Installation and Operation Instructions VAG ROTOP Portable Electric Drive KAT-B 5551 Edition 1-01/2018
Content 1 General 3 1.1 Safety 3 1.2 Proper use 3 2 Transport and Storage 3 2.1 Transport 3 2.2 Storage 3 3 Product features 3 3.1 Features and function description 3 3.2 Fields of application 3 3.3 Performance limits 3 3.4 Proper and improper mode of operation 4 VAG reserves the right to make technical changes and use materials of similar or better quality without express notice. The pictures are non-binding. 4 Set-up and operation 5 4.1 Visual inspection and preparation 5 4.2 Set-up and operation 6 4.3 Adjusting the speed 6 4.4 Adjusting the torque 6 4.5 Important note about torque shut-off! 6 4.6 Adjusting the direction of rotation 6 4.7 The counter 6 4.8 Starting the VAG ROTOP 6 4.9 Operation 6 5 Maintenance and repair 7 5.1 General safety instructions 7 5.2 Inspection and operation intervals 7 6 Trouble-shooting 7 7 How to contact us 7
1 General 1.1 Safety These Operation and Maintenance Instructions must be observed and applied at all times along with the general for Valves (see www.vag-group.com / Category: Installation and Operation Instructions). Arbitrary alterations of this product and of the parts and accessories supplied with it are not allowed. VAG does not assume any warranty or liability for consequential damage arising from noncompliance with these instructions. When using this drive, the generally acknowledged rules of technology have to be observed (e.g. DIN standards, DVGW data sheets, VDI directives, etc.). The installation may only be carried out by qualified staff (see also Section 7.1 General safety instructions). For further technical information such as dimensions, materials or applications, please refer to the respective documentation (KAT-A 5551). The VAG ROTOP is designed and manufactured to the state of the art and its safety of operation is ensured in general. However, the VAG ROTOP may be potentially dangerous if it is operated improperly or is not applied for the intended use. Everyone dealing with the assembly, disassembly, operation, maintenance and repair of the valves must have read and understood the complete Operating and Maintenance Instructions (Accident Prevention Regulations, VBG 1 14 ff and following). The operator must have a strong foothold when operating the valve with the VAG ROTOP. When using the VAG ROTOP great care must be taken that the end positions of the valve are approached slowly. Make sure to watch the display. Any sudden stop would otherwise threaten to turn the drive as well. Make sure to observe when in operation: For reasons of safety only adjust the torque and direction of rotation switch when shut down. To prolong the service life of the valve and the drive, always operate at the lowest possible torque. To avoid overloads to the valve and the drive, moving to end position must not be dependent on the torque, but the path, while watching the counter. Even with power switched off the drive will continue to turn until operating power has been completely dissipated. Use the supplied actuator column to give the operator a firm foothold, especially for stiff valves. For equipment for which monitoring is mandatory, the relevant laws and regulations such as the Industrial Code, Accident Prevention Regulations, VDE Guidelines, AD Data Sheets (AD = Boiler Study Group), etc. must be complied with. In addition to this, local accident prevention regulations must be complied with. 1.2 Proper use The VAG ROTOP is a portable electric drive. It is suitable for easily and ergonomically operating valves. For technical data concerning the operating limits such as medium or temperature, please refer to document KAT 5551-A. Any deviating operating conditions and applications require the manufacturer s prior written consent! These Installation and Operation Instructions contain important information on the safe and reliable operation of the VAG ROTOP. Observing these Operation and Maintenance Instructions helps you to: Prevent hazards Reduce repair costs and down-times of the drive and/or the complete system Improve the operational safety and useful life of the equipment 2 Transport and Storage 2.1 Transport The VAG ROTOP should be transported in such a way that it is protected from external influences such as cold and damp, soiling and mechanical influences. The carrying case available from the accessories programme reliably protects the drive. 2.2 Storage The VAG ROTOP should be stored in such a way that sufficient protection against damage from improper storage is ensured. Furthermore, the VAG ROTOP should be stored in such a way that avoids condensation forming in the machine. The VAG ROTOP may not be subjected to great heat for an extended period of time. The fitting can be stored in ambient temperatures ranging from -20 C to + 50 C (protected by adequate covers). 3 Product features 3.1 Features and function description The VAG ROTOP is a portable electric drive for the easy and ergonomic operation of valves with and without housing. The hightorque drive with up to 230 Nm enables the comfortable operation of gate valves, butterfly valves and underground hydrants. The application options offered by the different coupling sleeves make the VAG ROTOP compatible with any valve. An integrated torque control prevents unintentional damage to the valves. The VAG ROTOP is available in a version with infinitely variable speed or in a version with two pre-adjusted speeds. 3.2 Fields of application The standard version of the VAG ROTOP is suitable for all valve types via the use of different coupling sleeves. For technical data concerning temperature operating limits please refer to document KAT-A 5551. Contact the manufacturer in the event of divergent operating conditions and areas of application. 3.3 Performance limits Overload protection is triggered should the VAG ROTOP become overloaded. The trigger point of overload protection depends on the period of operation and the specified torque. The overload protector is located next to the motor on the right. A safety pin integrated into the overload protector pops out and the VAG ROTOP can no longer be operated. Only after a cooling
off period of several minutes can the safety pin be pushed back in and operation continued. 3.4 Proper and improper mode of operation At torque of up to 100 Nm one-man operation is possible when the actuator column is used. At higher torques the VAG ROTOP must be operated by two people. Use on valves with handwheels is not permitted. For operation with the VAG ROTOP the handwheel must first be disassembled from the valve. The maximum operating conditions specified in the technical documentation (KAT 5551-A) may not be exceeded. Duty cycle Figure 1: Torque duty cycle dependence Torque
4 Set-up and operation 4.1 Visual inspection and preparation Before putting the VAG ROTOP into operation, perform a visual inspection of all working parts. While doing so, make sure to check the integrity of the power cable including protective switch. Damaged power cables from both the VAG ROTOP and the supplied DI protective switches can pose a hazard to the user. (6) Digital counter (forward-backward) Inlet for power cable (4) Direction of rotation switch Protector (8) LED The machine is connected to mains power The electrical connection in accordance with prevailing regulations. In addition, DI, Fi or RCD protective switches can be used. Only change the direction of rotation when shut down. Watch the counter when approaching metallic end stops. Indicator plate, rear side (2) On/off switch (3) Torque control via step switch- adjustable in 4 steps (7) Counter reset button Rotations of standard valves on the front-rear side DN 40 50 65 80 100 125 150 200 250 300 Rot/stroke 11 13,5 14 17 21 26 31 34,5 43 51 Tolerance +/- 2 rotations/stroke (5) Temperature protection switch Name plate (1) On/off switch with speed control Figure 2: Detailed view of the VAG ROTOP
4.2 Set-up and operation Connect the supplied DI protective switch to the ROTOP connection cable. Connect the plug to the power source (generator or mains). Push in the function button in the middle of the DI protective switch until it locks into place (hold for up to 2 seconds). Any generators or cable reels used must be suitable for operation outdoors and comply with VDE regulations. The possible power output of the generator must be at least 2000 watts in order to guarantee the required current of 230V when under load. The generator must be earthed (an earthing device must be in the generator s scope of supply). The ROTOP and the protective switch are now ready for operation. The green power indicator (item 8) goes on. If the power circuit is interrupted or an operating failure occurs the protective switch pops out and must be locked back into position for continued operation. The DI protective switch is for personal protection and must be used in accordance with VDE regulations. 4.5 Important note about torque shut-off! After being switched on the motor starts up in soft start. In this brief time (approx. two seconds) the machine starts up to maximum torque. This phase can also be used as a breakaway function. Only afterwards is the value set for automatic torque shut-off activated. If the valve is already in end position and it should be turned closed even more, only switch on the machine for a brief moment. 4.6 Adjusting the direction of rotation The direction of rotation can be both clockwise and anti-clockwise. A change in the direction of rotation is done by using the switch (item 4). Caution: Only change the direction of rotation when shut down. 4.3 Adjusting the speed In order to operate the VAG ROTOP both switches (items 1 and 2) must be pushed simultaneously. After the VAG ROTOP starts up in soft start the speed can be varied, depending on the amount of pressure applied, between 10 rpm and 70 rpm on the right handle (item 1) of the VAG RO- TOP. Even mains fluctuations which may cause the speed to change can be compensated by the operator. Speed should be lowered in the end positions in particular, in order to gently move to the seat and thus avoid impacts. 4.4 Adjusting the torque The maximum torque required can be adjusted in 4 steps by means of a step switch (item 3). Step 1: 50 Nm Step 2: 70 Nm Step 3: 150 Nm Step 4: 230 Nm -> maximum torque Please note! Only adjust the torque and direction of rotation switch when shut down. To prolong the service life of the valve and the drive, always operate at the lowest possible torque. For valves with metallic limit stops (e.g. butterfly valves) overloads to valves and the drive should be avoided by moving to end position not dependent on the torque, but the path, by watching the counter. Pay attention to the overrun of the drive. 4.7 The counter The counter (item 6) displays the number of revolutions digitally. When rotating clockwise counting goes from 0 upwards (0, 1, 2, 3,...). When rotating anti-clockwise counting goes backwards from the current counter reading (3, 2, 1, 0, -1, -2, -3, ). The reset button (item 7) can be used to reset the counter to 0. 4.8 Starting the VAG ROTOP The VAG ROTOP is started by simultaneously pushing the on/ off switch on the left handle (item 2) along with the switch of the speed control on the right handle (item 1). The integrated soft start causes a delay of approx. two seconds until full operating speed is attained, even when the speed control is pushed in all the way. 4.9 Operation One man operation without any other equipment is possible up to approx. 100 Nm. If an actuator column permanently affixed to the device is used higher loads are also possible during one man operation. For higher loads two people should operate the machine. Make sure that the VAG ROTOP is not overloaded. Refer to the diagram for duty cycle. In two man operation the duty cycle falls off sharply and falls to approx. 1 minute at 230 Nm. Failure to observe these instructions will trigger the overload protector (item 5) integrated in the ROTOP. It is located next to the motor on the right. A safety pin integrated into the overload protector pops out and the VAG ROTOP can no longer be operated. Only after a cooling off period of several minutes can the safety pin be pushed back in and operation continued.
5 Maintenance and repair 5.1 General safety instructions Prior to the performance of inspection and maintenance work on the valve or its assemblies, shut-off the pressurised pipeline, depressurise it and secure it against inadvertent activation. Depending on the kind and dangerousness of the fluid conveyed, comply with all required safety regulations. After completing maintenance work and before resuming operation, check all connections for proper fastening and tightness. Perform the steps described for initial set-up as described under Section 5 Set-up and operation. Statutory and local provisions as well as the safety and accident prevention regulations must be observed and complied with at all times. Any damage that may be caused by electric current and current flow must be prevented. Couplings and connections must never be disassembled when they are under pressure or current-bearing. Servicing, maintenance and inspection work as well as the replacement of spare parts must only be done qualified staff. The plant operator is responsible for determining the suitability of the staff or for ensuring the relevant qualifications. In case the operator s employees do not have the qualifications required, they need to attend a training course. This training course can e.g. be held by VAG Service employees. In addition to this, the plant operator needs to ensure that all employees have understood these Operation and Maintenance Instructions as well as all further instructions referred to in them. Protective equipment such as safety boots, safety helmets, safety clothing, goggles, protective gloves, etc. must be worn during all work requiring such protective equipment or for which such protective equipment is prescribed. Improper or wrong use of the valve should be avoided. Prior to the performance of any work on the valve and equipment it must be ensured that the relevant pipeline section has been depressurised and/or de-energised. 5.2 Inspection and operation intervals Prior to each use of the VAG ROTOP we recommend checking whether the power cable, plug and operating controls meet regulations. Half-yearly: If the VAG ROTOP is used only rarely, a test run must be carried out approximately every 6 months. Failure to do so may result in the loss of warranty. Check cables and plug for any defects prior to the test run. Yearly: Check that are retaining bolts are secure and tighten if necessary. According to statutory regulations (Accident Prevention Regulations, VGB 4m 5) all portable machines, in particular those being used outdoors, must be inspected at least once per year by the manufacturer or by an authorised qualified person. Failure to do so may result in the loss of warranty. 6 Trouble-shooting For all repair and maintenance work, please observe the general safety instructions described in Section 7.1. 7 How to contact us Headquarters VAG GmbH Carl-Reuther-Str. 1 68305 Mannheim Germany Telephone: +49 (621) 749-0 Fax: +49 (621) 749-2153 info@vag-group.com http://www.vag-group.com Service Our service hotline can be reached 24/7 world-wide. In case of emergency, please contact us by phone. Service hotline: +49 621-749 2222 Service by e-mail: service@vag-group.com The VAG ROTOP requires only minimal maintenance. The gear housing is filled with lubricant at the factory. No topping off is necessary. Problem Possible causes Solutions Power supply not connected Connect to power VAG ROTOP won t start up Generator doesn t work Cable defective Protection switches not switched on Overload protector triggered Ensure proper working order of the generator Have cable repaired professionally Switch on DI protection switches Switch overload protector back on after a cooling off period Counter skips Unsuitable generator Replace or repair generator Power indicator LED won t go on LED defective Exchange indicator light at the factory
www.vag-group.com info@vag-group.com Edition 1-01/2018