Burkert 3003 User Manual [en, de, fr]

Type 3003
Electrical rotary Open/ClOse actuator Elektromotorischer Drehantrieb Actionneurs électriques Ouvert/fermé
Auf/Zu
Operating Instructions
Bedienungsanleitung Manuel d‘utilisation
© 2011 - 2013 Bürkert Werke GmbH
Operating Instructions 1307/01_EU-ML_00809466 / Original DE
Type 3003
Contents
1. OPERATING INSTRUCTIONS ...................................................................4
1.1. Symbols ..............................................................................................4
1.2. Definition of the term “device” .......................................................4
2. INTENDED USE ................................................................................................5
2.1. Restrictions ........................................................................................ 5
3. GENERAL SAFETY INFORMATION ........................................................5
4. GENERAL INFORMATION ...........................................................................7
4.1. Contact address ............................................................................... 7
4.2. Warranty ............................................................................................. 7
4.3. Informations in the Internet .............................................................7
5. SYSTEM DESCRIPTION ...............................................................................7
5.1. Intended area of application .......................................................... 7
5.2. General description ......................................................................... 7
5.3. Options ............................................................................................... 8
5.4. Marking ............................................................................................... 8
5.5. Type label ........................................................................................... 8
6. TECHNICAL DATA ...........................................................................................9
6.1. Conformity .........................................................................................9
6.2. Standards ...........................................................................................9
6.3. Operating conditions ....................................................................... 9
6.4. General technical data .................................................................... 9
7. INSTALLATION ............................................................................................... 13
7.1. Safety information ..........................................................................13
7.2. Power and control connections ..................................................13
7.3. Connecting the additional limit switches (optional) ...............13
7.4. Circuit board for actuator with standard signal input ............15
8. ROTARY ACTUATORS WITH INTEGRATED EMERGENCY
RESET ................................................................................................................18
8.1. Safety block for emergency power version ..............................18
8.2. Technical data .................................................................................18
8.3. Electric wiring ..................................................................................19
8.4. Circuit board ...................................................................................19
9. OPERATING .....................................................................................................20
9.1. Safety information ..........................................................................20
9.2. Manual operation of the rotary actuator ....................................21
9.3. Returning from manual to automatic operation .......................21
10. MAINTENANCE AND REPAIR ..............................................................22
10.1. Safety information ........................................................................22
10.2. Maintenance ..................................................................................22
10.3. Malfunctions ..................................................................................22
11. ACCESSORIES ...........................................................................................23
12. TRANSPORT, STORAGE, DISPOSAL ..............................................23

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3
Type 3003
Operating Instructions
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the device.
The operating instructions contain important safety information!
Failure to observe these instructions may result in hazardous situations.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning may result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderately severe or minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the device or the equipment.
Designates additional significant information, tips and recommendations.
Refers to information in these operating instructions or in other documentation.
→ designates a procedure which you must carry out.
1.2. Definition of the term “device”
In these instructions, the term device always refers to the electrical rotary actuator Type 3003.
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Type 3003
Intended use
2. INTENDED USE
Non-authorized use of the electrical rotary actuator Type 3003 may be dangerous to people, nearby equipment and the environment.
• The device may be used outside.
• During use observe the authorized data, the operating conditions and conditions of use specified in the contract documents and in the operating instructions. These are described in the chapter entitled “Technical Data”.
• The device may only be used in connection with third-party devices and components recommended or approved by Bürkert.
• Requirements for safe and proper operation are proper trans­port, storage and installation as well as careful operation and maintenance.
• Only use the device as intended.
2.1. Restrictions
Observe any existing restrictions that apply to the device to be exported.
3. GENERAL SAFETY INFORMATION
This safety information does not cover:
• Haphazard situations that can arise during installation, operation and
maintenance of the use.
• Locally applicable safety regulations which the operator and instal-
lation personnel are obligated to follow.
Hazard due to electrical voltage!
Intervention in the device poses an acute risk of injury.
• Before starting work, be sure to switch off the supply voltage and secure it to prevent restarting!
• Always connect multiple electrical rotary OPEN/CLOSED actuators with phase isolation via a switch.
• Observe all applicable accident protection and safety guidelines for electrical equipment!
Unintentional operation or impermissible damage can lead to generally dangerous situations as well as physical injury!
• Take appropriate measures to prevent the possibility of uninten­tional activation of the device!
The general rules of technology apply to the planning and operation of the device!
• Observe the general rules of technology!
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Type 3003
General safety information
General hazardous situations.
To prevent injury, ensure:
• The electrical rotary actuator Type 3003 may not be used in poten­tially explosive atmospheres (in this case please use type 3004).
• Do not put any loads on the body (e.g. by placing objects on it or standing on it).
• Do not make any external modifications to the device body. Do not paint the body parts or screws.
• Do not install the actuator with the cover facing down (head first).
• When installing the actuator, observe a minimum distance of 30 cm to electromagnetic sources of interference.
• Installation and repair work may be carried out by authorized technicians only and with the appropriate tools.
• After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined or controlled manner.
• The device may be operated only when in perfect condition and in consideration of the operating instructions.
• The general rules of technology apply to application planning and operation of the device.
NOTE!
Electrostatically sensitive components / modules!
The device contains electronic components that react sensitively to electrostatic discharge (ESD). Contact with electrostatically charged persons or objects will endanger these components. In the worst case, they will be immediately destroyed or will fail after commissioning.
• Observe the requirements according to EN 61340-5-1 in order to minimise or avoid the possibility of damage through sudden electrostatic discharge.
• You should also ensure that the electronic components do not come into contact with nearby operating voltage.
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Type 3003
General information
4. GENERAL INFORMATION
4.1. Contact address
Germany
Bürkert Fluid Control Systems Sales Center Christian-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. + 49 (0) 7940 - 10 91 111 Fax + 49 (0) 7940 - 10 91 448 E-mail: info@de.buerkert.com
International
Contact addresses are found on the final pages of this operating manual.
And also on the Internet under: www.burkert.com
4.2. Warranty
The warranty is only valid if the electromotive rotary actuator type 3003 is used as intended in accordance with the specified application conditions.
4.3. Informations in the Internet
The operating manual and the data sheets on Type 3003 can be found on the Internet under: www.burkert.com
5. SYSTEM DESCRIPTION
5.1. Intended area of application
The electrical rotary OPEN/CLOSED actuator type 3003 (referred to as rotary actuator in the following) is designed for ball or flap valves.
5.2. General description
Due to its modular construction, the basic device can be extended with many options.
Options for expanding the basis device are found in chapter “5.3. Options”.
The rotary actuator is designed for direct or alternating current with a varied rating and available for torques of 20, 35, 60 or 100 Nm. The materials used guarantee maintenance-free operation and ensure a low thermal load.
All rotary actuators are equipped with a standard emergency manual control and two additional limit switches and are tested by the manu­facturer. The limit switches are set for a 0 ... 90° operating range.
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Type 3003
System description
5.3. Options
• Additional limit switches
• Rotary actuator with feedback potentiometer:
- Potentiometer with resistance values of 100 W, 1 kW, 5 kW, 10 kW
- Analogue feedback via 4 ... 20 mA signal
• 3rd position (180°)
• Actuators with integrated fail safe function (see chapter “8. Rotary actuators with integrated emergency reset”)
5.4. Marking
The rotary actuator is fitted with a type label which enables clear iden­tification and provides the most important technical data.
Do not remove the type label from the rotary actuator! It is extremely important for identification during installation
and maintenance. The warranty is void without the type label.
5.5. Type label
Operating voltage
Type, Identification number
3003 / 225431
~ 24 V 50/60 Hz
24 V
90° 20 Nm 15W
IP66 OF N°460050/79
Fluid Control Systems
Protection class, Serial number (internal)
Torque, Rating
Operating voltage
Fig. 1: Location and description of the type label
10/11 S46
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Type 3003
Technical Data
6. TECHNICAL DATA
6.1. Conformity
In accordance with the EC Declaration of conformity, the electromotive rotary actuator type 3003 is compliant with the EC Directives.
6.2. Standards
The applied standards, which verify conformity with the EC Directives, can be found on the EC Type Examination Certificate and/or the EC Declaration of Conformity.
6.3. Operating conditions
Ambient temperature: -10 °C ... +55 °C
-10 °C ... +40 °C (Emergency reset)
Permissible areas of application: 0 ... 2000 m altitude
Permissible humidity: < 81 % to 31 °C (88 °F) with
linear decrease as far as 50 % at 40 °C (according to EN 61010-1)
Protection class: IP66 with cable bushing
6.4. General technical data
6.4.1. Mechanical data
Dimensions: See data sheet
Weight: 1.3 kg (20 Nm)
2.8 - 3.1 kg (35-100 Nm)
Materials
Cover: Nylon
Body: PA (Nylon with glass fibre)
Axis / screws: Stainless steel
Gears: Stainless steel and PC (Polycarbonate)
Actuating angle: 90° ± 5° (optional 180°, 270°)
Duty cycle: 50 % at max. torque
6.4.2. Electrical data
Electrical connections: Cable bushing according to
EN 175301-803 Cable gland ISO M20
Limit switches: 4 adjustable (2 for the motor and 2 addi-
tional ones for feedback signal) - max. 250 V AC / 5 A
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Type 3003
Technical Data
Electrical data for version without analog input signal:
90° Posi-
Torque
(Specifica­tions under
load)
20 12 s 15 W 15-30 V AC, 50-60 Hz /
35 7 s 45 W 15-30 V AC, 50-60 Hz /
60 12 s 45 W 15-30 V AC, 50-60 Hz /
100 23 s 45 W 15-30 V AC, 50-60 Hz /
1)
Other positioning times on request
2)
The operating voltage must not drop below 11.5 V
tioning time1)
Power
consumption
Voltage / Frequency
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
Electrical data for version with analog input signal:
90° Posi-
Torque
(Specifica­tions under
load)
20 25 s 15 W 15-30 V AC, 50-60 Hz /
35 40 s 45 W 15-30 V AC, 50-60 Hz /
60 79 s 45 W 15-30 V AC, 50-60 Hz /
100 119 s 45 W 15-30 V AC, 50-60 Hz /
1)
Other positioning times on request
2)
The operating voltage must not drop below 11.5 V
tioning time1)
Power
consumption
Voltage / Frequency
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
12-48 V DC
2)
100-240 V AC, 50-60 Hz / 100-350 V DC
We recommend an actuator designed with 1.5 times the maximum torque of the fitting (On/Off).
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We recommend an actuator designed with 2 times the maximum torque of the fitting (analog input signal).
Type 3003
Technical Data
6.4.3. Electrical circuit diagrams
3-Point mode
N
-
TP/PE
1
3
2
Ph
+
Open Close
On-Off-Mode
N
-
TP/PE
1
Ph
+
Close
Open
2
3
4 5 6 7
FC1
Symbol Description
FCO Limit switch ON
FCF Limit switch OFF FC1 Additional limit switch 1 FC2 Additional limit switch 2
Feedback
8 9
FC2
Fig. 2: Open/Closed Version
If voltage is applied simultaneously to terminals 2 and 3, terminal 2 is the leading one and the actuator moves to the OPEN position.
NOTE!
Make certain in 3-point mode that the pulse duration of a controller lasts for at least 1 second. A pause time of at least 500 ms is required before controller activation is repeated. Observe the duty cycle specified on the type label!
Please note the circuit board must remain power supplied to allow heating resistances working.
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Type 3003
Technical Data
N
TP/PE
-
1
3
1
3
1
15V-30V 50/60 Hz (12V-48V DC) 100V-240V 50/60 Hz (100V-350V DC)
TP/PE
17
18
17
18
P6 POSI
13 14 15 16
+ +- -
Output
signal
0-20 mA / 4-20 mA /0-10 V
Ph
+
2
2
2 3
Input
signal
D1 D2
A B
Error feedback
(24V DC/3A max)
FCO
A B
Motor
=
Feedback
4 5 6 7
FCF
~
+
­~
FC1
FC2
8 9
The resolution of the control mode is 1° The input resistance for control 0-10 V is 10 kW The input resistance for control 0-20 mA / 4-20 mA is 100 W
Fig. 3: Version with analog input signal
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Type 3003
Installation
7. INSTALLATION
7.1. Safety information
DANGER!
Hazard due to electrical voltage!
• Always switch off the power and secure it to prevent restarting before removing the cover, or using the lever.
• Always connect multiple rotary actuators with phase isolation via a switch!
• Protect electrical rotary actuators by using a mains-dependent safety!
• Observe all applicable accident protection and safety guidelines for electrical equipment!
WARNING!
Hazard due to improper installation!
• Installation may only be carried out by authorised technicians using appropriate tools!
• Before installation, ensure that the manual lever can move freely.
Danger due to unintentional activation of the device!
Unintended actuation of the device during installation can lead to injury and damage to property.
• Take appropriate measures to prevent the possibility of uninten­tional activation of the device.
7.2. Power and control connections
Procedure:
→ Disconnect the rotary actuator from the power supply. → Remove the position indicator from the axis. → Loosen the cover screws with a screwdriver and lift the cover off. → Disconnect the cable connector ISO20 and insert the cable. → Wire the connections according to the circuit diagram figures (see
“6.4.3. Electrical circuit diagrams”).
Use cables with a diameter of 7 ... 12 mm for the ISO20 cable fitting.
→ Set the cover in place and screw it tight. → Reinstall the position indicator.
7.3. Connecting the additional limit switches (optional)
In the standard variant, the rotary actuator has 2 additional limit switches (for 90º range of motion). Connect these as follows.
Procedure:
→ Disconnect the rotary actuator from the power supply. → Remove the position indicator from the axis. → Use a screwdriver to loosen the cover screws.
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Type 3003
Installation
→ Lift the cover off. → Wire the connections of the additional limit switches (FC1 and FC2)
according to the circuit diagram figures (see “Fig. 2” and “Fig. 3” ).
→ Tighten the cable gland after connecting the terminals. → Set the cover in place and screw it tight. → Reinstall the position indicator.
Only use 4 or 6 conductor cable with a diameter of 7 ... 12 mm for the ISO20 cable fitting.
Ensure that the cable in the ISO20 cable fitting is com­pletely sealed when tightening the union nut.
7.3.1. Setting the limit switches
The rotary actuator is supplied with the following factory settings:
• The CLOSED limit switches are activated with the cams 2 and 4 (closed position).
• The OPEN limit switches are preset at a 90° rotation
The procedure for setting the limit switches is shown in “Fig. 4” and “Fig. 5” .
angle.
Electronic card
Cam No. 4 Additional limit
black
switch
Cam
OPEN
Additional limit
white
switch Cam
Motor limit switch
black
CLOSED
Cam No. 1
OPEN
Motor limit switch OPEN
white
CLOSED
No. 3
OPEN
No. 2
Body
Motor
Wrench (00679946)
Shaft
CLOSED
CLOSED
Fig. 4: Setting the limit switches. Limit switches max. 250 V / 5 A
Cams
Wrench
Setting in clockwise or
setting in
clockwise
counter
direction
direction
Adjustment direction
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Fig. 5: Setting limit switches in counter clockwise and clockwise
directions
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Type 3003
Installation
7.4. Circuit board for actuator with standard signal input
D
N
E
F
L
G
H
B
C
A
M
Fig. 6: Circuit board
A Electrical power supply
24 V AC/DC
B Connection terminals of
the input signal
C Connection terminals of
the feedback
H K2 plug-in jumper
I K3 plug-in jumper
J Green and red LED
J
K
I
D MEM pushbutton K LED yellow: Indicates the
power supply E CLOSE pushbutton L Potentiometer F OPEN pushbutton M Motor connection G K1 plug-in jumper N Heat resistor connection
To prevent electromagnetic interference, shielded cables must be used.
Procedure:
→ Loosen the cable gland and feed the cable through. → Wire the signal transducer between terminals 15 and 16. Terminal
15 is the negative pole (-) and terminal 16 the positive pole (+).
→ Wire the position feedback sensor between terminals 13 and 14.
Terminal 13 is the positive pole (+) and terminal 14 the negative pole (-).
→ Re-attach the cable gland.
If the connection voltage is 100 V to 240 V, a fuse must be provided in the power supply.
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Type 3003
Installation
7.4.1. Specify position of the plug-in jumpers
ONOFF
Fig. 7: Plug-in
jumper K1 / K2
Signal trans­ducer
0-10 V 0-10 V ON OFF ON OFF OFF 0-10 V 0-20 mA ON OFF OFF ON OFF
0-10 V 4-20 mA ON OFF OFF ON ON 0-20 mA 0-10 V OFF ON ON OFF OFF 0-20 mA 0-20 mA OFF ON OFF ON OFF 0-20 mA 4-20 mA OFF ON OFF ON ON 4-20 mA 0-10 V OFF ON ON OFF OFF 4-20 mA 0-20 mA OFF ON OFF ON OFF 4-20 mA 4-20 mA OFF ON OFF ON ON
Feed-
back
Fig. 8: Plug-in
jumper K3 OFF
Plug-in jumper K1Plug-in jumper K2Plug-in
A B A B
Fig. 9: Plug-in
jumper K3 ON
jumper
K3
7.4.2. Parameterization steps
Specify direction of rotation of the shut-off valve
Normal direction of rotation (preset)
→ Press <OPEN> pushbutton and switch on
the card (hold down pushbutton).
G
The GREEN LED lights up.
→ Release <OPEN> pushbutton and disconnect
the card from the power supply.
Reverse direction of rotation
→ Press <CLOSE> pushbutton and switch on
the card (hold down pushbutton).
R
The RED LED lights up.
→ Release <CLOSE> pushbutton and disconnect
the card from the power supply.
Specify control signal type
Control signal when voltage 0 – 10 V
→ Press <MEM> pushbutton and switch on the
card (hold down pushbutton).
The RED LED lights up 3x.
R
→ Release <MEM> pushbutton and disconnect
the card from the power supply.
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Type 3003
Installation
Control signal when current 0 – 20 mA
→ Press <MEM> and <OPEN> push-
button and switch on the card (hold down pushbutton).
The RED LED lights up 3x.
R
→ Release <MEM> and <OPEN> push-
button and disconnect the card from the power supply.
Control signal when current 4 – 20 mA (preset)
→ Press <MEM> and <CLOSE> push-
button and switch on the card (hold down pushbutton).
The RED LED lights up 3x.
R
→ Release <MEM> and <CLOSE>
pushbutton and disconnect the card from the power supply.
Learning mode
Specify end positions
G R
R
R
G
R
→ Press <OPEN> and <CLOSE>
pushbutton and switch on the card (hold down pushbutton).
The RED and the GREEN LEDs light up.
→ Release <OPEN> and <CLOSE>
pushbutton. Both LEDs go out. Learning mode is selected.
→ Press <CLOSE> pushbutton to move
the shut-off valve into the closed
position. The RED LED lights up.
→ Press <MEM> and <CLOSE> push-
button to save the closed position. The RED LED lights up 2x.
→ Press <OPEN> pushbutton to move
the shut-off valve into the open
position. The GREEN LED lights up.
→ Press <MEM> and <OPEN> push-
button to save the open position. The GREEN LED lights up 2x.
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Type 3003
Rotary actuators with integrated emergency reset
Specify end positions
All positions are now saved.
→ Disconnect the card from the power
supply.
7.4.3. Normal operation
Display normal operation
→ Switch on card.
G
G
R
G
G R
The GREEN LED lights up 3x to indicate that the start process has been implemented correctly.
In normal operation the GREEN LED lights up when the rotary actuator opens the shut-off valve.
The RED LED lights up when the rotary actuator closes the shut-off valve.
If neither of the LEDs is lit, the actuator is not
R
actuated.
The RED and the GREEN LEDs light up if the torque is too high and the rotary actuator stops.
→ Change direction of rotation of the rotary
actuator or switch over the voltage OPEN/ CLOSED to restart the rotary actuator!
8. ROTARY ACTUATORS WITH INTEGRATED EMERGENCY RESET
8.1. Safety block for emergency power version
Circuit board
Battery
Fig. 10: Safety block for emergency power version
8.2. Technical data
Voltage: 18 V DC Currant nominal: 0.8 A
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Type 3003
Rotary actuators with integrated emergency reset
Max. current 2.4 A Charging time 14 h max Feedback relay for charge state 24 V DC - 1 A max Permitted ambient temperature -10 °C - +40 °C
8.3. Electric wiring
Battery block
Wire colour
F+
red
Wire colour
E-
black
Load state
feedback
Actuator
wiring
Suggestet customer
wiring
KM1 - Customer
switch
contactor
On / Off Mode
F+
E-
65
66
Safety block
Loaded battery: closed contact
24 V
DC
AC/
N
Total security mode
17
18
Fig. 11: Electric wiring
Configuration A or B
A-standard mode: If the actuator is controlled with a programmable controller, the feedback of the charge state can be connected to it.
Control and power
supply card
17
100V-240V 50/60 Hz
(100V-350V DC)
18
15V-30V 50/60 Hz
(12V-48V DC)
A
B
1 2 3 1 2 3
N
A1
Open
KM1
A2
Ph
A
B
D1
D2
Open
N
Ph
B-mode - increased safety (if the feedback relay is used, terminals 65 and 66): The actuator does not actuate the valve unless the safety block is loaded.
8.4. Circuit board
D
B
C
Fig. 12: Diagram: Circuit board
A 18 V DC connection D Green LED* B Battery block connection E Red LED ** C Connection for feedback
(charge state)
E
A
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Type 3003
Operating
Description of the LED:
Green LED Red LED Description
Off Blinks / Off /
Blinks
On Blinks Battery loading cycle in progress
On Off Battery loading cycle finished Blinks
rapidly Off Blinks
Off Actuator electrical supply during
rapidly
Battery off or out of service
(max. 14 h)
3 min. (failure mode) Microcontroller failure
9. OPERATING
9.1. Safety information
DANGER!
Hazard due to electrical voltage! Intervention in the device poses an acute risk of injury.
• Turn off the power before manually servicing the rotary actuator.
WARNING!
Hazard due to improper servicing!
Improper servicing can result in personal injury and in damage to the device and its surroundings.
• The operating personnel must be aware of and fully understand the operating instructions.
• Pay attention in particular to the safety information and the intended use.
• The device may only be serviced by properly trained personnel.
Hazardous situation due to manual intervention!
During manual intervention the process can change into an unde­fined state which can lead to hazardous situations.
• Ensure a defined and controlled restarting of the process fol­lowing manual intervention!
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Type 3003
Operating
9.2. Manual operation of the rotary actuator
The rotary actuator can be operated manually if there is a power failure. To do this, the handwheel must be turned to „MAN“ (see “Fig. 13” ).
Procedure:
→ During manual operation ensure that the rotary actuator is not
activated in automatic mode.
→ Remove the position indicator from the axle. → Turn the handwheel from “AUTO” to “MAN”. → Using a wrench, turn the actuator shaft into the required position.
In doing so, hold the handwheel.
Handwheel
For manual operation
turn the mark
downwards
Position indicator
Wrench
9.3. Returning from manual to automatic operation
Returning to automatic operation:
→ Let go off the handwheel to switch back into automatic operation.
The spring force automatically resets it to the „AUTO“ position.
→ Replace the position indicator.
The marking should now show the set position.
Fig. 13: Switching the rotary actuator from automatic to manual
operation
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