KSB EA-C Installation & Operating Manual

Control Valve Actuators

EA-C

For Type Series BOA-CVE H and BOA-H Mat E

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual EA-C

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB SE & Co. KGaA, Frankenthal 10/08/2018

Contents

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Contents

1 General.................................................................................................................................................... 5

1.1 Principles ...........................................................................................................................................................5

1.2 Target group.....................................................................................................................................................5

1.3 Symbols .............................................................................................................................................................5

2 Safety...................................................................................................................................................... 6

2.1 Key to safety symbols/markings.......................................................................................................................6

2.2 General..............................................................................................................................................................6

2.3 Intended use .....................................................................................................................................................7

2.4 Personnel qualification and training...............................................................................................................7

2.5 Consequences and risks caused by non-compliance with this manual .........................................................7

2.6 Safety awareness ..............................................................................................................................................7

2.7 Safety information for the user/operator.......................................................................................................7

2.8 Safety information for maintenance, inspection and installation ................................................................8

2.9 Unauthorised modes of operation..................................................................................................................8

3 Transport/Temporary Storage/Disposal............................................................................................... 9

3.1 Checking the condition upon delivery............................................................................................................9

3.2 Transport...........................................................................................................................................................9

3.3 Storage/preservation........................................................................................................................................9

3.4 Disposal/recycling .............................................................................................................................................9

4 Description............................................................................................................................................ 10

4.1 General description ........................................................................................................................................10

4.2 Designation.....................................................................................................................................................10

4.3 Name plate......................................................................................................................................................10

4.4 Design details..................................................................................................................................................11

4.5 Installation types ............................................................................................................................................12

4.6 Noise characteristics .......................................................................................................................................12

4.7 Dimensions and weights ................................................................................................................................12

5 Reassembly........................................................................................................................................... 13

5.1 Safety regulations...........................................................................................................................................13

5.2 Checking prior to installation/assembly........................................................................................................13

5.3 Mounting the actuator ..................................................................................................................................14

5.4 Electrical connection ......................................................................................................................................16

5.5 Interfaces.........................................................................................................................................................19

5.6 Heating resistor (optional).............................................................................................................................21

5.7 Setting the limit switches...............................................................................................................................21

6 Commissioning/Start-up/Shutdown................................................................................................... 23

6.1 Prerequisites for commissioning/start-up......................................................................................................23

6.2 Commissioning/Start-up.................................................................................................................................23

6.3 Operating limits..............................................................................................................................................24

6.4 Shutdown........................................................................................................................................................24

6.5 Returning to service .......................................................................................................................................24

7 Servicing/Maintenance........................................................................................................................ 25

7.1 Safety regulations...........................................................................................................................................25

7.2 Removing the actuator ..................................................................................................................................26

7.3 Maintenance/inspection.................................................................................................................................26

7.4 Lubrication......................................................................................................................................................27

7.5 Cleaning ..........................................................................................................................................................27

7.6 Mounting the actuator ..................................................................................................................................27

7.7 Spare parts stock.............................................................................................................................................27

Contents

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8 Trouble-shooting.................................................................................................................................. 28

9 Related Documents.............................................................................................................................. 30

9.1 General assembly drawing, handwheel on top (EA-C 20 to 140)................................................................30

9.2 General assembly drawing, side-mounted handwheel (EA-C 200 to 250)..................................................31

9.3 Wiring diagrams .............................................................................................................................................32

9.4 Technical data.................................................................................................................................................35

10 EU Declaration of Conformity............................................................................................................. 40

11 Declaration of Incorporation of Partly Completed Machinery ......................................................... 41

Index ..................................................................................................................................................... 42

1 General

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1 General

1.1 Principles

This operating manual is valid for the type series and variants indicated on the front
cover.

The manual describes the proper and safe use of this equipment in all phases of
operation.

The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.

In the event of damage, immediately contact your nearest KSB Service centre to
maintain the right to claim under warranty.

1.2 Target group

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.

1.3 Symbols

Table1: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions

⇨

Result of an action

⇨ Cross-references

1.

2.

Step-by-step instructions

Note
Recommendations and important information on how to handle
the product

2 Safety

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2 Safety

!

DANGER

All the information contained in this section refers to hazardous situations.

In addition to the present general safety information the action-related safety
information given in the other sections must be observed.

2.1 Key to safety symbols/markings

Table2: Definition of safety symbols/markings

Symbol Description

!

DANGER

DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.

!

WARNING

WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.

CAUTION

CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.

Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).

General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.

Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.

Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2.2 General

This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.

The safety information in all sections of this manual must be complied with.

The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.

The contents of this operating manual must be available to the specialist personnel
at the site at all times.

Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:

▪ Markings for connections

▪ Name plate

The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.

This electric motor has been designed and constructed in accordance with the
requirements of Directive 2014/35/EU (“Low-voltage Directive”). It is intended for use
in industrial plants.

If the motor is used in countries outside the European Community, adhere to the
regulations applicable to the relevant country. Also observe any local and industry­specific regulations governing installation and safety.

2 Safety

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2.3 Intended use

▪ Only operate actuators which are in perfect technical condition.

▪ Do not operate partially assembled actuators.

▪ Generally observe the operating limits given.

▪ Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

Prevention of foreseeable misuse

▪ Never exceed the permissible application and operating limits specified in the

data sheet or product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product this manual refers to. The responsibilities, competence and
supervision of all personnel involved in installation, operation, maintenance and
inspection must be clearly defined by the operator.

Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.

Training on the product must always be supervised by specialist technical personnel.

2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with these operating instructions will lead to forfeiture of

warranty cover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemical

effects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:

▪ Accident prevention, health regulations and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the user/operator

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪ Do not remove any protective equipment (e.g. contact guards) during operation.

▪ Provide the personnel with protective equipment and make sure it is used.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply
companies.)

2 Safety

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2.8 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the actuator are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.

▪ The operator ensures that maintenance, inspection and installation is performed

by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.

▪ Any work on the product shall only be performed when it has been disconnected

from the power supply (de-energised).

▪ Carry out work on the product during standstill only.

▪ As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.2,Page23)

2.9 Unauthorised modes of operation

Never operate the product outside the limits stated in the data sheet and in this
manual.

The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.

3 Transport/Temporary Storage/Disposal

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3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.

3.2 Transport

CAUTION

Impacts against the coupling when placing in a horizontal or vertical position

Damage to the coupling!

▷ Place a suitable support underneath the coupling half when placing it in a

horizontal or vertical position.

Transport the actuator carefully and in its original packaging. Avoid damaging the
coating.

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:

Table3: Ambient conditions for storage

Ambient condition Value

Storage temperature -20°C to +80°C

Humidity 5 % to 95 % rH

▪ Well-ventilated

▪ Dry

▪ Dust-free

▪ Shock-free

▪ Vibration-free

3.4 Disposal/recycling

Due to some components, the product is classified as special waste.

1. Dismantle the product.

2. Separate and sort the materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another
controlled manner. PCBs, power electronics, capacitors and electronic
components are all hazardous waste.

4 Description

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4 Description

4.1 General description

▪ Actuator for the automation of a control valve

Actuator with continuous-action or 3-point actuation in 24VAC/DC, 230VAC and
400VAC 3~. Actuator for valve type series BOA-CVE H and BOA-H Mat E.

Versions

Continuous-action actuators in 24VAC/DC, 230VAC and 400VAC 3~ versions and a
24VAC 3-point version

Variable speed actuator

control

▪ 24VDC motor, controlled by pulse-width modulation (PWM)

▪ Absolute-coded feedback via precision potentiometer

▪ Positioning function

▪ Active feedback function

▪ Automatic commissioning

▪ Comprehensive diagnosis options

Parameterisation by

software

▪ Actuator functions can be adapted to a wide variety of process conditions by

means of current and voltage monitoring.

▪ Setting of valve-specific details

▪ Setting of actuating force and actuating moment

▪ Setting of stroke and actuating speed

▪ Configuration of messages

▪ Freely programmable characteristic curve corrections

3-point actuators in 230VAC and 400V AC 3~ versions

▪ The actuator can be set by limit switches in both opening and closing direction

▪ Torque transmission by disc spring stack in closing direction.

▪ 2 limit switches for visualising the limit positions included as standard

4.2 Designation

Example: EA-C 250

Table4: Designation key

Code Description

EA-C Product name

250 Actuator size and maximum actuating force of 25kN

4.3 Name plate

EA-C Antrieb

Auftrag / Pos.:

order No. / pos.:

2120000000 / 0000

Stellkraft:
act. force:

....... N

Istwert:

feedback:

.......

Sollwert:

set value:

.......

Antrieb:

actuator:

EA- C ....

IP..

Betriebsspannung:

power supply:

....... V

Antriebsnummer:

actuator no.:

............

1 2 3

4 5 6 7 8 9 10

Fig.1: Actuator name plate (example)

1 Order number 2 Order item number

3 Product name 4 Supply voltage

4 Description

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5 Actuating force 6 Actual value

7 Setpoint 8 Actuator number

9 Actuator size 10 Enclosure

4.4 Design details

Operating modes

▪ IEC 34-1, 8: S2 for short-time duty

▪ IEC 34-1, 8: S4 for control duty

Actuating force

2kN to 25kN

Actuating speed

1)

▪ Continuous-action actuation: 0.2mm/s to 1.3mm/s

▪ 3-point actuation: 0.45mm/s to 1.4mm/s

Enclosure

▪ EA-C 20: IP65 to EN 60529

▪ EA-C 40: IP65 to EN 60529

▪ EA-C 80: IP65 to EN 60529

▪ EA-C 140: IP67 to EN 60529

▪ EA-C 200: IP65 to EN 60529

▪ EA-C 250: IP65 to EN 60529

Design

Handwheel on top (EA-C 20 to 140) Side-mounted handwheel (EA-C 200 to

250)

▪ Configurable, microprocessor-controlled actuators

– Supply voltage: 24VAC/DC, 230VAC, 400VAC 3~

– Position setpoint: 4-20 mA, 0/2-10V

– Actual-position feedback: 4-20 mA, 0/2-10V

– Limit switching is torque-dependent in closing direction and stroke-

dependent in opening direction.

▪ 3-point actuators

– Supply voltage: 230VAC, 400VAC 3~

1) Depending on the actuator type

4 Description

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– Actual-position feedback: 2 limit switches

– Stopping via limit switches in closing and opening direction

▪ Actuating time between 23 and 150seconds, depending on the stroke

▪ Operating data stored in permanent memory

▪ After a power failure, operation is resumed in accordance with the operating

data.

Variants

▪ Actuator configured to match the order specification

▪ Integrated process controller

▪ Power back-up unit

▪ Heating of the motor space

▪ Local control unit

▪ Additional limit switch for continuous-action actuators

▪ Optional potentiometer for 3-point actuators

▪ PSPT2) for 3-point actuators

4.5 Installation types

The installation position as shown in the drawing below must be adhered to.

Fig.2: Types of installation for EA-C actuator

4.6 Noise characteristics

The sound pressure level depends on the local conditions and the duty point. It is
≤70dB(A).

4.7 Dimensions and weights

For dimensions and weights please refer to the type series booklet.

2) Optional potentiometer with printed circuit board for converting the resistance into a 4-20 mA output current signal
(additional 24V DC power supply required)

5 Reassembly

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5 Reassembly

5.1 Safety regulations

DANGER

Electrical connection work by unqualified personnel

Risk of fatal injury due to electric shock!

▷ Always have any work on the connection to the power supply performed by a

trained electrician.

WARNING

Improper handling of an electric actuator

Crushing of fingers!

Damage to the actuator or the valve!

▷ When mounting the actuator onto the valve make sure that the power supply

has not yet been connected or that the actuator is secured against
unintentional start-up.

▷ Ensure that any objects and parts of the body are removed from the actuator

coupling area prior to starting the actuator.

WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

▷ Inspect the power cable for visible damage.

▷ Never connect damaged power cables.

CAUTION

Painting of pipes

Impairment of the valve's function and loss of information!

▷ Protect stem and plastic components prior to applying paint.

▷ Protect printed name plates prior to applying paint.

5.2 Checking prior to installation/assembly

▪ Check the actuator's compatibility with the valve.

▪ Check whether the valve has been prepared for assembly to the actuator.

▪ Check whether the actuator cover needs to be dismantled.

– The actuator cover on EA-C actuator sizes 200 to 250 and EA-C 3-point

actuators needs to be dismantled. (ðSection5.4,Page16)

▪ Make sure that there is a minimum wall clearance for removing the actuator

cover.

5 Reassembly

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A

X

X

X

Ø 180

Ø 180

Ø 250

A

A

50

52

EA-C 20, 40, 80 EA-C 140 EA-C 200, 250

Fig.3: Actuator with minimum wall clearance X

Table5: Dimensions [mm]

Actuator A Minimum wall clearance X

EA-C 20 478,2 100

EA-C 40 481 100

EA-C 80 510,3 100

EA-C 140 579 120

EA-C200 720 230

EA-C250 720 230

5.3 Mounting the actuator

WARNING

Electrical operation of the actuator

Crushing of hands!

▷ Use only the handwheel to operate the actuator during assembly/dismantling.