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Modbus with FO
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Foundation Fieldbus
Operation instructions
..
..
.
Operation instructions
Reference documents:
Manual (Operation and setting) AUMATIC AC 01.1.
Can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(addresses from page 70).
Table of contents
Page
1.
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.
1.2.
1.3.
1.4.
1.5.
2.
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.
2.2.
Name plate
Short description
3.
3.1.
3.2.
3.3.
Transport
Storage
Packaging
4.
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.
4.2.
4.2.1
4.2.2
4.3.
4.3.1
4.4.
Handwheel fitting
Multi-turn actuator mounting to valve/gearbox
Output drive types B1, B2, B3, B4, B, and E
Output drive type A
Accessories (option)
Protection tube for rising valve stem
Mounting positions of the local controls
5.
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.
5.2.
5.3.
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
General notes
Connection with AUMA plug/socket connector (S, SH, SE)
Accessories for electrical connection (option)
Controls mounted to wall bracket
Parking frame
Protection cover
Double sealed intermediate frame
Ground connection, external
6.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.
6.2.
6.2.1
6.2.2
6.3.
6.3.1
6.3.2
6.4.
Manual operation
Motor operation
Local operation
Operation from REMOTE:
Menu navigation via push buttons (for settings and indications)
Short overview: functions of the push buttons
Structural design and navigation
Language change in the display
4
5
6
7
7
8
10
11
11
11
12
13
13
14
16
16
17
18
19
22
22
23
23
23
23
24
25
25
25
26
26
27
28
Operation instructions
7.
Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1.
7.1.1
7.1.2
7.2.
7.3.
8.
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.
8.2.
9.
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.1.
9.2.
9.3.
9.4.
9.4.1
9.4.2
9.4.3
9.5.
9.6.
9.8.
9.11.
10.
Corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
30
30
31
32
32
33
33
35
38
41
44
44
45
45
46
46
47
49
50
50
50
50
51
51
52
53
54
55
55
56
11.
11.1.
11.2.
11.3.
12.
12.1.
12.2.
13.
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
14.
Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14.1.
57
58
58
60
62
68
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.
Safety instructions
1.1.
Operation instructions
AUMA products are designed and manufactured in compliance with recognised standards and directives. This is certified in a declaration of incorporation and a declaration of conformity.
The end user or the contractor must ensure that all requirements with
respect to assembly, electrical connection, and commissioning at the place
of installation are met. They include among others:
National regulations, laws, and prescriptions.
.
Safety instructions/
warnings
Qualification of staff
Assembly, electrical connection, commissioning, operation, and maintenance must be carried out exclusively by suitably qualified personnel having
been authorised by the end user or contractor of the plant.
Prior to working on this product, the staff must have thoroughly read and
understood these instructions and, furthermore, know and observe officially
recognised rules regarding occupational health and safety.
Commissioning
Prior to commissioning, it is important to check that all settings are in compliance with the requirements of the application. Incorrect settings might
present a danger to the application, e.g. cause damage to the valve or the
installation.
The manufacturer will not be held liable for any consequential damage. Such
risk lies entirely with the user.
Operation
Protective measures
Maintenance
All personnel working with this device must be familiar with the safety and
warning instructions in this manual and observe the instructions given.
Safety instructions and warning signs on the device must be observed to
avoid personal injury or property damage.
.
.
.
..
.
The end user or the contractor are responsible for implementing required
protective measures on site, such as enclosures, barriers, or personal
safety equipment for the staff.
To ensure safe device operation, the maintenance instructions included in
this manual must be observed.
Any device modification requires the consent of the manufacturer.
Operation instructions
1.2.
Range of application
AUMA multi-turn actuators are designed for the operation of industrial
valves, e.g. globe valves, gate valves, butterfly valves, and ball valves.
Other applications require explicit (written) confirmation by the manufacturer.
..
..
..
..
..
These operation instructions are only valid for the clockwise closing standard version, i.e. driven shaft turns clockwise to close the valve. Separate
instructions are available for the counterclockwise closing special version.
1.3.
Operation instructions
.
.
.
.
.
.
.
.
Operation instructions
1.4.
WARNING
CAUTION
NOTICE
DANGER
1.5.
Information
The term Information preceding the text indicates important notes and
information.
Step by step
Provides a detailed description of each step for setting/viewing the parameter.
2.
Identification
2.1.
Name plate
Operation instructions
1
2
3
4
1
2
a CC
1
2
1
2
3
1
2
3
auma
Figure 3
AC 01.1
P:1,5kW
Com No: 1309595
No: 0902MA97286
KMS: TP180/001
ACP:11F1-2M0CA-004
3 ~ 400V IP67
Control: 24V DC
Operation instructions
Commission number
Wiring diagram/control
The actuator controls are designed for the Non-Intrusive version (refer also
to page 10), if the 7th position in the ACP wiring diagram contains the character M, e.g.: ACP 11F1-2M0CA-004.
Controlling the actuator controls is performed via a parallel interface, if the
9th position in the ACP wiring diagram contains the character A, B, C, or 1,
e.g.: ACP 11F1-2M0CA-004.
2.2.
Short description
Multi-turn actuator
Actuator controls
Local controls/
COM-AC
Intrusive Non-Intrusive
10
Operation instructions
.
.
.
.
Intrusive version:
Limit and torque setting is performed via switches in the actuator.
Non-Intrusive version:
Limit and torque setting is performed via the controls, actuator and controls housings do not have to be opened.
For this purpose, the actuator is equipped with an MWG (magnetic limit
and torque transmitter), also supplying analogue torque feedback signals/torque indication.
Operation instructions
3.
3.1.
Transport
For transport to place of installation, use sturdy packaging.
DANGER
3.2.
Storage
NOTICE
Long-term storage:
3.3.
Hovering load!
Death or serious injury possible.
Do not place below hovering load.
Attach ropes or hooks for the purpose of lifting by hoist only to housing
and not to handwheel.
Actuators mounted on valves:
Attach ropes or hooks for the purpose of lifting by hoist to valve and not
to multi-turn actuator.
Actuators mounted to gearboxes:
Attach ropes or hooks for the purpose of lifting by hoist only to the gearbox using eyebolts and not to the actuator
Packaging
Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can easily be separated and recycled.
We use the following packaging materials: wood, cardboard, paper, and PE
foil. For the disposal of the packaging material, we recommend recycling
and collection centres.
11
4.
Assembly
4.1.
Handwheel fitting
Information
NOTICE
Operation instructions
For transport purposes, handwheels from a diameter of 400 mm are supplied separately.
Damage at the change-over mechanism due to incorrect assembly!
Only pivot the change-over lever manually.
Using extensions as a lever for operation is not permitted.
First engage manual operation correctly, then mount handwheel.
1. Manually lift the red change-over lever while slightly turning the shaft
back and forth until manual operation engages.
The manual operation is correctly engaged if the change-over lever can
be lifted by approx. 85.
85
2. Attach handwheel over the red change-over lever then on to the shaft.
12
Operation instructions
4.2.
2
4
1
2
Information
3
4
NOTICE
Screws
Thread
M8
M10
M12
M16
25
51
87
214
13
Design
..
Operation instructions
1
2
3
1
2
.
.
Stem nut
3
Axial needle roller and cage assembly 4
Spigot ring
Axial bearing washer
The internal thread of the stem nut must match the thread of the valve
stem.
If not ordered explicitly with thread, the stem nut is supplied unbored or
with a pilot bore.
14
A 14.2
3g
A 16.2
5g
Operation instructions
1
2
3
Valve stem
Output drive type A
Screw to actuator
4
5
Valve flange
Screws to output drive
1. Remove screws (3) and take off output drive type A (2) from multi-turn
actuator.
2. Check if the flange of output drive type A matches the valve flange (4).
3. Thoroughly degrease mounting faces of the mounting flanges.
4. Apply a small quantity of grease to the valve stem (1).
5. Place output drive type A on valve stem and fasten until it is seated solidly on the valve flange.
6. Turn output drive type A until alignment of the fastening holes.
7. Screw in fastening screws (5), however do not completely fasten.
8. Fit multi-turn actuator on the valve stem so that the hollow shaft pinions
engage into the stem nut. The flanges are flush with each other if properly engaged.
9. Turn multi-turn actuator until alignment of the fastening holes.
10 Fasten multi-turn actuator with screws (3) according to table 1, page 13.
11. Fasten screws crosswise with a torque according to table 1.
12. Engage manual operation at multi-turn actuator and turn handwheel in
direction OPEN until valve flange and output drive type A are firmly
placed together.
13. Tighten fastening screws (5) between valve and output drive type A
crosswise with a torque according to table 1, page 13.
NOTICE
15
4.3.
Operation instructions
Accessories (option)
1
2
3
1
2
1.
2.
3.
4.
16
Sealing ring
Operation instructions
4.4.
Hazardous voltage!
Electric shock possible.
Disconnect device from the mains before opening.
1. Loosen bolts and remove the local controls.
2. Check whether O-ring is in good condition, correctly place O-ring.
3. Turn local controls into new position and re-place.
NOTICE
17
5.
Electrical connection
5.1.
General notes
WARNING
Operation instructions
Protection on site
For short-circuit protection and for disconnecting the actuator from the
mains, fuses and disconnect switches have to be provided by the customer.
The current values for respective sizing can be derived from the current
consumption of the motor plus the current consumption of the controls.
Motor current consumption:
Refer to name plate on motor (nominal current).
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 650 mA
208 to 240 V AC = max. 325 mA
380 to 500 V AC = max. 190 mA
24 V DC (+10 %/15 %) = max. 500 mA, filter capacitor 2200 F
Current consumption for actuator with 1-ph DC motor:
24 V DC (+10 %/10 %) = max. 750 mA, filter capacitor 2200 F
The maximum permissible fuse for controls with a rated power of 1.5 kW is
16 A (gL/gG); for controls with a rated power of 7.5 kW, the value amounts
to 32 A (gL/gG).
.
.
.
.
.
18
Operation instructions
a CC
Hazardous voltage!
Electric shock possible.
Disconnect device from the mains before opening.
Figure 10 shows the connection using the example of version S:
Figure 10
1
8
7
6
3
5
4
1
2
3
4
1
Cover
Screws for cover
O-ring
Screws for socket carrier
Cover
5
6
7
8
5
Socket carrier
Cable entry
Screw plugs
Cable gland (not included in delivery)
Socket carrier
au
5.2.
IP 67 1680 rpm
Temp.Protection: Th
Insulation Class: F
4. Seal cable entries (6) which are not used with suitable screw plugs (7).
5. Insert the wires into the cable glands (8).
19
Operation instructions
WARNING
For some special motors, the connection of the power terminals (U1, V1,
W1, U2, V2, W2) is made via a terminal board at the motor.
In case of failure: Hazardous voltage while protective conductor is not
connected!
Electric shock possible.
Connect all protective conductors.
Connect PE connection with external protective conductor of connecting
cables.
Start running the device only after having connected the protective conductor.
5. Tighten PE conductors firmly to PE connection (symbol:
lugs (flexible cables) or loops (rigid cables).
) using ring
Figure 11
2
3
4
5
1
6
1
2
3
Socket carrier
Screw
Washer
4
5
6
20
Operation instructions
7
6
3
5
4
1
2
3
4
Cover
Screws for cover
O-ring
Screws for socket carrier
5
6
7
8
Socket carrier
Cable entry
Screw plugs
Cable gland (not included in delivery)
21
5.3.
Operation instructions
..
.
Figure 13
1
2
4
3
Wall bracket
Connecting cables
..
..
22
3
4
5
Operation instructions
23
6.
Operation
6.1.
Manual operation
Operation instructions
In case of motor failure or power failure, the actuator may be operated manually for purposes of setting and commissioning.
Manual operation is engaged by an internal change-over mechanism.
Engaging manual operation
NOTICE
24
Operation instructions
6.2.
Motor operation
Perform all commissioning settings prior to motor operation.
2 STOP
3
4 Reset
5
1
2
3
4
5
6
The actuator can now be operated using the push buttons (1 3).
1. Run actuator in direction OPEN:
2. Stop actuator:
3. Run actuator in direction CLOSE.
Information
Use the Mode input (refer to wiring diagram) to select between REMOTE
MODE (open-close duty) and SETPOINT MODE (modulating duty).
25
6.3.
Operation instructions
Push button p
Push button q
Push button C
Selector switch
Push button 8
Display
Now, settings and indications can be performed via the push buttons (1 4).
6.3.1 Short overview: functions of the push buttons
Table 3
Push
Functions
buttons
Scrolling within a group
pq
(The triangles
in the display show the direction of scrolling.)
Change values
Enter figures from 0 to 9
26
Operation instructions
6.3.2 Structural design and navigation
..
.
S0
E2
100%
OPEN POSITION
Change groups
Scrolling
Press qp:
The triangles
in the top left corner of the display indicate the possible
scrolling direction (within one group) of scrolling.
OFF
E2
S0
100%
OPEN POSITION
1.
2.
3.
4.
Information
:OK C:ESC
If no input is received over a longer period of time (approx. 10 min), the controls automatically returns to the status indication S0.
27
6.4.
Operation instructions
Step by step:
1. Set the selector switch to position 0 (OFF).
0
I
M00
4. Press q.
Display indicates:
LANGUAGE/CONTRAS
VIEW
EDIT
M01
5. Press 8 .
Display indicates:
ENTER PASSWORD
0 * * *
:EDIT
:OK C:ESC
6. Enter password:
Press 8 4 times = 0000 (default factory password).
28
Operation instructions
M010
7. Press 8 .
Display shows the set value.
EDIT
M010
LANGUAGE
ENGLISH
:EDIT C:ESC
8. Press 8 again to enter the edit mode.
Display indicates:
EDIT
M010
LANGUAGE
ENGLISH
:EDIT
:OK C:ESC
29
7.
Indications
7.1.
Operation instructions
For actuators equipped with process controllers, status indication S6 is displayed instead of status indication S0. The description below applies to both
indications (S0 and S6).
Line 1 indicates the current operation mode (LOCAL MODE, OFF,
SETPOINT MODE, ...).
LOCAL MODE
S0
OPEN
E2
Operation command/
setpoint display/
100 %
RUNNING OPEN
S0
OPEN
E2
100 %
RUNNING OPEN
S0
OPEN
E2
100%
RUNNING OPEN
S0
OPEN
E2
100%
RUNNING OPEN
RUNNING OPEN
Actuator runs logically OPEN (remains set during operation pauses).
RUNNING CLOSE
Actuator runs logically CLOSE (remains set during operation pauses).
OPEN POSITION
End position OPEN reached.
30
Operation instructions
CLOSED POSITION
End position CLOSED reached.
SETPOINT POSITION
Setpoint (modulating actuators only).
S4
TORQUE 50 %
31
7.2.
Operation instructions
Indication lights/LEDs
The indication lights/LEDs locally display the different operation states as
optical signals. The assignment of signals is freely selectable.
Figure 19 shows the indication lights/LEDs on the local controls:
Figure 19
Version (standard):
LED marking with letters
Version (option):
LED marking with figures
illuminated
blinking
LED 2 (T)
illuminated
LED 3 (Th)
illuminated
LED 4 (T)
illuminated
illuminated
blinking
LED 5 (right)
(
symbol)
Information
7.3.
.
..
auma
4
1
2
5
3
1
2
3
32
Cover
Indicator disc
Indicator mark
4
5
Operation instructions
8.
Signals
8.1.
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
CONTACT
CONTACT
CONTACT
CONTACT
CONTACT
1
2
3
4
5
=
=
=
=
=
CLOSED POSITION
OPEN POSITION
REMOTE SW. POSITION
TORQUE FAULT (CLOSE)
TORQUE FAULT (OPEN)
For further information on this topic refer to Manual (Operation and setting)
AUMATIC AC 01.1/ACExC 01.1.
8.2.
Torque feedback
33
9.
Operation instructions
Commissioning
Prior to any electrical operation (motor operation), ensure that all commissioning settings described in this clause have been performed.
1. Set the selector switch to position 0 (OFF).
0
I
Information
The selector switch is not a mains switch. The actuator control is disabled in
0 (OFF) position. The controls power supply is maintained.
2. Switch on the voltage supply.
3. Perform the settings described in this clause.
Please note that for low temperature versions, the controls require a heat-up
time.
This heat-up time is applicable in case the actuator and the controls are not
live and have cooled down to ambient temperature. Under these conditions,
the following heat-up times have been met prior to commissioning after connection to the voltage supply:
For 40 C = 30 min.
For 50 C = 60 min.
For 60 C = 100 min.
Figure 21: Sketch illustrating the heat-up time
Figure 21
t [min.]
100
60
50
30
34
10
20
30
40
50
60 [C]
Operation instructions
NOTICE
Limit seating
The limit switching is set in such a way that the actuator switches off at the
desired switching points. The torque switching acts as an overload protection for the valve.
Torque seating
The torque switching is set to the desired tripping torque. After reaching the
tripping torque the actuator is turned off.
The limit seating is used for signalling that the limit switching is tripped
shortly before reaching the set tripping torque. If this is not the case, one of
the following fault signals is displayed: TSO FAULTS or TSC FAULTS
(menu S1).
Step by step:
1. Set the selector switch to position 0 (OFF).
9.1.
SETTINGS
OPERATIONAL DATA
4. Press 8 .
35
Operation instructions
Display indicates:
SETTINGS
M10
SET LIMIT SWITCHES
SEATING MODE
TORQUE
5. Press q.
Display indicates:
SETTINGS
M11
SET LIMIT SWITCHES
SEATING MODE
TORQUE
6. Press 8 .
Display indicates:
SEATING MODE
VIEW
EDIT
M110
VIEW
M1101
OPEN POSITION
CLOSED POSITION
VIEW
CLOSED POSITION
LIMIT
C:ESC
OPEN POSITION
LIMIT
C:ESC
p q are also used here to change between the OPEN POSITION (left
figure) and CLOSED POSITION (right figure) displays.
10. Back to the VIEW/EDIT menu: Press C twice.
Change setting
Display indicates:
SEATING MODE
VIEW
EDIT
11. Press q.
36
M110
Operation instructions
M111
12. Press 8 .
Display indicates:
ENTER PASSWORD
0 * * *
:EDIT
:OK C:ESC
EDIT
M1111
OPEN POSITION
CLOSED POSITION
EDIT
M1111
CLOSED POSITION
LIMIT
:EDIT C:ESC
p q are also used here to change between the OPEN POSITION (left
figure) and CLOSED POSITION (right figure) displays.
15. Press 8 again to enter the edit mode.
Display indicates:
EDIT
M1110
OPEN POSITION
LIMIT
:EDIT
:OK C:ESC
EDIT
M1111
CLOSED POSITION
LIMIT
:EDIT
:OK C:ESC
EDIT
M1111
CLOSED POSITION
LIMIT
:EDIT C:ESC
37
9.2.
NOTICE
Step by step:
1. Set the selector switch to position 0 (OFF).
SETTINGS
OPERATIONAL DATA
4. Press 8 .
Display indicates:
SETTINGS
M10
SET LIMIT SWITCHES
SEATING MODE
TORQUE
5. Press q twice.
Display indicates:
SETTINGS
M12
SET LIMIT SWITCHES
SEATING MODE
TORQUE
38
Operation instructions
Operation instructions
M120
VIEW
M1201
OPENING
CLOSING
BY-PASS DURATION
VIEW
OPENING
65%
C:ESC
CLOSING
65%
C:ESC
p q are also used here to change between the OPENING (left figure)
and CLOSING (right figure) displays.
10. Back to the VIEW/EDIT menu:
Press C twice.
Change setting
Display indicates:
TORQUE
VIEW
EDIT
M120
11. Press q.
Display indicates:
TORQUE
VIEW
EDIT
M121
12. Press 8 .
Display indicates:
ENTER PASSWORD
0 * * *
:EDIT
:OK C:ESC
39
Operation instructions
EDIT
M1211
OPENING
CLOSING
BY-PASS DURATION
M1210
EDIT
CLOSING
M1211
100%
:EDIT
C:ESC
100%
:EDIT
C:ESC
p q are also used here to change between the OPENING (left figure)
and CLOSING (right figure) displays.
Information
M1210
OPENING
100%
:EDIT
:OK C:ESC
EDIT
M1211
CLOSING
100%
:EDIT
:OK C:ESC
M1210
100%
:EDIT C:ESC
EDIT
CLOSING
M1211
100%
:EDIT
C:ESC
The following fault signals are sent if torque setting performed has been
reached in mid-travel:
Status indication S0: FAULT IND.
Status indication S1: TORQUE FAULT (OPEN) or TORQUE FAULT
(CLOSE) (torque fault)
The fault has to be acknowledged before the operation can be resumed.
Either by
an operation command in the opposite direction.
For TORQUE FAULT (CLOSE): Operation command in direction OPEN
For TORQUE FAULT (OPEN): Operation command in direction CLOSE
or via the Reset push button in selector switch position LOCAL.
.
.
40
Operation instructions
Step by step:
1. Set the selector switch to position 0 (OFF).
9.3.
SETTINGS
OPERATIONAL DATA
4. Press 8 .
Display indicates:
SETTINGS
M10
SET LIMIT SWITCHES
SEATING MODE
TORQUE
5. Press 8 .
Display indicates:
ENTER PASSWORD
0 * * *
:EDIT
:OK C:ESC
6. Enter password:
Press 8 4 times = 0000 (default factory password).
The current actuator position is displayed:
SET LIMIT SWITC M100
CLOSED POSITION
63.3 %
:EDIT
C:ESC
Operation instructions
C:ESC
C:ESC
18. Press C several times until S0 is displayed to return to the status indication.
42
Operation instructions
Information
Information
The end positions can be approached (via push buttons and selector switch
in position LOCAL), even during motor operation. For setting, the selector
switch must be in position 0 (OFF).
NOTICE
Valve damage due to direct approaching of mechanical end stop during motor operation!
During motor operation, interrupt travel before reaching the mechanical
valve/gearbox end stop (press push button STOP ).
43
9.4.
Operation instructions
Test run
Perform test run only once all settings previously described in the Commissioning clause have been performed.
auma
44
Operation instructions
4
5
2
3
1
2
3
Screw plug
Seal
Hollow shaft
4
5
6
45
9.5.
Operation instructions
9.6.
46
Operation instructions
9.7.
1. Pull off indicator disc. Open end wrench may be used as lever.
RSD
RDW
2. Check if turns/stroke of the actuator correspond to the setting of the primary reduction gearing (figure 23: stages 1 9) using table 5.
3. If the setting is not correct: continue with point 4.
If the setting is correct: continue with point 7.
Table 5
Control unit MS5.2 (1 to 500 turns per stroke)
Turns/stroke
above to
Gear stage
Turns/stroke
above to
Gear stage
Turns/stroke
above to
Gear stage
1.0 1.9
1.9 3.9
3.9 7.8
1
2
3
7.8 15.6
15.6 31.5
31.5 62.50
4
5
6
62.5 125
125 250
250 500
7
8
9
Gear stage
Turns/stroke
above to
Gear stage
Turns/stroke
above to
Gear stage
10.0 19.5
19.5 39.0
39.0 78.0
1
2
3
78 156
156 315
315 625
4
5
6
625 1,250
1,250 2,500
2,500 5,000
7
8
9
47
Operation instructions
Figure 23
7 8 9
4 5 6
1 2
4.
5.
6.
7.
8.
48
Screw
Crown wheel
Operation instructions
9.8.
49
10.
Operation instructions
Corrective action
Remedy
Actuator runs to end stop although the limit switches work properly.
The overrun was not considered when setting the limit switching.
The overrun is generated by the inertia of both the actuator and the valve
and the delay time of the controls.
1. Determine overrun:
Overrun = travel covered from switching off until complete standstill.
2. Set limit switching again (page 41) considering the overrun (turn
handwheel back by the amount of the overrun).
E2
S0
100%
OPEN POSITION
EMERGENCY STOP
E2
S0
100%
OPEN POSITION
Possible cause
Remedy
50
.
.
RESTRICTED means that the local controls of the AUMATIC have not
been released yet.
EMERGENCY STOP signifies that the EMERGENCY STOP operation
mode has been activated upon operating an EMERGENCY STOP button
(option).
For RESTRICTED:
A release must be initiated externally via bus or input signal. See parameter ENABLE LOCAL MODE.
For EMERGENCY STOP:
Release EMERGENCY STOP button.
Operation instructions
S0
OPEN
E2
100%
FAULT IND.
FAULT IND.
A fault has occurred
For further information, press qp and go to status indication S1.
WARNING IND.
A warning has occurred
For further information, press qp and go to status indication S2.
FAULT + WARNING
Faults as well as warnings have occurred.
For further information, press qp and go to status indications S1
(faults) or S2 (warnings).
FLT + NR
Faults and the NOT READY IND. signal have occurred.
For further information, press qp and go to status indications S1 or
S3.
WRN + NR
Faults and the NOT READY IND. signal have occurred.
For further information, press qp and go to status indications S2 or
S3.
FLT + WRN + NR
Faults, warnings, and the NOT READY IND. signal have occurred.
For further information, press qp and go to status indications S1 to
S3.
51
Operation instructions
S1
NO FAULT
NO FAULT
No fault has occurred.
INTERNAL FAULT
Internal fault has occurred.
For further information:
1. Go to group D0: Press C and hold it down until diagnostic indication D0
is displayed.
2. Go to diagnostic indication D2: Press q twice.
LOSS OF PHASE
One phase is missing.
Test/connect phases.
THERMAL FAULT
Motor protection tripped.
Wait for cooling off.
If the fault indication display persists after cooling off:
Set selector switch to position Local control (LOCAL) and reset fault
indication via Reset push button
Check fuse F4.
CONFIGURATION FAULT
The controls configuration is incorrect.
For further information:
1. Go to group D0: Press C and hold it down until diagnostic indication D0
is displayed.
2. Go to diagnostic indication D4: Press q four times.
52
Operation instructions
S2
NO WARNING
NO WARNING
No warnings have occurred.
WARNING RUN.TIME
The preset running time for a travel between end position OPEN and end
position CLOSED has been exceeded.
Set the running time (MONITOR TRIGGERS parameter) in accordance
with the actual running time.
Check tripping behaviour of end position switches.
Check actuator mechanics.
WARNING STARTS/RUN
The preset values for max. starts/h or max. running time/h have been
exceeded.
Check modulating behaviour.
Increase dead time.
Reduce number of nominal value changes.
INTERNAL FEEDBACK
Position transmitter is not standardised.
Operate actuator into both end positions (OPEN and CLOSED).
INTERNAL WARNING
Internal warnings have occurred.
For further information:
1. Go to group D0: Press C and hold it down until diagnostic indication D0
is displayed.
2. Go to diagnostic indication D3: Press q three times.
FEEDBACK E2 LOSS
Signal loss of position transmitter.
Check position transmitter signal.
1. Go to group D0: Press C and hold it down until diagnostic indication D0
is displayed.
2. Go to diagnostic indication D7, D8, or D9: Press q either seven, eight,
or nine times.
Check position transmitter wiring.
Check POSITION E2. The setting must correspond to the wiring diagram.
SETPOINT E1 LOSS
Signal loss of the set point.
Check wiring.
TORQUE E6 LOSS
Signal loss of torque source.
Check wiring.
53
Operation instructions
S3
READY
READY
Actuator can be operated from REMOTE.
NOT REMOTE
Actuator cannot be operated from REMOTE because the selector switch is
either in position LOCAL or OFF.
54
Operation instructions
10.3. Fuses
Hazardous voltage!
Electric shock possible.
Disconnect device from the mains before opening.
DANGER
F1/F2
Rear cover
Electrical connection
F3
F4
F 1/F 2
Size
6.3 x 32 mm
Reversing contactors
Voltage supply 500 V
1 A T; 500 V
K002.277
Reversing contactors
Voltage supply 500 V
2 A FF; 660 V
K002.665
15 A FF; 500 V
K001.189
30 A FF; 500 V
K006.965
1 A T; 500 V
K002.277
Internal 24 V DC supply
Internal 24 V AC supply (115 V AC) for:
Heater, switch compartment, reversing contactors control,
PTC tripping device
for 115 V AC also control inputs OPEN - STOP - CLOSE
..
.
Table 7
F3
F4
5 x 20 mm
5 x 20 mm
1.0 A T; 250 V
1.25 A T; 250 V
1.0 A T; 250 V
0.315 A T; 250 V
F5
55
Operation instructions
..
..
56
Operation instructions
11.
CAUTION
Service
..
Figure 25
Grease nipple
..
57
11.2. Maintenance
Maintenance intervals
Lubricant change
.
..
.
Operation instructions
..
..
electronic scrap
various metals
plastics
greases and oils
.
.
.
58
Collect greases and oils during disassembly. Generally, these substances are hazardous to water and must not be released into the environment.
Arrange for controlled waste disposal of the disassembled material or for
separate recycling according to materials.
Observe the national regulations for waste disposal.
Operation instructions
Notes
59
12.
60
Operation instructions
Operation instructions
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No.
001.0
002.0
003.0
005.0
005.1
005.2
005.3
005.4
006.0
009.0
010.0
017.0
018.0
019.0
020.0
022.0
023.0
024.0
025.0
058.0
061.0
070.0
079.0
080.0
155.0
500.0
501.0
502.0
503.0
504.0
505.0
506.0
507.0
511.0
514.0
514.1
516.1
535.1
539.0
542.0
549.1
551.1
553.0
554.0
556.0
556.1
557.0
558.0
559.0-1
559.0-2
560.0-1
560.0-2
560.1
560.2
566.0
566.1
Designation
Housing
Bearing flange
Hollow shaft without worm wheel
Worm shaft
Motor coupling
Coupling pin
Manual drive coupling
Pull rod
Worm wheel
Planetary gear for manual drive
Retaining flange
Torque lever
Gear segment
Crown wheel
Swing lever
Drive pinion II for torque switching
Output drive wheel for limit switching
Intermediate wheel for limit switching
Locking plate
Wire for protective earth (pin)
Torque switching head
Motor (VD motor incl. no. 079.0)
Planetary gear for motor drive (SA/SAR
07.1 14.1 for VD motor)
Planetary gear for motor drive (SA/SAR
16.1 for AD90 motor)
Reduction gearing
Cover for switch compartment
Socket carrier (complete with sockets)
Pin carrier without pins
Socket for controls
Socket for motor
Pin for controls
Pin for motor
Plug cover
Screw plug
Output drive form A (without stem nut)
Axial needle roller bearing
Output drive shaft D
Snap ring
Screw plug
Handwheel with ball handle
Output socket B3/B4/E
Parallel key
Mechanical position indicator
Socket carrier with motor cable harness
Potentiometer for position transmitter
Potentiometer without slip clutch
Heater
Blinker transmitter including pins at wires
(without impulse disc and insulation plate)
Control unit without torque head, without
switches
Control unit with magnetic limit and torque
transmitter (MWG) for Non-intrusive version in combination with AUMATIC integral controls
Switch stack for OPEN direction
Switch stack for CLOSE direction
Switch for limit/torque switching
Switch case
Position transmitter RWG
Potentiometer for RWG without slip clutch
Type
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
No.
566.2
566.3
567.1
568.1
568.2
568.3
569.0
569.1
569.2
574.1
575.1
S1
S2
Designation
Electronic board RWG
Wire harness for RWG
Slip clutch for potentiometer/RWG
Stem protection tube
(without cap)
Cap for stem protection tube
V-seal
Change-over lever assly.
Change-over lever
Notched pin
Radial seal output drive A for ISO flange
Stem nut type A
Seal kit, small
Seal kit, large
Type
Sub-assembly
Sub-assembly
Sub-assembly
Set
Set
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
61
12.2. Controls AC 01.1 with AUMA plug/socket connector (S, SH, SE)
62
Operation instructions
Operation instructions
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No.
001.0
002.0
002.3
006.0
008.1
009.0
011.1
500.0
501.0
502.0
503.0
504.0
505.0
506.0
507.0
508.0
509.1
510.0
S
Designation
Housing
Local controls
Local controls board
Power supply
Interface board
Logic board
Relay board
Cover
Socket carrier (complete with sockets)
Pin carrier without pins
Socket for controls
Socket for motor
Pin for controls
Pin for motor
Plug cover
Switchgear
Padlock
Fuse kit
Seal kit
Type
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Sub-assembly
Set
Set
63
13.
Operation instructions
Technical data
Torque range
Output speed
Motors
Insulation class
Motor protection
Self-locking
Limit switching
Torque switching
Position feedback, analogue
Torque feedback signal,
analogue
Mechanical position indicator
(option)
Running indication
Heater in switch compartment
Motor heater (option)
SA
SAR
SA
SAR
Blinker transmitter
Resistance type heater with 5 W, 24 V DC (standard: internal supply)
SA/SAR 07.1 10.1: 12.5 W
SA/SAR 14.1 16.1: 25 W
Manual operation
Manual drive for setting and emergency operation, handwheel does not rotate during
electrical operation.
Option:
Handwheel lockable
Connection to controls
AUMA plug/socket connector with screw type connection
Output drive types
A, B1, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drives: AF, AK, AG, IB1, IB3
Features and functions for controls
Power supply
For mains voltage and mains frequency, refer to name plates at the controls and the motor
(for a description of the name plates, refer to page 8)
Permissible variation of the nominal voltage: 10 %
Permissible variation of the mains frequency: 5 %
Motor current consumption: Refer to motor name plate
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 650 mA
208 to 240 V AC = max. 325 mA
380 to 500 V AC = max. 190 mA
External supply of the electronics 24 V DC + 20 %/ 15 %,
(option)
Current consumption: Basic version approx. 200 mA, with options up to 500 mA
Rated power
Refer to motor name plate
The controls is designed for the rated power of the actuator
Overvoltage category
Category III according to IEC 60 644-1
Switchgear
Standard:
Reversing contactors2) (mechanically and electrically interlocked)
for motor power up to 1.5 kW, nominal motor current up to 9 A
(OPEN - CLOSE duty) or 5.2 A (modulating duty)
1) For nominal voltage and 20 C ambient temperature and at an average load with running torque or modulating torque according to Technical data SA or SAR
2) The reversing contactors are designed for a lifetime of 2 million starts. For applications requiring a high number of starts, we recommend the use of thyristor
units.
64
Operation instructions
Switchgear
Options:
Control
Standard:
Option:
Output signals
Standard:
Option:
Voltage output
Standard:
Option:
Local controls
Standard:
Options:
Functions
Standard:
2) The reversing contactors are designed for a lifetime of 2 million starts. For applications requiring a high number of starts, we recommend the use of wearless
thyristor units.
3) Not possible in combination with PTC tripping device
4) During an adjustable period (factory setting 10 seconds), faults in the supply voltage (e.g. voltage drops) will not lead to an fault signal.
65
Operation instructions
Positioner5):
Nominal position value via analogue input E1 = 0/4 20 mA
Programmable behaviour on loss of signal
Automatic adaptation of the dead band (adaptive behaviour selectable)
Split Range operation
MODE input for changing from OPEN - CLOSE duty
to modulating duty
Process controller PID5):
Process setpoint via analogue input E1 = 0/4 20 mA
Actual position value via analogue input E4 = 0/4 20 mA
Programmable behaviour on loss of signal
Limitation of the control range
MODE input for changing from OPEN - CLOSE duty
to modulating duty
Monitoring functions
Programmable monitoring of the max. number of starts, generates warning signal
Reaction monitoring for operation command (programmable from 1 to 15 seconds),
generates fault signal results in switching off
Operating time monitoring (programmable from 4 to 1,800 seconds), generates warning signal
Electronic name plate
Order data: AUMATIC commission number, actuator commission number,
KKS number (definition system for power plants), valve number,
plant number
Product data: Product name, actuator works number, AUMATIC works number,
logic software version, logic hardware version, date of final test,
wiring diagram, terminal plan
Project data: Project name, 2 freely definable customer fields with a max. of 19 digits each
Service data: Service telephone, Internet address, service text 1, service text 2
Logging of operating data
A resettable counter and a lifetime counter for:
Motor running time, number of starts, torque switch trippings in end position CLOSED, limit
switch trippings in end position CLOSED, torque switch trippings in end position OPEN, limit
switch trippings in end position OPEN, torque faults CLOSE, torque faults OPEN, motor
protection trippings
Motor protection evaluation
Standard:
Monitoring of the motor temperature in combination with thermoswitches
in the motor
Options:
Additional thermal overload relay in the controls in combination with
thermoswitches within the motor
PTC tripping device in combination with PTC thermistors in the motor
Electrical connection
Standard:
AUMA plug/socket connector with screw type connection:
Threads for cable glands:
M-threads:
1 x M20 x 1.5/2 x M25 x 1.5
Pg-threads:
1 x Pg13.5; 2 x Pg21
NPT-threads:
1 x NPT "; 2 x NPT "
Options:
M-threads:
1 x M20 x 1.5; 2 x M25 x 1.5; 1 x M32 x 1.5
1 x M20 x 1.5; 1 x M25 x 1.5; 1 x M32 x 1.5
Pg-threads:
1 x M20 x 1.5; 2 x M25 x 1.5; 1 x M32
1 x Pg13.5; 2 x Pg21; 1 x Pg29
NPT-threads:
2 x " NPT; 1 x 1" NPT
G-threads:
2 x G "; 1 x G 1"; 1 x G 1"
2 x G "; 1 x G 1"
Special threads, other than standard mentioned above, possible
Gold-plated control plug (pins and sockets)
Parking frame for wall mounting of the disconnected plug
Protection cover for plug compartment (when plug is removed)
Wiring diagram (basic version)
ACP 11F1-2M0CA-001 KMS TP180/001
Additional features (Non-intrusive version with MWG in the actuator)
Setting of limit and torque switching via the controls local controls
Position feedback
Galvanically isolated analogue output E2 = 0/4 20 mA (load max. 500 )
Torque feedback
Galvanically isolated analogue output E6 = 0/4 20 mA (load max. 500 )
Electronic timer
Start and end of stepping mode as well as ON and OFF time (1 up to 300 seconds) can be
programmed individually for the directions OPEN and CLOSE.
Intermediate positions
Any 8 intermediate positions between 0 and 100 %
Reaction and signal behaviour programmable
Functions
Options:
66
Operation instructions
Corrosion protection
Finish coating
Colour
Ambient temperature
Vibration resistance
according to IEC 60 068
Lifetime
Weight
Accessories
Wall bracket8)
67
14.
Certificates
68
Operation instructions
Operation instructions
Index
A
Accessories for mounting
Assembly
16
12
C
Cable installation
Cable installation
in accordance with EMC
Commission number
Commissioning
Connecting cables
Control
Corrective action
Corrosion protection
Cross sections
Current consumption
18
18
8
34
22
9
50
11
20
18
D
Declaration of Incorporation
Disconnect switches
Disposal and recycling
Double sealed intermediate frame
E
Electrical connection
Exchange control unit
68
18
58
23
18
47
F
Faults
Faults at commissioning
Fuses
Fuses on site
51
50
55
18
G
Ground connection, external
23
H
Handwheel
Handwheel fitting
Heater
Heat-up time
24
12
20
34
I
Indications
Indicator disc
Internet
Intrusive
30
46,47
9
10
L
Language change in the display
Long-term storage
Low temperature version
Lubricant change
M
Maintenance intervals
Manual operation
Mechanical position indicator
Motor heater
Motor operation
Motor protection
Mounting
Mounting positions of the local
controls
N
Non-Intrusive
O
Operation
Output drive type A
Output drive types
B1, B2, B3, B4, B, and E
Overrun
28
11
34
58
58
24
46
20
25
56
13
17
10
24
14
13
50
P
Packaging
Parking frame
Password entry
Plug/socket connector
Position indicator
Position transmitter RWG
Protection cover
Protection on site
Protection tube
Protective earth
PTC thermistors
Push-to-run operation
11
23
27
19
46
18
23
18
16
20
56
25
R
Rated power
Reduction gearing
Reference documents
Running indication
64
47
2
32
S
Safety instructions
Self-retaining mode
Service
Short-circuit protection
Signals
Size
Spare parts list
Controls
Multi-turn actuator
Status indication
Stem nut
Storage
4
25
57
18
33
9
60
62
60
30
14
11
T
Technical data
Terminal plan
Test run
Thermoswitches
Transport
Type
64
18
44
56
11
9
V
Valve position
30
W
Wall bracket
Warnings
Wiring diagram (name plate)
Wiring diagram locating
22
51
9
18
69
AUMA worldwide
Europe
AUMA Riester GmbH & Co. KG
Plant Mllheim
DE-79373 Mllheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
Plant Ostfildern-Nellingen
DE-73747 Ostfildern
Tel +49 711 34803 - 0
Fax +49 711 34803 - 3034
riester@wof.auma.com
Service-Center Kln
DE-50858 Kln
Tel +49 2234 2037 - 9000
Fax +49 2234 2037 - 9099
Service@sck.auma.com
Service-Center Magdeburg
DE-39167 Niederndodeleben
Tel +49 39204 759 - 0
Fax +49 39204 759 - 9429
Service@scm.auma.com
Service-Center Bayern
DE-85386 Eching
Tel +49 81 65 9017- 0
Fax +49 81 65 9017- 2018
Riester@scb.auma.com
AUMA Armaturenantriebe GmbH
AT-2512 Tribuswinkel
Tel +43 2252 82540
Fax +43 2252 8254050
office@auma.at
www.auma.at
AUMA (Schweiz) AG
CH-8965 Berikon
Tel +41 566 400945
Fax +41 566 400948
RettichP.ch@auma.com
INDUSTRA
PT-2710-297 Sintra
Tel +351 2 1910 95 00
Fax +351 2 1910 95 99
industra@tyco-valves.com
OY AUMATOR AB
FI-02230 Espoo
Tel +358 9 5840 22
Fax +358 9 5840 2300
auma@aumator.fi
www.aumator.fi
Africa
A.T.E.C.
EG- Cairo
Tel +20 2 23599680 - 23590861
Fax +20 2 23586621
atec@intouch.com
70
America
AUMA ACTUATORS INC.
US-PA 15317 Canonsburg
Tel +1 724-743-AUMA (2862)
Fax +1 724-743-4711
mailbox@auma-usa.com
www.auma-usa.com
AUMA Automao do Brasil Ltda.
BR-Sao Paulo
Tel +55 11 8114-6463
bitzco@uol.com.br
AUMA Chile Representative Office
CL-9500414 Buin
Tel +56 2 821 4108
Fax +56 2 281 9252
aumachile@adsl.tie.cl
LOOP S. A.
AR-C1140ABP Buenos Aires
Tel +54 11 4307 2141
Fax +54 11 4307 8612
contacto@loopsa.com.ar
TROY-ONTOR Inc.
CA-L4N 5E9 Barrie Ontario
Tel +1 705 721-8246
Fax +1 705 721-5851
troy-ontor@troy-ontor.ca
MAN Ferrostaal de Colombia Ltda.
CO- Bogot D.C.
Tel +57 1 401 1300
Fax +57 1 416 5489
dorian.hernandez@manferrostaal.com
www.manferrostaal.com
PROCONTIC Procesos y Control Automtico
EC- Quito
Tel +593 2 292 0431
Fax +593 2 292 2343
info@procontic.com.ec
IESS de Mexico, S.A. de C.V.
MX-C.P. 02900 Mexico D.F.
Tel +52 55 55 56 1701
Fax +52 55 55 56 3337
informes@iess.com.mx
Corsusa International S.A.C.
PE- Miralflores - Lima
Tel +511444-1200 / 0044 / 2321
Fax +511444-3664
corsusa@corsusa.com
www.corsusa.com
PASSCO Inc.
PR-00936-4153 San Juan
Tel +18 09 78 77 20 87 85
Fax +18 09 78 77 31 72 77
Passco@prtc.net
Suplibarca
VE- Maracaibo Estado, Zulia
Tel +58 261 7 555 667
Fax +58 261 7 532 259
suplibarca@intercable.net.ve
Asia
AUMA Actuators (Tianjin) Co., Ltd.
CN-300457 Tianjin
Tel +86 22 6625 1310
Fax +86 22 6625 1320
mailbox@auma-china.com
www.auma-china.com
AUMA (INDIA) PRIVATE LIMITED
IN-560 058 Bangalore
Tel +91 80 2839 4655
Fax +91 80 2839 2809
info@auma.co.in
www.auma.co.in
Australia
BARRON GJM Pty. Ltd.
AU-NSW 1570 Artarmon
Tel +61 294361088
Fax +61 294393413
info@barron.com.au
www.barron.com.au
2009-01-22
71
Y004.470/003/en/1.09