Sie sind auf Seite 1von 56

Technical Manual

Instructions for installation,


operation and maintenance

721
3-WAY CONTROL VALVES
Fig. 450/451, with electric actuator Ari-Premio

Publication nr
Supersedes

TIB-721-GB-0711
TIB-721-GB-1004

Operating and Installation Instructions


3-Way Control Valves Fig. 450/451

Fig. 12.450
22.450
23.450
34.450
35.450

Fig. 12.451
22.451
23.451
34.451
35.451
Contents

5.2 Requirements at the Place of Installation ................... 6


1.0 General Information on
Operating Instructions .........................................3 5.3 Installation Instructions Concerning Actuators .......... 7
2.0 Notes on Possible Dangers ....................................3 6.0 Notes on Dangers During Installation, Operation
and Maintenance .................................................. 7
2.1 Significance of Symbols ............................................. 3
2.2 Safety-Related Definitions.......................................... 3 7.0 Putting the Valve into Operation......................... 7
2.3 Qualified Personnel..................................................... 3 8.0 Care and Maintenance ......................................... 7
3.0 Handling .................................................................4 8.1 Spindle Packings......................................................... 8
3.1 Storage ........................................................................ 4
3.2 Transport..................................................................... 4
3.3 Handling Before Installation....................................... 4

4.0 Description .............................................................4


4.1
4.2
4.3
4.4

8.2
8.3
8.4
8.5

Packings with PTFE V-ring unit ................................. 8


Stuffing Box Packings................................................. 9
Bellow Seal ............................................................... 10
Replacing the Plug, Spindle and Seating .................. 11

Scope of Applications................................................. 4 9.0 Troubleshooting .................................................. 12


Operating Principles ................................................... 4 10.0 Troubleshooting Table ...................................... 13
Diagram ...................................................................... 5 11.0 Dismantling the Valve....................................... 14
Marking....................................................................... 6

5.0 Installation .............................................................6

12.0 Warranty ........................................................... 14

5.1 General Notes on Installation ..................................... 6

0040000093 4000 englisch

Operating and Installation Instructions


Control Valves Fig. 450/451

1.0 General Information on Operating Instructions


These operating instructions contain information necessary to install and operate the valve both safely
and effectively.
If problems arise which cannot be solved with the aid of these operating instructions, please contact the
supplier/manufacturer for further information. These operating instructions comply with applicable EN
safety standards as well as regulations and codes of practice applicable in the Federal Republic of
Germany. If the valve is used outside the Federal Republic of Germany, the operator or the person
responsible for the system design must ensure that valid national codes of practice are complied with.
The manufacturer reserves all rights to implement technical modifications and improvements at any
time.
The use of these operating instructions assumes the user is qualified as described under Section 2.3
"Qualified Personnel".
The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on Possible Dangers


2.1 Significance of Symbols
Warning of general danger

2.2 Safety-Related Definitions


The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.
DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or
considerable damage to property can occur.
WARNING means that if the relevant information is disregarded, there is a danger of serious injury and
/ or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or
damage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specifically emphasised such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product documentation
and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in
turn can cause serious injury to persons or damage to property.

2.3 Qualified Personnel


The term "qualified personnel" relates to persons who are familiarised with installation, assembly, startup, operation and maintenance of the product and have the qualifications corresponding to their
responsibilities such as:
Instruction and obligation to comply with all operational, regional and in-company regulations and
requirements;
Training or instruction in accordance with safety technology standards with regard to the upkeep and use
of appropriate safety and work protection equipment; First aid training, etc.
(see TRB 700).
0040000093 4000

page 3

Operating and Installation Instructions


Control Valves Fig. 450/451

3.0 Handling
3.1 Storage
- Storage temperature -20 to +65C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Dont
damage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport
- Transport temperature -20 to +65C.
- Protect against external force (impact, vibration etc.).
- Dont damage the paintwork.

3.3 Handling Before Installation


- If flange covers are fitted, remove shortly before maintenance!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.

4.0 Description
4.1 Scope of Applications
These servo controlled valves are suitable for controlling the flow of liquids, gases and vapours in
chemical and other processing plants and for plant engineering.
The materials have been selected and matched on the basis of current DIN, AD, TRD and UVV rules.
The mechanical and flow characteristics conform to standard DIN EN 60534.
The engineer planning a plant is responsible for selecting the correct valve for a given application. The
special features of the valve concerned must be taken into account.
Oil and grease free
for oxygen application

- Valves for oxygen application (O2) have a fixed plate.

- Valves for Ammonia (NH3) acc. to TRD 451-452 must be free from nonferrous metals
with flanges DIN 2512 form N.
- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.
- Valves for inflammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
-

-marking for applications acc. to Pressure Equipment Directive.

4.2 Operating Principles


ARI servo controlled valves are especially suitable for actuation by pneumatic or electrical actuators.
Depending on the mode of operation, two different execution methods are possible:
1. Execution with mixing plug
2. Execution with diverting plug
The execution with the mixing plug is the standard execution method .
This execution method is to be chosen when the valve is also employed as a mixer ( 2 entrances, 1 exit.)
In exceptional cases, the execution with the mixing plug can also be employed as a diverting plug
(1 entrance, 2 exits). This requires, however, low differential pressures and stable propulsion.
The execution method with the diverting plug is only to be employed with the operation of diverting.
Explanation:
Mixing operation
diverting operation
AB

page 4

AB

0040000093 4000

Operating and Installation Instructions


Control Valves Fig. 450/451
4.3 Diagram

rotated view

rotated view

fig. 1: Fig. ...450 with mixing plug

rotated view

fig. 2: Fig. ...451 with mixing plug

rotated view

rotated view

fig. 3: Fig. ...450 with diverting plug

rotated view

fig. 4: Fig. ...451 with diverting plug


0040000093 4000

page 5

Operating and Installation Instructions


Control Valves Fig. 450/451
4.4 Marking
Details of the CE-marking on the name plate of the valve:
CE-marking
0525
Notified body
Fig. ______ Figure-No. / Type-No.
SN _ _ ____ Serial-No.
Year of manufacture (clear speech)
(1. and 2. position of the serial-No.)

According to the Pressure Equipment


Directive part 3, valves without safety
function are only allowed to bear the CEmarking DN32 onwards.

5.0 Installation
5.1 General Notes on Installation
The following points should be taken into account besides the general principles governing installation
work:
- Remove flange covers if present.
- There must be no foreign bodies inside the valve or piping.
- Pay attention to the direction of flow: see markings on the valve and refer to the operation and
installation instructions (point 4.2).
- Centre sealings between the flanges.
- Connection flanges must mate exactly.
- If the valve is handling steam, the piping must be laid with a gradient to prevent water from
accumulating in pockets. Condensation traps are needed to prevent water-hammer.
- All parts must be free from stress after installation.
- The valve must not serve as a fixed point. It must be carried by the piping.
- Protect the valve from dirt, especially during construction work. Strainers or filters shoud be installed
before the valves.
- Install compensators to compensate for thermal expansion of the piping.
- Keep the thread and shaft of the spindle free from paint.

5.2 Requirements at the Place of Installation


The place of installation should be easily accessible and provide ample space for maintenance and
removing the actuator. Stopvalves shoud be installed before and after the controlvalve to enable
maintenance working without draining the piping system. The valve should preferably installed
vertically with the actuator at the top. Inclined or horizontal installation without supports is permissible
only with light actuators.
For this installallation position, the two distance columns (or joke) have to be above each other in the
verical plane.
Pipeline
Pipeline
horizontally
vertically

Permissible servo weights for valves with unsupported horizontal spindles:


20 kg for DN 15 - 32
25 kg for DN 40 - 65
35 kg for DN 80-100
40 kg for DN 125-150
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space must be left for
the maintenance of the spindle packing.
To ensure that the control valves function correctly, the pipe run should be straight for at least 2 x DN
upstream and 6 x DN downstream of the valve.
page 6

0040000093 4000

Operating and Installation Instructions


Control Valves Fig. 450/451
5.3 Installation Instructions Concerning Actuators
Normally, control valves are supplied complete with actuator fitted.
It is not permitted to mantle / dismantle actuators with valves operating at service conditions
(temperature and pressure) (see2.3). The actuators must be assembled as describe in the operating
instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seatring at closing pressure.

Caution!
Care must be taken with the bellow type valves when actuators are mounted or removed. Hold the valvespindle against turning with an open-end wrench.
When retrofitting actuators, the maximum permissible force for valve actuation must be taken into
account.
The maximum permissible actuation forces are:
BR450
BR451
12 kN for DN 15 - 50
18 kN for DN 15 - 100
29 kN for DN 65 - 100
37 kN for DN 125 - 150
40 kN for DN 125 - 150

6.0 Notes on Dangers During Installation, Operation and Maintenance


DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation and
maintained by trained personnel (cf. point 2.3 Qualified personnel) paying full attention to the
warnings in these operating instructions. In addition, the general installation and safety rules for piping
and plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.
Injury or damage can be caused by ignoring them.
When used as an end-blockage, a safety precaution is recommended by maintenance works.

7.0 Putting the Valve into Operation


- Before putting the valve into operation, check that the material, pressure, temperature and direction of
flow are as specified with the plans of the piping system.
- Regard the TRB 700.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modification, always make
sure that:
- all installation and assembly work has been completed!
- only qualfied personnel (see point 2.3) are employed to start the plant!
- the valve is in the correct position for its function!
- existing guards have been attached and in good order.

8.0 Care and Maintenance


Maintenance and maintenanceintervals have to be defined by the operator according to the service
conditions (see TRB 700).

0040000093 4000

page 7

Operating and Installation Instructions


Control Valves Fig. 450/451
8.1 Spindle Packings

rotated view

rotated view

fig. 5: PTFE V-ring unit

fig. 6: Stuffing box sealing

fig. 7: Bellow seal

8.2 Packings with PTFE V-ring unit


See Fig. 5 and 8
PTFE V-ring unit consisting of:

1 backing ring
4 sealing rings
1 cover ring

Owing to the installed compression spring, this spindle packing is selfadjusting. If the spindle starts leaking, the ring pack is worn out and
must be replaced.
Replacing PTFE V-ring unit:

Warning! See point 11.0 before dismantling the valve.


- Remove the actuator (see operating instructions for actuator).
- When replacing V-ring unit (12), make sure that the parts are installed
in the correct order and positions (see Fig. on right).
- Damaged spindles must also be replaced (see point 8.5 for
instructions) since a new ring pack will soon start leaking again with a
damaged spindle.
- Attention! Gasket (17) must be replaced.
fig. 8

page 8

0040000093 4000

Operating and Installation Instructions


Control Valves Fig. 450/451
8.3 Stuffing Box Packings
See Fig. 6 and 9
- Stuffing box packings require maintenance.
- If leaks develop, immediately tighten the hexagon nuts (42) gradually
until the packing stops leaking.
- The service life of stuffing box packings (13) can be increased by
checking regularly leakage.
- If leaks can no longer be stopped by tightening the nuts, a new
packing ring must be inserted into the gland.
Replacing a stuffing box packing:

Warning! See point 11.0 before dismantling the valve.


- Insert the new packing ring as shown in the Fig. on the right.
- If a split packing ring is used, cut with a chamfer as shown in Fig. 10

fig. 9
fig. 10: Split packing ring
- Damaged spindles must also be replaced (see point 8.5 for instructions) since a new ring pack will soon
start leaking again with a damaged spindle.

0040000093 4000

page 9

Operating and Installation Instructions


Control Valves Fig. 450/451
8.4 Bellow Seal
See Fig. 7, 11 and 12
If the spindle leaks, the bellow seal is defective. The leak can initially be stopped by tightening the screw
joint (20.17).
Replacing the bellow seal:

Warning! See point 11.0 before dismantling the valve.


- Remove the actuator (see operating instructions for actuator!).
- Unscrew the screw joint (20.17) by about one turn.
- Screw out the seating ring (2) (see point 8.5a) at execution with divertingplug (Fig. 12) not neccessary.
- Unscrew nut (4) and hold it against the spindle end.
- Remove the plug (3, 31).
- Unscrew the nuts (11) and
remove the bellows
housing.
- Unscrew the nuts (20.8) and
remove the mounting
bonnet (20.2).
- Take the spindle- / bellows
unit (20.3) out of the
bellows housing.
- Remove the straight pin (6).
- Unscrew the adapter (37,
38).
Notice:
Adapter (37) and straight
pin (6) are not existing at
Fig.451 DN40-50 with
mixing plug (fig. 11).
- Drill the new spindle- /
bellows unit and adapter.
fig. 11
- Replace 2 seals (20.6) and 1 seal (9).
- Assemble in the reverse order. Screw on the nuts (11 and 20.8)
and tighten them crosswise (See page 27 for tightening
torques).
Notice:
At DN125 and 150 Pos. 32 is dropped.

page 10

0040000093 4000

Operating and Installation Instructions


Control Valves Fig. 450/451
8.5 Replacing the Plug, Spindle and Seating

Warning! See point 11.0 before dismantling the valve.


a) A special wrench is needed to remove the seatring.
It can be obtained from ARI.
During the mixing plug operation, only the lower valve seatring in the
standard design at DN15 up to DN100 can be replaced, !
In special designs (standard at DN125 and 150) and general at
diverting plug operation, both seatrings are replaceable.
Only the bottom seatring ring can be replaced.
When fitting a new or reconditioned seatring, clean thread and
sealing plug in body and applied suitable lubricant.
See table below for seat ring tightening torques.
Tightening torques
DN 15/ 20
=
100 Nm
DN 25/ 32
=
150 Nm
DN 40/ 50
=
350 Nm
DN 65
=
480 Nm
DN 80
=
660 Nm
DN100
=
980 Nm
DN125
=
1450 Nm
DN150
=
2000 Nm
fig. 13
b) Control Valve - Fig. 1 and 1a
Warning! See point 11.0 before dismantling the valve.
Mixing plug operation: - see Figures 1, 2 and 13
- Screw out the seatring ring (2) (see point 8.5a).
- Unscrew the screw joint (19) by about one turn.
- Extract and replace the spindle with plug (3).
- Replace the seal (9).
- Assemble in the reverse order. Screw on the nuts (11)
and tighten them crosswise (See page 12 for tightening torques).
Diverting plug operation: - see Figures 3, 4 and 14
- Unscrew the screw joint (19) by about one turn.
- Loosen the nuts (4) and disassemble the plug (31)
with the spacer sleeve (32).
- By means of loosening the nuts (11), the traverse lid can be
disassembled (7).
- Extract the spindle (41) by pulling it up and out of the
casing and replace the respective parts.
- Replace the seal (9).
- Assemble in the reverse order. Screw on the nuts (11)
and tighten them crosswise
(See page 12 for tightening torques).
- At DN125 and 150 Pos. 32 is dropped.
fig. 14

0040000093 4000

page 11

Operating and Installation Instructions


Control Valves Fig. 450/451
c) Control valve with Bellows - Fig. 2, 11 and 4, 12

Warning! See point 11.0 before dismantling the valve.


- Screw out the seating ring (2)
(see point 8.5a) - for the diverting type plug, this is not necessary.
- Remove the plug (see point 8.4).
(The spindle can only be replaced complete with bellows).

d) Tightening torque for hexagon nuts:


Bolts
M 10
M 12
M 16
M 20

Torque
20 Nm
35 Nm
80 Nm
160 Nm

See operating instructions for actuator concerned for installing actuators!


9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described in
these instructions.
Regard the TRB 700.
Compare the material, pressure, temperature and direction of flow with the information given in the
plans of the piping system. Check also that the service conditions correspond to the data given on the
data plate and the technical data.
DANGER !
It is essential that the safety regulations are observed when identifying faults!
If malfunctions cannot be eliminate with the help of the following troubleshooting table, the supplier
or manufacturer should be consulted.

page 12

0040000093 4000

Operating and Installation Instructions


Control Valves Fig. 450/451

10.0 Troubleshooting Table


Fault

Possible cause

Corrective measures

No flow

Valve closed.

Open valve (using actuator).

Flange covers not removed.

Remove flange covers.

Valve not sufficiently open.

Open valve (using actuator).

Dirt sieve clogged.

Clean / replace sieve.

Little flow

Relieve pressure first!

Valve spindle moves in jerks.

Piping system clogged.

Check piping system.

Kvs value of valve unsuitable.

Fit valve with higher Kvs value.

Stuffing box sealing too tight (for valves


with graphite packings).

Slacken screw joint (42/20.17)


slightly.
Valve must nor start leaking!

Valve spindle or plug cannot


be moved.

Valve spindle leaking.

Leakage too high when valve


is closed.

Valve spindle hammers.

Valve plug slightly seized owing to solid


dirt particles.

Clean internals, smooth rough spots.


See points 7.0 and 11.0!

Seatring and plug clogged with dirt; especially with V-port and perforated plugs.

Clean seatring and plug with suitable solvent.


See points 7.0 and 11.0!

Valve plug seized in seatring or guide


owing to deposits or dirt in medium.

Replace plug and seatring; use parts made


from different material if necessary.

PTFE V-ring unit damaged or worn.

Replace ring pack - see point 8.2


See points 7.0 and 11.0!

In valves with packed stuffing boxes, tighten screw joint (42).

Tighten screw joint (42); replace packing


if necessary
See point 8.3.
See points 7.0 and 11.0!

Bellows defective in valves with bellow


seal.

Replace bellows unit - see point 8.4


See points 7.0 and 11.0!

Sealing surfaces of plug eroded or worn.

Replace plug - see point 8.5.


See points 7.0 and 11.0!

Sealing edge of seatring damages or worn.

Replace seatring (see point 8.5),


See points 7.0 and 11.0!

Seatring and/or plug dirty.

Clean internals of valve.


See points 7.0 and 11.0!

Pneumatic actuator not completely vented;


spring force not fully effective.

Vent actuator air chamber completely.


See points 7.0 and 11.0!

Actuator not powerful enough.

Install more powerful actuator.


Check service data.

flow in the closing direction

Compare the plug operation (mixing- or


diverting plug) with the application and if
necessary exchange the fittings or increase
actuator force.
Observe points 7.0 and 11.0 !

Caution: - Read point 11.0 prior to dismantling and repair work!


- Read point 7.0 before restarting the plant!

0040000093 4000

page 13

Operating and Installation Instructions


Control Valves Fig. 450/451

11.0 Dismantling the Valve


The following points must be observed beside the general principals rules and TRB 700 governing the
assembly work:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
- Have assembly work performed only by qualified personnel (see point 2.3).

12.0 Warranty
The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert
Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale
itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed
application.
No warranty claims can be made for any damage caused as the result of incorrect handling or disregard
of operating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and
other applicable codes of practice.
This warranty also does not cover any damage which occurs during operation under conditions deviating
from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is
excluded.
The warranty shall not cover maintenance work, installation of external parts, design modifications or
natural wear.
Any damage incurred during transport should not be reported to us but rather to the competent cargohandling depot, the railway company or carrier company immediately or else claims for replacements
from these companies will be invalidated.

Technology for the Future.


GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schlo Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com

page 14

0040000093 4000

EC declaration of conformity / Manufacturers declaration


EC declaration of conformity

as defined by
the Pressure Equipment Directive 97/23/EC and

Manufacturers declaration
as defined by
the Machinery Directive 98/37/EC
Herewith we declare,
ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, 33756 Schlo Holte-Stukenbrock
that according to the above mentioned Pressure Equipment Directive (PED) and Machinery Directive the below listed products comply and have been approved according to Category III , Module H
through Lloyds Register of Shipping (NB-No. 0525),
Mnckebergstr. 27, 20095 Hamburg
Certificate-No: 50003/1
3-way control valves
Type 450, 451, 423, 463, 483
Applied standards:
DIN EN 60534 part 1
VDI/VDE 3844 sheet 1
DIN 3840
If the supplied model is intended to be incorporated into machinery or assembled with other
machinery to constitute machinery covered by this directive and must be put into service until the
machinery into which it is be incorporated has been declared in conformity with the provisions of the
EC-Machinery Directive as amended by 98/37/EC.
Schlo Holte Stukenbrock, 13.12.2001

...................................................
(Brechmann, Managing director)

Operating and Installation Instructions


Thrust Actuator ARI-PREMIO

Contents
1.0 General information on operating instructions ..................................................................................................3
2.0 Notes on possible dangers .....................................................................................................................................3
2.1 Signicance of symbols ........................................................................................................................................................3
2.2 Safety-related denitions: .....................................................................................................................................................4
2.3 Qualied personnel ...............................................................................................................................................................4

3.0 Handling .................................................................................................................................................................4


3.1 Storage ..................................................................................................................................................................................4
3.2 Transport ...............................................................................................................................................................................4
3.3 Handling before installation..................................................................................................................................................4

4.0 Description .............................................................................................................................................................5


4.1 Field of application ...............................................................................................................................................................5
4.2 Method of functioning ..........................................................................................................................................................5
4.3 Technical data .......................................................................................................................................................................6
4.4 Diagram.................................................................................................................................................................................8
4.4.1 ARI-PREMIO 2,2 - 5 kN ....................................................................................................................................................8
4.4.2 ARI-PREMIO 12 - 15 kN ...................................................................................................................................................9
4.5 Parts list...............................................................................................................................................................................10
4.6 Dimensions .........................................................................................................................................................................11

5.0 Notes on dangers during installation, operation and maintenance ................................................................12

0040000107 2402 englisch

6.0 Installation ...........................................................................................................................................................12


6.1 General installation data .....................................................................................................................................................12
6.2 Manual operation ................................................................................................................................................................13
6.2.1 ARI-PREMIO 2.2 - 5 kN ..................................................................................................................................................13
6.2.2 ARI-PREMIO 12 - 15 kN .................................................................................................................................................14
6.3 Installation instructions for mounting to valves..................................................................................................................15
6.3.1 Mounting for valve-lift up to 30 mm (yoke version) ........................................................................................................15
6.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version) ....................................................................................16
6.4 Electrical connection...........................................................................................................................................................18
6.4.1 Wiring diagram ARI-PREMIO 2,2 - 5 kN........................................................................................................................18
6.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN.......................................................................................................................19
6.4.2.1ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor............................................................................................. 19
6.4.2.2ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor.................................................................................................. 20

6.4.3 Connection ........................................................................................................................................................................21


6.5 Settings................................................................................................................................................................................22
6.5.1 Torque and travel switches - standard feature...................................................................................................................22
6.5.2 Connection boards PA or NA (only 2.2 - 5 kN)................................................................................................................22
6.5.3 Travel switch .....................................................................................................................................................................23
6.5.3.1Installation of additional travel switches.......................................................................................................................................... 23
6.5.3.2Setting of standard travel switch (S3): ............................................................................................................................................. 25
6.5.3.3Setting the additional travel switches (S4/S5 and S24/S25) ............................................................................................................ 26

6.5.4 Potentiometers...................................................................................................................................................................26
6.5.4.1Installing the potentiometer.............................................................................................................................................................. 27
6.5.4.2Setting the potentiometer ................................................................................................................................................................. 28

6.5.5 Heating..............................................................................................................................................................................29
6.5.5.1Installation of heating....................................................................................................................................................................... 29

6.5.6 Electronic position indicator RI21 ....................................................................................................................................30


6.5.7 Electronic position controller ES11 ..................................................................................................................................30
6.5.8 Electronic position indicator (RI21) and position controller (ES11) together in the actuator..........................................31
6.5.9 Integrated temperature controller dTRON 16.1 ................................................................................................................32
6.5.9.1Installation of the dTRON 16.1........................................................................................................................................................ 32

6.5.10 Integrated reversing contactor.........................................................................................................................................33


6.5.10.1Installing the reversing contactor ................................................................................................................................................... 33
6.5.10.2Electrical connection with ES11 or dTRON 16.1 .......................................................................................................................... 33

6.5.11 Phase control relay..........................................................................................................................................................34


6.5.11.1Installing the phase control relay ................................................................................................................................................... 34

7.0 Starting up............................................................................................................................................................35


8.0 Care and maintenance ........................................................................................................................................35
9.0 Troubleshooting ...................................................................................................................................................35
10.0 Troubleshooting table........................................................................................................................................36
11.0 Dismantlement of thrust actuator....................................................................................................................36
12.0 Warranty ............................................................................................................................................................37
13.0 EC declaration of conformity ...........................................................................................................................38

Operating and installation instructions


Thrust actuator ARI-PREMIO

1.0 General information on operating instructions


These operating instructions contain information necessary to install and operate the thrust actuator
both safely and effectively.
If problems arise which cannot be solved with the aid of these operating instructions, please contact
the supplier/manufacturer for further information. These operating instructions comply with
applicable EN safety standards as well as regulations and codes of practice applicable in the Federal
Republic of Germany. If the electronic positioner is used outside the Federal Republic of Germany,
the operator or the person responsible for the system design must ensure that valid national codes of
practice are complied with.
The manufacturer reserves all rights to implement technical modifications and improvements at any
time.
The use of these operating instructions assumes the user is qualified as described under Section 2.3
"Qualified Personnel".
The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on possible dangers


2.1 Significance of symbols
Warning of general danger
Warning of dangerous voltage

Exposed to injury!
Dont touch the turning handwheel when the motor is running

Exposed to injury!
Dont put your hand into the up or downwards moving appliance

Danger when not observing the operating and installation instructions!


Before installing, operating, maintenance or dismantling read and observe the
instructions
Danger though voltage!
Before dismantling the hood, switch of the electrical source and secure against
turning on again

0040000107 2402

page 3

Operating and installation instructions


Thrust actuator ARI-PREMIO
2.2 Safety-related definitions:
The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.
DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and
/ or considerable damage to property can occur.
WARNING means that if the relevant information is disregarded, there is a danger of serious injury
and / or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or
damage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specifically emphasised such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product
documentation and on the device itself) must also be complied with to the fullest extent in order to
avoid faults which in turn can cause serious injury to persons or damage to property.

2.3 Qualified personnel


This refers to personnel possessing corresponding qualifications and familiar with the processes of
installing and assembling the product as well as with putting the product into service and operating
the same, e.g.
- Training or instruction or authorisation to switch on and off electric circuits and equipment/systems
and to disconnect, ground and identify the same in accordance with VDE 0100, the regulations
stipulated by the local electricity generating boards as well as technical safety standards.
- Instruction and obligation to comply with all regulations and requirements pertaining to use as well
as regional and in-house regulations and requirements, especially TRB 700.
- Training or instruction in accordance with technical safety standards in the use and maintenance of
pertinent safety equipment including job-safety equipment.
- Training in first-aid, etc.

3.0 Handling
3.1 Storage
- Storage temperature -20 to +70C dry, free of dirt
- Do not damage packing
- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport
- Transport temperature -20 to +70C
- Protect against external force (impact, vibration etc.).
- Do not damage packing.

3.3 Handling before installation


- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.
- Do not soil or damage type identification plate and wiring diagram on the controller.

page 4

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO

4.0 Description
4.1 Field of application
ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves requiring a
nominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN. The thrust actuators
are set to the thrust forces specified in the technical data. If supplied with the valve, the lift of the
thrust actuator will be set to the stroke distance of the valve.
Selection of the proper actuator version in alignment with the corresponding fitting as well as use of
the thrust actuator in accordance with the specified technical data is the responsibility of the systems
engineer.
Any use of the thrust actuator beyond the specified technical data or improper use of the actuator is
deemed to be not for the intended purpose.
The ambient conditions have to be conform to the actual electromagnetic compatibility directives.
Additional the compatibility to this directives has to be maintained in case of expansion or other
changing of the ambient conditions.

4.2 Method of functioning


The thrust actuator, fitted with a yoke or columns, is mounted to the valve.
Transfer of force is effected via a coupling safeguarded against torsion.
The torsion safeguarding feature also serves as a lift indicator.
The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear clamps
mounted to the column.
The electrical components are accommodated separately from the gearbox underneath a sealed hood,
thus being protected against operating and environmental effects.
Following removal of the hood, easy access is provided to the switchgear and indicating feature.
The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.
The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut and thus
performs a pull or push motion depending on the sense of rotation.
In the final positions of the valve, the spindle nut is pressed against a set of springs so as to produce
closing force.
The motor is switched off by means of two load-dependent switches and one stroke-dependent
switch. The load-dependent switches will also switch off the motor if foreign bodies have lodged
themselves between the valve seat and cone.
The load-dependent switches serve to protect the valve and thrust actuator against damage.

0040000107 2402

page 5

Operating and installation instructions


Thrust actuator ARI-PREMIO
4.3 Technical data
Type

ARI-PREMIO

Thrust force

kN

Stroke distance max.

mm/sec.

12.0

15.0

50

80

S1 - 100 % duty cycle; S4 - 80% duty cycle 1200 c/h

S1 - 100% ED;
S4 - 50% ED 1200 c/h

0.25

Motor voltage
Power consumptionW

5.0

mm

Duty classification in accordance


with DIN VDE 0530
Control speed

2.2

0.38

0.38

1,0
230V 50Hz

230V - 50Hz / 60Hz *


10.3

11.7

25.3

52.9

0.79

0.38

230V - 50Hz / 60Hz *


109

96

Torque switch

2 only, permanently wired,


switching capacity 10A, 250V~

2 pcs., permanently
wired
switching capacity 16A,
250V~

Travel switch

1 only, permanently wired,


switching capacity 10A, 250V~

1 pcs.,
permanently wired
switching capacity 16A,
250V~

Enclosure IEC 60529

IP 65

Max. permissible ambient


temperature

-20 C ... +70 C

Handwheel

Yes (rotating during operation)

Mounting position

Any. Exception: motor must not be suspended downwards

Gear lubricant

Weight kg

Klber Unigear LA02

5.4

* Control speed and power consumption are 20% higher at frequency of 60 Hz

page 6

Yes (engageable)

0040000107 2402

50/50-mix
Klber Isoflex NBU15
Ultra and
Klber Nontrop KR291
6.5

10,5

Operating and installation instructions


Thrust actuator ARI-PREMIO

Accessories
Type
Thrust force

ARI-PREMIO
kN

Additional travel switches


Additional travel switches for lowvoltage / electronic system
Potentiometer

2.2

5.0

12.0

15.0

2 additional travel switches, zero potential,


Switching capacity 10A, 250V ~
2 additional travel switches, zero potential, with gold contacts,
switching capacity max. 0,1A, 4-30V DC
max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt

Electronic position indicator RI 21

0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possible


Using the temperature controller, installation is only possible in the control cabinet

Electronic position controller ES 11

0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possible


Not compatible for use with the temperature controller.

Heating resistor

Additional voltages / frequencies

Standard-voltage connection board,


PA

Low-voltage connection board


(electronic system), NA

(with automatic switching)


230V-50Hz, 115V-50Hz, 24V-50Hz, 15 watt

24V - 50/60Hz
115V - 50/60Hz

24V - 50Hz
24V - 60Hz
115V - 50Hz
115V - 60Hz
230V - 60Hz

2 torque switches and 1 travel switch, zero potential,


for free wiring,
Switching capacity10A, 250V ~

--

2 torque switches and 1 travel switch,


for free wiring,

with gold contacts,


Switching capacity max. 01A, 4-30 VDC
Integrated temperature-controller
dTRON 16.1

24V - 50/60Hz
115V - 50/60Hz
3~400V - 50Hz
3~440V - 60Hz

--

Three-step temperature-controller in microprocessor-technology.


Control range: -200C to 850 C (resistance thermometer)
Voltage: 24V, 115V or 230V 50/60Hz
Compatible with resistance thermometers and thermocouples
(provided by customer), or standardized active current or voltage signals.

Integrated reversing contactor

--

Actuator with 400V-50Hz


and 440V-60Hz
Only 1 electronic module
possible!

Phase control relay

--

Only in addition with


integrated reversing contactor!

0040000107 2402

page 7

Operating and installation instructions


Thrust actuator ARI-PREMIO
4.4 Diagram
4.4.1 ARI-PREMIO 2,2 - 5 kN
Yoke Version

Column Version

Fig. 1
page 8

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
4.4.2 ARI-PREMIO 12 - 15 kN

Fig. 2

0040000107 2402

page 9

Operating and installation instructions


Thrust actuator ARI-PREMIO
4.5 Parts list
Designation

Designation

50.1

Gearbox

50.30

Driving spindle

50.1.1

Gearbox cover plate

50.31

Spindle safety feature

50.32

Torsion safety feature

50.2

Cable conduit fitting


2,2 - 5kN: 2 x PG11
12 - 15kN: 2 x PG13,5 / 1 x PG9

50.34

Bellow

50.35

Grub screw M6

50.4

Sealing plug 1 x PG11

50.36

Set collar

50.5

Gasket

50.37

Grub screw DIN 913-M3x5

50.6

Hood

50.38

Guide spindle

50.7

Hood seal

50.39

Hexagon nut DIN EN 24034-M5

50.8

Counter-sunk screw DIN 7991-M5x20

50.40

Synchronous motor, complete

50.9

Sealing washer DIN 125-5,3

50.41

Head cap screw DIN 912-M4

50.10

Column

50.42

Board support

50.12

Handwheel

50.43

Standard board

50.12.1 Turning handle of handwheel

50.45

Shift lever

50.14

Yoke

50.46

Washer

50.15

Flange

50.47

Wiring diagram sticker, standard

50.16

Spring washer DIN 128-A10

50.48

Connector, 3-pole (standard)

50.17

Hexagon head screw


DIN EN 24017-M10x30

50.50

Trip slide

50.51

Setting spindle for switch S3

50.52

Setting spindle for switch S4

50.53

Setting spindle for switch S5

50.18

Hexagon head screw


DIN EN 24017-M10x45

50.19

T-head bolt DIN 261-M12x40

50.54

Trip cam

50.20

Washer DIN 125-13

50.55

Lock washer DIN 6799-2,3

50.21

Spring washer DIN 128-A12

50.56

Spring PREMIO for trip slide

50.22

Hexagon nut DIN EN 24032-M12

50.57

Head cap screw


DIN 912-M4x10

50.23

Lift dial

50.58

Protective conductor terminal

50.24

Distance column

50.59

Head cap screw DIN 912-M4x6

50.25

Hexagon nut DIN 980-V-M16

50.87

Threaded bush

50.26

2-ear clamp (stroke indicator)

50.101 Connector, 8-pole

50.27

Coupling

page 10

0040000107 2402

ARI-PREMIO 2,2 - 5 kN
Nominal stroke max. 30 mm

Clearance required for


removal of hood

ARI-PREMIO 2,2 - 5 kN
Nominal stroke > 30 mm - 50 mm

Clearance required for


removal of hood

ARI-PREMIO 12 - 15 kN
Nominal stroke max. 80 mm

Clearance required for


removal of hood

X
236
256
271
286

L
633
653
668
683

h
max. 30 mm
max. 50 mm
max. 65 mm
max. 80 mm

Operating and installation instructions


Thrust actuator ARI-PREMIO

4.6 Dimensions

Fig. 3

0040000107 2402

page 11

Operating and installation instructions


Thrust actuator ARI-PREMIO

5.0 Notes on dangers during installation, operation and maintenance


DANGER!
Safe operation of the positioner is only ensured if it is installed, put into operation and maintained by
qualified personnel (refer to Point 2.3 "Qualified personnel"), while observing the warning notes
provided in these operating instructions. In addition, care must be taken to ensure that the general
equipment and safety regulations for electrical lines and installations are complied with and that
tools and protection devices are used professionally. The operating instructions for the electronic
positioner must be observed when carrying out all work on and when handling the electronic
positioner. Disregard of these instructions can result in injury to persons or damage to property.

6.0 Installation
6.1 General installation data
In addition to general installation guidelines, the following points are required to be observed:
- Existing operating instructions for valve.
- Complete valve with crossarm.
- Valve cone approximately in mid lift position - on no account supported inside a seat!
- Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricity
generating board.
- Conductor cross-section selected to correspond to the given drive power and existing line length.
- Mains fuse rating max. 6A.
- Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts intended for mounting
to the corresponding valve.
- Qualified personnel possessing knowledge of the regulations pertaining to the erection of power
installations.
- Ease of access to installation site.
- Adequate clearance space above the thrust actuator for removing the hood
(refer to point 4.6 Dimensions).
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must not exceed +70 C.

page 12

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
If installed outdoors, the thrust actuator must be provided with an additional cover to protect against
- rain,
- direct insulation,
- powerful draughts and
- dust.
In case of widely fluctuating ambient temperatures and high atmospheric humidity, your are
recommended to install a heating resistor to minimise condensation buildup in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
If installed with a horizontal connecting rod, the thrust actuator must be mounted so both yoke legs
or columns are on top of one another in the vertical plane (see fig. 4).

Correct

Incorrect

Fig. 4

6.2 Manual operation


6.2.1 ARI-PREMIO 2.2 - 5 kN
With the motor in the stationary state, the thrust actuator can be run in the open and closed state with
the handwheel firmly meshed with the gear.
Proceed as follows:
- Swing out lever (50.12.1) from handwheel (50.12).
- Turning in clockwise direction--> closes valve.
- Turning in counter-clockwise direction--> opens valve.
CAUTION !
In the manual operating mode pay careful attention in the final positions that the handwheel is
only turned to the point where the torque switch trips (audible click) as otherwise damage will
be caused to the thrust actuator! Since the handwheel always follows during motor-driven
operation (running indication), never operate by hand while the motor is running - potential
injury hazards!!!
Open

Close

Fig. 5
0040000107 2402

page 13

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.2.2 ARI-PREMIO 12 - 15 kN
With the motor in the stationary state, the thrust actuator can be run in the open and closed state with
the engageable handwheel.
Proceed as follows:
- Fold the turning handle out of the handwheel (A)
- Turn the handwheel slightly and push in the engaging button for manual mode (B) --> the button
engages
- Turning in clockwise direction --> closes valve
- Turning in counter-clockwise direction--> opens valve
The motor is no longer in mesh when the handwheel is engaged. The handwheel is automatically
disengaged when the motor starts and the handwheel is once more in mesh.

Engaging button
for manual mode

Open

Close

Fig. 6
CAUTION:
In the manual operating mode pay careful attention in the final positions that the handwheel is
only turned to the point where the torque switch trips (audible click) as otherwise damage will
be caused to the thrust actuator!

page 14

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.3 Installation instructions for mounting to valves
6.3.1 Mounting for valve-lift up to 30 mm (yoke version)

turn

Hexagon nut
Valve spindle

Hexagon nut
Valve spindle

Fig. 7
To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed as
follows:
- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A:

- Turn flat hexagon nut if not present on valve spindle.

Fig. A-B: - Slip coupling (50.27) over valve spindle.


- Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance
with setting dimension (Y) and lock with hexagon nut.
- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.
Fig. C:

- Place thrust actuator (50) on valve.


- Mount thrust actuator (50) on fitting with two T-head bolts (50.19), two washers
(50.20), two spring washers (50.21), two hexagon nuts (50.22).

Fig. D/E: - Swing out handwheel lever (50.12.1) and use it to move out the thrust actuator until the
driving spindle (50.30) comes to rest on the threaded bush (50.87).
Fig. F:

- Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure in
place using grub screw M6 (50.35).
- Run valve to lowest position.
- Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is in
alignment with tip of arrow mark on lift dial.
- Run valve to both final positions and check to ensure that these are safely reached
- Carry out electrical connection (refer to section 6.4.1).
- Set travel switch S3 (refer to section 6.5.3.2).

0040000107 2402

page 15

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version)

turn

Hexagon nut
Valve spindle

Hexagon nut
Valve spindle

Fig. 8
To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm, proceed
as follows:
- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A:

- Turn flat hexagon nut if not present on valve spindle.

Fig. A-B: - Slip coupling (50.27) over valve spindle.


- Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance
with setting dimension (Y) and lock with hexagon nut.
- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.
- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.
Fig. C:

- Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly.
- Screw distance column with 2-ear clamps on opposite side of handwheel into the flange
in such a way that one of the 2-ear clamps is situated above the torsion safety feature
(50.32) and the other below.
- Screw the other distance column into the flange likewise.
- Place thrust actuator (50) with distance columns onto valve and fix into position with
two self-locking hexagon nuts (50.25).

Fig. D/E: - Fold out turning handle of handwheel (50.12.1), slightly turn the handwheel and press
in the engaging button for manual mode (only 12 - 15 kN) (button engages). Having
done this, move out the thrust actuator until driving spindle (50.30) comes into contact
with threaded bush (50.87).

page 16

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
Fig. F:

- Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure using grub
screw M6 (50.35).
- Move the valve to the lowest position.
- Press 2-ear clamps (50.26) into position according to the stroke so they cannot slip,
with the bottom clamp in the lowest valve position located directly below torsion safety
feature (50.32) and the top clamp in the highest valve position located directly above
the torsion safety feature.
- Move the valve to both travel positions and check that it reaches them reliably.
- Fold turning handle of handwheel (50.12.1) back in.
- Make the electrical connection (see points 6.4.1 and 6.4.2). The engaging button for
manual mode (only 12 - 15 kN) disengages when the motor starts up.
- Set standard travel switch S3 (see point 6.5.3.2).

0040000107 2402

page 17

open

open

3-way valve
with diverting plug

open

open

3-way valve
with mixing plug

open

Fig. 9

0040000107 2402

Option NA:
same design but no RC circuit
and switches with gold contacts
(Switching capacity 0.1A, 4-30VDC)

Travel switch for traveling the stroke distance


in opening direction
Electronic position indicator

WE
(S3)
RI 21

Low-voltage connection board, zero potential


Standard-voltage connection board,
zero potential
Potentiometer
Travel switch, zero potential
Electronic temperature-controller dTRON 16.1

NA
PA
POT
WE
TTR

ES 11 Electronic position controller

Torque switch

DE

actual
external
set point input value input

interface

Heating resistor

binary input 2/
output 5

HZ

power
supply

output 1
(K1)
output 2
(K2)

page 18

closed

Straightway valve

accessoires

Operating and installation instructions


Thrust actuator ARI-PREMIO

6.4 Electrical connection

6.4.1 Wiring diagram ARI-PREMIO 2,2 - 5 kN

0040000107 2402

external
reversing
contactor

Please check the operating direction


of the actuator !

In all external reversing circuits the torque


switches S1 and S2 have to be used to
switch off the actuator motor.

External reversing contactor:


L1, L2, L3 - actuator spindle drives in
L3, L2, L1 - actuator spindle drives out

open

closed

Straightway valve

B-AB open

A-AB open

3-way valve
with mixing plug

AB-A open

AB-B open

3-way valve
with diverting plug

Wire connections of the different valve types

Travel switch for traveling the stroke


distance in opening direction
WE
(S3)

Low-voltage connection board,


zero potential
Standard-voltage connection
board, zero potential
Travel switch, zero potential

Reversing contactor
Phase control relay

WS
PR

TTR Temperature-controller

WE

POT Potentiometer

PA

NA

ES 11 Electronic position controller

RI 21 Electronic position indicator

Torque switch

actual value
input

DE

Option

external set
point input

interface

Heating resistor

binary input 2/
output 5

HZ

power
supply

output 1
(K1)
output 2
(K2)

Accessories

Operating and installation instructions


Thrust actuator ARI-PREMIO

6.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN


6.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor

Fig. 10

page 19

Fig. 11

page 20

0040000107 2402

3-step input signal

3-step input signal

Please check the operating direction


of the actuator !

Connect 3 phases L1, L2, L3 only here

Accessories WS

Connect 3 phases L1, L2, L3 only here

Accessories WS + PR

open

closed

Straightway valve

B-AB open

A-AB open

3-way valve
with mixing plug

AB-A open

AB-B open

3-way valve
with diverting plug

Wire connections of the different valve types

Operating and installation instructions


Thrust actuator ARI-PREMIO

6.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor

Operating and installation instructions


Thrust actuator ARI-PREMIO
DANGER!!!
The processes of mains connection and putting the thrust actuator into service call for
specialised knowledge of power installation erection (VDE 0100), knowledge of regulations for
the prevention of accidents and the specific conditions for putting this thrust actuator into
service. Such work may only be carried out by suitably qualified personnel in accordance with
section 2.3 "Qualified Personnel". The supply line for connecting up the thrust actuator must
be in the dead state i.e. disconnected from the mains while connection work is being carried
out. After being disconnected, the mains power must be prevented from being switched back
on again accidentally.
Failure to observe these instructions may lead to death, grievous bodily injury or substantial
property damage!
6.4.3 Connection
To connect the thrust actuator up to the electrical power supply, proceed as follows:
- Run the thrust actuator a few mm out of the lower final position applying the manual mode.
- Loosen countersunk screw in hood, carefully remove hood in upward direction.
- Screw out one of the two cable inlets and re-assemble in the same way without the supplied blank
flange.
- Insert the connection line through this cable inlet until sufficient conductor length is available up to
the corresponding terminals; then tighten the cable inlet until the connecting cable is clamped in
place inside it.
- Strip connecting cable approx. 1-1.5cm above cable inlet.
- Strip the individual conductors approx. 5mm away from the end and fit with conductor end sleeves.
- Connect protective conductor of connecting cable up to protective conductor terminal of thrust
actuator.
- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator terminal
strip.
- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator terminal strip.
- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal strip.
- Place hood on carefully from above and mount firmly onto thrust actuator with countersunk screw
and rubber gasket.
- Connect supply line to mains and run thrust actuator to each of the final positions so as to check
whether the final-position travel switches effect switching off, also checking to see whether the
direction of movement on the thrust actuator corresponds to the desired direction.
- If the directions of movement are contrary to those desired, the pulse lines governing the move-in
and move-out connecting rod will need to be exchanged.

0040000107 2402

page 21

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5 Settings
DANGER !!!
The thrust actuator may only be operated for a short time without the hood for unavoidable
setting operations to the potentiometers, travel switches and the electrical options. While these
operations are in progress, the thrust actuator has hazardous, live, uninsulated parts exposed
as well as moving and rotating parts. Improper execution of the setting operations or lack of
care may cause death, grievous bodily injury or substantial property damage. Only suitably
qualified personnel must be allowed to perform these operations (refer to section 2.3
"Qualified Personnel") . Operation of the thrust actuator without the hood for any purpose
other than that described above is strictly prohibited.
6.5.1 Torque and travel switches - standard feature
As standard, thrust actuators are equipped with a load-dependent travel switch for the closing
direction (S1), a load-dependent travel switch for the opening direction (S2) and a stroke-dependent
travel switch for the opening direction (S3).
The load-dependent travel switches (S1, S2) switch off the motor as soon as the factory-set thrust
force is attained.
NOTE: The settings of the load-dependent travel switches must on no account
whatsoever be changed!
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke is
attained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent travel switch
S3 is set in such a way that the motor of the thrust actuator is switched off as soon as the maximum
valve-lift is attained.
If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel switch S3 is
set in the opening direction in the trip slide to such a downward extent that the upper final position of
the valve is attained prior to travel switch S3 being reached, thus causing the load-dependent travel
switch S2 to switch off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the board.
If the standard travel switches are to be integrated directly into the facility control system, the
standard board can be replaced by optional boards PA or NA (only 2.2 - 5 kN).
6.5.2 Connection boards PA or NA (only 2.2 - 5 kN)
On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/S23 do not
reveal interlock-controlled circuitry and can be integrated individually into the facility control
system.
The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as double-throw
contacts, are - in the case of these boards - brought out on terminals 40-48 and can be freely
connected.
The switches on the PA optional board (standard-voltage connection board) are designed for
switching capacities of up to 10A, 250V AC.
The switches on the NA optional board (low-voltage connection board) are designed for switching
capacities of up to 0.1A, 4-30V (gold contacts).
The optional boards may only be installed at the factory due to the switching points of the loaddependent switches having to be reset following installation of these boards!

page 22

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
CAUTION !
When using optional boards PA or NA, it must be warranted - due to the operators individual
circuitry- that, when switching the load-dependent travel switches S11/21, S12/S22 and S13/
S23 the motor of the thrust actuator comes to a standstill without delay.
This function is not provided for on the optional boards PA and NA in the supplied state!
6.5.3 Travel switch
The thrust actuators can be equipped with an additional stroke-switch board containing two travel
switches (double-throw contact S4 and S5).
These switches can be set on infinitely variable lines over the entire stroke distance in both lift
directions and integrated at will into the facility control system (no interlock-controlled circuitry).
The maximum switching capacity of the switches (refer to section 4.3 Technical Data) must not be
exceeded.
For low voltage (refer to section 4.3 Technical Data), the additional travel switches are supplied with
gold contacts (option: low-voltage travel switch).
6.5.3.1 Installation of additional travel switches
To install additional travel switches, proceed as follows.
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen countersunk screw in hood, carefully remove hood.
- Disconnect motor plug and mains connection plug from board.
- Carefully ease open the lock washer (50.56) (open ends) with a screw driver while pulling the trip
slide (50.50) upwards from the board support.
- Remove trip slide (50.50) from board support by pulling upwards.
- Loosen head cap screws (50.57) on board support and remove this from gearbox (only necessary on
5kN thrust actuator).
- Insert stroke-switch board (50.61) in board support (50.42) and fix in place using the supplied
screws (50.44).
- Mount board support loosely on gearbox cover plate with two head cap screws (50.57) (only
necessary on 5kN).
- Push trip slide (50.50) back into board support (50.42) from above and onto the guide spindle
(50.38).
- Align board support (50.42) on gearbox cover plate in such a way that the guide spindle (50.38) is
centrally situated in the borehole of the board support (50.42); then screw down tightly on gearbox
cover plate (only necessary on 5kN).
- Mount the trip slide (50.50) so that the spring (50.56) clips into the groove of the guide spindle
(50.38).
- Insert 6-pole connector (50.62) in jack strip of stroke-switch board.
- Proceed to strip the connecting cable that has been led in through the cable inlet and fastened, and
connect the individual conductors to the terminal strip in accordance with the desired circuitry and
the wiring diagram.

0040000107 2402

page 23

Operating and installation instructions


Thrust actuator ARI-PREMIO
- Set switch points on travel switches in accordance with section 6.3.2. Setting the travel switches
- Insert motor connection plug in jack strip (50.43.4) provided for the purpose.
- Insert mains connection plug in jack strip (50.43.3) provided for the purpose.
- Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket and
countersunk screw.

Fig. 12 Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN


Designation

Designation

50.38

Guide spindle

50.52 Setting spindle for switch S4

50.42

Board support

50.53 Setting spindle for switch S5

50.43.3

Jack strip for mains connection

50.54 Trip cam

50.43.4

Jack strip for motor connection

50.56 Spring

50.44

Self-tapping screw

50.57 Head cap screws DIN 912-M4x10

50.50

Trip slide

50.61 Stroke-switch board

50.51

Setting spindle for switch S3

50.62 Connector, 6-pole


(option: travel switch)

page 24

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.3.2 Setting of standard travel switch (S3):
On delivery of the thrust actuator, the standard travel switch (S3) is already set to the existing valvelift and the setting spindle for the travel switch S3 (50.51) is sealed with screw glyptal.
This setting needs no changing for normal operation.
If reinstalling the thrust actuator on a straight-way valve, the travel switch S3 needs to be set
as follows:
Move valve out of the lowest position so as to run valve-lift to up position.
Using a screw driver, proceed to turn setting spindle for switch S3 (50.51) until the trip cam (50.54)
arriving from below trips the switch (audible click).
Run thrust actuator briefly in closing direction and then in opening direction once more, checking to
see whether the thrust actuator is switched off at the desired point (nominal lift).
If need be, correct the setting as described.
If reinstalling the thrust actuator on a three-way valve, the travel switch S3 needs to be set as
follows:
- Run valve in both final positions and check in each final position whether the valve switches off via
the load-dependent switch.
- Carry out a check in the top final position the see whether, after switching off the thrust actuator,
the trip cam (50.54) of the travel switch S3 is situated below switch S3 and has not tripped the
latter. If the trip cam (50.54) is situated above the travel switch S3 or trips the same, the setting
spindle governing the travel switch S3 (50.51) needs to be turned until the trip cam is situated
below travel switch S3 without tripping it.
- Run the thrust actuator in both final positions once more and check whether thrust actuator switches
off in both final positions via the load-dependent switches.
- If need be, correct the setting as described above.

0040000107 2402

page 25

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)
The two additional travel switches can be freely set in both lift directions for indicating certain valve
positions.
To do this, proceed as follows:
- Run valve to desired position due to be indicated by the corresponding switch.
- Proceed to turn the setting spindle belonging to the appurtenant switch until the switch is tripped
(audible click).
- Run thrust actuator briefly in both directions, checking and, if need be, correcting the setting.
The actuating feature on the travel switches is designed in such a way that both travel switches can
be overrun in both directions.
Standard design:
For that reason, care should be taken on additional travel switches to see that the actuating state of
the switches remains active only for a short time while the thrust actuator continues to run and that
switching back takes place afterwards.
The actuating state of the travel switches remains in force over a lift of 4 mm.
Special design:
At additional travel switches with extended switch levers, the actuating state of the travel switches
remains in force over a lift of 49 mm.
6.5.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility control system
or for the options - electronic position controller ES11 or electronic position indicator RI21
A maximum of 2 potentiometers can be installed (= 1 double potentiometer).
The potentiometers can be supplied with different resistance values (refer to section 4.3 Technical
Data).
For the electronic position controller ES11 and the electronic position indicator RI21 use must be
made solely of 1000 ohm potentiometers.
Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by means of
transmission determined in respect of each valve-lift between the toothed rack on the trip slide and
the pinion on the potentiometer shaft.
Use must only be made of the pinion specified for the valve-lift.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer is
assembled and set ready for operation.
To achieve optimal electromagnetic compatibility it is recommended to use shielded cables for
connecting potentiometers or standardized active current or voltage signals.

page 26

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.4.1 Installing the potentiometer
If retrofitting the potentiometer, proceed as follows:
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen countersunk screw in hood, carefully remove hood.
- Plug in the flat connectors on grey potentiometer cables onto the middle connector pins, those of
the red cables onto the upper connector pins and those of the yellow cables onto the lower
connector pins of the potentiometer (Fig 12).
- Insert the potentiometer into the guide in the way that the pinion (50.73) of the potentiometer
meshes with the gear stick of the trip slide.
- With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand window of board
support (50.42) above the potentiometer guide, insert into the guide between the slide block and
the potentiometer guide and hook into the cut-out below the potentiometer.
With a valve lift between 30 mm and 50mm, hook spiral spring (50.70) into the right-hand window
(for 12 - 15kN middle window) above the potentiometer guide, insert into the guide between the
slide block and the potentiometer guide and hook into the cut-out below the potentiometer.
With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70) into the middle window in
board support (50.42) above the potentiometer guide, insert into the guide between the slide block
and the potentiometer guide and hook into the cut-out below the potentiometer.
- Check to see whether pinion (50.73) is pressed into toothed rack by spiral spring (50.70) and is
positioned free from backlash.
- If this is not the case, remove spiral spring (50.70), readjust by bending a little, and place back in
position again.
- Screw jack strip of connecting cable (50.68) to board support (50.42) with two self-tapping screws
(50.69) (single potentiometer connectors 25-27).
- Insert additional 3-pole connector (50.74) in jack strip of connecting cable (50.68).
- Set potentiometer (refer to section 6.5.4.2).
- Place hood carefully onto thrust actuator and fasten it on the actuator with rubber gasket and
countersunk screw.
red

grey
red
grey
yellow
yellow

Fig. 13

0040000107 2402

page 27

Operating and installation instructions


Thrust actuator ARI-PREMIO

Fig. 14: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN


Designation
Designation
50.42
Board support
50.69
Self-tapping screw
50.47
Circuit-diagram sticker
50.70
Spiral spring (option: potentiometer)
50.67.1 Hexagon nut
50.71
Slide block (option: potentiometer)
50.67.2 Tooth lock washer
50.72
Set collar
50.67.3 Potentiometer
50.73
Pinion (selection depends on valvelift 20, 30, 50, 65 or 80 mm)
50.67.4 Washer from PA
50.74
Connector, 3-pole
(option: potentiometer)
50.68
Connecting cable for option:
50.95
Spring washer
potentiometer
6.5.4.2 Setting the potentiometer
To set the potentiometer, proceed as follows:
- Move thrust actuator to closing position.
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Using a screw driver, turn slotted potentiometer shaft in counter-clockwise direction until reaching
the travel stop. This places the potentiometer in the initial position (approx. 0 ohm).
- For checking purposes, the resistance of the potentiometer needs to be measured using an
ohmmeter.
- Measure resistance on potentiometer 1 between terminals 25 and 26.
- Measure resistance on potentiometer 2 between terminals 28 and 29.
- In this position of the actuator, the measured value should be approx. 0 ohm.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
- The resistance values thus measured need to be taken into account for the settings to the facility
control system.

page 28

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.5 Heating
A heating resistor can be fitted as a means of protection against the formation of condensation water
in cases involving widely varying ambient temperatures and high atmospheric humidity (outdoor
use). The heating resistor is self-regulating so that a continuous supply of current merely needs to be
connected up.
6.5.5.1 Installation of heating
On principle, the heating can be combined with all options. It is completely mounted on a holding
bracket.
If electronic system ES11 or RI21 is already installed, unscrew the electronic system from the
holding bracket, remove it, install the heating and attach the electronic system to the holding bracket
for the heating.
To install the heating proceed as follows:
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen countersunk screw in hood, carefully remove hood.
- Using the supplied screws, mount complete heating (on holding bracket) at the point on the gearbox
cover plate provided for the purpose. (Fig. 16).
- Lead continuous-current cable (mains voltage = rated voltage of heating) through cable inlet into
thrust actuator and fix in place with inlet.
- Strip continuous-current cable approx. 1-1.5cm above cable inlet.
- Strip individual conductors approx. 5mm away from the end and provide with conductor end
sleeves.
- Lay the individual conductors in such a way that they do not come into contact with moving parts.
- Connect the individual conductors up to the connection terminal block in accordance with the
wiring diagram.

Mounting thread M3
for heating reisistor

Mounting thread M3
for thermal circuit breaker
Mounting thread M4
for options ES11 and RI21

Mounting thread M3
for jack strip

Fig. 15
50.83.1
50.83.2
50.83.3

Designation
Holding bracket (Option:
heating)
Head cap screw DIN 84-M3x8
Thermal circuit breaker

50.83.4

Designation
Jack strip

50.83.6
50.83.10

Connector, 2-pole
Heating resistor

0040000107 2402

page 29

Operating and installation instructions


Thrust actuator ARI-PREMIO

Fig. 16: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN


Designation
Designation
50.67
Potentiometer
50.81
Head cap screw
DIN912 - M4x8
50.78/79 Option ES11 or RI21
50.82
Head cap screw
DIN912 - M4x12
50.80
Holding bracket
50.83
Heating

6.5.6 Electronic position indicator RI21


The electronic position indicator RI21 converts the resistance of the 1000 ohm potentiometer
corresponding to the lift into an optional output control signal 0 (2) ...10V DC
or 0 (4) ...20mA DC. For installing and setting the electronic position indicator RI21 the operating
instructions applicable to this unit must be observed in the appropriate valid version. The
corresponding operating instructions are supplied with each unit.
6.5.7 Electronic position controller ES11
The electronic position controller ES11 converts continuous input control signals 0 (2) ...10V DC or
0 (4) ...20mA into a 3-point output signal for the motor, in which case interrogation of the valve
position takes place via a 1000 ohm potentiometer. For installing and setting the electronic position
controller ES11 the operating instructions applicable to this unit must be observed in the appropriate
valid version. The corresponding operating instructions are supplied with each unit.

page 30

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.8 Electronic position indicator (RI21) and position controller (ES11) together in the
actuator
Except or the 5 kN, 12 kN and 15 kN type in 24V version, the electronic position indicator RI21 and
the electronic position controller ES11 can be build-in together in the ARI-PREMIO.
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI21 and ES11 proceed as follows:
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen counter-sunk screw in hood, carefully remove hood.
- Mount the electronic units by using the specific installation kits (Fig. 17).

Bild 17: Switchgear and indicating feature ARI-PREMIO 2,2 - 5 kN


Designation
Designation
50.67
Potentiometer
50.82
Head cap screw DIN912 - M4x12
50.78/79 Option ES11 or RI21
50.106
Metal sheet ES11 and RI21
50.81
Head cap screw DIN912 - M4x8
50.108
Distance bold

0040000107 2402

page 31

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.9 Integrated temperature controller dTRON 16.1
The integrated temperature controller controls temperatures, which are measured by input-connected
temperature sensors, to a manual given setpoint by means of a three-step output connected with the
actuator.
6.5.9.1 Installation of the dTRON 16.1
The dTRON 16.1 can be mounted in the ARI-PREMIO as a complete unit with a mounting kit.
It cannot be combined with ES11.
To install the dTRON 16.1 proceed as follows:
In addition to 6.4.2 Connection, the electrical connection of the dTRON 16.1 has to be done in the
following way:
- Mount the temperature controller on the gear plate by using the specific installation kit (Fig. 18).
- Plug in the connector X2 of the dTRON 16.1 to the plug-in connector X1 (1/N, 11, 14) of the
actuator terminal (Fig. 6).
- Connect the signal input and the individual wanted additional functions according the wiring
diagram (Fig. 6) to the dTRON 16.1.
- Connect the power supply to the dTRON 16.1 according to the wiring diagram (Fig. 6).
- For changing the working direction to heating signal = extending driving spindle, just change the
wires on the connectors 11 and 14.

50.81
50.97
50.98
50.99
50.100

Designation
Head cap screw DIN912 - M4x8
Temperature controller dTRON 16.1
Fixing bracket (option dTRON)
Holding bracket (option dTRON)
Self-locking nut (option dTRON)

Fig. 18: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

page 32

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO
6.5.10 Integrated reversing contactor
The integrated reversing contactor is actuated using a 3-step input signal.
The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction of rotation
of the three-phase motor.
6.5.10.1 Installing the reversing contactor
The reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a mounting
kit.
The reversing contactor can only be combined with one of the ES11, RI21 or temperature controller
options. It is also possible to install the heating and the phase control relay.
Proceed as follows to install the reversing contactor:
Switch off the mains voltage and take measures to prevent it being switched back on inadvertently.
The electrical connection procedure as described in 6.4.3 Connection is supplemented by the
following steps:
- Use the mounting kit to attach the reversing contactor to the gear plate (fig. 19).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in fig. 11.
- Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor without a
phase control relay.
- Refer to 6.5.11 Phase Control Relay regarding connecting with a phase control relay.

6.5.10.2 Electrical connection with ES11 or dTRON 16.1


Modify the 3P output cable of the ES11 or the dTRON 16.1 as follows:
- Remove plug X25.
- Strip off the outer cable insulation down to about 18 cm.
- Connect the individual conductors as follows:
Black (L)
S2/14
Brown (L)
S1/11
Blue (1/N)
K1/A2, K2/A2
CAUTION:
The thrust actuator may be damaged if phases L1, L2 and L3 are not connected correctly and
no phase control relay is fitted!

0040000107 2402

page 33

Operating and installation instructions


Thrust actuator ARI-PREMIO

50.57

Designation
Head cap screw DIN 912 - M4 x 10

50.59
50.81
50.102
50.103
50.105
50.107

Head cap screw DIN 912 - M4 x 6


Head cap screw DIN 912 - M4 x 8
Reversing contactor
Fixing plate (option reversing contactor)
Phase control relay
Bracket (option phase control relay)

Fig. 19: Switchgear and indicating feature ARI-PREMIO 12 - 15 kN


6.5.11 Phase control relay
The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The reversing
contactor is only activated by the phase control relay providing phases L1, L2 and L3 are connected
correctly. This protects the thrust actuator.
6.5.11.1 Installing the phase control relay
The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is only
possible to use the phase control relay in conjunction with the reversing contactor. It cannot be
combined with the dTRON 16.1 temperature controller in the actuator.
Proceed as follows to install the phase control relay:
Switch off the mains voltage and take measures to prevent it being switched back on inadvertently.
The electrical connection procedure as described in 6.4.3 Connection and 6.5.10 Integrated
Reversing Contactor is supplemented by the following steps:
- Attach the phase control relay next to the reversing contactor (fig. 19).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in fig. 10.

page 34

0040000107 2402

Operating and installation instructions


Thrust actuator ARI-PREMIO

7.0 Starting up
DANGER!
Check the following before starting up a new system or restarting a system after repairs or
conversion:
- Correct completion of all installation/assembly work!
- Circuits of the system in accordance with DIN VDE regulations and regulations of the
relevant power supply company as well as compliance with all safety regulations, especially
TRB 700.
- hood of thrust actuator assembled.
- Start up only by qualified personnel (see 2.3).
While in operation, the thrust actuator has moving and rotating parts as well as being
integrated in an electrical network system. Improper handling or failure to observe the
operating instructions or the valid regulations may lead to death, grievous bodily injury or
substantial property damage!
When placing into service proceed as follows:
- Using the handwheel, run the thrust actuator to approximately mid lift position.
- Apply brief pulses to the thrust actuator for each direction of movement and check whether the
directions of movement correspond to those desired. If this is not the case, the pulse lines
governing the opening and closing action must be exchanged on the thrust actuator.
- Run thrust actuator to the final position in each direction of movement and check whether it
switches off automatically and whether all externally moving parts are able to move freely.
- If failing to function properly, check all installation and setting work previously carried out,
correcting if necessary, and afterwards place into service once again.

8.0 Care and maintenance


The thrust actuator requires very little maintenance. Accordingly maintenance in specified intervals
is not necessary.
Depending on the conditions governing use, the maintenance and maintenance-intervals have to be
defined by the operator (see TRB 700).
The thrust actuator must not be cleaned with high-pressure equipment or aggressive solvents or
detergents injurious to health or highly inflammable.
During and after cleaning, an inspection should be carried out of the sealing points on the thrust
actuator.
If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements must be
repaired.

9.0 Troubleshooting
In the event of malfunctions or disturbances in operation, first check whether the installation and
adjustment work has been carried out and concluded in accordance with these operating instructions.
Compare the data referring to operating voltage, actuating signal and temperature to the data
specified on the layout drawing of the control system. Also check whether the given operating
conditions correspond to those specified in the data sheet or to the technical data specified on the
type identification plate.

DANGER!
All relevant safety regulations must be observed when carrying out the troubleshooting procedure,
especially TRB 700.
Contact the supplier/manufacturer if faults cannot be rectified on the basis of the following
troubleshooting table.

0040000107 2402

page 35

Operating and installation instructions


Thrust actuator ARI-PREMIO

10.0 Troubleshooting table


During the process of trouble shooting, all safety regulations previously mentioned and
corresponding to the various operations must definitely be observed!!
Fault
Thrust actuator fails to move

Possible Causes
Power failure
Fuse has blown
Thrust actuator not properly
connected
Short circuit due to:

Remedy
Ascertain and eliminate cause
Replace fuse
Rectify connection on thrust actuator
in accordance with wiring diagram
Ascertain exact cause,

- moisture

- Dry the thrust actuator and eliminate


leakage
- Rectify connection on thrust actuator
in accordance with wiring diagram
- Check whether the mains voltage
agrees with the voltage specified on
the rating plate. Have motor
changed.
Insert connector firmly in jack strip
thus affected

- wrong connection
- motor has burned out

Connector contacts not plugged in/


not properly plugged into jack strip

Thrust actuator alternates between


clockwise and counter-clockwise
rotation
Thrust actuator fails to run to final
positions and also produces chatter

Periodic failure on thrust actuator


Thrust actuator is switched off in
opening direction prior to loaddependent switch (three-way
valve)

(Only for 12 - 15 kN)


Handwheel is still engaged and
does not disengage when the motor
starts up

Unscrew the motor mounting


screw closest to the cable feedthrough. (Manual release of the
handwheel disengagement
mechanism.)

Motor operating capacitor defective

Have motor operating capacitor


replaced

Load-dependent travel switches out of


adjustment / defective
Voltage drop due to excessively long
connecting cables or inadequate
conductor cross-section
Mains fluctuations beyond
permissible tolerance travels
System pressure too high
Loose connection on feedline
Travel switch S3 not set
corresponding to use

Remove thrust actuator and send to


factory for repair
Lay connecting cables in accordance
with requisite output
Arrange for "clean" mains system
within requisite tolerances
Reduce system pressure
Tighten connections on terminal strips
Set travel switch S3 in accordance
with operating instructions

11.0 Dismantlement of thrust actuator


In addition to general installation guidelines, the following points are required to be observed:
- Dismantlement of the thrust actuator from the fitting must only to be carried out by suitably
qualified personnel (refer to section 2.3).
- Regard TRB 700.
- The supply line for connecting up the thrust actuator must be in the dead state i.e. disconnected
while dismantlement work is being carried out. After being disconnected, the mains power must be
prevented from being switched back on again accidentally.
- The system must be run down (depressurised state) as the valve cone is not held without the thrust
actuator and would thus be conducted by the system pressure.
- Valve cone approximately in mid lift position - on no account supported inside a seat!
0040000107 2402

page 36

Operating and installation instructions


Thrust actuator ARI-PREMIO
To dismantle the thrust actuator proceed as follows:
- Loosen counter-sunk screw in hood, carefully remove hood.
- Disconnect all cables led into thrust actuator from outside and remove from thrust actuator.
- Place hood on carefully from above and fix in place with counter-sunk screw and rubber gasket.
- Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety feature.
- Loosen clamping bolts connecting the thrust actuator to the fitting.
- Remove thrust actuator from valve.

12.0 Warranty
The extent and period of warranty cover are specified in the "Standard Terms and Conditions of
Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract
of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed
application.
No warranty claims can be made for any damage caused as the result of incorrect handling or
disregard of operating and installation instructions, accident prevention regulations, EN, DIN, VDE
standards and other applicable codes of practice.
This warranty also does not cover any damage which occurs during operation under conditions
deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is
excluded.
The warranty shall not cover maintenance work, installation of external parts, design modifications
or natural wear.
Any damage incurred during transport should not be reported to us but rather to the competent
cargo-handling depot, the railway company or carrier company immediately or else claims for
replacements from these companies will be invalidated.

Technology for the Future.


GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schlo Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com

0040000107 2402

page 37

Operating and installation instructions


Thrust actuator ARI-PREMIO

13.0 EC declaration of conformity


EC declaration of conformity
as defined by
Directive about electromagnetic compatibility 89/336/EEC and the
EG-Low voltage directive 73/23/EEC

Declaration of the manufacturer


as defined by
the Machinery Directive 98/37/EC
Herewith we declare,
ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, 33756 Schlo Holte-Stukenbrock
that the supplied model of
electric thrust actuator ARI-PREMIO
in the delivered version complies with the following regulations:
- Directive about electromagnetic compatibility 89/336/EEC
(amended by 92/31/EEC and 93/68/EEC)
Applied harmonized standards:
EN 55011; EN 50081-1; EN 50082-2
- EG-Low voltage directive 73/23/EEC
(amended by 93/68/EEC)
Applied harmonized standards:
EN 60204-1, EN 60335-1, EN 60730-1
- EG-Machinery Directive 98/37/EC
Applied harmonized standards:
EN 292-1; EN 292-2; EN 294; EN 349; EN 60204-1
The supplied model is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must be put into service until the machinery
into which it is be incorporated has been declared in conformity with the
provisions of the directive as amended by 98/37/EC.

Schlo Holte-Stukenbrock, 15.04.1999

........................................................
(Brechmann, Managing director)

0040000107 2402

page 38

Revision 0711
House style change

Represented by

VAF Instruments B.V.

Specifications subject to change without notice.

Vierlinghstraat 24, 3316 EL Dordrecht, The Netherlands

Agents and distributors in more than 50 countries.

P.O. Box 40, 3300 AA Dordrecht, The Netherlands


T +31 (0) 78 618 3100, F +31 (0) 78 617 7068
sales@vaf.nl, www.vaf.nl