AUMA SAEx 07.2, SAEx 10.2, SAEx 07.6, SAEx 14.6, SAEx 16.2 Operation Instructions Manual

...

0 (0)

Multi-turn actuators SAEx 07.2 – SAEx 16.2 SAREx 07.2 – SAREx 16.2 Control unit - electromechanical with actuator controls AUMATIC ACExC 01.2 Intrusive

Control

Parallel Profibus DP Modbus Foundation Fieldbus

→ HART

Assembly, operation, commissioningOperation instructions

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Table of contents ACExC 01.2 Intrusive HART

Read operation instructions first.

●

Observe safety instructions.

●

These operation instructions are part of the product.

●

Retain operation instructions during product life.

●

Pass on instructions to any subsequent user or owner of the product.

Purpose of the document:

This document contains information for installation, commissioning, operation and maintenance staff . It is intended to support device installation and commissioning.

Reference documents:

●

Manual (Operation and setting) AUMATIC AC 01.2 HART

●

Manual (Device integration) AUMATIC AC 01.2 HART

Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA (refer to <Addresses>).

Table of contents Page

112.2. Short description

123. Transport, storage and packaging........................................................................................

123.1. Transport

123.2. Storage

123.3. Packaging

134. Assembly................................................................................................................................

134.1. Mounting position

134.2. Handwheel fitting

134.3. Multi-turn actuator: mount to valve/gearbox

134.3.1. Output drive types B, B1 – B4 and E

144.3.1.1. Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox

144.3.2. Output drive type A

154.3.2.1. Stem nut: finish machining

164.3.2.2. Multi-turn actuator (with output drive type A): mount to valve

174.4. Accessories for assembly

174.4.1. Stem protection tube for rising valve stem

174.5. Mounting positions of local controls

184.5.1. Mounting positions: modify

51. Safety instructions.................................................................................................................

51.1. Basic information on safety

51.2. Range of application

61.3. Warnings and notes

71.4. References and symbols

82. Identification...........................................................................................................................

82.1. Name plate

195. Electrical connection.............................................................................................................

195.1. Basic information

215.2. Connecting via Ex plug/socket connector with screw-type terminals (KP, KPH)

215.2.1. Terminal compartment: open

215.2.2. Cable connection

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Table of contents

235.2.3. Terminal compartment: close

245.3. Connecting via Ex plug/socket connector with terminal blocks (KES)

245.3.1. Terminal compartment: open

255.3.2. Cable connection

265.3.3. Terminal compartment: close

265.4. Accessories for electrical connection

265.4.1. Controls mounted to wall bracket

275.4.2. Parking frame

285.4.3. Protection cover

285.4.4. Earth connection, external

296. Operation................................................................................................................................

296.1. Manual operation

296.1.1. Manual operation: engage

296.1.2. Manual operation: disengage

296.2. Motor operation

296.2.1. Local actuator operation

306.2.2. Actuator operation from remote

306.3. Menu navigation via push buttons (for settings and indications)

316.3.1. Menu layout and navigation

326.4. User level, password

336.4.1. Password entry

336.4.2. Password change

346.5. Language in the display

346.5.1. Language change

367. Indications..............................................................................................................................

367.1. Indications during commissioning

367.2. Indications in the display

377.2.1. Feedback indications from actuator and valve

407.2.2. Status indications according to AUMA classification

417.2.3. Status indications according to NAMUR recommendation

427.3. Mechanical position indicator/running indication

437.4. Indication lights

448. Signals.....................................................................................................................................

448.1. Signals via HART

448.2. Status signals via output contacts (digital outputs)

448.2.1. Assignment of outputs

448.2.2. Encoding of outputs

448.3. Analogue signals

459. Commissioning (basic settings)...........................................................................................

459.1. Type of seating: set

469.2. HART address (slave address): set

479.3. Switch compartment: open

489.4. Torque switching: set

489.5. Limit switching: set

499.5.1. End position CLOSED (black section): set

499.5.2. End position OPEN (white section): set

509.6. Intermediate positions: set

509.6.1. Running direction CLOSE (black section): set

509.6.2. Running direction OPEN (white section): set

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Table of contents ACExC 01.2 Intrusive HART

519.7. Test run

519.7.1. Direction of rotation: check

529.7.2. Limit switching: check

529.7.3. Reference operation position feedback: perform

539.8. Potentiometer

539.8.1. Potentiometer setting

539.9. Electronic position transmitter RWG

549.9.1. Measuring range: set

549.10. Mechanical position indicator: set

559.11. Switch compartment: close

5710. Corrective action....................................................................................................................

5710.1. Faults during commissioning

5710.2. Fault indications and warning indications

6010.3. Fuses

6010.3.1. Fuses within the actuator controls

6210.3.2. Motor protection (thermal monitoring)

6311. Servicing and maintenance...................................................................................................

6311.1. Preventive measures for servicing and safe operation

6311.2. Disconnection from the mains

6411.3. Maintenance

6511.4. Disposal and recycling

connector and screw-type terminals (KP, KPH)

minals (KP, KPH)

(KES)

6612. Technical data.........................................................................................................................

6612.1. Technical data Multi-turn actuators

6912.2. Technical data Actuator controls

7513. Spare parts.............................................................................................................................

7513.1. Multi-turn actuators SAEx 07.2 – SAEx 16.2/SAREx 07.2 – SAREx 16.2 with Ex plug/socket

7713.2. Actuator controls AUMATIC ACExC 01.2 with Ex plug/socket connector and screw-type ter-

7913.3. Actuator controls AUMATIC ACExC 01.2 with Ex plug/socket connector and terminal blocks

8114. Certificates..............................................................................................................................

8114.1. Declaration of Incorporation and EC Declaration of Conformity

8214.2. ATEX certificate

87Index........................................................................................................................................

89Addresses...............................................................................................................................

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Safety instructions

1. Safety instructions

1.1. Basic information on safety Standards/directives

Safety instructions/warn-

ings

Qualification of staff

AUMA products are designed and manufactured in compliance with recognised standards and directives.This is certified in a Declaration of Incorporation and an EC Declaration of Conformity.

The end user or the contractor must ensure that all legal requirements, directives, guidelines, national regulations and recommendations with respect to assembly, electrical connection, commissioning and operation are met at the place of installation.

They include among others standards and directives such as IEC/EN 60079 “Electrical apparatus for explosive atmospheres" –

●

Part 14: Electrical installations in hazardous areas (other than mines).

●

Part 17: Inspection and maintenance of electrical installations in hazardous areas (other than mines).

All personnel working with this device must be familiar with the safety and warning instructions in this manual and observe the instructions given. Safety instructions and warning signs on the device must be observed to av oid personal injury or property damage.

Assembly, electrical connection, commissioning, operation, and maintenance must be carried out exclusively by suitab ly qualified personnel ha ving been authorised by the end user or contractor of the plant only.

Prior to working on this product, the staff must have thoroughly read and understood these instructions and, furthermore, know and observe officially recognised rules regarding occupational health and safety.

Work performed in potentially explosiv e atmospheres is subject to special regulations which have to be observed.The end user or contractor of the plant are responsible for respect and control of these regulations, standards, and laws.

Commissioning

Operation

Protective measures

Maintenance

Prior to commissioning, it is important to check that all settings meet the requirements of the application. Incorrect settings might present a danger to the application, e.g. cause damage to the valve or the installation.The manufacturer will not be held liable for any consequential damage. Such risk lies entirely with the user.

Prerequisites for safe and smooth operation:

●

Correct transport, proper storage, mounting and installation, as well as careful commissioning.

●

Only operate the device if it is in perf ect condition while observing these instructions.

●

Immediately report any faults and damage and allow for corrective measures.

●

Observe recognised rules for occupational health and safety.

●

Observe the national regulations.

●

During operation, the housing warms up and surface temperatures > 60 °C may occur.To prevent possible burns, we recommend checking the surf ace temperature using an appropriate thermometer and wearing protective gloves, if required, prior to working on the device.

The end user or the contractor are responsible for implementing required protective measures on site, such as enclosures, barriers, or personal protective equipment for the staff.

T o ensure saf e device operation, the maintenance instructions included in this manual must be observed.

Any device modification requires prior consent of the manufacturer.

1.2. Range of application

AUMA multi-turn actuators are designed for the operation of industrial valves, e.g. globe valves, gate valves, butterfly valves, and ball valves.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Safety instructions ACExC 01.2 Intrusive HART

The devices described below are approved for use in the potentially explosive atmospheres of zones 1, 2, 21, and 22.

If temperatures >40 °C are to be expected at the valve mounting flange or the valve stem (e.g. due to hot media), please consult AUMA.Temperatures > 40 °C are not considered with regards to the non-electrical explosion protection.

Other applications require explicit (written) confirmation by the manufacturer. The following applications are not permitted, e.g.:

●

Industrial trucks according to EN ISO 3691

●

Lifting appliances according to EN 14502

●

Passenger lifts according to DIN 15306 and 15309

●

Service lifts according to EN 81-1/A1

●

Escalators

●

Continuous duty

●

Buried service

●

Continuous submersion (observe enclosure protection)

●

Potentially explosive areas of zones 0 and 20

●

Potentially explosive areas of group I (mining)

●

Radiation exposed areas in nuclear power plants

No liability can be assumed for inappropriate or unintended use. Observance of these operation instructions is considered as part of the device's

designated use.

Information

These operation instructions are only valid for the "clockwise closing" standard version, i.e. driven shaft turns clockwise to close the valve.

1.3. Warnings and notes

The following warnings draw special attention to saf ety-rele v ant procedures in these operation instructions, each marked by the appropriate signal word (DANGER, WARNING, CAUTION, NOTICE).

Indicates an imminently hazardous situation with a high level of risk. Failure to observe this warning could result in death or serious injury.

Indicates a potentially hazardous situation with a medium level of risk. F ailure to observe this warning could result in death or serious injury.

Indicates a potentially hazardous situation with a low level of risk. Failure to observe this warning may result in minor or moderate injury . Ma y also be used with property damage.

Potentially hazardous situation. Failure to observe this warning may result in property damage. Is not used for personal injury.

Arrangement and typographic structure of the warnings

Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)

→

Measures to avoid the danger

→

Further measure(s)

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Safety instructions

Safety alert symbol warns of a potential personal injury hazard. The signal word (here: DANGER) indicates the level of hazard.

1.4. References and symbols

The following references and symbols are used in these instructions:

Information The term Information preceding the text indicates important notes and information.

Symbol for CLOSED (valve closed) Symbol for OPEN (valve open) Important information before the next step.This symbol indicates what is required

for the next step or what has to be prepared or observed.

Via the menu to parameter

Describes the path within the menu to the parameter. By using the push buttons of the local controls you may quickly find the desired parameter in the display.

< > Reference to other sections

T erms in brack ets shown abov e refer to other sections of the document which provide further information on this topic.These terms are either listed in the index, a heading or in the table of contents and may quickly be found.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Identification ACExC 01.2 Intrusive HART

2. Identification

2.1. Name plate

Each device component (actuator, controls, motor) is equipped with a name plate. Figure 1: Arrangement of name plates

[1] Actuator name plate [2] Actuator controls name plate [3] Motor name plate [4] Additional plate, e.g. KKS plate (Power Plant Classification System) [5] Explosion protection approval plate

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Identification

Actuator name plate

Figure 2: Actuator name plate (example)

[1] Name of manufacturer [2] Address of manufacturer [3] Type designation [4] Order number [5] Actuator serial number [6] Speed [7] Torque range in direction CLOSE [8] Torque range in direction OPEN [9] Type of lubricant [10] Enclosure protection [11] Permissible ambient temperature [12] Can be assigned as an option upon customer request [13] Can be assigned as an option upon customer request [14] Data Matrix code

Actuator controls name plate

[1] Type designation [2] Order number [3] Serial number [4] Actuator terminal plan [5] Actuator controls terminal plan [6] Mains voltage [7] AUMA power class for switchgear [8] Permissible ambient temperature [9] Enclosure protection [10] Control [11] Data Matrix code

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Identification ACExC 01.2 Intrusive HART

Descriptions

Type designation Figure 3:Type designation (example)

1. Type and size of actuator

2. Flange size

3. Ex marking

Type and size

These instructions apply to the following devices types and sizes: SAEx 07.2, 07.6, 10.2, 14.2, 14.6, 16.2 = multi-turn actuators for open-close duty SAREx 07.2, 07.6, 10.2, 14.2, 14.6, 16.2 = multi-turn actuators for modulating duty ACExC 01.2 = AUMATIC actuator controls

Ex marking

Table 1: Marking for explosion protection (with example)

1b3a-/

1st position: Not used

–

2nd position: motor type

ADX or VDX: 3-phase AC motor

AEX, ACX, VEX and VCX: 1-phase AC motor

3rd position: protection type of electrical connection

Terminal compartment Ex e increased safety:

Types: KP, KPH or KES Terminal compartment Ex d flameproof enclosure:

Type: KES-Exd

4th position: protection type of position transmitter

Without intrinsically safe electric circuita Electric circuit Ex i Intrinsic safety:

Type: RWG 5020.2Ex

5th position: protection type of position transmitter

Standard fieldbus connection1 Ex nL non incendive fieldbus connection2 Ex ic intrinsically safe fieldbus connection3

Order number

The product can be identified using this number and the technical data as well as order-related data pertaining to the device can be compiled.

Please always state this number for any product inquiries. On the Internet at http://www.auma.com, we offer a service allowing authorised

users to download order-related documents such as wiring diagrams and technical data (both in German and English), inspection certificates and the operation instructions when entering the order number.

Serial number

Table 2: Description of serial number (with example)

MD123451405

1st+2nd position: Assembly in week

Week 0505

3rd+4th position:Year of production

Year of production: 201414

All other positions

Internal number for unambiguous product identificationMD12345

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Identification

Actuator terminal plan

AUMA power class for

switchgear

Data Matrix code

9th position after TPA: Position transmitter version 0 = Without position transmitter A, B, J, K, L, N, R,T = Potentiometer C, D, E, G, H, M, P, S, U = Electronic position transmitter

The switchgear used in the actuator controls (reversing contactors/thyristors) are

classified according to AUMA power classes (e.g. A1, B1, ....).The power class

defines the max. permissible rated power (of the motor) the switchgear has been designed for.The rated power (nominal power) of the actuator motor is indicated in kW on the motor name plate. For the assignment of the AUMA po w er classes to the nominal power of the motor types, refer to the separate electrical data sheets.

For switchgear without assignment to an y power classes, the actuator controls name plate does not indicate the power class but the max. rated power in kW.

When registered as authorised user, you may use the AUMA Support App to scan the Data Matrix code and directly access the order-related product documents without having to enter order number of serial number.

Figure 4: Link to the App store:

Control

2.2. Short description

Multi-turn actuator

Actuator controls

Local con-

trols/AUMA CDT

Intrusive - Non-Intrusive

Table 3: Control examples (indications on controls name plate)

DescriptionInput signal

Control via HART interfaceHART

HART/24 V DC

Control via HART interface and control voltage for OPEN - CLOSE Control via digital inputs (OPEN, STOP, CLOSE)

Definition in compliance with EN ISO 5210: A multi-turn actuator is an actuator which transmits to the valve a torque for at least

one full revolution. It is capable of withstanding thrust. AUMA multi-turn actuators are driven by an electric motor and are capable of

withstanding thrust in combination with output drive type A. For manual operation, a handwheel is provided. Switching off in end positions may be either by limit or torque seating. Controls are required to operate or process the actuator signals.

The AUMATIC actuator controls are used to operate AUMA actuators and are supplied ready for use.The controls may be mounted directly to the actuator or separately on a wall bracket.

When set to local control, it is possible to

●

operate the actuator via the local controls (push buttons and display) and perf orm settings (contents of these instructions).

●

read in or out data or modify and save settings via the AUMA CDT software (accessories), using a computer (laptop or PC).The connection between computer and AUMATIC is wireless via Bluetooth interface (not included in these instructions).

●

Intrusive version (control unit: electromechanical): Limit and torque setting is performed via switches in the actuator.

●

Non-Intrusive version (control unit: electronic): Limit and torque setting is performed via the controls, actuator and controls housings do not have to be opened. For this purpose, the actuator is equipped with an MWG (magnetic limit and torque transmitter), also supplying analogue torque feedback signals/torque indication and analogue position feedback signals/position indication.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Transport, storage and packaging ACExC 01.2 Intrusive HART

3. Transport, storage and packaging

3.1. Transport

For transport to place of installation, use sturdy packaging.

Hovering load!

Risk of death or serious injury.

→

Do NOT stand below hovering load.

→

Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT to handwheel.

→

Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting by hoist to valve and NOT to actuator.

→

Actuators mounted to gearboxes: Attach ropes or hooks f or the purpose of lifting by hoist only to the gearbox using eyebolts and NOT to the actuator.

→

Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting by hoist only to the actuator and NOT to the controls.

3.2. Storage

Long-term storage

3.3. Packaging

Danger of corrosion due to inappropriate storage!

→

Store in a well-ventilated, dry room.

→

Protect against floor dampness by storage on a shelf or on a wooden pallet.

→

Cover to protect against dust and dirt.

→

Apply suitable corrosion protection agent to uncoated surfaces.

Damage on display caused by temperatures below permissible level!

→

The AUMATIC actuator controls must NOT be stored below –30 °C.

If the device must be stored for a long period (more than 6 months) the following points must be observed in addition:

1. Prior to storage: Protect uncoated surfaces, in particular the output drive parts and mounting surface, with long-term corrosion protection agent.

2. At an interval of approx. 6 months: Check for corrosion. If first signs of corrosion show , apply ne w corrosion protection.

Our products are protected by special packaging for transport when leaving the factory .The packaging consists of environmentally friendly materials which can easily be separated and recycled.We use the following packaging materials: wood, cardboard, paper, and PE foil. For the disposal of the packaging material, we recommend recycling and collection centres.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Assembly

4. Assembly

4.1. Mounting position

AUMA actuators and actuator controls can be operated without restriction in any mounting position.

4.2. Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are supplied separ-

ately. Figure 5: Handwheel

[1] Spacer [2] Input shaft [3] Handwheel [4] Circlip

1. If required, fit spacer [1] onto input shaft [2].

2. Slip handwheel [3] onto input shaft.

3. Secure handwheel [3] using the circlip [4] supplied.

4.3. Multi-turn actuator: mount to valve/gearbox

Danger of corrosion due to damage to paint finish and condensation!

→

Touch up damage to paint finish after work on the device.

→

After mounting, connect the device immediately to electrical mains to ensure that heater minimises condensation.

4.3.1. Output drive types B, B1 – B4 and E

●

Application

Design

For rotating, non-rising valve stem

●

Not capable of withstanding thrust

Output drive bore with keyway:

●

Types B1 – B4 with bore according to EN ISO 5210

●

Types B and E with bore according to DIN 3210

●

Later change from B1 to B3, B4, or E is possible.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Assembly ACExC 01.2 Intrusive HART

Figure 6: Output drive

[1] Output drive types B, B1 – B4, E and C [2] Output drive sleeve/output drive plug sleve with bore and keyway [3] Circlip

Information Spigot at flanges should be loose fit.

4.3.1.1. Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox

1. Check if mounting flanges fit together.

2. Check whether bore and keyway match the input shaft.

3. Apply a small quantity of grease to the input shaft.

4. Place multi-turn actuator. Information: Ensure that the spigot fits uniformly in the recess and that the

mounting faces are in complete contact.

5. Fasten multi-turn actuator with screws according to table. Information: We recommend applying liquid thread sealing material to the

screws to avoid contact corrosion.

6. Fasten screws crosswise to a torque according to table.

Table 4: Tightening torques for screws

Tightening torque TA [Nm]Screws Strength class 8.8Threads

25M8 51M10 87M12 214M16 431M20

4.3.2. Output drive type A

●

Application

Output drive for rising, non-rotating valve stem

●

Capable of withstanding thrust

Information To adapt the actuators to output drive types A av ailab le on site with flanges F10 and

F14 (year of manufacture: 2009 and earlier), an adapter is required.The adapter can be ordered from AUMA.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Assembly

4.3.2.1. Stem nut: finish machining

This working step is only required if stem nut is supplied unbored or with pilot

✔

bore.

Figure 7: Design of output drive type A

[1] Stem nut [2] Bearing [2.1] Bearing race [2.2] Bearing rim [3] Spigot ring

1. Remove spigot ring [3] from output drive.

2. Remove stem nut [1] together with bearings [2].

3. Remove bearing races [2.1] and bearing rims [2.2] from stem nut [1].

4. Drill and bore stem nut [1] and cut thread. Information: When fixing in the chuck, make sure stem nut runs true!

5. Clean the machined stem nut [1].

6. Apply sufficient Lithium soap EP multi-purpose grease to bearing rims [2.2] and bearing races [2.1], ensuring that all hollow spaces are filled with grease.

7. Place greased bearing rims [2.2] and bearing races [2.1] onto stem nut [1].

8. Re-insert stem nut [1] with bearings [2] into output drive. Information:Ensure that dogs or splines are placed correctly in the keyway of

the hollow shaft.

9. Screw in spigot ring [3] until it is firm against the shoulder.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Assembly ACExC 01.2 Intrusive HART

4.3.2.2. Multi-turn actuator (with output drive type A): mount to valve

Figure 8: Assembly with output drive type A

[1] Valve stem [2] Output drive type A [3] Screws to actuator [4] Valve flange [5] Screws to output drive

1. If the output drive type A is already mounted to the multi-turn actuator: Loosen screws [3] and remove output drive type A [2].

2. Check if the flange of output drive type A matches the valve flange [4].

3. Apply a small quantity of grease to the valve stem [1].

4. Place output drive type A on valve stem and turn until it is flush on the valve flange.

5. Turn output drive type A until alignment of the fixing holes.

6. Screw in fastening screws [5], however do not completely tighten.

7. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into the output drive sleeve.

The flanges are flush with each other if properly engaged.

➥

8. Adjust multi-turn actuator until alignment of the fixing holes.

9. Fasten multi-turn actuator with screws [3].

10. Fasten screws [3] crosswise with a torque according to table.

Table 5: Tightening torques for screws

Tightening torque TA [Nm]Screws Strength class 8.8Threads

11M6 25M8 51M10 87M12 214M16 431M20

11. Turn multi-turn actuator with handwheel in direction OPEN until valve flange and output drive A are firmly placed together.

12. Tighten fastening screws [5] between valve and output drive type A crosswise applying a torque according to table.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Assembly

4.4. Accessories for assembly

4.4.1. Stem protection tube for rising valve stem — Option —

Figure 9: Assembly of the stem protection tube

[1] Cap for stem protection tube [2] Stem protection tube [3] Sealing ring

1. Seal thread with hemp, Teflon tape, or thread sealing material.

2. Screw stem protection tube [2] into thread and tighten it firmly.

3. Push down the sealing ring [3] onto the housing.

4. Check whether cap for stem protection tube [1] is available and in perfect con-

dition.

4.5. Mounting positions of local controls

The mounting position of the local controls is selected according to the order. If , after mounting the actuator to the valve or the gearbox on site, the local controls are in an unfav ourable position, the mounting position can be changed at a later date . F our mounting positions are possible.

Figure 10: Mounting positions A and B

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Assembly ACExC 01.2 Intrusive HART

Figure 11: Mounting positions C and D

4.5.1. Mounting positions: modify

Flameproof enclosure, danger of explosion!

Risk of death or serious injury.

→

Before opening, ensure that there is no explosive gas and no voltage.

→

Handle cover and housing parts with care.

→

Joint surfaces must not be damaged or soiled in any way.

→

Do not jam cover during fitting.

Electrostatic discharge ESD!

Risk of damage to electronic components.

→

Earth both operators and devices.

1. Loosen screws and remove the local controls.

2. Check whether O-ring is in good condition, correctly insert O-ring.

3. Turn local controls into new position and re-place.

Cable damage due to twisting or pinching!

Risk of functional failures.

→

Turn local controls by a maximum of 180°.

→

Carefully assemble local controls to avoid pinching the cables.

4. Fasten screws evenly crosswise.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Electrical connection

5. Electrical connection

5.1. Basic information

Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury , or property damage.

→

The electrical connection must be carried out exclusively by suitably qualified personnel.

→

Prior to connection, observe basic information contained in this chapter.

→

After connection but prior to applying the voltage, observe the <Commissioning> and <Test run> chapters.

Wiring diagram/terminal

plan

Permissible networks

(supply networks)

Protection on site

The pertaining wiring diagram/terminal plan (both in German and English) is attached to the device in a weather-proof bag, together with these operation instructions. It can also be requested from AUMA (state order number, refer to name plate) or downloaded directly from the Internet (http://www.auma.com).

The controls (actuators) are suitable for for use in TN and TT networks with directly earthed star point and a maximum voltage of 690 V AC. Use in IT networks is permitted while observing the respective <Protection on site> for for maiximum supply voltages of 600 V AC.

For short-circuit protection and for disconnecting the actuator from the mains, fuses and disconnect switches have to be provided by the customer.

The current values for respective sizing is derived from the current consumption of the motor (refer to electrical data sheet) plus the current consumption of the controls.

Table 6: Current consumption controls

Max. current consumptionMains voltage

–30 %±10 %Permissible variation of the mains voltage 1,200 mA750 mA100 to 120 V AC 750 mA400 mA208 to 240 V AC 400 mA250 mA380 to 500 V AC 400 mA200 mA515 to 690 V AC

Power supply for the

controls (electronics)

Safety standards

Table 7: Maximum permissible protection

Max. protectionRated powerSwitchgear

16 A (gL/gG)up to 1.5 kWReversing contactor A1 32 A (gL/gG)up to 7.5 kWReversing contactor A2 63 A (gL/gG)up to 11 kWReversing contactor A3 16 A (g/R) I²t<1,500A²sup to 1.5 kWThyristor B1 32 A (g/R) I²t<1,500A²sup to 3 kWThyristor B2 63 A (g/R) I²t<5,000A²sup to 5.5 kWThyristor B3

If controls are mounted separately from actuator (controls on wall brack et): Consider length and cross section of connecting cable when defining the protection required.

Use appropriate insulation monitors when working in power installations, for e xample an insulation monitor measuring the pulse code.

In case of external supply of the controls (electronics):The external power supply must have a reinforced insulation against the mains voltage in accordance with IEC 61010-1 and may only be supplied by a circuit limited to 150 VA in accordance with IEC 61010-1.

All externally connected devices shall comply with the relevant safety standards.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Electrical connection ACExC 01.2 Intrusive HART

Cable installation in ac-

cordance with EMC

Type of current, mains voltage and mains fre-

quency

Signal and bus cables are susceptible to interference. Motor cables are interference sources.

●

Lay cables being susceptible to interference or sources of interference at the highest possible distance from each other.

●

The interference immunity of signal and bus cables increases if the cables are laid close to the earth potential.

●

If possible, avoid laying long cables and make sure that they are installed in areas being subject to low interference.

●

Avoid long par allel paths with cab les being either susceptible to interf erence or interference sources.

●

For the connection of remote position transmitters, screened cables must be used.

Type of current, mains voltage and mains frequency must match the data on the motor name plate.

Figure 12: Motor name plate (example)

Connecting cables

HART cable recommend-

ation:

[1] Type of current [2] Mains voltage [3] Mains frequency (for 3-ph and 1-ph AC motors)

●

For device insulation, appropriate (v oltage-proof) cables must be used. Specify cables for the highest occurring rated voltage.

●

Use connecting cables with a minimum temperature range of +80 °C.

●

For connecting cables exposed to UV radiation (outdoor installation), use UV resistant cables.

Twisted wire pair, shielded. For cable length <1 500 m: cross section min. 0.2 mm² For cable length <1 500 m: cross section min. 0.5 mm² We recommend selecting 0.75 mm² cross section. For smaller cable length cross

section, the cross section must be enlarged to min. 0.75 mm² using a wire end sleeve if required and performing an appropriate concentric crimping.

Multiple-twisted pair cables must not be used.

Prior to installation, please note:

●

Connection is made as point-to-point topology.

●

Respect a distance of minimum 20 cm between HART cab les and other cables if possible. If possible, the cab les should be laid in a separ ate , conductive, and earthed cable tray.

●

Make sure that there are no potential differences between participants.

●

Maximum cable length depends on characteristics of devices connected (impedance), of cables used (cable capacity and resistance) and the impedance of all devices installed between two end devices.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Electrical connection

5.2. Connecting via Ex plug/socket connector with screw-type terminals (KP, KPH)

5.2.1. Terminal compartment: open

Figure 13: Ex plug/socket connector KPH

[1] Cover [2] Screws for cover [3] O-ring [4] Terminal compartment [5] Terminal board

5.2.2. Cable connection

Hazardous voltage!

Risk of electric shock.

→

Disconnect device from the mains before opening.

1. Loosen screws [2] and remove cover [1].

Terminal compartment [4] is designed for explosion protection Ex e (increased

➥

safety).The flameproof compartment (type of protection Ex d) remains hereby closed.

2. Insert cable glands with Ex e approv al and of size suitable f or connection cables.

The enclosure protection IP… stated on the name plate is only ensured if suit-

➥

able cable glands are used. Example: Name plate shows enclosure protection IP68.

3. Seal cable entries which are not used with approved plugs suitable for the re-

quired protection type.

4. Insert the wires into the cable glands.

Table 8: Cross sections and tightening torques

Power terminals (U1, V1, W1) PE connection

Control contacts (1 to 38)

(flexible or solid)

Tightening torquesCross sectionsType

2 Nm(1.5)1) 2.5 – 6 mm²

1 Nm0.75 – 1.5 mm²

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Electrical connection ACExC 01.2 Intrusive HART

with small clamp washers1)

Danger of corrosion: Damage due to condensation!

→

After mounting, commission the device immediately to ensure that heater minimises condensation.

1. Remove cable sheathing in a length of 120 – 140 mm.

2. Strip wires.

→

Controls max. 8 mm, motor 12 mm

3. For flexible cables: Use end sleeves according to DIN 46228.

4. Connect cables according to order-related wiring diagram. Information: Two wires for each connection permitted.

→

When using motor cables with a cross section of 1.5 mm²: Use small clamp washers for connection to terminals U1, V1, W1 and PE (the small clamp washers are provided in the electrical connection cover).

In case of a fault: Hazardous voltage while protective earth conductor is NOT connected!

Risk of electric shock.

→

Connect all protective earth conductors.

→

Connect PE connection to external protective earth conductor of connecting cables.

→

Start running the device only after having connected the protective earth conductor.

5. Tighten protective earth firmly to PE connection Figure 14: PE connection

[1] PE connection, control cable [2] PE connection, motor cable

Information Some actuators are equipped with an additional motor heater.The motor heater

minimises condensation in the motor.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Electrical connection

5.2.3. Terminal compartment: close

Figure 15: Ex plug/socket connector KPH

[1] Cover [2] Screws for cover [3] O-ring [4] Terminal compartment [5] Terminal board

1. Clean sealing faces of cover [1] and housing.

2. Check whether O-ring [3] is in good condition, replace if damaged.

3. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and insert it correctly.

4. Fit cover [1] and fasten screws [2] evenly crosswise.

5. Fasten cable glands with the specified torque to ensure the required enclosure protection.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Electrical connection ACExC 01.2 Intrusive HART

5.3. Connecting via Ex plug/socket connector with terminal blocks (KES)

5.3.1. Terminal compartment: open

Figure 16: Ex plug/socket connector: left KES, right KES flameproof

[1] Cover [2] Screws for cover [3] O-ring [4] Terminal compartment: Type of protection Ex e [5] Terminal compartment: Type of protection Ex d [6] Frame

Hazardous voltage!

Risk of electric shock.

→

Disconnect device from the mains before opening.

1. Loosen screws [2] and remove cover [1]. Terminal compartments [4] and [5] are designed either in type of protection Ex

➥

e (increased safety) or in type of protection Ex d (flameproof enclosure). Hereby, the flameproof interior compartment of the actuator (Ex d) remains closed.

2. Insert cable glands with Ex e approval and suitable for connection cables. The enclosure protection IP… stated on the name plate is only ensured if suit-

➥

able cable glands are used. Example: Name plate shows enclosure protection IP68.

3. Seal cable entries unused cable entries with approved plugs suitable for the required protection type.

4. Remove cable sheathing and insert the wires into the cable glands.

5. Fasten cable glands with the specified torque to ensure required enclosure protection.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Electrical connection

5.3.2. Cable connection

Table 9: Cross sections and tightening torques

Tightening torquesCross sectionsType

1.5 – 1.8 Nmmax. 10 mm² (flexible or solid)Power terminals (U, V, W)

3.0 – 4.0 Nmmax. 10 mm² (flexible or solid)PE connection

Control contacts (1 to 50)

max. 4 mm² (solid)

0.6 – 0.8 Nmmax.2.5 mm² (flexible), or

Danger of corrosion: Damage due to condensation!

→

After mounting, commission the device immediately to ensure that heater minimises condensation.

1. Strip wires.

2. For flexible cables: Use end sleeves according to DIN 46228.

3. Connect cables according to order-related wiring diagram.

In case of a fault: Hazardous voltage while protective earth conductor is NOT connected!

Risk of electric shock.

→

Connect all protective earth conductors.

→

Connect PE connection to external protective earth conductor of connecting cables.

→

Start running the device only after having connected the protective earth conductor.

4. Tighten protective earth firmly to PE connection Figure 17: PE connection

[1] Terminal blocks [2] Terminal housing [3]

PE connection, symbol:

Information Some actuators are equipped with an additional motor heater.The motor heater

minimises condensation in the motor.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Electrical connection ACExC 01.2 Intrusive HART

5.3.3. Terminal compartment: close

Figure 18: Ex plug/socket connector: left KES, right KES flameproof

[1] Cover [2] Screws for cover [3] O-ring [4] Terminal compartment: Type of protection Ex e [5] Terminal compartment: Type of protection Ex d [6] Frame

1. Clean sealing faces of cover [1] and housing.

2. Ex plug/socket connector designed as KES flameproof: Preserve joint surf aces with an acid-free corrosion protection agent.

3. Check whether O-ring [3] is in good condition, replace if damaged.

4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and insert it correctly.

Flameproof enclosure, danger of explosion!

Risk of death or serious injury.

→

Handle cover and housing parts with care.

→

Joint surfaces must not be damaged or soiled in any way.

→

Do not jam cover during fitting.

5. Fit cover [1] and fasten screws [2] evenly crosswise.

5.4. Accessories for electrical connection

5.4.1. Controls mounted to wall bracket

The wall bracket allows separate mounting of controls and actuator.

●

Application

If the actuator cannot be accessed.

●

If the actuator is subjected to high temperatures.

●

In case of heavy vibration of the valve.

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical ACExC 01.2 Intrusive HART Electrical connection

Design Figure 19: Design principle with wall bracket

[1] Wall bracket [2] Connecting cables [3] Electrical connection of wall bracket (XM) [4] Electrical connection of actuator (XA) [5] Electrical connection of controls (XK) – customer connector

Observe prior to connec-

tion

5.4.2. Parking frame Application

●

Permissible length of connecting cables: max. 100 m.

●

If the actuator is equipped with a position transmitter (RWG): Connecting cables must be available as shielded version.

●

Versions with potentiometer in the actuator are not suitable.

●

We recommend: AUMA cable sets LSW8-KES or LSW9-KP.

●

If the AUMA cab le set is not used: Use suitab le flexib le and screened connecting cables.

●

When using connecting cables, e.g. of the heater or switch, requiring direct wiring from the actuator to the XK customer connector (XA-XM-XK, refer to wiring diagram), these connecting cables must be subject to an insulation test in compliance with EN 50178. Connecting cab les of position transmitters (RWG, IWG, potentiometer) do not belong to this group.They may not be subject to an insulation test.

Parking frame for safe storage of a disconnected plug. For protection against touching the bare contacts and against environmental

influences. Figure 20: Parking frame and Ex plug/socket connector with screw-type terminals

(KP/KPH)

SAEx 07.2 – SAEx 16.2 / SAREx 07.2 – SAREx 16.2 Control unit - electromechanical

Electrical connection ACExC 01.2 Intrusive HART

Figure 21: Parking frame and Ex plug/socket connector with terminal blocks (KES)

5.4.3. Protection cover

Protection cover for plug compartment when plug is removed. The open terminal compartment can be closed using a protective cover (not

illustrated).

5.4.4. Earth connection, external

The housing is equipped with an external earth connection (U-bracket) to connect the device to the equipotential earth bonding.

Figure 22: Earth connection

+ 64 hidden pages