Georg Fischer 107 Operating Manual

Instruction Manual

Electrical Actuator Unit
Type EA ¢1

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The technical data is not
binding and not an expressly
warranted characteristic of the
goods. It is subject to change.
Please consult our General
Conditions of Supply.

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Table of Contents

Page

1. Introduction/General Information 60

2. Manufacturer‘s Declaration 60

3. Intended Use 61

4. Safety Tips 62

4.1 Due Care Required of the Operator

4.2 Special Hazards

4.3 Transport and Storage

5. Actuator Design 64

5.1 Wiring Diagram for Standard Version

6. Valve Design 66

6.1 Mounting on the Ball Valve ¢07

6.2 Overview of Ball Valve System
Type ¢07

7. Setting Up the Actuator/Valve 70

7.1 Emergency Manual Override

8. Technical Specifications for EA ¢1 72

9. Mounting and Connecting 73
the Supplementary Kits

9.1 Heating Element

9.2 Fail-safe Return

9.3 Additional Limit Switches

10. Fastening Plate 82

11. Troubleshooting 83

12. Subcomponents/Spare Parts 84

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¢. Introduction

This instruction manual contains all the pertinent
information on the design, installation and opera­tion of the electrical actuator type EA 11 .

General Information

Hazard notices

Hazard notices are used in this manual to warn you
of possible injuries or damages to property. Please
read and abide by these warnings at all times!

Warning symbols

Danger

Warning

Caution

Meaning

Imminent acute danger!

Failure to comply could result in death
or extremely serious injury.

Possible acute danger!

Failure to comply could result in
serious injury.

Dangerous situation!

Failure to comply could lead to injury
or damage to property.

2. EC Manufacturer‘s Declaration

The manufacturer, Georg Fischer Piping Systems
Ltd, CH-8201 Schaffhausen, declares that the
electrical actuator EA 11 is not a ready-to-use

machine in the sense of the EC Machine Directive
and cannot therefore meet all the requirements of
this directive.

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Operation of these actuators is prohibited until
conformity of the entire system into which the
valve and the actuator have been installed is
established according to the EC Directives listed
below.

Applicable EC Directives:

72/23 EEC EC Low Voltage Directive
89/336 EEC EC Directive on Electromagnetic

Compatibility

Modifications to the actuator which have an
effect on the technical data given in this instruc­tion manual and its intended use, i.e. signi­ficantly alter the actuator, render this
manufacturer‘s declaration null and void.

3. Intended Use

Warning

When mounted on a valve and connected to a
system control, the purpose of this actuator is to
ł actuate valves with 90° pivoting (ball valves and

butterfly valves),

ł indicate the previously calibrated end positions

of the valve via electrical signal to the system
control (accessory), and

ł provided that the actuator data corresponds to

the electrical control and the valve and

ł in case of interruption in the supply voltage,

warrant that the actuator/valve remains in the
current position. Please use emergency manual

override or install fail-safe return.
The actuator is not intended for uses other than
those listed here. If the instructions contained in this
manual are not observed, the manufacturer is
excluded from all liability for the above mentioned
products.

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Warning

61

Warning

4. Safety Tips

4.1 Due care required of the operator

The actuator described herein was designed and
manufactured with consideration to the respective
harmonized European standards. It corresponds to
the latest technology and the technical specifica­tions contained under Section 8.

Safety on the job can, however, only be realized if
the operator warrants that
ł the actuator is only used as indicated under

Section 3,

ł he is familiar with this instruction manual and the

manual of the corresponding valve and adheres
to the instructions contained therein and

ł he has taken the necessary measures against

electrostatic influence.

4.2 Special hazards

62

Warning

Under normal conditions, the actuator may only
be operated with the cover closed.
If work is performed on the actuator with the
cover removed, the supply and control voltage
must first be disconnected. Adjustments, which
need to be done in the energized state, should
be carried out with special insulated tools.

In addition, the operating instructions of the
manual valve must be observed. They are an
integral component of this manual.

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4.3 Transport and storage

The actuators must be handled, transported and
stored with care. Please note the following points:

ł The actuators should be transported and/or

stored in their original unopened packaging.
ł The actuators must be protected from harmful

physical influences such as dust, heat (humidity).
ł It is important that the connections are neither

damaged by mechanical nor thermal influences.
ł Prior to installation, the actuators should be in-

spected for transport damages. Damaged actu-

ators must not be installed.

Warning

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5. Actuator Design

The standard version of the EA 11 electrical
actuator consists of the following elements:
gear unit, direct current motor, electrical board,
and components for end position limiting.

For special applications, the actuator can be
equipped additionally with various supplementary
kits (see Section 9).

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1 Limit switches S1 and S2
2 Direct current motor
3 Optical position indicator
4 Plug for accessories
5 Terminal strip for external connections

max. ¢.5 mm

2

6 Electrical supply unit, without protection

against accidental contact
7 Shaft for emergency manual override
8 Connections for DIN plug or

cable gland
9 Assembly bolt for accessories

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5.1 Wiring Diagram for Standard Version

Position indicator

2/2-way3/2-way

horizontal

A

B

B–C

A–C

vertical

A

C

B

B–C

A–C

A

C

B

C

A–B

C

closed

open

Installation note

If the actuator is connected
direct to the power-supply,
it is necessary to install a
switch-disconnector between
the actuator and the power­supply (do not disconnect the
earthcable).
To avoid water flowing into
the actuator it is necessary
that the cable insertion ist not
upturned.

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6. Valve Design

The EA ¢1 electrical actuator can be mounted on
ball valves type 546, DN10–50, by using the cor­rect coupling piece and selecting a suitable adap­ter plate with clamps.
The actuators are supplied ex works in the «open»
position. See Section 6.¢ for the individual assembly
components required for the ball valve type ¢07.
Both end positions in the actuator have been preset
in the factory. It is necessary to readjust these after
installation at the customer (see Section 7).

How to assemble (see Fig. 6.1)

3a

close

open

Screw the adapter plate with the fixed clamps

2

tightly onto the actuator (note the cam positions).

3

Mount the multifunctional module on the ball valve.
1 Housing
2 Housing cover
3 Indexing disk* with switching cams 3a

4

5

4 Screws
5 Connector plug 3P + E per DIN EN

175301-803* (formerly DIN 43650)

1

* only for MF module version with pre-assembled

microswitches

Remove housing cover (2).

The MF module can be mounted on the ball
valve type 546 in the opened or closed
position.

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Spigot is asymmetrical.

The spigot position must be idential with one of the
two illustrations.

A Stem position for closed ball valve

B Stem position for open ball valve

Place the MF module on the ball valve

Make sure the contours match!

Note the square (a) and round (b) contours as well
as the position of the asymmetrical recesses (c) of
the stem.

Tighten the 4 pre-assembled screws (Torx).
The MF module is now firmly connected with the
ball valve.

Insert the coupling and the coupling piece* in the
multifunctional module.

Fasten the actuator with the adapter plate to the
multifunctional housing using the provided clamps.

*coupling piece only for DN10–25

Actuator and valve must have the same posi­tion, «open» or «closed».

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Actuator
Type EA ¢1

Coupling piece
Adapter plate
PT-Schr KA 4x¢6
Clamp

Allen screws

Coupling

6.1 Ball Valve Type ¢07

Screws

Multifunctional module
(without microswitches)

Ball valve type 546

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6.2 Overview of Ball Valve System
Type ¢07

1 Actuator type EA ¢1
2 Coupling piece DN10–25
3 Adapter plate DN10–50
4 Multifunctional module DN10–50
5 Ball valve type 546 DN10–50

1

2

3

4

DN 10/155DN 20

Note: Screw saving

The actuator fixing screws are assured with «Locitite 243» or equivalent.

Note: Mounting of coupling and coupling piece

First plug the coupling piece into the actuator. Then fix the adapter plate
with four screws on the actuator. Next push the coupling into the coup­ling piece.
The coupling with the mounted coupling piece does not fit through the
hole of the adapter plate!

2

3

4

DN 25

5

5

3

4

DN 32

5

DN 40

5

3

4

DN50

5

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7. Setting Up the Actuator

Attention

Check the following before connecting the actuator
to the mains:
ł Does the mains voltage correspond to the speci-

fications given on the typeplate

ł Has the actuator been connected correctly

(see Section 5.1)

Adjustments

If a complete valve is supplied by Georg Fischer,
no further adjustments are required.
After installation by the customer or after repair
work, the end positions should be checked and if
necessary adjusted.

Limit switch allocation

Switch S1 (bottom) opens at «open» position
Switch S2 (top) opens at «closed» position

Procedure

Set both switching cams (1) to S1* and S2* so that
the rotating angle is less than 90°.
Let the actuator turn until a limit switch is activated.
By adjusting the respective switching cam, the end
position can be set since the actuator follows the
cam.

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* S1: «open», bottom

S2: «closed», top

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7.1 Emergency Manual Override

Assembly and function

Assembly

Pull the crank (1) out of the retainer

Remove cover screw (2) with the crank (1)

Insert the crank in the hexagon shaft* under the
opening

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* see illustration, page 60, no. 7

Function

Push the crank down to the stop.
With nine revolutions, the ball is rotated by 90° .

Direction of rotation:
Clockwise = CW = close
Counterclockwise = CCW = open

Note the «open» and «closed» position
on the optical indicator.

Disconnect the connector plug.
If that is not possible, pull the crank
rapidly out of the opening.

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8. Technical Specifications
Actuator EA ¢1

Rated voltage 100–230 V, 50/60 Hz

24 V =/24 V, 50/60 Hz
Rated voltage tolerance w 10%
Rated output 22 VA at 24 V AC/DC

40 VA at 100–230 V AC
Electric impedance 230V, 100k

24V, 4k7
Altitude l 2000m
Protection class IP 65 per EN 60529

3)

UL/CSA: Indoor use
Duty cycle 40% at 25 °C / ¢5 min
Overload protection current/time dependent

(resetting)

1)

Electrical connections Connector plug 3 P+E per

DIN EN 175301-803

(formerly DIN 43650)

additional cable entry point

for PG ¢1
Control time 5 s / 90° at Mdn
Actuating angle max. 270°, set to 90°
Nominal torque 10 Nm
Peak torque 20 Nm
Ambient temperature –10° to +45 °C
Allowable humidity max. 80% up to 31 °C
Pollutiongrade
Overvoltage-category

5)

5)

2

II

2)

4)

Housing materials PP fiberglass reinforced,

flame retardant,

external stainless steel screws
Position indicator optical, integrated
Emergency manual override integrated

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1)

Overload protection of the motor is dimensioned so that the motor
and the power supply board are protected. As soon as the load is
in the torque range, the actuator runs again.

2)

For temperatures below –10 °C as well as condensation, the
heating element no. 198 ¢90 086 should be built in (see Section 9.1).

3)

Protection rating IP67 for use of cable glands and vertical
installation.

4)

Linear decreasing to 50% relative humidity with 40 °C

5)

Per EN 6¢0¢0-¢

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9. Mounting and Connecting
Supplementary Kits

9.1 Heating element

Description Technical data Code
Heating element 24 V= 199 190 086

Wiring diagram

The heating element is mounted on the base board
and is connected electrically via a flat cable (X1).
The temperature is measured with a temperature
sensor, which is mounted on this element, and
between approx. 0–5 °C the heating element is
switched on or off, respectively.

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LED shines
= heating operation

Heating element kit

LED shines
= normal operation

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Mounting the heating element (board)

Disconnect the actuator from the supply vol­tage.

Take the board out of its packaging and
check for damages.

Do not touch the board itself. Electrostatic
discharge can damage the components.

Screw the three distance bolts (1) into the
assembly bolts.

Screw hand-tight.

Fasten the board (3) to the distance bolts
with the screws (2).

Plug the flat cable into the X1 connector.

Reconnect to supply voltage.
The heating element may not heat at tempe­ratures over +5 °C.

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9.2 Fail-safe Return

Description Technical data Code
Fail-safe return 24 V= 199 190 085

Wiring diagram

OPEN

CLOSE

76

The fail-safe return unit is mounted on the base
board and is connected electrically via a flat cable.
If the supply voltage is interrupted, the electronics
will switch to the storage battery automatically
after 5 sec. With a touch control, the function «Go
to the CLOSED or OPEN position» can be selected.

Position ¢/2: CLOSED, position ON: OPEN
(always both, see at left). The storage battery is

charged continuously.
Full recharging takes approximately ¢5 hours.

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Fail-safe return kit

LED shines
= normal operation

LED shines
= accu operation

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Mounting the fail-safe return (board)

Disconnect the actuator from the supply vol­tage.

Take the board out of its packaging and
check for damages.

Do not touch the board itself. Electrostatic
discharge can damage the components.

V

Screw the three distance bolts (1) into the
assembly bolts.

Screw hand-tight.

Fasten the board (3) to the distance bolts
with the screws (2).

Plug the flat cable into the X1 connector.

Reconnect to supply voltage.

LxWxH ¢86x80x55

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Rechargeable battery

Connect the battery via the second plug or cable
gland to the terminals ¢6 and ¢7 (4).

Attention must be given to the polarity.
Charge the battery for at least ¢2 hours.

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9.3 Additional 2 Limit Switches

Description Technical data Code
Kit with 2 additional 250 V p, 6 A 199 190 092

limit switches Ag, Ni

If the limit switch kit is mounted in the factory, the
switches are wired as opener according to the
diagram. It is possible for the customer to convert to
closer by rewiring.
(8 . 7 and ¢0 . 9).

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Limit switches kit

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Mounting the limit switches

Disconnect the device from the supply
voltage.

Remove the screws from the limit switch S2 and S1.

Mount the limit switch kit (1) on S1 and S2 as
shown.

Tighten with the new, longer screws.

Mount the additional switching cams (2) as well as
the spacer rings.

Setting the limit switch position

Reconnect to the supply voltage.

The switching cams can be adjusted with a screw­driver size 2.

An instrument (e.g. ohm meter) must be used
for setting the switching position.

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Move the actuator to the two end positions and set
the respective switching points.

Connect limit switches (disconnect the device from
the supply voltage).

Close the actuator with the housing cover and
connect to the supply voltage.

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¢0. Fastening Plate

With the fastening plate for the ball valve type 546,
forces are absorbed which could occur during
valve operation (e.g. initial breakaway torque). In
implementing the fastening plate, working forces
are not transmitted to the piping system.

In piping systems which are subject to temperature
fluctuations, longitudinal or bending forces occur if
thermal expansion is hindered. So as not to impair
valve functioning, these forces must be absorbed
by the appropriate fixed points
the valve.

The fastening plate is available in two sizes for the
dimension range DN 10 to DN 50. Two screws to
fasten on the ball valve are included in the scope
of delivery.

Measurement d ¢6–32 d 40–63

L 106 149
B 48 54
H 20 20
L1 92 134
L2 62 104
L3 31 52
L4 41 62
L5 25 45
H1 14 14
H2 24 24
D 6.5 8.5
Fastening

screws M6x14 M8x18

in front of or behind

DN ¢5–25 DN 32–50

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¢¢. Troubleshooting

Problem Possible causes Remedy

Motor does not run No mains voltage Error at customer

Motor only runs in Change-over relay Replace base
one direction does not work board

Overload protection Friction torque of Clean and lubricate
reacts (self re- valve too high valve
setting)

Valve does not close Switching cams S1 See Point 7
or open correctly and/or S2 not

(Kl 1, 2, 3) side
Internal wiring Check wiring of

error actuator
Switching cams S1 See Point 4

and S2 incorrectly set
Motor blocked Use emergency

manual override,
check valve,
replace motor

Motor defective Replace motor
Duty cycle too Increase cycle time

high

Reduce ambient
temperature

adjusted

For service please contact the specialist at your
Georg Fischer sales company.

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¢2. Subassemblies/Spare Parts

Description Code

Actuator EA¢1 100–230 V~ 198 150 180
Actuator EA¢1 24 V=/~ 198 150 181
Base circuit board 100–230 V~ 198 140 000
Base circuit board 24 V=/~ 198 140 001
Limit switch kit Ag, Ni 199 190 092
Fail-safe return with battery 199 190 085
Heating element 199 190 086
Heating element + fail-safe return with battery 199 190 087
Battery kit 198 151 317
Plug complete 198 000 502
Crank 198 151 307
Cover Screw kit 198 000 503

Multifunctional module without limit switches
(empty)

Dimensions Code

DN 10/15 167 482 680
DN 20/25 167 482 681
DN 32/40 167 482 682
DN 50 167 482 683

84

Adapter plate incl. coupling

Dimensions Code

DN 10/15 198 150 556
DN 20/25 198 150 557
DN 32/40 198 150 558
DN 50 198 150 559

Ball valve type 546 see separate datasheet

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Notes

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86

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Piping Systems

A Georg Fischer Rohrleitungssysteme GmbH, Sandgasse 16, 3130 Herzogenburg

Tel. [phone], Fax [phone], [e-mail], www.georgfischer.at

AUS George Fischer Pty Ltd, 186–190 Kingsgrove Road, Kingsgrove NSW 2008, Tel. [phone], Fax [phone]

[e-mail], www.georgefischer.com.au

B/L Georg Fischer NV/SA, Digue du Canal 109-¢¢¢ — Vaartdijk 109-¢¢¢, 1070 Bruxelles/Brüssel

Tél. [phone], Fax [phone], [e-mail], www.georgfischer.be

BR George Fischer Ltda, Av. das Nações Unidas 21689, 04795-100 São Paulo, Brasil,

Tel. [phone], Fax [phone]

CH Georg Fischer Rohrleitungssysteme (Schweiz) AG, Amsler-Laffon-Strasse ¢, Postfach, 8201 Schaffhausen

Tel. [phone], Fax [phone], [e-mail], www.piping.georgfischer.ch

CHINA Georg Fischer Piping Systems Ltd Shanghai, No. 2Ý8 Kang Qiao Dong Rd., Shanghai 201319

Tel. +86(0)2¢/58 13 33 33, Fax +86(0)2¢/58 13 33 66, [e-mail], www.cn.piping.georgfischer.com

D Georg Fischer GmbH, Daimlerstraße 6, 73095 Albershausen, Tel. [phone], Fax [phone]

[e-mail], www.rls.georgfischer.de
Georg Fischer DEKA GmbH, Kreuzstrasse 22, 35232 Dautphetal-Mornshausen
Tel. [phone], Fax [phone]/222, [e-mail], www.dekapipe.de

DK/IS Georg Fischer A/S, Rugvænget 30, 2630 Taastrup, Tel. [phone], Fax [phone]

[e-mail], www.georgfischer.dk

E Georg Fischer S.A., Alcalá, 85, 2

[e-mail], www.georgfischer.es

F George Fischer S.A.S., 105–1¢3, rue Charles Michels, 93208 Saint-Denis Cedex 1

Tél. [phone] ¢3 4¢, Fax +33(0)¢/49 22 ¢3 00, [e-mail], www.georgefischer.fr

GB George Fischer Sales Limited, Paradise Way, Coventry, CV2 2ST, Tel. [phone], Fax [phone]

[e-mail], www.georgefischer.co.uk

GR Georg Fischer S.p.A., Athens Branch, 101, 3rd September Str., 10434 Athen

Tel. [phone], Fax [phone], [e-mail]

I Georg Fischer S.p.A., Via Sondrio 1, 20063 Cernusco S/N (MI), Tel. [phone], Fax [phone]

[e-mail], www.georgfischer.it

ID George Fischer Representative Office, c/o Wisma Aria, 3rd Floor, Jl. H.O.S. Cokroaminoto 81, Jakarta 10310, Indonesia

Tel. [phone], Fax [phone]

IND George Fischer Piping Systems Ltd, India Branch Office, Solitaire Corporate Park, 532, Building No. 5, 3rd Floor, Chakala

Ghatkopar Link Road, Andheri (E), 400 093 Mumbai, Tel. [phone], Fax [phone],
[e-mail]

J Georg Fischer Ltd, 13–8, Nanbanaka 1-chome, Naniwa-ku, 556-0011 Osaka

Tel. [phone], Fax [phone], [e-mail], www.georgfischer.jp

N Georg Fischer AS, Rudsletta 97, ¢35¢ Rud, Tel. [phone], Fax [phone]

[e-mail], www.georgfischer.no

NL Georg Fischer N.V., Postbus 35-8160, 8161 PA Epe, Tel. [phone], Fax [phone]

[e-mail], www.georgfischer.nl

PL Georg Fischer Sp. z o.o., ul. Radiowa 1A, 01-485 Warszawa, Tel. [phone], Fax [phone]

www.georgfischer.pl

RO Georg Fischer Rohrleitungssysteme AG, Rep. Office Romania, 11 Barbu Delavrancea, 70000 Bucharest - Sector 1

Tel. [phone], Fax [phone], [e-mail]

S/FIN Georg Fischer AB, Box113, 12523 Älvsjö-Stockholm, Tel. [phone], Fax [phone]

[e-mail], www.georgfischer.se

SGP George Fischer Pte Ltd, ¢5 Kaki Bukit Road 2, KB Warehouse Complex, 4¢7 845 Singapore

Tel. [phone] ¢¢, Fax [phone], [e-mail], www.georgefischer.com.sg

USA George Fischer Inc., 2882 Dow Avenue, Tustin, CA 92780-7258 Tel. [phone], Toll Free 800/854 40 90

Fax +1(714) 7 3¢ 62 01, [e-mail], www.us.piping.georgefischer.com

Export Georg Fischer Rohrleitungssysteme AG, Ebnatstrasse ¢¢¢, Postfach, CH-820¢ Schaffhausen, Tel. [phone]¢ ¢¢ ¢¢

Fax [phone]¢ 28 93/631 28 58, [e-mail], www.piping.georgfischer.com

198.151.118
Fi 5746/¢,2,4 (7.05) © Georg Fischer Rohrleitungssysteme AG, CH-820Ý Schaffhausen/Schweiz, 2004 Printed in Switzerland

a

, 28009 Madrid, Tel. +34(0)9¢/781 98 90, Fax +34(0)9¢/426 08 23,