AUMA A 25.2 Operation Instructions Manual Download

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Control

→

Parallel

Profibus DP

Modbus RTU

Modbus TCP/IP

Foundation Fieldbus

HART

Profinet

Multi-turn actuators

SAEx 25.1 – SAEx 40.1

SAREx 25.1 – SAREx 30.1

Control unit - electromechanical

with actuator controls

ACExC 01.2 on wall bracket

Assembly, operation, commissioning

Operation instructions

Summary of Contents for A 25.2

Page 1: ...us TCP IP Foundation Fieldbus HART Profinet Multi turn actuators SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Control unit electromechanical with actuator controls ACExC 01 2 on wall bracket Assembly ope...

Page 2: ...late 15 3 Transport and storage 15 3 1 Transport 16 3 2 Storage 17 4 Assembly 17 4 1 Mounting position 17 4 2 Handwheel fitting 18 4 3 Multi turn actuator mount to valve gearbox 18 4 3 1 Design of out...

Page 3: ...uator operation from remote 50 6 3 Menu navigation via push buttons for settings and indications 51 6 3 1 Menu layout and navigation 52 6 4 User level password 53 6 4 1 Password entry 53 6 4 2 Passwor...

Page 4: ...tions and warning indications 80 11 3 Fuses 80 11 3 1 Fuses within the actuator controls 81 11 3 2 Fuse replacement 81 11 3 2 1 Replace fuses F1 F2 82 11 3 2 2 Test replace fuses F3 F4 82 11 3 3 Fuses...

Page 5: ...108 Index 111 Addresses 5 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 ACExC 01 2 Table of contents...

Page 6: ...ect and control of these regulations standards and laws Commissioning Prior to commissioning imperatively check that all settings meet the requirements of the application Incorrect settings might pres...

Page 7: ...upplement must be observed in addition to these operation instructions 1 3 Warnings and notes The following warnings draw special attention to safety relevant procedures in these operation instruction...

Page 8: ...quickly found on the display Display texts are shaded in grey Display Wiring diagram Texts extracted from other documents Texts extracted from other documents are highlighted in a different font For e...

Page 9: ...REx 25 1 SAREx 30 1 they are mounted separately on a wall bracket For high nominal motor currents of the actuator the switchgear of the actuator controls additionally require a control box Figure 2 Ac...

Page 10: ...4 Actuator name plate example manufacturer logo CE mark 1 Name of manufacturer 2 Address of manufacturer 3 Type designation 4 Order number 5 Serial number 6 Speed 7 Torque range in direction CLOSE 8...

Page 11: ...rotection 10 Control 11 Data Matrix code Motor name plate Figure 6 Typenschild Motor Beispiel manufacturer logo CE mark 1 Motor type 2 Motor article number 3 Serial number 4 Current type mains voltage...

Page 12: ...ype and size These instructions apply to the following devices types and sizes Type SAEx Multi turn actuators for open close duty Sizes 25 1 30 1 35 1 40 1 Type SAREx Multi turn actuators for modulati...

Page 13: ...T Potentiometer C D E G H M P S U Electronic position transmitter AUMA power class for switchgear The switchgear used in the actuator controls reversing contactors thyristors are classified according...

Page 14: ...Figure 9 Link to AUMA Assistant App For further Service Support software apps refer to www auma com 14 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Identification ACExC 01 2...

Page 15: ...se of lifting by hoist only to the actuator and NOT to the controls Respect total weight of combination actuator actuator controls gearbox valve Secure load against falling down sliding or tilting Per...

Page 16: ...2 180 F35 AF 35 2 320 F40 AF 40 2 3 2 Storage Danger of corrosion due to inappropriate storage Store in a well ventilated dry room Protect against floor dampness by storage on a shelf or on a wooden p...

Page 17: ...Do NOT use extensions as lever for operation First engage manual operation correctly then mount handwheel 1 Manually lift the red change over lever while slightly turning the shaft back and forth unti...

Page 18: ...upling 3 Valve stem Output mounting flange 1 with axial bearing stem nut 2 form one unit Torque is transmitted to valve stem 3 via stem nut 2 To adapt the actuators to available output drive types A w...

Page 19: ...4 Drill and bore stem nut 1 and cut thread 5 Clean the machined stem nut 1 6 Apply sufficient Lithium soap EP multi purpose grease to axial needle roller and cage assemblies 2 2 and axial bearing wash...

Page 20: ...etely tightening them 6 Fit multi turn actuator on the valve stem so that the stem nut dogs engage into the output drive sleeve The flanges are flush with each other if properly engaged 7 Adjust multi...

Page 21: ...ve types B3 B4 E the connection is made via output drive sleeve which is inserted into the bore of the hollow shaft of the multi turn actuator and fixed by a retaining ring When exchanging the output...

Page 22: ...for screws Tightening torque Nm Threads Strength class A2 80 8 8 200 214 M16 392 431 M20 1 422 1 489 M30 2 481 2 594 M36 4 4 Accessories for assembly 4 4 1 Stem protection tube for rising valve stem F...

Page 23: ...sh down the sealing ring 3 onto the housing Information For mounting segments push down seals of segments down to the sleeve connecting piece 4 Check whether protective cap 1 for stem protection tube...

Page 24: ...tor measuring the pulse code is required Current type mains voltage mains fre quency Type of current mains voltage and mains frequency must match the data on the actuator controls and motor name plate...

Page 25: ...u verwenden der Einsatz von Sicherungsautomaten ist aber grunds tzlich zul ssig We recommend refraining from using residual current devices RCD However if an RCD is used within the mains the residual...

Page 26: ...e earth potential If possible avoid laying long cables and make sure that they are installed in areas being subject to low interference Avoid parallel paths with little cable distance of cables being...

Page 27: ...t Control box For actuators with high nominal motor current AUMA power class switchgear from category A4 a control box is additionally required Switchgear reversing contactors will then be installed i...

Page 28: ...open Figure 25 Open motor connection compartment 1 Cover 2 Screws for cover 3 O ring 4 Cable gland Electric shock due to presence of hazardous voltage Failure to observe this warning results in death...

Page 29: ...2 8 22 6 0 12 Nm 16 70 mm 2 32 45 4 0 5 0 Nm 10 35 mm 2 4 11 SAEx 40 1 6 0 12 Nm 16 70 mm 2 16 32 1 Remove cable sheathing and insert the wires into the cable glands 2 Fasten cable gland with the spec...

Page 30: ...maged 3 Apply a thin film of non acidic grease e g petroleum jelly to the O ring and insert it correctly 4 Fit cover 1 and fasten screws 2 evenly crosswise 5 3 2 Electrical connection K KR 5 3 2 1 Ter...

Page 31: ...68 Information For shielded cables Use EMV cable glands 3 Seal cable entries which are not used with approved plugs suitable for the re quired protection type 5 3 2 2 Cable connection Table 15 Termina...

Page 32: ...n 1 U bracket for PE connection 7 For shielded cables Link the cable shield end via the cable gland to the housing earthing 5 3 2 3 Terminal compartment close Figure 31 Close terminal compartment for...

Page 33: ...rt description KP KPH plug in electrical connection with screw type terminals for power and control contacts KP version standard with three cable entries KPH version enlarged with additional cable ent...

Page 34: ...tment open Figure 33 Open terminal compartment 1 Cover figure shows KP version 2 Screws for cover 3 O ring 4 Blanking plugs 5 Cable gland example 6 Flameproof frame Electric shock due to presence of h...

Page 35: ...h connection PE With large clamp washers 2 5 6 mm 2 flexible or solid 0 5 0 7 Nm 0 75 1 5 mm 2 flexible or solid Control contacts 1 to 24 31 to 40 47 to 50 PE 1 Remove cable sheathing in a length of 1...

Page 36: ...ection 1 PE connection control cable 2 PE connection motor cable 5 4 1 3 Terminal compartment close Figure 36 Close terminal compartment 1 Cover figure shows KP version 2 Screws for cover 3 O ring 4 B...

Page 37: ...d flameproof enclosure Plug in connection is made via the connection frame For cable connection simply remove the cover The connection frame remains within the device The flameproof interior of the c...

Page 38: ...on Ex d flameproof enclosure refer to Ex marking on name plate The flameproof interior of the connected device remains closed when removing the cover 1 2 Insert cable glands suitable for connecting ca...

Page 39: ...s Link the cable shield end via the cable gland to the housing earthing 3 Strip wires 4 For flexible cables Use end sleeves according to DIN 46228 5 Connect cables according to order related wiring di...

Page 40: ...int sur faces with an acid free corrosion protection agent 3 Check whether O ring 3 is in good condition replace if damaged 4 Apply a thin film of non acidic grease to the O ring and insert it correct...

Page 41: ...ction is made via the connection frame For cable connection simply remove the cover The connection frame with the cable entries remains within the device The flameproof interior of the connected devic...

Page 42: ...injury Disconnect device from the mains before opening 1 Loosen screws 2 and remove cover 1 2 Insert cable glands suitable for connecting cables Information When selecting cable glands observe type of...

Page 43: ...asten cable glands with the specified torque to ensure required enclosure protection Information For shielded cables Link the cable shield end via the cable gland to the housing earthing 4 Strip wires...

Page 44: ...h con ductor 7 Firmly tighten protective earth to PE connection M6 Figure 46 Protective earth connections within connection frame M6 Customer protective earth connection for M6 ring lug or with U brac...

Page 45: ...is in good condition replace if damaged 4 Apply a thin film of non acidic grease e g petroleum jelly to the O ring and insert it correctly 5 Fit cover 1 and fasten screws 2 evenly crosswise For design...

Page 46: ...ss sections and earth connection tightening torques Tightening torques Terminal cross sections Conductor type 3 4 Nm 6 mm to 16 mm Solid wire and stranded 3 4 Nm 4 mm to 10 mm Fine stranded For fine s...

Page 47: ...cted plug or cover For protection against touching the bare contacts and against environmental influences Explosion hazard Risk of death or serious injury Prior to opening the device removing the plug...

Page 48: ...g manual operation The load must be sustained via the handwheel Damage at the change over mechanism due to faulty operation Engage manual operation only during motor standstill Only pivot change over...

Page 49: ...ue to incorrect basic setting Prior to electric actuator operation perform the basic settings for type of seating and torque switching 6 2 1 Operating the actuator from local controls Local actuator o...

Page 50: ...itch to 0 OFF Check input signals and functions Set selector switch to position Remote control REMOTE Now it is possible to operate the actuator via remote control via operation commands OPEN STOP CLO...

Page 51: ...etails Enter Main menu Setup 4 C Cancel process Esc Return to previous display Backlight The display is illuminated in white during normal operation It is illuminated in red in case of a fault The scr...

Page 52: ...display example Display indicates in the bottom row Go to 1 Press push button Go to Display indicates Go to menu M0000 2 Use push buttons Up Down to select figures 0 to 9 3 Press push button Ok to con...

Page 53: ...tons Up Down to select figures 0 to 9 4 Confirm first digit of password via push button Ok 5 Repeat steps 1 and 2 for all further digits Having confirmed the last digit with Ok access to all parameter...

Page 54: ...word Display indicates Change passwords For user 4 example 8 Select next user level via push buttons Up Down or cancel the process via Esc 6 5 Language in the display The display language can be selec...

Page 55: ...new language via Up Down resulting in the following significations black triangle current setting white triangle selection not saved yet 11 Confirm selection via Save The display changes to the new la...

Page 56: ...nu loading please wait Figure 62 Self test The language selection menu follows the startup menu Startup menu The current firmware version is displayed during the startup procedure Figure 63 Startup me...

Page 57: ...sition 0 OFF to fade in the navigation support 7 2 1 Feedback indications from actuator and valve Display indications depend on the actuator version Valve position S0001 This indication is only availa...

Page 58: ...al torque Operation commands S0003 The display S0003 indicates active operation commands like e g Operation in direction CLOSE or in direc tion OPEN the actual value E2 as bar graph indication and as...

Page 59: ...ate positions on the right stepping mode Table 25 Symbols along the pivot point axis Stepping mode Pivot point intermediate position with operation profile Symbol End of stepping mode Pivot point with...

Page 60: ...f faults occurred a blinking exclamation mark after approx 3 seconds Figure 76 Fault For further information please also refer to Corrective action 7 2 3 Status indications according to NAMUR recommen...

Page 61: ...ations according to NAMUR recommendation NE 107 If such an indication has occurred the display shows S0010 the number of indications occurred a blinking square with an oilcan after approx 3 seconds Fi...

Page 62: ...cations Different indications can be assigned to LEDs 1 5 Device configuration M0053 Local controls M0159 Indication light 1 left M0093 Indication light 2 M0094 Indication light 3 M0095 Indication lig...

Page 63: ...f power supply Used as running indication Indicator disc rotates during actuator operation and continuously indicates the valve position For clockwise closing version the symbols rotate in countercloc...

Page 64: ...T 4 Torque sw CLOSED Signal DOUT 11 Torque fault CLOSE Signal DOUT 5 Torque sw OPEN Signal DOUT 12 Torque fault OPEN Signal DOUT 6 8 1 2 Coding the outputs The output signals Coding DOUT 1 Coding DOUT...

Page 65: ...prior to commissioning For 30 C 5 min For 40 C 40 min For 60 C 80 min 9 2 Type of seating set Valve damage due to incorrect setting The type of seating setting limit or torque seating must match the...

Page 66: ...ection not saved yet 8 Press Ok Display indicates Password 0 9 Enter password enter password The screen indicates the pre set type of seating Limit or Torque by means of a black triangle Change settin...

Page 67: ...re 83 Torque measuring heads 1 Torque switching head black in direction CLOSE 2 Torque switching head white in direction OPEN 3 Lock screws 4 Torque dials 1 Loosen both lock screws 3 at the indicator...

Page 68: ...ete 7 If you override the tripping point inadvertently ratchet click is heard after the pointer has snapped Continue turning the setting spindle in the same direction and repeat setting process 9 5 2...

Page 69: ...tch off before reaching the end position 1 Move actuator manually to intermediate position or to sufficient distance from end position 2 Switch on actuator in direction CLOSE and observe the direction...

Page 70: ...ve actuator manually to intermediate position or to sufficient distance from end position 2 Depending on the version Unscrew threaded plug 1 with seal 2 protective cap 4 or stem protection tube 6 3 Sw...

Page 71: ...operation has to be performed once the limit switching setting was changed to ensure that the position feedback 0 4 20 mA supplies correct values Operate actuator electrically via the push buttons OPE...

Page 72: ...0 End position OPEN corresponds to 100 3 Turn potentiometer 1 slightly in opposite direction 4 Perform fine tuning of the zero point at external setting potentiometer for remote indication 10 2 RWG e...

Page 73: ...r to Switch compartment open Setting is made via three potentiometers 1 2 and 3 Figure 89 View on control unit when switch compartment is open 1 Potentiometer travel sensor 2 Potentiometer min 4 mA 3...

Page 74: ...in direction CLOSE to desired intermediate position 2 If you override the tripping point inadvertently Turn valve into the opposite dir ection and approach intermediate position again in direction CL...

Page 75: ...tripping point inadvertently ratchet click is heard after the pointer has snapped Continue turning the setting spindle in the same direction and repeat setting process 10 4 Mechanical position indica...

Page 76: ...replace the switches if required Switch is defective or switch setting is incorrect Limit and or torque switches do not trip Switch check The red test buttons 1 and 2 are used for manual operation of...

Page 77: ...intenance S0010 Maintenance required For indicated value 0 Press push button Details to display a list of detailed indications For details refer to Faults and Failure table Collective signal 10 Indica...

Page 78: ...que wrn OPEN Check parameter Wrn torque CLOSE M0769 re set if required Limit value for torque warning in direction CLOSE exceeded Torque wrn CLOSE Refer to separate Manual Functional Safety SIL sub as...

Page 79: ...display persists after cool ing down Set selector switch to position Local con trol LOCAL and reset fault indication via push button RESET Check fuses Motor protection tripped Thermal fault Check move...

Page 80: ...e Apply 24 V DC at EMERGENCY input Operation mode EMERGENCY is active EMER GENCY signal was sent 0 V are applied at the EMERGENCY input EMCY behav active Check I O interface The actuator is controlled...

Page 81: ...rcuit protection for external 24 V DC supply for customer see wiring diagram 11 3 2 Fuse replacement 11 3 2 1 Replace fuses F1 F2 Information Only valid for version with electrical connection of KES o...

Page 82: ...nit 3 and pull out The fuses are on the equipped part of the power supply board Cable damage due to pinching Risk of functional failures Carefully assemble power supply unit to avoid pinching the cabl...

Page 83: ...en LED 3 motor protection trippped on the local controls is illuminated The status indications S0007 or S0011 Failure display a fault The fault Details is displayed when selecting Thermal fault The mo...

Page 84: ...ate motor protection simulation Press Ok push button The safety function is correct if no fault signal is displayed 4 Reset simulation Press Ok push button or exit the simulation menu and reset the se...

Page 85: ...cable glands and blanking plugs with torque in compliance with the manufacturer s specifications Check fastening screws between actuator and gearbox valve for tightness If required fasten screws whil...

Page 86: ...l connection 1 Cover 2 Screws for housing 3 O ring 4 Plug in frame KP KPH 5 Connection frame KES Removing the plug 1 Loosen the screws 2 2 Remove electrical connection Cover 1 and plug in type frame 4...

Page 87: ...oof enclosure Remove grub screws 6 inside the connection frame 4 Loosen screws 4 inside the connection frame 5 Remove electrical connection Fitting the plug socket connector 6 Clean sealing faces of p...

Page 88: ...fastened correctly Take care of possible discolouration of the terminals and wires This would in dicate an increased temperature For Ex housings pay special attention to a possible collection of wate...

Page 89: ...to water and must not be released into the environment Arrange for controlled waste disposal of the disassembled material or for sep arate recycling according to materials Observe the national regulat...

Page 90: ...g to IEC 60364 4 443 Overvoltage category F tropicalized Standard Insulation class H tropicalized Option PTC thermistors according to DIN 44082 Standard Motor protection Thermoswitches NC in the actua...

Page 91: ...ation with AMExC or ACExC actuator controls Service conditions Indoor and outdoor use permissible Use Any position Mounting position 2 000 m above sea level 2 000 m above sea level on request Installa...

Page 92: ...Technical data for limit and torque switches 2 x 10 6 starts Mechanical lifetime Silver plated contacts 30 V AC DC U min 250 V AC DC U max 20 mA I min 5 A at 250 V AC AC 15 Rated voltage current 0 15...

Page 93: ...designed for the nominal motor power refer to motor name plate Rated power Reversing contactors mechanically and electrically interlocked for AUMA power classes A1 A2 Standard Switchgear Reversing co...

Page 94: ...esistive load 1 potential free NO contact max 250 V AC 1 A resistive load 1 potential free change over contact max 250 V AC 5 A resistive load 6 programmable output contacts 4 mains failure proof pote...

Page 95: ...haviour selectable Split Range operation MODE input for selecting between OPEN CLOSE and setpoint control PID process controller with adaptive positioner via 0 4 20 mA analogue inputs for process setp...

Page 96: ...for cable entries Pg threads NPT threads G threads Options Refer to name plate Wiring diagram Service conditions Indoor and outdoor use permissible Use Any position Mounting position 2 000 m above sea...

Page 97: ...o the device All standards applied and their respective issues are indicated on these certificates Certificates and standards The specific conditions of use are listed on the certificates supplied Spe...

Page 98: ...14 Spare parts 14 1 Multi turn actuators SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 98 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Spare parts ACExC 01 2...

Page 99: ...G 566 3 Crown wheel 019 0 Slip clutch for potentiometer 567 1 Swing lever 020 0 Stem protection tube without cap 568 1 Drive pinion II for torque switching 022 0 Sub assembly Protective cap for stem p...

Page 100: ...14 2 Actuator controls ACExC 01 2 KP KPH 100 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Spare parts ACExC 01 2...

Page 101: ...b assembly Logic board 009 0 Sub assembly Relay board 011 1 Option board 012 0 Sub assembly Cover 500 0 Sub assembly Ex plug socket connector with screw type terminals KP KPH 501 0 Screw for control t...

Page 102: ...14 3 Actuator controls AUMATIC ACExC 01 2 KES 102 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Spare parts ACExC 01 2...

Page 103: ...I O board 008 1 Sub assembly Fieldbus board 008 1 Sub assembly Logic board 009 0 Sub assembly Relay board 011 1 Option board 012 0 Sub assembly Cover 500 0 Pin carrier without pins 502 0 Pin for contr...

Page 104: ...14 4 Actuator controls ACExC 01 2 KT KM 104 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Spare parts ACExC 01 2...

Page 105: ...board 002 3 Face plate for display 002 4 Sub assembly Power supply unit 006 0 I O board 008 1 Fieldbus board 008 1 Sub assembly Logic board 009 0 Sub assembly Relay board 011 1 Option board 012 0 Sub...

Page 106: ...14 5 ExC wall bracket 106 SAEx 25 1 SAEx 40 1 SAREx 25 1 SAREx 30 1 Spare parts ACExC 01 2...

Page 107: ...epresentation of spare parts may slightly vary from actual delivery Type Designation Ref no Sub assembly Wire for protective earth 058 0 Sub assembly Cover 500 0 Sub assembly Terminal frame without te...

Page 108: ...sal 88 DUO limit switching 74 E Earth connection 46 Electrical connection 24 Electronic position transmitter 72 EMC 26 Enclosure protection 10 11 11 91 96 Error indication on display 56 Ex certificate...

Page 109: ...ition transmitter 13 Potentiometer 72 Power class 11 Power class for switchgear 13 Power factor 11 Power supply of electronics 24 Production year 13 Protection on site 24 Protection types 12 Protectiv...

Page 110: ...Transport 15 Type device type 12 Type designation 10 11 Type of current 11 Type of duty 11 90 Type of lubricant 10 Type of networks 24 U User level 52 V Valve position indication on display 57 Valve...

Page 111: ...111...

Page 112: ...er GmbH Co KG P O Box 1362 DE 79373 Muellheim Tel 49 7631 809 0 Fax 49 7631 809 1250 info auma com www auma com Y005 733 003 en 1 20 For detailed information on AUMA products refer to the Internet www...

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AUMA A 25.2, Operation Instructions Manual

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