ANTRIEB

'DC' TYPE ..MF Electro-Mechanical ActuatorsIP68

With Compact Control. .ELECTRONIC

-Operating and Maintenance instructions -Spare Parts (E-CARD)

ANTRIEB ACTUATORS

01.Compact Housing 02.Allen Cap Screw 03. End Cover ( Terminal Assembly ) 04. Terminal Block assembly Cpl. 05. End Cover ( Plug & Socket Assembly ) 06. Plug & Sockets Assembly Cpl. 07. Front Cover Assembly Cpl. 08. Base Plate Assembly Cpl.

Fig.1. Compact Control Module Sectional View 2

General
Antrieb 'DC' Type..MF Electro Mechanical Actuators with Compact Control - ELECTRONIC are specially designed for operating various types of valves, dampers, pen stock etc. either with local controls or from remote (DCS). They are used in various industries such as power, paper, water / sewage, cement, chemical etc. The 'DC' Type MF Actuator with Compact Control have IP68 enclosure, Certified by CPRI Bangalore With the advancement of technology, it has been accepted that the actuator has to be operated locally during commissioning / emergency operations. To facilitate the above, Antrieb Actuators are now being manufacture with Locally available integral starters, which can operate the valve either locally or from remote (DCS).

b) Connect 3 phase 415 V AC to R, Y, B in 8 pin socket.

c) Connect control connection as per the wiring diagram on the 32 pin sockets d) Re-assemble the socket assembly to the end cover. e) Fix the end cover assembly to the plug assembly Provided in the compact housing(1).

Checking The Direction Of Rotation (Refer fig-2)

Before switching on the main supply, Ensure that the actuator / valve should be in mid position.

Local Operation

Mechanical Mounting
The flange of the actuator is equipped with threaded holes for fitting on the valve. The dimension of the Mounting flange and the connection arrangement comply with, ISO 5210 or DIN 3210. For mechanical mounting of the actuator please refer page No.2 in Installation And Operating Instructions Catalogue No. ATPLMF-003 Fig-2 Front Cover Assembly cpl. a) Switch ON the 3phase 415V AC mains. b) Check the power `ON indicating LED (Amber) is glowing c) Select the selector switch to Local mode d) Press the OPEN push button switch e) The actuator should rotate in counter clockwise (Open) direction

Electrical Connections
Electrical connections are to be made according to the wiring diagram provided in the terminal assembly compartment Removal of End Cover (Terminal Assembly Refer Fig-1) a) Use 6mm size ( For std Actuator ) allen key to loosen the 4 nos.allen cap screws (2). b) Remove the End Cover (3) from the compact housing. c) connect the power cable, Control cables via cable glands (provided on the compact housing(1)) d) Connect 3 phase 415V AC main to R, Y, B terminals in the terminal assembly(4). e) Connect control Connection as per the wiring diagram in the terminal assembly. Note:-1 In case of plug and sockets assembly (6), remove the socket assembly fixed with the end cover(5). by removing 4 nos. of M5 CHS screw.

f) The indicating LED for OPEN (Green) should blink.

g) Press the STOP push button switch. The actuator should stop. h) Press the CLOSE push button switch i) The actuator should rotate in clockwise (Close) direction j) The indicating LED for CLOSE (Red) should blink k) Press the STOP push button switch. The actuator should stop If the above operations are ok the phase sequence is working satisfactorily. If the above operations are not ok, please check for any loose connection in the phase / control connections. Removal Of Limit Switch Cover For setting the Limit switches, remove the limit switch cover provided in the actuator. Use 6mm Allen key to remove the 4 nos.of Allen cap screws.

a) connect the power cable, Control wires via cable

gland provided with the End cover(5)

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Setting of Torque / Limit / Cam / Potentiometer / EPT

Please refer Installation And Operating Instructions Catalogue No. ATPLMF003 for the following a) Torque switch setting b) Limit switch setting c) Setting the Limit switch with Counter unit d) Setting the Limit switch with Cam switch unit e) Changing the stroke range on the counter unit f) Changing the stroke range on the Cam switch unit g) Limit switch repositioning Table for DCO, DC1,

CAUTION :-2 The dipswitches have been preset at works in OFF position. Kindly do not alter the settings, unless required

DC2, DC3 with pick-off gear

h) Setting the Mechanical Position Indicator i) Setting the Resistance Transducer

j) Setting the Electronic Position Transducer

Dip Switch Fig-3. Base Plate Assembly Incase the dipswitch settings and delay time settings have to be altered Please refer the various combination of dipswitches and the corresponding functionality as listed below. Dip Switch No.
01. Set tings

Checking the Limit Switch and Torque Switch function

a) Operate the actuator in OPEN direction. b) Switch off by manually tripping the OPEN limit switch (S4) c) The actuator should stop. d) Operate the actuator again in OPEN direction. Switch off by manually tripping the OPEN torque switch (S2) e) The actuator should stop only after 3seconds of delay time. f) Operate the actuator in CLOSE direction

Functions
Local non-maintained Local maintained Remote non-maintained Remote maintained Thermostat over ride Thermostat input accept Open / Close interlock over ride Open / Close interlock input accept Close torque ignores Close limit switch Both torque switch and limit switch in operation Valve jammed

g) Switch off by manually tripping CLOSE limit switch and CLOSE torque switch
h) The actuator should stop.

02. 03. 04. 05.

Compact Control Electronic Construction

The compact control module consists of Contactors (K1, K2), Over load relay, Transformers, Rectifier 24V DC Indicating Lamps, Push buttons and Electronic card, which have been assembled on a base plate and wired as per the wiring diagram. CAUTION:1 OLR SETTING Normally the OLR set valve is preset at our works in auto mode. The customers are advised not to disturb the setting of the OLR unless required

ON OFF ON OFF ON OFF ON OFF ON OFF Refer Delay Time list.

06, 07, 08

TABLE-1

Delay Time List

Nos.6 7 OFF OFF OFF OFF OFF ON OFF ON ON OFF ON OFF ON ON ON ON 8 OFF ON OFF ON OFF ON OFF ON Delay time (sec) 05 Sec Delay time to 10 sec switch off the 15 sec actuator when the 20 sec valve gets jammed. 25 sec After this delay the 30 sec actuator relay 35 sec automatically 40 sec switches off.

Dip Switch Setting On Electronic Card

The electronic card has programmable 8 bit dipswitches which can be easily changed to work with various requirements.
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TABLE-2
4

Connections & Checking for REMOTE Operation:The wires from Remote ( DCS ) are terminated at TB as below. Connect the push button switch in between the terminal as mentioned below. 80 (Common) 80 (Common) 80 ( Common)

.
60 . R.Open

.
61 0 R.Close

.
62 R. Stop .

.
Fig-4. Dip Switch Setting

For setting the Dip switch

a) Switch off the main supply 415V AC b) Use 6mm size Allen key to loosen the 4 screws from housing. c) Remove the front cover Assy.(1) (Ref. fig-4) d) Use 4mm size Allen key to loosen the 2 Nos. M5 screws (4) e) Pull out the base plate assembly (3) to the required length-using clamp (2) Set the dipswitches as per your requirement (Refer table-1 and Table -2)

NOTE:- Incase of Separate interposing relays used for remote operation (refer wiring diagram-rev.07). Connect as per the wiring diagram. 1) Select the LOCAL / OFF / REMOTE selector switch to REMOTE mode 2) Check the 24V DC healthy indicating LED is glowing 3) Press the remote OPEN push button switch 4) The actuator will run in open direction 5) Press the remote STOP switch 6) The actuator will stop 7) Press the remote CLOSE push button switch 8) The actuator will run in Close direction 9) Press the remote STOP switch 10) The actuator will stop. Connections& Checking for OPEN/CLOSE interlock 80 (Common) Connect the push Open / Close . button switch in 63 Inter lock Between terminal 80 63 .

Local Operation
1) Switch on the main 3 phase 415V AC supply. 2) Check the power on indicating LED (amber) is glowing 3) Select the LOCAL / OFF / REMOTE Selector switch to Local mode 4) Press the OPEN push button switch 5) The actuator will rotate in OPEN direction 6) The open indicating LED (green) Will blink 7) When the actuator reaches the open end position, the LED will glow steadily 8) Press the CLOSE push button switch 9) The actuator will rotate in CLOSE direction 10) The close indicating LED (red) will blink 11) When the actuator reaches the close end position, the LED will glow steadily

1) Start the actuator in OPEN / CLOSE Direction 2) Press the OPEN CLOSE interlock push switch 3) The actuator should stop 4) If the actuator does not stop check the setting of the Dipswitch No. 4 and correct as required.

Monitoring Relay
The Monitoring Relay De-energizes on the following conditions when the Local - Off - Remote Selector switch is in Remote mode. 1. Loss of power supply (415v 10%) 2. Loss of control supply 3. Motor thermostat trip 4. Thermal over load relay trip 5. Valve jammed 6. Emergency shutdown 7. Torque open cut off 8. Torque close cut off 9. Local / Off / Remote Selector switch in Local or Off mode. 10. 24V DC healthy failure 11. Open / Close interlock trip
5

Remote Operation
24V DC supply For remote operation the 24V DC supply is inbuilt in the Electronic card. Customers need not have to connect the external power supply for remote operation. 24VDC Healthy Indication Connection For Wiring Diagram upto rev.5B,Connect the LED in between the terminal 89 90 89 90

. . rev-07, Connect ( NOTE:-For Wiring Diagram the LED in between the terminal 53-54 )
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NOTE:- The monitoring relay will not de energize, if the close limit switch ignores (bypassed) and switching off by torque switch while the valve jammed in mid travel. Monitoring relay

Diagnostic Module The Diagnostic module has up and down switches (6) to monitor the actuator status. The status annunciations (display mode)are orderly listed in the diagnostic module so that it is easy to view.

68

69

The `NO' point 68,69 left out for Customers scope. An Indicating lamp or an Alarm can be connected at this terminal.

4 5 2

(For rev-07 the monitoring relay terminal 39-NC, 40-C, 41 - NO left out for customers scope.) Rectifier (Internal 24VDC) The output voltage from the Rectifier (24VDC) is terminated in between the terminals 77&78.(33&34 for rev-07 )It can be used externally for maximum load of 350mA. Fig-5
NOTE-3

Closing the Front Cover Assembly

1) Push the base plate assembly (2) inside and fix the clamps with screws (5). ref.fig.5 2) Close the front cover assembly (1) 3) While closing the front cover assembly, Ensure that the knob groove to locate with selector switch dowel pin. 4) Ensure that the `O ring is seated Properly Closing the End Cover (Terminal assembly) and Limit Switch Cover 1) Close the End cover and Limit switch cover 2) Use 6mm Allen key for tightening the M8 Allen cap screws 3) Ensure that the `O rings are seated properly 4) Ensure the Allen cap screws are tightened properly. NOW THE VALVE AND THE ACTUATOR ARE READY FOR OPERATION.

For example if the Actuator is running in close direction at local mode, then the Diagnostic module will display `Monitoring Relay Off (refer Sl. No.6 ) , Local close On (refer Sl. No.10 ) and Actuator close 'ON' (refer Sl. No.12 ) vice versa SL.NO DISPLAY MODE : Supply Phase Fail : Thermostat Trip

01. Supply Phase Present

02. Thermostat Normal

Maintenance
For maintenance or any rectification on the compact control unit (ref.fig.5) 1) Switch off the main supply 2) Remove the front cover assembly cpl (1) 3) Remove 2 Nos of M5 CH Screw (5 and Pull the base plate assembly (2) to the required length by using clamp (3) 4) Connect the diagnostic module (4) to the serial port on the Electronic card Note:- No external power supply is required for the diagnostic module. It derives power from the Electronic Card.
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03. No Emergency Shutdown : Emergency Shutdown 04. Open Torque Normal : Open Torque Trip 05. Close Torque Normal : Close Torque Trip 06. Monitor Relay Off : Monitor Relay On 07. Remote Close Off : Remote Close On 08. Remote Open Off : Remote Open On 09. Remote Stop Off : Remote Stop On 10. Local Close Off : Local Close On 11. Local Open Off : Local Open On 12. Actuator Close Off : Actuator Close On 13. Actuator Open Off : Actuator Open On 14 No Open / Close Interlock : Open / Close Trip Interlock Trip 15. Thermal Over Load Relay : Thermal Over Load Off Load Relay On 16. End Limit Open Off : End Limit Open On 17. End Limit Close Off : End Limit Close On 18 .No Valve Jam Trip : Valve Jam Tripped After rectification is over, push the Base plate assy. inside and fix the 2 Nos. of M5 CH screws and close the Front cover by using M8 Allen cap screws. NOTE:The user should purchase the diagnostic module separately. (Refer Catalogue no.ATPL-MF-CC-001)
6

Spares

ANTRIEB CC E-CARD

POS
1.0 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 2.01 2.02 2.03 2.04 3.01 3.03 4.01 4.02 4.03 4.04

PART NUMBER
ANT -WT -CC-Z033 ANT -WT -CC-033 ANT -CC-NMP-001 ANT -WT -CC-015 ANT -WT -CC-016 ANT -WT -CC-014 ANT -WT -CC-010 ANT -WT -CC-011 2006 ANT -WT -CC-012 ANT -WT -CC-013 3008 ( 3 X 12 ) 3009 ( 20 DIN471 ) 3010 ANT -WT -CC-017 3011 ( 11 x 2.6 ) ANT -WT -CC-018 3012 ( 7 X 0.7 ) ANT -WT -CC-022 ANT -WT -CC-021 ANT -WT -CC-019 ANT -WT -CC-020 ANT -CC-072 3002 ( 210 X 3 ) ANT -WT -CC-008 ANT -WT -CC-048 3013 3014 ANT -DC0-Z3-MS ANT -WT -CC-Z061 ANT -WT -CC-Z002A ANT -WT -CC-007 ANT -DC0-039 ANT -DC0-162

DESCRIPTION
Front Cover Assy Cpl. Front Cover Name Plate Toughened Glass Gasket Spacer Ring Bush-1 Shaft Square Ring Knob Locating Pin Spring Dowel Circlip Chain With Ring Bush-2 `O Ring Plunger E-Clip Spring Clamp-1 Stopper-1 Stopper-2 Socket Head Cap Screw `O Ring Plate-2 Plate-6 32 Pin Plug & Socket 8 Pin Plug & Socket Terminal box cover assy cpl Terminal Assy Cpl. End Cover Assy Cpl. Plate-1 Cable Gland 1 cable Gland

POS
5.01

PART NUMBER
ANT -WT -CC-001 ANT -WT -CC-001M

DESCRIPTION
Compact Housing With CG Hole Compact Housing Without CG Hole (For Plug & Socket model)

5.02 5.03 5.04 5.05 6.02 6.04 6.05 6.06 6.07 6.08 6.09 6.10 6.15 7.01 7.02 7.03 7.04 7.05 7.06 7.07 7.08 7.09 7.11 7.12 7.13 7.14 7.19 7.20

ANT -WT -CC-006 ANT -WT -CC-058 ANT -WT -CC-037M ANT -WT -CC-038M ANT -WT -CC-005 ANT -WT -CC-035 ANT -WT -CC-059 ANT -WT -CC-060 ANT -WT -CC-049 ANT -WT -CC-036 ANT -WT -CC-033 ANT -WT -CC-031 ANT -WT -CC-024 3016 3018 ANT -WT -CC-Z062 3030 3021 3022 3023 As Per specification 3024 ANT -WT -CC-041 ANT -WT -CC-042 ANT -WT -CC-044 3025 3015 ANT -WT -CC-Z069

Rail Spacer Clamp-6 Clamp-7 Base Plate-2 Indicating Plate-2 Clamp-11 Clamp-12 Clamp-10 Clamp-5 Bottom Plate Clamp-4 Clamp-3 L/O/R Selector Switch Push Button Switch LED Assy Cpl. Mechanical Interlock Contactor Contactor Top Mounting Contactor Side Mounting OverLoad Relay Fuse Holder with fuse Transformer-1 &2 Transformer-3 Electronic Card Rectifier Toggle Switch PC Relay assembly cpl.

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Faults
The diagnostic port is showing supply phase fail

Remedies
a) Check the three phase input power supply b) Check the Fuses, transformers c) Check the control voltage (30VAC) in between the terminal No.48-47, 48-46, 48-45 in the electronic card d) Check the control voltage (26V AC) in between the terminal No.43, 44. a) Check the motor thermostat point b) Check the Dip switch -3 a) Check the input voltage (24V DC) b) Check the local / off / remote selector switch c) Check the terminal No.11, 12 in the Electronic card a) Check the Fuses b) Check the voltage (110VAC) in between F3 fuse and Terminal No.28 in Electronic card. c) Check the NC point of the K1 contactor d) Check the coil point of the K2 contactor e ) Check the open input electronic card terminal no. 14 f) Check the NO point of the push button switch g) Check the open direction micro switches Same as above mentioned for Close direction but NC point of the K2 contactor ,coil point of the K1 contactor and close direction micro switches. a) Check the NO point of the monitoring relay b) Check the external control source c) Refer page No.5 a) Check the input voltage 24V DC at the terminal no .80 b) Check the NC, NO point of the external switch provided for open / close interlock trip e) Check the dipswitch position a) Check the 24V DC healthy indication. b) Check the Transformer input and output connections,

Thermostat not working Local / Off / Remote function not working

Open direction not working

Close direction not working

Monitoring relay not working

Open / close interlock not working

Three Phase available in the Actuator but not Working

DO'S
Do ensure the proper voltage to motor and control circuit. Do proper ear thing arrangement. Do ensure torque switch and limit switch connections in proper connection. For any rectification on the compact control unit, ensure the supply is switched off. After rectification is over ensure that the removed items are fixed properly Do ensure while closing the covers the `o' rings are seated properly. Do ensure while closing the compact control front cover, the selector switch knob should align with selector switch dowel pin.

DONTS
Do not open the compact control front cover unnecessarily. Do not use damaged cables. Do not open the covers without switching off the power supply . Do not remove the Electronic card from the compact control Base plate assy. Do not use the damaged `O' rings.

ANTRIEB TECHNIK PRIVATE LIMITED 59 (Old No. 349) SIDCO Industrial Estate, Ambattur, Chennai - 600 098. Telephone : 26258303, 26253241, 26248983. Fax : 009144-28193718 Cable :ANTRIEB: CHENNAI E-Mail : : antrieb @ vsnl.com antrieb @ sancharnet.in
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Technology EMG Germany

CATALOGUE No.ATPL-MF-CC-002 082K6-5000

SUBJECT To MODIFICATION