723 2-WAY CONTROL VALVES

Transcription

1 Technical Manual Instructions for installation, operation and maintenance WAY CONTROL VALVES Fig , with electric actuator Ari-Premio Publication nr Supersedes TIB-723-GB-0613 TIB-723-GB-0711

2 Operating and Installation Instructions Straightway Control Valves Fig Fig General Information on Operating Instructions Notes on Possible Dangers Significance of Symbols Safety-Related Definitions Qualified Personnel Handling Storage Transport Handling Before Installation Description Scope of Applications Operating Principles Diagram / Plug Designs Marking Installation General Notes on Installation Requirements at the Place of Installation... 5 Contents Fig Installation Instructions Concerning Actuators Notes on Dangers During Installation, Operation and Maintenance Putting the Valve into Operation Care and Maintenance Spindle Packings / Assembly Packings with PTFE V-ring unit Stuffing Box Packings Bellow Seal Replacing the Plug, Spindle and Seating Troubleshooting Troubleshooting Table Dismantling the Valve Warranty englisch

3 Operating and Installation Instructions Control Valves Fig General Information on Operating Instructions These operating instructions contain information necessary to install and operate the valve both safely and effectively. If problems arise which cannot be solved with the aid of these operating instructions, please contact the supplier/manufacturer for further information. These operating instructions comply with applicable EN safety standards as well as regulations and codes of practice applicable in the Federal Republic of Germany. If the valve is used outside the Federal Republic of Germany, the operator or the person responsible for the system design must ensure that valid national codes of practice are complied with. The manufacturer reserves all rights to implement technical modifications and improvements at any time. The use of these operating instructions assumes the user is qualified as described under Section 2.3 "Qualified Personnel". The operating personnel must be instructed in accordance with the operating instructions. 2.0 Notes on Possible Dangers 2.1 Significance of Symbols Warning of general danger 2.2 Safety-Related Definitions The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating instructions as indications for particular hazards or for important information requiring special signs. DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or considerable damage to property can occur. WARNING means that if the relevant information is disregarded, there is a danger of serious injury and / or damage to property can occur. CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or damage to property can occur. NOTE means that particular attention must be paid to certain technical aspects. All other information not specifically emphasised such as transport, installation, operating and maintenance instructions as well as technical data (in the operating instructions, product documentation and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to persons or damage to property. 2.3 Qualified Personnel The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-up, operation and maintenance of the product and have the qualifications corresponding to their responsibilities such as: Instruction and obligation to comply with all operational, regional and in-company regulations and requirements; Training or instruction in accordance with safety technology standards with regard to the upkeep and use of appropriate safety and work protection equipment; First aid training, etc. (see TRB 700). page

4 Operating and Installation Instructions Control Valves Fig Handling 3.1 Storage - Storage temperature -20 to +65 C dry, free of dirt - The painting is only a primer, intending to guard against rust during stock or transportation. Don t damage the paintwork. - A desiccant or heating to prevent condensation is necessary in damp rooms. 3.2 Transport - Transport temperature -20 to +65 C. - Protect against external force (impact, vibration etc.). - Don t damage the paintwork. 3.3 Handling Before Installation - If flange covers are fitted, remove shortly before maintenance! - Protect against atmospheric conditions e.g. wetness (applicate a desiccant). - Correct handling protects against damage. 4.0 Description 4.1 Scope of Applications These control valves are suitable for controlling the flow of liquids, gases and vapours in chemical and other processing plants and for plant engineering. The materials have been selected and matched on the basis of current DIN, AD, TRD and UVV rules. The mechanical and flow characteristics conform to standard DIN EN The engineer planning a plant is responsible for selecting the correct valve for a given application. The special features of the valve concerned must be taken into account. - Valves for oxygen application (O 2 ) have a fixed plate. - Valves for Ammonia (NH 3 ) acc. to TRD must be free from nonferrous metals with flanges DIN 2512 form N. acc. to TRB 801 No.34 for ammonia storage tank systems, bodies with shoed ends must be stress-relief-annealed. - ARI-Valves of GG-25 are not allowed in systems acc. to TRD Valves for inflammable, aggressive or toxic media, must be off tensile material. - With applications for media that demand special criteria, please consult. - -marking for applications acc. to Pressure Equipment Directive. 4.2 Operating Principles Oil and grease free for oxygen application ARI control valves are especially suitable for actuation by pneumatic or electrical actuators. Three plug types are available to suit the various applications: parabolic plug (standard pattern) perforated plug V-port plug The flow through control valves with parabolic and V-port plugs is always against the closing direction. In the case of control valves with perforated plugs, gases and vapours flow against the closing directions, but liquids flow through in the closing direction. If a pneumatic actuator is to be used on a straight-way valve with a perforated plug with the fluid moving in the closing direction, a higher closing force will be needed. This is to prevent vibration as the plug approaches the closed position. Pressure-balanced plugs can be provided if the actuator force is inadequate page 3

5 Operating and Installation Instructions Control Valves Fig Diagram / Plug Designs rotated view rotated view rotated view fig. 1: Fig standard design fig. 2: Fig standard design fig. 3: Design with perforated plug fig. 4: Design with V-port plug page

6 Operating and Installation Instructions Control Valves Fig Marking Details of the CE-marking on the name plate of the valve: CE-marking 0525 Notified body Fig. Figure-No. / Type-No. SN Serial-No. Year of manufacture (clear speech) (1. and 2. position of the serial-no.) 5.0 Installation 5.1 General Notes on Installation The following points should be taken into account besides the general principles governing installation work: - Remove flange covers if present. - There must be no foreign bodies inside the valve or piping. - Pay attention to the direction of flow: see markings on the valve and refer to the operation and installation instructions (point 4.2). - Centre sealings between the flanges. - Connection flanges must mate exactly. - If the valve is handling steam, the piping must be laid with a gradient to prevent water from accumulating in pockets. Condensation traps are needed to prevent water-hammer. - All parts must be free from stress after installation. - The valve must not serve as a fixed point. It must be carried by the piping. - Protect the valve from dirt, especially during construction work. Strainers or filters shoud be installed before the valves. - Install compensators to compensate for thermal expansion of the piping. - Keep the thread and shaft of the spindle free from paint. 5.2 Requirements at the Place of Installation The place of installation should be easily accessible and provide ample space for maintenance and removing the actuator. Stopvalves shoud be installed before and after the controlvalve to enable maintenance working without draining the piping system. The valve should preferably installed vertically with the actuator at the top. Inclined or horizontal installation without supports is permissible only with light actuators. For this installallation position, the two distance columns (or joke) have to be above each other in the verical plane. Pipeline vertically According to the Pressure Equipment Directive part 3, valves without safety function are only allowed to bear the CE-marking DN32 onwards. Valves with safety function are: Type 440 DP-G / 441 DP-G and Type 440 / 440-D with FR2.1 and Ü-sign Pipeline horizontally Permissible servo weights for valves with unsupported horizontal spindles: 20 kg for DN kg for DN kg for DN The pipes must be lagged to protect the actuators from excessive heat. Sufficient space must be left for the maintenance of the spindle packing. To ensure that the control valves function correctly, the pipe run should be straight for at least 2 x DN upstream and 6 x DN downstream of the valve page 5

7 Operating and Installation Instructions Control Valves Fig Installation Instructions Concerning Actuators Normally, control valves are supplied complete with actuator fitted. It is not permitted to mantle / dismantle actuators with valves operating and service conditions (temperature and pressure) (see 2.3). The actuators must be assemble as describe in the operating instructions during conversion and maintenance. During assembly work, the plug is not be turned on its seating at closing pressure. Caution! Care must be taken with the bellow type valves when actuators are mounted or removed. Hold the valvespindle against turning with an open-end wrench. When retrofitting actuators, the maximum permissible force for valve actuation must be taken into account. The maximum permissible actuation forces are: Fig. 440 / 445 Fig. 441 / kn for DN kn for DN kn for DN Notes on Dangers During Installation, Operation and Maintenance DANGER! Operation can be completely safe only if the valve is properly installed, put into operation and maintained by trained personnel (cf. point 2.3 Qualified personnel ) paying full attention to the warnings in these operating instructions. In addition, the general installation and safety rules for piping and plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict attention must be paid to the operating instructions during all work on the valve and when handling it. Injury or damage can be caused by ignoring them. When used as an end-blockage, a safety precaution is recommended by maintenance works. 7.0 Putting the Valve into Operation - Before putting the valve into operation, check that the material, pressure, temperature and direction of flow are as specified with the plans of the piping system. - Regard the TRB Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage. DANGER! Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that: - All installation and assembly work has been completed! - Only qualfied personnel (see point 2.3) are employed to start the plant! - The valve is in the correct position for its function! - Existing guards have been attached and in good order. page

8 Operating and Installation Instructions Control Valves Fig Care and Maintenance Maintenance and maintenanceintervals have to be defined by the operator according to the service conditions (see TRB 700). 8.1 Spindle Packings / Assembly rotated view rotated view fig. 5: PTFE V-ring unit fig. 6: Stuffing box sealing fig. 7: Bellow seal 8.2 Packings with PTFE V-ring unit See Fig. 5 and 8 PTFE V-ring unit consisting of: 1 backing ring 4 sealing rings 1 cover ring Owing to the installed compression spring, this spindle packing is self-adjusting. If the spindle starts leaking, the ring pack is worn out and must be replaced. Replacing PTFE V-ring unit: Warning! See point 11.0 before dismantling the valve. - Remove the actuator (see operating instructions for actuator). - When replacing PTFE V-ring unit (12), make sure that the parts are installed in the correct order and positions (see Fig. on right). - Damaged spindles must also be replaced (see point 8.5 for instructions) since a new ring pack will soon start leaking again with a damaged spindle. - Attention! Gasket (17) must be replaced. fig page 7

9 Operating and Installation Instructions Control Valves Fig Stuffing Box Packings See Fig.6 and 10 - Stuffing box packings require maintenance. - If leaks develop, immediately tighten the screw joint (25) gradually until the packing stops leaking. - The service life of stuffing box packings (23) can be increased by checking regularly leakage. - If leaks can no longer be stopped by tightening the nuts, a new packing ring must be inserted into the gland. Replacing a stuffing box packing: Warning! See point 11.0 before dismantling the valve. - Insert the new packing ring as shown in the Fig. on the right. - If a split packing ring is used, cut with a chamfer as shown in Fig. 9 fig. 9: Split packing ring fig Damaged spindles must also be replaced (see point 8.5 for instructions) since a new ring pack will soon start leaking again with a damaged spindle. page

10 Operating and Installation Instructions Control Valves Fig Bellow Seal See Fig. 7 and 11 If the spindle leaks, the bellow seal is defective. The leak can initially be stopped by tightening the screw joint (20.17). Replacing the bellow seal: Warning! See point 11.0 before dismantling the valve. - Remove the actuator (see operating instructions for actuator). - Slacken the screw joint (20.17) by about one turn. - Remove the bellows housing by unscrewing the nuts (11). - Remove the plug as described in point 8.5b. - Detach the mounting bonnet (20.2) after unscrewing the nuts (20.8). - Extract the spindle from the bellows housing. - Drill new spindle with plug. - Replace 2 seals (20.6) and 1 seal (9). - Assemble in the reverse order. Screw on the nuts (11, 20.8) and tighten them crosswise (See page 11 for tightening torque s). (The spindle can only be replaced complete with bellows.) 8.5 Replacing the Plug, Spindle and Seating Warning! See point 11.0 before dismantling the valve. - Remove the actuator (see operating instructions for actuator) a) Control valves (cf. Fig. 1 and 12) - Detach the mounting bonnet (7). - Slacken screw joint (19) by about one turn. - Extract and replace the plug with spindle. - Replace the gasket (9). - Set the mounting bonnet cover in place and secure it with nuts (11) tightened crosswise. (See page 11 for tightening torque s.) fig. 11 (Plug and spindle can only be replaced completely.) fig page 9

11 Operating and Installation Instructions Control Valves Fig b) Control Valves with Bellow Seal (cf. Fig. 2 and 11) - Unscrew the nuts (11). - Remove the bellows housing (20.1) with plug (3). - Keep the spindle pressed down. - Remove the clamping sleeve (4). - Unscrew the plug (3). - Fit the new plug in the reverse order. - Drill the plug and insert new pin. The spindle can only be replaced complete with bellows (see point 8.4) c) Replacing the Seating Ring (only Fig and Fig ) The seating ring is screwed into the valve body and can be unscrewed for replacement or remachining. A special wrench is needed to remove the seating. It can be obtained from the manufacturer. When fitting a new or reconditioned seating, clean thread and sealing taper in body and apply suitable lubricant. See table below for seat ring tightening torque s. Tightening torque s DN 15/ 20 = 100 Nm DN 25/ 32 = 150 Nm DN 40/ 50 = 350 Nm DN 65 = 480 Nm DN 80 = 660 Nm DN100 = 980 Nm rotated view fig. 13 page

12 Operating and Installation Instructions Control Valves Fig d) Pressure-balanced Plug - Replacing the Seals Warning! See point 11.0 before dismantling the valve. - Detach valve top part and remove plug (replace if necessary) as described in point 8.5 a or b. - Prise worn piston seal (32) out of groove in plug with suitable tool (e.g. screwdriver). - Insert new piston seal, taking care that it is in the correct position (cf. Fig. 14). - Replace guide ring (31). fig. 14: Pressure-balanced plug - Clean sliding surface of guide bush (30); smooth with fine abrasive if necessary. - Before assembly, remember that two seals (9) must be replaced. - Set valve top part in place. - Tighten the hexagon nuts of the cover gradually crosswise. Tightening torque for hexagon nuts: Bolts M 10 M 12 M 16 Torque 20 Nm 35 Nm 80 Nm See operating instructions for actuator concerned for installing actuators! 9.0 Troubleshooting In the event of failures or malfunctions, check that the valve was assembled and installed as described in these instructions. Regard the TRB 700. Compare the material, pressure, temperature and direction of flow with the information given in the plans of the piping system. Check also that the service conditions correspond to the data given on the data plate and the technical data. DANGER! It is essential that the safety regulations are observed when identifying faults! If malfunctions cannot be eliminate with the help of the following troubleshooting table, the supplier or manufacturer should be consulted page 11

13 Operating and Installation Instructions Control Valves Fig Troubleshooting Table Fault Possible cause Corrective measures No flow Valve closed. Open valve (using actuator). Flange covers not removed. Remove flange covers. Little flow Valve not sufficiently open. Open valve (using actuator). Dirt sieve clogged. Clean / replace sieve. Relieve pressure first! Piping system clogged. Check piping system. Kvs value of valve unsuitable. Fit valve with higher Kvs value. Valve spindle moves in jerks. Stuffing box sealing too tight (for valves with graphite packings). Slacken screw joint (25/20.17) slightly. Valve must nor start leaking! Valve spindle or plug cannot be moved. Valve plug slightly seized owing to solid dirt particles. Seating and plug clogged with dirt; especially with V-port and perforated plugs. Valve plug seized in seating or guide owing to deposits or dirt in medium. Caution: - Read point 11.0 prior to dismantling and repair work! - Read point 7.0 before restarting the plant! Clean internals, smooth rough spots. See points 7.0 and 11.0! Clean seating and plug with suitable solvent. See points 7.0 and 11.0! Replace plug and seating; use parts made from different material if necessary. Valve spindle leaking. PTFE V-ring unit damaged or worn. Replace ring pack - see point 8.2 See points 7.0 and 11.0! Leakage too high when valve is closed. In valves with packed stuffing boxes, tighten sleeve nut (25). Tighten screw joint (25); replace packing if necessary. See point 8.3. See points 7.0 and 11.0! Bellows defective in valves with bellow seal. Replace bellows unit - see point 8.4 See points 7.0 and 11.0! Sealing surfaces of plug eroded or worn. Replace plug - see point 8.5. See points 7.0 and 11.0! Sealing edge of seating damages or worn. Replace seating (see point 8.5), (only Fig /446) See points 7.0 and 11.0! Piston sealing ring worn (pressure-balanced valves). Seating and/or plug dirty. Pneumatic actuator not completely vented; spring force not fully effective. Actuator not powerful enough. Replace sealing ring. See points 7.0 and 11.0! Clean internals of valve. See points 7.0 and 11.0! Vent actuator air chamber completely. See points 7.0 and 11.0! Install more powerful actuator. Check service data. page

14 Operating and Installation Instructions Control Valves Fig Dismantling the Valve The following points must be observed beside the general principals rules and TRB 700 governing the assembly work: - Pressureless pipe system. - Medium must be cool. - Plant must be drained. - Purge piping systems in case of caustic, inflammable, aggressive or toxic media. - Have assembly work performed only by qualified personnel (see point 2.3) Warranty The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself. We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed application. No warranty claims can be made for any damage caused as the result of incorrect handling or disregard of operating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and other applicable codes of practice. This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements. Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us. No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is excluded. The warranty shall not cover maintenance work, installation of external parts, design modifications or natural wear. Any damage incurred during transport should not be reported to us but rather to the competent cargohandling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated. Technology for the Future. GERMAN QUALITY VALVES ARI-Armaturen Albert Richter GmbH & Co. KG, D Schloß Holte-Stukenbrock Telephone ( ) Telefax ( ) or 159 Internet: info.vertrieb@ari-armaturen.com page

15 EC declaration of conformity / Manufacturers declaration Herewith we declare, EC declaration of conformity as defined by the Pressure Equipment Directive 97/23/EC and Manufacturers declaration as defined by the Machinery Directive 98/37/EC ARI-Armaturen Albert Richter GmbH & Co. KG, Mergelheide 56-60, Schloß Holte-Stukenbrock that according to the above mentioned Pressure Equipment Directive (PED) and Machinery Directive the below listed products comply and have been approved according to Category III, Module H or Category IV, Module H1 (with safety function) through Lloyd s Register of Shipping (NB-No. 0525), Mönckebergstr. 27, Hamburg Category III, Module H, Certificate-No: 50003/1 Straightway stop and control valves Type 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 480 Applied standards : DIN EN Part 1 VDI/VDE 3844 sheet 1 DIN 3840 Category IV, Module H1, Certificate-No: 50003/2 Straightway control valves with safety function Type 440, 441 Applied standards : DIN EN Part 1 VDI/VDE 3844 sheet 1 DIN 3840 If the supplied model is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must be put into service until the machinery into which it is be incorporated has been declared in conformity with the provisions of the EC-Machinery Directive as amended by 98/37/EC. Schloß Holte Stukenbrock, (Brechmann, Managing director)

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17 ARI-STEVI 440 / 441 with electric and pneumatic actuators Control valve - straight through with flanges DN ARI-STEVI 440 / 441 Electric actuator ARI-PREMIO Enclosure IP 65 2 torque switches Handwheel Additional devices available, e.g. potentiometer Page 2 ARI-STEVI 440 Electric actuator FR1 with safety reset Operating mode for safety reset CLOSE Enclosure IP 66 Operating time adjustable Additional devices available, e.g. potentiometer Fig. 440 Page 6 ARI-STEVI 440 / 441 Electric actuator FR2 with safety reset Type approval acc. to DIN for Fig. 440 with FR 2.1 CE-marking from DN15 Optional direction for safety reset, OPEN or CLOSE, as required Enclosure IP 54 1 travel switch for OPEN and CLOSE Additional devices available, e.g. potentiometer Page 10 ARI-STEVI 440 / 441 Electric actuator AUMA SAR Electric multiturn actuator capable of high closing pressures Enclosure IP 67 2 torque switches 2 travel switches Handwheel Overheating protection for motor as standard Additional devices available, e.g. potentiometer Explosion proof version available Page 14 Fig. 441 ARI-STEVI 440 / 441 Pneumatic actuator ARI-DP Reversible pneumatic actuator Actuator with rolling diaphragm Air supply pressure max. 6 bar Stem protection by bellow Maintenance-free O-ring sealing Assembly of additional devices acc. to DIN IEC Page 18 Features: Compact design Precision guided stem Burnished stem Tapered seat ring Rangeability 50 : 1 Spring loaded PTFE-V ring packing unit Two-ply bellows seal as standard Travel indicator Edition 12/07 - Data subject to alteration Data sheet englisch (english)

18 ARI-STEVI 440 / 441 Electric actuator ARI-PREMIO Control valve straight through with electric actuator ARI-PREMIO Figure Nominal pressure Material Nominal diameter Fig / PN16 EN-JL1040 DN / PN16 EN-JS1049 DN / PN25 EN-JS1049 DN / PN N DN / PN N DN / PN DN Other materials and versions on request. Stem sealing Fig. 440: PTFE-V-ring unit -10 C up to +220 C PTFE-packing -10 C up to +250 C Pure graphite-packing -10 C up to +450 C Fig. 441: Stainless steel bellows seal with safety stuffing box -60 C up to +450 C Plug design standard: Parabolic plug, metal seat optional: Parabolic plug with PTFE soft seat (max. 200 C) V-port plug, metal seat Parabolic pressure balanced plug, metal seat, Material of piston seal: PTFE with stainless steel spring (max. 200 C) Guiding Parabolic plug: Stem guiding V-port plug: Stem and port guiding Flow characteristic Equal percentage or linear Rangeability 50 : 1 on parabolic plug 30 : 1 on V-port plug Shut off class (seat / plug leackage classes) Metal seat - Leakage class IV acc. to DIN EN 1349 or IEC Soft seat - Leakage class VI acc. to DIN EN 1349 or IEC Closing pressures refer to page 4. Technical data for actuator refer to data sheet. Selection of possible applications Industrial installations, processing technology, plant manufacturing, etc. (other applications on request) Selection of possible flow media Fig. 440: Cooling water, cooling brine, warm water, hot water, steam, gas, etc. Fig. 441: Refrigerant, cooling water, warm water, hot water, thermal oil, steam, gas, etc. (other flow media on request) Fig Edition 12/07 - Data subject to alteration

19 Dimensions and weights DN L (mm) Fig. 440 H (mm) ARI-PREMIO 2,2 kn PN16 (kg) 9 9,7 10,6 12,2 14, ,1 27, PN25/40 (kg) 9,8 10,6 11,9 13,7 16,2 18,9 26,1 32, ARI-PREMIO 5 kn PN16 (kg) 10,1 10,8 11,7 13,3 15,2 18,1 23,2 28, PN25/40 (kg) 10,9 11, ,8 17, ,2 33, H (mm) ARI-PREMIO 12 kn PN16 (kg) ,2 22,1 27,2 32, ARI-PREMIO 15 kn PN25/40 (kg) , ,2 37, Fig. 441 H (mm) ARI-PREMIO 2,2 kn PN16 (kg) 13,4 13,4 14,4 16,9 19,4 21,9 24,9 35, PN25/40 (kg) 15,4 16,9 19,4 22,4 28,4 30,9 37,9 47, ARI-PREMIO 5 kn PN16 (kg) 14,5 14,5 15, , PN25/40 (kg) 16, ,5 23,5 29, H (mm) ARI-PREMIO 12 kn PN16 (kg) , ARI-PREMIO 15 kn PN25/40 (kg) , Standard-flange dimensions refer to page 23. Face-to-face dimension FTF series 1 according to DIN EN ARI-STEVI 440 / 441 Electric actuator ARI-PREMIO Parts Pos. Description Fig Fig / Fig Fig / Fig Fig Fig Fig / Fig Fig / Fig Fig Body EN-GJL-250, EN-JL1040 EN-GJS U-LT, EN-JS1049 GP240GH+N, N GX5CrNiMo , Seat ring X20Cr13+QT, QT X20Cr13+QT, QT >DN50: G19 9 Nb Si, Plug * X20Cr13+QT, QT X6CrNiMoTi , Straight pin * X10CrNi18-8, A Stem X20Cr13+QT, QT (DN ) X6CrNiMoTi , Mounting bonnet EN-GJS U-LT, EN-JS1049 GP240GH+N, N GX5CrNiMo , Guide bushing X20Cr13+QT, QT (hardened) X6CrNiMoTi , Gasket * Pure graphite (CrNi laminated with graphite) 10 Studs 25CrMo4, A Hexagon nuts C35E, A4 12 V-ring unit * PTFE 14 Washer * X5CrNi18-10, Spring * X10CrNi18-8, Bushing * PTFE (reinforced) 17 Sealing ring * Cu / Soft iron 18 Scraper * PTFE (reinforced) 19 Screw joint * X8CrNiS18-9, Bellows housing EN-GJS U-LT, EN-JS1049 GP240GH+N, N GX5CrNiMo , Mounting bonnet EN-GJS U-LT, EN-JS1049 GP240GH+N, N GX5CrNiMo , Stem- / Bellows unit * X20Cr13+QT, QT / X6CrNiTi18-10, X6CrNiMoTi , Guide bushing X20Cr13+QT, QT (hardened) X6CrNiMoTi , Guide bushing X20Cr13+QT, QT (hardened) X6CrNiMoTi , Gasket * Pure graphite (CrNi laminated with graphite) 20.7 Studs 25CrMo4, A Hexagon nuts C35E, A Packing ring * Pure graphite Washer * X5CrNi18-10, Screw joint * X8CrNiS18-9, * Spare parts Information / restriction of technical rules need to be observed! ARI-Valves of EN-JL1040 are not allowed to be operated in systems acc. to TRD 110. A production allowance acc. to TRB 801 No. 45 exists (acc. to TRB 801 No. 45 EN-JL1040 is not allowed.) The engineer, designing a system or a plant, is responsible for the selection of the correct valve. Edition 12/07 - Data subject to alteration 3

20 max. permissible closing pressures on flow-to-open P2 = 0 (Observe regulations, refer to page 23. Plug design acc. to Selection STEVI, refer to techn. annex.) DN Seat-ø (mm) Standard Kvs-values 4 6, Reduced Kvs-values 3) 2,5 4; 2,5 6, Travel (mm) I ,8 23,1 12,8 8 4,3 2,7 1,5 Actuator 1) Closing pressure (bar) II ,8 21,6 11,9 7,4 3,9 2,3 1,3 ARI-PREMIO III. 30,7 30,7 27,1 20,4 10,6 6,5 3,6 2,2 1,2 2,2 kn Operating time 2) (s) (Op. speed 0,38 mm/s) Actuator 1) ARI-PREMIO 5 kn Actuator 1) ARI-PREMIO 12 kn Actuator 1) ARI-PREMIO 15 kn Closing pressure (bar) Operating time 2) (s) (Op. speed 0,38 mm/s) Closing pressure (bar) Operating time 2) (s) (Op. speed 0,79 mm/s) Closing pressure (bar) Operating time 2) (s) (Op. speed 0,38 mm/s) ARI-STEVI 440 / 441 Closing pressures: Electric actuator ARI-PREMIO I ,3 21,3 12,3 8 4,9 3 2 II ,3 20,7 11,9 7,6 4,7 2,9 1,9 III ,8 11,6 7,5 4,6 2,7 1, I ,3 21,2 13,5 8,5 5,9 II ,8 20,9 13,3 8,4 5,8 III ,6 20,7 13,2 8,3 5, I ,9 17,2 10,9 7,5 II , ,8 7,4 III ,4 16,9 10,6 7, I. Fig. 440: PTFE-V-ring unit; II. Fig. 440: PTFE- / pure graphite-packing; III. Fig. 441: Bellows seal 1) Motor voltage: 230V 50Hz Other voltages: 24V 50/60Hz; 115V 50/60Hz; 230V 60Hz Technical data for actuator refer to data sheet ARI-PREMIO. 2) Indicated operating times with 50Hz. 3) Other Kvs-value-reductions are possible with Fig. 445 / 446 (Stainless steel body with screwed seat ring). For max. permissible closing pressures refer to separate data sheet. 4 Edition 12/07 - Data subject to alteration

21 ARI-STEVI 440 / 441 Flange dimensions / Pressure-temperature-ratings Standard-flange dimensions Flanges acc. to DIN EN /-2 (Flange holes / -thickness tolerances acc. to DIN 2533/2544/2545) DN (mm) PN16 ØD (mm) PN16 ØK (mm) PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 PN25 ØD (mm) PN25 ØK (mm) PN25 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 8x18 8x18 8x22 8x26 8x26 PN40 ØD (mm) PN40 ØK (mm) PN40 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 8x18 8x18 8x22 8x26 8x26 Pressure-temperature-ratings acc. to DIN EN Material PN -60 C to <-10 C* -10 C to 120 C 150 C 200 C 250 C 300 C 350 C 400 C 450 C EN-JL bar ,4 12,8 11,2 9, EN-JS bar on request 16 15,5 14,7 13,9 12,8 11, EN-JS bar on request 25 24, , , Pressure-temperature-ratings acc. to DIN EN Material PN -60 C to <-10 C* -10 C to 50 C 100 C 150 C 200 C 250 C 300 C 350 C 400 C 450 C N 25 bar 18, ,3 21,7 19,4 17,8 16, ,4 13, N 40 bar ,3 34,7 30,2 28,4 25, ,1 22, bar ,3 33,8 31,1 29,3 27,6 26,7 25,6 -- Intermediate values for max. permissible operational pressures can be determined by linear interpolation of the given temperature / pressure chart. * Valve with extended bonnet, studs and nuts made of A4-70 (at temperatures below -10 C) Please indicate when ordering - Figure-No. - Nominal diameter - Nominal pressure - Body material - Plug design - Kvs-value - Flow characteristic - Stem sealing - Actuator - Special design / accessories Example: Figure ; Nominal diameter DN100; Nominal pressure PN40; Body material N; Parabolic plug; Kvs 160; GLP; Stem sealing PTFE-V-ring unit; Actuator ARI-PREMIO 5 kn. Dimensions in mm Weights in kg Pressures in barg (gauge) 1 bar ^= 10 5 Pa ^= 0,1 MPa Kvs in m 3 /h Edition 12/07 - Data subject to alteration 23

22 ARI-STEVI 440 / 441 Constructions Stem sealing Spring loaded PTFE-V ring packing unit Pos. Description 23 Packing ring * PTFE or Pure graphite 25 Screw joint * X8CrNiS18-9, * Spare part PTFE-/ Pure graphite-packing Body design Bellows seal with safety stuffing box Body with pressed seat ring (EN-JL1040, EN-JS1049) Body with welded seat ( N) Body with machined seat (1.4408) Plug design Parabolic plug with PTFE soft seat and stem guiding V-port plug with stem and port guiding Parabolic pressure balanced plug Technology for the Future. G E R M A N Q U A L I T Y V A L V E S ARI-Armaturen Albert Richter GmbH & Co. KG, D Schloß Holte-Stukenbrock, Tel / 994-0, Telefax / or 159 Internet: info.vertrieb@ari-armaturen.com 24 Edition 12/07 - Data subject to alteration

23

24 Operating and Installation Instructions Thrust Actuator ARI-PREMIO Contents 1.0 General information on operating instructions Notes on possible dangers Significance of symbols Safety-related definitions: Qualified personnel Handling Storage Transport Handling before installation Description Field of application Method of functioning Technical data Diagram ARI-PREMIO 2,2-5 kn ARI-PREMIO kn Parts list Dimensions Notes on dangers during installation, operation and maintenance englisch

25 6.0 Installation General installation data Manual operation ARI-PREMIO kn ARI-PREMIO kn Installation instructions for mounting to valves Mounting for valve-lift up to 30 mm (yoke version) Mounting for valve lift over 30 mm to 80 mm, (column version) Electrical connection Wiring diagram ARI-PREMIO 2,2-5 kn Wiring diagram ARI-PREMIO kn ARI-PREMIO kn 1 Ph~ / 3 Ph~ without reversing contactor ARI-PREMIO kn 1 Ph~ / 3 Ph~ with reversing contactor Connection Settings Torque and travel switches - standard feature Connection boards PA or NA (only kn) Travel switch Installation of additional travel switches Setting of standard travel switch (S3): Setting the additional travel switches (S4/S5 and S24/S25) Potentiometers Installing the potentiometer Setting the potentiometer Heating Installation of heating Electronic position indicator RI Electronic position controller ES Electronic position indicator (RI21) and position controller (ES11) together in the actuator Integrated temperature controller dtron Installation of the dtron Integrated reversing contactor Installing the reversing contactor Electrical connection with ES11 or dtron Phase control relay Installing the phase control relay Starting up Care and maintenance Troubleshooting Troubleshooting table Dismantlement of thrust actuator Warranty EC declaration of conformity...38

26 1.0 General information on operating instructions Operating and installation instructions These operating instructions contain information necessary to install and operate the thrust actuator both safely and effectively. If problems arise which cannot be solved with the aid of these operating instructions, please contact the supplier/manufacturer for further information. These operating instructions comply with applicable EN safety standards as well as regulations and codes of practice applicable in the Federal Republic of Germany. If the electronic positioner is used outside the Federal Republic of Germany, the operator or the person responsible for the system design must ensure that valid national codes of practice are complied with. The manufacturer reserves all rights to implement technical modifications and improvements at any time. The use of these operating instructions assumes the user is qualified as described under Section 2.3 "Qualified Personnel". The operating personnel must be instructed in accordance with the operating instructions. 2.0 Notes on possible dangers 2.1 Significance of symbols Warning of general danger Warning of dangerous voltage Exposed to injury! Don t touch the turning handwheel when the motor is running Exposed to injury! Don t put your hand into the up or downwards moving appliance Danger when not observing the operating and installation instructions! Before installing, operating, maintenance or dismantling read and observe the instructions Danger though voltage! Before dismantling the hood, switch of the electrical source and secure against turning on again page 3

27 Operating and installation instructions 2.2 Safety-related definitions: The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating instructions as indications for particular hazards or for important information requiring special signs. DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or considerable damage to property can occur. WARNING means that if the relevant information is disregarded, there is a danger of serious injury and / or damage to property can occur. CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or damage to property can occur. NOTE means that particular attention must be paid to certain technical aspects. All other information not specifically emphasised such as transport, installation, operating and maintenance instructions as well as technical data (in the operating instructions, product documentation and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to persons or damage to property. 2.3 Qualified personnel This refers to personnel possessing corresponding qualifications and familiar with the processes of installing and assembling the product as well as with putting the product into service and operating the same, e.g. - Training or instruction or authorisation to switch on and off electric circuits and equipment/systems and to disconnect, ground and identify the same in accordance with VDE 0100, the regulations stipulated by the local electricity generating boards as well as technical safety standards. - Instruction and obligation to comply with all regulations and requirements pertaining to use as well as regional and in-house regulations and requirements, especially TRB Training or instruction in accordance with technical safety standards in the use and maintenance of pertinent safety equipment including job-safety equipment. - Training in first-aid, etc. 3.0 Handling 3.1 Storage - Storage temperature -20 to +70 C dry, free of dirt - Do not damage packing - A desiccant or heating to prevent condensation is necessary in damp rooms. 3.2 Transport - Transport temperature -20 to +70 C - Protect against external force (impact, vibration etc.). - Do not damage packing. 3.3 Handling before installation - Protect against atmospheric conditions e.g. wetness (applicate a desiccant). - Correct handling protects against damage. - Do not soil or damage type identification plate and wiring diagram on the controller. page

28 Operating and installation instructions 4.0 Description 4.1 Field of application ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 kn to 15 kn. The thrust actuators are set to the thrust forces specified in the technical data. If supplied with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve. Selection of the proper actuator version in alignment with the corresponding fitting as well as use of the thrust actuator in accordance with the specified technical data is the responsibility of the systems engineer. Any use of the thrust actuator beyond the specified technical data or improper use of the actuator is deemed to be not for the intended purpose. The ambient conditions have to be conform to the actual electromagnetic compatibility directives. Additional the compatibility to this directives has to be maintained in case of expansion or other changing of the ambient conditions. 4.2 Method of functioning The thrust actuator, fitted with a yoke or columns, is mounted to the valve. Transfer of force is effected via a coupling safeguarded against torsion. The torsion safeguarding feature also serves as a lift indicator. The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear clamps mounted to the column. The electrical components are accommodated separately from the gearbox underneath a sealed hood, thus being protected against operating and environmental effects. Following removal of the hood, easy access is provided to the switchgear and indicating feature. The rotary motion of the motor is transmitted to the spindle nut by means of spur gear. The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut and thus performs a pull or push motion depending on the sense of rotation. In the final positions of the valve, the spindle nut is pressed against a set of springs so as to produce closing force. The motor is switched off by means of two load-dependent switches and one stroke-dependent switch. The load-dependent switches will also switch off the motor if foreign bodies have lodged themselves between the valve seat and cone. The load-dependent switches serve to protect the valve and thrust actuator against damage page 5

29 4.3 Technical data Type Operating and installation instructions ARI-PREMIO Thrust force kn Stroke distance max. mm Duty classification in accordance with DIN VDE 0530 S1-100 % duty cycle; S4-80% duty cycle 1200 c/h S1-100% ED; S4-50% ED 1200 c/h Control speed mm/sec , Motor voltage 230V - 50Hz / 60Hz * 230V - 50Hz 230V - 50Hz / 60Hz * Power consumptionw Torque switch Travel switch 2 only, permanently wired, switching capacity 10A, 250V~ 1 only, permanently wired, switching capacity 10A, 250V~ Enclosure IEC IP 65 Max. permissible ambient temperature -20 C C 2 pcs., permanently wired switching capacity 16A, 250V~ 1 pcs., permanently wired switching capacity 16A, 250V~ Handwheel Yes (rotating during operation) Yes (engageable) Mounting position Any. Exception: motor must not be suspended downwards Gear lubricant Klüber Unigear LA02 50/50-mix Klüber Isoflex NBU15 Ultra and Klüber Nontrop KR291 Weight kg ,5 * Control speed and power consumption are 20% higher at frequency of 60 Hz page

30 Operating and installation instructions Accessories Type ARI-PREMIO Thrust force kn Additional travel switches Additional travel switches for lowvoltage / electronic system Potentiometer Electronic position indicator RI 21 Electronic position controller ES 11 Heating resistor Additional voltages / frequencies Standard-voltage connection board, PA Low-voltage connection board (electronic system), NA Integrated temperature-controller dtron additional travel switches, zero potential, Switching capacity 10A, 250V ~ 2 additional travel switches, zero potential, with gold contacts, switching capacity max. 0,1A, 4-30V DC max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt 0(2)... 10V. 0(4)...20mA, Only 1 potentiometer possible Using the temperature controller, installation is only possible in the control cabinet 0(2)... 10V. 0(4)...20mA, Only 1 potentiometer possible Not compatible for use with the temperature controller. (with automatic switching) 230V-50Hz, 115V-50Hz, 24V-50Hz, 15 watt 24V - 50/60Hz 115V - 50/60Hz 24V - 50Hz 24V - 60Hz 115V - 50Hz 115V - 60Hz 230V - 60Hz 2 torque switches and 1 travel switch, zero potential, for free wiring, Switching capacity10a, 250V ~ 2 torque switches and 1 travel switch, for free wiring, with gold contacts, Switching capacity max. 01A, 4-30 VDC Integrated reversing contactor -- Phase control relay -- 24V - 50/60Hz 115V - 50/60Hz 3~400V - 50Hz 3~440V - 60Hz Three-step temperature-controller in microprocessor-technology. Control range: -200 C to 850 C (resistance thermometer) Voltage: 24V, 115V or 230V 50/60Hz Compatible with resistance thermometers and thermocouples (provided by customer), or standardized active current or voltage signals Actuator with 400V-50Hz and 440V-60Hz Only 1 electronic module possible! Only in addition with integrated reversing contactor! page 7

31 Operating and installation instructions 4.4 Diagram ARI-PREMIO 2,2-5 kn Yoke Version Column Version Fig. 1 page

32 Operating and installation instructions ARI-PREMIO kn Fig page 9

33 4.5 Parts list Designation Operating and installation instructions Designation 50.1 Gearbox Driving spindle Gearbox cover plate Spindle safety feature 50.2 Cable conduit fitting 2,2-5kN: 2 x PG kN: 2 x PG13,5 / 1 x PG Torsion safety feature Bellow Grub screw M Sealing plug 1 x PG Set collar 50.5 Gasket Grub screw DIN 913-M3x Hood Guide spindle 50.7 Hood seal Hexagon nut DIN EN M Counter-sunk screw DIN 7991-M5x Synchronous motor, complete 50.9 Sealing washer DIN 125-5, Head cap screw DIN 912-M Column Board support Handwheel Standard board Turning handle of handwheel Shift lever Yoke Washer Flange Wiring diagram sticker, standard Spring washer DIN 128-A Connector, 3-pole (standard) Hexagon head screw DIN EN M10x Hexagon head screw DIN EN M10x Trip slide T-head bolt DIN 261-M12x Trip cam Setting spindle for switch S Setting spindle for switch S Setting spindle for switch S Washer DIN Lock washer DIN , Spring washer DIN 128-A Spring PREMIO for trip slide Hexagon nut DIN EN M Head cap screw DIN 912-M4x Lift dial Protective conductor terminal Distance column Head cap screw DIN 912-M4x Hexagon nut DIN 980-V-M Threaded bush ear clamp (stroke indicator) Connector, 8-pole Coupling page

34 Operating and installation instructions 4.6 Dimensions Clearance required for removal of hood ARI-PREMIO 2,2-5 kn Nominal stroke max. 30 mm Clearance required for removal of hood ARI-PREMIO 2,2-5 kn Nominal stroke > 30 mm - 50 mm Clearance required for removal of hood ARI-PREMIO kn Nominal stroke max. 80 mm X L h max. 30 mm max. 50 mm max. 65 mm max. 80 mm Fig page 11

35 Operating and installation instructions 5.0 Notes on dangers during installation, operation and maintenance DANGER! Safe operation of the positioner is only ensured if it is installed, put into operation and maintained by qualified personnel (refer to Point 2.3 "Qualified personnel"), while observing the warning notes provided in these operating instructions. In addition, care must be taken to ensure that the general equipment and safety regulations for electrical lines and installations are complied with and that tools and protection devices are used professionally. The operating instructions for the electronic positioner must be observed when carrying out all work on and when handling the electronic positioner. Disregard of these instructions can result in injury to persons or damage to property. 6.0 Installation 6.1 General installation data In addition to general installation guidelines, the following points are required to be observed: - Existing operating instructions for valve. - Complete valve with crossarm. - Valve cone approximately in mid lift position - on no account supported inside a seat! - Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricity generating board. - Conductor cross-section selected to correspond to the given drive power and existing line length. - Mains fuse rating max. 6A. - Circuit breakers to EN in the plant to cut off the mains supply to the actuator. - Conformity of technical data on thrust actuator with field conditions. - Mains voltage in accordance with data specified on rating plate of thrust actuator. - Thrust actuator complete with yoke or distance columns and coupling parts intended for mounting to the corresponding valve. - Qualified personnel possessing knowledge of the regulations pertaining to the erection of power installations. - Ease of access to installation site. - Adequate clearance space above the thrust actuator for removing the hood (refer to point 4.6 Dimensions). - Install where there is protection against high-energy heat radiation. - The ambient temperature must not exceed +70 C. page

36 Operating and installation instructions If installed outdoors, the thrust actuator must be provided with an additional cover to protect against - rain, - direct insulation, - powerful draughts and - dust. In case of widely fluctuating ambient temperatures and high atmospheric humidity, your are recommended to install a heating resistor to minimise condensation buildup in the actuator. - Thrust actuator mountable in any position except in downward suspended position. If installed with a horizontal connecting rod, the thrust actuator must be mounted so both yoke legs or columns are on top of one another in the vertical plane (see fig. 4). Correct Incorrect Fig Manual operation ARI-PREMIO kn With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the handwheel firmly meshed with the gear. Proceed as follows: - Swing out lever ( ) from handwheel (50.12). - Turning in clockwise direction--> closes valve. - Turning in counter-clockwise direction--> opens valve. CAUTION! In the manual operating mode pay careful attention in the final positions that the handwheel is only turned to the point where the torque switch trips (audible click) as otherwise damage will be caused to the thrust actuator! Since the handwheel always follows during motor-driven operation (running indication), never operate by hand while the motor is running - potential injury hazards!!! Open Close Fig page 13

37 Operating and installation instructions ARI-PREMIO kn With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the engageable handwheel. Proceed as follows: - Fold the turning handle out of the handwheel (A) - Turn the handwheel slightly and push in the engaging button for manual mode (B) --> the button engages - Turning in clockwise direction --> closes valve - Turning in counter-clockwise direction--> opens valve The motor is no longer in mesh when the handwheel is engaged. The handwheel is automatically disengaged when the motor starts and the handwheel is once more in mesh. Engaging button for manual mode Open Close Fig. 6 CAUTION: In the manual operating mode pay careful attention in the final positions that the handwheel is only turned to the point where the torque switch trips (audible click) as otherwise damage will be caused to the thrust actuator! page

38 6.3 Installation instructions for mounting to valves Mounting for valve-lift up to 30 mm (yoke version) Operating and installation instructions turn Hexagon nut Valve spindle Hexagon nut Valve spindle Fig. 7 To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed as follows: Fig. A: Fig. A-B: Fig. C: Fig. D/E: Fig. F: - Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). - Position valve cone approximately in mid lift position. - Turn flat hexagon nut if not present on valve spindle. - Slip coupling (50.27) over valve spindle. - Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (Y) and lock with hexagon nut. - Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm. - Place thrust actuator (50) on valve. - Mount thrust actuator (50) on fitting with two T-head bolts (50.19), two washers (50.20), two spring washers (50.21), two hexagon nuts (50.22). - Swing out handwheel lever ( ) and use it to move out the thrust actuator until the driving spindle (50.30) comes to rest on the threaded bush (50.87). - Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure in place using grub screw M6 (50.35). - Run valve to lowest position. - Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is in alignment with tip of arrow mark on lift dial. - Run valve to both final positions and check to ensure that these are safely reached - Carry out electrical connection (refer to section 6.4.1). - Set travel switch S3 (refer to section ) page 15

39 6.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version) Operating and installation instructions turn Hexagon nut Valve spindle Hexagon nut Valve spindle Fig. 8 To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm, proceed as follows: Fig. A: Fig. A-B: Fig. C: Fig. D/E: - Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). - Position valve cone approximately in mid lift position. - Turn flat hexagon nut if not present on valve spindle. - Slip coupling (50.27) over valve spindle. - Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (Y) and lock with hexagon nut. - Setting dimension (Y) for fitting-projection (X) 83mm = 102mm. - Setting dimension (Y) for fitting-projection (X) 98mm = 116mm. - Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly. - Screw distance column with 2-ear clamps on opposite side of handwheel into the flange in such a way that one of the 2-ear clamps is situated above the torsion safety feature (50.32) and the other below. - Screw the other distance column into the flange likewise. - Place thrust actuator (50) with distance columns onto valve and fix into position with two self-locking hexagon nuts (50.25). - Fold out turning handle of handwheel ( ), slightly turn the handwheel and press in the engaging button for manual mode (only kn) (button engages). Having done this, move out the thrust actuator until driving spindle (50.30) comes into contact with threaded bush (50.87). page

40 Operating and installation instructions Fig. F: - Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure using grub screw M6 (50.35). - Move the valve to the lowest position. - Press 2-ear clamps (50.26) into position according to the stroke so they cannot slip, with the bottom clamp in the lowest valve position located directly below torsion safety feature (50.32) and the top clamp in the highest valve position located directly above the torsion safety feature. - Move the valve to both travel positions and check that it reaches them reliably. - Fold turning handle of handwheel ( ) back in. - Make the electrical connection (see points and 6.4.2). The engaging button for manual mode (only kn) disengages when the motor starts up. - Set standard travel switch S3 (see point ) page 17

41 Operating and installation instructions 6.4 Electrical connection Wiring diagram ARI-PREMIO 2,2-5 kn accessoires output 1 (K1) output 2 (K2) actual value input binary input 2/ output 5 Straightway valve closed open 3-way valve with mixing plug open open 3-way valve with diverting plug open open Option NA: same design but no RC circuit and switches with gold contacts (Switching capacity 0.1A, 4-30VDC) power supply interface external set point input HZ Heating resistor DE Torque switch WE (S3) Travel switch for traveling the stroke distance in opening direction RI 21 Electronic position indicator ES 11 Electronic position controller NA Low-voltage connection board, zero potential PA Standard-voltage connection board, zero potential POT Potentiometer WE Travel switch, zero potential TTR Electronic temperature-controller dtron 16.1 Fig. 9 page

42 Operating and installation instructions Wiring diagram ARI-PREMIO kn ARI-PREMIO kn 1 Ph~ / 3 Ph~ without reversing contactor Accessories output 1 (K1) output 2 (K2) power supply interface binary input 2/ output 5 Wire connections of the different valve types Straightway valve 3-way valve with mixing plug 3-way valve with diverting plug closed A-AB open AB-B open open B-AB open AB-A open External reversing contactor: L1, L2, L3 - actuator spindle drives in L3, L2, L1 - actuator spindle drives out In all external reversing circuits the torque switches S1 and S2 have to be used to switch off the actuator motor. Please check the operating direction of the actuator! external set point input actual value input Option HZ Heating resistor DE Torque switch WE (S3) Travel switch for traveling the stroke distance in opening direction RI 21 Electronic position indicator ES 11 Electronic position controller NA Low-voltage connection board, zero potential PA Standard-voltage connection board, zero potential POT Potentiometer WE Travel switch, zero potential TTR Temperature-controller WS Reversing contactor PR Phase control relay Fig. 10 external reversing contactor page 19

43 Operating and installation instructions ARI-PREMIO kn 1 Ph~ / 3 Ph~ with reversing contactor Accessories WS + PR 3-step input signal Connect 3 phases L1, L2, L3 only here Accessories WS 3-step input signal Connect 3 phases L1, L2, L3 only here Please check the operating direction of the actuator! Wire connections of the different valve types Straightway valve 3-way valve with mixing plug 3-way valve with diverting plug closed A-AB open AB-B open open B-AB open AB-A open Fig. 11 page

44 Operating and installation instructions DANGER!!! The processes of mains connection and putting the thrust actuator into service call for specialised knowledge of power installation erection (VDE 0100), knowledge of regulations for the prevention of accidents and the specific conditions for putting this thrust actuator into service. Such work may only be carried out by suitably qualified personnel in accordance with section 2.3 "Qualified Personnel". The supply line for connecting up the thrust actuator must be in the dead state i.e. disconnected from the mains while connection work is being carried out. After being disconnected, the mains power must be prevented from being switched back on again accidentally. Failure to observe these instructions may lead to death, grievous bodily injury or substantial property damage! Connection To connect the thrust actuator up to the electrical power supply, proceed as follows: - Run the thrust actuator a few mm out of the lower final position applying the manual mode. - Loosen countersunk screw in hood, carefully remove hood in upward direction. - Screw out one of the two cable inlets and re-assemble in the same way without the supplied blank flange. - Insert the connection line through this cable inlet until sufficient conductor length is available up to the corresponding terminals; then tighten the cable inlet until the connecting cable is clamped in place inside it. - Strip connecting cable approx cm above cable inlet. - Strip the individual conductors approx. 5mm away from the end and fit with conductor end sleeves. - Connect protective conductor of connecting cable up to protective conductor terminal of thrust actuator. - Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator terminal strip. - Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator terminal strip. - Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal strip. - Place hood on carefully from above and mount firmly onto thrust actuator with countersunk screw and rubber gasket. - Connect supply line to mains and run thrust actuator to each of the final positions so as to check whether the final-position travel switches effect switching off, also checking to see whether the direction of movement on the thrust actuator corresponds to the desired direction. - If the directions of movement are contrary to those desired, the pulse lines governing the move-in and move-out connecting rod will need to be exchanged page 21

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

46 Operating and installation instructions CAUTION! When using optional boards PA or NA, it must be warranted - due to the operator s individual circuitry- that, when switching the load-dependent travel switches S11/21, S12/S22 and S13/ S23 the motor of the thrust actuator comes to a standstill without delay. This function is not provided for on the optional boards PA and NA in the supplied state! Travel switch The thrust actuators can be equipped with an additional stroke-switch board containing two travel switches (double-throw contact S4 and S5). These switches can be set on infinitely variable lines over the entire stroke distance in both lift directions and integrated at will into the facility control system (no interlock-controlled circuitry). The maximum switching capacity of the switches (refer to section 4.3 Technical Data) must not be exceeded. For low voltage (refer to section 4.3 Technical Data), the additional travel switches are supplied with gold contacts (option: low-voltage travel switch) Installation of additional travel switches To install additional travel switches, proceed as follows. - Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. - Loosen countersunk screw in hood, carefully remove hood. - Disconnect motor plug and mains connection plug from board. - Carefully ease open the lock washer (50.56) (open ends) with a screw driver while pulling the trip slide (50.50) upwards from the board support. - Remove trip slide (50.50) from board support by pulling upwards. - Loosen head cap screws (50.57) on board support and remove this from gearbox (only necessary on 5kN thrust actuator). - Insert stroke-switch board (50.61) in board support (50.42) and fix in place using the supplied screws (50.44). - Mount board support loosely on gearbox cover plate with two head cap screws (50.57) (only necessary on 5kN). - Push trip slide (50.50) back into board support (50.42) from above and onto the guide spindle (50.38). - Align board support (50.42) on gearbox cover plate in such a way that the guide spindle (50.38) is centrally situated in the borehole of the board support (50.42); then screw down tightly on gearbox cover plate (only necessary on 5kN). - Mount the trip slide (50.50) so that the spring (50.56) clips into the groove of the guide spindle (50.38). - Insert 6-pole connector (50.62) in jack strip of stroke-switch board. - Proceed to strip the connecting cable that has been led in through the cable inlet and fastened, and connect the individual conductors to the terminal strip in accordance with the desired circuitry and the wiring diagram page 23

47 Operating and installation instructions - Set switch points on travel switches in accordance with section Setting the travel switches - Insert motor connection plug in jack strip ( ) provided for the purpose. - Insert mains connection plug in jack strip ( ) provided for the purpose. - Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket and countersunk screw. Fig. 12 Switchgear and indicating feature ARI-PREMIO kn Designation Designation Guide spindle Setting spindle for switch S Board support Setting spindle for switch S Jack strip for mains connection Trip cam Jack strip for motor connection Spring Self-tapping screw Head cap screws DIN 912-M4x Trip slide Stroke-switch board Setting spindle for switch S Connector, 6-pole (option: travel switch) page

48 Operating and installation instructions Setting of standard travel switch (S3): On delivery of the thrust actuator, the standard travel switch (S3) is already set to the existing valvelift and the setting spindle for the travel switch S3 (50.51) is sealed with screw glyptal. This setting needs no changing for normal operation. If reinstalling the thrust actuator on a straight-way valve, the travel switch S3 needs to be set as follows: Move valve out of the lowest position so as to run valve-lift to up position. Using a screw driver, proceed to turn setting spindle for switch S3 (50.51) until the trip cam (50.54) arriving from below trips the switch (audible click). Run thrust actuator briefly in closing direction and then in opening direction once more, checking to see whether the thrust actuator is switched off at the desired point (nominal lift). If need be, correct the setting as described. If reinstalling the thrust actuator on a three-way valve, the travel switch S3 needs to be set as follows: - Run valve in both final positions and check in each final position whether the valve switches off via the load-dependent switch. - Carry out a check in the top final position the see whether, after switching off the thrust actuator, the trip cam (50.54) of the travel switch S3 is situated below switch S3 and has not tripped the latter. If the trip cam (50.54) is situated above the travel switch S3 or trips the same, the setting spindle governing the travel switch S3 (50.51) needs to be turned until the trip cam is situated below travel switch S3 without tripping it. - Run the thrust actuator in both final positions once more and check whether thrust actuator switches off in both final positions via the load-dependent switches. - If need be, correct the setting as described above page 25

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

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

51 Operating and installation instructions Fig. 14: Switchgear and indicating feature ARI-PREMIO kn Designation Designation Board support Self-tapping screw Circuit-diagram sticker Spiral spring (option: potentiometer) Hexagon nut Slide block (option: potentiometer) Tooth lock washer Set collar Potentiometer Pinion (selection depends on valvelift 20, 30, 50, 65 or 80 mm) Washer from PA Connector, 3-pole (option: potentiometer) Connecting cable for option: potentiometer Spring washer Setting the potentiometer To set the potentiometer, proceed as follows: - Move thrust actuator to closing position. - Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. - Using a screw driver, turn slotted potentiometer shaft in counter-clockwise direction until reaching the travel stop. This places the potentiometer in the initial position (approx. 0 ohm). - For checking purposes, the resistance of the potentiometer needs to be measured using an ohmmeter. - Measure resistance on potentiometer 1 between terminals 25 and Measure resistance on potentiometer 2 between terminals 28 and In this position of the actuator, the measured value should be approx. 0 ohm. - Run thrust actuator to upper final position and read off corresponding resistance value on ohmmeter. - The resistance values thus measured need to be taken into account for the settings to the facility control system. page

52 Operating and installation instructions Heating A heating resistor can be fitted as a means of protection against the formation of condensation water in cases involving widely varying ambient temperatures and high atmospheric humidity (outdoor use). The heating resistor is self-regulating so that a continuous supply of current merely needs to be connected up Installation of heating On principle, the heating can be combined with all options. It is completely mounted on a holding bracket. If electronic system ES11 or RI21 is already installed, unscrew the electronic system from the holding bracket, remove it, install the heating and attach the electronic system to the holding bracket for the heating. To install the heating proceed as follows: - Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. - Loosen countersunk screw in hood, carefully remove hood. - Using the supplied screws, mount complete heating (on holding bracket) at the point on the gearbox cover plate provided for the purpose. (Fig. 16). - Lead continuous-current cable (mains voltage = rated voltage of heating) through cable inlet into thrust actuator and fix in place with inlet. - Strip continuous-current cable approx cm above cable inlet. - Strip individual conductors approx. 5mm away from the end and provide with conductor end sleeves. - Lay the individual conductors in such a way that they do not come into contact with moving parts. - Connect the individual conductors up to the connection terminal block in accordance with the wiring diagram. Mounting thread M3 for heating reisistor Mounting thread M3 for thermal circuit breaker Mounting thread M4 for options ES11 and RI21 Mounting thread M3 for jack strip Fig. 15 Designation Designation Holding bracket (Option: Jack strip heating) Head cap screw DIN 84-M3x Connector, 2-pole Thermal circuit breaker Heating resistor page 29

53 Operating and installation instructions Fig. 16: Switchgear and indicating feature ARI-PREMIO kn Designation Designation Potentiometer Head cap screw DIN912 - M4x /79 Option ES11 or RI Head cap screw DIN912 - M4x Holding bracket Heating Electronic position indicator RI21 The electronic position indicator RI21 converts the resistance of the 1000 ohm potentiometer corresponding to the lift into an optional output control signal 0 (2)...10V DC or 0 (4)...20mA DC. For installing and setting the electronic position indicator RI21 the operating instructions applicable to this unit must be observed in the appropriate valid version. The corresponding operating instructions are supplied with each unit Electronic position controller ES11 The electronic position controller ES11 converts continuous input control signals 0 (2)...10V DC or 0 (4)...20mA into a 3-point output signal for the motor, in which case interrogation of the valve position takes place via a 1000 ohm potentiometer. For installing and setting the electronic position controller ES11 the operating instructions applicable to this unit must be observed in the appropriate valid version. The corresponding operating instructions are supplied with each unit. page

54 Operating and installation instructions Electronic position indicator (RI21) and position controller (ES11) together in the actuator Except or the 5 kn, 12 kn and 15 kn type in 24V version, the electronic position indicator RI21 and the electronic position controller ES11 can be build-in together in the ARI-PREMIO. It must be used a double potentiometer with 1000/1000 Ohm. To install the RI21 and ES11 proceed as follows: - Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. - Loosen counter-sunk screw in hood, carefully remove hood. - Mount the electronic units by using the specific installation kit s (Fig. 17). Bild 17: Switchgear and indicating feature ARI-PREMIO 2,2-5 kn Designation Designation Potentiometer Head cap screw DIN912 - M4x /79 Option ES11 or RI Metal sheet ES11 and RI Head cap screw DIN912 - M4x Distance bold page 31

55 Operating and installation instructions Integrated temperature controller dtron 16.1 The integrated temperature controller controls temperatures, which are measured by input-connected temperature sensors, to a manual given setpoint by means of a three-step output connected with the actuator Installation of the dtron 16.1 The dtron 16.1 can be mounted in the ARI-PREMIO as a complete unit with a mounting kit. It cannot be combined with ES11. To install the dtron 16.1 proceed as follows: In addition to Connection, the electrical connection of the dtron 16.1 has to be done in the following way: - Mount the temperature controller on the gear plate by using the specific installation kit (Fig. 18). - Plug in the connector X2 of the dtron 16.1 to the plug-in connector X1 (1/N, 11, 14) of the actuator terminal (Fig. 6). - Connect the signal input and the individual wanted additional functions according the wiring diagram (Fig. 6) to the dtron Connect the power supply to the dtron 16.1 according to the wiring diagram (Fig. 6). - For changing the working direction to heating signal = extending driving spindle, just change the wires on the connectors 11 and 14. Designation Head cap screw DIN912 - M4x Temperature controller dtron Fixing bracket (option dtron) Holding bracket (option dtron) Self-locking nut (option dtron) Fig. 18: Switchgear and indicating feature ARI-PREMIO kn page

56 Operating and installation instructions Integrated reversing contactor The integrated reversing contactor is actuated using a 3-step input signal. The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction of rotation of the three-phase motor Installing the reversing contactor The reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a mounting kit. The reversing contactor can only be combined with one of the ES11, RI21 or temperature controller options. It is also possible to install the heating and the phase control relay. Proceed as follows to install the reversing contactor: Switch off the mains voltage and take measures to prevent it being switched back on inadvertently. The electrical connection procedure as described in Connection is supplemented by the following steps: - Use the mounting kit to attach the reversing contactor to the gear plate (fig. 19). - Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in fig Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor without a phase control relay. - Refer to Phase Control Relay regarding connecting with a phase control relay Electrical connection with ES11 or dtron 16.1 Modify the 3P output cable of the ES11 or the dtron 16.1 as follows: - Remove plug X25. - Strip off the outer cable insulation down to about 18 cm. - Connect the individual conductors as follows: Black (L ) - S2/14 Brown (L ) - S1/11 Blue (1/N) - K1/A2, K2/A2 CAUTION: The thrust actuator may be damaged if phases L1, L2 and L3 are not connected correctly and no phase control relay is fitted! page 33

57 Operating and installation instructions Designation Head cap screw DIN M4 x Head cap screw DIN M4 x Head cap screw DIN M4 x Reversing contactor Fixing plate (option reversing contactor) Phase control relay Bracket (option phase control relay) Fig. 19: Switchgear and indicating feature ARI-PREMIO kn Phase control relay The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The reversing contactor is only activated by the phase control relay providing phases L1, L2 and L3 are connected correctly. This protects the thrust actuator Installing the phase control relay The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is only possible to use the phase control relay in conjunction with the reversing contactor. It cannot be combined with the dtron 16.1 temperature controller in the actuator. Proceed as follows to install the phase control relay: Switch off the mains voltage and take measures to prevent it being switched back on inadvertently. The electrical connection procedure as described in Connection and Integrated Reversing Contactor is supplemented by the following steps: - Attach the phase control relay next to the reversing contactor (fig. 19). - Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in fig. 10. page

58 Operating and installation instructions 7.0 Starting up DANGER! Check the following before starting up a new system or restarting a system after repairs or conversion: - Correct completion of all installation/assembly work! - Circuits of the system in accordance with DIN VDE regulations and regulations of the relevant power supply company as well as compliance with all safety regulations, especially TRB hood of thrust actuator assembled. - Start up only by qualified personnel (see 2.3). While in operation, the thrust actuator has moving and rotating parts as well as being integrated in an electrical network system. Improper handling or failure to observe the operating instructions or the valid regulations may lead to death, grievous bodily injury or substantial property damage! When placing into service proceed as follows: - Using the handwheel, run the thrust actuator to approximately mid lift position. - Apply brief pulses to the thrust actuator for each direction of movement and check whether the directions of movement correspond to those desired. If this is not the case, the pulse lines governing the opening and closing action must be exchanged on the thrust actuator. - Run thrust actuator to the final position in each direction of movement and check whether it switches off automatically and whether all externally moving parts are able to move freely. - If failing to function properly, check all installation and setting work previously carried out, correcting if necessary, and afterwards place into service once again. 8.0 Care and maintenance The thrust actuator requires very little maintenance. Accordingly maintenance in specified intervals is not necessary. Depending on the conditions governing use, the maintenance and maintenance-intervals have to be defined by the operator (see TRB 700). The thrust actuator must not be cleaned with high-pressure equipment or aggressive solvents or detergents injurious to health or highly inflammable. During and after cleaning, an inspection should be carried out of the sealing points on the thrust actuator. If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements must be repaired. 9.0 Troubleshooting In the event of malfunctions or disturbances in operation, first check whether the installation and adjustment work has been carried out and concluded in accordance with these operating instructions. Compare the data referring to operating voltage, actuating signal and temperature to the data specified on the layout drawing of the control system. Also check whether the given operating conditions correspond to those specified in the data sheet or to the technical data specified on the type identification plate. DANGER! All relevant safety regulations must be observed when carrying out the troubleshooting procedure, especially TRB 700. Contact the supplier/manufacturer if faults cannot be rectified on the basis of the following troubleshooting table page 35

59 10.0 Troubleshooting table Operating and installation instructions During the process of trouble shooting, all safety regulations previously mentioned and corresponding to the various operations must definitely be observed!! Fault Possible Causes Remedy Thrust actuator fails to move Power failure Ascertain and eliminate cause Fuse has blown Replace fuse Thrust actuator not properly Rectify connection on thrust actuator connected in accordance with wiring diagram Short circuit due to: Ascertain exact cause, - moisture - Dry the thrust actuator and eliminate leakage - wrong connection - Rectify connection on thrust actuator in accordance with wiring diagram - motor has burned out - Check whether the mains voltage agrees with the voltage specified on the rating plate. Have motor changed. Thrust actuator alternates between clockwise and counter-clockwise rotation Thrust actuator fails to run to final positions and also produces chatter Connector contacts not plugged in/ not properly plugged into jack strip (Only for kn) Handwheel is still engaged and does not disengage when the motor starts up Motor operating capacitor defective Insert connector firmly in jack strip thus affected Unscrew the motor mounting screw closest to the cable feedthrough. (Manual release of the handwheel disengagement mechanism.) Have motor operating capacitor replaced Load-dependent travel switches out of adjustment / defective Remove thrust actuator and send to factory for repair Voltage drop due to excessively long connecting cables or inadequate Lay connecting cables in accordance with requisite output conductor cross-section Mains fluctuations beyond permissible tolerance travels Arrange for "clean" mains system within requisite tolerances System pressure too high Reduce system pressure Periodic failure on thrust actuator Loose connection on feedline Tighten connections on terminal strips Thrust actuator is switched off in opening direction prior to loaddependent switch (three-way valve) Travel switch S3 not set corresponding to use Set travel switch S3 in accordance with operating instructions 11.0 Dismantlement of thrust actuator In addition to general installation guidelines, the following points are required to be observed: - Dismantlement of the thrust actuator from the fitting must only to be carried out by suitably qualified personnel (refer to section 2.3). - Regard TRB The supply line for connecting up the thrust actuator must be in the dead state i.e. disconnected while dismantlement work is being carried out. After being disconnected, the mains power must be prevented from being switched back on again accidentally. - The system must be run down (depressurised state) as the valve cone is not held without the thrust actuator and would thus be conducted by the system pressure. - Valve cone approximately in mid lift position - on no account supported inside a seat! page 36

60 Operating and installation instructions To dismantle the thrust actuator proceed as follows: - Loosen counter-sunk screw in hood, carefully remove hood. - Disconnect all cables led into thrust actuator from outside and remove from thrust actuator. - Place hood on carefully from above and fix in place with counter-sunk screw and rubber gasket. - Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety feature. - Loosen clamping bolts connecting the thrust actuator to the fitting. - Remove thrust actuator from valve Warranty The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself. We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed application. No warranty claims can be made for any damage caused as the result of incorrect handling or disregard of operating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and other applicable codes of practice. This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements. Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us. No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is excluded. The warranty shall not cover maintenance work, installation of external parts, design modifications or natural wear. Any damage incurred during transport should not be reported to us but rather to the competent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated. Technology for the Future. GERMAN QUALITY VALVES ARI-Armaturen Albert Richter GmbH & Co. KG, D Schloß Holte-Stukenbrock Telephone ( ) Telefax ( ) or 159 Internet: info.vertrieb@ari-armaturen.com page 37

61 Operating and installation instructions 13.0 EC declaration of conformity EC declaration of conformity as defined by Directive about electromagnetic compatibility 89/336/EEC and the EG-Low voltage directive 73/23/EEC Declaration of the manufacturer as defined by the Machinery Directive 98/37/EC Herewith we declare, ARI-Armaturen Albert Richter GmbH & Co. KG, Mergelheide 56-60, Schloß Holte-Stukenbrock that the supplied model of electric thrust actuator ARI-PREMIO in the delivered version complies with the following regulations: - Directive about electromagnetic compatibility 89/336/EEC (amended by 92/31/EEC and 93/68/EEC) Applied harmonized standards: EN 55011; EN ; EN EG-Low voltage directive 73/23/EEC (amended by 93/68/EEC) Applied harmonized standards: EN , EN , EN EG-Machinery Directive 98/37/EC Applied harmonized standards: EN 292-1; EN 292-2; EN 294; EN 349; EN The supplied model is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must be put into service until the machinery into which it is be incorporated has been declared in conformity with the provisions of the directive as amended by 98/37/EC. Schloß Holte-Stukenbrock, (Brechmann, Managing director) page 38

62 For 3504 controller

63 For 3504 controller

64 For CM30 controller

65 For CM30 controller

66 Revision 0508: Parts list Control Valve added Revision 0711: House style change Revision 0613: Connection diagram new controller added

67 Represented by VAF Instruments B.V. Vierlinghstraat 24, 3316 EL Dordrecht, The Netherlands P.O. Box 40, 3300 AA Dordrecht, The Netherlands T sales@vaf.nl, Specifications subject to change without notice. VAF Instruments B.V. is an ISO 9001 Certified Company. Agents and distributors in more than 50 countries.