ANTRIEB 'DC' TYPE………..MF Electro-Mechanical Actuators ………IP68 With Compact Control…..ELECTRONIC Operating and Maintenance Instructions

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Fig-1.Compact Control Module Sectional View

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

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

Mechanical Mounting

The flange of the actuator is equipped with threaded holes for fitting on the valve. The dimension of the Mounting flange and the connection arrangement comply with, ISO 5210 or DIN 3210.

For mechanical mounting of the actuator please refer page No.2 in Installation And Operating Instructions Catalogue No. ATPL–MF-003

Electrical Connections

Electrical connections are to be made according to the wiring diagram provided in the terminal assembly compartment

Removal of End Cover (Terminal Assembly Refer Fig-1)

a) Use 6mm size allen key to loosen the 4 nos.allen cap screws (2).

b) Remove the End Cover (3) from the compact housing.

c) connect the power cable, Control

cables via cable gland (provided on the compact housing(1))

d) Connect 3 phase 415V AC main to R, Y, B terminals in the terminal assembly(4).

e) Connect control Connection as per the wiring diagram in the terminal assembly.

Note:-1

In case of plug and sockets assembly (6), remove the socket assembly fixed with the end cover(5). by removing 4 nos. of M5 CHS screw. a) connect the power cable, Control

wires via cable gland provided with the End cover(5)

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

c) Connect control connection as per the wiring diagram on the 32 pin sockets

d) Re-assemble the socket assembly to the end cover.

e) Fix the end cover assembly to the plug assembly fixed in the compact housing(1).

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External 24VDC OPTION (Toggle Switch)

Where the customer prefers to use their own 24V DC power supply for the electronic card .

Select the toggle switch to external mode Connect 24V DC supply in between the terminal 82 & 59 refer wiring diagram.

Checking The Direction Of Rotation (Refer fig-2)

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

Local Operation

a) Switch ON the 3phase 415V AC mains.

b) Check the power on indicating LED (Amber) is glowing

c) Select the selector switch to Local mode

d) Press the Open push button switch

e) The actuator should rotate in counter clock wise (Open) direction

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

g) Press the stop push button switch.

The actuator should stop. h) Press the close push button switch i) The actuator should rotate in clock

wise (Close) direction j) The indicating LED for close (Red)

should blink k) Press the stop push button switch.

The actuator should stop If the above operation are ok the phase sequence is working satisfactorily.

If the above operation are not ok, please check for any loose connection in the phase / control connections.

Removal Of Limit Switch Cover

For setting the Limit switches, remove the limit switch cover provided in the actuator. Use 6mm Allen key to remove the 4 nos.of Allen cap screws.

Setting of Torque / Limit / Cam / Potentiometer / EPT

Please refer Installation And Operating Instructions Catalogue No. ATPL–MF–003 for the following a) Torque switch setting b) Limit switch setting c) Setting the Limit switch with

Counter unit d) Setting the Limit switch with Cam

switch unit e) Changing the stroke range on the

counter unit f) Changing the stroke range on the

Cam switch unit g) Limit switch repositioning Table for

Fig-2 Front Cover Assembly cpl.

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The dipswitch have been preset at works in OFF position. Kindly do not alter the settings.

DCO, DC1, DC2, DC3 with pick- off gear

h) Setting the Mechanical Position Indicator

i) Setting the Resistance Transducer j) Setting the Electronic Position

Transducer Checking the Limit Switch and Torque Switch function a) Operate the actuator open direction. b) Switch off by manually tripping the

open limit switch (S4) c) The actuator should stop. d) Operate the actuator again in open

direction. Switch off by manually tripping the open torque switch (S2)

e) The actuator should stop only after 3seconds of delay time.

f) Operate the actuator in close direction

g) Switch off by manually tripping close limit switch and close torque switch

h)The actuator should stop.

Compact Control –Electronic Construction The compact control module consists of Contactors (K1, K2), Over load relay, Transformers, Rectifier 24V DC and Electronic card, which have been assembled on a base plate and wired as per the wiring diagram. CAUTION:1

Dip Switch Setting On Electronic Card The electronic card has programmable 8 bit dip switches which can be easily changed to work with various requirements

CAUTION :-2 Incase the dipswitch setting and delay time setting have to be altered Please refer the various combination of dip switches and the corresponding functionality are listed below.

Dip Switch

OLR SETTING – Normally the OLR set valve preset at works in auto mode. The customer are advised not to disturb the setting of the OLR.

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Fig-3. Base Plate Assembly

Dip Switch No.

Functions Settings

01. Local non-maintained Local maintained

ON OFF

02. Remote non-maintained Remote maintained

ON OFF

03. Thermostat over ride Thermostat input accept

ON OFF

04. Open / Close interlock over ride Open / Close interlock input accept

ON OFF

Close torque ignores Close limit switch ON 05. Both torque switch and limit switch in

operation OFF

06, 07, 08 Valve jammed Refer delay

time list.

Delay Time List Nos.6 7 8 Delay time (sec) OFF OFF OFF 05 Sec OFF OFF ON 10 sec OFF ON OFF 15 sec OFF ON ON 20 sec ON OFF OFF 25 sec ON OFF ON 30 sec ON ON OFF 35 sec ON ON ON 40 sec

For setting the Dip switch

a) Switch off the main supply 415V AC b) Use 6mm size Allen key to lossen the 4

screws from housing. c) Remove the front cover Assy.(1) (Ref. fig-

4) d) Use 4mm size Allen key to lossen the 2

Nos. M5 screws e) Pull the base plate assembly (3) to

the required length using clamp (2) Set the dipswitch as per your requirement

Delay time to switch off the actuator when the valve gets jammed. After this delay the actuator relay automatically switches off.

Fig-4. Dip Switch Setting

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Local Operation

1) Switch on the main 3 phase 415V AC supply.

2) Check the power on indicating LED (amber) is glowing

3) Select the Local / Off / Remote selector switch to Local mode

4) Press the open push button switch 5) The actuator will rotate in open

direction 6) The open indicating LED (green) will blink 7) The actuator reaches the open end

position, the LED will glow steadily

8) Press the close push button switch 9) The actuator will rotate in close

direction 10) The close indicating LED (red)

will blink 11) The actuator reaches the close end

position, the LED will glow steadily

Remote Operation

For remote operation the 24V DC

supply inbuilt in the Electronic card. Customer need not to connect the external power supply for remote operation. connect the push button switch in between the terminal as mentioned below. NOTE:- Incase of interposing relays used for remote operation (refer wiring diagram-rev.07). connect as per the wiring diagram. Connect the LED in between the terminal 89 – 90

For wiring diagram rev.07 Connect the LED in between the terminal 53 – 54.

1) Select the Local / Off / Remote selector switch to remote mode

2) Check the 24V DC indicating LED is glowing

3) Press the remote open push button switch

4) The actuator will run in open direction

5) Press the remote stop switch 6) The actuator will stop The above test is then carried out in close direction.

Connect the push button switch in between the terminal 80 – 63 2) Start the actuator in open / close

Direction 3) Press the open close interlock push

switch 4) The actuator should stop 5) If the actuator does not stop check

the setting of the Dip switch No. 4.

R.Open .

80 . 60 .

R.Close .

80 . 610

R. Stop .

80 . 62 .

24V DC Healthy .

89 .

90 .

Open / Close Inter lock .

80 . 63 .

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Monitoring Relay

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

in Local or Off mode. 10. 24V DC healthy failure 11. Open / Close interlock trip NOTE:- The monitoring relay will not de energize, if the close limit switch ignores (bypassed) and switching off by torque switch while the valve jammed in mid travel.

The `NO' point

68,69 left out for Customer’s scope. An indicating lamp or an Alarm can be connected at this terminal. (For rev-07 the monitoring relay terminal 39-NC, 40-C, 41-NO left out for customer’s scope.) Rectifier (Internal 24VDC):-

Check the supply voltage of 24VDC between the terminals 77&78.(33&34 for rev-07 )It can be used externally for the maximum load of 350mA. Closing the Front Cover Assembly 1) Push the base plate assembly inside

and fix the clamps. 2) Close the front cover

3)While closing the front cover assembly, Align the selector switch knob to Local / Off / Remote selector switch position. 4) Ensure that the `O’ ring seated properly Closing the End Cover (Terminal assembly) and Limit Switch Cover:- 1) Close the End cover and Limit switch

cover 2) Use 6mm allen key for tightening the

M8 allen cap screws 3) Ensure that the `O‘ rings are seated

properly 4) Ensure the allen cap screws are

tightened properly. NOW THE VALVE AND THE ACTUATOR ARE READY FOR OPERATION.

Monitoring relay

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Maintenance For maintenance or any rectification on the compact control unit (ref.fig.5) 1) Switch off the main supply 2) Remove the front cover assembly cpl (1) 3) Use 4mm allen key to remove the

M5 allen cap screws 2 nos. 4) Pull the base plate assembly (2)

to the required length by using clamp (3)

5) Fix the diagnostic module (4) to the port provided in the Electronic card

Diagnostic Module

The Diagnostic module has increment and decrement switches to monitor the actuator status. The status annunciations are orderly listed in the diagnostic module so that it is easy to view.

NOTE-3 For example if the Actuator is unning in close direction at local mode then the Diagnostic module will show the SL. No.6 will be `Monitoring Relay Off, SL No.10 – Local close on and SL No.12 Actuator close 'ON' vice versa……

NOTE:- The user should purchase the diagnostic module separately.

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Faults Remedies

The diagnostic port is showing supply phase fail

a) Check the three phase input power supply b) Check the Fuses, transformers c) Check the control voltage (30VAC) in between the

terminal No.48-47, 48-46, 48-45 in the electronic card d) Check the control voltage (26V AC) in between the terminal No.43, 44.

Thermostat not working a) Check the motor thermostat point b) Check the Dip switch -3

Local / Off / Remote function not working a) Check the input voltage (24V DC) b) Check the local / off / remote selector switch c) Check the terminal No.11, 12 in the Electronic card

Open direction not working a) Check the Fuses b) Check the control voltage in between the terminal 28 in

the Electronic card and neutral 28 in the Electronic card and neutral

c) Check the NC point of the k1 contactor d) Check the coil point of the k2 contactor e ) Check the open input electronic card terminal no. 14 f) Check the NO point of the push button switch g) Check the open direction micro switches

Close direction not working Same as above mentioned for Close direction but NC point of the k2 contactor ,coil point of the k1 contactor and close direction micro switches.

Monitoring relay not working a) Check the NO point of the monitoring relay

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Faults Remedies b) Check the external control connection

c) Check the local / off / remote selector switch Open / close interlock not working a) Check the input voltage 24V DC at the terminal no .80

b) Check the NC, NO point of the external switch provided for open / close interlock trip e)Check the dipswitch position

Three Phase available in the Actuator but not Working a) Check the 24V DC healthy indication. b) Check the position of the Toggle switch. c) If the Toggle switch is in external mode, check the

external feeding supply 24V DC.

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

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

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Reference Details (For customer use) 1. Actuator Type 2. Sl. No. of Actuator 3. Wiring Diagram Number 4. Torque Range (NM) 5. Motor Make 6. Motor Rating (KW) 7. Motor RPM 8. Motor Frame Size 9. Ouput Flange Dimensions ANTRIEB TECHNIK PRIVATE LIMITED 59 (Old No. 349) SIDCO Industrial Estate, Technology Ambattur, Chennai - 600 098. Telephone : 26258303, 26253241, 26248983. Fax : 044-28193718 Cable : ANTRIEB: CHENNAI Germany E-Mail : : antrieb @ vsnl.com

antrieb @ sancharnet.in

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