex zone 22 (option) 6
2. Identification........................................................................................................................... 8
2.1. Name plate 8
3.1. Transport 10
3.2. Storage 10
3.3. Packaging 10
4. Assembly................................................................................................................................ 11
4.1. Mounting position 11
4.3. Multi-turn actuator: mount to valve/gearbox 11
4.3.1 Output drive types B, B1 – B4 and E 11
4.3.1.1 Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox 12
4.3.2 Output drive type A 12
4.3.2.1 Stem nut: finish machining 13
4.3.2.2 Multi-turn actuator (with output drive A): mount to valve 14
4.4. Accessories for assembly 15
4.4.1 Stem protection tube for rising valve stem 15
4.5. Mounting positions of local controls 15
4.5.1 Mounting positions: modify 16
5. Electrical connection............................................................................................................. 17
5.1. Basic information 17
5.2. Connection with AUMA plug/socket connector 18
5.2.1 Terminal compartment: open 19
5.2.2 Cable connection 19
5.2.3 Terminal compartment: close 21
2
AC 01.2 Non-Intrusive Table of contents
5.3. Accessories for electrical connection 21

5.3.1 Controls mounted to wall bracket 21
5.3.2 Parking frame 22
5.3.3 Protection cover 23
5.3.4 Double sealed intermediate frame 23
5.3.5 Earth connection, external 23
6. Operation................................................................................................................................ 24
6.1. Manual operation 24
6.1.1 Manual operation: engage 24
6.1.2 Manual operation: disengage 24
6.2. Motor operation 24
6.2.1 Local actuator operation 24
6.2.2 Actuator operation from remote 25
6.3. Menu navigation via push buttons (for settings and indications) 26
6.3.1 Menu layout and navigation 26
6.4. User level, password 27
6.4.1 Password entry 28
6.4.2 Password change 28
6.5. Language in the display 29
6.5.1 Change language 29
7. Indications.............................................................................................................................. 31
7.1. Indications during commissioning 31
7.2. Indications in the display 31
7.2.1 Feedback indications from actuator and valve 32
7.2.2 Status indications according to AUMA classification 34
7.2.3 Status indications according to NAMUR recommendation 35
7.4. Indication lights 37
8. Signals..................................................................................................................................... 39
8.1. Status signals via output contacts (digital outputs) 39
8.1.1 Assignment of outputs 39
8.1.2 Encoding of outputs 39
8.2. Analogue signals 39
9. Commissioning (basic settings)........................................................................................... 40
9.1. Type of seating: set 40
9.2. Torque switching: set 41
9.3. Limit switching: set 42
9.4. Test run 44
9.4.1 Direction of rotation: check 44
9.4.2 Limit switching: check 45
9.5. Switch compartment: open 46
9.7. Gear stage of the reduction gearing: test/set 47
9.8. Switch compartment: close 48
10. Corrective action.................................................................................................................... 49
10.1. Faults during commissioning 49
10.2. Fault indications and warning indications 49
10.3. Fuses 52
3
10.3.1 Fuses within the actuator controls 52

10.3.2 Motor protection (thermal monitoring) 54
11.2. Maintenance 55
12. Technical data......................................................................................................................... 57
12.1. Features and functions of actuator 57
12.2. Features and functions of actuator controls 58
12.4. Accessories 61
13. Spare parts............................................................................................................................. 62
13.1. Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2 62
13.2. Actuator controls AUMATIC AC 01.2 64
14. Certificates.............................................................................................................................. 66
15. Index........................................................................................................................................ 67
Addresses............................................................................................................................... 69
4
1.1 Basic information on safety
Safety instructions/war- All personnel working with this device must be familiar with the safety and warning
nings instructions in this manual and observe the instructions given. Safety instructions
damage.

commissioning.
tions.
● During operation, the housing warms up and surface temperatures > 60 °C may
occur. To prevent possible burns, we recommend checking the surface tempe-
rature using an appropriate thermometer and wearing protective gloves, if re-
for the staff.
must be observed.
1.2 Range of application
AUMA multi-turn actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves, and ball valves.

5
Safety instructions AC 01.2 Non-Intrusive
● Roller conveyors according to EN 14673 (draft)

● Continuous operation
● Buried service
● Continuous immersion (observe enclosure protection)
● Potentially explosive areas, with the exception of zone 22
designated use.
Information These operation instructions are only valid for the "clockwise closing" standard
version, i.e. driven shaft turns clockwise to close the valve.
1.3 Applications in Ex zone 22 (option)
Actuators of the indicated series basically meet the requirements for applications in
dust hazardous locations of ZONE 22 in compliance with the ATEX directive 94/9/EC.
The actuators are designed to meet enclosure protection IP 68 and fulfil the
requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for use in
presence of combustible dust, requirements for category 3 electrical equipment -
protected by enclosures.
To comply with all requirements of EN 50281-1-1:1998, it is imperative that the
following points are observed:
● In compliance with the ATEX directive 94/9/EC, the actuators must be equipped
with an additional identification – II3D IP6X T150 °C.
● The maximum surface temperature of the actuators, based on an ambient
temperature of +40 °C in accordance with EN 50281-1-1 section 10.4, is +150
°C. In accordance with section 10.4, an increased dust deposit on the equipment
was not considered for the determination of the maximum surface temperature.
● The correct connection of the thermoswitches or the PTC thermistors as well
as fulfilling the requirements of the duty type and the technical data are prere-
quisites for compliance with the maximum surface temperature of devices.
● The connection plug may only be plugged in or pulled out when device is dis-
connected from the mains.
● The cable glands used also have to meet the requirements of category II3 D
and must at least comply with enclosure protection IP 67.
● The actuators must be connected by means of an external ground connection
(accessory part) to the potential compensation or integrated into an earthed
piping system.
● The screw plug (part no. 511.0) or the stem protection tube with protective cap
(part nos. 568.1 and 568.2) for sealing the hollow shaft must imperatively be
mounted to guarantee tightness and therefore the combustible dust hazard
protection.
● As a general rule, the requirements of EN 50281-1-1 must be respected in dust
hazardous locations. During commissioning, service, and maintenance, special
care as well as qualified and trained personnel are required for the safe opera-
tion of actuators.
1.4 Warnings and notes


6





1.5 References and symbols

Via the menu to parameter
Describes the path within the menu to the parameter. By using the push buttons of
the local controls you may quickly find the desired parameter in the display.
7
2. Identification
2.1 Name plate
Each device component (actuator, controls, motor) is equipped with a name plate.
[1] Actuator name plate

[2] Controls name plate
[3] Motor name plate
Data for identification Figure 2: Actuator name plate
[1] Type and size of actuator

Figure 3: Controls name plate
[1] Type and size of the controls

[3] Wiring diagram
[4] Control
Type and size
These instructions apply to the following devices:
Multi-turn actuators for open-close duty: SA 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
Multi-turn actuators for modulating duty: SAR 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
AC 01.2 = Actuator controls AUMATIC
8
AC 01.2 Non-Intrusive Identification
Commission number An order-specific commission number is assigned to each device. This commission
number can be used to directly download the wiring diagram, inspection records and
further information regarding the device from the Internet: http://www.auma.com.
Wiring diagram The 9th position in the TPA wiring diagram: Position transmitter (actuator)
Control unit: electronic:
I = MWG (magnetic limit and torque transmitter)
Control
24 V DC = Control via parallel interface at 24 V DC control voltage
115 V AC = Control via parallel interface at 115 V AC control voltage
0/4 – 20 mA = Control via parallel interface via analogue input 0/4 – 20 mA
2.2 Short description
Multi-turn actuator Definition in compliance with EN ISO 5210:

A multi-turn actuator is an actuator which transmits to the valve a torque for at least
one full revolution. It is capable of withstanding thrust.
AUMA multi-turn actuators are driven by an electric motor and are capable of
withstanding thrust in combination with output drive type A. For manual operation,
a handwheel is provided. Switching off in end positions may be either by limit or
torque seating. Controls are required to operate or process the actuator signals.
Actuator controls The AUMATIC actuator controls are used to operate AUMA actuators and are supplied
ready for use. The controls may be mounted directly to the actuator or separately
on a wall bracket.
The functions of the AUMATIC controls include standard valve control in OPEN -
CLOSE duty, positioning, process control, logging of operating data right through to
diagnostic functions.
Local controls/AUMA Operation, setting, and display can be performed on site directly at the controls.
ToolSuite On site it is possible to
● operate the actuator via the local controls (push buttons and display) and perform
settings (contents of these instructions).
● read in or out data or modify and save settings via the AUMA ToolSuite software
(option), using a computer (laptop or PC). The connection between computer
and AUMATIC is wireless via Bluetooth interface (not included in these instruc-
tions).
Intrusive - Non-Intrusive ● Intrusive version (control unit: electromechanical):
Limit and torque setting is performed via switches in the actuator.
● Non-Intrusive version (control unit: electronic):
Limit and torque setting is performed via the controls, actuator and controls
housings do not have to be opened. For this purpose, the actuator is equipped
with an MWG (magnetic limit and torque transmitter), also supplying analogue
torque feedback signals/torque indication and analogue position feedback si-
gnals/position indication.
9
Transport, storage and packaging AC 01.2 Non-Intrusive

3.1 Transport
Hovering load!
to handwheel.
→ Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting
by hoist to valve and NOT to actuator.
→ Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
→ Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting
by hoist only to the actuator and NOT to the controls.
3.2 Storage

→ Store in a well-ventilated, dry room.
Damage on display caused by temperatures below permissible level!

→ The AUMATIC actuator controls must NOT be stored below –30 °C.
Long-term storage If the device must be stored for a long period (more than 6 months) the following
tion.
3.3 Packaging
Our products are protected by special transport packaging when leaving the factory.
The packaging consists of environmentally friendly materials which can easily be
separated and recycled. We use the following packaging materials: wood, cardboard,
paper, and PE foil. For the disposal of the packaging material, we recommend
recycling and collection centres.
10
4. Assembly
4.1 Mounting position
AUMA actuators and actuator controls can be operated without restriction in any
mounting position.
4.2 Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are supplied sepa-
rately.
Figure 4: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
1. If required, fit spacer [1] onto input shaft [2].

4.3 Multi-turn actuator: mount to valve/gearbox

→ After mounting, connect the device immediately to electrical mains to ensure
that heater minimises condensation.
4.3.1 Output drive types B, B1 – B4 and E

Application ● For rotating, non-rising valve stem
● Not capable of withstanding thrust
Design Output drive bore with keyway:
● Types B1 – B4 with bore according to ISO 5210
● Types B and E with bore according to DIN 3210
● Later change from B1 to B3, B4, or E is possible.
11
Figure 5: Output drive
[1] Output drive types B, B1 – B4, E and C

[2] Output drive sleeve/plug sleeve with bore and keyway
[3] Circlip
Information Spigot at flanges should be loose fit.
4.3.1.1 Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox
1. Check if mounting flanges fit together.

2. Check whether bore and keyway match the input shaft.
3. Apply a small quantity of grease to the input shaft.
4. Place multi-turn actuator.
Information: Ensure that the spigot fits uniformly in the recess and that the
mounting faces are in complete contact.
5. Fasten multi-turn actuator with screws according to table.
6. Fasten screws crosswise to a torque according to table.

M8 25
M10 51
M12 87
M16 214
M20 431
4.3.2 Output drive type A

Application ● Output drive for rising, non-rotating valve stem
● Capable of withstanding thrust
Information To adapt the actuators to output drive types A available on site with flanges F10 and
F14 (year of manufacture: 2009 and earlier), an adapter is required. The adapter
can be ordered from AUMA.
12
4.3.2.1 Stem nut: finish machining
✔ This working step is only required if stem nut is supplied unbored or with pilot
bore.
Figure 6: Design of output drive type A
[1] Stem nut

[2] Bearing
[2.1] Bearing race
[2.2] Bearing rim
[3] Spigot ring
1. Remove spigot ring [3] from output drive.

2. Remove stem nut [1] together with bearings [2].
3. Remove bearing races [2.1] and bearing rims [2.2] from stem nut [1].
4. Drill and bore stem nut [1] and cut thread.
Information: When fixing in the chuck, make sure stem nut runs true!
5. Clean the machined stem nut [1].
6. Apply sufficient Lithium soap EP multi-purpose grease to bearing rims [2.2] and
bearing races [2.1], ensuring that all hollow spaces are filled with grease.
7. Place greased bearing rims [2.2] and bearing races [2.1] onto stem nut [1].
8. Re-insert stem nut [1] with bearings [2] into output drive.
Information: Ensure that dogs or splines are placed correctly in the keyway of
the hollow shaft.
9. Screw in spigot ring [3] until it is firm against the shoulder.
13
4.3.2.2 Multi-turn actuator (with output drive A): mount to valve
Figure 7: Assembly with output drive type A
[1] Valve stem

[2] Output drive type A
[3] Screws to actuator
[4] Valve flange
[5] Screws to output drive
1. If the output drive type A is already mounted to the multi-turn actuator: Loosen
screws [3] and remove output drive type A [2].
2. Check if the flange of output drive type A matches the valve flange [4].
3. Apply a small quantity of grease to the valve stem [1].
4. Place output drive type A on valve stem and turn until it is flush on the valve
flange.
5. Turn output drive type A until alignment of the fixing holes.
6. Screw in fastening screws [5], however do not completely tighten.
7. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into
the output drive sleeve.
➥ The flanges are flush with each other if properly engaged.
8. Adjust multi-turn actuator until alignment of the fixing holes.
9. Fasten multi-turn actuator with screws [3].
10. Fasten screws [3] crosswise with a torque according to table.

M6 11
M8 25
M10 51
M12 87
M16 214
M20 431
11. Turn multi-turn actuator with handwheel in direction OPEN until valve flange
and output drive A are firmly placed together.
12. Tighten fastening screws [5] between valve and output drive type A crosswise
applying a torque according to table.
14
4.4 Accessories for assembly
4.4.1 Stem protection tube for rising valve stem

— Option —
Figure 8: Assembly of the stem protection tube
[1] Cap for stem protection tube

[2] Stem protection tube
[3] Sealing ring
1. Seal thread with hemp, Teflon tape, or thread sealing material.

2. Screw stem protection tube [2] into thread and tighten it firmly.
3. Push down the sealing ring [3] onto the housing.
4. Check whether cap for stem protection tube [1] is available and in perfect con-
dition.
4.5 Mounting positions of local controls
The mounting position of the local controls is selected according to the order. If, after
mounting the actuator to the valve or the gearbox on site, the local controls are in
an unfavourable position, the mounting position can be changed at a later date. Four
mounting positions are possible.
Figure 9: Mounting positions A and B
15
Figure 10: Mounting positions C and D
4.5.1 Mounting positions: modify
Hazardous voltage!
1. Loosen screws and remove the local controls.

2. Check whether O-ring is in good condition, correctly insert O-ring.
3. Turn local controls into new position and re-place.
Cable damage due to twisting or pinching!

→ Turn local controls by a maximum of 180°.
→ Carefully assemble local controls to avoid pinching the cables.
4. Fasten screws evenly crosswise.
16
5. Electrical connection
5.1 Basic information
Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury, or property damage.
→ The electrical connection must be carried out exclusively by suitably qualified
personnel.
→ Prior to connection, observe basic information contained in this chapter.
→ After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
Wiring diagram/terminal
The pertaining wiring diagram/terminal plan is attached to the device in a
plan weather-proof bag, together with these operation instructions. It can also be obtained
from AUMA (state commission no., refer to name plate) or downloaded directly from
the Internet (www.auma.com).
Permissible networks
The controls (actuators) are suitable for for use in TN and TT networks with directly
(supply networks) earthed star point and a maximum voltage of 690 V AC. Use in IT networks is
permitted while observing the respective <Protection on site> for for maiximum supply
voltages of 600 V AC.
Protection on site
For short-circuit protection and for disconnecting the actuator from the mains, fuses
and disconnect switches have to be provided by the customer.
The current values for respective sizing is derived from the current consumption of
the motor (refer to electrical data sheet) plus the current consumption of the controls.
Table 3: Current consumption controls

Mains voltage Max. current consumption
Permissible variation of the mains voltage ±10 % –30 %
100 to 120 V AC 750 mA 1,200 mA
208 to 240 V AC 400 mA 750 mA
380 to 500 V AC 250 mA 400 mA
515 to 690 V AC 200 mA 400 mA
Table 4: Maximum permissible protection

Switchgear Rated power max. protection
Reversing contactor up to 1.5 kW 16 A (gL/gG)
Reversing contactor up to 7.5 kW 32 A (gL/gG)
Reversing contactor up to 11 kW 63 A (gL/gG)
Thyristor up to 1.5 kW 16 A (g/R) I²t<1,500A²s
Thyristor up to 3 kW 32 A (g/R) I²t<1,500A²s
Thyristor up to 5.5 kW 63 A (g/R) I²t<5,000A²s
If controls are mounted separately from actuator (controls on wall bracket): Consider
length and cross section of connecting cable when defining the protection required.
Use appropriate insulation monitors when working in power installations, for example
an insulation monitor measuring the pulse code..
Power supply for the
In case of external supply of the controls (electronics): The external power supply
controls (electronics) must have a reinforced insulation against the mains voltage in accordance with IEC
61010-1 and may only be supplied by a circuit limited to 150 VA in accordance with
IEC 61010-1.
Potential of customer All input signals (control) must be supplied with the same potential.
connections All output signals (status signals) must be supplied with the same potential.
17
Safety standards All externally connected devices shall comply with the relevant safety standards.
Cable installation in ac-
Signal and bus cables are susceptible to interference.
cordance with EMC
Motor cables are interference sources.
● Lay cables being susceptible to interference or sources of interference at the
highest possible distance from each other.
● The interference immunity of signal and bus cables increases if the cables are
laid close to the earth potential.
● If possible, avoid laying long cables and make sure that they are installed in
areas being subject to low interference.
● Avoid long parallel paths with cables being either susceptible to interference or
interference sources.
● For the connection of remote position transmitters, screened cables must be
used.
Type of current, mains Type of current, mains voltage and mains frequency must match the data on the
voltage and mains fre- motor name plate.
quency
Figure 11: Motor name plate (example)
[1] Type of current

[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ● For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
● Use connecting cable with appropriate minimum rated temperature.
● For connecting cables exposed to UV radiation (outdoor installation), use UV
resistant cables.
5.2 Connection with AUMA plug/socket connector
Cross sections AUMA plug/socket connector:
● Power terminals (U1, V1, W1, U2, V2, W2): max. 6 mm² flexible/10 mm² solid
●
PE connection : max. 6 mm² flexible/10 mm² solid
● Control contacts (1 to 50): max. 2.5 mm²
18
5.2.1 Terminal compartment: open
Figure 12: Connection AUMA plug/socket connector, version S
[1] Cover
[3] O-ring
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
Hazardous voltage!
1. Loosen screws [2] and remove cover [1].

2. Loosen screws [4] and remove socket carrier [5] from cover [1].
3. Insert cable glands [8] suitable for connecting cables.
➥ The enclosure protection IP... stated on the name plate is only ensured if suitable
cable glands are used. Example: Name plate shows enclosure protection IP
68.
4. Seal unused cable entries [6] with suitable blanking plugs [7].
5. Insert the cables into the cable glands [8].
5.2.2 Cable connection
✔ Observe permissible cross sections.

1. Remove cable sheathing.
2. Strip wires.
3. For flexible cables: Use end sleeves according to DIN 46228.
4. Connect cables according to order-related wiring diagram.
19
In case of a fault: Hazardous voltage while protective earth conductor is NOT

connected!
→ Connect all protective earth conductors.
→ Connect PE connection to external protective earth conductor of connecting
cables.
→ Start running the device only after having connected the protective earth con-
ductor.
5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables)

or loops (rigid cables).
Figure 14: PE connection
[1] Socket carrier

[2] Screw
[3] Washer
[4] Lock washer
[5] Protective earth with ring lugs/loops
[6] PE connection, symbol:
Danger of corrosion: Damage due to condensation!

→ After mounting, commission the device immediately to ensure that heater mini-
mises condensation.
Information Some actuators are equipped with an additional motor heater. The motor heater
minimises condensation within the motor and improves the start-up behaviour for
extremely low temperatures.
20
5.2.3 Terminal compartment: close
Figure 15: Example: Version S
[1] Cover
[3] O-ring
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
Short-circuit due to pinching of cables!

Risk of electric shock and functional failures.
→ Carefully fit socket carrier to avoid pinching the cables.
1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4].
2. Clean sealing faces of cover [1] and housing.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
6. Fasten cable glands [8] applying the specified torque to ensure the required
enclosure protection.
5.3 Accessories for electrical connection
— Option —
5.3.1 Controls mounted to wall bracket
The wall bracket allows separate mounting of controls and actuator.
Application ● If the actuator cannot be accessed.
● If the actuator is subjected to high temperatures.
● In case of heavy vibration of the valve.
21
Design Figure 16: Design principle with wall bracket
[1] Wall bracket

[2] Connecting cables
[3] Electrical connection of wall bracket (XM)
[4] Electrical connection of actuator (XA)
[5] Electrical connection of controls (XK) – customer connector
Observe prior to ● Permissible length of connecting cables: max. 100 m.
connection ● We recommend: AUMA cable set LSW20.
● If the AUMA cable set is not used:
- Use suitable flexible and screened connecting cables.
- Use separate, CAN bus data cable for MWG of 120 Ohm character impe-
dance (e.g. UNITRONIC BUS-FD P CAN UL/CSA - 2 x 2 x 0.5 mm², ma-
nufacturer: Lapp).
- Data cable connection: XM2-XA2 = CAN L, XM3-XA3 = CAN H.
- Voltage supply MWG: XM6-XA6 = GND, XM7-XA7 = + 24 V DC (refer to
wiring diagram).
- For the electrical connection at wall bracket [3], the terminals are made
as crimp connections.
- Use a suitable four indent crimp tool for crimping.
- Cross sections for flexible wires:
- Control cables: max. 0.75 to 1.5 mm²
- Mains connection: max. 2.5 to 4 mm²
● When using connecting cables, e.g. of the heater, requiring direct wiring from
the actuator to the XK customer connector (XA-XM-XK, refer to wiring diagram),
these connecting cables must be subject to an insulation test in compliance
with EN 50178. Connecting cables for MWG do not belong to this group. They
may not be subject to an insulation test.
5.3.2 Parking frame
Application Parking frame for safe storage of a disconnected plug.
For protection against touching the bare contacts and against environmental
influences.
22
Figure 17: Parking frame
5.3.3 Protection cover

Protection cover for plug compartment when plug is removed.
The open terminal compartment can be closed using a protective cover (not
illustrated).
5.3.4 Double sealed intermediate frame
When removing the electrical connection or due to leaky cable glands, ingress of
dust and water into the housing may occur. This is prevented effectively by inserting
the double sealed intermediate frame [2] between the plug/socket connector [1] and
the housing of the device. The enclosure protection of the device (IP 68) will not be
affected, even if the electrical connection [1] is removed.
Figure 18: Electrical connection with double sealed intermediate frame
[1] Electrical connection

[2] Double sealed intermediate frame
5.3.5 Earth connection, external

As an option, the housing is equipped with an external earth connection (U-bracket)
to connect the device to the equipotential earth bonding.
Figure 19: Earth connection
23
6. Operation
Valve damage due to incorrect basic setting!

→ Prior to electrical operation of the actuator, the basic settings i.e. type of seating,
torque and limit switching have to be completed.
6.1 Manual operation

For purposes of setting and commissioning, in case of motor failure or power failure,
the actuator may be operated manually. Manual operation is engaged by an internal
change-over mechanism.
6.1.1 Manual operation: engage
Damage at the motor coupling due to faulty operation!

→ Engage manual operation only during motor standstill.
1. Press push button.
2. Turn handwheel in desired direction.

→ To close the valve, turn handwheel clockwise:
➥ Drive shaft (valve) turns clockwise in direction CLOSE.
6.1.2 Manual operation: disengage
Manual operation is automatically disengaged when motor is started again. The

handwheel does not rotate during motor operation.
6.2 Motor operation
✔ Perform all commissioning settings and the test run prior to motor operation.
6.2.1 Local actuator operation

Local actuator operation is performed using the push buttons of the local controls of
the AC.
24
Figure 22: Local controls
[1] Push button for operation command in direction OPEN

[2] Push button STOP
[3] Push button for operation command in direction CLOSE
[4] Push button RESET
[5] Selector switch
Hot surfaces, e.g. possibly caused by high ambient temperatures or strong

direct sunlight!
Danger of burns
→ Check surface temperature and wear protective gloves, if required.
→ Set selector switch [5] to position Local control (LOCAL).
➥ The actuator can now be operated using the push buttons [1 – 3].
- Run actuator in direction OPEN: Press push button [1] .
- Stop actuator: Press push button STOP [2].
- Run actuator in direction CLOSE: Press push button [3] .
Information OPEN - CLOSE operation commands can be given either in push-to-run or in self-
retaining operation mode. In self-retaining mode, the actuator runs to the defined
end position after pressing the button, unless another command has been received
beforehand. For further information, please refer to Manual (Operation and setting).
6.2.2 Actuator operation from remote
→ Set selector switch to position Remote control (REMOTE).
➥ Now, it is possible to operate the actuator via remote control, via operation
commands (OPEN, STOP, CLOSE) or analogue setpoints (e.g. 0 – 20 mA).
Information For actuators equipped with a positioner, it is possible to select between open-close
control (Remote OPEN-CLOSE) and setpoint control (remote SETPOINT). Selec-
tion is made via MODE input, e.g. based on a 24 V DC signal (refer to wiring diagram).
25
6.3 Menu navigation via push buttons (for settings and indications)
Menu navigation for display and setting is made via the push buttons [1 – 4] of the
local controls.
Set the selector switch [5] to position 0 (OFF) when navigating through the menu.
The bottom row of the display [6] serves as navigation support and explains which
push buttons [1 – 4] are used for menu navigation.
Figure 26:
[1–4] Push buttons or navigation support

[5] Selector switch
[6] Display
Table 5: Important push button functions for menu navigation

Push buttons Navigation sup- Functions
port on display
[1] Up ▲ Change screen/selection
Change values
[2] Down ▼ Change screen/selection
Change values
[3] Ok Confirm selection
Save Save
Edit Enter <Edit> menu
Details Display more details
[4] C Setup Enter Main menu
Esc Cancel process
Return to previous display
Backlight ● The display is illuminated in white during normal operation. The backlight turns
to red under fault conditions.
● The screen illumination is brighter when operating a push button. If no push
button is operated for 60 seconds, the display will become dim again.
6.3.1 Menu layout and navigation
Groups The indications on the display are divided into 3 groups:
26
Figure 27: Groups
[1] Startup menu

[2] Status menu
[3] Main menu
ID Status menu and main menu are marked with an ID.

Figure 28: Marking with ID
S ID starts with S = status menu

M ID starts with M = main menu
Group selection It is possible to select between status menu S and main menu M:
For this, set selector switch to 0 (OFF), hold down push button C for approx. 2
seconds until a screen containing the ID M... appears.
Figure 29: Select menu groups
You return to the status menu if:

● the push buttons on the local controls have not been operated within 10 minutes
● or by briefly pressing C
Direct display via ID When entering the ID within the main menu, screens can be displayed directly (without
clicking through).
Figure 30: Direct display (example)
Display indicates in the bottom row: Go to

1. Press push button Go to.
Display indicates: Go to menu M0000
3. Press push button Ok to confirm first digit.
5. To cancel the process: Press C Esc.
6.4 User level, password
User level The user level defines which menu items or parameters can be displayed or modified
by the active user.
There are 6 different user levels. The user level is indicated in the top row:
27
Figure 31: User level display (example)
Pasword A password must be entered to allow parameter modification. The display indicates:
Password 0***
A specific password is assigned to each user level and permits different actions.
Table 6: User levels and authorisations

Designation (user level) Authorisation/password
Observer (1) Verify settings
No password required
Operator (2) Change settings
Maintenance (3) Reserved for future extensions
Specialist (4) Change device configuration
e.g. type of seating, assignment of output
contacts
Service (5) Service staff
Change configuration settings
AUMA (6) AUMA administrator
6.4.1 Password entry

Display indicates: Password 0***
1. Select desired menu and hold doen push button for approx. 3 seconds.
➥ Display indicates the set user level, e.g Observer (1)
2. Press Up ▲to select a higher user level and press Ok to confirm.
➥ Display shows: Password 0***
4. Confirm first digit of password via push button Ok.
➥ Having confirmed the last digit with Ok, access to all parameters within one
user level is possible if the password entry is correct.
6.4.2 Password change

Only the passwords of same or lower user level may be changed.
Example: The user is signed in as Specialist (4). This authorises him or her to modify
the passwords between user levels (1) to (4).
Service functions M0222
Change passwords M0229
Menu point Service functions M0222 is only visible if user level has been set to
Specialist (4) or higher.
28
Change passwords 3. Select parameter Change passwords either:

→ via direct display: press and enter ID M0229
- Display indicates: ▶ Change passwords
- The user level is indicated in the top row (1 – 6), e.g.:
- For user level 1 (view only), passwords cannot be changed. To change pass-
words, you must change to a higher user level. For this, enter a password via
a parameter.
4. For a user level between 2 and 6: Press push button Ok.
➥ The display indicates the highest user level, e.g.: For user 4
5. Select user level via push buttons Up ▲ Down ▼ and confirm with Ok.
➥ Display indicates: ▶ Change passwords Password 0***
6. Enter current password (→ enter password).
➥ Display indicates: ▶ Change passwords Password (new) 0***
7. Enter new password (→ enter password).
➥ Display indicates: ▶ Change passwords For user 4 (example)
8. Select next user level via push buttons Up ▲ Down ▼ or cancel the process
via Esc.
6.5 Language in the display
The AUMATIC display is multilingual.
6.5.1 Change language
Display... M0009
Language M0049
Change language 3. Press Ok.
➥ Display indicates: ▶ Language
4. Press Ok.
➥ Display indicates the selected language, e.g.: ▶ Deutsch
5. The bottom row of the display indicates:
→ Save → continue with step 10
→ Edit → continue with step 6
6. Press Edit.
➥ Display indicates: ▶ Observer (1)
7. Select user level via Up ▲ Down ▼ resulting in the following significations:
8. Press Ok.
29

➥ Display indicates: ▶ Language and Save (bottom row)
Language selection 10. Select new language via Up ▲ Down ▼ resulting in the following significati-
ons:
➥ The display changes to the new language.The new language selection is saved.
30
7. Indications
7.1 Indications during commissioning
LED test When switching on the power supply, all LEDs on the local controls illuminate for
approx. 1 second. This optical feedback indicates that the voltage supply is connected
to the controls and all LEDs are operable.
Figure 35: LED test
Language selection During the self-test, the language selection can be activated so that the selected
language is immediately indicated in the display. For this, set selector switch [5] to
position 0 (OFF).
Activate language selection:
1. Display indicates in the bottom row: Language selection menu? 'Reset'
2. Press push button RESET and hold it down until the following text is displayed
in the bottom line: Language menu loading, please wait.
Figure 36: Self-test
The language selection menu follows the startup menu.

Startup menu The current firmware version is displayed during the startup procedure:
Figure 37: Startup menu with firmware version: 03.01.00–00
If the language selection feature has been activated during the self-test, the menu
for selecting the display language will now be indicated. For further information on
language setting, please refer to chapter <Language in the display>.
Figure 38: Language selection
If no entry is made over a longer period of time (approx. 1 minute), the display
automatically returns to the first status indication.
7.2 Indications in the display
Status bar
The status bar (first row in the display) indicates the operation mode [1], the presence
of an error [2] and the ID number [3] of the current display indication.
31
Figure 39: Information in the status bar (top)
[1] Operation mode

[2] Error symbol (only for faults and warnings)
[3] ID number: S = Status page
Navigation support If further details or information are available with reference to the display, the following
indications Details or More appear in the navigation support (bottom display row).
Then, further information can be displayed via the push button.
Figure 40: Navigation support (bottom)
[1] shows list with detailed indications

[2] shows further available information
The navigation support (bottom row) is faded out after approx. 3 seconds. Press any
push button (selector switch in position 0 (OFF)) to fade in the navigation support.
7.2.1 Feedback indications from actuator and valve
Display indications depend on the actuator version.

Valve position (S0001)
This indication is only available if a position transmitter (potentiometer, RWG or
MWG) is installed in the actuator.
● S0001 on the display indicates the valve position in % of the travel.
● When issuing an operation command, an arrow indicates the direction
(OPEN/CLOSE).
Figure 41: Valve position and direction of operation
Reaching the preset end positions is additionally indicated via symbols (CLOSED)
and (OPEN).
Figure 42: End position CLOSED/OPEN reached
0% Actuator is in end position CLOSED

100% Actuator is in end position OPEN
32
Torque (S0002)
The indication is only available if the actuator is equipped with an MWG (magnetic
limit and torque transmitter).
● S0002 on the display indicates the torque applied at the actuator output.
Figure 43: Torque
Select unit The push button allows to select the unit displayed (percent %, Newton metre Nm
or pounds per foot Lbs/ft.
Figure 44: Units of torque
Display in percent 100 % indication equals the max. torque indicated on the name plate of the actuator.
Example: SA 07.5 with 20 – 60 Nm.
Operation commands (S0003)
The display S0003 indicates:
● active operation commands, like e.g.: Operation in direction CLOSE or in direc-
tion OPEN
● the actual value E2 as bargraph indication and as value between 0 and 100 %.
● for setpoint control (positioner): setpoint E1
● for stepping mode or for intermediate positions with operation profile: pivot
points and operation behaviour of pivot points
The navigation support (bottom row) is faded out after approx. 3 seconds and the
axis/axes for pivot point display are shown.
OPEN - CLOSE control Active operation commands (OPEN, CLOSE, ...) are shown above the bargraph
display. The figure below shows the operation command in direction CLOSE.
Figure 45: Display for OPEN - CLOSE control
33
Setpoint control If the positioner is enabled and activated, the bargraph indication for E1 (position
setpoint) is displayed.
The direction of the operation command is displayed by an arrow above the bargraph
indication. The figure below shows the operation command in direction CLOSE.
Figure 46: Display for setpoint control (positioner)
E1 Position setpoint
Pivot point axis The pivot points and their operation behaviour (operation profile) are shown on the
pivot point axis by means of symbols.
The symbols are only displayed if at least one of the following functions is activated:
Operation profile M0294
Timer CLOSE M0156
Timer OPEN M0206
Figure 47: Examples: on the left pivot points (intermediate positions); on the right
stepping mode
Table 7: Symbols along the pivot point axis

Symbol Pivot point (intermediate position) Stepping mode
with operation profile
| Pivot point without reaction End of stepping mode
CLOSE CLOSE
OPEN OPEN
Stop during operation in directions –
OPEN and CLOSE
Pause for operation in direction CLOSE –
Pause for operation in direction OPEN –
Pause for operation in directions OPEN –
and CLOSE
7.2.2 Status indications according to AUMA classification
These indications are available, if the Diagnostic classific. M0539 parameter is set
to AUMA.
Warnings (S0005)
If a warning has occurred, the display shows S0005:
● the number of warnings occurred
● a blinking question mark after approx. 3 seconds
34
Figure 48: Warnings

Not ready REMOTE (S0006)
The S0006 display shows indications of the Not ready REMOTE group.
● a blinking crossbar after approx. 3 seconds
Figure 49: Not ready REMOTE indications

Fault (S0007)
If a fault has occurred, the display shows S0007:
● the number of faults occurred
● a blinking exclamation mark after approx. 3 seconds
Figure 50: Fault

7.2.3 Status indications according to NAMUR recommendation
These indications are available, if the Diagnostic classific. M0539 parameter is set
to NAMUR.
Out of Specification (S0008)
The S0008 indication shows out of specification indications according to NAMUR
● a blinking triangle with question mark after approx. 3 seconds
35
Figure 51: Out of specification

Function check (S0009)
The S0009 indication shows function check indications according to NAMUR
If an indication has occurred via the function check, the display shows S0009:
● a blinking triangle with a spanner after approx. 3 seconds
Figure 52: Function check

Maintenance required (S0010)
The S0010 indication shows maintenance indications according to NAMUR
● a blinking square with an oil can after approx. 3 seconds
Figure 53: Maintenance required

Failure (S0011)
The S0011 indication shows the causes of the failure indication according to NAMUR
● a blinking circle with a cross after approx. 3 seconds
Figure 54: Failure
36
7.3 Mechanical position indicator/running indication

— Option —
● Continuously indicates the valve position
(For complete travel from OPEN to CLOSED or vice versa, the indicator disc
[2] rotates by approximately 180° to 230°.)
● Indicates whether the actuator is running (running indication)
● Indicates that the end positions are reached (via indicator mark [3])
[1] Cover
[2] Indicator disc
[3] Mark
7.4 Indication lights

Figure 56: Arrangement and signification of indication lights
[1] Marking with symbols (standard)

[2] Marking with figures 1 – 6 (option)
1 End position CLOSED reached (blinking: for operation in direction CLOSE)
2 Tc Torque fault CLOSE
3 Motor protection tripped
4 To Torque fault OPEN
5 End position OPEN reached (blinking: for operation in direction OPEN)
6 Bluetooth connection
Modify indication light assignment (indications)
Different indications can be assigned to LEDs 1 – 5.

Local controls M0159
Indication light 1 (left) M0093
37
Indicat. light 5 (right) M0097

Signal interm. pos. M0167
Defaut values (Europe):
Indication light 1 (left) = End p. CLOSED, blink
Indication light 2 = Torque fault CLOSE
Indication light 3 = Thermal fault
Indication light 4 = Torque fault OPEN
Indicat. light 5 (right) = End p. OPEN, blink
Signal interm. pos. = OPEN/CLOSED = Off
Further setting values:
Refer to Manual (Operation and setting).
38
AC 01.2 Non-Intrusive Signals
8. Signals
8.1 Status signals via output contacts (digital outputs)
Characteristics Output contacts are used to send status signals (e.g. reaching the end positions,
selector switch position, faults...) as binary signals to the control room.
Status signals only have two states: active or inactive. Active means that the
conditions for the signal are fulfilled.
8.1.1 Assignment of outputs
The output contacts (outputs DOUT 1 – 12) can be assigned to various signals.
I/O interface M0139
Signal DOUT 1 M0109
Default values:
8.1.2 Encoding of outputs
The output signals DOUT 1 – 12 can be set either to high active or low active.
● High active = output contact closed = signal active
● Low active = output contact open = signal active
I/O interface M0139
Coding DOUT 1 M0102
Default values for DOUT 1 – 12: High active
8.2 Analogue signals
Valve position Signal: E2 = 0/4 – 20 mA (galvanically isolated)
ANOUT1 (position)
Torque feedback Signal: E6 = 0/4 – 20 mA (galvanically isolated)
ANOUT2 (torque)
For further information on this topic, please refer to Manual (Operation and setting).
39
9. Commissioning (basic settings)

1. Set selector switch to position 0 (OFF).
Information: The selector switch is not a mains switch. When positioned to 0

(OFF), the actuator cannot be operated. The controls' power supply is
maintained.
2. Switch on the power supply.
Information: Please consider the heat-up time for ambient temperatures below
–20 °C.
3. Perform basic settings.
9.1 Type of seating: set
Valve damage due to incorrect setting!

→ The type of seating must suit the valve.
→ Only change the setting with prior consent of the valve manufacturer.

Type of seating M0012
End position CLOSED M0086
End position OPEN M0087
Default value: Limit
Setting values:
Limit Seating in end positions via limit switching.
Torque Seating in end positions via torque switching.
→ via direct display: press and enter ID M0086 or M0087
➥ Display indicates: End position CLOSED
CLOSE or OPEN 4. Use Up ▲ Down ▼ to select:
→ ▶ End position CLOSED
→ ▶ End position OPEN
5. Press Ok.
➥ Display indicates the current setting: Limit or Torque
➥ The bottom row of the display indicates either:
- Edit → continue with step 6
- Save → continue with step 10
40
6. Press Edit.
➥ Display indicates: ▶ Specialist (4)
8. Press Ok.
➥ The screen indicates the pre-set type of seating (▶ Limit or ▶ Torque) by means
of a black triangle ▶.
Change settings 10. Select new setting Up ▲ Down ▼ resulting in the following significations:
➥ The setting for the type of seating is complete.
12. Back to step 4 (CLOSED or OPEN): Press Esc .
9.2 Torque switching: set
Once the set torque is reached, the torque switches will be tripped (overload protection
of the valve)
Information The torque switches may also trip during manual operation.
Valve damage due to excessive tripping torque limit setting!

→ The tripping torque must suit the valve.

Torque switching M0013
Trip torque CLOSE M0088
Trip torque OPEN M0089
Default value: According to order data
Setting range: Torque range according to actuator name plate
➥ Display indicates: Trip torque CLOSE
41
CLOSE or OPEN 4. Select via Up ▲ Down ▼:

→ ▶ Trip torque CLOSE
→ ▶ Trip torque OPEN
5. Press Ok.
6. Press Edit.
➥ Display indicates:
- in bottom row Up ▲ Down ▼ Esc → continue with step 11
➥ The symbols have the following meanings:
8. Press Ok.
10. Press Edit.
Change value 11. Enter new value for tripping torque via Up ▲ Down ▼.
Information: The adjustable torque range is shown in round brackets
12. Save new value via Save.
➥ The tripping torque is set.
13. Back to step 4 (CLOSED or OPEN): Press Esc.
Information The following fault signals are sent if the set torque is reached in mid-travel:
● Status indication S0007 Fault = Torque fault OPEN or Torque fault CLOSE
The fault has to be acknowledged before the operation can be resumed. The
acknowledgement is made:
1. either by an operation command in the opposite direction.
- For Torque fault OPEN : Operation command in direction OPEN
- For Torque fault CLOSE : Operation command in direction CLOSE
2. or, in case the torque applied is lower than the preset tripping torque:
- via the RESET push button in selector switch position Local control
(LOCAL).
9.3 Limit switching: set
Valve damage at valve/gearbox due to incorrect setting!

→ When setting with motor operation: Stop actuator before reaching end of travel
(press push button STOP).
→ Allow for overrun when selecting limit seating.

Limit switching M0010
Set end pos.CLOSED? M0084
42
Set end pos. OPEN? M0085
2. Press push button C and hold it down for approx. 3 seconds.

➥ Display indicates: Set end pos.CLOSED?
CLOSED or OPEN 4. Use Up ▲ Down ▼ to select:
→ ▶ Set end pos.CLOSED? M0084
→ ▶ Set end pos. OPEN? M0085
5. Press Ok.
Log on user 6. Use Up ▲ Down ▼to select a user:
7. Press Ok to confirm selected user level.
Set end position CLO- 9. Re-set end position CLOSED:
SED CMD0009 9.1 For large strokes: Set selector switch in position Local control (LOCAL)
and operate actuator in motor operation via push button (CLOSED) in
9.3 Turn handwheel until valve is closed.
9.4 Turn handwheel by approximately half a turn (overrun) in the opposite di-
rection of end position.
➥ Display indicates: Set end pos.CLOSED? Yes No
43

➥ Display indicates: End pos. CLOSED set!
➥ The left LED is illuminated (standard version) and thus indicates that the end
position CLOSED setting is complete.
11. Make selection:

→ Edit → back to step 9: Set end position CLOSED "once again"
→ Esc → back to step 4; either set end position OPEN or exit the menu.
Set end position OPEN 12. Re-set end position OPEN:
CMD0010 12.1 For large strokes: Set selector switch in position Local control (LOCAL)
and operate actuator in motor operation via push button (OPEN) in di-
rection of the end position.
12.3 Turn handwheel until valve is open.
12.4 Turn handwheel by approximately half a turn (overrun) in the opposite di-
rection of end position.
➥ Display indicates: Set end pos. OPEN? Yes No
➥ Display indicates: End pos. OPEN set!
➥ The right LED is illuminated (standard version) and thus indicates that the end
position setting is complete.
14. Make selection:

→ Edit → back to step 9: Set end position OPEN "once again"
→ Esc → back to step 4; either set end position CLOSED or exit the menu.
Information If an end position cannot be set: Check the type of control unit in actuator.
9.4 Test run

Perform test run only once all settings previously described have been performed.
9.4.1 Direction of rotation: check
1. Move actuator manually to intermediate position or to sufficient distance from

end position.
44
3. Switch on actuator in running direction CLOSE and observe the direction of

rotation:
with indicator disc: step 4
without indicator disc: step 5 (hollow shaft)
→ Switch off before reaching the end position.
4. With indicator disc:
→ Observe direction of rotation.
➥ The direction of rotation is correct, if actuator runs in direction
CLOSE and indicator disc turns counterclockwise.
5. Without the indicator disc:

→ Unscrew screw plug [1] and seal [2] or cap for stem protection tube [4]
and observe direction of rotation at hollow shaft [3] or the stem [5].
➥ The direction of rotation is correct, if actuator runs in direction CLOSE and
hollow shaft or stem turn clockwise.
Figure 65: Hollow shaft/stem
[1] Screw plug

[2] Seal
[3] Hollow shaft
[4] Cap for stem protection tube
[5] Stem
[6] Stem protection tube
9.4.2 Limit switching: check
45
2. Operate actuator using push buttons OPEN - STOP - CLOSE.

➥ The limit switching is set correctly if (default indication):
- the yellow indication light/LED1 is illuminated in end position CLOSED
- the green indication light/LED5 is illuminated in end position OPEN
- the indication lights go out after travelling into opposite direction.
➥ The limit switching is set incorrectly if:
- the actuator comes to a standstill before reaching the end position
- one of the red indication lights/LEDs is illuminated (torque fault)
- the status indication S0007 in the display signals a fault.
3. If the end position setting is incorrect: Reset limit switching.
9.5 Switch compartment: open
The switch compartment must be opened to perform the following settings (options).
→ Loosen screws [2] and remove cover [1] from the switch compartment.
9.6 Mechanical position indicator: set

— Option —

2. Turn lower indicator disc until symbol (CLOSED) is in alignment with the
mark on the cover.
3. Move actuator to end position OPEN.

4. Hold lower indicator disc in position and turn upper disc with symbol (OPEN)
until it is in alignment with the mark on the cover.
5. Move valve to end position CLOSED again.
46
6. Check settings:
If the symbol (CLOSED) is no longer in alignment with mark on the cover:
6.1 Repeat setting procedure.
6.2 Gear stage of the reduction gearing: test/set
9.7 Gear stage of the reduction gearing: test/set

This test/setting is only required if the turns/stroke of the actuator have been modified
after the initial setting.
The control unit may possibly have to be exchanged:
Control unit MS5.2: 1 to 500 turns per stroke
Control unit MS50.2: 10 to 5,000 turns per stroke
1. Pull off indicator disc. Open end spanner may be used as lever.
2. Refer to table and check if turns/stroke of the actuator correspond to the setting
of the primary reduction gearing (stages 1– 9).
If the setting is wrong: continue with 3.
If the setting is correct: continue with 6.
Control unit MS5.2 (1 to 500 turns per stroke)
Turns/stroke above – to Gear stage
1.0 – 1.9 1
1.9 – 3.9 2
3.9 – 7.8 3
7.8 – 15.6 4
15.6 – 31.5 5
31.5 – 62.5 6
62.5 – 125 7
125 – 250 8
250 – 500 9
Control unit MS50.2 (10 to 5,000 turns per stroke)

Turns/stroke above – to Gear stage
10.0 – 19.5 1
19.5 – 39.0 2
39.0 – 78.0 3
78 – 156 4
156 – 315 5
315 – 625 6
625 – 1,250 7
1,250 – 2,500 8
2,500 – 5,000 9
3. Loosen screw [1].

4. Set crown wheel [2] to desired level according to table.
47
5. Tighten screw [1].

6. Place indicator disc on shaft.
7. Set mechanical position indicator.
Figure 71: Control unit with reduction gearing
[1] Screw
[2] Crown wheel
9.8 Switch compartment: close
Danger of corrosion due to damage to paint finish!

1. Clean sealing faces of housing and cover.

4. Place cover [1] on switch compartment.

5. Fasten screws [2] evenly crosswise.
48
10. Corrective action
10.1 Faults during commissioning
Table 8: Faults during commissioning

Fault description Possible causes Remedy
Mechanical position indicator Reduction gearing is not suitable for Set gear stage of the reduction gearing.
cannot be set. turns/stroke of the actuator. The control unit might have to be exchanged.
Fault in end position The overrun was not considered when setting Determine overrun: Overrun = travel covered
Actuator runs to end stop alt- the limit switching. from switching off until complete standstill.
hough the limit switches work The overrun is generated by the inertia of Set limit switching again considering the
properly. both the actuator and the valve and the delay overrun (turn handwheel back by the amount
time of the controls. of the overrun).
10.2 Fault indications and warning indications
Faults interrupt or prevent the electrical actuator operation. In the event of a fault,
the display backlight is red.
Warnings have no influence on the electrical actuator operation. They only serve
for information purposes.
Collective signals include further indications which can be displayed via the
Details push button.
Table 9: Faults and warnings via status indications in the display

Indication on display Description/cause For indicated value > 0:
Warnings S0005 Collective signal 02: Press push button Details.
Indicates the number of active warnings. For details refer to <Warnings> table.
Not ready REMOTE S0006 Collective signal 04: Press push button Details.
Indicates the number of active signals. For details, refer to <Not ready REMOTE and
Function check> table.
Fault S0007 Collective signal 03: Press push button Details to display a list
Indicates the number of active faults. of detailed indications.
The actuator cannot be operated. For details, refer to <Faults> table.
Out of specification S0008 Collective signal 07: Press push button Details.
Indication according to NAMUR recommenda- For details refer to <Warnings> table.
tion NE 107
Actuator is operated outside the normal ope-
ration conditions.
Function check S0009 Collective signal 08: Press push button Details.
Indication according to NAMUR recommenda- For details, refer to <Not ready REMOTE and
tion NE 107 function check> table.
The actuator is being worked on; output si-
gnals are temporarily invalid.
Maintenance required S0010 Collective signal 09: Press push button Details to display a list
tion NE 107
Recommendation to perform maintenance.
Failure S0011 Collective signal 10: Press push button Details to display a list
tion NE 107 For details, refer to <Faults> table.
Actuator function failure, output signals are
invalid
49
Table 10: Warnings

Config. warning Collective signal 06: Press push button Details to display a list
Possible cause: of individual indications.
Configuration setting is incorrect. For a description of the individual signals, refer
The device can still be operated with restricti- to Manual (Operation and setting).
ons.
Internal warning Collective signal 15: Press push button Details to display a list
Device warnings of individual indications.
The device can still be operated with restricti- For a description of the individual signals, refer
ons. to Manual (Operation and setting).
Failure behav. active The failure behaviour is active since all requi- Verify signals:
red setpoints and actual values are incorrect. ● Setpoint E1
● Actual value E2
● Actual process value E4
Torque wrn OPEN Limit value for torque warning in direction Check Wrn torque OPEN M0768 parameter,
OPEN exceeded. re-set if required.
Torque wrn CLOSE Limit value for torque warning in direction Check Wrn torque CLOSE M0769 parameter,
CLOSE exceeded. re-set if required.
Wrn on time running Warning On time max. running time/h excee- ● Check modulating behaviour of actuator.
ded ● Check Perm. running time/h M0768 para-
meter, re-set if required.
Wrn on time starts Warning On time max. number of motor starts ● Check modulating behaviour of actuator.
(starts) exceeded ● Check Permissible starts/h M0357 parame-
ter, re-set if required.
Op. time warning The set time (Perm.op. time, manual M0570 The warning indications are automatically
parameter) has been exceeded. The preset cleared once a new operation command is
operating time is exceeded for a complete executed.
travel from end position OPEN to end position ● Check valve.
CLOSED. ● Check Perm.op. time, manual M0570 pa-
rameter.
Wrn no reaction No actuator reaction to operation commands ● Check movement at actuator.
within the set reaction time. ● Check Reaction time M0634 parameter.
24 V DC external The external 24 V DC voltage supply of the Check 24 V DC voltage supply.
controls has exceeded the power supply limits.
RTC not set Real time clock has not yet been set. ● Set time.
● Replace button cell.
Wrn controls temp. Temperature within controls housing too high Measure/reduce ambient temperature.
Wrn motor temp. Temperature within motor winding too high Check actuator sizing, correct accordingly.
Wrn gearbox temp. Temperature within actuator gear housing too Check actuator sizing, correct accordingly.
high
Wrn FOC Optical receiving signal (channel 1) incorrect Check/repair FO cables.
(no or insufficient Rx receive level) or RS-485
format error (incorrect bit(s))
Wrn FOC connection Warning FO cable connection is not available.
Wrn FO cable budget Warning: FO cable system reserve reached Check/repair FO cables.
(critical or permissible Rx receive level)
Wrn setpoint position Warning: Loss of signal of actuator setpoint Check setpoint signal.
position
Possible causes:
Input signal for setpoint = 0 (signal loss)
50
Table 11: Not ready REMOTE and Function check

Wrong oper. cmd Collective signal 13: ● Check operation commands (send one
Possible causes: operation command only).
● Several operation commands (e.g. OPEN ● Set Positioner parameter to Function acti-
and CLOSE simultaneously, or OPEN and ve.
SETPOINT operation simultaneously)
● Check setpoint.
● A setpoint is present and the positioner is
not active Press push button Details to display a list
● For fieldbus: Setpoint exceeds 100.0 %
For a description of the individual signals, refer
to Manual (Operation and setting).
I/O interface The actuator is controlled via the I/O interface Check I/O interface.
(parallel).
Interlock An interlock is active. Check interlock signal.
Handwheel active Manual operation is activated. Start motor operation.
Sel. sw. not REMOTE Selector switch is not in position REMOTE. Set selector switch to position REMOTE.
Local STOP A local STOP is active. Release push button STOP.
Push button STOP of the local controls is
operated.
EMCY stop active The EMERGENCY stop switch has been ● Enable EMERGENCY stop switch.
operated. The motor control power supply ● Reset EMERGENCY Stop state by means
(contactors or thyristors) is disconnected. of Reset command.
Service active Operation via service interface (Bluetooth) and Exit service software.
service software AUMA ToolSuite.
EMCY behav. active Operation mode EMERGENCY is active ● Detect cause for EMERGENCY signal.
(EMERGENCY signal was sent). ● Verify failure source.
0 V are applied at the EMERGENCY input.
● Apply +24 V DC at EMERGENCY input.
FailState fieldbus Fieldbus connection available, however no Verify master configuration
process data transmission by the master.
Table 12: Faults

Configuration error Collective signal 11: Press push button Details to display a list
Internal fault Collective signal 14: AUMA service
Internal error has occurred. Press push button Details to display a list
Torque fault OPEN Torque fault in direction OPEN Perform one of the following measures:
CLOSE.
push button RESET.
Torque fault CLOSE Torque fault in direction CLOSE Perform one of the following measures:
OPEN.
push button RESET.
51

Thermal fault Motor protection tripped ● Cool down, wait.
● If the fault indication display persists after
cooling down:
- Set selector switch to position Local
control (LOCAL) and reset fault indica-
tion via push button RESET.
● Check fuses.
Fault no reaction No actuator reaction to operation commands Check movement at actuator.
within the set reaction time.
Incorrect phase seq The phase conductors L1, L2 and L3 are Correct the sequence of the phase conductors
connected in the wrong sequence. L1, L2 and L3 by exchanging two phases.
Only applicable if connected to a 3-ph AC
system.
Phase fault ● When connecting to a 3-ph AC system and Test/connect phases.
with internal 24 V DC supply of the electro-
nics: Phase 2 is missing.
● When connecting to a 3-ph or 1-ph AC
system and with external 24 V DC supply
of the electronics: One of the phases L1,
L2 or L3 is missing.
Mains quality Due to insufficient mains quality, the controls ● Check mains voltage.
cannot detect the phase sequence (sequence ● Check Tripping time M0172 parameter,
of phase conductors L1, L2 and L3) within the extend time frame if required.
pre-set time frame provided for monitoring.
10.3 Fuses
10.3.1 Fuses within the actuator controls
Fuses used
F1/F2 Primary fuses on power supply unit
G fuse F1/F2 AUMA art. no.

Size 6.3 x 32 mm
Reversing contactors 1 A T; 500 V K002.277
Power supply ≤ 500 V
Reversing contactors 2 A FF; 690 V K002.665
Power supply > 500 V
Thyristor units for motor power up to 1.5 kW 1 A T; 500 V K002.277
F3 Internal 24 V DC supply
G fuse according to IEC 60127-2/III F3 AUMA art. no.

Size 5 x 20 mm
F4 Internal 24 V AC supply (115 V AC) for:

● Heater, switch compartment, reversing contactors control
● PTC tripping device
● for 115 V AC also control inputs OPEN - STOP - CLOSE
G-fuse according to IEC 60127-2/III F4 AUMA art. no.

Size 5 x 20 mm
Voltage output (power supply unit) = 115 V — —
52
F5 Automatic reset fuse as short-circuit protection for external 24 V DC supply for

customer (see wiring diagram)
Replace fuses F1/F2
Hazardous voltage!
1. Loosen screws [1] and remove plug/socket connector [2].
2. Pull fuse holder [3] out of pin carrier, open fuse cover and replace old fuses by
new ones.
Fuses F3/F4 - test/replace
Information For versions with electrical connection type KP/KPH, the fuses (F1/F2) are located
on the PSU board.
1. Loosen screws [1] and remove cover [2] on the rear of the actuator controls.
The power supply unit has measurement points (solder pins) allowing to perform
a resistance (continuity) measurement:
Verifying Measuring points
F1 MTP1 – MTP2
F2 MTP3 – MTP4
F3 MTP5 – MTP6
F4 MTP7 – MTP8
53
2. To replace defective fuses:. Carefully loosen power supply unit [3] and pull out.
(The fuses are on the equipped part of the power supply board).
Cable damage due to pinching!

→ Carefully assemble power supply unit to avoid pinching the cables.
10.3.2 Motor protection (thermal monitoring)
In order to protect against overheating and impermissibly high surface temperatures

at the actuator, PTC thermistors or thermoswitches are embedded in the motor
winding. The thermoswitch is tripped as soon as the max. permissible winding
temperature has been reached.
The actuator is switched off and the following signals are given:
● LED 3 (thermal fault) on the local controls is illuminated.
● Status indication S0007 displays an error. The error Thermoswitch is displayed
when selecting Details.
The motor has to cool down before the operation can be resumed. Depending on
the parameter setting, the fault signal is either automatically reset or the fault signal
has to be reset using the push button Reset in selector switch position LOCAL.
For further information to this topic, please refer to Manual (Operation and setting).
54
AC 01.2 Non-Intrusive Servicing and maintenance

Service
AUMA offers extensive service such as servicing and maintenance as well as
customer product training. For the relevant contact addresses, please refer to
<Addresses> in this document or to the Internet (www.auma.com).
11.1 Preventive measures for servicing and safe operation

Every 6 months after commissioning and then every year
● Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing.
Respect torques according to manufacturer's details.
chapter <Assembly>.
● For devices with output drive A: Press in Lithium soap EP multi-purpose grease
on mineral oil base at the grease nipple with a grease gun.
● Lubrication of the valve stem must be done separately.
Figure 75: Output drive type A
[1] Output drive type A

[2] Grease nipple
Table 13: Grease quantities for bearing of output drive type A

Output drive A 07.2 A 10.2 A 14.2 A 16.2
Quantity [g] 1) 1.5 2 3 5
1) For grease at density r = 0.9 kg/dm³
For enclosure protection IP 68

● Check actuator.
● In case of ingress of water, locate leaks and repair, dry device correctly and
11.2 Maintenance
Lubrication ● In the factory, the gear housing is filled with grease.
55
Servicing and maintenance AC 01.2 Non-Intrusive
● Grease change is performed during maintenance

- Generally after 4 to 6 years for modulating duty.
- Generally after 6 to 8 years if operated frequently (open-close duty).
- Generally after 10 to 12 years if operated rarely (open-close duty).
● We recommend exchanging the seals when changing the grease.
● No additional lubrication of the gear housing is required during operation.
11.3 Disposal and recycling
● various metals
● plastics
environment.
● Arrange for controlled waste disposal of the disassembled material or for sepa-
rate recycling according to materials.
56
12. Technical data

This data sheet can be downloaded from the Internet at http://www.auma.com (in-
dication of commission number required).
12.1 Features and functions of actuator
Type of duty1) Standard:

● SA: Short-time duty S2 - 15 min
● SAR: Intermittent duty S4 - 25 %
Options:
● SA: Short-time duty S2 - 30 min
● SAR: Intermittent duty S4 - 50 %
● SAR: Intermittent duty S5 – 25 %
Torque range Refer to actuator name plate
Output speed Refer to actuator name plate
Motor Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 60034
Motor voltage and frequency Refer to motor name plate
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Self-locking Self-locking: Output speeds up to 90 rpm (50 Hz), 108 rpm (60 Hz)
NOT self-locking: Output speeds up to 125 rpm (50 Hz), 150 rpm (60 Hz)
Multi-turn actuators are self-locking, if the valve position cannot be changed from standstill
while torque acts upon the output drive.
Limit switching Magnetic limit and torque transmitter MWG for 1 to 500 turns per stroke or 10 to 5,000 turns
per stroke
Torque switching Via MWG (like limit switching)
Position feedback signal, ana- Via MWG
logue (option)
Torque feedback signal, ana- Via MWG
logue (option)
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Heater in switch compartment Standard: Resistance type heater, 5 W, 24 V DC, (internal supply)
Motor heater (option) Voltages: 110 – 220 V AC, 220 – 240 V AC or 400 V AC (externally supplied)
Power depending on the size 12.5 – 25 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during electrical
operation.
Option: Handwheel lockable
Connection to controls AUMA plug/socket connector with screw-type connection
Valve attachment Standard: B1 according to EN ISO 5210
Options:
A, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drive types: AF, B3D, ED, DD, IB1, IB3
A prepared for stem lubrication
Sensor system
Indication for manual operation Indication whether manual operation is active/not active via switch (1 change-over contact)
(option)
Temperature for motor (option) Temperature sensor PT 100
Temperature for gear housing Temperature sensor PT 100
(option)
57
1) For nominal voltage and 40 °C ambient temperature and an average load with running torque or modulating torque according to sepa-
rate technical data. The type of duty must not be exceeded.
Technical data for handwheel activation switches

Mechanical lifetime 106 starts
Silver plated contacts:
U min. 12 V DC
U max. 250 V AC
I max. AC current 3 A at 250 V (inductive load, cos phi = 0.8)
I max. DC current 3 A at 12 V (resistive load)
12.2 Features and functions of actuator controls
Power supply For mains voltage and mains frequency, refer to name plates at the controls and the motor
Mains frequency Permissible variation of the mains voltage: ±10 %
Permissible variation of the mains frequency: ±5 %
Option: Permissible variation of the mains voltage: ±30 %
External supply of the electro- 24 V DC +20 % / –15 %
nics (option) Current consumption: Basic version approx. 250 mA, with options up to 500 mA
The external power supply must have a reinforced insulation against the mains voltage in
accordance with IEC 61010-1 and may only be supplied by a circuit limited to 150 VA in ac-
cordance with IEC 61010-1.
Current consumption Current consumption of the controls depending on the mains voltage:
● 100 to 120 V AC = max. 740 mA
● 208 to 240 V AC = max. 400 mA
● 380 to 500 V AC = max. 250 mA
● 515 to 690 V AC = max. 200 mA
● 100 to 120 V AC = max. 1,200 mA
● 208 to 240 V AC = max. 750 mA
● 380 to 500 V AC = max. 400 mA
● 515 to 690 V AC = max. 400 mA
Motor current consumption: Refer to motor name plate
Overvoltage category Category III according to IEC 60634-4-443
Rated power The controls are designed for the rated motor power, refer to motor name plate
Switchgear1) 2) Standard:
Reversing contactors (mechanically and electrically interlocked) for motor power up to power
class A1
Options:
● Reversing contactors (mechanically and electrically interlocked) for motor power up to
power class A2
● Thyristor unit for mains voltage up to 500 V AC (recommended for modulating actuators)
for AUMA power classes B1, B2 and B3
Control Standard:
Via digital inputs OPEN, STOP, CLOSE, EMERGENCY (via opto-isolator, OPEN, STOP,
CLOSE with one common), respect minimum pulse duration for modulating actuators
Option:
Additional enable inputs for directions OPEN and CLOSE
Voltage and current values for Standard:
control inputs3) 24 V DC, current consumption: approx. 10 mA per input
Options:
115 V AC, current consumption: approx. 15 mA per input
58
Status signals Standard:

● 5 potential-free NO contacts with one common, max. 250 V AC, 1 A (resistive load)
- Default configuration: End position OPEN, end position CLOSED, selector switch in
REMOTE, torque fault CLOSE, torque fault OPEN
- Default configuration: Collective fault signal (torque fault, phase failure, motor protec-
tion tripped)
Options:
● 5 change-over contacts with one common, max. 250 V AC, 5 A (resistive load)
● 10 potential-free NO contacts, one common for respectively 5 contacts, max. 250 V AC,
● 2 potential-free change-over contacts, max. 250 V AC, 5 A (resistive load)
● 6 potential-free change-over contacts without one common, per contact max. 250 V AC,
● 10 potential-free change-over contacts without one common, per contact max. 250 V
AC, 5 A (resistive load)
All output signals must be supplied with the same potential.
Position feedback signal Galvanically isolated analogue output E2 = 0/4 – 20 mA (load max. 500 Ω)
Voltage output Standard:
Auxiliary voltage 24 V DC, max. 100 mA for supply of the control inputs, galvanically isolated
Option:
Auxiliary voltage 115 V AC, max. 30 mA to supply the control inputs4), galvanically isolated
Local controls Standard:
● Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
● Push buttons OPEN, STOP, CLOSE, RESET
● 6 indication lights:
- End position CLOSED (yellow), torque fault CLOSE (red), motor protection tripped
(red), torque fault OPEN (red), end position and running indication OPEN (green),
Bluetooth (blue)
● Graphic LC display, illuminated
Options:
● Special colours for the 5 indication lights:
- End position CLOSED (green), torque fault CLOSE (blue), torque fault OPEN (yellow),
motor protection tripped (white), end position OPEN (red)
Bluetooth Bluetooth class II chip, version 2.0 with a range up to 10 m in industrial environments. Supports
Communication interface the SPP Bluetooth profile (Serial Port Profile).
Programming software:
AUMA ToolSuite, commissioning and diagnostic tool for windows based PCs, PDAs and
smart phones
Application functions Standard:
● Switch-off mode adjustable
- Limit or torque seating for end position OPEN and end position CLOSED
● Torque by-pass, adjustable up to 5 seconds (no torque monitoring during this time)
● Start and end of stepping mode as well as ON and OFF time (1 up to 1,800 seconds)
can be programmed individually for directions OPEN and CLOSE.
● Any 8 intermediate positions between 0 and 100 %, reaction and signal behaviour pro-
grammable
Options:
● Positioner
- Position setpoint via analogue input E1 = 0/4 – 20 mA
- Automatic adaptation of the dead band (adaptive behaviour can be selected)
- Split Range operation
- MODE input for selecting between OPEN - CLOSE duty and modulating duty
59
Failure functions Standard:

● EMERGENCY operation, behaviour programmable
- Digital input low active, reaction can be selected: Stop, move to end position CLOSED,
move to end position OPEN, move to intermediate position
- Torque monitoring can be by-passed during EMERGENCY operation.
- Thermal protection can be by-passed during EMERGENCY operation (only in combi-
nation with thermoswitch in the actuator, not with PTC thermistor).
Options:
● Enabling local controls via digital input Enable LOCAL. Thus, the actuator operation can
be enabled or disabled via push buttons on the local controls.
● Local Stop
- The actuator can be stopped via push button Stop of local controls if the selector
switch is in position REMOTE. Not activated when leaving the factory.
● EMERGENCY stop button (latching) interrupts electrical operation irrespective of the
selector switch position.
● Interlock, enabling the operation commands OPEN or CLOSE via digital inputs Interlock
OPEN or Interlock CLOSE
Monitoring functions Standard:
● Torque monitoring: Valve overload protection (adjustable), results in switching off and
generates fault indication
● Motor temperature monitoring (thermal monitoring), results in switching off and generates
fault indication
● Monitoring the heater within the actuator, generates warning signal
● Monitoring of permissible on-time and number of starts (adjustable), generates warning
signal
● Operation time monitoring (adjustable), generates warning signal
● Phase failure monitoring, results in switching off and generates fault indication
● Automatic correction of the direction of rotation upon wrong phase sequence (3-phase
AC currrent)
Diagnostic functions ● Electronic device ID with order and product data
● Logging of operating data: A resettable counter and a lifetime counter each for:
- Motor running time, number of starts, torque switch trippings in end positions CLOSED,
limit switch trippings in end position CLOSED, torque switch trippings in end position
OPEN, limit switch trippings in end position OPEN, torque faults CLOSE, torque faults
OPEN, motor protection trippings
● Time-stamped event report with setting, operation and fault history:
- Status signals in compliance with NAMUR recommendation NE 107: "Failure",
”Function check", "Out of specification", "Maintenance required"
● Torque characteristics
- 3 torque characteristics (torque-travel characteristic) for opening and closing directions,
can be saved separately. Torque characteristics stored can be shown on the display.
Electrical connection Standard:
AUMA plug/socket connector (S) with screw-type connection and M-threads
Options:
● Pg-threads, NPT-threads, G-threads, special threads
● Gold-plated control contacts (pins and sockets)
● Parking frame for wall mounting of the disconnected plug
● Protection cover for plug compartment (when plug is removed)
Wiring diagram Refer to name plate
1) The reversing contactors are designed for a lifetime of 2 million starts.
2) For the assignment of AUMA power classes, please refer to electrical data on actuator.
3) All input signals must be supplied with the same potential.
4) Not possible in combination with PTC tripping device
Further options for Non-intrusive version with MWG in the actuator

Setting limit and torque switching via the controls’ local controls
Torque feedback signal Galvanically isolated analogue output E6 = 0/4 – 20 mA (max. load 500 Ω), only possible in
combination with output contacts
60
12.3 Service conditions

Use Indoor and outdoor use permissible
Enclosure protection according Standard: IP 68 with AUMA 3-ph AC motor/1-ph AC motor
to EN 60529 According to AUMA definition, enclosure protection IP 68 meets the following requirements:
● Depth of water: maximum 8 m head of water
● Duration of continuous immersion in water: max. 96 hours
● Up to 10 operations during flooding.
● Modulating duty is not possible during continuous immersion.
● KS: Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration as well as for installation in occasionally or permanently aggressive atmo-
sphere with a moderate pollutant concentration (e.g. in wastewater treatment plants,
chemical industry)
Options:
Installation altitude Standard: ≤ 2,000 m above sea level
Option: > 2,000 m above sea level, please contact AUMA
Humidity Up to 100 % relative humidity over the entire permissible temperature range
Pollution degree Within controls: Pollution degree 2
Outside controls (when closed): Pollution degree 4
Finish coating Standard: Paint based on polyurethane (powder coating)
Colour Standard: AUMA silver-grey (similar to RAL 7037)
Ambient temperature Standard:
● Open-close duty: –25 °C to +70 °C
● Modulating duty: –25 °C to +60 °C
Vibration resistance according 1 g, from 10 to 200 Hz
to IEC 60068-2-6 Resistant to vibration during start-up or for failures of the plant. However, a fatigue strength
may not be derived from this. Not valid in combination with gearboxes.
Lifetime Open-close duty (operating cycles (OPEN - CLOSE - OPEN):
SA 07.2/07.6 – SA 10.2: 25,000
SA 14.2/14.6 – SA 16.2: 20,000
Modulating duty:1)
SAR 07.2/07.6 – SAR 10.2: 7.5 million modulating steps
SAR 14.2/14.6 – SAR 16.2: 5.0 million modulating steps
Weight Refer to separate technical data
1) The lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To
reach the longest possible maintenance and fault-free operating time, the number of starts per hour chosen should be as low as possible
for the process.
12.4 Accessories
Wall bracket1) AUMATIC mounted separately from the actuator, including plug/socket connector. Connecting
cables on request. Recommended for high ambient temperatures, difficult access, or in case
of heavy vibration during service
Programming software for PC AUMA ToolSuite
1) Cable distance between actuator and AUMATIC max. 100 m. Requires separate data cable for MWG. If actuator and AUMATIC are
separated at a later date, the max. cable length is 10 m.
12.5 Further information
EU Directives ● Electromagnetic Compatibility (EMC): (2004/108/EC)

● Low Voltage Directive: (2006/95/EC)
61
13. Spare parts

13.1 Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
62
No. Designation Type No. Designation Type
001.0 Housing Sub-assembly 553.0 Mechanical position indicator Sub-assembly
002.0 Bearing flange Sub-assembly 554.0 Socket carrier with motor cable har- Sub-assembly
ness
003.0 Hollow shaft with worm wheel Sub-assembly 556.0 Potentiometer for position transmitter Sub-assembly
005.0 Drive shaft Sub-assembly 556.1 Potentiometer without slip clutch Sub-assembly
005.1 Motor coupling on output drive shaft 557.0 Heater Sub-assembly
005.3 Manual drive coupling 558.0 Blinker transmitter including pins at Sub-assembly
wires (without impulse disc and insula-
tion plate)
009.0 Planetary gear for manual drive Sub-assembly 559.0–1 Control unit without torque switching Sub-assembly
heads and switches
017.0 Torque lever Sub-assembly 559.0–2 Control unit with magnetic limit and Sub-assembly
torque transmitter (MWG) for Non-
intrusive version in combination with
AUMATIC integral controls
018.0 Gear segment 560.0–1 Switch stack for direction OPEN Sub-assembly
019.0 Crown wheel 560.0–2 Switch stack for direction CLOSE Sub-assembly
022.0 Drive pinion II for torque switching Sub-assembly 560.1 Switch for limit/torque switching Sub-assembly
023.0 Output drive wheel for limit switching Sub-assembly 560.2 Switch case
024.0 Drive wheel for limit switching Sub-assembly 566.0 Position transmitter RWG Sub-assembly
025.0 Locking plate Sub-assembly 566.1 Potentiometer for RWG without slip Sub-assembly
clutch
058.0 Wire for protective earth (pin) Sub-assembly 566.2 Electronic board RWG Sub-assembly
070.0 Motor (VD motor incl. no. 079.0) Sub-assembly 566.3 Wire harness for RWG Sub-assembly
079.0 Planetary gear for motor drive Sub-assembly 567.1 Slip clutch for potentiometer/RWG Sub-assembly
(SA/SAR 07.2 — 16.2 for VD motor)
155.0 Reduction gearing Sub-assembly 568.1 Stem protection tube (without cap)
500.0 Cover for switch compartment Sub-assembly 568.2 Cap for stem protection tube
501.0 Socket carrier (complete with sockets) Sub-assembly 568.3 V-seal
502.0 Pin carrier without pins Sub-assembly 574.1 Radial seal output drive A for ISO
flange
503.0 Socket for controls Sub-assembly 575.1 Stem nut type A
504.0 Socket for motor Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly
505.0 Pin for controls Sub-assembly 583.1 Pin for motor coupling
506.0 Pin for motor Sub-assembly 584.0 Retaining spring for motor coupling Sub-assembly
507.0 Plug cover Sub-assembly S1 Seal kit, small Set
511.0 Screw plug Sub-assembly S2 Seal kit, large Set
514.0 Output drive form A (without stem nut) Sub-assembly
514.1 Axial needle roller bearing Sub-assembly
516.0 Output drive D Sub-assembly
535.1 Snap ring
539.0 Screw plug Sub-assembly
542.0 Handwheel with ball handle Sub-assembly
549.0 Output drive B1/B3/B4/C Sub-assembly
549.1 Output drive sleeve B1/B3/B4/C
551.1 Parallel key
63
13.2 Actuator controls AUMATIC AC 01.2
64
002.0 Local controls Sub-assembly
002.3 Local controls board Sub-assembly
002.4 Display faceplate Sub-assembly
006.0 Power supply Sub-assembly
008.1–1 I/O board Sub-assembly
009.0 Logic board Sub-assembly
011.1 Relay board Sub-assembly
012.0 Option board Sub-assembly
500.0 Cover Sub-assembly
501.0 Socket carrier complete with sockets Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
508.0 Switchgear Sub-assembly
509.1 Padlock
510.0 Fuse kit Sub-assembly
S Seal kit Set
65
Certificates AC 01.2 Non-Intrusive
14. Certificates
14.1 Declaration of Incorporation and EC Declaration of Conformity
66
AC 01.2 Non-Intrusive Index
I
Index Identification 8
Indication lights 37
31 Indications 31
A Indications on display 31
Accessories (electrical 21 Indicator disc 37 , 46
connection) Inspection record 9
Accessories for assembly 15 Intermediate frame 23
Actual value - indication on 33 Intermediate position indicati- 37
display on via LEDs
Actuator operation at the local 24 Intrusive 9
controls L
Actuator operation from remo- 25 LEDs (indication lights) 37
te Language in the display 29
Ambient temperature 61 Local actuator operation 24
Analogue signals 39 Local control 24
Applications 5 Local controls 24
Assembly 11 Local setting 26
C Lubrication 55
Cable set 21 M
Commission number 9 Main menu 27
Commissioning 5 Mains frequency 18
Commissioning (indications 31 Mains voltage 18
on display) Maintenance 5 , 55 , 55
Connecting cable 21 Maintenance required - indica- 36
Control 9 tion on display
Corrective action 49 Manual operation 24
Corrosion protection 10 , 61 Mechanical position indicator 37 , 46
Cross sections 18 Menu navigation 26
Current consumption 17 Motor heater 20
D Motor operation 24
Declaration of Incorporation 66 N
Digital outputs 39 Name plate 8 , 18
Direct display via ID 27 Network types 17
Direction of rotation 44 Non-Intrusive 9
Directives 5 Not ready REMOTE - indicati- 35
Display (indications) 31 on on display
Disposal 56
Double sealed 23 O
Operation 5 , 24
E Operation commands - indica- 33
EC Declaration of Conformity 66 tions on display
EMC 18 Out of specification - indicati- 35
Earth connection 23 on on display
Electrical connection 17 Output contacts 39
Enclosure protection 61 Output drive type A 12
Error - indication on display 31 Output drive types B, B1, B2, 11
F B3, B4, and E
Failure - indication on display 36
Fault - indication on display 35
Function check - indication on 36
display
H
Handwheel 11
67
Index AC 01.2 Non-Intrusive
P W
Packaging 10 Wall bracket 21
Parking frame 22 Warnings - indication on dis- 34
Password 27 play
Password change 28 Wiring diagram 9 , 17
Password entry 28
Position indicator 46
Positioner - indication on dis- 34
play
Power supply 17 , 18
Protection cover 23
Protection on site 17
Protective measures 5
Q
Qualification of staff 5
R
Range of application 5
Recycling 56
Reduction gearing 47
Remote actuator operation 25
Running indication 37
S
Safety instructions 5
Safety instructions/warnings 5
Service 55
Service conditions 61
Servicing 55
Setpoint - indication on dis- 34
play
Short-circuit protection 17
Signals 39
Signals (analogue) 39
Spare parts 62
Standards 5
Status menu 27
Status signals 39
Stem nut 13
Stem protection tube 15
Storage 10
Supply networks 17
T
Technical data 57
Terminal plan 17
Test run 44
Torque - indication on display 33
Torque switching 41
Transport 10
Type and size 8
Type of current 18
U
User level 27
V
Valve position - indication on 32
display
Valve stem 15
68
AUMA worldwide
Europe AUMA ACTUATORS Ltd. MEGA Endüstri Kontrol Sistemieri Tic. Ltd.
UK Clevedon, North Somerset BS21 6TH Sti.
AUMA Riester GmbH & Co. KG Tel +44 1275 871141 TR 06810 Ankara
Fax +44 1275 875492 Tel+90 312 217 32 88
Plant Müllheim mail@auma.co.uk Fax+90 312 217 33 88
DE 79373 Müllheim www.auma.co.uk megaendustri@megaendustri.com.tr
Tel +49 7631 809 - 0 www.megaendustri.com.tr
Fax +49 7631 809 - 1250 AUMA ITALIANA S.r.l. a socio unico
riester@auma.com IT 20023 Cerro Maggiore (MI) AUMA Technology utomations Ltd.
www.auma.com Tel +39 0331 51351 UA 02099 Kiyiv
Fax +39 0331 517606 Tel+38 044 586-53-03
Plant Ostfildern - Nellingen info@auma.it Fax+38 044 586-53-03
DE 73747 Ostfildern www.auma.it auma-tech@aumatech.com.ua
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Service@scm.auma.com
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AUMA Armaturenantriebe GmbH ERICHS ARMATUR AB America

AT 2512 Tribuswinkel SE 20039 Malmö
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69
AUMA worldwide
PROCONTIC Procesos y Control AUMA Actuators Middle East W.L.L.

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70
AUMA worldwide
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Y004.761/003/en/4.11

Part-turn gearboxes
GS 50.3 – GS 250.3

GS 50.3 – GS 250.3
Table of contents

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


2. Identification........................................................................................................................... 7
2.1. Name plate 7
3.1. Transport 9
3.2. Storage 9
3.3. Packaging 10
4. Assembly................................................................................................................................ 11
4.2. Multi-turn actuators for motor operation 11
4.3. Mount gearbox to valve 13
5. Indications.............................................................................................................................. 16
6. Commissioning...................................................................................................................... 17
6.1. End stops in gearbox 17
6.1.1 End stop CLOSED: set 17
6.1.2 End stop OPEN: set 18
6.2. Seating in end positions via multi-turn actuator 19
6.2.1 Seating in the end position CLOSED: set 19
6.2.2 Seating in end position OPEN: set 19
6.3. Swing angle 20
6.3.1 Swing angle: modify at gearboxes up to size 125.3 20
6.3.2 Swing angle: modify at gearboxes from size 160.3 21
7.2. Maintenance intervals 24
7.3. Grease and seal change 25
7.3.1 Grease change GS 50.3 – GS 125.3 (VZ 2.3 – VZ 4.3) 25
7.3.2 Grease change GS 160.3 – GS 250.3 (GZ 160.3 – GZ 250.3) 27
2
GS 50.3 – GS 250.3
Table of contents
8. Technical data......................................................................................................................... 31
8.1. Features and functions 31
8.3. Accessories 34
9. Spare parts............................................................................................................................. 36
9.1. Part-turn gearboxes GS 50.3 – GS 125.3 and primary reduction gearings VZ 2.3 – VZ 4.3 36
9.2. Part-turn gearboxes GS 160.3 – GS 250.3 38
9.3. Reduction gearings GZ 160.3 – GZ 250.3 40
10. Certificates.............................................................................................................................. 42
11. Index........................................................................................................................................ 45
Addresses............................................................................................................................... 46
3
GS 50.3 – GS 250.3
Safety instructions
1.1 Basic information on safety
Safety instructions/war- All personnel working with this device must be familiar with the safety and warning
nings instructions in this manual and observe the instructions given. Safety instructions
damage.
Work performed in potentially explosive atmospheres is subject to special regulations
which have to be observed. The end user or contractor of the plant are responsible
for respect and control of these regulations, standards, and laws.

commissioning.
tions.
● During operation, the device warms up and increased surface temperature may
occur. To prevent possible burns, we recommend checking the surface tempe-
rature using an appropriate thermometer and wearing protective gloves, if re-
for the staff.
must be observed.
1.2 Range of application
AUMA part-turn gearboxes are designed for the operation of industrial valves, e.g.
butterfly valves and ball valves.
The devices described herein are also approved for use in the potentially explosive
atmospheres of zones 1, 2, 21, and 22 and for use in mining (category M2). For use
in potentially explosive atmospheres, special conditions such as explosion protection,
output torque, type of duty and ambient temperatures indicated in the technical data
must imperatively be observed.
4
GS 50.3 – GS 250.3
Safety instructions

● Roller conveyors according to EN 14673 (draft)
● Continuous operation
designated use.
1.3 Warnings and notes







1.4 References and symbols

5
GS 50.3 – GS 250.3
Safety instructions

6
GS 50.3 – GS 250.3
Identification
2. Identification
2.1 Name plate
[1] Gearbox name plate

Data for identification Figure 2: Gearbox name plate (example GS 250.3)
[1] Type and size - valve attachment (flange)

[3] Works number
[4] Reduction ratio — [5] swing angle
[6] Factor — [7] version
[8] Max. output torque (depending on flange size)
[9] Lubricant — [10] enclosure protection
[11] Ambient temperature
[12] Explosion-proof version (option)
[13] Customer information (option)
Figure 3: Explosion protection approval plate (option)
[1] Ex symbol, CE mark, number of notified body

[2] EC type examination certificate
[3] Explosion protection classification - dust protection
[4] Explosion protection classification - non-electrical explosion protection
Type and size

These instructions apply to the following devices:
Part-turn gearboxes: GS 50.3 – GS 250.3
7
GS 50.3 – GS 250.3
Identification
Primary reduction gearings: VZ 2.3 – VZ 4.3

Primary reduction gearings: GZ 160.3 – GZ 250.3
Commission number
An order-specific commission number is assigned to each device. This commission
number can be used to directly download the inspection records and further
information regarding the device from the Internet: http://www.auma.com.
Reduction ratio The reduction ratio within the gearing and primary reduction gearing reduces the
required input torques and increases the operating time.
Factor Mechanical gearbox factor to determine the actuator size: Input torque = required
output torque/factor
Version Figure 4: Version
For clockwise rotation of the input shaft (view on pointer cover/protection cover), the
first character of the version indicates the worm shaft position with reference to the
worm wheel, the second character indicates the valve shaft rotary direction.
Table 1: Version (with view on point cover)

Version Rotary direction at in- Position of worm shaft Rotary direction of val-
put shaft ve shaft
RR clockwise right clockwise
LL clockwise left counterclockwise
RL clockwise right counterclockwise
LR clockwise left clockwise
2.2 Short description
AUMA worm gearboxes are part-turn gearboxes converting a rotary movement at

the input shaft into a part-turn movement at the output drive. They are driven either
via electric motor (by means of a multi-turn actuator) or manually (via a handwheel).
The required input torques are reduced due to high reduction ratios. In standard
version, internal end stops limit the swing angle to 100°.
Worm gearboxes are available in different versions to implement various mounting
conditions and rotary directions.
8
GS 50.3 – GS 250.3
Transport, storage and packaging

3.1 Transport
Transport gearbox and actuator separately.
Hovering load!
to handwheel.
→ Check available eyebolt for tight seat in housing (verify reach of the screw).
→ Fix ropes or hooks to gearbox using available eyebolts only.
→ Respect total weight of combination (gearbox, primary reduction gearing, actua-
tor).
Table 2: Weight with coupling (without bore) and grease filling in the gear housing
Type Weight [kg]
GS 50.3 7
GS 63.3 12
GS 80.3 16
GS 100.3 33
GS 100.3 with primary reduction gearing VZ 39
GS 125.3 40
GS 125.3 with primary reduction gearing VZ 46
GS 160.3 80
GS 160.3 with primary reduction gearing GZ 160.3 (4:1) 91
GS 200.3 140
GS 200.3 with primary reduction gearing GZ 200.3 (4:1/8:1) 160
GS 250.3 273
GS 250.3 with primary reduction gearing GZ 250.3 (4:1/8:1) 296
3.2 Storage

→ Store in a well-ventilated, dry room (maximum humidity 70 %).
Long-term storage If the device must be stored for a long period (more than 6 months), the following
tion.
9
GS 50.3 – GS 250.3
Transport, storage and packaging
3.3 Packaging
Our products are protected by special packaging for the transport ex works. The
packaging consists of environmentally friendly materials which can easily be separated
and recycled. We use the following packaging materials: wood, cardboard, paper,
and PE foil. For the disposal of the packaging material, we recommend recycling
and collection centres.
10
GS 50.3 – GS 250.3
Assembly
4. Assembly
4.1 Handwheel fitting

For gearboxes designed for manual operation, a handwheel is supplied separately.
Fitting is done on site according to the description below.
Figure 5: Handwheel
[1] Circlip of gear input shaft

[2] Gear input shaft
[3] Spacer (partly required)
[4] Handwheel
[5] Spacer (partly required)
[6] Circlip
[7] Ball handle (option)
1. Place circlip [1] onto input shaft [2].

2. If required, fit spacer [3].
4. If required, fit spacer [5].
6. Fit ball handle [7] to handwheel.
4.2 Multi-turn actuators for motor operation
Refer to the operation instructions pertaining to the multi-turn actuator for indications
on mounting multi-turn actuators to gearboxes.
This chapter supplies basic information and notes which should be considered in
addition to the operation instructions of the multi-turn actuator.
Mounting positions Up to size GS 125.3, the actuator-gearbox combination is delivered in the ordered
mounting position. For packing reasons, actuator and gearbox will be delivered
separately from size GS 160.3.
Figure 6: Versions RR and LL
11
GS 50.3 – GS 250.3
Assembly
Limitation: For SA/SAR 14.1/14.5 with GS 125.3, mounting position “C” in versions
RR/RL is only possible for a handwheel diameter up to 315 mm.
Figure 7: Version LL and LR
Limitation: For SA/SAR 14.1/14.5 with GS 125.3, mounting position “A” in versions
LL/LR is only possible for a handwheel diameter up to 315 mm.
Flanges
Table 3: Suitable flanges for actuators
Gearing Primary reduction Flange for mounting of multi-turn actuator
gearing EN ISO 5210 DIN 3210
GS 50.3 — F07, F10 G0
GS 63.3 — F07, F10 G0
GS 80.3 — F07, F10 G0
GS 100.3 — F10, F14 G0, G1/2
GS 100.3 VZ 2.3/3.3/4.3 F10 G0
GS 125.3 — F14 G1/2
GS 125.3 VZ 2.3 F10, F14 G0
GS 125.3 VZ 3.3/VZ 4.3 F10 G0
GS 160.3 — F14, F16 G1/2, G3
GS 160.3 GZ 160.3 (4:1) F10, F14 G0, G1/2
GS 160.3 GZ 160.3 (8:1) F10 G0
GS 200.3 — F16, F25 G3
GS 200.3 GZ 200.3 (4:1) F14 G1/2
GS 200.3 GZ 200.3 (8:1) F10, F14 G0, G1/2
GS 200.3 GZ 200.3 (16:1) F10 G0
GS 250.3 — F25, F30 –
GS 250.3 GZ 250.3 (4:1) F14, F16 G1/2, G3
GS 250.3 GZ 250.3 (8:1) F14 G1/2
GS 250.3 GZ 250.3 (16:1) F10, F14 G0, G1/2
Screws to actuator For mounting AUMA multi-turn actuators, screws are supplied together with the
gearboxes. When mounting other actuators, the screws might be either too long or
too short (insufficient reach of screws).
Danger of falling actuator due to fracturing when using inappropriate screws!

→ Check length of screws.
The reach of screws must be sufficient for the internal threads to ensure the
supporting strength of the device and to accept the lateral forces due to the applied
torque.
Screws which are too long could make contact with the housing parts. This causes
a risk that the device could shift radially with respect to the gearbox. This can lead
to shearing off the screws.
12
GS 50.3 – GS 250.3
Assembly
Mount flange for actua- A flange for actuator is required for mounting a multi-turn actuator. Depending on
tor the version, the flange for mounting the multi-turn actuator is already mounted in the
factory.
Figure 8: Mounting flange for actuator to gearbox with primary reduction gearing
[1] Gearbox with primary reduction gearing

[2] Grub screw
[3] Flange for actuator
1. Clean mounting faces (mounting faces at gearbox bearing flange or at housing

cover of primary reduction gearing and at flange for actuator), thouroghly degre-
ase uncoated surfaces.
2. Fasten grub screw [2].
3. Place flange for actuator [3] and fasten with screws/lock washers.
4. Fasten screws crosswise to a torque according to table <Fastening torques for
screws>.
5. Mount AUMA actuator in compliance with the operation instructions pertaining
to the multi-turn actuator.
Table 4: Fastening torques for screws

(for mounting of multi-turn actuator and mounting flange for actuator)
Screws Fastening torque TA [Nm]
Threads Strength class A2-80
M8 24
M10 48
M12 82
M16 200
M20 392
4.3 Mount gearbox to valve

Mounting position The gearboxes described here can operated without restriction in any mounting
position.
Coupling For gearbox mounting to the valve, a plug-in coupling is included in the scope of
delivery.
When supplied in basic version, the coupling is generally provided with a pilot bore
from size 160.3. Prior to mounting the gearbox to the valve, finish machining the
coupling to match the valve shaft (e.g. with bore and keyway, two-flats or square
bore).
13
GS 50.3 – GS 250.3
Assembly
Figure 9: Coupling fitting dimensions
[1] Coupling
[2] Valve shaft
[3] Grub screw
[4] Screw with washer
Table 5: Coupling fitting dimensions

Type, size - mounting flange X max [mm] Y max [mm] L max [mm]
GS 50.3-F05 6 5 65
GS 50.3-F07 14 5 61
GS 50.3-F10 14 5 61
GS 63.3-F10 7 18 73
GS 63.3-F12 10 13 76
GS 80.3-F12 13 18 78
GS 80.3-F14 23 5 88
GS 100.3-F14 22 13 123
GS 100.3-F16 22 8 123
GS 125.3-F16 17 35 126
GS 125.3-F25 17 27 126
GS 160.3-F25 15 11 130
GS 160.3-F30 30 0 140
GS 200.3-F30 19 19 160
GS 200.3-F35 44 0 190
GS 250.3-F35 8 8 220
GS 250.3-F40 13 0 230
Hovering load!
→ For lifting, respect transport instructions.
Information Assemble valve and gearbox in the same end position. As a standard, the gearbox
is supplied in end position CLOSED.
● Recommended mounting position for butterfly valves: End position CLOSED.
● Recommended mounting position for ball valves: End position OPEN.
1. If required, move gearbox in same end position as valve using the handwheel.
2. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
3. Apply a small quantity of grease to the valve shaft [2].
14
GS 50.3 – GS 250.3
Assembly
4. Place coupling [1] onto valve shaft [2] and secure against axial slipping by using
a grub screw [3] or a washer and a screw [4]. Thereby, ensure that dimensions
X, Y or L are observed (refer to figure and table <Coupling fitting dimensions>).
5. Apply non-acidic grease at splines of coupling (e.g. Gleitmo by Fuchs).
6. Experience showed that it is very difficult to fasten screws or nuts of M30 or
larger with the defined torques. The worm gearbox may be moved radially
against the valve flange. To improve adhesion between valve and gearbox, we
recommend to apply Loctite 243 (or similar) for screws and nuts from size M30
(or similar adhesive products) to the mounting faces.
7. Fit gearbox. If required, turn gearbox slightly until the toothing of the coupling
gets engaged.
Information: Ensure that the spigot (if provided) fits uniformly in the recess
and that the flanges are in complete contact.
8. If flange bores do not match thread:
8.1 Slightly rotate handwheel until bores line up.
8.2 If required, shift gearbox position by one tooth on the coupling.
9. Fasten gearbox with screws (strength class min. 8.8).

Threads Strength class
8.8 A2-70/A4-70 A2-80/A4-80
M6 11 8 10
M8 25 18 24
M10 51 36 48
M12 87 61 82
M16 214 150 200
M20 431 294 392
M30 1,489 564 –
M36 2,595 – –
15
GS 50.3 – GS 250.3
Indications
5. Indications
5.1 Mechanical position indicator/running indication
● continuously indicates the valve position
(pointer cover [2] follows the valve movement)
● indicates whether the actuator is moving (running indication)
● indicates that end positions have been reached
(mark on pointer cover [3] points to symbols OPEN [4] or CLOSED [5])
[1] Housing cover

[2] Pointer cover
[3] Indicator mark
16
GS 50.3 – GS 250.3
Commissioning
6. Commissioning
6.1 End stops in gearbox

The internal end stops limit the swing angle and protect the valve against overload.
End stop setting is generally performed by the valve manufacturer prior to installing
the valve into the pipework.
Exposed, rotating parts (discs/balls) at the valve!

Pinching and damage at the valve.
→ End stops should be set by suitably qualified personnel only.
→ Set end stops as to ensure that they are NOT reached during normal operation.
Information The setting sequence depends on the valve:

● Recommendation for butterfly valves: Set end stop CLOSED first.
● Recommendation for ball valves: Set end stop OPEN first.
Information ● In general, gearboxes with a swing angle > 190° are multi-turn (without end
stops). Consequently, end position setting is not possible. Thus, no protective
function is available for the valve.
● In general, only one end stop (either OPEN or CLOSED) must be set, due to
fact that the swing angle was already set in the factory.
6.1.1 End stop CLOSED: set
Figure 11: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
1. Remove the four screws [1] at end stop [2].
No overload protection at valve for unfastened end stop!

→ In motor operation: Stop travel on time before reaching the valve end position
(consider overrun).
→ The last part of the travel must be completed in manual operation mode.
2. Turn valve via handwheel to position CLOSED. Check whether end stop [2]
rotates simultaneously.
→ Otherwise: Turn end stop [2] clockwise to the stop.
3. With mounted multi-turn actuator (not required for manual operation): Turn end
stop [2] counterclockwise by 1/4 turn.
➥ This ensures that the gearbox end stop cannot be approached during motor
operation if a multi-turn actuator is mounted and that the valve can close tightly
for torque seating.
17
GS 50.3 – GS 250.3
Commissioning
4. In case the four holes of the end stop [2] do not match the four threaded bores
within the housing [3]: Remove end stop [2] until it disengages from the toothing
and replace in correct position.
5. Fasten screws [1] crosswise with a torque according to table <Tightening torques
for screws at end stop>.
Table 7: Tightening torques for screws at end stop

Gearing Screws [1] Tightening torque TA [Nm]
GS 50.3 M6 10
GS 50.3 – GS 80.3 M8 24
GS 100.3 – GS 125.3 M12 82
GS 160.3 M10 48
GS 200.3 M12 82
GS 250.3 M16 200
Further settings hereafter:

1. If the gearbox is equipped with a pointer cover: Check whether the mark aligns
with the symbol CLOSED. Refer to <Mechanical position indicator: set>.
2. If the gearbox is mounted to a multi-turn actuator, set the seating in end position
CLOSED straight after completion of the current setting position: <Seating in
end positions via multi-turn actuator>.
6.1.2 End stop OPEN: set
Figure 12: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
1. Remove the four screws [1] at end stop [2].
No overload protection at valve for unfastened end stop!

→ In motor operation: Stop travel on time before reaching the valve end position
(consider overrun).
→ The last part of the travel must be in manual operation mode.
2. Turn valve via handwheel in position OPEN. Check whether end stop [2] rotates
simultaneously.
→ Otherwise: Turn end stop [2] counterclockwise to the stop.
3. With mounted multi-turn actuator (not required for manual operation): Turn end
stop [2] clockwise by 1/4 turn.
➥ This ensures that the gearbox end stop cannot be approached during motor
operation if a multi-turn actuator is mounted and that the valve can close tightly
for torque seating.
18
GS 50.3 – GS 250.3
Commissioning
4. In case the four holes of the end stop [2] do not match the four threaded bores
within the housing [3]: Remove end stop [2] until it disengages from the toothing
and replace in correct position.
5. Fasten screws [1] crosswise with a torque according to table <Tightening torques
for screws at end stop> .
Further settings hereafter:
1. If the gearbox is equipped with a pointer cover: Check whether the mark aligns
with the symbol OPEN. Refer to <Mechanical position indicator: set>.
2. If the gearbox is mounted to a multi-turn actuator, set the seating in end position
OPEN straight after completion of the current setting position: <Seating in end
positions via multi-turn actuator>.
6.2 Seating in end positions via multi-turn actuator
Important information regarding setting:
End position seating must be set in compliance with the operating instructions
pertaining to the multi-turn actuator.
This chapter supplies basic information and notes which should be considered in
addition to the operation instructions of the multi-turn actuator.
● The valve manufacturer has to determine whether the valve is limit or torque
seated.
● For limit seating, determine overrun, i.e. how much does the valve move after
the motor has been switched off?
● For torque seating, the maximum permissible input torque of the gearbox must
not be exceeded for neither direction. Set the torque switching within the multi-
turn actuator to the following value to prevent damage to the valve:
T torque switch = T valve/factor (refer to name plate)
● If the swing angle set in the factory for opening and closing the valve is not
sufficient: refer to <Swing angle>.
6.2.1 Seating in the end position CLOSED: set

Information: The last part of the travel must be in manual operation mode!
2. For limit seating in end position CLOSED:
2.1 Turn back the valve from the valve end position by an amount equal to
the overrun.
2.2 Set limit switching for the end position CLOSED according to the operation
instructions for the multi-turn actuator.
3. For torque seating in end position CLOSED:
3.1 Gearbox without primary reduction gearing: Turn handwheel in the oppo-
site direction of the valve end position by approx. 4 – 6 turns.
3.2 Gearbox with primary reduction gearing VZ/GZ: Turn handwheel in the
opposite direction of the valve end position by approx. 10 – 15 turns.
3.3 Check torque switching for end position CLOSED according to operation
instructions for multi-turn actuator and, if necessary, set to required value.
3.4 Set limit switching for signalling end position CLOSED according to opera-
tion instructions for multi-turn actuator.
6.2.2 Seating in end position OPEN: set
1. Move valve to end position OPEN.

Information: The last part of the travel must be in manual operation mode!
19
GS 50.3 – GS 250.3
Commissioning
2. For limit seating in end position OPEN:

2.1 Turn back the valve from the valve end position by an amount equal to
the overrun.
2.2 Set limit switching for end position OPEN according to the operation in-
structions for the multi-turn actuator.
3. For torque seating in end position OPEN:
3.1 Gearbox without primary reduction gearing: Turn handwheel in the oppo-
site direction of the valve end position by approx. 4 – 6 turns.
3.2 Gearbox with primary reduction gearing VZ/GZ: Turn handwheel in the
opposite direction of the valve end position by approx. 10 – 15 turns.
3.3 Check torque switching for end position OPEN according to operation in-
structions for multi-turn actuator and, if necessary, set to required value.
3.4 Set limit switching for signalling end position OPEN according to operation
instructions for multi-turn actuator.
6.3 Swing angle

The swing angle must only be changed if the swivel range for end stop setting is not
sufficient.
Figure 13: Name plate indicating the swing angle
Versions Sizes GS 50.3 – GS 125.3 = adjustable swing angle - option

Sizes GS 160.3 – GS 250.3 = adjustable swing angle - standard
Accuracy Sizes GS 50.3 – GS 125.3 = 0.6°
Sizes GS 160.3 – GS 250.3 = 0.11° up to 0.14°
6.3.1 Swing angle: modify at gearboxes up to size 125.3
The adjustment is made in end position OPEN.

Special tools: Pin drive for roll pin
● for GS 50.3 (AUMA art. no. V001.367-Pos.003)
● for GS 63.3 – GS 80.3 (AUMA art. no. V001.367-Pos.002)
● for GS 100.3 – GS 125.3 (AUMA art. no. V001.367-Pos.001)
20
GS 50.3 – GS 250.3
Commissioning
Figure 14: End stop (figure shows size 80.3)
[1] Protective cap

[2] End stop
[3] Roll pin
[4] End stop nut
[5] Pair of safety wedge discs (for OPEN and CLOSE)
1. Unscrew protective cap [1] at end stop [2].

2. Remove roll pin [3] with suitable pin drive (special tool).
3. Swing angle increase:
3.1 Turn end stop nut [4] counterclockwise.
Information: When turning back the end stop nut [4] make sure that the
roll pin [3] can still be tapped within the oblong hole.
3.2 Move valve manually to the desired end position OPEN.
3.3 Turn end stop nut [4] clockwise until it is tight to the travelling nut.
4. Swing angle reduction:
4.2 Turn end stop nut [4] clockwise until it is tight to the travelling nut.
Information: Roll pin [3] must remain completely covered by end nut [4].
5. Drive in the roll pin [3] using the appropriate tool.
→ If the slot provided in the end stop nut [4] does not align with the bore of
the worm shaft: Turn end stop nut [4] slighty counterclockwise until the
hole is aligned; then drive in roll pin [3].
6. Check whether O-ring at protective cap is in good condition, replace if damaged.
7. Fasten protective cap [1].
Information If the gearbox is mounted to a multi-turn actuator, the limit switching for the end po-
sition OPEN must be set first in compliance with the operation instructions of the
multi-turn actuator. Allow for overrun!
6.3.2 Swing angle: modify at gearboxes from size 160.3
Adjustments are generally made in end position OPEN.
21
GS 50.3 – GS 250.3
Commissioning
Figure 15: End stop (figure shows size 200.3)
[1] Screws
[2] Protective cap
[3] Screw with lock washer
[4] Clamping washer
[5] Setting ring
[6] End stop nut
[7] Travelling nut
[8] Pair of safety wedge discs (for OPEN and CLOSE)
1. Remove all four screws [1] and pull off protective cap [2].
2. Remove the screw with the lock washer [3] and clamping washer [4].
3. Pull off setting ring [5].
4. Swing angle increase:
4.1 Turn end stop nut [6] counterclockwise.
4.3 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
5. Swing angle reduction:
5.2 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
6. Fit setting ring [5], secure with clamping washer [4], lock washer [5] and screw
[3].
7. Check whether O-ring at protective cap is in good condition, replace if damaged.
8. Place protective cap [2] and fasten screws [1] crosswise with a torque according
to table <Tightening torques for screws at end stop>.
Information If the gearbox is mounted to a multi-turn actuator, the limit switching for the end po-
sition OPEN must be set first in compliance with the operation instructions of the
multi-turn actuator.
6.4 Mechanical position indicator: set
End position CLOSED 1. Move valve to end position CLOSED and check setting.
➥ The setting is correct if the mark aligns with the symbol CLOSED.
22
GS 50.3 – GS 250.3
Commissioning
2. If the mark position is not correct:

2.1 Slightly loosen screws [1] at pointer cover [two screws up to size 125.3,
four screws as from size 160.3).
2.2 Turn pointer cover to symbol for position CLOSED [5].
2.3 Fasten screws again.
End position OPEN 3. Move valve to end position OPEN and check setting.
➥ The setting is correct if the mark aligns with the symbol OPEN.
23
GS 50.3 – GS 250.3
Servicing and maintenance

Service
AUMA offers extensive service such as servicing and maintenance as well as
customer product training. For the relevant contact addresses, please refer to
<Addresses> in this document or to the Internet (www.auma.com).
7.1 Preventive measures for servicing and safe operation

These measures are based on the assumption that the unit is operated on an average
less than 10 times per year.
Every 6 months after commissioning and then once a year
● Perform visual inspection for grease leakage and paint damage (corrosion).
chapter <Assembly>.
Every 5 years after commissioning
Test gearbox function in detail. Record the results for future reference.
For enclosure protection IP 68 (option)

● Check gearbox.
● In case of ingress of water, locate leaks and repair. Dry device correctly and
7.2 Maintenance intervals
Recommendation for grease change and seal replacement:
● Generally after 6 to 8 years if operated frequently (open-close duty).
● Generally after 10 to 12 years if operated rarely (open-close duty).
● Generally after 4 to 6 years for modulating duty.
Gearing damage due to using inappropriate grease!

→ Only use original lubricants supplied by AUMA.
→ Do not mix lubricants.
Instructions for use in potentially explosive atmospheres of categories M2,

2G, 3G, 2D and 3D
● The technical data as well as the ambient temperatures, type of duty and running
times indicated on the name plate must imperatively be observed.
● In hazardous areas where combustible dust is present in particular, perform
visual inspection for deposit of dirt or dust on a regular basis. Clean devices if
required.
● The pointer cover with indicator glass (option) is only approved for use in poten-
tially explosive atmospheres according to ATEX II2G c IIB T4 or T3.
● When using mechanical microswitches (option), additionally observe the
mounting and wiring instructions of the manufacturer.
24
GS 50.3 – GS 250.3
7.3 Grease and seal change
Hovering load!
to handwheel.
→ Check available eyebolts for tight seat in housing (verify reach of the screw).
→ Fix ropes or hooks to gearbox using available eyebolts only.
High pressure, high temperatures, mechanical stress!

Danger of crushing and burns!
→ Piping must be free of pressure.
→ No mechanical forces must be applied to the valve (discs, levers)

Grease and sealing change can only be performed if device is dismantled.
Preparations:
1. Detach actuator or handwheel.
2. Mark gearbox position at valve, unfasten screws to valve and dismount the
gearbox.
After grease and sealing change:
3. For manually operated gearboxes: <Handwheel fitting>
4. For motor-operated gearboxes: <Mount multi-turn actuator to gearbox> (also
refer to operation instructions on the actuator)
5. <Mount gearbox to valve>
6. <End stops in gearbox> setting
7. Perform test run to ensure the proper function.
7.3.1 Grease change GS 50.3 – GS 125.3 (VZ 2.3 – VZ 4.3)
Grease type: Refer to gearbox name plate
Cleaning agent: Petroleum jelly or similar cleaning agent.
Reference documents: Spare parts list Part-turn gearboxes GS 50.3 – GS 125.3
Spare parts: seal kit S1 (order indicating commission number)
Table 8: Grease quantities for gearboxes (grease with density r = 0.9 kg/dm³)
GS 50.3 63.3 80.3 100.3 125.3
Quantity [kg] 0.09 0.27 0.36 0.9 1.17
Table 9: Grease quantities for primary reduction gearings VZ (grease with density
r = 0.9 kg/dm³)
VZ 2.3 3.3 4.3
Quantity [kg] 0.32 0.32 0.32
25
GS 50.3 – GS 250.3
Figure 17: Working steps for grease change on GS 50.3 – GS 125.3
Flange for actuator 1. If a flange for actuator [512.0] is mounted: Remove screws at flange for actuator
[512.0] and detach flange for actuator [512.0].
Bearing cover 2. If a bearing cover [522.0] is mounted: Remove screws at bearing cover [522.0]
and bearing cover [522.0]. (For sizes GS 100.3 – GS 125.3, the bearing cover
is removed including the drive shaft [538.0].
Primary reduction 3. If a primary reduction gearing VZ is mounted:
gearing VZ 3.1 Remove screws at housing cover VZ [020.0] and remove housing cover
VZ [020.0] including the drive shaft VZ [021.0].
3.2 Take off hollow wheel VZ [045.5] as well as planet carrier [022.0].
3.3 Completely remove old grease from the housing and the individual parts
and clean the primary reduction gearing.
3.4 Remove screws at housing VZ [019.0] and detach housing VZ [019.0].
Housing cover 4. Remove screws at housing cover [518.0] and detach housing cover [518.0].
End stop 5. Dismantle end stop:
5.1 For adjustable end stop: Unscrew protective cap [536.0].
5.2 Remove screws at end stop [523.0] and take off end stop [523.0].
Worm shaft/worm wheel 6. Dismantle and clean both worm shaft [525.0] and worm wheel [519.1]:
6.1 Carefully lift worm wheel [519.1] out of housing. For this, pull out worm
wheel [520.0] from bearings and slightly incline the wheel within the worm
channel.
6.2 Completely remove old grease from housing and gear housing and clean
all individual parts.
6.3 Replace used O-rings [S1(010)] at worm wheel [519.1] with new O-rings.
6.4 Carefully fit worm wheel [519.1] and correctly position worm shaft [520.0].
26
GS 50.3 – GS 250.3
End stop 7. Fitting end stop:

Information: For devices with safety wedge discs [1] in the end stop:
If the safety wedge discs [1] have been dismantled for cleaning, make sure the
discs are installed with the wedge surfaces pointing to the inner side (radial
teeth) or the radial splines to the outer side (cams).
7.1 Clean all mounting faces (gearbox housing, end stop and protective cap).
7.2 Fit end stop [523.0] with new O-ring and and fasten with screws.
7.3 For adjustable end stop: Fit protective cap [536.0] with new O-ring.
8. Fill gear housing with new grease.
Housing cover 9. Mount housing cover [518.0]:
9.1 Clean mounting faces at housing and housing cover [518.0].
9.2 Replace used O-ring [S1(012)] at housing cover [518.0] with a new O-ring.
9.3 Fit housing cover [518.0] and fasten with screws according to table.
Table 10: Tightening torques for screws of housing cover
Type Screws Tightening torque TA [Nm]
Size Threads Strength class A2-80
GS 50.3 M5
GS 63.3 M6 10
GS 80.3 M8 25
GS 100.3 M10 50
GS 125.3 M12 85
Primary reduction 10. For gearboxes with primary reduction gearings VZ:
gearing VZ 10.1 Clean all mounting surfaces (gearbox housing, housing VZ [019.0], hollow
shaft VZ [045.0] and housing cover VZ [020.0].
10.2 Replace all used sealing elements S1 with new seals.
10.3 Place housing VZ [019.0] and fasten with screws.
10.4 Insert planet carrier [022.0].
10.5 Fill with new grease.
10.6 Place hollow wheel VZ [045.0].
10.7 Fit housing cover VZ [020.0] with drive shaft [021.1] and fasten with screws.
11. For gearboxes without primary reduction gearings VZ: Fit bearing cover [522.0]
and fasten with screws.
12. If a mounting flange is required for actuator installation: Place flange for actuator
[512.0] and fasten with screws.
7.3.2 Grease change GS 160.3 – GS 250.3 (GZ 160.3 – GZ 250.3)
Grease type: Refer to gearbox name plate
Cleaning agent: Petroleum jelly or similar cleaning agent.
● Spare parts list Part-turn gearboxes GS 160.3 – GS 250.3
● Spare parts list Primary reduction gearings GZ 160.3 – GZ 250.3
Spare parts: seal kit S1 (order indicating commission number)
27
GS 50.3 – GS 250.3
Special tools: Lock nut key

Table 11: Grease quantities for gearboxes (grease at density r = 0.9 kg/dm³)
GS 160.3 200.3 250.3
Quantity [kg] 3.0 6.0 11.0
Table 12: Grease quantities for primary reduction gearing GZ (grease with density
r = 0.9 kg/dm³)
GZ 160.3 200.3 200.3 (16:1) 250.3 250.3 (16:1)
(4:1/8:1) (4:1/8:1)
Quantity [kg] 0.9 1.4 1.8 2.0 2.25
Figure 19: Working steps for grease change on GS 160.3 – GS 250.3
Flange for actuator 1. If a flange for actuator [512.0] is mounted: Remove screws at flange for actuator
[512.0] and detach flange for actuator [512.0].
Bearing cover 2. If a bearing cover [522.0] is mounted: Remove screws at bearing cover [522.0]
and pull of bearing with drive shaft [538.0].
Primary reduction 3. If a primary reduction gearing GZ is mounted, remove primary reduction gearing:
gearing GZ 3.1 Remove screws at housing cover GZ [002.0] and remove housing cover
GZ [002.0] including the drive shaft GZ [534.0].
3.2 Remove planetary gearings [006.0/007.0/008.0].
3.3 Completely remove old grease from the housing and the individual parts
and clean the primary reduction gearing.
3.4 Remove screws at housing GZ [001.0] and detach housing GZ [001.0].
Housing cover 4. Remove screws at housing cover [518.0] and detach housing cover [518.0].
End stop 5. Dismantle end stop:
5.1 Remove all four screws and lift protective cap [536.0].
5.2 Remove screws at end stop [523.0] and take off end stop [523.0].
28
GS 50.3 – GS 250.3
Worm shaft/worm wheel 6. Dismantle and clean both worm shaft [525.0] and worm wheel [519.1]:
6.1 Loosen grub screw and unfasten lock nut [537.0] using the lock nut key.
6.2 Carefully lift worm wheel [519.1] out of housing. For this, pull out worm
wheel [520.0] from bearings and slightly incline the wheel within the worm
channel.
6.3 Completely remove old grease from housing and gear housing and clean
all individual parts.
6.4 Replace used O-rings [S1(010)] at worm wheel [519.1] with new O-rings.
6.5 Carefully fit worm wheel [519.1] and correctly position worm shaft [520.0].
6.6 Screw in lock nut [537.0] using the lock nut key and secure with grub
screw.
End stop 7. Fitting end stop:
Information: For devices with safety wedge discs [1] in the end stop:
If the safety wedge discs [1] have been dismantled for cleaning, make sure the
discs are installed with the wedge surfaces pointing to the inner side (radial
teeth) or the radial splines to the outer side (cams).
7.1 Clean all mounting faces (gearbox housing, end stop and protective cap).
7.2 Fit end stop [523.0] with new O-ring and and fasten with screws.
7.3 Place protective cap [536.0] fitted with new O-ring and fasten the screws.
8. Fill gear housing with new grease.
Housing cover 9. Mount housing cover [518.0]:
9.1 Clean mounting faces at housing and housing cover [518.0].
9.2 Replace used O-ring [S1(012)] at housing cover [518.0] with a new O-ring.
9.3 Fit housing cover [518.0] and fasten with screws according to table.
Table 13: Tightening torques for screws of housing cover
Type Screws Tightening torque TA [Nm]
Size Threads Strength class A2-80
GS 160.3 M16 210
GS 200.3 M20 425
GS 250.3 M24 730
Primary reduction 10. For gearboxes equipped with primary reduction gearings GZ, mount primary
gearings GZ reduction gearing:
10.1 Clean all mounting surfaces (gearbox housing, housing GZ [001.0], hollow
shaft of planetary gearing [006.0/007.0/008.0] and housing cover GZ
[002.0].
10.2 Replace all used sealing elements S1 with new seals.
10.3 Place housing GZ [001.0] and fasten with screws.
10.4 Fill housing GZ [001.0] with new grease.
10.5 Insert planetary gearings [006.0/007.0/008.0] and apply grease.
10.6 Fit housing cover GZ [002.0] with drive shaft [534.0] and fasten with screws.
29
GS 50.3 – GS 250.3
11. For gearboxes without primary reduction gearings GZ: Fit bearing cover [522.0]
with drive shaft [534.0] and fasten with screws.
12. If a mounting flange is required for actuator installation: Place flange for actuator
[512.0] and fasten with screws.
7.4 Disposal and recycling
● various metals
● plastics
environment.
● Arrange for controlled waste disposal of the disassembled material or for sepa-
rate recycling according to materials.
30
GS 50.3 – GS 250.3
Technical data
8. Technical data
This data sheet can be downloaded from the Internet at http://www.auma.com (in-
dication of commission number required).
8.1 Features and functions
Version Standard: clockwise rotation RR, counterclockwise rotation LL

Option: RL or LR
Housing material Standard: Cast iron (GJL-250)
Option: Spheroidal cast iron (GJS-400-15)
Self-locking The gearboxes are self-locking when at standstill under normal service conditions; strong
vibration may cancel the self-locking effect. While in motion, safe breaking is not guaranteed.
If this is required, a separate brake must be used.
End stops Positive for both end positions by travelling nut, sensitive adjustment
Strength of end stop Guaranteed strength of end stop (in Nm) for input side operation according to AWWA
● GS 50.3 = 250 Nm (not qualified in accordance with AWWA)
● GS 63.3 = 450 Nm
● GS 80.3 = 450 Nm
● GS 100.3 with VZ 2.3/3.3 = 500 Nm
● GS 100.3 with VZ 4.3 = 250 Nm (not qualified in accordance with AWWA)
● GS 125.3 with VZ 2.3/3.3 = 500 Nm
● GS 125.3 with VZ 4.3 = 250 Nm (not qualified in accordance with AWWA)
● GS 160.3 with VZ 160.3 (4:1) = 500 Nm
● GS 160.3 with VZ 160.3 (8:1) = 450 Nm
● GS 200.3 with VZ 200.3 (4:1/8:1/16:1) = 500 Nm
● GS 250.3 with VZ 250.3 (4:1/8:1/16:1) = 500 Nm
Swing angle GS 50.3 – GS Standard:
125.3 Fixed swing angle between 10° and max. 100°; set in the factory to 92° unless ordered
otherwise.
Options:
● Adjustable in steps of: 10° – 35°, 35° – 60°, 60° – 80°, 80° – 100°, 100° – 125°, 125° –
150°, 150° – 170°, 170° – 190°
● Swing angle > 190°, multi-turn version without end stops, worm wheel made of bronze
required, GSD version, special sizing necessary
Swing angle GS 160.3 – GS Standard:
250.3 Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise.
Options:
● Adjustable in steps of: 0° – 20°, 20° – 40°, 40° – 60°, 60° – 80°, 90° – 110°, 11° – 130°,
130° – 150°, 150° – 170°, 170° – 190°
● Swing angle > 190°, multi-turn version without end stops, worm wheel made of bronze
required, GSD version, special sizing necessary
Mechanical position indicator Standard:
Pointer cover for continuous position indication
Options:
● Pointer cover sealed for horizontal outdoor installation (for gas applications with sealed
pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting
flange must be provided)
● Protection cover instead of pointer cover, e.g. for buried service
Mechanical limit switches Single switches (1 NC and 1 NO) for each end position, switches not galvanically isolated,
(option) please contact us
Input shaft Cylindrical with parallel key according to DIN 6885.1
31
GS 50.3 – GS 250.3
Technical data
Operation
Motor operation With electric multi-turn actuator, directly or through primary reduction gearing
Type of duty For version with worm wheel made of spheroidal cast iron:
● Short-time duty S2 - 15 min (open-close duty)
● Push-to-run operation permissible, max. 10 steps in one direction and max. of 30 starts
per hour
For version with worm wheel made of bronze:
● Intermittent duty S4 - 25 % (modulating duty)
Manual operation Via handwheel in aluminium, directly or through primary reduction gearing VZ/GZ
Available handwheel diameters, selection according to the max. output torque:
● GS 50.3 = 160, 200, 250 mm
● GS 63.3 = 250, 315 mm
● GS 80.3 = 315, 400mm
● GS 100.3 = 400, 500 mm
● GS 100.3 with VZ 2.3/3.3 = 315, 400 mm
● GS 100.3 with VZ 4.3 = 250, 315 mm
● GS 125.3 = 500, 630, 800 mm
● GS 125.3 with VZ 2.3/3.3 = 400, 500 mm
● GS 125.3 with VZ 4.3 = 315, 400 mm
● GS 160.3 = 630, 800 mm
● GS 160.3 with GZ 160.3 (4:1) 400 mm, (8:1) = 315 mm
● GS 200.3 with GZ 200.3 (4.1) = 500/630 mm, (8:1) = 400 mm, (16:1) = 315 mm
● GS 250.3 with GZ 250.3 (4:1) = 800 mm, (8:1) = 500/630 mm, (16:1) = 400 mm
Standard: without ball handle
Option: with ball handle, material GJL-200
Primary reduction gearing

Primary reduction gearing ● Types VZ and GZ as planetary gears with various reduction ratios for reducing the input
torques
● Combination with GK bevel gearbox directly on GS or on GS with VZ/GZ possible
Valve attachment
Valve attachment Dimensions according to EN ISO 5211
Standard:
● GS 50.3 – GS 125.3: without spigot
● GS 160.3 – GS 250.3: with spigot
Options:
● GS 50.3 – GS 125.3: with spigot
● GS 160.3 – GS 250.3: without spigot
Coupling Splined coupling for connection to the valve shaft
Standard: Without bore or pilot bore from GS 160.3
Options:
● Finish machining with bore and keyway
● Square bore or two-flats with grub screw to secure on valve shaft
32
GS 50.3 – GS 250.3
Technical data
8.2 Service conditions

Enclosure protection according Refer to name plate
to EN 60529 Standard:
● IP 68-3 dust-tight, submersible in water up to 3 m head of water
Options:1)
● KN: Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration
Options:
● KS: Suitable for installation in occasionally or permanently aggressive atmosphere with
a moderate pollutant concentration (e.g. in wastewater treatment plants, chemical industry)
Finish coating Standard:
● GS 50.3 – GS 125.3: Two-component iron-mica combination
● GS 160.3 – GS 250.3: Primer coated
Option:
● GS 160.3 – GS 250.3: Two-component iron-mica combination
Colour Standard: AUMA silver-grey (similar to RAL 7037) if finish painting is applied
Option: Other colours on request
Ambient temperature Refer to name plate
Standard: –40 °C to +80 °C
Options:
● –60 °C to +60 °C, version EL
● 0 °C to + 120 °C, version H
Note: When using mechanical microswitches, the temperature ranges indicated here are
reduced to –30 °C up to max. +90 °C.
Lifetime Open-close duty (number of cycles according to standard EN 15714-2 for max. torque and
90° rotary movement):
GS 50.3/GS 63.3: 10 000
GS 80.3/GS100.3/VZ: 5 000
GS 125.3/VZ, GS 200.3/GZ: 2 500
GS 250.3/GZ: 1,000
Modulating duty:2)
2.5 million modulating steps
1) Not for size GS 50.3

2) The lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To
reach the longest possible maintenance and fault-free operating time, the number of starts per hour chosen should be as low as permis-
sible for the process.
33
GS 50.3 – GS 250.3
Technical data
Special features for use in potentially explosive atmospheres

Explosion protection Standard:
according to ATEX 94/9/EC ● II2G c IIC T4
● II2D c T130°C
Options:
● II2G c IIC T3
● II2D c T190°C
● IM2 c
Type of duty For version with worm wheel made of spheroidal cast iron:
Short-time duty S2 – 15 min., max. 3 cycles (OPEN-CLOSE-OPEN) 90°; on following average
output torques (then cool-down to ambient temperature)
● GS 50.3 = 250 Nm
● GS 63.3 = 500 Nm
● GS 80.3 = 1,000 Nm
● GS 100.2 = 2,000 Nm
● GS 125.3 = 4,000 Nm
● GS 160.3 = 8,000 Nm
● GS 200.3 = 16,000 Nm
● GS 250.3 = 32,000 Nm
For version with worm wheel made of bronze:
Intermittent duty S4 – 25 % with modulating torque, exception: GS 200.3 with modulating
torque up to 4,800 Nm
Max. input speed:
Standard: 45 rpm, exception: GS 200.3 and GS 250.3 up to 11 rpm
The type of duty must not be exceeded.
● For special reduction ratios, refer to separate technical data sheets.
Ambient temperature (Temperature range depending on application and worm wheel material)
Standard:
● –40 °C to +40 °C (II2G c IIC T4; II2D c T130°C) bronze
● –40 °C to +60 °C (II2G c IIC T4; II2D c T130°C) bronze/spheroidal cast iron
Options:
● –50 °C to +60 °C (II2G c IIC T4; II2D c T130°C) spheroidal cast iron
● –40 °C to +80 °C (II2G c IIC T3; II2D c T190°C) bronze/spheroidal cast iron
● 0 °C to +120 °C (II2G c IIC T3; II2D c T190°C) bronze/spheroidal cast iron
● –20 °C to +40 °C (IM2 c) bronze/spheroidal cast iron
Mechanical position indicator Pointer cover with indicator glass (option) only approved for IIG c IIB T4 or T3
Mechanical microswitches Explosion-proof switches with external test certificate PTB 03 ATEX 1068 X
(option) Temperature ranges for ambient temperatures:
● –20 °C to +60 °C (II2G c IIC T4; II2D c T130°C)
● –20 °C to +80 °C (II2G c IIC T3; II2D c T190°C)
8.3 Accessories
Valve position indicators WSG valve position indicator for signalling intermediate and end positions to ensure precise
and low-backlash feedback for swing angles ranging from 82° – 98°
Limit switching device WSH limit switching device for manually operated valves. For signalling intermediate and
end positions
34
GS 50.3 – GS 250.3
Technical data
8.4 Further information
EU Directives ● ATEX Directive: (94/9/EC)

35
GS 50.3 – GS 250.3
Spare parts
9. Spare parts
9.1 Part-turn gearboxes GS 50.3 – GS 125.3 and primary reduction gearings VZ 2.3 – VZ 4.3
36
GS 50.3 – GS 250.3
Spare parts
003.0 Housing cover with drive shaft VZ Sub-assembly
019.0 Housing VZ Sub-assembly
020.0 Housing cover VZ Sub-assembly
021.0 Drive shaft VZ Sub-assembly
022.0 Planet carrier VZ Sub-assembly
045.0 Internal geared wheel VZ Sub-assembly
512.0 Flange for actuator Sub-assembly
513.1 Grub screw
518.0 Housing cover Sub-assembly
519.1 Worm wheel
520.0 Worm shaft Sub-assembly
521.0 Travelling nut with two pairs of safety wedge discs Sub-assembly
521.1 Travelling nut
521.12 Pair of safety wedge discs
522.0 Bearing cover Sub-assembly
523.0 End stop Sub-assembly
524.0 Pointer cover Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
534.0 Drive shaft Sub-assembly
538.0 Bearing cover with drive shaft Sub-assembly
S1 Seal kit Set
37
GS 50.3 – GS 250.3
Spare parts
9.2 Part-turn gearboxes GS 160.3 – GS 250.3
38
GS 50.3 – GS 250.3
Spare parts
513.1 Grub screw
519.1 Worm wheel
520.0 Worm shaft Sub-assembly
521.0 Travelling nut with two pairs of safety wedge discs Sub-assembly
521.1 Travelling nut
521.2 Pair of safety wedge discs
522.0 Bearing cover Sub-assembly
523.0 End stop Sub-assembly
524.0 Pointer cover Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
536.0 Protective cap Sub-assembly
537.0 Lock nut Sub-assembly
538.0 Bearing cover with drive shaft Sub-assembly
S1 Seal kit Set
39
GS 50.3 – GS 250.3
Spare parts
9.3 Reduction gearings GZ 160.3 – GZ 250.3
40
GS 50.3 – GS 250.3
Spare parts
003.0 Housing cover with drive shaft Sub-assembly
006.0 Planetary gearing first stage (GZ 160.3) 4:1 and 8:1 Sub-assembly
or first stage (GZ 200.3 – GZ 250.3) 16:1
or second stage (GZ 200.3) 16:1
or second stage (GZ 250.3) 16:1
513.1 Grub screw
S1 Seal kit Set
41
GS 50.3 – GS 250.3
Certificates
10. Certificates
10.1 Declaration of Incorporation and EC Declaration of Conformity
42
GS 50.3 – GS 250.3
43
GS 50.3 – GS 250.3
44
GS 50.3 – GS 250.3
Index
P
Index Packaging 10
Pointer cover 16 , 22
A Position indicator 22
Ambient temperature 33 Protective measures 4
Applications 5
Approved mark 7 Q
Assembly 11 Qualification of staff 4
C R
Commission number 8 Range of application 4
Commissioning 4 , 17 Recycling 30
Corrosion protection 9 , 33 Replacing the seals 24
Coupling 13 Running indication 16
D S
Declaration of Incorporation 42 Safety instructions 4
Directives 4 Safety instructions/warnings 4
Disposal 30 Screws to actuator 12
Seating 19
E Service 24
EC Declaration of Conformity 42 Service conditions 33
EC type examination certifica- 7 Servicing 24
te Spare parts 36
Enclosure protection 33 Standards 4
End stops 17 Storage 9
Explosion protection 7 Swing angle 20
F T
Flanges 12 Technical data 31
G Terminal plan 8
Grease change GS 160.3 – 27 Transport 9
GS 250.3 Type and size 7
Grease change GS 50.3 – GS 25
125.3
H
Handwheel 11
I
Identification 7
Indications 16
Inspection record 8
M
Maintenance 4 , 24
Maintenance intervals 24
Mechanical position indicator 16 , 22
Mount flange for actuator 13
Mounting position 13
Mounting positions 11
N
Name plate 7
O
Operation 4
45
AUMA worldwide
Europe AUMA ACTUATORS Ltd. MEGA Endüstri Kontrol Sistemieri Tic. Ltd.
UK Clevedon, North Somerset BS21 6TH Sti.
AUMA Riester GmbH & Co. KG Tel +44 1275 871141 TR 06810 Ankara
Fax +44 1275 875492 Tel+90 312 217 32 88
Plant Müllheim mail@auma.co.uk Fax+90 312 217 33 88
DE 79373 Müllheim www.auma.co.uk megaendustri@megaendustri.com.tr
Tel +49 7631 809 - 0 www.megaendustri.com.tr
Fax +49 7631 809 - 1250 AUMA ITALIANA S.r.l. a socio unico
riester@auma.com IT 20023 Cerro Maggiore (MI) AUMA Technology utomations Ltd.
www.auma.com Tel +39 0331 51351 UA 02099 Kiyiv
Fax +39 0331 517606 Tel+38 044 586-53-03
Plant Ostfildern - Nellingen info@auma.it Fax+38 044 586-53-03
DE 73747 Ostfildern www.auma.it auma-tech@aumatech.com.ua
Tel +49 711 34803 - 0
Fax +49 711 34803 - 3034 AUMA BENELUX B.V. Africa
riester@wof.auma.com NL 2314 XT Leiden
Tel +31 71 581 40 40 AUMA South Africa (Pty) Ltd.
Service-Center Köln Fax +31 71 581 40 49 ZA 1560 Springs
DE 50858 Köln office@benelux.auma.com Tel +27 11 3632880
Tel +49 2234 2037 - 900 www.auma.nl Fax +27 11 8185248
Fax +49 2234 2037 - 9099 aumasa@mweb.co.za
service@sck.auma.com AUMA Polska Sp. z o.o.
PL 41-219 Sosnowiec A.T.E.C.
Service-Center Magdeburg Tel +48 32 783 52 00 EG Cairo
DE 39167 Niederndodeleben Fax +48 32 783 52 08 Tel +20 2 23599680 - 23590861
Tel +49 39204 759 - 0 biuro@auma.com.pl Fax +20 2 23586621
Fax +49 39204 759 - 9429 www.auma.com.pl atec@intouch.com
Service@scm.auma.com
OOO Priwody AUMA MANZ INCORPORATED LTD.
Service-Center Bayern RU 124365 Moscow a/ya 11 NG Port Harcourt
DE 85386 Eching Tel +7 495 221 64 28 Tel +234-84-462741
Tel +49 81 65 9017- 0 Fax +7 495 221 64 38 Fax +234-84-462741
Fax +49 81 65 9017- 2018 aumarussia@auma.ru mail@manzincorporated.com
Riester@scb.auma.com www.auma.ru manzincorporated.com
AUMA Armaturenantriebe GmbH ERICHS ARMATUR AB America

AT 2512 Tribuswinkel SE 20039 Malmö
Tel +43 2252 82540 Tel +46 40 311550 AUMA ACTUATORS INC.
Fax +43 2252 8254050 Fax +46 40 945515 US PA 15317 Canonsburg
office@auma.at info@erichsarmatur.se Tel +1 724-743-AUMA (2862)
www.auma.at www.erichsarmatur.se Fax +1 724-743-4711
mailbox@auma-usa.com
AUMA (Schweiz) AG GRØNBECH & SØNNER A/S www.auma-usa.com
CH 8965 Berikon DK 2450 København SV
Tel +41 566 400945 Tel+45 33 26 63 00 AUMA Argentina Representative Office
Fax +41 566 400948 Fax+45 33 26 63 21 AR 1609 Boulogne
RettichP.ch@auma.com GS@g-s.dk Tel/Fax +54 232 246 2283
www.g-s.dk contacto@aumaargentina.com.ar
AUMA Servopohony spol. s.r.o.
CZ 250 01 Brandýs n.L.-St.Boleslav IBEROPLAN S.A. AUMA Automação do Brasil Ltda.
Tel +420 326 396 993 ES 28027 Madrid BR São Paulo
Fax +420 326 303 251 Tel+34 91 3717130 Tel +55 11 8114-6463
auma-s@auma.cz Fax+34 91 7427126 bitzco@uol.com.br
www.auma.cz iberoplan@iberoplan.com
AUMA Chile Representative Office
OY AUMATOR AB D. G. Bellos & Co. O.E. CL 9500414 Buin
FI 02230 Espoo GR 13671 Acharnai Athens Tel +56 2 821 4108
Tel +358 9 5840 22 Tel+30 210 2409485 Fax +56 2 281 9252
Fax +358 9 5840 2300 Fax+30 210 2409486 aumachile@adsl.tie.cl
auma@aumator.fi info@dgbellos.gr
www.aumator.fi TROY-ONTOR Inc.
SIGURD SØRUM AS CA L4N 8X1 Barrie Ontario
AUMA France S.A.R.L. NO 1300 Sandvika Tel +1 705 721-8246
FR 95157 Taverny Cedex Tel+47 67572600 Fax +1 705 721-5851
Tel +33 1 39327272 Fax+47 67572610 troy-ontor@troy-ontor.ca
Fax +33 1 39321755 post@sigum.no
info@auma.fr Ferrostaal de Colombia Ltda.
www.auma.fr INDUSTRA CO Bogotá D.C.
PT 2710-297 Sintra Tel +57 1 401 1300
Tel+351 2 1910 95 00 Fax+57 1 416 5489
Fax+351 2 1910 95 99 dorian.hernandez@ferrostaal.com
industra@talis-group.com www.ferrostaal.com
46
AUMA worldwide
PROCONTIC Procesos y Control AUMA Actuators Middle East W.L.L.

Automático AE 15268 Salmabad 704
EC Quito Tel +973 17877377
Tel +593 2 292 0431 Fax +973 17877355
Fax +593 2 292 2343 Naveen.Shetty@auma.com
info@procontic.com.ec
PERFECT CONTROLS Ltd.
Corsusa International S.A.C. HK Tsuen Wan, Kowloon
PE Miraflores - Lima Tel +852 2493 7726
Tel +511444-1200 / 0044 / 2321 Fax +852 2416 3763
Fax +511444-3664 joeip@perfectcontrols.com.hk
corsusa@corsusa.com
www.corsusa.com DW Controls Co., Ltd.
KR 153-702 Seoul
PASSCO Inc. Tel +82 2 2624 3400
PR 00936-4153 San Juan Fax +82 2 2624 3401
Tel +18 09 78 77 20 87 85 sichoi@actuatorbank.com
Fax +18 09 78 77 31 72 77 www.actuatorbank.com
Passco@prtc.net
Sunny Valves and Intertrade Corp. Ltd.
Suplibarca TH 10120 Yannawa Bangkok
VE Maracaibo Estado, Zulia Tel +66 2 2400656
Tel +58 261 7 555 667 Fax +66 2 2401095
Fax +58 261 7 532 259 sunnyvalves@inet.co.th
suplibarca@intercable.net.ve www.sunnyvalves.co.th/
Asia Top Advance Enterprises Ltd.

TW Jhonghe City Taipei Hsien (235)
AUMA Actuators (Tianjin) Co., Ltd. Tel +886 2 2225 1718
CN 300457 Tianjin Fax +886 2 8228 1975
Tel +86 22 6625 1310 support@auma-taiwan.com.tw
Fax +86 22 6625 1320 www.auma-taiwan.com.tw
mailbox@auma-china.com
www.auma-china.com Australia
AUMA (INDIA) PRIVATE LIMITED BARRON GJM Pty. Ltd.
IN 560 058 Bangalore AU NSW 1570 Artarmon
Tel +91 80 2839 4656 Tel +61 294361088
Fax +91 80 2839 2809 Fax +61 294393413
info@auma.co.in info@barron.com.au
www.auma.co.in www.barron.com.au
AUMA JAPAN Co., Ltd.

JP 210-0848 Kawasaki-ku, Kawasaki-shi
Kanagawa
Tel +91 80 2839 4655
Fax +81 44 366 2472
mailbox@auma.co.jp
www.auma.co.jp

SG 569551 Singapore
Tel +65 6 4818750
Fax +65 6 4818269
sales@auma.com.sg
www.auma.com.sg
47
P.O.Box 1362
D 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
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Orton GS Series Valve Manual

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Orton GS Series Valve Manual

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Centred Rubber Seated Valves

SECTION 1 PRECOMMISSIONING & COMMISSIONING ……………………………….. Pag.1

SECTION 2 VALVE HANDLING & ERECTION ……………………….……………………. Pag.5

SECTION 3 STORAGE ……………………………………….……………………………….. Pag.7

SECTION 4 MAINTENANCE ………………………………………………………………... Pag.9

SECTION 5 VALVE SERVICE CONDITION …………………………...……………………………….. Pag.15

SECTION 6 P.E.D. OPERATING & SAFETY INSTRUCTION …………………...…………………………… Pag.17

SECTION 7 ATEX OPERATING & SAFETY INSTRUCTION ………………...……………………………….. Pag.20

SECTION 8 OPERATIONAL TESTS ………………...……………………………….. Pag.26

SECTION 1 PRECOMMISSIONING & COMMISSIONING

General information for installation on site

 The valve can be installed in the pipeline in any position

1.3 Correct Installing Procedure

 Spread flanges to facilitate valve insertion with disc in semi-closed position

1.4 Uncorrect Installing Procedure

1.5 Functional Test

Warning - Safety rules for operation

Symptom Cause Resolution

2. Valve packed with debris 2. Flush or clean the valve

2. Seat o’rings damage 2. Replace seat o’rings

3. Plug / Bottom flange gasket damage 2. Check and replace gasket

Valve leaking 1. Valve not fully closed 1. Close the valve

4. Seat ring damaged 4. Replace seat ring

SECTION 2 VALVE HANDLING & ERECTION

2.1 Packaging for shipment

SECTION 3 STORAGE PROCEDURE

3.1 PRESERVATION PROCEDURE AND STORAGE ACTIVITIES

 The suggested environmental conditions for the storage are:

 Series Ds butterfly valve do not require maintenance or periodical lubrication.

At this point maintenance changes depending on valve diameter.

4.3 A: for DS series from 1” ½ to 12”

4.3 B: for DS series from 14” to 24”

4.3 C: for DS series over 24”

Valve disassembly from 1” ½ to 12” FIG.1 VALVE DISASSMBLY FROM 1” ½ TO 12”

1- Remove the seeger (9) from upper shaft (4)

Valve assembly from 1” ½ to 12”

1- Apply silicon grease on body internal diameter (1)

1- Unloose anti blow out screws (12.2) and remove

Valve assembly from 14” to 24”

1- Insert bearing (9) in the upper body hub (1)

Valve disassembly over 24” FIG.3 VALVE OVER 24”

Valve assembly over 24”

NOTE : If the valve is supplied with P.E.D. certification

SECTION 5 VALVE SERVICE CONDITION

DS-DL SERIES VALVES MUST BE USED IN STRICT ACCORDANCE WITH THE

PERIODIC INSPECTION IS HIGHLY RECOMMENDED. CONSULT ORTON.

FCx ORTON DECLINES ANY RESPONSIBILITY IN CASE OF APPLICATIONS

SECTION 6 P.E.D. OPERATING & SAFETY INSTRUCTION

According to directive 97/23/EC valves installed in the European Community

SECTION 6 P.E.D. OPERATING & SAFETY INSTRUCTION

ESSENTIAL SAFETY REQUIREMENTS (to be followed by the end user)

SECTION 7 ATEX OPERATING & SAFETY INSTRUCTION

According to ATEX directive 94/9/CE valves installed in the European

1 – Valve series according to Orton std

SECTION 7 ATEX OPERATING & SAFETY INSTRUCTION

II 2 GD c II Tx min/max WT (*) Tech.File: ST 04-215

II 2 = Group II (surface), category 2

Correspondence between hazardous areas, substances and categories

Zona pericolosa Categories in accordance with Directive

 PREVENTION OF POTENTIAL IGNITION SOURCES

FLAMES AND HOT GASES:

STRAY ELECTRICAL CURRENT AND PROTECTION AGAINST CATHODIC CORROSION

EXOTHERMIC REACTION (INCLUDED DUST IGNITION)