Part-turn actuators - Auma...1. Safety instructions 1.1 Range of application AUMA part-turn...

Part-turn actuators

AS 6 - AS 50ASO 3 - ASO 6

ASR 6 - ASR 50

Operation instructions

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Part-turn actuators ASO 3 - ASO 6 / AS 6 - AS 50 / ASR 6 - ASR 50AUMA VARIOMATIC Operation instructions

Scope of these instructions: These instructions are only valid for part-turn actuators wired accordingto wiring diagrams CI V . . . AI . . . (3. digit ”V”),refer to name plate AUMA VARIOMATIC.

TABLE OF CONTENTS1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 Range of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Short description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 Commissioning (electrical connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.5 Warnings and notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.6 Further notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5. Mounting to valve/ gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6. Test of the mechanical end positions CLOSED and OPEN . . . . . . . . . . . . . . . . . . . . . . . 66.1 End position CLOSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.2 Limit seating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.3 Torque seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.4 Setting for CLOSED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.5 End position OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.6 Setting values for end stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7. Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8. Setting of the internal end position detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.1 Setting for end position OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.2 Setting for end position CLOSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9. Setting of the torque switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

10. Setting of the mechanical position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

11. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

12. Setting of the potentiometer (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

13. Setting of the position feedback 0/4 - 20 mA (option) . . . . . . . . . . . . . . . . . . . . . . . . . 11

14. Programming AUMA VARIOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1214.1 Programming with BUS board installed (MODBUS, PROFIBUS and INTERBUS S) . . . . . . . . . . 13

15. Electronic positioner (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415.2 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415.3 Programming of the positioner board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415.4 Positioner adjustment end position CLOSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1515.5 Positioner adjustment end position OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1615.6 Setting of the sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

16. Setting of the operating time (output speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1716.1 Setting of the operating time via internal command signal . . . . . . . . . . . . . . . . . . . . . . . 1716.2 Setting of the operating time via the speed-interface board (option) . . . . . . . . . . . . . . . . . . 1816.3 Further functions of the speed-interface board in conjunction with the positioner (option) . . . . . . . 19

17. Signal board (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

18. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

19. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

20. Declaration of Conformity and Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . 22

1. Safety instructions1.1 Range of application AUMA part-turn actuators are designed for the operation of industrial valves,

e.g. butterfly valves and ball valves.AUMA is not liable for any possible damages resulting from otherapplications. Such risk lies entirely with the user.Observance of these operation instructions is considered as part of theactuator’s designated use.

1.2 Short description AUMA part-turn actuators type ASO 3 - ASO 6 and AS(R) 6 - AS(R) 50have a modular design. Motor and gearing are mounted in a commonhousing and make up a coaxial unit together with the output drive.Manual operation is possible without change-over.The actuators are driven by an electric motor and controlled with theelectronic controls AUMA VARIOMATIC. The controls are included in thescope of delivery.The operating time can be adjusted for 90° swing angle within the range4 - 60 / 6 - 90 s (dependent on size).

1.3 Commissioning(electrical connection)

During electrical operation certain parts inevitably carry lethal voltages.Work on the electrical system or equipment must only be carried out by askilled electrician himself or by specially instructed personnel under thecontrol and supervision of such an electrician and in accordance with theapplicable electrical engineering rules.

1.4 Maintenance The maintenance instructions (refer to page 21) must be observed,otherwise a safe operation of the part-turn actuator is no longer guaranteed.

1.5 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries ordamages. Qualified personnel must be thoroughly familiar with all warningsand notes in these operation instructions.Correct transport, proper storage, mounting and installation, as well ascareful commissioning are essential to ensure a trouble-free and safeoperation.The following references draw special attention to safety-relevantprocedures in these operation instructions. Each is marked by theappropriate pictograph.

This pictograph means: Note!”Note” marks activities or procedures which have major influence on thecorrect operation. Non-observance of these notes may lead toconsequential damage.

This pictograph means: Electrostatically endangered parts (ESD)!If this pictograph is attached to a printed circuit board, it contains partswhich may be damaged or destroyed by electrostatic discharges. If theboards need to be touched during setting, measurement or for exchange, itmust be assured that immediately before a discharge through contact withan earthed metallic surface (e.g. the housing) has taken place.

This pictograph means: Warning!”Warning” marks activities or procedures which, if not carried out correctly,can affect the safety of persons or material.

1.6 Further notes This pictograph means: Procedure may have been performed byvalve manufacturer!If actuators are delivered mounted to a valve, this step has been done in thevalve manufacturer’s plant.Setting must be checked during commissioning!

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Part-turn actuators ASO 3 - ASO 6 / AS 6 - AS 50 / ASR 6 - ASR 50Operation instructions AUMA VARIOMATIC

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2. Technical data

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Tripping torque bothdirections

max. Nm 321) 631) 63 125 250 500

min. Nm – – 25 50 100 200

AUMA part-turn actuatorsfor OPEN - CLOSE duty

Type ASO 3 ASO 6 AS 6 AS 12 AS 25 AS 50

AUMA part-turn actuatorsfor modulating duty

Type – – ASR 6 ASR 12 ASR 25 ASR 50

Torque for modulating Nm – – 30 60 120 240

Factor 2) (manual operation) 15

Handwheel turns for 90o 13,5

Swing angle (end stops are adjustablewithin this range) Standard 90o (82o - 98o)

Operating time for 90o 3) s 4 - 60 6 - 90

Type of dutyVDE0530 /IEC 34

OPEN-CLOSEActuators Short-time duty S2 - 15 min

Modulatingactuators

Intermittent duty S5 -40% EDNumber of starts max. 1 800 c/h4)

Impulse time (for controlsignals) min. ms – – 50 50 70 70

Insulation class (motor windings) F

Current values for single-phaseconnection 5) Effective values

220 - 240 V; 50 / 60Hz max. A 0,7 1,5 1,5 2,4 3,2

110 -120 V; 50 / 60Hz max. A 1,5 3,0 3,0 4,8 6,4

Fuses Recommended fuses in mains: 6 A8),characteristic D according to VDE 0641 and IEC/EN 60 898

Electrical input power atshortest operating time approx. W 75 160 160 260 360

Weight with controls approx. kg 8 8 11 16 24

Enclosure protectionaccording to EN 60 529 Standard: IP 67 6); Option: Actuator IP 68 7), controls IP 67 for mounting on wall

Ambient temperature OPEN-CLOSE actuators: – 25 oC to +70 oC /modulating actuators: – 25 oC to +60 oC

Electrical connectionswith electronic controlsAUMA VARIOMATICdirectly installed

Remotecontrol/signals

Plug/socket connector with 48-pole screw cable terminations, max. 2,5 mm2

Option: Crimp connection for flexible cables, 40-pole; 0,75 - 1,0 mm2

on request 0,5 mm2 or 1,5 mm2 are possible

Mains Plug/socket connector with screw cable terminations; max.6 mm2

Option: Crimp connection for flexible cables, 0,75 - 1,5 mm2

Electrical connections forwith electronic controlsAUMA VARIOMATICinstalled separately

Controls Plug socket connector with crimp connection for flexible cables, 40-pole;0,75 -1 mm2, on request 0,5 mm2 or 1,5 mm2 are possible

Motor Plug/socket connector with crimp connection for flexible cables,0,75 - 1,5 mm2

For the electrical operation of the part-turn actuators the electronic controls AUMA VARIOMATIC arenecessary. The controls are available for direct fitting or for mounting on wall. A separate installation of theelectronic controls requires screened connecting cables. Notes concerning screening and earthingaccording to wiring diagram and legend must be observed. The max. permissible cable length betweenpart-turn actuator and VARIOMATIC for types AS and ASR is: 100 m, for types ASO: 15 m.

1) Torque sensor not provided. Switching offby motor current monitoring.

2) Conversion factor output torque to input torqueat handwheel

3) Adjustable by potentiometer in electronic controls4) To reach the longest possible maintenance and fault-free

operation time, the number of starts during normal operationshould be chosen as low as permissible for the process.

5) Max. values for shortest operating time.6) IP 67 means: Protection against short-time immersion into water;

max. 1 m head of water for 30 min.7) IP 68 means: Protection against submersion up to max. 6 m head of

water for the duration of 72 hours, up to 10 operations duringthe submersion.

8) Groups of up to 4 actuators can be protected with a safety cutout20 A, characteristic according to VDE 0641 and IEC/EN 60 898.

3. Transport and storage .Transport to place of installation in sturdy packing..Do not attach ropes or hooks to the handwheel for the purpose of lifting byhoist.. If part-turn actuator is mounted on valve, attach ropes or hooks for thepurpose of lifting by hoist to valve and not to part-turn actuator..Store in well-ventilated, dry room..Protect against floor dampness by storage on a shelf or on a woodenpallet..Cover to protect against dust and dirt..Apply suitable corrosion protection agent to bright surfaces.

If part-turn actuators are to be stored for a long time (more than 6 months),the following points must be observed additionally:

.Prior to storage: Protect unfinished surfaces, especially of output driveparts and mounting surface with long-term corrosion protection agent..Check for corrosion approximately every 6 months. If first signs ofcorrosion show, apply new corrosion protection.

After mounting, connect part-turn actuator immediately to electrical system,so that condensation is prevented by the heater.

4. Manual operation Manual operation is activated by turning the handwheel. A change-over isnot required. The handwheel does not rotate during motor operation.

Turning the handwheel during motor operation results inan extension or reduction of the operating time, dependingon the direction of rotation.

5. Mounting to valve/ gearbox .Prior to mounting the part-turn actuator must be checkedfor any damage..Damaged parts must be replaced by original spare parts.

The easiest position for mounting is when the valve shaft points upright. Butmounting is also possible in any other position.The part-turn actuator is delivered ex works in position CLOSED..For butterfly valves the mounting position is end position OPEN..For ball valves the mounting position is end position OPEN.

Prior to mounting, the part-turn actuator must be driven to the mechanicalend stop OPEN by turning the handwheel counter-clockwise..Thoroughly degrease mounting faces of part-turn actuator and valve..Put coupling sleeve on valve shaft and secure it (figure A). Ensure thatdimensions X and Y are observed.

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Figure A

.Apply non-acidic grease at toothing of coupling..Fit actuator so that fixing holes in actuator and valve mounting flangealign. If necessary, move actuator upward one tooth on the coupling.If required, turn handwheel a little in direction OPEN or CLOSE until holesalign..Ensure that spigot mates uniformly in the recess and that the mountingfaces are in complete contact..Fasten actuator with bolts. Fasten bolts crosswise with torque wrench(fastening torques see table 1).

6. Test of the mechanical end positions CLOSED and OPENThis test can only be performed on valves which have not been mountedinto a pipeline.

6.1 End positionCLOSED

.Check if mechanical end position of the valve corresponds to mechanicalend stop of actuator by turning at handwheel (clockwise for end positionCLOSED)

6.2 Limit seating .For limit seating, the actuator always runs up to the mechanical end stop.

6.3 Torque seating .For torque seating in end position CLOSED the mechanical end stop ofthe actuator must be set to a swing angle larger than actually required bythe valve.

6.4 Setting for CLOSED .Remove screw plug (22.1, figure B1) and adjust mechanical end positionat hex. socket head cap screw (21.1, figure B2). Turning clockwise resultsin smaller, turning counter-clockwise results in larger swing angle.

Never remove the screws (21.1 and 21.2, figure B2)completely, because this will cause oil leakage.

.Replace and fasten screw plug (22.2, figure B1).

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22.122.2

Figure B1

ASO 3ASO 6AS 6

ASR 6

AS 12ASR 12

AS 25ASR 25

AS 50ASR 50 Fastening torques

X max. mm 3 3 2,5 2,5 3,5 Strength class 8.8Y max. mm 5 5 6 6 10 Threads M 6 M 8 M 10 M 12Z max. mm 28 28 38 48 48 Fastening torques Nm 10 25 50 85

Table 1

6.5 End position OPEN The swing angle has been set in the factory to approx. 90° or to the swingangle stated in the order. An adjustment might be necessary if anadjustment of the end position CLOSED has been performed.

.Check if mechanical end position of the valve corresponds to mechanicalend stop of actuator by turning at handwheel(counter-clockwise for end position OPEN).Remove screw plug (22.2) and adjust mechanical end position at hex.socket head cap screw (21.1, figure B3)..Replace and fasten screw plug (22.2).

6.6 Setting values for end stops

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CLOSED OPENFigure B4 (top view) Figure B5 (top view)

Dimension T in mmSwing angle 1) ASO 3 / ASO 6

AS 6 / ASR 6AS 12

ASR 12AS 25

ASR 25AS 50

ASR 50Basic factorysetting for 90°swing angle

13,5 13 16 19

For each turn of the hex. socket head cap screw, the setting of the end position changes by:ASO 3 / ASO 6AS 6 / ASR 6

AS 12ASR 12

AS 25ASR 25

AS 50ASR 50

for clockwise turn appr.: 3,3° 2,4° 3° 2,4°for counter-clockwiseturn appr.:

2,4° 1,9° 2,1° 1,8°

1) By turning at the hex. socket head cap screw for end stop CLOSED or OPEN the end position changes accordingly.

The swing angle can be checked and set by using the dimension T.

CLOSED OPENFigure B2 (top view) Figure B3 (top view)

7. Electrical connection Work on the electrical system or equipment must only becarried out by a skilled electrician himself or by speciallyinstructed personnel under the control and supervision ofsuch an electrician and in accordance with the applicableelectrical engineering rules.

AUMA part-turn actuators are operated via the electronic controls AUMAVARIOMATIC. The controls may either be mounted directly to the actuatoror to a separate wall bracket.The electrical connection to the power supply is made at a plug / socketconnector with screw cable terminations as standard.

When mounting the AUMA VARIOMATIC separately to a wall bracket,suitable flexible and screened connecting cables are additionallyrequired. The max. permissible cable length between part-turn actuator andVARIOMATIC for types AS and ASR is: 100 m, for types ASO: 15 m.On request, complete cable sets may also be purchased subsequently fromour factory..Check whether power supply (type of current, voltage and frequency) suits

the motor (see name plate on controls AUMA VARIOMATIC)..Remove plug cover.. Install suitable cable glands with enclosure protection IP 67 (option IP 68)which suit the cable diameters..Ensure professional connection of the screening for the connectingcables for AUMA VARIOMATIC (on wall bracket) and/or when continuousposition indication signal (option) is provided..Connect cables according to wiring diagram CI V... AI...(refer to name plate).Cross sections: control cables max. 2,5 mm2,

power supply max. 6 mm2.

Connection in Crimp version (figure C):For AUMA VARIOMATIC on wall bracket the connection for the cablesbetween actuator and controls is always realised in Crimp version (controlsmax. 40 poles).Crimp socket carriers are supplied loose in sufficient numbers in the plugcover. For crimping a suitable tool, e.g. the BUCHANAN four indent crimptool, must be used.Cross sections: for flexible cables, 0,75 - 1,0 mm2, or (if ordered) 0,5 mm2 or1,5 mm2.Optionally the power supply connection can also be realised in Crimpversion (number of poles and cable cross sections see above).

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Figure CPole diagram for:a) Customer connection for Crimp version (option)b) Connection between actuator and controls VARIOMATIC

8. Setting of the internal end position detection

For the setting of the end position detection the actuator must be mountedto the valve.

The internal end position detection is set to a swing angle of 90° in thefactory. A subsequent change is only necessary if another swing angle isrequired. Prior to the setting of the electrical swing angle the end stops mustbe set to the appropriate value according to clause 6, page 6.

8.1 Setting for end position OPEN .Take off cover at switch compartment (figure K, page 12)..Turn handwheel firmly in direction OPEN until valve is closed ormechanical end stop OPEN is reached.Set selector switch to position LOCAL..Switch on power supply..Loosen both screws (4.06) (figure E)..Rotate control disc(4.2) clockwise, untilgreen LED lights upto indicate switchingpoint OPEN. In caseof having turned toofar, the green LEDgoes out again. Thecontrol disc should bepositioned in such away that it is situatedmidway between thegreen LED lighting upand going out.

.Hold control disc inposition and tightenscrews (4.06)..Check setting byapproaching theswitching point underelectrical operation indirection OPEN anew.

8.2 Setting for end position CLOSED.Turn handwheel up to mechanical end stop CLOSED..Check if switching point is reached (yellow LED CLOSED is illuminated).If not, correct setting value on dial as follows:.Loosen screw (4.8) (figure E)..Remove control disc (4.2) (figure E)..Loosen screw (4.01) at lower side of control disc (figure D)..Fit control disc (4.2) (figure E)..Rotate control disc (4.2) clockwise, until yellow LED lights up to indicateswitching point CLOSED.In case of having turned too far, the yellow LED goes out again. Thecontrol disc should be positioned in such a way that it is situated midway,between the yellow LED lighting up and going out..Pull off control disc (4.2) again and fasten screw (4.01) (figure E). Ensurethat the graduated control disc (4.02) is not moved..Fit control disc (4.2) and secure with screw (4.8)..Check setting:Move valve manually to intermediate position.Approach switching point in direction CLOSE electrically with push-buttonCLOSE.

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Figure D

Figure E

9. Setting of the torque switching(not possible for types ASO 3 and ASO 6)

.Set torque must suit the valve!.When part-turn actuators were delivered by a valvemanufacturer, setting was made during testing..This setting should only be changed with the consent ofthe valve manufacturer.

.Determine the required setting values for opening and closing direction onscale (5.0) of board (4.3) (figure G)..Set the value determined for direction CLOSE (0 - 9) at rotary switch (5.1)..Set the value determined for direction OPEN (0 - 9) at rotary switch (5.2).

10. Setting of the mechanical position indicator

The mechanical position indicator is realised with the white clamping pointer(4.4, figure H) below the sight glass (of the switch compartment cover). Theclamping pointer (4.4) shows only the position CLOSED or OPEN withrespect to the pipeline. With the sight glass removed the symbols on theboard (4.3) show the electrically set end position points..Run part-turn actuator manually to end position CLOSED..Lift clamping pointer (4.4) at indentation slightly and turn it so that it

points crosswise to the pipeline.

When changing the mounting position of the actuator, themechanical position indication may have to be re-set!

11. Test run .Approach end position CLOSED and end position OPEN electrically andcheck seating..Clean sealing faces at cover and housing; check whether O-ring is in goodcondition..Apply a thin film of non-acidic grease to the sealing faces..Replace cover and fasten hex. bolts evenly crosswise.

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5.2

4.3

Figure G

Example (scale for part-turn actuator AS 12)Setting values atrotary switch

0 1 2 3 4 5 6 7 8 9

Torque Nm 50 60 65 75 85 90 100 110 115 125

CLOSED

Switchcompartment

4.4

OPEN

4.4

Figure H

12. Setting of the potentiometer (option)

.Take off cover at switch compartment (figure K, page 12)..Run part-turn actuator to end position CLOSED..Turn potentiometer R11 (figure J) counter-clockwise until the mechanicalstop is reached. Afterwards turn minimally in clockwise direction.

13. Setting of the position feedback 0/4 - 20 mA (option)

.Take off cover at switch compartment (figure K, page 12)..Run part-turn actuator to end position CLOSED..Turn potentiometer R11 (figure J) counter-clockwise until the mechanicalstop is reached. Afterwards turn minimally in clockwise direction..Set to 0 or 4 mA with setting potentiometer Rmin. For 2-wire systems theminimum current is always 4 mA (see wiring diagram)..Run part-turn actuator to end position OPEN..Set to 20 mA with setting potentiometer Rmax..Check setting by running valve to end positions again..Replace cover and fasten 4 bolts evenly crosswise.

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Rmax

Rmin

R11

Figure J

14. Programming AUMA VARIOMATIC

.Remove 4 screws at VARIOMATIC (figure K / 8.1) and take off cover.

. In the factory push-to-run operation REMOTE and push-to-run operationLOCAL are programmed (refer to table 2, page 13).

.The type of seating - limit or torque seating - (DIP switch S1 pos. 5 andpos. 6) must be determined by the valve manufacturer.

.Set desired programming according to table 2 at DIP switch S1(figure L).

If no positioner (figure N, page 14) or speed-interface board(figure R, page 18) is fitted, the DIP switch S1 pos. 7 mustalways be in position ”ON”.

.Replace cover and fasten 4 bolts (figure K / 8.1) evenly crosswise.

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Local controls

AUMA VARIOMATIC Switch compartmentcover

8.1 AUMA VARIOMATIC

Figure K: Part-turn actuator ASO/ AS(R) with controls AUMA VARIOMATIC

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DIP switch S1for programming

Cover platestandard

ON12

34

56

7

Potentiometerfor setting ofOPERATING TIME

Diagnosis LED (green):Illuminated whenready

Diagnosis LED (red):Motor protectiontripped

Diagnosis LED (green):Enable REMOTE (option)always installed,illuminated during normaloperation

Diagnosis LEDs foractive REMOTEcontrol commands:run command STOP (red)run command OPEN (green)run command CLOSE (yellow)

Logic board

Figure L: VARIOMATIC Standard

Self-retaining REMOTE must be switched off when used inconjunction with the positioner (clause 15, page 14).

14.1 Programming with BUS board installed (MODBUS, PROFIBUS and INTERBUS S)

Refer to separate instructions for appropriate bus system.

1) PROFIBUS-FMS and switch position S1 pos. 7 to ”ON”.MODBUS (no nominal output speed possbible via bus)Profibus DP andINTERBUS-S switch position S1 pos. 7 to ”OFF”.

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DIP switch S1(on logic board)

Programming

Direction CLOSE Direction OPEN

Self-retaining REMOTE

Push-to-run operationREMOTE

Self-retaining LOCAL

Push-to-run operation LOCAL

Type of seatingfor end position

CLOSEDfor end position

OPEN

limit seating

torque seating

With positioner installed:

Speed dependent onerror variable

Speed not dependent onerror variable

Table 2


Programming

Self-retaining REMOTE (not applicable for BUS systems)

Push-to-run operationREMOTE



Type of seatingfor end position

CLOSEDfor end position

OPEN

limit seating

torque seating

externally (via BUS) internally

Nominal output speed 1)

Table 3

ON

1 2 3 4 5 6 7OFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF 1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

1 2 3 4 5 6 7

ONOFF

BarthK

1) PROFIBUS-FMS and switch position S1 pos. 7 to ”ON”. MODBUS (no nominal output speed possbible via bus) Profibus DP and INTERBUS-S switch position S1 pos. 7 to ”OFF”. DIP switch S1 (on logic board) Programming Self-retaining REMOTE (not applicable for BUS systems) Push-to-run operation REMOTE Self-retaining LOCAL Push-to-run operation LOCAL Type of seating for end position CLOSED for end position OPEN limit seating torque seating externally (via BUS) internally Nominal output speed 1) 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF 1 2 3 4 5 6 7 ON OFF

15. Electronic positioner (option)15.1 Technical data

15.2 Setting .Remove 4 screws at cover of AUMA VARIOMATIC (8.1, figure K, page 12)and take off cover..For the functions of the LEDs installed on positioner board: refer to figure N..Check programming of the logic board according to pages 12/13,clause 14:Pos. 1 and Pos. 3 must be in Pos. ”OFF” (figure N).If no speed variation is desired, the DIP switch S1 pos. 7 must be inposition ”ON”.If an error-dependent speed variation is required (figure M), set DIP switchS1 pos. 7 to ”OFF”.

1) Enable REMOTE (option) refer to appropriate wiring diagram:Analogue command signal or run command via local controls arenot accepted without external enable signal (24V DC).

15.3 Programming of the positioner board.Remove cover plate (figure N)..Set switch S2 pos. 5 (figure O1, page 16) according to input signal(nominal value) E1:

0 - 20 mA: Position ”OFF”4 - 20 mA: Position ”ON”.Set switch S2 pos. 6 for E2 (actual value) = 4 mA to position ”ON”.

(for E2 position feedback via potentiometer 0 - 5 V in position ”OFF”)

14


Command signal (input signal E1, nom. value) 0/4 - 20 mA (option 0 - 5 V)Feedback (input signal E2, actual value) 0/4 - 20 mA (option 0 - 5 V)

Sensitivity (dead band) ∆E (R35) 0,5 % - 2,5 %

Fine adjustment ”Sens” (R31) min 0,25 %Time delay ”toff ”(R88) 0,5 - 10 sInput resistance 250 Ohm

MOV

M

Figure M: Speed dependent on error variable

1)Diagnosis LED (green)Enable REMOTE (option)always installed,illuminated during normaloperation

V24: Run command OPEN (green)

V23: Run command CLOSE (yellow)

V35: Permissible number of startsexceeded (red)

V37: Signals E1 or E2not available (red)

R88: Delay time

12

34

56

7


Cover platepositioner



Logic board


Figure N: VARIOMATIC with positioner

In standard version switch S3 (figure O1, page 16) for command signal E1 =0/4 - 20 mA, i.e. end position ”OPEN” = 20 mA, must be in position 1.Version for inverse operation (i.e. end position ”OPEN” = 0/4 mA) must beordered accordingly from the factory.

Programming for faults:Behaviour on loss of input signal E1 and / or

on loss of feedback signal E2.Pre-condition: Signals 4 - 20 mA

Before beginning the positioner setting it has to be ensuredthat the internal end position recognition (clause 8), thetorque switching of the actuator (clause 9) as well as theposition feedback (clauses 12 and 13) have been set.

15.4 Positioner adjustment end position CLOSED.Set selector switch (local controls) to position I (LOCAL)..Run part-turn actuator with push-button to end position CLOSED ..Supply nominal value E1 of 0 or 4 mA (see wiring diagram).

Missing signal E1 and / or E2 is indicated by”LED E1/E2 < 4 mA” (figures O1+O2 / V37).

.Connect voltmeter to measuring points M1 and M2 (0 - 5 V) for measuringof the nominal value (figure O1, page 16).For a nominal value E1 of 0 mA the Voltmeter shows 0 V.For a nominal value E1 of 4 mA the Voltmeter shows 1 V..Connect Voltmeter to measuring points M3 and M4 for measuring the actualvalue signal.For an actual value E2 of 0 mA the Voltmeter shows 0 V.For an actual value E2 of 4 mA the Voltmeter shows 1 V.If measured value is not correct:Adjust position feedback signal according to page 11, clause 12 or 13..Set potentiometer R35 (∆E) and R31 (sens) to minimal value by turningcounter-clockwise.

15


If

Possible LED indication:(refer to figures O1 and O2)

Th

en

Required setting in end position CLOSED:(refer to figures O1 and O2)

LEDs are not illuminated Turn potentiometer ”0” (R25) slightly clockwise untilLED (V23 yellow) lights up.

LED (V24 green) isilluminated

Turn potentiometer ”0” (R25) slightly clockwise until LED(V24) goes out and LED (V23 yellow) lights up.

LED (V23 yellow) isilluminated

Turn potentiometer ”0” (R25) counter-clockwise until LED (V23yellow) goes out.Then turn potentiometer ”0” (R25) slightly clockwise until LED(V 23 yellow) lights up again.

Process related (desired)behaviour:

Programming:(figure O1, page 16)

fail as is, i.e. part-turn actuatorstops immediately and remains inthis position

fail close, i.e. part-turn actuatormoves the valve to the end positionCLOSED

fail open, i.e. part-turn actuatormoves the valve to the end positionOPEN

15.5 Positioner adjustment end position OPEN.Run part-turn actuator by depressing push-button (local controls) toend position OPEN..Connect Voltmeter to measuring points M3 and M4 (figure O1)for measuring of the actual value E2. When position feedback is setcorrectly the Voltmeter shows 5 V.If measured value is not correct:Perform feedback adjustment according to page 11, clause 12 or clause13 and continue with page 15 subclause 15.4..Connect max. command signal (nominal value E1) = 20 mA..Connect Voltmeter to measuring points M1 and M2 (figure O1)for measuring of the nominal value E1.For a measured value of 20 mA the Voltmeter shows 5 V.If measured value is not correct:Check the externally supplied command signal E1.

15.6 Setting of the sensitivity .Set selector switch to position II (REMOTE) at local controls (figure P,page 17)..Set command signal E1 according to sticker on cover plate (see figure O2)..Set dead band with potentiometer ∆E (R35) so that part-turn actuatordoes not readjust after a single control operation:- turning clockwise results in reduced sensitivity (dead band increased)

When setting E the following must be observed by allmeans:If the number of starts is too high, this will lead tounnecessary wear at the valve and actuator.Therefore the maximum possible sensitivity (dead band)acceptable for the process must be set.

.To prevent an exceeding of the max. permissible number of starts (1 500c/h) in extreme cases, a time delay between 0,5 s (left stop) and 10s (rightstop) may be set with potentiometer ”t-off” (R88).

16


If

LED indication:(refer to figures O1 and O2)

Th

en

Required setting in end position OPEN:(refer to figures O1 und O2)

LEDs are not illuminated Turn potentiometer ”max” (R28) slightly counter-clockwise untilLED (V24 green) lights up.

LED (V24 green) isilluminated

Turn potentiometer ”max” (R28) clockwise until LED(V24 green) goes out.Then turn potentiometer ”max” (R28) slightly counter-clockwiseuntil LED (V24) lights up again.

LED (V23 yellow) isilluminated

Turn potentiometer ”max” (R28) slightly counter-clockwise untilLED (V23) goes out and LED (V24 green) lights up.

X7 X8 X9

max0

sens

E

t-off

t-off

E1/E2<4 mA

R28

R25

R31

R35

V24

STELLZEITOPERATINGTIME

ENABLEFREIGABE

READYBEREIT V23

V35V37

R88

J

- +

Sticker with signal details(example: E1 = 4-20 mA, E2 = 4-20 mA)

E1 4-20mAE2 4-20mA

auma

variomatic

Figure O2: Cover plate positioner

1

R28

R25

R31

R35

M4M3M2M1E1

Meas.points

{

S3

S2

V24V23V35V37

R88

E2{

Figure O1: Positioner board

16. Setting of the operating time (output speed)16.1 Setting of the operating time via internal command signal

.Loosen 4 screws (8.1) and remove cover (figure P)..Set required operating time at potentiometer OPERATING TIME(figure Q).Short operating time: turn counter-clockwise.Long operating time: turn clockwise.Speed ranges see technical data sheet.Replace cover and fasten 4 bolts (8.1) evenly crosswise.

17


Local controls

AUMA VARIOMATIC Switch compartmentcover

8.1 AUMA VARIOMATICFigure P: Actuator ASO/AS(R) with controls AUMA VARIOMATIC


Cover platestandard




Diagnosis LED (green):Enable REMOTE (option)always installed,illuminated during normaloperation

Diagnosis LEDs foractive REMOTEcontrol commands:run command STOP (red)run command OPEN (green)run command CLOSE (yellow)

Logic board

Figure Q: VARIOMATIC Standard

16.2 Setting of the operating time via the speed-interface board (option)

(refer to order-related wiring diagram CI V... AI...)With the speed-interface board the operating time (speed) can also bepre-determined through an external signal, either analogue (commandsignal E3 = 0 - 20 mA or 4 - 20 mA) or binary (command signal n1, n2).

The simultaneous use of the analogue and the digitalnominal operating time is not possible!

.Loosen 4 screws (8.1) and remove cover (figure P, page 17)..The speed-interface board (figure R) is situated directly above the logicboard. Depending on version (with or without positioner), remove theboards above (cover plate, positioner board and additional board).

Settingon logic board:

.Check on the logic board whether the DIP switch S1, pos. 7 (nominaloutput speed) is in position ”OFF”. If necessary, correct the switch position(see clause 14, pages 12/13)..Set the potentiometer ”OPERATING TIME” (figure Q, page 17) on thelogic board to the fully clockwise position (max. speed) to make use of theentire range of operating time. If the minimal operating time (max. speed)has to be limited to a higher value as the operating time possible by theactuator (see technical data sheet), set potentiometer to this value (e.g. toavoid water hammer).

Setting onspeed-interface board:

When using the option positioner (see clause 15, page 14) set the selectorswitch S2-2.2 (figure R) on the speed-interface board to position‘positioner’. For all other versions the switch S2-2.2 has to be set to position‘speed-interface board’.

18



LED’s:V4: nominal operating

time n1V6: nominal operating

time n2

Logic board

ON

Speed-interfaceboard

Range switch S1-2.2(component A2.2)for analogue nominaloperating time E3

Range switch S2-2.2(component A2.2)for analogue nominaloperating time E3

Dot visible:4 - 20 mA

Dot visible:positioner

Dot not visible:0 - 20 mA

Dot not visible:interface board

Potentiometer R9:for setting of the binarynominal operating time n1

Potentiometer R16:adjustment analoguenominal operating time E3

Potentiometer R10:for setting of the binarynominal operating time n2

Measuring point MP2 Measuring point MP1

Figure R: Speed-interface board

Analoguenominal operating time E3:

The analogue operating time range E3 (refer to wiring diagram CI V... AI...)can be set with the switch S1-2.2 (figure R) to either 0 - 20 mA or 4 - 20 mA.After a change, adjustment of the max. value (20 mA) is necessary.The adjustment is performed as follows:.Connection of 24 V DC +/- 10 % to the analogue input of the

speed-interface board (see wiring diagram CI V... AI...)max. current input ≤30mA.Connection of 20 mA at nominal operating time E3 of the speed-interfaceboard (see wiring diagram CI V... AI...).Measure voltage between MP1 and MP2 (figure R)..Adjust the voltage to 10,00 V +/- 0,01 V by using the potentiometer R16(figure R).

Binarynominal operating time n1, n2

Two inputs are available for the setting of the operating time via binarysignals.The adjustment of the two operating times is performed as follows:Control of the binary nominal operating time n1 by.connection of 24 V DC to the binary input n1 of the speed-interface board

(see wiring diagram CI V... AI...)A visual check of the connected signal with LED V4 is possible (figure R)..The setting of the operating time is done via potentiometer R9 (figure R),clockwise rotation equals higher speed = shorter operating time.

Control of the binary nominal operating time n2 by.connection of 24 V DC to the binary input n2 of the speed-interface board(see wiring diagram CI V... AI...)A visual check of the connected signal with LED V6 is possible (figure R)..The setting of the operating time is done via potentiometer R10 (figure R),clockwise rotation equals higher speed = shorter operating time.

.During simultaneous control of n1 and n2, the shortestoperating time has priority..Without control of n1 and n2, the max. operating time isavailable.

.When operated via local controls, the actuator always runswith max. speed (shortest operating time)..Control of the set speed (operating time) is only possiblevia REMOTE commands.

16.3 Further functions of the speed-interface board in conjunction with the positioner (option)

.Remote change-over of the nominal operating time

This function is only possible in combination with theanalogue or binary nominal operating time (selector switchS2-2.2 in position ‘positioner’, figure R).

From Remote, the nominal operating time can be changed over with a+ 24 V DC signal between the operating time determined by the positionerand the operating time set by the customer via the speed-interface board.

19


.Change-over AUTO/REMOTE

The positioner can be completely switched off from Remote with a + 24 VDC signal. This permits the use of the binary control signals (OPEN,STOP, CLOSE) in conjunction with the analogue or digital nominaloperating time.

1) The binary control signals must be externally deactivated(customer) as long as the positioner is active.

2) This function is only possible in combination with theanalogue or binary nominal operating time (selectorswitch S2-2.2 in position ‘positioner’, figure R, page 18).

3) If no external signal is present, the actuator runs with itsslowest speed (or longest operating time).

17. Signal board (option) Signal boards with the option ”Running indication” (blinker transmitter) offerthe possibility to switch over from impulse to continuous signal by way of asliding switch (see wiring diagram).The signal board (figure S) is accessible after taking off the green coverplate (figure L, page 12, or figure N, page 14).

20


for connectionat AUMA

plug/socketconnector

XKsee wiringdiagram

CI V... AI...

Voltage Function

0 V DC

Run commandsby positioner1)

(operating time dependent on error variable)

24 V DC

Run commandsby binary REMOTE commands 2) 3)

(OPEN, STOP, CLOSE and analogue orbinary nominal operating time)

Switch for running indication(blinker transmitter)

OFF ON

Figure S: Signal board

for connectionat AUMA

plug/socketconnector

XKsee wiringdiagram

CI V... AI...

Voltage Function

0 V DCinternal nominal operating time

by positioner(operating time dependent on error variable)

24 V DC

external nominal operating timeby speed interface board 3)

(analogue or binary nominal operating time)

18. FusesFuses (figure T) are accessible after removing the localcontrols (figure P, page 17)

Observe recommended fuses in mains: See ”Technicaldata”, page 4.

Disconnect actuator from the mains before changing thefuses.

19. Maintenance After commissioning, check for damages on paint of part-turn actuator. Do athorough touch-up to prevent corrosion. Original paint in small quantitiescan be supplied by AUMA.

AUMA part-turn actuators require very little maintenance.Precondition for reliable service is correct commissioning.

Seals made of elastomers are subject to aging and must therefore regularlybe checked and, if necessary, exchanged.

It is also very important that the O-rings at the covers are placed correctlyand cable glands fastened firmly to prevent ingress of dirt or water.

We recommend:

. If operated seldom, perform a test run about every 6 months. Thisensures that the actuator is always ready to operate..Approximately six months after commissioning and then every year checkbolts between part-turn actuator and valve/gearbox for tightness. Ifrequired, re-tighten applying the torques given in table 1, page 6.

The gear housing is filled with lubricant in the factory. This filling lasts forseveral years of service.

The described actuators are high-precision electro mechanical devices.Defective actuators can therefore only be repaired in the factory or in anauthorised workshop.

21


F2

F1

Figure T: Fuses

Fuses:(figure T)

F 1 F 2

20 x 5 20 x 5

10 A T;250 V

1 A T;250 V

20. Declaration of Conformity and Declaration of Incorporation

22


23


Y000.237/003/en/1.00

Worm gearboxesGS 40.3 – GS 125.3GS 160 – GS 500Torques up to 360 000 Nm

Lever gearboxesGF 50.3 – GF 125.3GF 160 – GF 250Torques up to 32 000 Nm

Part-turn actuatorsAS 6 – AS 50Torques from 25 to 500 NmSpeeds for 90° from 4 to 90 s

Part-turn actuatorsSG 05.1 – SG 12.1Torques from 100 to 1 200 NmSpeeds for 90° from 4 to 180 s

Bevel gearboxesGK 10.2 – GK 40.2Torques up to 16 000 Nm

Linear thrust units LEwith multi-turn actuators SAThrusts from 4 kN to 217 kNStrokes up to 400 mmRunning speedsfrom 20 to 360 mm/min

Multi-turn actuatorsSA 07.1 – SA 16.1 / SA 25.1 – SA 48.1Torques from 10 to 32 000 NmSpeeds from 4 to 180 min-1

Spur gearboxesGST 10.1 – GST 40.1Torques up to 16 000 Nm

Controls AUMA MATICwith multi-turn actuators SA/ SARTorques from 10 to 1 000 NmSpeeds from 4 to 180 min-1

WERNER RIESTER GmbH & Co. KGArmaturen- und MaschinenantriebeP.O.Box 1362 D - 79373 MüllheimTel 07631/809-0 Fax 07631/13218e-mail [email protected]://www.auma.com

WERNER RIESTER GmbH & Co. KGArmaturen- und MaschinenantriebeP.O. Box 1151 D - 73747 OstfildernTel 0711/34803-0 Fax 0711/34803-34e-mail [email protected]

Insert to operation instructionsASO 3 - ASO 6/ AS 6 - AS 50/ ASR 6 - ASR 50Issue 1.00

AUMA VARIOMATICBus

R

Issue 1.00Y000.584/003/en

The following changes in the operation instructions must be observed:

Page 13, subclause 14.1, programming with bus board installed (MODBUS, PROFIBUS and INTERBUS-S):

1) Profibus FMS and Set switch position S1 pos. 5 to ”ON”MODBUS (no nominal output speed possbible via bus)

Profibus DP andINTERBUS-S Set switch position S1 pos. 5 to ”OFF”

The setting for the type of seating - limit or torque seating - must be identical on thePROFIBUS DP board (switch S4, � already set in the factory, refer to operation instructionsAUMA VARIOMATIC PROFIBUS DP) and on the logic board (DIP switch S1/ DIP 3).


Programming(ON = switch pressed)

Self-retaining REMOTE (not applicable for bus systems)

Push-to-run operation REMOTE



Type of seating for end position CLOSED for end position OPEN

Limit seatingset DIP switch on logic board always to torque seating,refer to operation instructions, subclause 6.2, page 6

Torque seating

external(setting via bus possible)

internal (fixed setting viapotentiometer ‘operating time’)

Nominal output speed 1)

Table 3

1 2 3 4 5

ONOFF

1 2 3 4 5

ONOFF

1 2 3 4 5

ONOFF

1 2 3 4 5

ONOFF

1 2 3 4 5

ONOFF

1 2 3 4 5

ONOFF

1 2 3 4 5

ONOFF

S1

Potentiometeroperating time

Figure: Logic board for AUMA VARIOMATIC Bus

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