MOV O&M - Butterfly - Actuator

INSTALLATION & MAINTENANCE MANUAL
CONCENTRIC BUTTERFLY VALVE
AV - C Series
ACE VALVE CO., LTD.

278-4, MangDeok-Ri, JuChon-Myeon, KimHae, KyeongNam, Korea
Tel : +82-55-329-0651~6, Fax : +82-55-329-0657
E-mail : ace-valve@ace-valve.co.kr
1/8
Electric multi-turn actuators
SA 07.1 SA 30.1
SAR 07.1 SAR 30.1
with actuator controls
AUMA MATIC AM 01.1 / AM 02.1
Certificate Registration No.

Operation instructions
12 100/104 4269
Multi-turn actuators SA 07.1 SA 30.1/ SAR 07.1 SAR 30.1
with actuator controls AUMA MATIC AM 01.1 / AM 02.1 Operation instructions
Scope of these instructions: These instructions valid for multi-turn actuators of the type range
SA 07.1 SA 30.1/ SAR 07.1 SAR 30.1 with
the actuator controls AM 01.1 / AM 02.1.
These operation instructions are only valid for clockwise closing,
i.e. driven shaft turns clockwise to close the valve.
Table of contents Page

1. Safety instructions 4
1.1 Range of application 4
1.2 Electrical connection 4
1.3 Maintenance 4
1.4 Warnings and notes 4
2. Short description 5
3. Technical data 6
4. Additional information to the wiring diagram legend 9
5. Transport, storage and packaging 10
5.1 Transport 10
5.2 Storage 10
5.3 Packaging 10
6. Mounting to valve/ gearbox 11
7. Mounting positions of the local controls 13
8. Electrical connection 14
8.1 Connection with AUMA plug/ socket connector (S, SH, SE) 16
9. Manual operation 18
10. Operation and indications of the local controls 19
11. Opening the switch compartment 21
11.1 Removing the cover from the switch compartment 21
11.2 Pulling off the indicator disc (option) 21
12. Setting the limit switching 22
12.1 Setting end position CLOSED (black section) 22
12.2 Setting end position OPEN (white section) 22
12.3 Checking the limit switches 22
13. Setting the DUO limit switching (option) 23
13.1 Setting direction CLOSE (black section) 23
13.2 Setting direction OPEN (white section) 23
13.3 Checking the DUO limit switches 23
14. Setting the torque switching 24
14.1 Setting 24
14.2 Checking the torque switches 24
15. Test run 25
15.1 Checking the direction of rotation 25
15.2 Checking the setting of the limit switching 26
15.3 Checking the type of seating 26
15.4 Checking the PTC tripping device (option) 26
16. Setting the potentiometer (option) 27
17. Setting the electronic position transmitter RWG (option) 28
17.1 Setting 2-wire system 4 20 mA and 3- /4-wire system 0 20 mA 29
17.2 Setting 3- / 4- wire system 4 20 mA 30
2
Operation instructions with actuator controls AUMA MATIC AM 01.1 / AM 02.1
Page
18. Setting the mechanical position indicator (option) 31
19. Closing the switch compartment 31
20. Actuator controls AUMA MATIC 32
20.1 Functions of the diagnosis LEDs on the interface board (standard version) 32
20.2 Programming the logic board 33
20.3 EMERGENCY - OPEN and EMERGENCY - CLOSE signal (option) 34
21. Electronic positioner (option) 35
21.1 Technical data 35
21.2 Setting 35
21.2.1 Setting type of signal 36
21.2.2 Setting actuator behaviour on loss of signal 37
21.3 Positioner adjustment for end position CLOSED (standard version) 38
21.4 Positioner adjustment for end position OPEN (standard version) 39
21.5 Setting the sensitivity 39
21.6 Positioner adjustment for end position OPEN (inverse operation) 41
21.7 Positioner adjustment end position CLOSED (inverse operation) 42
21.8 Positioner in Split Range version (option) 43
21.8.1 Split Range: description of functions 43
21.8.2 Programming 43
21.8.3 Positioner adjustment for Split Range 43
22. Timer (option) 45
22.1 Functions of the diagnosis LEDs (timer) 45
22.2 Setting start and end of stepping mode via DUO limit switching (option) 46
22.3 Setting ON and OFF times 47
23. Fuses 48
23.1 Fuses within the actuator controls 48
23.2 Motor protection 49
24. Enclosure protection IP 68 (option) 50
25. Applications in Ex zone 22 (option) 51
26. Maintenance 52
27. Lubrication 52
28. Disposal and recycling 52
29. Service 52
30. Spare parts list multi-turn actuator SA(R) 07.1 SA(R) 16.1 54
31. Spare parts list controls AUMA MATIC 56
32. Declaration of Conformity and Declaration of Incorporation 58
Index 59
Addresses of AUMA offices and representatives 60
3
1. Safety instructions
1.1 Range of application
AUMA actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves and ball valves.
For other applications, please consult us. The manufacturer is not liable for
any possible damage resulting from use in other than the designated appli-
cations. Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the con-
trols/ actuators designated use.
1.2 Electrical connection

During electrical operation, certain parts inevitably carry lethal voltages.
Work on the electrical system or equipment must only be carried out by a
skilled electrician himself or by specially instructed personnel under the con-
trol and supervision of such an electrician and in accordance with the appli-
cable electrical engineering rules.
1.3 Maintenance
The maintenance instructions (refer to page 52) must be observed, other-
wise a safe operation of the actuator is no longer guaranteed.
1.4 Warnings and notes

Failure to observe the warnings and notes may lead to serious injuries or
damage. Qualified personnel must be thoroughly familiar with all warnings
and notes in these operation instructions.
Correct transport, proper storage, mounting and installation, as well as care-
ful commissioning are essential to ensure a trouble-free and safe operation.
During operation, the multi-turn actuator warms up and surface tempera-
tures > 60 C may occur. Check the surface temperature prior to contact in
order to avoid burns.
The following references draw special attention to safety-relevant proce-
dures in these operation instructions. Each is marked by the appropriate
pictograph.
This pictograph means: Note!

Note marks activities or procedures which have major influence on the cor-
rect operation. Non-observance of these notes may lead to consequential
damage.
This pictograph means: Electrostatically endangered parts!

If this pictograph is attached to a printed circuit board, it contains parts
which may be damaged or destroyed by electrostatic discharges. If the
boards need to be touched during setting, measurement, or for exchange, it
must be assured that immediately before a discharge through contact with
an earthed metallic surface (e.g. the housing) has taken place.
This pictograph means: Warning!

Warning marks activities or procedures which, if not carried out correctly,
can affect the safety of persons or material.
4
2. Short description
AUMA multi-turn actuators of the type range SA 07.1 SA 30.1/ SAR 07.1
SAR 30.1 are driven by an electric motor and controlled by the actuator con-
trols AUMA MATIC AM 01.1/ AM 02.1, which is included in the scope of deliv-
ery.
A handwheel is provided for manual operation.
The limitation of travel is realised via limit switches in both end positions.
Torque seating is also possible in both end positions. The type of seating is
determined by the valve manufacturer.
Both the multi-turn actuator and the controls have a modular design, i.e.
they are designed in accordance with the principle of a modular construction
system.
This means that each actuator or each controls are individually manufac-
tured and combined for a specific valve automation task. An order-specific
commission number, printed on the name plate, is assigned to each actua-
tor/ controls. You can use this commission number to download the wiring
diagram, inspection records and further information from the Internet.
Our website: http://www.auma.com
Commissioning
Please note that for low temperature versions ( 50 C), the controls
requires a heat-up time.
This heat-up time is applicable in case the actuator and the controls are not
live and have cooled down to ambient temperature. In case commissioning
has to be performed under these conditions, the following heat-up times
have to be observed:
60 min. at 50 C
80 min. at 60 C
Figure 1: Heat-up time chart
t [min.]
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 [C]
5
3. Technical data
Features and functions
Type of duty 1) Standard: SA Short time duty S2 - 15 min
SAR Intermittent duty S4 - 25 %
Option: SA Short time duty S2 - 30 min
SAR Intermittent duty S4 - 50 %
Intermittent duty S5 25 %
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34
Option: Special motors
Insulation class F, tropicalized
H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Self-locking Yes, for output speeds from 4 to 90 rpm
Limit switching Counter gear mechanism for end positions CLOSED and OPEN
for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke)
Standard: Single switch (1 NC and 1 NO) for each end position
Options: Tandem switch (2 NC and 2 NO) for each end position,
switches galvanically isolated
Triple switch (3 NC and 3 NO) for each end position, switches galvanically isolated
Intermediate position switch (DUO limit switching),
adjustable for any intermediate position
Torque switching Infinitely adjustable torque switching for direction OPEN and CLOSE
Standard: Single switch (1 NC and 1 NO) for each direction
Options: Tandem switch (2 NC and 2 NO) for each direction,
Position feedback signal, Potentiometer or 0/4 20 mA (RWG)
analogue (options) For further details, see separate data sheet
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Running indication Blinker transmitter (standard for SA, option for SAR)
Heater in switch compartment Standard: Resistance type heater with 5 W, 24 V DC
Options: Self-regulating PTC heater, 5 20 W
24 48 V AC/DC, 110 250 V AC/DC or 380 400 V AC
Motor heater (option) SA(R) 07.1 10.1: 12.5 W
SA(R) 14.1 16.1: 25 W
SA(R) 25.1 30.1: 50 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during
electrical operation.
Option: Handwheel lockable
Connection to controls AUMA plug/ socket connector with screw type connection
Output drive types A, B1, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drives: AF, AK, AG, IB1, IB3
Power supply, mains For mains voltage and mains frequency, refer to name plates at the controls and the motor
frequency and current Permissible variation of the nominal voltage: 10 %
consumption Permissible variation of the mains frequency: 5 %
Motor current consumption: Refer to motor name plate
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 600 mA
208 to 240 V AC = max. 300 mA
380 to 500 V AC = max. 150 mA
External supply of the 24 V DC + 20 % / 15 %,
electronics (option) Observe current consumption of the controls
Rated power Refer to motor name plate
Note: The controls is designed for the rated power of the actuator
Overvoltage category Category III
1) Based on 20 C ambient temperature and at an average load with running torque according to Technical data SA or SAR
6
Switchgear Standard: Reversing contactors2) (mechanically and electrically interlocked)

for motor power up to 1.5 kW
Options: Reversing contactors2) (mechanically and electrically interlocked)
for nominal motor current up to 18 A (OPEN - CLOSE- duty)
or 16 A (modulating duty)
Thyristor unit3) (recommended for modulating actuators)
for motor power up to 1.5 kW, 500 V AC with internal fuses
for motor power up to 5.5 kW, 500 V AC, external fuses required
Control Standard: Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator,
with one common), current consumption: approx. 10 mA per input
Observe min. duration of impulse for modulating actuators
Option: Control inputs 220 V AC, OPEN - STOP - CLOSE (via opto-isolator,
Output signals Standard: 5 output relays with gold-plated contacts:
4 potential-free NO contacts with one common:
max. 250 V AC, 0.5 A (resistive load)
Standard configuration:
End position OPEN, end position CLOSED, selector switch REMOTE,
selector switch LOCAL
1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load)
for collective fault signal
Torque fault, phase failure, motor protection tripped
Option: Signals in connection with positioner:
End position OPEN, end position CLOSED
(requires tandem switch within actuator)
Selector switch REMOTE, selector switch LOCAL via 2nd level
selector switch
for collective fault signal:
Voltage output Standard: Auxiliary voltage 24 V DC, max. 50 mA for supply of the control inputs,
galvanically isolated from internal voltage supply
Option: Auxiliary voltage 115 V AC, max. 30 mA for supply of the control inputs,3),
Local controls Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
Push buttons OPEN - STOP - CLOSE
3 indication lights:
End position CLOSED (yellow), collective fault signal (red),
end position OPEN (green)
Option: Protection cover, lockable
Functions Standard: Switch-off mode adjustable
Limit or torque seating for end position OPEN and end position CLOSED
Overload protection against excessive torques over the whole travel
Excessive torque (torque fault) can be excluded from collective fault signal
Phase failure monitoring with automatic phase correction
Push-to-run operation or self-retaining in REMOTE
Push-to-run operation or self-retaining in LOCAL
Blinker transmitter signal of actuator can be switched on or off (option)
Options: Positioner4):
Nominal position value via analogue input E1 = 0/4 20 mA
Adjustable behaviour on loss of signal
Adjustable sensitivity (dead band) and pause time
Split Range operation
Motor protection evaluation Standard: Monitoring of the motor temperature in combination with thermoswitches
in the actuator motor
Options: Additional thermal overload relay in the controls in combination with
thermoswitches within the actuator
PTC tripping device in combination with PTC thermistors in the actuator motor
Electrical connection Standard: AUMA plug/ socket connector with screw type connection
Options: Parking frame for wall mounting of the disconnected plug
Protection cover for plug compartment (when plug is removed)
Threads for cable glands Standard: Metric threads
Options: Pg-threads, NPT-threads, G-threads
Wiring diagram Wiring diagram according to commission number included in delivery
2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles is to be expected, thyristor units with
virtually unlimited lifetime should be used
3) Not possible in combination with PTC tripping device
4) Requires position transmitter (potentiometer or RWG) in actuator
7
Further options for version with RWG in the actuator

Position feedback (option) Analogue output E2 = 0/4 20 mA (load max. 500 )
Service conditions
Enclosure protection according Standard: IP 67
to EN 60 529 5) Options: IP 68
IP 67-DS (Double Sealed)
(Double Sealed = Electrical connection compartment additionally sealed
against interior)
Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plants
with a low pollutant concentration
Options: KS Suitable for installation in occasionally or permanently aggressive
atmosphere with a moderate pollutant concentration
(e.g. in wastewater treatment plants, chemical industry)
KX Suitable for installation in extremely aggressive atmosphere
with high humidity and high pollutant concentration
KX-G Same as KX, however aluminium-free version (outer parts)
Finish coating Standard: Two-component iron-mica combination
Standard colour Standard: Grey (DB 702, similar to RAL 9007)
Option: Other colours are possible on request
Ambient temperature Standard: SA: 25 C to + 70 C
SAR: 25 C to + 60 C
Options: 40 C to + 60 C, low temperature version
50 C to + 60 C, extreme low temperature version incl. heating system
60 C to + 60 C, extreme low temperature version incl. heating system
Vibration resistance 1 g, from 10 Hz to 200 Hz
according to IEC 60 068-2-6 Resistant to vibrations during start-up or for failures of the plant. However, a fatigue strength
may not be derived from this.
Applies to actuator with actuator controls, not valid in combination with gearboxes
Lifetime SA 07.1 10.1: 20,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
SA 14.1 16.1: 15,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
SA 25.1 30.1: 10,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
SAR 07.1 10.1: 5 million operations/ starts6)
SAR 14.1 16.1: 3.5 million operations/ starts6)
SAR 25.1 30.1: 2.5 million operations/ starts6)
Weight Multi-turn actuator: Refer to Technical data SA/ SAR
Actuator controls: Approx. 7 kg (including AUMA plug/ socket connector)
Accessories
Wall bracket7) AUMA MATIC mounted separately from the actuator, including plug/ socket connector.
Connecting cables on request.
Recommended for high ambient temperatures, difficult access, or in case of heavy vibrations
during service.
Further information
EU Directives Electromagnetic Compatibility (EMC): (89/336/EEC)
Low Voltage Directive: (73/23/EEC)
Machinery Directive: (98/37/EC)
Reference documents Product description Electric multi-turn actuators SA/ SAR
Product description Actuator controls AUMA MATIC
Dimension sheets SA/ SAR ...with integral controls AUMA MATIC
Technical data sheets AM 01.1/AM 02.1
Technical data sheets SA/ SAR
Electrical data sheets SA/ SAR
5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended. Additionally, for enclosure
protection IP 68, we recommend to use the double sealed terminal compartment DS. For special motors, the enclosure protection according to the name plate
applies
6) The lifetime of modulating actuators depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To
reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process
7) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an RWG
has to be used in the actuator
8
4. Additional information to the wiring diagram legend
Information A:
A running indication is possible if blinker transmitter (S5) is installed
(opening and closing of contacts).
Direction CLOSE: Connections XK 6 - XK 7
Direction OPEN: Connections XK 6 - XK 8
Contacts remain closed in end position.
When connected to an external PLC, the blinking signal can be switched off
via the DIP-switches (table 4, page 33).
Information B:
The type of seating in the end positions is determined by the valve manufac-
turer. The setting is done at the programming switches S1-2 and S3-2
(see page 33). The tripping of a torque switch in an intermediate position
switches off the actuator and causes a fault signal.
The limit switches serve for signalisation when switching off by torque seat-
ing. They need to be set so that the appropriate switch is tripped shortly
before reaching the end position. If the torque switch trips before the limit
switch, the actuator is switched off and a fault signal is generated.
For further programming possibilities, e.g. self-retaining in operation mode
REMOTE, see table 4, page 33.
Information D:
The following faults are registered and can be transmitted to the control
room as a potential-free collective fault signal:
- Power failure
- Phase failure
- Motor protection tripped
- Torque switch tripped in mid-travel.
This signal can be switched off on the logic board, see table 4, page 33.
Information E:
Input signals according to DIN 19 240.
The nominal operation current of inputs XK 2, XK 3, and XK 4 amounts to
10 15 mA. If the internal voltage 24 V DC is used for remote control, it
must only be connected via potential-free contacts.
Information F:
In case of wrong phase sequence, the running direction is automatically
adjusted. In case of a phase failure, the actuator stops. The fault is indicated
at LED V14 on the interface board (see page 32). For collective fault signal,
see information D.
Information G:
Potential-free contacts are available for signals. The internal control voltage
(XK 11 / + 24 V and XK 5 / 24V) must not be used for external lamps,
relays, etc.
9
5. Transport, storage and packaging

5.1 Transport
..For transport to place of installation, use sturdy packaging.
Do not attach ropes or hooks to the handwheel for the purpose of lifting by
.hoist.
If multi-turn actuator is mounted on valve, attach ropes or hooks for the
purpose of lifting by hoist to valve and not to multi-turn actuator.
Fitting the handwheel:
For transport purposes, handwheels as from a diameter of 400 mm are sup-
plied separately.
Engage manual operation prior to mounting the handwheel!
If the manual operation is not engaged, damage can occur at
. the change-over mechanism.

Engage manual operation (figure 2):
Manually lift the red change-over lever while slightly turning the shaft back
and forth until manual operation engages. The manual operation is cor-
rectly engaged if the change-over lever can be lifted by approx. 85.
Manual force is sufficient for operating the change-over
lever. It is not necessary to use an extension. Excessive
.. force may damage the change-over mechanism.

Attach handwheel onto the red change-over lever on shaft (figure 3).
Secure handwheel using the circlip supplied.
Figure 2 Figure 3
85
5.2 Storage
.. Store in 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 bare surfaces.
If multi-turn actuators are to be stored for a long time (more than 6 months),
.
the following points must be observed additionally:
Prior to storage: Protect bare surfaces, in particular the output drive parts
. and mounting surface, with long-term corrosion protection agent.

Check for corrosion approximately every 6 months. If first signs of corro-
sion show, apply new corrosion protection.
After mounting, connect actuator immediately to electrical

system, so that the heater prevents condensation.
5.3 Packaging
Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can eas-
ily 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.
10
.
6. Mounting to valve/ gearbox
Prior to mounting the multi-turn actuator must be checked
for damage. Damaged parts must be replaced by original
. spare parts.
After mounting to valve/ gearbox, touch up any possible
damage to paint finish.
The multi-turn actuator leaves the factory in position CLOSED (limit switch
CLOSED tripped).
. Check if mounting flange fits the valve/ gearbox.
Spigot at flanges should be loose fit!
The output drive types B1, B2, B3, or B4 (figure 4) are delivered with bore
and keyway (usually according to ISO 5210).
Figure 4
Output drive type B1/B2 Output drive type B3/B4
Plug sleeve Bore with keyway
For output drive type A (figure 5), the internal thread of the stem nut must
match the thread of the valve stem. If not ordered explicitly with thread, the
stem nut is unbored or with pilot bore when delivered. For finish machining
..
of stem nut, refer to next page.
Check whether bore and keyway match the input shaft of valve/ gearbox.
Thoroughly degrease mounting faces at multi-turn actuator and valve/
..
gearbox.
Apply a small quantity of grease to input shaft of valve/ gearbox.
Place actuator on valve/ gearbox and fasten. Fasten bolts
(quality min. 8.8, refer to table 1) evenly crosswise.
Table 1: Fastening torque for bolts
Strength class 8.8 TA (Nm)
M 8 25
M 10 50
M 12 87
M 16 220
M 20 420
11
Finish machining of stem nut (output drive type A):

Figure 5
Output drive type A
Stem nut
80.3
80.01/80.02
80.2
The output drive flange does not have to be removed from the actuator.
.. Remove spigot ring (80.2, figure 5) from mounting flange.

Take off stem nut (80.3) together with thrust bearing (80.01) and thrust
.. bearing races (80.02).

Remove thrust bearing and thrust bearing races from stem nut.
Drill and bore stem nut and cut thread.
.. When fixing in the chuck, make sure stem nut runs true!
Clean the machined stem nut.
Apply Lithium soap EP multi-purpose grease to thrust bearing and races,
. then place them on stem nut.

Re-insert stem nut with thrust bearings into the mounting flange. Ensure
.. that dogs are placed correctly in the slots of the hollow shaft.
Screw in spigot ring until it is firm against the shoulder.
Press Lithium soap EP multi-purpose grease on mineral oil base into the
grease nipple with a grease gun (for quantities, please refer to table):
Table 2: Grease quantities for output drive type A

Output
A 07.2 A 10.2 A 14.2 A 16.2 A 25.2 A 30.2 A 35.2 A 40.2 A 48.2
drive
Qty1) 1.5 g 2g 3g 5g 10 g 14 g 20 g 25 g 30 g
1) For greases with a density = 0.9 kg/dm
..
Protection tube for rising valve stem
Seal thread with hemp, Teflon tape, or thread sealing material.
..
Screw protection tube (1) into thread (figure 6) and tighten it firmly.
Push down the sealing (2) to the housing.
Check whether cap (3) is available and without damage.
Figure 6: Protection tube for rising valve stem
12
7. Mounting positions of the local controls

The mounting position of the local controls is designed according to the
order. If, after mounting the actuator to the valve or the gearbox on site, the
local controls is in an unfavourable position, the mounting position can eas-
ily be changed at a later date.
Four mounting positions are possible:

Figure 7: Mounting position A Figure 8: Mounting position B
Actuator Actuator
Figure 9: Mounting position C Figure 10: Mounting position D
Actuator Actuator
Changing the mounting position
.. Disconnect actuator from the mains before opening.
. Turn local controls by a maximum of 180!

Ensure that the wires are neither twisted nor jammed.
.. Loosen 4 bolts and remove the local controls.
.. Turn local controls in one of the four positions and re-place on the actuator.
Clean sealing faces of housing and cover.
. Check whether O-ring is in good condition.

Replace cover on switch compartment and fasten bolts evenly crosswise.
13
8. Electrical connection
Work on the electrical system or equipment must only be
carried out by a skilled electrician himself or by specially
instructed personnel under the control and supervision of
such an electrician and in accordance with the applicable
electrical engineering rules.
Wiring diagram
The wiring diagram applicable to the actuator is attached to the handwheel
in a weather-proof bag, together with the operation instructions. In case the
wiring diagram is not available, it can be obtained from AUMA (state com-
mission no., refer to name plate) or downloaded directly from the Internet
(www.auma.com).
External fuse
For short-circuit protection and for releasing the actuator, fuses and discon-
nect switches have to be provided by the customer.
The current values for sizing the switch can be derived from the current con-
sumption of the motor plus the current consumption of the controls.
Motor current consumption:
Refer to name plate on motor (nominal current).
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 650 mA
208 to 240 V AC = max. 325 mA
380 to 500 V AC = max. 190 mA
The maximum permissible fuse for controls with a rated power of 1.5 kW is
16 A (gL/ gG), and for controls with a rated power of 7.5 kW, the value
amounts to 32 A (gL/ gG).
Cable installation in accordance with EMC

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 ground potential.

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

Avoid long parallel paths with cables being either susceptible to interfer-
.ence or interference sources.

For the connection of remote position transmitters (potentiometer, RWG),
screened cables must be used.
Heater
As standard, the control unit of the actuator is equipped with a heater to pre-
vent condensation within the actuator. Unless ordered otherwise, the heater
is internally supplied. For external supply (option), the heater always has to
be connected.
Some actuators are optionally equipped with an additional motor heater.
The motor heater is always externally supplied and has to be connected
according to the wiring diagram.
14
Actuator controls on wall bracket (accessory)
For version on wall bracket, please observe the following:

Figure 11: AUMA MATIC on wall bracket
Connecting cables
to actuator
. Versions with potentiometer in the actuator are not suitable. Instead of the
. potentiometer, an RWG has to be used in the actuator

Permissible cable distance between actuator and AUMA MATIC amounts
. to a maximum of 100 m.
Preconfectioned cables for the connection between actuator and AUMA
MATIC on wall bracket can be obtained from AUMA on request.
In case no preconfectioned cables are used, the following additionally has
.. to be observed:
Use suitable flexible and screened connecting cables.
Connect the wires in correct phase sequence.
Check the direction of rotation before switching on (see page 25)
Subsequent mounting of the actuator controls on the actuator

In case the actuator and the actuator controls have different commission
numbers (refer to name plates), the designations of the terminal plan and
the wiring diagram (KMS . . .) have to match for both devices.
15
8.1 Connection with AUMA plug/ socket connector (S, SH, SE)
Figure12: Version S (standard) Figure 13: Version SH Figure 14: Version SE
Before mains connection

Check whether type of current, supply voltage, and frequency comply with
motor data (refer to name plate at motor):
VD00 63-4/45
Art. No.: Z006.413
3 ~ 400V 60Hz Current type/ mains voltage/ mains frequency
0.09 kW
Y 0.60A
..
Opening the terminal compartment
Loosen bolts (1) and remove cover (figure 15).
.
Loosen screws (2) and remove socket carrier from cover.
Insert cable glands suitable for connecting cables
(The enclosure protection stated on the name plate is only ensured if suit-
able cable glands are used.).
IP67 Enclosure protection

Thermal protection: Th
Insulation class: F
. Seal cable entries which are not used with suitable plugs.
Figure 15: Opening the terminal compartment
Cover
Cable gland and
(1) screw plug
in enclosure protection
according to name plate
Socket carrier
(2)
16
.
Connecting the cables
Connect cables according to order-related wiring diagram.
Cross sections:
- Power terminals (U1, V1, W1, U2, V2, W2) and
protective earth (symbol: )
max. 6 mm flexible, max. 10 mm solid
..
- Control contacts (1 to 50) = max. 2.5 mm
For stranded wires use end-sleeves according to DIN 46228.
All PE conductors have to be tightened firmly to the PE connection
(symbol: ) using either ring lugs (flexible cables), or lugs (solid cables)
(figure 17).
Each time the PE connection has been disconnected, it has

to be ensured that the PE conductors are firmly connected.
Figure 17: PE connection

Screw
Washer
Circlip
Protective earth with ring lugs/ lugs
PE connection
Socket carrier
..
Closing the terminal compartment
Insert socket carrier into the cover and fasten with screws (2) (figure 15).
..
Clean sealing faces at the cover and the housing.
Check whether O-ring is in good condition.
..
Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.
Replace cover and fasten bolts (1) evenly crosswise.
Fasten cable glands with the specified torque to ensure the required
enclosure protection.
Parking frame, protection cover (accessories)

A special parking frame (figure 16) for protection against touching the bare
contacts and against environmental influences is available.
The open terminal compartment can be closed using a protective cover
(not illustrated).
Figure 16: Parking frame (accessory)
Parking frame
17
9. Manual operation
The actuator may be operated manually for purposes of setting and com-
missioning and in case of motor failure or power failure.
Manual operation is engaged by an internal change-over mechanism.
.
Engaging manual operation
Lift up change-over lever in the centre of the handwheel to approx. 85,
while slightly turning the handwheel back and forth until manual operation
engages (figure 18).
Figure 18 Figure 19
Manual force is sufficient for operating the change-over

lever. It is not necessary to use an extension. Excessive
force may damage the change-over mechanism.
. Release change-over lever (should snap back into initial position by spring
action, figure 19), if necessary, push it back manually.
Operating the change-over lever while the motor is running

(figure 20) can lead to increased wear at the change-over
mechanism.
Figure 20 Figure 21
. Turn handwheel into desired direction (figure 21).
Disengaging manual operation

Manual operation is automatically disengaged when motor is started again.
The handwheel does not rotate during motor operation.
18
10. Operation and indications of the local controls
Figure 22: Local controls
Push buttons Indication lights
Selector switch
Selector switch
0
I I Position OFF (0):
- No remote control possible
- No local control possible
- Actuator remains ready for signalisation
signalisation (the controls power supply is maintained)
0
I I Position Local control (I):
The actuator can be operated locally via the push buttons
OPEN - STOP - CLOSE.
0
I I Position Remote control (II):
The actuator can be controlled from remote, e.g. via the
control room.
Position Test (III):

0
Test PTC tripping device (refer to page 26)
Only available in combination with motor protection

Test Reset (PTC thermistor).
Red indication light (fault) is illuminated.
Position Reset (III):

0
Reset fault signal (red indication light) after the motor pro-
tection has tripped (refer to page 49).

Test Reset Only available in combination with motor protection
(PTC thermistor).
19
Push buttons
If the selector switch is in position local control (I), use the push buttons
OPEN - STOP - CLOSE to operate the actuator locally.
OPEN: Actuator runs in direction OPEN
STOP: Actuator stops
CLOSE: Actuator runs in direction CLOSE
The operation commands OPEN - CLOSE can be used for control during
push-to-run operation or in the self-retaining mode.
In the push-to-run operation, the actuator runs as long as the push button is
pressed.
In the self-retaining mode, the actuator runs to the defined end position,
unless another command has been received beforehand.
For further information on the programming, refer to page 33.
Indication lights
The 3 indication lights give the following signals (standard indication).
Illuminated (green): Actuator is in end position OPEN
Collective fault signal (red)
Illuminated (yellow): Actuator is in end position CLOSED
Collective fault signal:

The collective fault signal (red indication light) will be activated if one of the
.
following events occurs:
Torque fault, i.e. the set torque (page 24) was exceeded before reaching
..an end position.

Motor protection has tripped (refer to page 49), i.e. the motor is overheated.
.A phase failure (for 3-phase AC motors) has occurred.

Test PTC tripping device
Indication lights are blinking:

If the actuator is equipped with a blinker, the indication lights can be used as
running indication.
If the blinker transmitter is active (page 33), the respective indication light
blinks during operation.
20
11. Opening the switch compartment

To be able to carry out the following settings (up to and including clause
18.), the switch compartment must be opened and, if installed, the indicator
disc must be removed.
These settings are only valid for clockwise closing, i.e. driven shaft turns
clockwise to close the valve.

11.1 Removing the cover from the switch compartment
. Remove 4 bolts and take off the cover at the switch compartment
(figure 23 or figure 24).
Figure 23: Cover with Figure 24: Cover without
indicator glass indicator glass
11.2 Pulling off the indicator disc (option)
. If installed, pull off indicator disc (figure 25) Open end wrench
(approx. 14 mm) may be used as lever.
Figure 25: Pulling off the indicator disc
RSD
RDW
Indicator disc
21
12. Setting the limit switching

12.1 Setting end position CLOSED (black section)
.. Turn handwheel clockwise until valve is closed.

Turn handwheel back by approximately half a turn (overrun). During test
. run check overrun and, if necessary, correct setting of the limit switching.
Press down and turn setting spindle A (figure 26) with screw driver
(5 mm) in direction of arrow, thereby observe pointer B.
While a ratchet is felt and heard, the pointer B moves 90 every time.
When pointer B is 90 from mark C, continue turning slowly. When pointer
B has reached the mark C, stop turning and release setting spindle. If you
override the tripping point inadvertently (ratchet is heard after the pointer
has snapped), continue turning the setting spindle in the same direction
and repeat setting process.
Figure 26: Control unit
A D
T P
B E
C F
12.2 Setting end position OPEN (white section)
.. Turn handwheel counterclockwise until valve is open.

Turn handwheel back by approximately half a turn (overrun). During test
. run check overrun and, if necessary, correct setting of the limit switching.
Press down and turn setting spindle D (figure 26) with screw driver
(5 mm) in direction of arrow, thereby observe pointer E.
While a ratchet is felt and heard, the pointer E moves 90 every time.
When pointer E is 90 from mark F, continue turning slowly.
When pointer E has reached the mark F, stop turning and release setting
spindle. If you override the tripping point inadvertently (ratchet is heard
after the pointer has snapped), continue turning the setting spindle in the
same direction and repeat setting process.
12.3 Checking the limit switches

The red test buttons T and P (figure 26) are used for manual operation of
the limit switches.
. Turning T in direction of the arrow LSC (WSR) triggers limit switch CLOSED.
The yellow indication light on the local controls is illuminated as long as
. the test button is pushed down.

Turning P in direction of the arrow LSO (WL) triggers limit switch OPEN.
. The red indication light (fault) on the local controls is illuminated.

The green indication light on the local controls is illuminated as long as the
test button is pushed down.
22
13. Setting the DUO limit switching (option)

Any application can be switched on or off via the two intermediate position
switches.
For setting, the switching point (intermediate position) must

be approached from the same direction as afterwards in
..
13.1 Setting direction CLOSE (black section)
Move valve to desired intermediate position.
Press down and turn setting spindle G (figure 27) with screw driver
(5 mm) in direction of arrow, while observing pointer H.
While a ratchet is felt and heard, the pointer H moves 90 every time.
When pointer H is 90 from mark C, continue turning slowly. When pointer
H has reached the mark C, stop turning and release setting spindle. If you
T P
C F
H L
G K
..
13.2 Setting direction OPEN (white section)
Press down and turn setting spindle K (figure 27) with screw driver
(5 mm) in direction of arrow, while observing pointer L.
While a ratchet is felt and heard, the pointer L moves 90 every time.
When pointer L is 90 from mark F, continue turning slowly. When pointer
L has reached the mark F, stop turning and release setting spindle. If you
13.3 Checking the DUO limit switches

.
the DUO limit switches.
Turning T in direction of the arrow TSC (DSR) triggers DUO limit switch CLOSED.
.
The torque switch CLOSED is actuated at the same time.
Turning P in direction of the arrow TSO (DL) triggers DUO limit switch OPEN.
.
The torque switch OPEN is actuated at the same time.
After checking the switches, the fault (red indication light) has to be reset using
the OPEN or CLOSE push buttons of the local controls for operation in the oppo-
site direction.
23
14. Setting the torque switching

14.1 Setting
.. The set torque must suit the valve!
This setting must only be changed with the consent of the
valve manufacturer!
Figure 28: Torque switching heads
Setting CLOSED Setting OPEN
O O O
.. Loosen both lock screws O at the torque dial (figure 28).

Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm).
Example:
Figure 28 shows the following setting:
3.5 da Nm = 35 Nm for direction CLOSE
. 4.5 da Nm = 45 Nm for direction OPEN

Tighten lock screws O again
. The torque switches can also be operated in manual
. operation.
The torque switching acts as overload protection over full
travel, also when stopping in the end positions by limit
switching.
14.2 Checking the torque switches

the torque switches:
. Turning T in direction of the arrow TSC (DSR) triggers torque switch

CLOSED.

Turning P in direction of the arrow TSO (DL) triggers torque switch
OPEN.

If a DUO limit switching (optional) is installed in the actuator, the intermedi-
. ate position switches will be operated at the same time.

After checking the switches, the fault (red indication light) has to be reset
using the OPEN or CLOSE push buttons of the local controls for operation
in the opposite direction.
24
15. Test run

15.1 Checking the direction of rotation
This check is only necessary for mounting on wall bracket.
When the AUMA MATIC controls are mounted directly to the actuator, the
automatic phase correction ensures the correct direction of rotation, even if
the phases are crossed over during electrical installation.
. If provided, place indicator disc on shaft.

The direction of rotation of the indicator disc (figure 29) indicates the
. direction of rotation of the output drive.

If there is no indicator disc, the direction of rotation can also be observed
on the hollow shaft. For this purpose, remove screw plug (no. 27)
(figure 30).
Figure 29: Indicator disc Figure 30: Opening the hollow shaft
CLOSED OPEN 27
S1/S2
. Move actuator manually to intermediate position or to sufficient distance
. from end position.

Set selector switch to local control (I) (figure 31).
Figure 31: Selector switch LOCAL
.. Switch on the voltage supply.

Press push button CLOSE (figure 32) and observe the direction
of rotation:
If the indicator disc turns counterclockwise, the direction of rotation
is correct.
Figure 32: Push button CLOSE Figure 33: Push button STOP
If the direction of rotation is wrong, switch off immediately.

Afterwards, correct phase sequence in the connecting cable from
the wall bracket to the actuator and repeat test run.
25
.
15.2 Checking the setting of the limit switching
Set selector switch to position OFF (0) (figure 34).
Figure 34: Selector switch OFF
The controls power supply is maintained in position OFF.
.. Move actuator manually into both end positions of the valve.

Check if limit switching is set correctly for both end positions. Hereby
observe that the appropriate switch is tripped in each end position and
released again after the direction of rotation is changed. If this is not the
case, the limit switching must be set again.
..
When limit switching is set correctly:
Perform test run at the local controls via push buttons OPEN - STOP -
CLOSE.
15.3 Checking the type of seating

The valve manufacturer states whether switching off in the end positions
.
should be by limit switch (limit seating) or torque switch (torque seating).
For checking the setting, refer to page 33, subclause 20.2.
.
15.4 Checking the PTC tripping device (option)
Turn selector switch to position TEST (wiping) (figure 35).
If the PTC tripping device is working properly, the tripping of the motor pro-
tection is signalled via the collective fault signal (refer to wiring diagram)
and via the fault indication light on the local controls.
Figure 35: Selector switch TEST
. Turn selector switch to position RESET (wiping) (figure 36):

The fault signal is reset if the device is working properly.
Figure 36: Selector switch RESET
In case the selector switch position TEST does not initiate a fault signal, the
wiring and the selector switch have to be checked by the AUMA service.
.
If no other options (clauses 16. to 18.) require setting:
Close switch compartment (see page 31, clause 19.).
26
16. Setting the potentiometer (option)

For remote indication
.. Move valve to end position CLOSED.

Turn potentiometer (E2) clockwise to the stop.
. End position CLOSED corresponds to 0 %, end position OPEN to 100 %.

Turn potentiometer (E2) slightly back.
Due to the ratio of the reduction gearings for the position

transmitter, the complete resistance range is not always
utilized for the whole travel. Therefore, an external possi-
bility for adjustment (setting potentiometer) must be
provided.
. Perform fine-tuning of the zero point at external setting potentiometer

(for remote indication).
E2
27
17. Setting the electronic position transmitter RWG (option)

For remote indication or external control
After mounting the actuator on the valve, check setting and adjust, if neces-
sary (refer to subclauses 17.1 or 17.2).
Table 3: Technical data RWG 4020

Terminal plans KMS TP_ _ 4 / _ _ _ KMS TP _ 4 _ / _ _ _
KMS TP _ 5 _ / _ _ _
3- or 4- wire system 2-wire system
Output current Ia 0 20 mA, 4 20 mA 4 20 mA
Power Uv 24 V DC, 15 % 14 V DC + (I x RB),
supply smoothed max. 30 V
Max. input I 24 mA at 20 mA 20 mA
current output current
Max. load RB 600 W (Uv - 14 V) / 20 mA
The position transmitter board (figure 38) is located under the cover plate
(figure 39).
Figure 38: Position transmitter board
S1
28
17.1 Setting 2-wire system 4 20 mA and 3- /4-wire system 0 20 mA
.. Connect voltage to electronic position transmitter.
. Move valve to end position CLOSED.

Connect ammeter for 0 20 mA to measuring points (figure 39).
The circuit (external load) must be connected

(observe max. load RB), or the appropriate poles at the termi-
nals (refer to wiring diagram) must be linked, otherwise no
value can be measured.
.. Turn potentiometer (E2) clockwise to the stop.

Figure 39
0 (0/4 mA) max. (20 mA)
Cover plate E2
Meas.point (+) Meas.point ()

0/4 20 mA 0/4 20 mA
.. Turn potentiometer 0 clockwise until output current starts to increase.

Turn potentiometer 0 back until the following value is reached:
for 3- or 4-wire system: approx. 0.1 mA
for 2-wire system: approx. 4.1 mA.
.. This ensures that the signal remains above the dead and live zero point.
Move valve to end position OPEN.
. Set potentiometer max. to end value 20 mA.

Approach end position CLOSED again and check minimum value
(0.1 mA or 4.1 mA). If necessary, correct the setting.
If the maximum value cannot be reached, the selection of the

reduction gearing must be checked.
29
17.2 Setting 3- / 4- wire system 4 20 mA
.. Connect voltage to electronic position transmitter.

The circuit (external load) must be connected

(observe max. load RB), or the appropriate poles at the termi-
nals (refer to wiring diagram) must be linked, otherwise no
.. Turn potentiometer (E2) clockwise to the stop.

Figure 40
0 (0/4 mA) max. (20 mA)
Cover plate E2
Meas. point (+) Meas. point ()

0/4 20 mA 0/4 20 mA

Turn back potentiometer 0 until a residual current of approx. 0.1 mA is
.. reached.
.. Set potentiometer max. to end value 16 mA.

Move valve to end position CLOSED.
Set potentiometer 0 from 0.1 mA to initial value 4 mA.
This results in a simultaneous shift of the end value by 4 mA, so that the
. range is now 4 20 mA.

Approach both end positions again and check setting. If necessary, correct
the setting.

30
18. Setting the mechanical position indicator (option)
.. Place indicator disc on shaft.

Turn lower indicator disc (figure 41) until symbol CLOSED is in align-
.. ment with the mark on the cover (figure 42).

Move actuator to end position OPEN.
Hold lower indicator disc CLOSED in position and turn upper disc with
symbol OPEN until it is in alignment with the mark on the cover.
Figure 41 Figure 42
Indicator disc
Mark
Indicator disc rotates approximately 180 to 230 at full travel from OPEN to
CLOSED or vice versa. For this purpose, a suitable reduction gearing was
installed in our works.
If the turns per stroke of the actuator are changed at a later date, the reduc-
tion gearing may have to be exchanged.
19. Closing the switch compartment
.. Clean sealing faces of housing and cover
.. Check whether O-ring is in good condition.

Apply a thin film of non-acidic grease to the sealing faces.
Check the multi-turn actuator for damage to paint finish. If

damage to paint-finish has occurred after mounting, it has to
be touched up to avoid corrosion.
31
20. Actuator controls AUMA MATIC
Figure 43: Positions of the boards within the controls
Cover
Timer board
(option)
Cover plate
Interface board
Logic boards
Positioner board
(option)
20.1 Functions of the diagnosis LEDs on the interface board (standard version)
V14 is illuminated: Phase failure and/ or motor protection tripped.

In combination with motor protection (PTC thermistor)
(option):
Reset by selector switch position III at local controls
V15 is illuminated: Torque fault: Torque switch operated in mid-travel
The LEDs STOP, CLOSE, OPEN indicate the available control commands
(only in selector switch position REMOTE).
Figure 44: Cover plate on interface board
32
20.2 Programming the logic board
The type of seating limit or torque seating (switch S1-2 and switch S3-2,
figure 45) must be determined by the valve manufacturer.
Figure 45: Logic board A2

Position 1:
Limit
seating
in end position OPEN
Position 2:
Torque
S3-2 seating
S2-2
Position 1:
Limit
S1-2 seating
in end position CLOSED
Position 2:
Torque
seating
. Set desired programming according to table 4 at the switch S2-2.
Table 4
DIP switch S2-2 Programming
(ON = pressed)
Direction CLOSE Direction OPEN
Self-retaining REMOTE
Push-to-run operation REMOTE
Self-retaining LOCAL
Push-to-run operation LOCAL
activated deactivated
Blinker transmitter (option)
Torque fault: Torque switch trip- included not included

ping (in mid-travel) contained in
collective fault signal
33
20.3 EMERGENCY - OPEN and EMERGENCY - CLOSE signal (option)
(5th digit in wiring diagram MSP C, D, or P)
When an EMERGENCY run command is given, the actuator operates the

valve to the predetermined end position (effective in all three selector switch
positions: LOCAL, OFF, REMOTE).
. The input at terminal XK 1 (refer to wiring diagram) must be connected to
. an NC contact (closed circuit principle) at + 24 V DC.

If EMERGENCY - OPEN or EMERGENCY - CLOSE signal is generally
not desired:
Take off cover plate and disconnect links B1 (for EMERGENCY - CLOSE)
and B2 (for EMERGENCY - OPEN).
Figure 46: Cover plate for EMERGENCY - OPEN or EMERGENCY - CLOSE option
Links:B1 (EMERGENCY-CLOSE) LED for
B2 (EMERGENCY-OPEN) EMERGENCY run command
B2
B1
34
21. Electronic positioner (option)

21.1 Technical data
Table 5: Technical data for positioner

Command signal (input signal E1, set value) 0/4 20 mA (option: 0 5 V)
Feedback (input signal E2, actual value) 0/4 20 mA (option: 0 5 V)
Sensitivity (dead band) E (P9) 0.5 % 2.5 %
Fine tuning Sens (P7)
min. 0.25 %
(useful for output speeds < 16 rpm only)
Pause time t-off (P10) 0.5 10 s
Input resistance 250 Ohm
Modulating duty with stepping mode (not required for modulating setting):
Running time t-on (P8)
effective until error is 25 %; then set value is 0.5 15 s
automatically reduced by 3.
21.2 Setting
The positioner in the actuator controls AUMA MATIC is programmed
according to the purchase order details and is set together with the actuator
prior to delivery.
Due to peculiarities of the regulating system not known beforehand, a read-
justment may become necessary. Before adjusting the positioner, the pro-
gramming of the positioner should be checked.
. Check programming of the logic board according to subclause 20.2.
The self-retaining REMOTE function (see table 4) must be

switched off in conjunction with the positioner.
. Take off cover plate (figure 47) and carry out required programming at
positioner board (figure 48) according to tables 6 and 7.
Prior to setting, it must be ensured that the circuit for the

position feedback E2 (see wiring diagram) is closed
(measuring device or link). In case of missing signal E2, the
LED (V10) E1/E2 < 4 mA (figure 47) is illuminated and the
positioner shows no reaction.
Figure 47: Cover plate positioner
Label with signal indication

(in our example: E1 = 4 20 mA, E2 = 4 20 mA)
V10 (red)
P10
P8
35
Figure 48: Positioner board A7

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
Meas. V27
points: V18
V10
E1{ MP4()
MP3(+) P10
E2{
MP2(+)
MP1()
S1-7
21.2.1 Setting type of signal

The signal type (current/ voltage signal) of nominal value E1 and actual
value E2 is set in the factory and marked with a label on the cover plate of
the positioner (refer to figure 47).
If the setting is subject to subsequent change, the marking also has to be
changed. Furthermore, the wiring diagram indicated on the name plate of
the actuator controls also changes (see page 56).
Table 6: Possible settings

Programming
Command signal Feedback via DIP switch S1-7
Setpoint E1 Actual value E21) (see figure 48)
4 20 mA 4 20 mA
0 20 mA 0 20 mA
4 20 mA
05V
0 20 mA
4 20 mA
05V
0 20 mA
05V 05V
4 20 mA
0 10 V
0 20 mA
0 10 V 05V
1) Signals for internal feedback:

0/4 20 mA from electronic position transmitter
or 0 5 V from precision potentiometer 5 k
36
21.2.2 Setting actuator behaviour on loss of signal
In case of a loss of signal of nominal value E1 or actual value E2, the reac-
tion of the actuator can be programmed via the switch S2-7. The complete
range of choices, however, is only available with signals 4 20 mA.
The following reactions are possible:

Fail as is:
Actuator stops immediately and remains in this position.
Fail close
Actuator moves the valve to the end position CLOSED.
Fail open:
Actuator moves the valve to the end position OPEN.
Table 7: Possible settings (recommended settings are shaded in grey)

Behaviour on loss of signal of Prerequisite1) Programming
E1 E2
fail as is 4 20 mA 4 20 mA
4 20 mA 4 20 mA
fail close
0 20 mA
4 20 mA
05V
4 20 mA 4 20 mA
fail open
0 20 mA
4 20 mA
05V
fail as is fail open 4 20 mA 05V
4 20 mA
05V
0 20 mA
fail close fail open 0 20 mA 4 20 mA
0 20 mA
0 20 mA
05V
05V
0 10 V
0 20 mA 4 20 mA
fail close fail as is
0 10 V 4 20 mA
1) During loss of signal, signals from 0 20 mA and 0 5 V may be misinterpreted since E1 or E2 (without any fault) can also
be < 4 mA (end position CLOSED = 0 mA or 0 V) when working properly.
0/4 20 mA from electronic position transmitter or 0 5 V from precision potentiometer 5 k
37
21.3 Positioner adjustment for end position CLOSED (standard version)
Before beginning the setting of the positioner, it has to be

ensured that the limit and torque switching of the actuator
as well as the feedback have been set (clauses 16. and 17.).
.. Set selector switch (local controls) to position LOCAL.

Move multi-turn actuator by pressing push button to
.. end position CLOSED.

Supply nominal value E1 of 0 or 4 mA (see wiring diagram).
Turn potentiometer t-off (P10) counterclockwise to the stop
(figure 49).
Missing signals E1/ E2 or wrong polarity are indicated by

LED (V10) E1/E2 < 4 mA" (figures 47 or 49)
. Connect voltmeter to measuring points MP3 and MP4 (figure 49) for mea-
suring the nominal value (0 5 V).
For a nominal value E1 of 0 mA, the voltmeter shows 0 V.
In case nominal value (0 V or 1 V) is not correct:
. Correct nominal value signal in control room.

Connect voltmeter to measuring points MP2 and MP1 for measuring the
actual value signal.
For an actual value E2 of 0 mA, the voltmeter shows 0 V.
If measured value is not correct:
Adjust position feedback according to clause 16. and 17. and repeat
positioner adjustment.
Table 8
Possible LED display: Required setting in end position CLOSED:
(refer to figures 49 and 50) (refer to figures 49 and 50)
Turn potentiometer 0 (P3) slightly clockwise until
the LEDs are not illuminated
LED (V27 yellow) is illuminated
Then

LED (V28 green) is
LED (V28 green) is no longer illuminated and
illuminated
If

Turn potentiometer 0 (P3) counterclockwise until
LED (V27 yellow) LED (V27 yellow) is no longer illuminated.
is illuminated Then turn potentiometer 0 (P3) slightly clockwise until

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
Meas. V27
points: V18
V10
E1{ MP4()
MP3(+) P10
E2{ MP1()
MP2(+)
S1-7
38
21.4 Positioner adjustment for end position OPEN (standard version)
. Run multi-turn actuator by pressing push button (local controls) to end
. position OPEN.
actual value E2:
When position feedback is set correctly, the voltmeter shows 5 V.
.. positioner adjustment.
Connect max. command signal (nominal value E1) = 20 mA.
nominal value E1:
For a nominal value of 20 mA, the voltmeter shows 5 V.
If measured value is not 5 V:
Check the externally supplied command signal E1.
Table 9
LED display: Required setting in end position OPEN:
Turn potentiometer max. (P4) slightly counterclockwise until
LED (V28 green) is illuminated
Then
Turn potentiometer max (P4) clockwise until LED (V28 green)

LED (V28 green) is no longer illuminated.
If
is illuminated Then turn potentiometer max (P4) slightly counterclockwise until

Turn potentiometer max (P4) slightly counterclockwise until
LED (V27 yellow)
LED (V27 yellow) is no longer illuminated and
is illuminated
21.5 Setting the sensitivity

.. Set selector switch at the local controls to position REMOTE.
Set command signal E1 according to label on cover plate (see figure 50).
The sensitivity (DE / dead band) is set to maximum value (2.5 %) in the
. factory.
The deadband can be increased by turning the potentiometer DE (P9)
clockwise. Left stop = small dead band (= high sensitivity). For a precise
setting of the dead band, a set point device with setting options in the 0.1
. mA range is required.
A better sensitivity (DEmin= 0.25 %) can be achieved by turning the poten-
tiometer P7 (sens) clockwise.
When setting DE, the following must be observed:

If the number of starts is too high, this will lead to unneces-
sary wear at the valve and actuator. Therefore the maximum
possible dead band acceptable for the process must be set.
To prevent exceeding the max. permissible number of starts (refer to Techni-

cal data sheets for modulating actuators) in extreme cases, a pause time
between 0.5 s (left stop) and 10s (right stop) may be set with the potentio-
meter t-off (P10).
39
Figure 50: Cover plate for positioner

V28 (green)
V27 (yellow)
V18 (red)
V10 (red)
P10
Figure 51: Cover plate for positioner A7

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
Meas. V27
points: V18
V10
E1{ MP4()
MP3(+) P10
E2{
MP2(+)
MP1()
S1-7
40
21.6 Positioner adjustment for end position OPEN (inverse operation)
In standard version the maximum input signal (E1 = 20 mA) results in opera-
.
tion to end position OPEN.
By switching the code switch S3-7 (figure 52) to position 1, an inversion
. of this signal definition (inverse operation) can be achieved.

In case an RWG (option) is installed, the connections 7 (red) and 5 (black)
. on the positioner board (figure 38) of the actuator have to be exchanged.

In case a potentiometer is installed, (option) the connections 21 (red) and
22 (black) at XA (connection for actuator) must be interchanged.

.. Set selector switch (local controls) to position LOCAL.
.. Run actuator with push button to end position OPEN .

(figure 52).

. Connect voltmeter to measuring points MP3 and MP4 (figure 52) for mea-
suring the nominal value (0 5 V).
. Correct nominal value signal in control room.

Table 10
Possible LED display: Required setting in end position OPEN:
Then

LED (V27 yellow)
is illuminated
If

LED (V28 green) LED (V28 green) is no longer illuminated.
41
21.7 Positioner adjustment end position CLOSED (inverse operation)
. Run actuator with push button (local controls) to end position
. CLOSED.
actual value E2:
Adjust position feedback according to clauses 16. and 17. and repeat
.. positioner adjustment.
nominal value E1:
Table 11
LED display: Required setting in end position CLOSED:
Then
Turn potentiometer max (P4) clockwise until LED (V27 yellow)

LED (V27 yellow) is no longer illuminated.
If

LED (V27 yellow) is illuminated.
Turn potentiometer max (P4) slightly counterclockwise until the
LED (V28 green)
is illuminated

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
V27
Meas. V18
points: V10
MP4()
MP3(+) P10
MP2(+)
MP1()
S1-7
42
21.8 Positioner in Split Range version (option)
For Split Range, a modified version of the positioner is used. The standard
version is not suitable for Split Range operation.
Split Range operation is only possible with the position transmitter RWG.
21.8.1 Split Range: description of functions
In Split Range operation, a setpoint is shared by up to four positioners. A

typical example is a pipeline with a bypass. The actuator mounted on the
bypass reacts in the lower range (0 10 mA), the actuator on the main
valve in the upper range (10 20 mA). Other values such as 4 12 mA and
12 20 mA can also be set.
21.8.2 Programming
DIP 5 at code switch S1-7 must always be in position ON for Split Range
version.
Table 12: Possible settings for Split Range operation

Programming
Command signal Feedback1) via DIP switch S1-7
Setpoint E1 Actual value E2 (see figure 53)
4 12/12 20 mA 4 20 mA
0 10/10 20 mA 0 20 mA
4 12/12 20 mA
05V
0 10/10 20 mA
The further programming of the positioner via the code switches S2-7 and
S3-7 can be made in the same way as during normal operation.
21.8.3 Positioner adjustment for Split Range (see also example further down the page)
. Supply the specified minimum command signal (nominal value E1) for the
positioner and check by measuring with voltmeter at the measuring points
. MP3 and MP4 (figure 53).

Connect voltmeter between measuring point M3 and measuring point MP1.
Calculate setting value:
Initial value = E 1min [in Ampere] x 250 Ohm
. Set initial value with potentiometer P5.

Supply specified maximum command signal (nominal value E1) and check
. by measuring at the measuring points MP3 and MP4.

. Set potentiometer P6 to 5 V.
Supply input signal E1 from minimum to maximum value and check the set
. range 0 5 V at measuring point M9. If necessary, readjust with P5 or P6.

Apply the same procedure to the second actuators positioner and set
. according to the specified nominal values E1.

After setting the Split Range operation, perform further readjustment as
described on page 38.
43
Figure 53: Positioner board A7, Split Range version

P9 (E)
P7 (Sens)
P3 (0) S2-7
P4 (max)
P6 S3-7
P5
Meas.points
V28 (green)
M9
M3 V27 (yellow)
V18 (red)
V10 (red)
E1{ P10
Meas.points
E2{
S1-7
Example:
Two actuators are to be operated in Split Range version. Actuator 1 must be
in position CLOSED with a nominal value signal E1 of 0 mA and in position
OPEN with a signal of 10 mA.
Actuator 2 must be in position CLOSED with a nominal value signal of
10 mA and in position OPEN with a signal of 20 mA.
. Positioner actuator 1:
Supply E1 = 0 mA, set with P5 = 0 V at M3 (measured against MP1),
. supply E1 = 10 mA, set with P6 = 5V at M9 (measured against MP1).

Positioner actuator 2:
. supply E1 = 20 mA, set with P6 = 5V at M9 (measured against MP1).

Perform adjustments and settings for E2, etc. Afterwards the nominal
value E1 can be transmitted through both actuators (connected in series).
When operating within range E1 = 0 10 mA, actuator 1 moves, actuator
2 remains in end position CLOSED. When operating within range
E1 = 10 20 mA, actuator 2 moves, actuator 1 remains in end position
OPEN.
44
22. Timer (option)

The timer board is used to increase the operating time for the entire or any
portion of the valve travel.
Example:
In order to avoid water hammer in long pipelines, stepping mode can be
chosen for any part of the travel.
. The timer is installed in the actuator controls AUMA MATIC instead of the
. interface board.
Electronic timer is not possible in combination with positioner.
22.1 Functions of the diagnosis LEDs (timer)
Figure 54: Cover plate for timer A1.6
V14 is illuminated: Phase failure and/ or motor protection tripped, reset by

selector switch position III at local controls.
V15 is illuminated: Torque fault: Tripping torque was exceeded before
reaching the end position.
V21 is illuminated: Stepping mode in direction CLOSE is switched on.
V22 is illuminated: Stepping mode in direction OPEN is switched on.
45
22.2 Setting start and end of stepping mode via DUO limit switching (option)
Start and end of stepping mode can also be set via external switches
(use potential-free contacts).
..
Direction OPEN, first normal operation then stepping mode
Run valve in direction OPEN to the desired start of stepping mode.
normal operation stepping (5 mm) in direction of arrow, thereby observe LED V22 (figure 54).
Start of stepping mode in direction OPEN is set correctly if the LED chan-
V 22 off V22 on ges from off to on (see sketch on the left).
Start stepping mode OPEN
..
Direction CLOSE, first normal operation then stepping mode
Run valve in direction CLOSE to the desired start of stepping mode.
stepping normal operation (5 mm) in direction of arrow, thereby observe LED V21 (figure 54).
Start of stepping mode in direction CLOSE is set correctly if the LED
V 21 on V21 off changes from off to on (see sketch on the left).
Start stepping mode CLOSED
G K
..
Direction OPEN, first stepping mode then normal operation
Run valve in direction OPEN to the desired end of stepping mode.
End of stepping mode is correctly set if the LED changes from on to off
V 22 on V22 off (see sketch on the left).
End stepping mode OPEN
..
Direction CLOSE, first stepping mode then normal operation
Run valve in direction CLOSE to the desired end of stepping mode.
V 21 off V21 on (see sketch on the left).
End stepping mode CLOSED
46
22.3 Setting ON and OFF times
ON and OFF times can be set independently of each other between 1 30

seconds at the 4 potentiometers R10 to R13.
Clockwise rotation: Time extension

Counterclockwise rotation: Time reduction
R10 (t-off) : OFF time in direction OPEN
R11 (t-on) : Running time in direction OPEN
R12 (t-off) : OFF time in direction CLOSE
R13 (t-on) : Running time in direction CLOSE

R 10 R 12
R 11 R 13
47
..
23. Fuses
Switch off the mains before changing the fuses.
When replacing fuses, only fuses according to table 13
may be used.
23.1 Fuses within the actuator controls
Fuses (figures 58 and 57) are accessible after removal of the local controls.
Figure 58: Fuses on signal and control board Figure 57: Fuses on power supply board
1F1 1F2 F3 F4
Table 13
Switchgear Voltage supply Voltage output G fuses: (figures 58 and 57)
(mains voltage) (power supply unit)
F 1/F 2 F 3*) F 4*)
(Board A20, refer to (Boards A2, refer to (Boards A8, refer to
wiring diagram) wiring diagram) wiring diagram)
24 V 1 A T; 500 V 1.6 A T; 250 V
500 V AUMA article no.:
115 V K002.277 0.4 A T; 250 V
Reversing
contactors 24 V 2 A FF; 660 V 1.6 A T; 250 V
> 500 V AUMA article no.: 500 mA T; 250 V
115 V K002.665 0.4 A T; 250 V
24 V 16 A FF; 500 V 1.6 A T; 250 V
Thyristors 500 V AUMA article no.:
115 V K001.189 0.4 A T; 250 V
Size 6.3 x 32 mm 5 x 20 mm 5 x 20 mm
*) according to IEC 60127-2/III
F1/ F2: Primary fuses on power supply unit

F3: Internal 24 V DC supply, RWG, logic board
F4: Internal 24 V AC supply (optional: 115 V AC);
Heater, tripping device for PTC thermistors,
control reversing contactors
. After replacing the fuses, screw local controls back on again.
Carefully lead cables back into the housing to prevent them

from jamming.
48
23.2 Motor protection

In order to protect against overheating and impermissibly high temperatures
at the actuator, PTC thermistors or thermoswitches are embedded in the
motor winding. The thermoswitch is tripped as soon as the max. permissible
winding temperature has been reached.
The actuator is stopped and the red indication light on the local controls is
illuminated.
The motor has to cool down before the operation can be resumed.
Version with thermoswitch (standard)

The actuator can be controlled again after the motor has cooled down.
As soon as the actuator receives a run command (OPEN - CLOSE), the
fault signal (red indication light) is no longer illuminated.
Version with thermoswitch and additional thermal overload relay

within the controls (option):
The operation can only be continued after the fault signal (red indication
light) has been reset. The fault signal is reset via the overload relay inte-
grated in the actuator controls. Therefore the controls has to be opened at
the cover (15.0 page 56) and the relay held down. The relay is located on
the contactors (4.1).
Version with PTC thermistor (option)

The operation can only be continued after the fault signal (red indication
light) has been reset. The fault signal is reset via selector switch position
RESET (figure 59) of the local controls.
Figure 59: Selector switch RESET
49
24. Enclosure protection IP 68 (option)

Definition
According to EN 60 529, the conditions for meeting the requirements of
enclosure protection IP 68 are to be agreed between manufacturer and
user.
AUMA actuators and controls in enclosure protection IP 68 meet the follow-
..
ing requirements according to AUMA:
Duration of submersion in water max. 72 hours
..
Head of water max. 6 m
Up to 10 operations during submersion
Modulating duty is not possible during submersion
Enclosure protection IP 68 refers to the interior of the actuators (motor,

gearing, switch compartment, controls, and terminal compartment).
Inspection
AUMA actuators and controls in enclosure protection IP 68 undergo a rou-
tine testing for tightness in the factory.
.
Cable glands
For the entries of the motor and control cables, appropriate cable glands
in enclosure protection IP 68 must be used. The size of the cable glands
must be suitable for the outside diameter of the cables, refer to recommen-
.dations of the cable gland manufacturers.

As standard, actuators and controls are delivered without cable glands.
.For delivery, the threads are sealed with plugs in the factory.
When ordered, cable glands can also be supplied by AUMA at an addi-
tional charge. For this, it is necessary to state the outside diameter of the
.cables.
The cable glands must be sealed against the housing at the thread with an
.O-ring.
It is recommended to additionally apply a liquid sealing material
(Loctite or similar).
Commissioning
..
When commissioning, the following should be observed:
Sealing faces of housing and covers must be clean.
..
O-rings of the covers must not be damaged.
A thin film of non-acidic grease should be applied to sealing faces.
Covers should be tightened evenly and firmly.
..
After submersion
Check actuator.
In case of ingress of water, dry actuator correctly and check for proper
function.
Further notes
When using output drive types A and AF (stem nut), it cannot be prevented
that water enters the hollow shaft along the valve stem during submersion.
This leads to corrosion. The water also enters the thrust bearings of output
drive type A, causing corrosion and damage to the bearings. The output
drive types A and AF should therefore not be used during submersion.
50
25. Applications in Ex zone 22 (option)
Multi-turn actuators of type range SA 07.1 SA 16.1/SAR 07.1 SAR 16.1

in version AUMA MATIC basically meet the requirements for applications in
dust hazardous locations of ZONE 22, in compliance with the ATEX direc-
tive 94/9/EC.
The actuators are designed to meet enclosure protection IP 67 or IP 68 and

fulfil the requirements of EN 50281-1-1:1998 section 6 Electrical appara-
tus for use in presence of combustible dust hazards, requirements for elec-
trical equipment of category 3 protected by enclosures.
To comply with all requirements of EN 50281-1-1: 1998, the following points
must imperatively be observed:
. In compliance with the ATEX directive 94/9/EC, the actuators must be

equipped with an additional identification II3D IP6X T150 C.
. The maximum surface temperature of the actuators, based on an ambient

temperature of + 40 C in accordance with EN 50281-1-1 section 10.4, is
150 C. In accordance with section 10.4, an increased dust deposit on the
equipment was not considered for the determination of the max. surface
temperature.
. The correct connection of the thermoswitches or the PTC thermistors as

well as the fulfilment of the type of duty and the technical data are prereq-
uisites for compliance with the maximum surface temperature of part-turn
actuators.
. The connection plug may only be plugged in or pulled out when actuator
and controls are disconnected from the mains.
. The cable glands used also have to meet the requirements of category
II3D and must at least comply with enclosure protection IP 67.
. The actuators must be connected by means of an external ground con-

nection (accessory part) to the potential equalization or integrated into a
grounded piping system.
. The screw plug (part no. 27) or the protection tube with cap
(part nos. 160.1 and 160.2) for sealing the hollow shaft must imperatively
be mounted to guarantee the combustible dust hazard protection.
. As a general rule, the requirements of EN 50281-1-1 must be respected in

dust hazardous locations. During commissioning, service, and mainte-
nance, respective special care as well as qualified and trained personnel
is required for the safe operation of multi-turn actuators.
51
26. Maintenance
After commissioning, check multi-turn actuator for damage to paint finish.
Do a thorough touch-up to prevent corrosion. Original paint in small quantities
can be supplied by AUMA.
AUMA multi-turn actuators require very little maintenance.

Precondition for reliable service is correct commissioning.
Seals made of elastomers are subject to ageing and must therefore regu-
larly be checked and, if necessary, be exchanged.
It is also very important that the O-rings at the covers are placed correctly
and cable glands fastened firmly to prevent ingress of dirt or water.
.
We recommend additionally:
If rarely operated, perform a test run about every 6 months. This ensures
.that the actuator is always ready to operate.

Approximately six months after commissioning and then every year check
bolts between multi-turn actuator and valve/ gearbox for tightness. If
.required, tighten applying the torques given in table 1, page 11.

For multi-turn actuators with output drive type A: At intervals of approx. 6
months from commissioning, press in Lithium soap EP multi-purpose
grease on mineral oil base at the grease nipple with grease gun (quantity
see table 2, page 12).
..
27. Lubrication
The gear housing is filled with lubricant in the factory.
.. A grease change is recommended after the following operation time:

If rarely operated, after 10 12 years.
If operated frequently, after 6 8 years.
Lubrication of the valve stem must be done separately.
28. Disposal and recycling

AUMA actuators have an extremely long lifetime. However, they have to be
replaced at one point in time.
The actuators have a modular design and may therefore easily be disas-
..
sembled, separated, and sorted according to materials, i.e.:
electronic scrap
.. various metals
plastics
greases and oils
.
The following generally applies:
Collect greases and oils during disassembly. As a rule, these substances
. are hazardous to water and must not be released into the environment.
Arrange for controlled waste disposal of the disassembled material or for
29. Service
. separate recycling according to materials.
Observe the national regulations for waste disposal.
AUMA offers extensive services such as maintenance and inspection for

actuators as well as various training courses. Addresses of AUMA offices
and representatives can be found on page 60 and on the Internet
(www.auma.com).
52
Notes
53
54
79.0 Sample name plate
S2
SA 07.1-F07 - Actuator type

S2
Com. No. 1309533 - Commission number
S2 No.: 3302MD 19302 - Works number
11 1/min - Output speed
T close: 120-300Nm
T open: 120-300Nm Torque range in
SA 16.1 CLOSED/OPEN
Lube: F1 IP67
SAR 16.1 27 Temp -25C/+70C - Lubricant/encl. protection
auma CC
S1/S2 - Temperature range
160.2
50.0
79.0
S2 53.0 54.0 160.1
S1/S2
51.0 S1/S2
S2
SA 07.1 SA 14.1 55.0
SAR 07.1 SAR 14.1
58.0
56.0 57.0 52.0
70.1 20.0 153.2

151.0
S2 19.0 17.0
59.0 152.2
with actuator controls AUMA MATIC AM 01.1 / AM 02.1
25.0 153.1
S1/S2 153.0
24 152.1 153.3
39
019 5.0 153.5

S1/S2 49.0 020
5.12 155.0
70.0 24.0/23.0 5.7
9.0
22.0
5.8
5.37 10.0
1.0
S2 S2
30.0
5.32 S2
S2
30. Spare parts list multi-turn actuator SA(R) 07.1 SA(R) 16.1
105.0 18 053
S1/S2 3.0
6 80.0 012
80.001 14
60.0
107 90.001
156.0
100 80.3
S2 85.001
106.0
S2 80.001
90.0
61.0 2.0 85.0
15.0
S2
90.001 85.001
B1 / C A D B3 / B4 / E
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used.
Delivered spare parts may slightly vary from the representation in these instructions.
No. Type Designation No. Type Designation

012 E Notched pin Pin for motor and thermoswitch in motor plug/
59.0 1) B socket connector
019 E Cheese head screw
020 E Clamping washer Control unit assly. without torque switching
60.0 B heads, without switches
053 E Screw
1.0 B Housing assly. 61.0 B Torque switching head
2.0 B Flange, bottom assly. 70.0 B Motor
3.0 B Hollow shaft assly. (without worm wheel) Motor pin carrier
70.1 1) B (without pins)
5.0 B Worm shaft assly.
5.12 E Grub screw 79.0 2) B Planetary gearing assly. for motor drive
5.32 E Coupling pin Output drive form A assly.
80.0 3) B (without thread in stem nut)
5.37 B Pull rod assly.
5.7 E Motor coupling 80.0013 E Thrust bearing set
5.8 B Manual drive coupling assly. 80.3 3) E Stem nut (without thread)
3)
6 E Worm wheel 85.0 B Output drive B3
9.0 B Planetary gear assly. for manual drive 85.0013) E Snap ring
3)
10.0 B Retaining flange assly. 90.0 B Output drive D
14 E Change-over lever 90.0013) E Snap ring
15.0 B Cover for switch compartment assly. Switch for limit/ torque switching (including
100 B pins at wires)
17.0 B Torque lever assly.
18 E Gear segment Blinker transmitter including pins at wires
105.0 B (without impulse disc and insulation plate)
19.0 B Crown wheel assly.
20.0 B Swing lever assly. 106.0 B Stud bolt for switches
22.0 B Drive pinion II for torque switching assly. 107 E Spacer
23.0 B Drive wheel for limit switching assly. 151.0 B Heater
24 E Drive wheel for limit switching 152.1 3) B Potentiometer (without slip clutch)
24.0 B Intermediate wheel for limit switching assly. 152.2 3) B Slip clutch for potentiometer
3)
25.0 E Locking plate 153.0 B RWG assly.
27 E Screw plug Potentiometer for RWG
153.1 3) B (without slip clutch)
30.0 B Handwheel with ball handle
39 E Screw plug 153.2 3) B Slip clutch for RWG
49.0 1)
B Motor plug, socket assly. 153.3 3) B Electronic board RWG
3)
52.0 B Pin carrier (without pins) 153.5 B Wires for RWG
53.0 B Socket for control 155.0 3) B Reduction gearing
54.0 B Socket for motor 156.0 3) B Mechanical position indicator
3)
56.0 B Pin for controls 160.1 E Protection tube (without cap)
57.0 B Pin for motor 160.2 3) E Cap for stem protection tube
58.0 B Wire for protective earth S1 S Seal kit (small)
S2 S Seal kit (large)
1) SA 16.1 with output speeds 32 to 180 rpm without motor plug; motor directly wired to pin carrier (no. 52.0).
2) not available for all output speeds
3) not included in basic equipment
55
56
15.0
10.2
10.0
10.1 8.2
8.0
8.1
9.0 11.2
11.0
6.1 11.1
6.0
6.01
53.0
56.0 4.5 4.1
54.0
50.0 57.0 4.0

with actuator controls AUMA MATIC AM 01.1 / AM 02.1
31. Spare parts list controls AUMA MATIC
4.2 5.1
51.0
5.2 5.0
4.3 4.2
52.0 1.0
4.4
4.3
4.4
13.1
3.01
2.0
55.0
58.0
3.02
1.01 3.03
1.02 13.0 3.0
2.3
Sample name plate

2.1
2.5
AM 01.1 P:1.5kW - Type of controls
Com. no:1309533 - Commission number
No.: 2302MA04225 - Works number
KMS: TP101/001 2.2
- Terminal plan actuator
MSP:1Q1-C3Q-F18E1 - Wiring diagram
3 ~ 400V IP67 - Mains voltage/ Enclosure protection
Control: 24V DC - Control voltage
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Delivered spare
parts may slightly vary from the representation in these instructions.

1.0 E Housing 8.0 B Interface board assly.
1.01 E Hex. socket head cap screw 8.1 B Interface board
1.02 E Lock washer 8.2 E Cover plate for interface board
2.0 B Cover local controls 9.0 B Logic board
2.1 B Switching knob 10.0 B Timer board assly.
2.2 E Padlock 10.1 B Timer board
2.3 E Face-plate for local controls 10.2 E Cover plate for timer board
2.5 E Selector switch 11.0 B Electronic positioner assly.
3.0 B Push-button/ relay board 11.1 B Electronic positioner board
3.01 E Primary fuse 11.2 E Cover plate for positioner board
3.02 E Fuse cover 13.0 B Adapter board
3.03 E Bulb for indication light 13.1 E Stud
4.0 B Contactors assly. 15.0 B Cover assly.
4.1 E Reversing contactors 50.0 B Plug cover assly.
4.2 E Carrier for contactors 51.0 B Socket carrier (with sockets)
4.3 E Socket carrier assly. (with sockets) 52.0 B Pin carrier (without pins)
4.4 E Grub screw 53.0 B Socket for controls
4.5 E RC network 54.0 B Socket for motor
5.0 B Thyristor reversing unit assly. 55.0 B Socket for protective earth
5.1 E Varistor board 56.0 B Pin for controls
5.2 E Thyristor reversing unit 57.0 B Pin for motor
6.0 B Power supply unit 58.0 B Protective earth
6.1 B Mounting plate for power supply S1 S Seal kit
6.01 S Secondary fuse
57
14. Declaration of Conformity and Declaration of Incorporation
58
Index
A L S
Ambient temperature 8 Limit switching 22,23,26 Safety instructions 4
Local controls 26 Selector switch 26
B
Logic board 33 Self-retaining 20,33
Blinker transmitter 33
Loss of signal 37 Sensitivity 39
C Lubrication 52 Service 52
Collective fault signal 32,33 Short description 5
M
Command signal 35,36,37 Short-circuit protection 14
Mains frequency 6
Corrosion protection 10,52 Signals 9
Maintenance 4
Cross sections 17 Spare parts list 54
Manual operation 18
Current consumption 6,14 Multi-turn actuator 54
Mechanical position indicator 31
Controls 56
D Motor protection 49
Split Range Version 43
Declaration of Conformity 58 Mounting positions of the local
Stepping mode
Declaration of Incorporation 58 controls 13
Operating time 45
Direction of rotation 25 Mounting to valve/ gearbox 11
Pause time 47
Disconnect switches 14 N Storage 10
Disposal and recycling 52
Name plate 54,56 T
DUO limit switching 23
O Technical data 6
E
Output drive types 11 TEST (Selector switch position) 26
Electrical connection 14 Test run 25
Overvoltage category 6
Electronic position transmitter Thermoswitches 49
RWG 28 P
Timer 45
2-wire system 29 Packaging 10 Torque setting 24
3-/ 4-wire system 30 Pause time 35,47 Transport 10
EMERGENCY signal 34 Position indicator 31 Tripping torque 24
Enclosure protection IP 68 50 Position transmitter RWG 14,28 Type of duty 6
Positioner 35 Type of seating 33
F
Potentiometer 27
Finish machining of the stem nut12 W
Power supply 6
Fuses 48 Wall bracket 15
Protection tube 12
H Protective earth 17
Handwheel 18 PTC thermistors 49
Heater 14 PTC tripping device 26
Push-to-run operation 20,33
I
Indicator disc 21,31 R
Interface board 32 Rate power 6
Internet 5 Remote indication 27,28
Inverse operation 41,42 RESET
(Selector switch position) 26
Running time 35,47
59
GRNBECH & SNNER A/S Corsusa S.A.C.
Europe DK-2450 Kbenhavn SV PE- Miralflores - Lima
AUMA Riester GmbH & Co. KG Tel +45 33 26 63 00 Tel +511444-1200 / 0044 / 2321
Factory Mllheim GS@g-s.dk corsusa@corsusa.com
DE-79373 Mllheim www.g-s.dk www.corsusa.com
Tel +49 7631 809 - 0 IBEROPLAN S.A. PASSCO Inc.
riester@auma.com ES-28027 Madrid PR-00936-4153 San Juan
www.auma.com Tel +34 91 3717130 Tel +18 09 78 77 20 87 85
Factory Ostfildern-Nellingen iberoplan@iberoplan.com Passco@prtc.net
DE-73747 Ostfildern D. G. Bellos & Co. O.E. Suplibarca
Tel +49 711 34803 - 0 GR-13671 Acharnai Athens VE- Maracaibo Estado, Zulia
riester@wof.auma.com Tel +30 210 2409485 Tel +58 261 7 555 667
Service Centre Cologne info@dgbellos.gr suplibarca@intercable.net.ve
DE-50858 Kln SIGURD SRUM A. S.
Tel +49 2234 2037 - 9000 NO-1301 Sandvika Asia
Service@sck.auma.com Tel +47 67572600 AUMA Actuators (Tianjin) Co., Ltd.
Service Centre Magdeburg post@sigurd-sorum.no CN-300457 Tianjin
DE-39167 Niederndodeleben INDUSTRA Tel +86 22 6625 1310
Tel +49 39204 759 - 0 PT-2710-297 Sintra mailbox@auma-china.com
Service@scm.auma.com Tel +351 2 1910 95 00 www.auma-china.com
AUMA Armaturenantriebe GmbH jpalhares@tyco-valves.com AUMA (INDIA) PRIVATE LIMITED
AT-2512 Tribuswinkel MEGA Endstri Kontrol Sistemieri Tic. Ltd. Sti. IN-560 058 Bangalore
Tel +43 2252 82540 TR-06460 vecler Ankara Tel +91 80 2839 4655
office@auma.at Tel +90 312 472 62 70 info@auma.co.in
www.auma.at megaendustri@megaendustri.com.tr www.auma.co.in
AUMA (Schweiz) AG CTS Control Limited Liability Company AUMA JAPAN Co., Ltd.
CH-8965 Berikon UA-02099 Kiyiv JP-210-0848 Kawasaki-ku, Kawasaki-shi Kanagawa
Tel +41 566 400945 Tel +38 044 566-9971, -8427 Tel +81 44 329 1061
RettichP.ch@auma.com v_polyakov@cts.com.ua mailbox@auma.co.jp
AUMA Servopohony spol. s.r.o. AUMA ACTUATORS (Singapore) Pte Ltd.
CZ-10200 Praha 10 Africa SG-569551 Singapore
Tel +420 272 700056 AUMA South Africa (Pty) Ltd. Tel +65 6 4818750
auma-s@auma.cz ZA-1560 Springs sales@auma.com.sg
www.auma.cz Tel +27 11 3632880 www.auma.com.sg
OY AUMATOR AB aumasa@mweb.co.za Al Ayman Industrial. Eqpts
FI-02270 Espoo A.T.E.C. AE- Dubai
Tel +35 895 84022 EG- Cairo Tel +971 4 3682720
auma@aumator.fi Tel +20 2 3599680 - 3590861 auma@emirates.net.ae
AUMA France S.A.R.L. atec@intouch.com PERFECT CONTROLS Ltd.
FR-95157 Taverny Cdex HK- Tsuen Wan, Kowloon
Tel +33 1 39327272 America Tel +852 2493 7726
stephanie.vatin@auma.fr AUMA ACTUATORS INC. joeip@perfectcontrols.com.hk
www.auma.fr US-PA 15317 Canonsburg DW Controls Co., Ltd.
AUMA ACTUATORS Ltd. Tel +1 724-743-AUMA (2862) KR-153-803 Seoul Korea
GB- Clevedon North Somerset BS21 6QH mailbox@auma-usa.com Tel +82 2 2113 1100
Tel +44 1275 871141 www.auma-usa.com sichoi@actuatorbank.com
mail@auma.co.uk AUMA Chile Respresentative Office www.actuatorbank.com
www.auma.co.uk CL- Buin AL-ARFAJ Eng. Company W. L. L.
AUMA ITALIANA S.r.l. a socio unico Tel +56 2 821 4108 KW-22004 Salmiyah
IT-20023 Cerro Maggiore (MI) aumachile@adsl.tie.cl Tel +965 4817448
Tel +39 0331 51351 LOOP S. A. arfaj@qualitynet.net
info@auma.it AR-C1140ABP Buenos Aires Petrogulf W.L.L
www.auma.it Tel +54 11 4307 2141 QA- Doha
AUMA BENELUX B.V. contacto@loopsa.com.ar Tel +974 4350 151
NL-2314 XT Leiden Asvotec Termoindustrial Ltda. pgulf@qatar.net.qa
Tel +31 71 581 40 40 BR-13190-000 Monte Mor/ SP. Sunny Valves and Intertrade Corp. Ltd.
office@benelux.auma.com Tel +55 19 3879 8735 TH-10120 Yannawa Bangkok
www.auma.nl atuador.auma@asvotec.com.br Tel +66 2 2400656
AUMA Polska Sp. z o.o. TROY-ONTOR Inc. sunnyvalves@inet.co.th
PL-41-310 Dabrowa Grnicza CA-L4N 5E9 Barrie Ontario www.sunnyvalves.co.th/
Tel +48 32 26156 68 Tel +1 705 721-8246 Top Advance Enterprises Ltd.
R.Ludzien@auma.com.pl troy-ontor@troy-ontor.ca TW- Jhonghe City Taipei Hsien (235)
www.auma.com.pl Tel +886 2 2225 1718
MAN Ferrostaal de Colombia Ltda.
OOO Priwody AUMA CO- Bogot D.C. support@auma-taiwan.com.tw
RU-141400 Moscow region for mail: 124365 Moscow Tel +57 1 401 1300 www.auma-taiwan.com.tw
a/ya 11 dorian.hernandez@manferrostaal.com
Tel +7 495 221 64 28 www.manferrostaal.com Australia
aumarussia@auma.ru BARRON GJM Pty. Ltd.
www.auma.ru PROCONTIC Procesos y Control Automtico
EC- Quito AU-NSW 1570 Artarmon
ERICHS ARMATUR AB Tel +593 2 292 0431 Tel +61 294361088
SE-20039 Malm info@procontic.com.ec info@barron.com.au
Tel +46 40 311550 www.barron.com.au
info@erichsarmatur.se IESS DE MEXICO S. A. de C. V.
www.erichsarmatur.se MX-C.P. 02900 Mexico D.F.
Tel +52 55 55 561 701
informes@iess.com.mx
2006-08-18
AUMA Riester GmbH & Co. KG AUMA Riester GmbH & Co. KG
P.O. Box 1362 P. O. Box 1151
79373 Mllheim, Germany D - 73747 Ostfildern
Tel +49 7631 - 809-0 Tel +49 711 - 34803 0
Fax +49 7631 - 809 1250 Fax +49 711 - 34803 34
riester@auma.com riester@wof.auma.com Certificate Registration No.
12 100/104 4269
www.auma.com www.auma.com
For detailed information about AUMA products, refer to the Internet:

www.auma.com Y000.176/003/en/3.06
Electric part-turn actuators
SG 05.1 SG 12.1
SGR 05.1 SGR 12.1
with actuator controls
AUMA MATIC AM 01.1

12 100/104 4269
Part-turn actuators SG 05.1 SG 12.1 / SGR 05.1 SGR 12.1
with actuator controls AUMA MATIC AM 01.1 Operation instructions
Scope of these instructions: These instructions are valid for part-turn actuators of the type ranges
SG 05.1 SG 12.1 and SGR 05.1 SGR 12.1
with the actuator controls AM 01.1.
These operation instructions are only valid for clockwise closing,
i.e. driven shaft turns clockwise to close the valve.

1.2 Commissioning (electrical connection) 4
1.3 Maintenance 4
2. Short description 4
3. Technical data 5
4. Additional information to the wiring diagram legend 8
5.1 Transport 9
5.2 Storage 9
5.3 Packaging 9
6. Manual operation 10
7. Mounting to valve 11
8. Electrical connection 12
8.1 Connection with AUMA plug/ socket connector 12
8.2 AUMA MATIC on wall bracket (accessory) 13
8.3 Heater 13
8.4 Motor protection 13
8.5 Remote position transmitter 13
8.6 Fitting the cover 13
9. Setting the end stops for part-turn actuators on butterfly valves 14
9.1 Setting end stop CLOSED 14
9.2 Setting end stop OPEN 14
9.3 Setting limit switching CLOSED 14
10. Setting the end stops for part-turn actuators on ball valves 15
10.1 Setting end stop OPEN 15
10.2 Setting end stop CLOSED 15
10.3 Setting limit switching OPEN 15
11. Changing the swing angle 16
11.1 Increasing the swing angle 16
11.2 Reducing the swing angle 16
12. Opening the switch compartment 17
12.1 Removing the cover from the switch compartment 17
12.2 Pulling off the indicator disc 17
13. Setting the limit switching 18
13.1 Setting end position CLOSED (black section) 18
13.2 Setting end position OPEN (white section) 18
13.3 Checking the limit switches 18
14. Setting of the DUO limit switching (option) 19
14.1 Setting direction CLOSE (black section) 19
14.2 Setting direction OPEN (white section) 19
14.3 Checking the DUO limit switches 19
2
Operation instructions with actuator controls AUMA MATIC AM 01.1
Page
15. Setting the torque switching 20
15.1 Setting 20
15.2 Checking the torque switches 20
16. Test run 21
16.1 Checking the direction of rotation 21
16.2 Checking the setting of the limit switching 22
16.3 Checking the type of seating 22
17. Setting the potentiometer (option) 23
18. Setting the electronic position transmitter RWG (option) 24
18.1 Setting 2-wire system 4 20 mA and 3- /4-wire system 0 20 mA 25
18.2 Setting 3- / 4- wire system 4 20 mA 26
19. Setting the mechanical position indicator 27
20. Closing the switch compartment 27
21. Setting the operating time 28
22. Actuator controls AUMA MATIC 29
22.1 Functions of the diagnosis LEDs on the interface board (standard version) 29
22.2 Programming the logic board 30
22.3 EMERGENCY-OPEN and EMERGENCY-CLOSE signal (option) 31
23. Electronic positioner (option) 32
23.1 Technical data 32
23.2 Setting 32
23.2.1 Setting type of signal 33
23.2.2 Setting actuator behaviour on loss of signal 34
23.3 Positioner adjustment end position CLOSED (standard version) 35
23.4 Positioner adjustment end position OPEN (standard version) 36
23.5 Setting the sensitivity 36
23.6 Positioner adjustment end position OPEN (inverse operation) 38
23.7 Positioner adjustment end position CLOSED (inverse operation) 39
23.8 Positioner in Split Range version (option) 40
23.8.1 Split Range: description of functions 40
23.8.2 Programming 40
23.8.3 Positioner adjustment for Split Range 40
24. Timer (option) 42
24.1 Function of the diagnosis LEDs (timer) 42
24.2 Setting start and end of stepping mode via DUO limit switching (option) 43
24.3 Setting ON and OFF times 44
25. Fuses 45
26. Enclosure protection IP 68 (option) 46
27. Applications in Ex zone 22 (option) 47
28. Maintenance 48
29. Lubrication 48
31. Service 49
32. Spare parts list part-turn actuator SG(R) 05.1 SG(R) 12.1 with plug/ socket connector 50
33. Spare parts list controls AUMA MATIC 52
Index 55
3
1.1 Range of application AUMA actuators are designed for the operation of industrial valves,
e.g. butterfly valves and ball valves.
Observance of these operation instructions is considered as part of the
controls/ actuators designated use.
1.2 Commissioning During electrical operation, certain parts inevitably carry lethal voltages.
(electrical connection) Work on the electrical system or equipment must only be carried out by a
skilled electrician himself or by specially instructed personnel under the
control and supervision of such an electrician and in accordance with the
applicable electrical engineering rules.
1.3 Maintenance The maintenance instructions (refer to page 48) must be observed, other-
wise a safe operation of the actuator is no longer guaranteed.
1.4 Warnings and notes Failure to observe the warnings and notes may lead to serious injuries or
Correct transport, proper storage, mounting and installation, as well as
careful commissioning are essential to ensure a trouble-free and safe oper-
ation.
During operation, the part-turn actuator warms up and surface temperatures
> 60 C may occur. Check the surface temperature prior to contact in order
to avoid burns.

pictograph.
Note marks activities or procedures which have major influence on the
correct operation. Non-observance of these notes may lead to consequen-
tial damage.
This pictograph means: Electrostatically endangered parts!
If this pictograph is attached to a printed circuit board, it contains parts
which may be damaged or destroyed by electrostatic discharges. If the
boards need to be touched during setting, measurement, or for exchange, it
must be assured that immediately before a discharge through contact with
an earthed metallic surface (e.g. the housing) has taken place.
2. Short description AUMA part-turn actuators type SG 05.1 SG 12.1 and SGR 05.1 SGR 12.1
have a modular design. The actuators are driven by an electric motor and
controlled with the electronic controls AM 01.1, which are included in the
scope of delivery.
A handwheel is provided for manual operation.
The limitation of travel is realised via limit switches in both end positions.
Torque seating is also possible in both end positions. The type of seating is
determined by the valve manufacturer. Additionally, a mechanical end stop is
provided for the protection of the valve. This is not, however, designed to be
approached during normal operation.
4
3. Technical data
Type of duty 1) SG: Short time duty S2 - 15 min
SGR: Intermittent duty S4 - 25 %
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34 (SG and SGR)
Options: 1-phase AC motor (SG only)
DC shunt motor (SG only)
Insulation class Standard: F, tropicalized
Option: H, tropicalized (3-phase AC motors only)
Motor protection Standard: Thermoswitches (NC)
(DC motors without motor protection)
Option: PTC thermistors (according to DIN 44082)
Self-locking Yes
Swing angle Standard: 80 to 110 adjustable between min. and max. value.
Options: 30 40, 40 55, 55 80, 110 160, 160 230 or 230 320
Limit switching Counter gear mechanism for end positions CLOSED and OPEN
Standard: Single switch (1 NC and 1 NO) for each end position
Options: Tandem switch (2 NC and 2 NO) for each end position,
Triple switch (3 NC and 3 NO) for each end position, switches
galvanically isolated
Intermediate position switch (DUO limit switching), available
for any intermediate position
Torque switching Infinitely adjustable torque switching for direction OPEN and CLOSE
Standard: Single switch (1 NC and 1 NO) for each direction
Options: Tandem switch (2 NC and 2 NO) for each direction, switches
galvanically isolated
Position feedback signal, Potentiometer or 0/4 20 mA (RWG)
analogue (options) For further details, see separate data sheet
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
Running indication (option) Blinker transmitter
Heater in switch compartment Standard: Resistance type heater with 5 W, 24 V DC
Options: Self-regulating PTC heater, 5 20 W
24 48 V AC/DC, 110 250 V AC/DC or 380 400 V AC
Motor heater (option) 12.5 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during
Option: Handwheel lockable
Connection to controls AUMA plug/ socket connector with screw type connection
Splined coupling for connection Standard: Coupling without bore
to the valve shaft Options: Machined coupling with bore and keyway, square bore or bore with two-flats
according to EN ISO 5211
Valve attachment Dimensions according to EN ISO 5211
Voltage supply Refer to name plate of actuator controls

External supply of the electronics 24 V DC + 20 % / 15 %,
(option) Current consumption: Basic version approx. 200 mA, with options up to 500 mA
Switchgear Standard: Reversing contactors2) (mechanically and electrically interlocked)
for motor power up to 1.5 kW
Options: Thyristor unit (recommended for modulating actuators)
for motor power up to 1.5 kW, 500 V AC with internal fuses
Control Standard: Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator,
Observe min. duration of impulse for modulating actuators
Option: Control inputs 220 V AC, OPEN - STOP - CLOSE (via opto-isolator,
1) Based on 20 C ambient temperature and at an average load with running torque according to Technical data SG or SGR
2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles is to be expected, thyristor units with
virtually unlimited lifetime should be used
5
Operation instructions SG 05.1 SG 12.1 / SGR 05.1 SGR 12.1
Output signals Standard:

5 output relays with gold-plated contacts:
4 potential-free NO contacts with one common:
max. 250 V AC, 0.5 A (resistive load)
End position OPEN, end position CLOSED, selector switch REMOTE,
selector switch LOCAL
Option: Signals in connection with positioner:
End position OPEN, end position CLOSED (requires tandem switch
within actuator)
Selector switch REMOTE, selector switch LOCAL via selector switch
2nd level
Voltage output Standard: Auxiliary voltage 24 V DC, max. 50 mA for supply of the control inputs,
Option: Auxiliary voltage 115 V AC, max. 30 mA for supply of the control inputs,3),
Local controls Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
Push buttons OPEN - STOP - CLOSE
3 indication lights:
End position CLOSED (yellow), collective fault signal (red),
end position OPEN (green)
Option: Protection cover, lockable
Functions Standard: Switch-off mode adjustable
Limit or torque seating for end position OPEN and end position CLOSED
Overload protection against excessive torques over the whole travel
Excessive torque (torque fault) can be excluded
by collective fault signal
Phase failure monitoring with automatic phase correction
Push-to-run operation or self-retaining in REMOTE
Push-to-run operation or self-retaining in LOCAL
Blinker transmitter signal can be switched on or off by actuator (option)
Options: Positioner4):
Nominal position value via analogue input E1 = 0/4 20 mA
Adjustable behaviour on loss of signal
Adjustable sensitivity (dead band) and pause time
Split Range operation
Motor protection evaluation Standard: Monitoring of the motor temperature in combination with thermoswitches
Options: Additional thermal overload relay in the controls
PTC tripping device in combination with PTC thermistors
Electrical connection Standard: AUMA plug/ socket connector with screw type connection
Threads for cable glands Standard: Metric threads
Options: Pg-threads, NPT-threads, G-threads
Wiring diagram Wiring diagram according to commission number included in delivery
Further options for version with RWG in the actuator
Position feedback Analogue output E2 = 0/4 20 mA (load max. 500 )
(Option)
3) Not possible in combination with PTC tripping device

4) Requires position transmitter in actuator
6
Service conditions
Enclosure protection according Standard: IP 67
to EN 60 529 5) Options: IP 68
(Double Sealed: electrical connection compartment additionally sealed
against interior)
KX-G same as KX, however aluminium-free version (outer parts)
Finish coating Standard: Two-component iron-mica combination
Standard colour Standard: Grey (DB 702, similar to RAL 9007)
Option: Other colours are possible on request
Ambient temperature Standard SG: 25 C to + 70 C
Standard SGR: 25 C to + 60 C (with 3-phase AC motor)
Options: 40 C to + 60 C, low temperature incl. heating system
50 C to + 60 C, extreme low temperature incl. heating system
(SG with 3-phase AC current only)
Lifetime SG 05.1/ SG 07.1: 20,000 operating cycles (OPEN - CLOSE - OPEN) for 90
SG 10.1: 15,000 operating cycles (OPEN - CLOSE - OPEN) for 90
SG 12.1: 10,000 operating cycles (OPEN - CLOSE - OPEN) for 90
SGR 05.1 12.1:6) min. 2.5 million operations (control steps)
Accessories
Wall bracket7) AUMA MATIC mounted separately from the actuator, including plug/ socket connector.
Connecting cables on request.
Recommended for high ambient temperatures, difficult access, or in case of heavy
vibrations during service.
Other information
EU Directives Electromagnetic Compatibility (EMC): (89/336/EEC)
Low Voltage Directive: (73/23/EEC)
Machinery Directive: (98/37/EC)
Reference documents Product description Electric part-turn actuators SG
Product description, Actuator controls AUMA MATIC
Dimension sheets SG/ SGR with integral controls AUMA MATIC
Technical data SG/ SGR
Technical data AM 01.1
Electrical data SG/ SGR
5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended. Additionally, for enclosure
protection IP 68, we recommend to use the double sealed terminal compartment DS.
For special motors, the enclosure protection according to the name plate applies
6) The lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the longest possible
maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process
7) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an RWG
has to be used in the actuator
7
4. Additional information to the wiring diagram legend

Information A: A running indication is possible if blinker transmitter (S5) is installed
(opening and closing of contacts).
Direction CLOSE: Connections XK 6 - XK 7
Direction OPEN: Connections XK 6 - XK 8
Contacts remain closed in end position.
When connected to an external PLC, the blinking signal can be switched off
via the DIP-switches (table 6, page 30).
Information B: The type of seating in the end positions is determined by the valve manufac-
turer. The setting is done at the programming switches S1-2 and S3-2 (see
page 30). The tripping of a torque switch in an intermediate position
switches off the actuator and causes a fault signal.
The limit switches serve for signalisation when switching off by torque
seating. They need to be set so that the appropriate switch is tripped shortly
before reaching the end position. If the torque switch trips before the limit
switch, the actuator is switched off and a fault signal is generated.
For further programming possibilities, e.g. self-retaining in operation mode
REMOTE, see table 6, page 30.
Information D: The following faults are registered and can be transmitted to the control
room as a potential-free collective fault signal:
- Power failure
- Phase failure
- Motor protection tripped
- Torque switch tripped in mid-travel.
This signal can be switched off on the logic board, see table 6, page 30.
Information E: Input signals according to DIN 19 240.

The nominal operation current of inputs XK 2, XK 3, and XK 4 amounts to
10 15 mA. If the internal voltage 24 V DC is used for remote control, it
must only be connected via potential-free contacts.
Information F: In case of wrong phase sequence, the running direction is automatically

adjusted. In case of a phase failure, the actuator stops. The fault is indicated
at LED V14 on the interface board (see page 29). For collective fault signal,
see information D.
Information G: Potential-free contacts are available for signals. The internal control voltage
(XK 11 / + 24 V and XK 5 / 24V) must not be used for external lamps,
relays etc.
8
5.
5.1 Transport ..
Transport, storage and packaging
For transport to place of installation, use sturdy packaging.
.
Do not attach ropes or hooks to the handwheel for the purpose of lifting by
hoist.
If part-turn actuator is mounted on valve, attach ropes or hooks for the
purpose of lifting by hoist to valve and not to part-turn actuator.
Fitting the ball handle: To avoid damage during transport, the ball handles are fitted to the inside of
the handwheel. Prior to commissioning, the ball handle has to be fitted in
..
the correct position.
..
Remove cap nut (figure 1).
Pull out ball handle and re-insert in correct position.
Fasten with cap nut.
Remove label from the handwheel for fitting the ball handle.
Figure 1
Cap nut
Ball handle
Ball handle
5.2 Storage .. Store in well-ventilated, dry room.
..
Protect against floor dampness by storage on a shelf or on
a wooden pallet.
If part-turn actuators are to be stored for a long time (more than 6 months),
.
the following points must be observed additionally:
.
and mounting surface, with long-term corrosion protection agent.
After mounting, connect part-turn actuator immediately to

electrical mains, so that condensation is prevented by the
heater.
5.3 Packaging Our products are protected by special packaging for the transport ex works.
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.
9
6. Manual operation
The actuator may be operated manually for purposes of setting and
commissioning, and in case of motor failure or power failure.
Engaging manual operation: Manual operation is activated by pulling at the handwheel. A change-over is
.
not required. The handwheel does not rotate during motor operation.
Turning the handwheel during motor operation results in

an extension or reduction of the operating time, depending
. on the direction of rotation.

It is not necessary to use an extension for manual opera-
tion. Excessive force may cause damage.
Disengaging manual operation: Release handwheel.

Handwheel has to engage.
10
7. Mounting to valve . Prior to mounting, the part-turn actuator must be checked

for any damage. Damaged parts must be replaced by origi-
. nal spare parts.

After mounting, check part-turn actuator for damage to
paint finish. If damage to paint-finish has occurred after
.
mounting, it has to be touched up to avoid corrosion.
For butterfly valves, the recommended mounting position is end position
.
CLOSED (Prior to mounting, bring the part-turn actuator to the mechan-
ical end stop CLOSED by turning the handwheel clockwise.).
For ball valves, the recommended mounting position is end position
OPEN (Prior to mounting, bring the part-turn actuator to the mechanical
..
end stop OPEN by turning the handwheel counterclockwise.).
.
Thoroughly degrease mounting faces of part-turn actuator and valve.
Apply a small quantity of grease to the valve shaft.
Place coupling sleeve onto valve shaft and secure
..
(refer to figure 2, detail A or B), ensure that dimensions X, Y, and Z are
observed (refer to table 1).
Apply non-acidic grease at splines of coupling.
Fit actuator so that fixing holes in actuator and valve mounting flange are
in alignment.
If necessary, move actuator up or down one tooth on the coupling. If
.
required, turn handwheel/ crank a little in direction OPEN or CLOSE until
holes align to the threads.
.
Ensure that the spigot (if provided) mates uniformly in the recess and that
the mounting faces are in complete contact.
Fasten the actuator with bolts of minimum quality 8.8 using lock washers.
Fasten bolts evenly crosswise to the appropriate torque according to table 1.
Figure 2
A B
Coupling
Grub screw Z
X Y
Valve
Table 1: Dimensions for couplings/ fastening torques for bolts
Type X max. Y max. Z max. 8.8 TA [Nm]

SG(R) 05.1-F05 5 3 60 4xM6 11
SG(R) 05.1-F07 5 3 60 4xM8 25
SG(R) 07.1-F07 7 3 60 4xM8 25
SG(R) 07.1-F10 7 3 60 4 x M 10 51
SG(R) 10.1-F10 10 3 77 4 x M 10 51
SG(R) 10.1-F12 10 3 77 4 x M 12 87
SG(R) 12.1-F12 10 6 100 4 x M 12 87
SG(R) 12.1-F14 10 6 100 4 x M 12 87
11
8. Electrical connection Work on the electrical system or equipment must only be

In case the actuator controls is equipped with a fieldbus interface

(Profibus DP or Modbus), refer to the operation instructions of the respective
fieldbus for a description of the bus and electrical connection.
Make sure to respect electromagnetic compatibility (EMC) when installing

cables:
.
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 ground potential.
.
If possible, avoid laying long cables and make sure that they are installed
in areas being subject to low interference.
Avoid long parallel paths with cables being either susceptible to interfer-
ence or interference sources.
.
8.1 Connection with AUMA plug/ socket connector
Figure 3: Connection Check if type of current, supply voltage, and frequency correspond to
..
50.0
control and motor data (refer to name plates at part-turn actuator and
controls).
Loosen bolts (50.01) (figure 3) and remove plug cover.
.
Loosen screws (51.01) and remove socket carrier (51.0) from plug cover
(50.0).
50.01
Insert cable glands suitable for connecting cables.
..
(The enclosure protection stated on the name plate is only ensured if suit-
51.0 able cable glands are used).
.
Seal cable entries which are not used with suitable plugs.
Connect cables according to order-related wiring diagram.
51.01
The wiring diagram applicable to the actuator is attached to the handwheel
in a weather-proof bag, together with the operation instructions. In case
the wiring diagram is not available, it can be obtained from AUMA (state
Figure 4: Parking frame (accessory) commission no., refer to name plate) or downloaded directly from the
Internet (www.auma.com).
A special parking frame (figure 4) for protection against touching the bare
contacts and against environmental influences is available.
Parking frame
Table 2: Technical data AUMA plug/ socket connector

Technical data Power terminals1) Protective earth Control terminals
No. of contacts max. 6 (3 are used) 1 (leading contact) 50 pins/ sockets
Marking U1, V1, W1, U2, V2, W2 1 to 50
Connecting voltage max. 750 V 250 V
Current max. 25 A 16 A
Type of customer connection Screws Screw for ring lug Screws
Cross section max. 6 mm2 6 mm2 2.5 mm2
Material: Pin/ socket carrier Polyamide Polyamide Polyamide
Contacts Brass (Ms) Brass (Ms) Brass, tin plated or gold plated (option)
1) Suitable for copper wires. For aluminium wires, please contact AUMA
12
8.2 AUMA MATIC on wall bracket (accessory)

Figure 5: AM on wall bracket
.
The AUMA MATIC can also be mounted separately from the actuator on a
wall bracket.
For the connection of actuator and AUMA MATIC on wall bracket, use suit-
.
able flexible and screened connecting cables
(Connecting cables are available on request.).
.
Permissible cable distance between actuator and AUMA MATIC amounts
to a max. of 100 m.
.
Versions with potentiometer in the actuator are not suitable. Instead of the
potentiometer, an RWG has to be used in the actuator.
Connect the wires to the actuator in correct phase sequence.
Check the direction of rotation before switching on (see page 21).
Connecting cable to actuator
8.3 Heater AUMA part-turn actuators have a heater installed as standard. Unless
ordered otherwise, the heater is internally supplied.
8.4 Motor protection In order to protect against overheating and impermissibly high temperatures
at the actuator, PTC thermistors or thermoswitches are embedded in the
motor winding. The thermoswitch is tripped as soon as the max. permissible
winding temperature has been reached.
8.5 Remote position transmitter For the connection of remote position transmitters (potentiometer, RWG),
screened cables must be used.
.
8.6 Fitting the cover After connection:
..
Insert the socket carrier (51.0) into the plug cover (50.0) and fasten it with
screws (51.01).
..
Clean sealing faces at the plug cover and the housing.
.
Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.
Replace plug cover (50.0) and fasten bolts (50.01) evenly crosswise.
Fasten cable glands with the specified torque to ensure the required
enclosure protection.
13
9. Setting the end stops for part-turn actuators on butterfly valves

For actuators on ball valves refer to page 15, clause 10.
The settings can only be performed if the valve has not yet been mounted in
.
a pipeline.
If part-turn actuators are supplied without a valve:
. hex. bolts (03, figure 6) are not fastened.

If part-turn actuators are supplied with a valve:
hex. bolts (03, figure 6) are fastened.
End stops and limit switching have already been set and
only have to be checked.
.
.
9.1 Setting end stop CLOSED If hex. bolts (03, figure 6) are fastened:
loosen by approx. 3 turns.
Turn handwheel clockwise (closing direction), until valve is closed
(end position CLOSED).
.
Check whether end stop (10) has rotated, otherwise turn end stop (10)
clockwise up to the stop.
.
In case end position CLOSED has been passed:
reverse several turns at the handwheel and approach end position again.
Turn end stop (10) by 1/8 turn counterclockwise
(Protective cap (16) must not be loosened in the process.).
The end stops are designed for the protection of the valve.
They have to be set as to ensure that they are not used
.
during normal operation.
Fasten hex. bolts (03) crosswise with torque 25 Nm.
Figure 6: Setting end stop CLOSED
16 10
03
9.2 Setting end stop OPEN The swing angle has been set in the factory. Therefore, the end stop OPEN
need not be set.
9.3 Setting limit switching After setting the end stop CLOSED, the limit switching for end position
CLOSED CLOSED can be set immediately (page 18, clause 13.). For this, the switch
compartment has to be opened and the indicator disc has to be removed
(refer to page 17, clause 12.).
14
10. Setting the end stops for part-turn actuators on ball valves
For actuators on butterfly valves refer to page 14, clause 9.
The settings can only be performed if the valve has not yet been mounted in
.
a pipeline.
If part-turn actuators are supplied without a valve:
. hex. bolts (03, figure 7) are not fastened.

If part-turn actuators are supplied with a valve:
hex. bolts (03, figure 7) are fastened.
End stops and limit switching have already been set and
only have to be checked.
.
.
10.1 Setting end stop OPEN If hex. bolts (03, figure 7) are fastened:
loosen by approx. 3 turns.
Turn handwheel counterclockwise (opening direction), until valve is open
(end position OPEN).
.
Check whether end stop (10) has rotated, otherwise turn end stop (10)
counterclockwise up to the stop.
In case end position OPEN has been passed:
.
reverse several turns at the handwheel and approach end position OPEN
again.
Turn end stop (10) by 1/8 turn clockwise.
(Protective cap (16) must not be loosened in the process).
The end stops are designed for the protection of the valve.
They have to be set as to ensure that they are not used
.
during normal operation.
Fasten hex. bolts (03) crosswise with torque 25 Nm.
Figure 7: Setting end stop OPEN
16 10
03
10.2 Setting end stop CLOSED The swing angle has been set in the factory. Therefore, the end stop
CLOSED need not be set.
10.3 Setting limit switching OPEN After setting the end stop OPEN, the limit switching for end position OPEN
can be set immediately (page 18, clause 13.). For this, the switch compart-
ment has to be opened and the indicator disc has to be removed
(refer to page 17, clause 12.).
15
11. Changing the swing angle The swing angle only has to be changed if the swing range for setting the
end stops (clauses 9. and 10.) is not sufficient.
Unless ordered otherwise, the swing angle is set to 90.

In the standard version, the swing angle can be adjusted within the range of
80 to 110.
For optional swing angle ranges, refer to Technical data, page 5.
11.1 Increasing the swing angle .. Unscrew protective cap (16) (figure 8).
.
While holding end stop nut (2.4) in position with open end wrench
(19 mm), remove grub screw (2.02).
..
Turn end stop nut (2.4) counterclockwise.
Do not exceed dimension A max. (table 3).
..
Move valve manually to the desired end position OPEN.
Turn end stop nut (2.4) clockwise until it is tight up to the stop nut (7).
Degrease face of grub screw (2.02).
..
Hold end stop nut in position (2.4) with open end wrench (19 mm) and
fasten grub screw (2.02) with torque 85 Nm.
Check O-ring (016) and replace if damaged.
Replace protective cap (16).
Figure 8: Setting the swing angle

16 2.4 7
2.02 016
A min.
max.
Table 3
Type A min. [mm] A max. [mm]
SG 05.1/ SGR 05.1 10 22
SG 07.1/ SGR 07.1 10 22
SG 10.1/ SGR 10.1 8 17
SG 12.1/ SGR 12.1 12 23
11.2 Reducing the swing angle .. Unscrew protective cap (16) (figure 8).
..
While holding end stop nut (2.4) in position
with open end wrench (19 mm), remove grub screw (2.02).
Move valve into the desired end position OPEN.
..
Turn end stop nut (2.4) clockwise until it is tight up to the stop nut (7) and
do not fall below dimension A min.
Degrease face of grub screw (2.02).
..
Hold end stop nut in position (2.4) with open end wrench (19 mm) and
fasten grub screw (2.02) with torque 85 Nm.
Check O-ring (016) and replace if damaged.
16
12. Opening the switch To be able to carry out the following settings (clauses 13. to 19.), the switch
compartment compartment must be opened and the indicator disc must be removed.
These settings are only valid for clockwise closing, i.e. driven shaft turns
clockwise to close the valve.

.
12.1 Removing the cover from the switch compartment
Remove 4 bolts and take off the cover at the switch compartment (figure 9).
Figure 9: Cover with indicator glass
12.2 Pulling off the indicator disc

. Pulling off the indicator disc (figure 10). Open end wrench
(approx. 14 mm) may be used as lever.
Figure 10: Pulling off the indicator disc
RSD
RDW
Indicator disc
17
13. Setting the limit switching
..
13.1 Setting end position CLOSED (black section)
Turn handwheel clockwise until valve is closed.

To prevent that the end stop is reached (due to overrun) before the limit
switch has tripped, turn handwheel 4 turns (overrun) in counterclockwise
.
direction. During test run check overrun and, if necessary, correct setting
of the limit switching.
Press down and turn setting spindle A (figure 11) with screw driver
(5 mm) in direction of arrow, thereby observe pointer B.
While a ratchet is felt and heard, the pointer B moves 90 every time.
When pointer B is 90 from mark C, continue turning slowly.
When pointer B has reached the mark C, stop turning and release setting
A D
T P
B E
C F
..
13.2 Setting end position OPEN (white section)
Turn handwheel counterclockwise until valve is open.

To prevent that the end stop is reached (due to overrun) before the limit
switch has tripped, turn handwheel 4 turns (overrun) in clockwise direction.
.
During test run check overrun and, if necessary, correct setting of the limit
switching.
Press down and turn setting spindle D (figure 11) with screw driver
(5 mm) in direction of arrow, thereby observe pointer E.
While a ratchet is felt and heard, the pointer E moves 90 every time.
When pointer E is 90 from mark F, continue turning slowly.
When pointer E has reached the mark F, stop turning and release setting
13.3 Checking the limit switches The red test buttons T and P (figure 11) are used for manual operation of
.
the limit switches.
.
Turning T in direction of the arrow LSC (WSR) triggers limit switch
CLOSED.
Turning P in direction of the arrow LSO (WL) triggers limit switch OPEN.
18
14. Setting of the DUO limit switching (option)

Any application can be switched on or off via the two intermediate position
switches.
For setting, the switching point (intermediate position) must

be approached from the same direction as afterwards in
..
14.1 Setting direction CLOSE (black section)

(5 mm) in direction of arrow, while observing pointer H.
While a ratchet is felt and heard, the pointer H moves 90 every time.
When pointer H is 90 from mark C, continue turning slowly. When pointer
H has reached the mark C, stop turning and release setting spindle. If you
T P
C F
H L
G K
..
14.2 Setting direction OPEN (white section)

(5 mm) in direction of arrow, while observing pointer L.
While a ratchet is felt and heard, the pointer L moves 90 every time.
When pointer L is 90 from mark F, continue turning slowly. When pointer
L has reached the mark F, stop turning and release setting spindle. If you
.
14.3 Checking the DUO The red test buttons T and P (figure 12) are used for manual operation of the DUO
limit switches limit switches.
Turning T in direction of the arrow TSC (DSR) triggers DUO limit switch
.
CLOSED.
The torque switch CLOSED is actuated at the same time.
.
Turning P in direction of the arrow TSO (DL) triggers DUO limit switch OPEN.
The torque switch OPEN is actuated at the same time.
After checking the switches, the fault (red indication light) has to be reset using
the OPEN or CLOSE push buttons of the local controls for operation in the
opposite direction.
19
15. Setting the torque switching
15.1 Setting .. The set torque must suit the valve!

This setting must only be changed with the consent of the
valve manufacturer!
Figure 13: Torque switching heads
Setting CLOSED Setting OPEN
O O O
15
9
9 13
P 11
15
11 13
.. Loosen both lock screws O at the torque dial (figure 13).

Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm).
Example:
Figure 13 shows the following setting:
.
11.5 da Nm = 115 Nm for direction CLOSE
12.5 da Nm = 125 Nm for direction OPEN
.
Tighten lock screws O again
The torque switches can also be operated in manual
. operation.
The torque switching acts as overload protection over full
travel, also when stopping in the end positions by limit
switching.
15.2 Checking the torque switches The red test buttons T and P (figure 11) are used for manual operation of
.
the torque switches:
Turning T in direction of the arrow TSC (DSR) triggers torque switch
.
CLOSED.
The red indication light (fault) on the local controls is illuminated.
Turning P in direction of the arrow TSO (DL) triggers torque switch
.
OPEN.
The red indication light (fault) on the local controls is illuminated.
.
If a DUO limit switching (optional) is installed in the actuator, the interme-
diate position switches will be operated at the same time.
After checking the switches, the fault (red indication light) has to be reset
using the OPEN or CLOSE push buttons of the local controls for operation
in the opposite direction.
20
16. Test run

16.1 Checking the direction This check is only necessary for mounting on wall bracket.
of rotation When the AUMA MATIC controls are mounted directly to the actuator, the
automatic phase correction ensures the correct direction of rotation, even if
.
the phases are crossed over during electrical installation.
Place indicator disc on shaft.

The direction of rotation of the indicator disc (figure 14) indicates the
direction of rotation of the output drive.
Figure 14: Indicator disc
OPEN CLOSED
.
.
Move actuator manually to intermediate position or to sufficient distance
from end position.
Figure 15: Selector switch LOCAL
.. Switch on the power supply.

Press push button CLOSE (figure 16) and observe the direction of rota-
tion:
If the indicator disc turns clockwise, the direction of rotation is correct.
Figure 16: Push button CLOSED Figure 17: Push button STOP
If the direction of rotation is wrong, switch off immediately.

Afterwards correct phase sequence in the connecting cable from
the wall bracket to the actuator and repeat test run.
21
.
16.2 Checking the setting of the limit switching
Set selector switch to position OFF (0) (figure 18).
Figure 18: Push button LOCAL
The controls power supply is maintained in position OFF.
.. Move actuator manually into both end positions of the valve.

Check if limit switching is set correctly for both end positions. Hereby
observe that the appropriate switch is tripped in each end position and
released again after the direction of rotation is changed. If this is not the
case, the limit switching must be set again.
..
When limit switching is set correctly:
Perform test run at the local controls via push buttons OPEN - STOP -
CLOSE.
.
16.3 Checking the type of seating The valve manufacturer states whether switching off in the end positions
should be by limit switch (limit seating) or torque switch (torque seating).
For checking the setting, refer to page 30, subclause 22.2.
.
If no other options (clauses 17. to 19.) require setting:
Close switch compartment (see page 27, clause 20.).
22
17. Setting the potentiometer (option)
..
For remote indication
.
Pull off indicator disc.
.
Turn potentiometer (E2) counterclockwise until stop is felt.
End position CLOSED corresponds to 0 %, end position OPEN to 100 %.
Turn potentiometer (E2) back a little.
Due to the ratio of the reduction gearings for the position

transmitter, the complete resistance range is not always
utilized for the whole travel. Therefore, an external possi-
bility for adjustment (setting potentiometer) must be
.
provided.
Perform fine-tuning of the zero point at external setting potentiometer

(for remote indication).
E2
23
18. Setting the electronic position transmitter RWG (option)

For remote indication or external control
After mounting the part-turn actuator to the valve, check setting by

measuring the output current (see subclauses 18.1 or 18.2) and re-adjust, if
necessary.
Table 4: Technical data RWG 4020

Terminal plans KMS TP_ _ 4 / _ _ _ KMS TP _ 4 _ / _ _ _
KMS TP _ 5 _ / _ _ _
3- or 4- wire system 2-wire system
Output current Ia 0 20 mA, 4 20 mA 4 20 mA
Power Uv 24 V DC, 15 % 14 V DC + (I x RB),
supply smoothed max. 30 V
Max. input I 24 mA at 20 mA 20 mA
current output current
Max. load RB 600 W (Uv - 14 V) / 20 mA
The position transmitter board (figure 20) is located under the cover plate
(figure 21).
Figure 20: Positioner board
24
..
18.1 Setting 2-wire system 4 20 mA and 3- /4-wire system 0 20 mA
..
Connect voltage to electronic position transmitter.
Pulling off the indicator disc.
The circuit (external load) must be connected (observe

max. load RB), or the appropriate poles at the terminals
(refer to wiring diagram) must be linked, otherwise no
..

Figure 21
0 (0/4 mA) max. (20 mA)
Cover plate E2

0/4 20 mA 0/4 20 mA

Turn potentiometer 0 back until the following value is reached:
for 3- or 4-wire system: approx. 0.1 mA
..
for 2-wire system: approx. 4.1 mA.
This ensures that the signal remains above the dead and live zero point.
.
Set potentiometer max. to end value 20 mA.
Approach end position CLOSED anew and check minimum value
(0.1 mA or 4.1 mA). If necessary, correct the setting.

25
..
18.2 Setting 3- / 4- wire system 4 20 mA
..
Connect voltage to electronic position transmitter.
Pull off indicator disc.
The circuit (external load) must be connected (observe

max. load RB), or the appropriate poles at the terminals
(refer to wiring diagram) must be linked, otherwise no
..

Figure 22
0 (0/4 mA) max. (20 mA)
Cover plate E2

0/4 20 mA 0/4 20 mA
..
Turn back potentiometer 0 until a residual current of approx. 0.1 mA is
reached.
..
Set potentiometer max. to end value 16 mA.
Set potentiometer 0 from 0.1 mA to initial value 4 mA.
.
This results in a simultaneous shift of the end value by 4 mA, so that the
range is now 4 20 mA.
Approach both end positions anew and check setting. If necessary, correct
the setting.

26
19. Setting the mechanical position indicator

..
.
Place indicator disc on shaft.
..
Turn lower indicator disc (figure 23) until symbol CLOSED is in align-
ment with the mark on the cover (figure 24).
Move actuator to end position OPEN.
Hold lower indicator disc in position and turn upper disc with symbol
OPEN until it is in alignment with the mark on the cover.
Figure 23 Figure 24
Indicator disc
Mark
The indicator disc turns approx. 180 for a swing angle of 90.
20. Closing the switch compartment

..
..
Clean sealing faces of housing and cover
Check the part-turn actuator for damage to paint finish. If

27
21. Setting the operating time For part-turn actuators with 1-phase AC motors, the operating time can be
adjusted.

..
..
Remove motor cover (figure 25).
Set required operating time with potentiometer (figure 26).
..
Clean sealing faces of housing and motor cover.
Fit and fasten motor cover.
(For enclosure protection IP 68, the motor cover is additionally sealed with
thread sealing material.)
Check the part-turn actuator for damage to paint finish. If

Figure 25: Part-turn actuator with 1-phase AC motor
Motor cover
Figure 26: Setting the operating time

Operating time
potentiometer
STELLZEIT
OPERATING TIME
Z 026.161
Table 5: Operating times for 90

SG 05.1 5.6 to 45 seconds
SG 07.1 11 to 90 seconds
28
22. Actuator controls AUMA MATIC
Figure 27: Positions of the boards within the controls
Cover
Timer board
(option)
Cover plate
Interface board
Logic board
Positioner board
(option)
22.1 Functions of the diagnosis LEDs on the interface board (standard version)
V14 is illuminated: Phase failure and/ or motor protection tripped.

In combination with motor protection (PTC thermistor):
Reset by selector switch position III at local controls
V15 is illuminated: Torque fault: Torque switch operated in mid-travel
The LEDs STOP, CLOSE, OPEN indicate the available control commands
(only in selector switch position REMOTE).
Figure 28: Cover plate on interface board
29
22.2 Programming the logic board
The type of seating limit or torque seating (switch S1-2 and switch S3-2,
figure 29) must be determined by the valve manufacturer.
Figure 29: Logic board A2

Position 1:
Limit
seating
Position 2:
Torque
S3-2 seating
S2-2
Position 1:
Limit
S1-2 seating
Position 2:
Torque
seating
. Set desired programming according to table 6 at the switch S2-2.
Table 6
DIP switch S2-2 Programming
(ON = pressed)
Direction CLOSE Direction OPEN
Self-retaining REMOTE
Push-to-run operation REMOTE
Self-retaining LOCAL
Push-to-run operation LOCAL
activated deactivated
Blinker transmitter (option)
Torque fault: Torque switch trip- included not included

ping (in mid-travel) contained in
collective fault signal
30
22.3 EMERGENCY-OPEN and EMERGENCY-CLOSE signal (option)

(5th digit in wiring diagram MSP C, D, or P)
When an EMERGENCY run command is given the actuator operates the

valve to the predetermined end position (effective in all three selector switch
.
positions: LOCAL, OFF, REMOTE).
.
The input at terminal XK 1 (refer to wiring diagram) must be connected to
an NC contact (closed circuit principle) at + 24 V DC.
If EMERGENCY - OPEN or EMERGENCY - CLOSE signal is generally
not desired:
Take off cover plate and disconnect links B1 (for EMERGENCY - CLOSE)
and B2 (for EMERGENCY - OPEN).
Figure 30: Cover plate for EMERGENCY - OPEN or EMERGENCY - CLOSE option
Links: B1 (EMERGENCY - CLOSE) LED for
B2 (EMERGENCY - OPEN) EMERGENCY run command
B2
B1
31
23. Electronic positioner (option)

23.1 Technical data
Table 7: Technical data for positioner
Command signal (input signal E1, set value) 0/4 20 mA (Option: 0 5 V)
Feedback (input signal E2, actual value) 0/4 20 mA (Option: 0 5 V)
Sensitivity (dead band) E (P9) 0.5 % 2.5 %
Fine tuning Sens (P7)
min. 0.25 %
(useful for output speeds <16 rpm only)
Pause time t-off (P10) 0.5 10 s
Input resistance 250 Ohm
Modulating duty with stepping mode (not required for modulating setting):
Running time t-on (P8)
effective until error is 25 %; then set value is 0.5 15 s
automatically reduced by 3.
23.2 Setting The positioner in the actuator controls AUMA MATIC is programmed
according to the purchase order details and is set together with the actuator
prior to delivery.
Due to peculiarities of the regulating system not known beforehand, a read-
justment may become necessary. Before adjusting the positioner, the
.
programming of the positioner should be checked.
Check programming of the logic board according to subclause 22.2.
The self-retaining REMOTE function (see table 6) must be
.
switched off in conjunction with the positioner.
Take off cover plate (figure 31) and carry out required programming at
positioner board (figure 32) according to tables 8 and 9.
Prior to setting, it must be ensured that the circuit for the

position feedback E2 (see wiring diagram) is closed
(measuring device or link). In case of missing signal E2, the
LED (V10) E1/E2 < 4 mA (figure 31) is illuminated and the
positioner shows no reaction.
Figure 31: Cover plate positioner

V10 (red)
P10
P8
32

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
Meas. V27
points: V18
V10
E1{ MP4()
MP3(+) P10
E2{
MP2(+)
MP1()
S1-7
23.2.1 Setting type of signal The signal type (current/ voltage signal) of nominal value E1 and actual
value E2 is set in the factory and marked with a label on the cover plate of
the positioner (refer to figure 31).
If the setting is subject to a subsequent change, the marking also has to be
changed. Furthermore the wiring diagram indicated on the name plate of the
actuator controls also changes (see page 52).
Table 8: Possible settings

Programming
4 20 mA 4 20 mA
0 20 mA 0 20 mA
4 20 mA
05V
0 20 mA
4 20 mA
05V
0 20 mA
05V 05V
4 20 mA
0 10 V
0 20 mA
0 10 V 05V
33
23.2.2 Setting actuator behaviour on loss of signal
In case of a loss of signal of nominal value E1 or actual value E2, the reac-
tion of the actuator can be programmed via the switch S2-7. The complete
range of choices, however, is only available with signals 4 20 mA.
The following reactions are possible:

Fail as is:
Actuator stops immediately and remains in this position.
Fail close
Actuator moves the valve to the end position CLOSED.
Fail open:
Actuator moves the valve to the end position OPEN.
Table 9: Possible settings (recommended settings are shaded in grey)

Behaviour on loss of signal of Prerequisite1) Programming
E1 E2
fail as is 4 20 mA 4 20 mA
4 20 mA 4 20 mA
fail close
0 20 mA
4 20 mA
05V
4 20 mA 4 20 mA
fail open
0 20 mA
4 20 mA
05V
fail as is fail open 4 20 mA 05V
4 20 mA
05V
0 20 mA
fail close fail open 0 20 mA 4 20 mA
0 20 mA
0 20 mA
05V
05V
0 10 V
0 20 mA 4 20 mA
fail close fail as is
0 10 V 4 20 mA
1) During loss of signal, signals from 0 20 mA and 0 5 V may be misinterpreted since E1 or E2 (without any fault) can also
be 4 mA (end position CLOSED = 0 mA or 0 V) when working properly.
34
23.3 Positioner adjustment end position CLOSED (standard version)

..
Set selector switch (local controls) to position LOCAL.
..
Move multi-turn actuator by pressing push button to
end position CLOSED.
(figure 33).
.
Connect voltmeter to measuring points MP3 and MP4 (figure 33) for
measuring the nominal value (0 5 V).
.
Correct nominal value signal in control room.
Table 10
Possible LED display: Required setting in end position CLOSED:
Then

LED (V28 green) is
illuminated
If

LED (V27 yellow) LED (V27 yellow) is no longer illuminated.
is illuminated Then turn potentiometer 0 (P3) slightly to clockwise until

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
Meas. V27
points: V18
V10
E1{ MP4()
MP3(+) P10
E2{ MP1()
MP2(+)
S1-7
35
.
23.4 Positioner adjustment end position OPEN (standard version)
.
Run multi-turn actuator by pressing push button (local controls) to end
position OPEN.
actual value E2:
..
nominal value E1:
Table 11
LED display: Required setting in end position OPEN:
Turn potentiometer max. (P4) slightly counterclockwise until
Then
Turn potentiometer max (P4) clockwise until LED (V28 green)

LED (V28 green) is no longer illuminated.
If

LED (V28 green) is illuminated.
LED (V27 yellow)
is illuminated
LED (V28 green) is illuminated.
23.5 Setting the sensitivity .. Set selector switch at the local controls to position REMOTE.
Set command signal E1 according to label on cover plate (see figure 34).
.
The sensitivity (DE / dead band) is set to maximum value (2.5 %) in the
factory.
With the potentiometer DE (P9) the dead band can be increased by
turning clockwise. Left stop = small dead band (= high sensitivity). For a
.
precise setting of the dead band, a set point device with setting options in
the 0.1 mA range is required.
A better sensitivity (DEmin= 0.25 %) can be achieved by turning the potenti-
ometer P7 (sens) clockwise.
When setting DE, the following must be observed:

If the number of starts is too high, this will lead to unneces-
sary wear at the valve and actuator. Therefore the maximum
possible dead band acceptable for the process must be set.
To prevent exceeding the max. permissible number of starts (refer to Tech-

nical data sheets for modulating actuators) in extreme cases, a pause time
between 0.5 s (left stop) and 10s (right stop) may be set with the potentio-
meter t-off (P10).
36
Figure 34: Cover plate for positioner

V28 (green)
V27 (yellow)
V18 (red)
V10 (red)
P10
Figure 35: Cover plate for positioner A7

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
Meas. V27
points: V18
V10
E1{ MP4()
MP3(+) P10
E2{
MP2(+)
MP1()
S1-7
37
23.6 Positioner adjustment end position OPEN (inverse operation)
.
In standard version the maximum input signal (E1 = 20 mA) results in opera-
tion to end position OPEN.
.
By switching the code switch S3-7 (figure 36) to position 1 an inversion of
this signal definition (inverse operation) can be achieved.
.
In case an RWG (option) is installed, the connections 7 (red) and 5 (black)
on the positioner board (figure 20) of the actuator have to be exchanged.
In case a potentiometer is installed, (option) the connections 21 (red) and
22 (black) at the potentiometer must be interchanged.

..
..
Set selector switch (local controls) to position LOCAL.
Run actuator with push button to end position OPEN .
(figure 36).
.
LED (V10) E1/E2 4 < mA" (figures 34 or 36)
Connect voltmeter to measuring points MP3 and MP4 (figure 36) for
measuring the nominal value (0 5 V).
.
Correct nominal value signal in control room.
Table 12
Possible LED display: Required setting in end position OPEN:
Then

LED (V27 yellow)
is illuminated
If

LED (V28 green) LED (V28 green) is no longer illuminated.
38
.
23.7 Positioner adjustment end position CLOSED (inverse operation)
.
Run actuator with push button (local controls) to end position
CLOSED.
actual value E2:
When position feedback is set correctly the voltmeter shows 5 V.
..
Adjust position feedback according to clauses 17. and 18. and repeat
nominal value E1:
Table 13
LED display: Required setting in end position CLOSED:
Then
Turn potentiometer max (P4) clockwise until LED (V27 yellow)

LED (V27 yellow) is no longer illuminated.
If

Turn potentiometer max (P4) slightly counterclockwise until the
LED (V28 green)
is illuminated
the LED (V27 yellow) is illuminated.

P9 (E) S2-7
P7 (Sens) S3-7
P3 (0)
P4 (max)
V28
V27
Meas. V18
points: V10
MP4()
MP3(+) P10
MP2(+)
MP1()
S1-7
39
23.8 Positioner in Split Range version (option)

For Split Range, a modified version of the positioner is used. The standard
version is not suitable for Split Range operation.
Split Range operation is only possible with the position transmitter RWG.
23.8.1 Split Range: description of functions

In Split Range operation a set point is shared by up to four positioners. A
typical example is a pipeline with a bypass. The actuator mounted on the
bypass reacts in the lower range (0 10 mA), the actuator on the main
valve in the upper range (10 20 mA). Other values such as 4 12 mA and
12 20 mA can also be set.
23.8.2 Programming DIP 5 at code switch S1-7 must always be in position ON for Split Range
version.
Table 14: Possible settings for Split Range operation

Programming
Command signal Feedback1) via DIP switch S1-7
Setpoint E1 Actual value E2 (see figure 37)
4 12/12 20 mA 4 20 mA
0 10/10 20 mA 0 20 mA
4 12/12 20 mA
05V
0 10/10 20 mA
The further programming of the positioner via the code switches S2-7 and
S3-7 can be made in the same way as during normal operation.
23.8.3 Positioner adjustment (See also example further down the page)
for Split Range
. Supply the specified minimum input signal (nominal value E1) for the
.
positioner and check by measuring with voltmeter at the measuring points
MP3 and MP4 (figure 37).
Calculate setting value:
.
Initial value = E 1min [in Ampere] x 250 Ohm
Set initial value with potentiometer P5.
.
Supply specified maximum command signal (nominal value E1) and check
by measuring at the measuring points MP3 and MP4.
Connect voltmeter between measuring point M9 and measuring point
.
MP1.
Set 5 V with potentiometer P6.
.
Supply input signal E1 from minimum to maximum value and check the set
range 0 5 V at measuring point M9. If necessary, readjust with P5 or P6.
.
Apply the same procedure to the second actuators positioner and set
according to the specified nominal values E1.
After setting the Split Range operation, perform further readjustment as
described in subclause 23.3, page 35.
40
Figure 37: Positioner board A7, Split Range version

P9 (E)
P7 (Sens)
P3 (0) S2-7
P4 (max)
P6 S3-7
P5
Meas. points
V28 (green)
V27 (yellow)
V18 (red)
V10 (red)
E1{ P10
Meas. points
E2{
S1-7
Example:
Two actuators are to be operated in Split Range version. Actuator 1 must be
in position CLOSED with a nominal value signal E1 of 0 mA,
and in position OPEN with a signal of 10 mA.
Actuator 2 must be in position CLOSED with a nominal value signal of
.
10 mA, and in position OPEN with a signal of 20 mA.
.
supply E1 = 10 mA, set with P6 = 5V at M9 (measured against MP1).
.
supply E1 = 20 mA, set with P6 = 5V at M9 (measured against MP1).
Perform adjustments and settings for E2 etc. Afterwards the nominal value
E1 can be transmitted through both actuators (connected in series). When
operating within range E1 = 0 10 mA, actuator 1 moves, actuator 2
remains in end position CLOSED. When operating within range
E1 = 10 20 mA, actuator 2 moves, actuator 1 remains in end position
OPEN.
41
24. Timer (option) The timer board is used to increase the operating time for the entire or any
portion of the valve travel.
Example:
In order to avoid water hammer in long pipelines, stepping mode can be
.
chosen for any part of the travel.
.
Instead of the interface board the timer is installed in the actuator controls
AUMA MATIC.
Electronic timer is not possible in combination with positioner.
24.1 Function of the diagnosis LEDs (timer)
V14 is illuminated: Phase failure and/ or motor protection tripped, reset by

selector switch position III at local controls.
V15 is illuminated: Torque fault: Tripping torque was exceeded before
reaching the end position.
V21 is illuminated: Stepping mode in direction CLOSE is switched on.
V22 is illuminated: Stepping mode in direction OPEN is switched on.
42
24.2 Setting start and end of stepping mode via DUO limit switching (option)
Start and end of stepping mode can also be set via external switches
(use potential-free contacts).
..
Direction OPEN, first normal operation then stepping mode
Run valve in direction OPEN to the desired start of stepping mode.
Start of stepping mode in direction OFF is set correctly if the LED
V 22 off V22 on changes from off to on (see sketch on the left).
Start stepping mode OPEN
..
Direction CLOSE, first normal operation then stepping mode
Run valve in direction CLOSE to the desired start of stepping mode.
Start of stepping mode in direction CLOSE is set correctly if the LED
V 21 on V21 off changes from off to on (see sketch on the left).
Start stepping mode CLOSED Figure 39: Control unit
G K
..
Direction OPEN, first stepping mode then normal operation
Run valve in direction OPEN to the desired end of stepping mode.
(5 mm) in direction of arrow, thereby observe LED V22 (figure 38).
stepping normal operation
V 22 an V22 off (see sketch on the left).
End stepping mode OPEN
..
Direction CLOSE, first stepping mode then normal operation
Run valve in direction CLOSE to the desired end of stepping mode.
normal operation stepping
(5 mm) in direction of arrow, thereby observe LED V21 (figure 38).
V 21 off V21 on (see sketch on the left).
End stepping mode CLOSED
43
24.3 Setting ON and OFF times
ON and OFF times can be set independently of each other between 1 30

seconds at the 4 potentiometers R10 to R13.
Clockwise rotation: Time extension

Counterclockwise rotation: Time reduction
R10 (t-off) : OFF time in direction OPEN
R11 (t-on) : Running time in direction OPEN
R12 (t-off) : OFF time in direction CLOSE
R13 (t-on) : Running time in direction CLOSE

R 10 R 12
R 11 R 13
44
25. Fuses . Fuses (figures 41 and 42) are accessible after removal of
. the local control cover.

When exchanging the fuses, only fuses according to table
15 may be used.
Figure 41: Fuses on the signal and control board Figure 42: Fuses on the power supply board
1F1 1F2 F3 F4
Table 15
Switchgear Voltage supply Voltage output G fuses: (figures 41 and 42)
(mains voltage) (power supply unit)
F 1/F 2 F 3*) F 4*)
(Board A20, (Boards A2, (Boards A8,
refer to wiring dia- refer to wiring refer to wiring dia-
gram) diagram) gram)
24 V 1 A T; 500 V 1.6 A T; 250 V

500 V AUMA article no.:
115 V K002.277 0.4 A T; 250 V
Reversing
contactors
24 V 2 A FF; 660 V 1.6 A T; 250 V
> 500 V AUMA article no.: 500 mA T; 250 V
115 V K002.665 0.4 A T; 250 V
24 V 16 A FF; 500 V 1.6 A T; 250 V

Thyristors 500 V AUMA article no.:
115 V K001.189 0.4 A T; 250 V
Size 6.3 x 32 mm 5 x 20 mm 5 x 20 mm
*) according to IEC 60127-2/III
F1/F2: Primary fuses power supply unit
F3: Internal 24 V DC supply, RWG, logic board

F4: Internal 24 V AC supply (option: 115 V AC);
Heater, tripping device for PTC thermistors, control reversing
contactors
. After exchanging the fuses, screw local controls back on again.
Carefully lead cables back into the housing to prevent them

from jamming.
45
26. Enclosure protection IP 68 (option)

Definition According to DIN EN 60 259, the conditions for meeting the requirements of
enclosure protection IP 68 are to be agreed between manufacturer and
user.
..
AUMA actuators and controls in enclosure protection IP 68 meet the
following requirements according to AUMA:
..
Duration of submersion in water max. 72 hours
Head of water max. 6 m
Up to 10 operations during submersion
Modulating duty is not possible during submersion
Enclosure protection IP 68 refers to the interior of the actuators (motor,

gearing, switch compartment, controls, and terminal compartment).
Inspection AUMA actuators and controls in enclosure protection IP 68 undergo a
.
routine testing for tightness in the factory.
Cable glands For the entries of the motor and control cables, appropriate cable glands
in enclosure protection IP 68 must be used. The size of the cable glands
.
must be suitable for the outside diameter of the cables, refer to recommen-
dations of the cable gland manufacturers.
.
As standard, actuators and controls are delivered without cable glands.
For delivery, the threads are sealed with plugs in the factory.
When ordered, cable glands can also be supplied by AUMA at an addi-
.
tional charge. For this, it is necessary to state the outside diameter of the
cables.
.
The cable glands must be sealed against the housing at the thread with an
O-ring.
It is recommended to additionally apply a liquid sealing material (Loctite or
similar).
Commissioning
..
When commissioning, the following should be observed:
..
Sealing faces of housing and covers must be clean
O-rings of the covers must not be damaged
A thin film of non-acidic grease should be applied to sealing faces
..
Covers should be tightened evenly and firmly
After submersion Check actuator.

In case of ingress of water, dry actuator correctly and check for proper
function.
46
27. Applications in Ex zone 22 (option)

Part-turn actuators of type range SG 05.1 SG 12.1/ SGR 05.1 SGR 12.1
in version AUMA MATIC basically meet the requirements for applications in
dust hazardous locations of ZONE 22, in compliance with the ATEX
directive 94/9/EC.
The actuators are designed to meet enclosure protections IP 67 or IP 68

and fulfil the requirements of EN 50281-1-1:1998 section 6 Electrical
apparatus for use in presence of combustible dust hazards, requirements for
electrical equipment of category 3 protected by enclosures.
To comply with all requirements of EN 50281-1-1: 1998, the following points
.
must imperatively be observed:
In compliance with the ATEX directive 94/9/EC, the part-turn actuators
.
must be equipped with an additional identification II3D IP6X T150C.
The maximum surface temperature of the actuators, based on an ambient

temperature of + 40 C in accordance with EN 50281-1-1 section 10.4, is
150 C. In accordance with section 10.4, an increased dust deposit on the
equipment was not considered for the determination of the max. surface
.
temperature.
The correct connection of the thermoswitches or the PTC thermistors, as

well as the fulfilment of the type of duty and the technical data are
prerequisites for compliance with the maximum surface temperature of
.
part-turn actuators.
The connection plug may only be plugged in or pulled out when actuator
.
and controls are disconnected from the mains.
The cable glands used have also to meet the requirements of category
.
II3D and must at least comply with enclosure protection IP 67.
The actuators must be connected by means of an external ground

connection (accessory part) to the potential equalization or integrated into
.
a grounded piping system.
As a general rule, the requirements of EN 50281-1-1 must be respected in

dust hazardous locations. During commissioning, service, and mainte-
nance, respective special care as well as qualified and trained personnel
is required for the safe operation of part-turn actuators.
47
28. Maintenance After maintenance, check part-turn actuator for damage to paint finish. If
damage to paint-finish has occurred after mounting, it has to be touched up
to avoid corrosion. Original paint in small quantities can be supplied by
AUMA.
AUMA part-turn actuators require very little maintenance.

Precondition for reliable service is correct commissioning.
Seals made of elastomers are subject to ageing and must therefore regu-
larly be checked and, if necessary, be exchanged.
It is also very important that the O-rings at the covers are placed correctly
and cable glands fastened firmly to prevent ingress of dirt or water.
.
We recommend additionally:
.
If rarely operated, perform a test run about every 6 months. This ensures
that the actuator is always ready to operate.
Approximately six months after commissioning and then every year check
bolts between part-turn actuator and valve/gearbox for tightness. If
required, tighten applying the torques given in table 1, page 11.
29. Lubrication AUMA part-turn actuators are filled with grease for lifetime.
A change of grease or re-lubrication is not necessary.
48

AUMA actuators have an extremely long lifetime. However, they have to be
The actuators have a modular design and may therefore easily be disas-
..
sembled, separated, and sorted according to materials, i.e.:
..
electronic scrap
various metals
plastics
greases and oils
.
.
are hazardous to water and must not be released into the environment.
.
See disassembled material to a sound disposal or to separate recycling
according to materials.
31. Service AUMA offers extensive services such as maintenance and inspection for
actuators. Addresses of AUMA offices and representatives can be found on
page 56 and on the Internet (www.auma.com).
49
50
153.2
152.2 35.0
153.1
153.0
152.1 S1 / S2
153.3 36.1
connector
36.10 36.5
38.2.4
39.2.4 36.0 36.2 36.6
34.23
34.24
36.3.2 34.22
38.2.3
36.3.4
39.2.3 38.2.2 36.3.1 34.7
3-ph AC 34.8
39.2.2 38.0 34.9
39.2 1
with actuator controls AUMA MATIC AM 01.1
41
S1 / S2
39.0 32.0
S2
17.0
1-ph AC
21.0
S2
S1 / S2
34.0
3.0 S2
S2
S1 / S2
29.0
4.0
2.4
2.0
40.043
S2
S2
16 10.0
5.0
Sample name plate
40.0 40.43
SG 07.1-F7 - Actuator type
14
Comm. no.:1309533 - Commission number
32. Spare parts list part-turn actuator SG(R) 05.1 SG(R) 12.1 with plug/ socket
No: 3302MD 19302 - Works number

IP67 11 rpm - Enclosure protection/ output
T Close: 120-300Nm speed
T Open 120-300Nm Torque range in CLOSED /
Grease: F1 OPEN
auma CC
Temp.: -25C/+80 C - Lubricant

- Temperature range
Note:
Please state type and commission no. of the actuator (see name plate) when ordering spare parts. Delivered spare

1 E Housing 36.5 B Mechanical position indicator
2.0 B Worm shaft assly. Blinker transmitter including pins at wires
36.6* B (without impulse disc and insulation plate)
2.4 E End stop nut (included in sub-assembly 2.0)
3.0 B Manual drive worm assly. 36.10 E Cover plate
4.0 B Worm wheel 38.0 B Pin carrier (without pins)
5.0 B Mounting flange assly. 38.2.2 B Pin for motor
10.0 B Limit stop housing assly. 38.2.3 B Pin for controls
14 E Coupling 38.2.4 B Wire for protective earth
16 E Cap 39.0 B Plug cover assly.
17.0 B Torque finger assly. Socket carrier
39.2 B (complete with sockets)
21.0 B Limit drive finger assly.
29.0 B Manual drive bearing assly. Socket for motor
39.2.2 B (included in sub-assembly 39.2)
32.0 B Planetary gearing assly.
34.0 B Motor assly. Socket for control
Motor plug pin carrier
34.22 B (without pins) Socket for protective earth
34.23 B Pin for motor
34.24 B Pin for thermoswitch 40 B Handwheel assly.
34.7 B Motor brake 40.043 E Cap assly.
34.8 B Motor electronic board 40.43 B Ball handle assly.
34.9 B Cover plate 41 B Motor plug, socket assly.
35.0 B Cover assly. 152.1* B Potentiometer (without slip clutch)
36.0 B Control unit assly. (without switches) 152.2* B Slip clutch for potentiometer
36.1 B Torque switching head 153.0* B Electronic position transmitter (RWG)
36.2 B Heater 153.1* B Potentiometer for RWG (without slip clutch)
36.3.1 B Stud bolt for switches 153.2* B Slip clutch for RWG
Switch for limit/ torque switching 153.3* B Electronic board RWG
36.3.2 B (including pins at wires) S1 S Seal kit (small)
36.3.4 E Spacer S2 S Seal kit (large)
* not included in basic equipment Motor plug; motor directly wired to pin carrier (no. 52.0).
51
52
500.0
S1
008.2
008.0
008.1
009.0
006.1
006.2-1
006.0
006.2-2
with actuator controls AUMA MATIC AM 01.1
503.0 504.0 505.0 506.0 006.2
508.1
S1 004.0
33. Spare parts list controls AUMA MATIC
004.2
501.0
502.0
004.3
013.0
507.0 003.1
002.0
S1
003.2
S1
Sample name plate

001.0
003.0
AM 01.1 P:1.5kW - Type of controls
Comm. no:1309533 - Commission number
No.: 2302MA04225 - Works number
KMS: TP101/001 - Terminal plan actuator
MSP:1Q1-C3Q-F18E1 - Wiring diagram
3 ~ 400V IP67 - Mains voltage/ Enclosure protection 002.5 509.1
Controls: 24V DC - Control voltage
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Delivered spare
No. Designation No. Designation

001.0 Housing 008.1 Interface board
002.0 Local controls 009.0 Logic board
003.0 Local controls board 013.0 Adapter board
003.1 Primary fuse 500.0-1 Cover
003.2 Cover for fuse 501.0 Socket carrier (complete with sockets)
004.0 Switchgear 502.0 Pin carrier (without pins)
004.2 Carrier for contactors 503.0 Socket for control
004.3 Socket carrier (complete with sockets) 504.0 Socket for motor
006.0 Power supply unit including mounting plate 505.0 Pin for controls
006.1 Mounting plate for power supply unit 506.0 Pin for motor
006.2 Power supply unit 507.0 Plug cover
006.2-1 Secondary fuse F3 508.1 Reversing contactors
006.2-2 Secondary fuse F3 509.1 Padlock
008.0 Interface board S1 Seal kit
53
54
Index
A L S
Ambient temperature 7 Limit switching 18,19,22 Safety instructions 4
Local controls 22 Selector switch 22
B
Logic board 30 Self-retaining 30
Blinker transmitter 30
Loss of signal 34 Sensitivity 36
C Lubrication 48 Service 49
Certificate of Conformity 54 Signals 8
M
Collective fault signal 29,30 Spare parts list
Maintenance 4
Command signal 32,33,34 Controls 52
Manual operation 10
Corrosion protection 9,48 Part-turn actuator 50
Mechanical position indicator 27
Split Range Version 40
D Motor protection 13
Stepping mode
Declaration of Incorporation 54 Mounting to valve/ gearbox 11
Operating time 42
DUO limit switching 19 N Pause time 44
E Name plate 50,52 Storage 9
Electrical connection 12 Swing angle 16
O
Electronic position transmitter RWG T
Operating time 28
24 Technical data 5
2-wire system 25 P
Test run 21
3-/ 4-wire system 26 Packaging 9 Thermoswitches 13
EMERGENCY signal 31 Pause time 32,44 Timer 42
Enclosure protection IP 68 46 Position indicator 27 Torque setting 20
End stops 14 Position transmitter RWG 24 Transport 9
SG on ball valves 15 Positioner 32 Tripping torque 20
SG on butterfly valves 14 Potentiometer 23 Type of duty 5
PTC thermistors 13 Type of seating 30
F
Push-to-run operation 30
Fitting the ball handle 9
Fuses 45 R
Remote indication 23,24
H
Running time 32,44
Handwheel 10
Heater 13
I
Indicator disc 27
Interface board 29
Inverse operation 38,39
Information also available Wiring diagram, inspection records and further actuator information
on the Internet: can be downloaded directly from the Internet by entering the order no. or
comm. no. (refer to name plate).
Visit us at: http://www.auma.com
55
IBEROPLAN S.A. Suplibarca
Europe ES-28027 Madrid VE- Maracaibo Estado, Zulia
AUMA Riester GmbH & Co. KG Tel +34 91 3717130 Tel +58 261 7 555 667
Factory Mllheim iberoplan@iberoplan.com suplibarca@intercable.net.ve
DE-79373 Mllheim D. G. Bellos & Co. O.E.
Tel +49 7631 809 - 0 GR-13671 Acharnai Athens Asia
riester@auma.com Tel +30 210 2409485 AUMA Actuators (Tianjin) Co., Ltd.
www.auma.com info@dgbellos.gr CN-300457 Tianjin Teda District
Factory Ostfildern-Nellingen SIGURD SRUM A. S. Tel +86 22 6625 1310
DE-73747 Ostfildern NO-1301 Sandvika mailbox@auma-china.com
Tel +49 711 34803 - 3000 Tel +47 67572600 www.auma-china.com
riester@wof.auma.com post@sigurd-sorum.no AUMA (INDIA) PRIVATE LIMITED
Service Centre Cologne INDUSTRA IN-560 058 Bangalore
DE-50858 Kln PT-2710-297 Sintra Tel +91 80 2839 4655
Tel +49 2234 20379 - 00 Tel +351 2 1910 95 00 info@auma.co.in
Service@sck.auma.com jpalhares@tyco-valves.com www.auma.co.in
Service Centre Magdeburg MEGA Endstri Kontrol Sistemieri Tic. Ltd. Sti. AUMA JAPAN Co., Ltd.
DE-39167 Niederndodeleben TR-06460 vecler Ankara JP-210-0848 Kawasaki-ku, Kawasaki-shi
Tel +49 39204 759 - 0 Tel +90 312 472 62 70 Kanagawa
Service@scm.auma.com megaendustri@megaendustri.com.tr Tel +81 44 329 1061
AUMA Armaturenantriebe GmbH CTS Control Limited Liability Company mailbox@auma.co.jp
AT-2512 Tribuswinkel UA-02099 Kiyiv AUMA ACTUATORS (Singapore) Pte Ltd.
Tel +43 2252 82540 Tel +38 044 566-9971, -8427 SG-569551 Singapore
office@auma.at v_polyakov@cts.com.ua Tel +65 6 4818750
www.auma.at sales@auma.com.sg
AUMA (Schweiz) AG Africa www.auma.com.sg
CH-8965 Berikon AUMA South Africa (Pty) Ltd. AUMA Middle East Rep. Office
Tel +41 566 400945 ZA-1560 Springs AE- Dubai
RettichP.ch@auma.com Tel +27 11 3632880 Tel +971 4 3682720
AUMA Servopohony spol. s.r.o. aumasa@mweb.co.za auma@emirates.net.ae
CZ-10200 Praha 10 A.T.E.C. PERFECT CONTROLS Ltd.
Tel +420 272 700056 EG- Cairo HK- Tsuen Wan, Kowloon
auma-s@auma.cz Tel +20 2 3599680 - 3590861 Tel +852 2493 7726
www.auma.cz atec@intouch.com joeip@perfectcontrols.com.hk
OY AUMATOR AB DW Controls Co., Ltd.
FI-02270 Espoo America KR-153-803 Seoul Korea
Tel +35 895 84022 AUMA ACTUATORS INC. Tel +82 2 2113 1100
auma@aumator.fi US-PA 15317 Canonsburg sichoi@actuatorbank.com
AUMA France Tel +1 724-743-AUMA (2862) www.actuatorbank.com
FR-95157 Taverny Cdex mailbox@auma-usa.com AL-ARFAJ Eng. Company W. L. L.
Tel +33 1 39327272 www.auma-usa.com KW-22004 Salmiyah
stephanie.vatin@auma.fr AUMA Chile Respresentative Office Tel +965 4817448
www.auma.fr CL- Buin arfaj@qualitynet.net
AUMA ACTUATORS Ltd. Tel +56 2 821 4108 BEHZAD Trading Enterprises
GB- Clevedon North Somerset BS21 aumachile@adsl.tie.cl QA- Doha
6QH LOOP S. A. Tel +974 4433 236
Tel +44 1275 871141 AR-C1140ABP Buenos Aires behzad@qatar.net.qa
mail@auma.co.uk Tel +54 11 4307 2141 Sunny Valves and Intertrade Corp. Ltd.
www.auma.co.uk contacto@loopsa.com.ar TH-10120 Yannawa Bangkok
AUMA ITALIANA S.R.L. Asvotec Termoindustrial Ltda. Tel +66 2 2400656
IT-20023 Cerro Maggiore Milano BR-13190-000 Monte Mor/ SP. sunnyvalves@inet.co.th
Tel +39 0331-51351 Tel +55 19 3879 8735 www.sunnyvalves.co.th/
info@auma.it atuador.auma@asvotec.com.br Top Advance Enterprises Ltd.
www.auma.it TW- Jhonghe City Taipei Hsien (235)
TROY-ONTOR Inc.
AUMA BENELUX B.V. CA-L4N 5E9 Barrie Ontario Tel +886 2 2225 1718
NL-2314 XT Leiden Tel +1 705 721-8246 support@auma-taiwan.com.tw
Tel +31 71 581 40 40 troy-ontor@troy-ontor.ca www.auma-taiwan.com.tw
office@benelux.auma.com
www.auma.nl MAN Ferrostaal de Colombia Ltda.
CO- Bogot D.C.
Australia
AUMA Polska Sp. z o.o. Tel +57 1 401 1300 BARRON GJM Pty. Ltd.
PL-41-310 Dabrowa Grnicza dorian.hernandez@manferrostaal.com AU-NSW 1570 Artarmon
Tel +48 32 26156 68 www.manferrostaal.com Tel +61 294361088
R.Ludzien@auma.com.pl info@barron.com.au
www.auma.com.pl PROCONTIC Procesos y Control Automtico
www.barron.com.au
EC- Quito
OOO Priwody AUMA Tel +593 2 292 0431
RU-141400 Moscow region for mail: info@procontic.com.ec
124365 Moscow a/ya 11
Tel +7 495 221 64 28 IESS DE MEXICO S. A. de C. V.
aumarussia@auma.ru MX-C.P. 02900 Mexico D.F.
www.auma.ru Tel +52 55 55 561 701
informes@iess.com.mx
ERICHS ARMATUR AB
Corsusa S.A.C.
SE-20039 Malm
Tel +46 40 311550 PE- Miralflores - Lima
info@erichsarmatur.se Tel 00511444-1200 / 0044 / 2321
www.erichsarmatur.se corsusa@corsusa.com
www.corsusa.com
GRNBECH & SNNER A/S
PASSCO Inc.
DK-2450 Kbenhavn SV
Tel +45 33 26 63 00 PR-00936-4153 San Juan
GS@g-s.dk Tel +18 09 78 77 20 87 85
www.g-s.dk Passco@prtc.net
2006-04-20
P. O. Box 1362 P. O. Box 1151
D - 79373 Mllheim D - 73747 Ostfildern
Tel +49 (0)7631/809-0 Tel +49 (0)711 / 34803 0
Fax +49 (0)7631/809 250 Fax +49 (0)711 / 34803 34 Certificate Registration No.
riester@auma.com riester@wof.auma.com 12 100/104 4269
For detailed information on AUMA products refer to the Internet:

www.auma.com Y000.238/003/en/1.06
Part-turn gearboxes
Worm gearboxes
GS 50.3 GS 250.3

12 100/104 4269
Worm gearboxes GS 50.3 GS 250.3 Operation instructions
Scope of these instructions: These operation instructions are valid for worm gearboxes of the type range
GS 50.3 GS 125.3 with primary reduction gearings VZ 2.3 VZ 4.3. and
GS 160.3 GS 250.3 with primary reduction gearings GZ 160.3 250.3.

1.2 Maintenance 3
2. Technical data 4
3.1 Transport 7
3.2 Storage 7
3.3 Packaging 7
4. Fitting of handwheel 7
5. Mounting positions of the different versions 8
6. Mounting of multi-turn actuators SA/SAR 9
7. Mounting to valve 11
8. Setting the end stops for manual operation 12
8.1 Worm gearboxes on butterfly valves 12
8.2 Worm gearboxes on ball valves 13
9. Setting the end stops with mounted multi-turn actuator 13
9.1 Worm gearboxes on butterfly valves 13
9.2 Worm gearboxes on ball valves 14
10. Changing the swing angle 16
10.1 Changing the swing angle for sizes GS 50.3 GS 125.3 (option) 16
10.2 Changing the swing angle for sizes GS 160.3 GS 250.3 17
11. Enclosure protection IP 68 18
12. Maintenance 19
12.1 General notes 19
12.2 Grease change for worm gearboxes GS 50.3 GS 125.3 and primary reduction gearing
VZ 2.3 VZ 4.3 20
12.2.1 Worm gearboxes 20
12.2.2 Primary reduction gearing 20
VZ 160.3 VZ 250.3 21
12.3.1 Worm gearboxes 21
12.3.2 Single-stage reductions gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1 and 8:1) 21
12.3.3 Double-stage primary reduction gearing GZ 200.3 GZ 250.3 (reduction ratio 16:1) 22
12.4 After maintenance 22
14. Service 23
15. Spare parts list worm gearboxes GS 50.3 GS 125.3 and reduction gearing VZ 2.3 VZ 4.3 24
16. Spare parts list worm gearboxes GS 160.3 GS 250.3 26
17. Spare parts list reduction gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) 28
Index 31
2
Operation instructions Worm gearboxes GS 50.3 GS 250.3
1.1 Range of application AUMA worm gearboxes GS 50.3 GS 250.3 are used for the operation of
valves (e.g. butterfly valves and ball valves).
They are designed for manual operation as well as motor operation in
conjunction with electric actuators.
Observance of these operation instructions is considered as part of the
gearboxes designated use.
1.2 Maintenance The maintenance instructions (refer to page 19) must be observed, other-
wise a safe operation of the worm gearbox is no longer guaranteed.
1.3 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries or
Correct transport, proper storage, mounting and installation, as well as
careful commissioning are essential to ensure a trouble-free and safe oper-
ation.
pictograph.

Note marks activities or procedures which have major influence on the
correct operation. Non-observance of these notes may lead to consequen-
tial damage.

3
2. Technical data
Version Standard: clockwise rotation RR, counterclockwise rotation LL, option: RL or LR
Housing material Standard: cast iron (GJL-250), Option: spheroidal cast iron (GJS-400-15)
Self-locking The gearboxes are self-locking when at stand-still under normal service conditions; strong
vibrations may cancel the self-locking effect. While in motion, safe breaking is not
guaranteed. If this is required, a separate brake must be used.
Output torques Type Output torques

100 % 140 % 175 %1) 200 %1) Modulating torque2)
max. Nm max. Nm max. Nm max. Nm max. Nm
GS 50.3 250 350 500 125
GS 63.3 500 700 1,000 250
GS 80.3 1,000 1,400 2,000 500
GS 100.3 2,000 2,800 4,000 1,000
GS 125.3 4,000 5,600 8,000 2,000
GS 160.3 8,000 11,250 14,000 4,000
GS 200.3 16,000 22,500 28,000 8,000
GS 250.3 32,000 45,000 56,000 16,000
End stops Positive for both end positions by travelling nut, sensitive adjustment
Strength of end stop Guaranteed strength of end stop (in Nm) for input side operation
Type GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
Reduction gearing VZ 2.3 VZ 3.3 VZ 4.3 VZ 2.3 VZ 3.3 VZ 4.3
Nm 250 450 450 500 250 500 250
Type GS 160.3 GS 200.3 GS 250.3

Reduction gearing GZ 160.3 GZ 200.3 GZ 250.3
Reduction ratio 4:1 8:1 4:1 8:1 16:1 4:1 8:1 16:1
Nm 500 450 500 500
Swing angle Standard: Fixed swing angle up to max. 100; set in the factory to 92 unless ordered
GS 50.3 GS 125.3 otherwise.
Options: Adjustable in steps of:
10 35, 35 60, 60 80, 80 100, 100 125, 125 150,
150 170, 170 190
For version with worm wheel made of bronze: swing angle > 190,
Multi-turn version without end stops, version GSD
Swing angle Standard: Adjustable 80 - 100; set in the factory to 92 unless ordered otherwise.
GS 160.3 GS 250.3 Options: Adjustable in steps of: 20 40, 40 60, 60 80,
For version with worm wheel made of bronze: swing angle > 100,
Multi-turn version without end stops, version GSD
Mechanical position indicator Standard: Pointer cover for continuous position indication
Options: Sealed pointer cover for horizontal outdoor installation3)
Protection cover for buried service instead of pointer cover
Input shaft Cylindrical with parallel key according to DIN 6885.1
Operation
Motor operation With electric multi-turn actuator, directly or through primary reduction gearing VZ/ GZ
Flanges for mounting of actuator, refer also to separate Technical data sheets.
Type of duty According to actuator
Manual operation Via handwheel, directly or through primary reduction gearing VZ/ GZ
Available handwheel diameters, selection according to the max. output torque:
Type GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
Reduction gearing VZ 2.3 VZ 3.3 VZ 4.3 VZ 2.3 VZ 3.3 VZ 4.3
Handwheel 160 250 315 400 315 315 250 500 400 400 315
mm 200 315 400 500 400 400 315 630 500 500 400
250 800
Type GS 160.3 GS 200.3 GS 250.3

Reduction gearing GZ 160.3 GZ 200.3 GZ 250.3
Handwheel 630 400 315 500 400 315 800 500 400
mm 800 630 630
1) With worm wheel made of spheroidal cast iron

2) Requires worm wheel made of bronze
3) For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided
4
Primary reduction gearing

Primary reduction gearing Planetary gear with various reduction ratios for reducing the input torques
Valve attachment
Valve attachment Dimensions according to EN ISO 5211
Standard: GS 50.3 GS 125.3: without spigot
GS 160.3 GS 250.3: with spigot
Options: GS 50.3 GS 125.3: with spigot
GS 160.3 GS 250.3: without spigot
Splined coupling for connection Standard: without bore or pilot bore from GS 160.3
to the valve shaft Worm gearbox can be repositioned 4 x 90 on coupling
Options: Machined with bore and keyway, square bore or bore with two-flats
Service conditions
Enclosure protection according Standard: IP 68-3, dust and water tight up to max. 3 m head of water
to EN 60 5294) Options5): IP 68-6, dust and water tight up to max. 6 m head of water
IP 68-10, dust and water tight up to max. 10 m head of water
IP 68-20, dust and water tight up to max. 20 m head of water
Paint Standard: GS 50.3 GS 125.3: Two-component iron-mica combination
GS 160.3 GS 250.3: Primer coating
Option: GS 160.3 GS 250.3: Two-component iron-mica combination
Colour Standard: Grey (DB 702, similar to RAL 9007)
Option: Other colours on request
Ambient temperature Standard: 25 C to + 80 C
Options: 40 C to + 60 C (low temperature), version L
60 C to + 60 C (extreme low temperature), version EL
0 C to + 120 C (high temperature), version H
Lifetime Open-close duty: The lifetime is based on a load profile typical for part-turn valves
Type Operating cycles (OPEN - CLOSE - OPEN)
for swivel movements of 90 (max. 100)
and a maximum output torque of
100 % 140 % 175 %6) 200 %6)
GS 50.3 15 000 5 000 1 000
GS 63.3 15 000 5 000 1 000
GS 80.3 15 000 5 000 1 000
GS 100.3 15 000 5 000 1 000
GS 125.3 15 000 5 000 1 000
GS 160.3 15 000 5 000 1 000
GS 200.3 15 000 5 000 1 000
GS 250.3 10 000 3 000 750
Modulating duty: min. 2.5 million operations7)
4) Refer to clause enclosure protection IP 68

5) Not available for GS 50.3
6) With worm wheel made of spheroidal cast iron
7) The lifetime for modulating duty depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach
the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process
5
Accessories
Valve position indicators Valve position indicator WSG for the signalisation of intermediate and end positions for
precise and low-backlash feedback for swing angles ranging from 82 98
(refer to separate data sheet)
Valve position indicator WGD for signalisation of intermediate and end positions for swing
angles > 180 (refer to separate data sheet)
Limit switching Limit switching WSH for manually operated valves. For the signalisation of intermediate and
end positions (refer to separate data sheet)
Special features for use in potentially explosive atmospheres
Explosion protection II2G c IIC T4 according to ATEX 94/9/EC
Type of duty Short-time duty S2 - 15 min., max. 3 cycles (OPEN - CLOSE - OPEN) 90, then cool-down
to ambient temperature
Intermittent duty S4 - 25 % up to the maximum modulating torque
Swing angle Swing angle > 90 on request
Ambient temperature Standard: 20 C to + 40 C
Options: 40 C to + 40 C (low temperature)
20 C to + 60 C
40 C to + 60 C (low temperature)
50 C to + 60 C (extreme low temperature)
60 C to + 60 C (extreme low temperature)
Combinations with actuators SA(R)ExC at ambient temperatures > 40 C with special sizing
Further information
Reference documents Product description Worm gearboxes GS 50.3 GS 250.3 / GS 315 GS 500
Dimension sheets GS 50.3 GS 125.3, GS 160.3 GS 250.3
Technical data GS 50.3 GS 125.3, GS 160.3 GS 250.3
Technical data SA, SAR, WSG, WGD, WSH
Lever gearboxes See separate documents
6
3. Transport, storage and packaging
3.1 Transport .. Transport to place of installation in sturdy packing.

If mounted together with actuator:
Attach ropes or hooks for the purpose of lifting by hoist only to the
gearbox and not to the actuator.
3.2 Storage .. Store in well-ventilated, dry room.
..
Protect against floor dampness by storage on a shelf or on a
wooden pallet.
In case worm gearboxes are to be stored for a long period
.
(more than 6 months), the following points must be observed additionally:
.
and mounting surface, with long-term corrosion protection agent.
3.3 Packaging Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can
easily be separated and recycled.
For the disposal of the packaging material, we recommend recycling and
collection centres.
We use the following packaging materials:
Wooden material boards (OSB)/ cardboard/ paper/ PE film
4. Fitting the handwheel For worm gearboxes designed for manual operation the handwheel is
supplied separately. Fitting is done on site according to figure 1.
Figure 1: Handwheel
Ball handle
Spacer (option)
(may be required)
Spacer
Circlip (may be required)
Circlip
Worm shaft gearbox Handwheel
7
5. Mounting positions of the different versions
RR LL RL LR
Description of the 4 versions (viewed at the pointer cover):
Code Direction of rotation at input shaft Position of worm shaft Direction of rotation at output drive
RR clockwise Right side clockwise
LL clockwise Left side counterclockwise
RL clockwise Right side counterclockwise
LR clockwise Left side clockwise
Mounting positions of AUMA multi-turn actuator with AUMA worm gearbox (please indicate when ordering)
GS versions RR / RL
RR RR RR RR
RL RL RL RL
A B C D
GS versions LL / LR
LL LL LL LL
LR LR LR LR
A B C D
Mounting positions can easily be changed at a later date.
Limitation: For SA/ SAR 14.1/ 14.5 with GS 125.3, mounting position C in version RR/ RL and A in version LL/ LR
is only possible for a handwheel diameter up to 315 mm.
Up to size GS 125.3, the actuator-gearbox combination is delivered in the ordered mounting position. For packing
reasons, actuator and gearbox will be delivered separately from size GS 160.3.
8
6. Mounting multi-turn actuators SA/SAR

When gearboxes and multi-turn actuators are supplied together, the
mounting has been done in the factory up to gearbox size GS 125.3. For
sizes GS 160.3 and larger, the mounting of gearboxes is performed as
follows.
.
In case flange for actuator is not attached to gearbox or
reduction gearing:
..
Thoroughly degrease the mounting faces of the gearbox or reduction
gearing as well as the flange for actuator.
Fit flange for actuator and fasten with bolts and lock washers.
Fasten bolts crosswise with a torque according to table 2.
Figure 2: Mounting multi-turn actuator to worm gearbox
Flange for actuator
Bearing flange
Flange for actuator
Primary reduction
gearing
Bearing flange
.
Mounting the multi-turn actuator:
.
Thoroughly degrease the faces of the flange for actuator at the gearbox or
reduction gearing as well as the actuators bearing flange.
Place the multi-turn actuator on the worm gearbox or reduction gearing.
.
The multi-turn actuator can be mounted on the valve at every 90
(see page 8, mounting positions).
.
Ensure that the spigot mates uniformly in the recess and that the
mounting faces are in complete contact.
.
Fasten actuator with bolts and lock washers (see table 1) at the flange of
the worm gearbox.
Do not attach ropes or hooks for the purpose of lifting the

actuator by hoist to the handwheel. If multi-turn actuator is
mounted on gearbox, attach ropes or hooks for the purpose
of lifting by hoist to gearbox and not to multi-turn actuator.
9
Table 1: Bolts for mounting AUMA actuators to worm gearboxes/ primary reduction gearing
(strength class min. 8.8)
Worm gearbox/ SA(R) 07.1-F07 SA(R) 07.1-F10/G0 SA(R) 07.5-F07 SA(R) 07.5-F10/G0
primary Lock
reduction gearing Lock Lock Lock
Bolt Pcs. Bolt Pcs. Bolt washe Pcs. Bolt Pcs.
washer washer washer
r
GS 50.3 M 8 x 20 B8 4 M 10 x 25 B 10 4
GS 63.3 M 8 x 20 B8 4 M 10 x 25 B 10 4 M 8 x 20 B8 4 M 10 x 25 B 10 4
GS 80.3 M 8 x 20 B8 4 M 10 x 25 B 10 4
GS 100.3
GS 100.3/VZ M 10 x 25 B 10 4 M 10 x 25 B 10 4
GS 125.3
GS 125.3/VZ M 10 x 25 B 10 4
GS 160.3
GS 160.3/GZ M 10 x 25 B 10 4
GS 200.3
GS 200.3/GZ M 10 x 25 B 10 4
Worm gearbox/ SA(R) 10.1-F10/G0 SA(R) 14.1-F14/G SA(R) 14.5-F14/G SA(R) 16.1-F16/G3
primary Lock Lock Lock Lock
reduction gearing Bolt Pcs. Bolt Pcs. Bolt Pcs. Bolt Pcs.
washer washer washer washer
GS 63.3 M 10 x 25 B 10 4
GS 80.3 M 10 x 25 B 10 4
GS 100.3 M 10 x 25 B 10 4 M 16 x 40 B 16 4
GS 100.3/VZ M 10 x 25 B 10 4
GS 125.3 M 16 x 40 B 16 4 M 16 x 40 B 16 4
GS 125.3/VZ M 10 x 25 B 10 4 M 16 x 40 B 16 4
GS 160.3 M 16 x 40 B 16 4 M 20 x 50 B 20 4
GS 160.3/GZ M 10 x 25 B 10 4 M 16 x 40 B 16 4
GS 200.3 M 20 x 50 B 20 4
GS 200.3/GZ M 10 x 25 B 10 4 M 16 x 40 B 16 4 M 16 x 40 B 16 4
GS 250.3
GS 250.3/GZ M 10 x 25 B 10 4 M 16 x 40 B 16 4 M 16 x 40 B 16 4 M 20 x 50 B 20 4
Worm gearbox/ SA(R) 25.1-F25 SA(R) 30.1-F30

primary Lock Lock
reduction gearing Bolt Pcs. Bolt Pcs.
washer washer
GS 160.3
GS 160.3/GZ
GS 200.3 M 16 x 50 B 16 8
GS 200.3/GZ
GS 250.3 M 16 x 50 B 16 8 M 20 x 50 B 20 8
GS 250.3/GZ
10
7. Mounting to valve AUMA worm gearboxes GS and primary reduction gearings VZ/ GZ can be
.
operated in any mounting position.
For butterfly valves, the recommended mounting position is end position
CLOSED
.
(Prior to mounting, bring the gearbox to the mechanical end stop
CLOSED by turning the handwheel clockwise).
For ball valves, the recommended mounting position is end position
OPEN
(Prior to mounting, bring the gearbox to the mechanical end stop OPEN
..
by turning the handwheel counterclockwise).
Thoroughly degrease mounting faces of gearbox and valve.
..
Place coupling sleeve onto valve shaft and secure (refer to figure 3, detail A
or B), ensure that dimensions X, Y, and Z are observed (refer to table 2).
..
Mount gearbox on valve. Ensure that the spigot (if provided) mates
uniformly in the recess and that the mounting faces are in complete contact.
Fasten gearbox with bolts (quality min. 8.8) and lock washers.
Figure 3
A B
Coupling
Grub screw
Z
X Y
Valve
Table 2: Fastening torques for bolts with different strength classes

Gearbox Dimensions Bolts Strength class Strength class Strength class
8.8 A2-70/A4-70 A2-80/A4-80
Flange type X max Y max Z max Qty. x threads Fastening torque TA [Nm]
GS 50.3-F05 6 5 65 4xM 6 11 8 10
GS 50.3-F07 14 5 61 4xM 8 25 18 24
GS 50.3-F10 14 5 61 4 x M 10 51 36 48
GS 63.3-F10 7 18 73 4 x M 10 51 36 48
GS 63.3-F12 10 13 76 4 x M 12 87 61 82
GS 80.3-F12 13 18 78 4 x M 12 87 61 82
GS 80.3-F14 23 5 88 4 x M 16 214 150 200
GS 100.3-F14 22 13 123 4 x M 16 214 150 200
GS 100.3-F16 22 8 123 4 x M 20 431 294 392
GS 125.3-F16 17 35 126 4 x M 20 431 294 392
GS 125.3-F25 17 27 126 8 x M 16 214 150 200
GS 160.3-F25 15 11 130 8 x M 16 214 150 200
GS 160.3-F30 30 0 140 8 x M 20 431 294 392
GS 200.3-F30 19 19 160 8 x M 20 431 294 392
GS 200.3-F35 44 0 190 8 x M 30 (1489) 564
GS 250.3-F35 8 8 220 8 x M 30 (1489) 564
GS 250.3-F40 13 0 230 8 x M 36 (2594)
Note:
Experience showed that it is very difficult to fasten bolts or nuts of M30 or
larger with the defined torques. The worm gearbox may be moved radially
against the valve flange by accident.
To improve adhesion between valve and gearbox, we recommend to apply
Loctite 243 (or similar products) on mounting faces.
11
8. Setting the end stops for manual operation

If worm gearboxes GS are supplied on a valve the end stops
are already set.
..
8.1 Worm gearboxes on butterfly valves
Setting end position CLOSED Remove all bolts (03) at limit stop housing (figures 4, 5).
. Turn valve manually to end position CLOSED.
.
In case limit stop housing (10) has not yet rotated, turn it clockwise up to
the stop.
If the holes of limit stop housing (10) do not align with the threads of the
..
housing (1), take off the limit stop housing (10) and replace it in the
required position.
Fasten bolts (03) with lock washers (04).
Fasten bolts (see table 3) crosswise with a torque according to table 2.
Table 3:
Gearbox End stops fastened Material Protective cap fas- Material
with tened with
bolts (03) bolts (054)
GS 50.3 M8 A2-80
GS 63.3 M8 A2-80
GS 80.3 M8 A2-80
GS 100.3 M12 A2-80
GS 125.3 M12 A2-80
GS 160.3 M10 A2-80 M6 A2-80
GS 200.3 M12 A2-80 M6 A2-80
GS 250.3 M16 A2-80 M6 A2-80
Figure 4: End stop up to GS 125.3 Figure 5: End stop from GS 160.3
03/04
03/04
.
10 1 10 1
If the position of the pointer cover does not correspond to the symbol
CLOSED, slightly loosen the screws of the pointer cover. Turn the pointer
cover to the CLOSED symbol and fasten the screws again.
Setting end position OPEN The end stop need not be set since the required swing angle has been set
in the factory.
If the swing angle does not match, refer to clause 10.
12
8.2 Worm gearboxes on ball valves
In case end stops require adjustment, set end position

OPEN first. If the exact end position of the valve cannot be
seen through a position marking at the valve shaft, the
Setting end position OPEN .. setting may have to be done with the valve removed.
Remove all bolts (03) at limit stop housing (10) (figures 4, 5).
.
Turn valve manually to end position OPEN.
.
In case limit stop housing (10) has not yet rotated, turn it counterclockwise
up to the stop.
..
required position.
.
Fasten bolts (refer to table 3) crosswise with a torque according to table 2.
OPEN, slightly loosen the screws of the pointer cover. Turn the pointer
cover to the OPEN symbol and fasten the screws again.
Setting end position CLOSED The end stop need not be set since the required swing angle has been set
in the factory.
9. Setting the end stops with mounted multi-turn actuator

. If worm gearboxes GS and multi-turn actuators are sup-
plied on a valve, the end stops as well as limit and torque
. switching are already set.

If the limit and torque switching have not yet been set, they
have to be set according to the operation instructions SA/
. SAR and the specifications of the valve manufacturer.

The valve manufacturer states whether the valve should
be limit or torque seated.
9.1 Worm gearboxes on butterfly valves
.
..
Determine the overrun of the multi-turn actuator for both directions, i. e. how
much does the valve move after the motor has been switched off?
Setting end position CLOSED Remove all bolts (03) at limit stop housing (figures 4, 5).
.
Change actuator to manual drive and move the valve manually to end
position CLOSED.
.
In case limit stop housing (10) has not yet rotated, turn it clockwise up to
the stop.
Turn limit stop housing (10) back counterclockwise by turn. This
ensures that the mechanical end stop is not reached in electric operation
.
and thus the valve can close tightly, provided that torque seating has been
specified.
If the fixing holes of limit stop housing (10) do not align with the threads of
..
the housing (1), take off the limit stop housing (10) and replace it in
required position.
.
CLOSED, slightly loosen the screws of the pointer cover. Turn the pointer
cover to the CLOSED symbol and fasten the screws again.
13
.
Limit seating in end position CLOSED
..
Turn back the valve from the end position by an amount equal to the
overrun.
Set limit switching according to the operation instructions SA/ SAR.
Check torque switching for end position CLOSED according to the opera-
tion instructions SA/ SAR, and, if necessary, set to the required value.
..
Torque seating in end position CLOSED
Turn handwheel counterclockwise by approx. 4 6 turns.
.
Set limit switching for the end position CLOSED according to the operation
instructions SA/ SAR (for signalisation).
Check torque switching for end position CLOSED or set to the required
value.
Setting end position OPEN The end stop need not be set since the required swing angle has been set
.
in the factory.
Move gearbox to the end stop in position OPEN.
The last part of the travel has to be made manually.
. To turn the valve back manually from the end position by an amount equal
to the overrun, proceed as follows:
For actuators mounted directly:
by approx. 4 to 6 turns at the handwheel.
With mounted primary reduction gearing VZ/ GZ:
by approx. 10 to 15 turns at the handwheel, according to the reduction
. ratio of the primary reduction gearing.

Set limit switching in actuator for the end position OPEN according to the
operation instructions SA/ SAR.
03/04
03/04
10 1 10 1
9.2 Worm gearboxes on ball valves In case end stops need to be adjusted, set end position
OPEN first. If the exact end position of the valve cannot be
seen through a position marking at the valve shaft, the
setting may have to be done with the valve removed.
. Determine overrun of the actuator for both directions, i. e. how much does the
valve move after the motor has been switched off?
14
Setting end position OPEN .. Remove all bolts (03) at limit stop housing (10) (figures 6, 7).
.
Change to manual drive and move the valve manually to end position
OPEN.
.
In case limit stop housing (10) has not yet rotated, turn it counterclockwise
up to the stop.
.
Turn limit stop housing (10) back by turn clockwise. This ensures that
the mechanical end stop is not reached in electric operation.
..
required position.
.
OPEN, slightly loosen the screws of the pointer cover. Turn the pointer
.
cover to the OPEN symbol and fasten the screws again.
Switching off in end position Turn back the valve from the end position by an amount equal to the
OPEN
. overrun.
Set limit switching according to the operation instructions SA/ SAR.
Setting end position CLOSED The end stop need not be set since the required swing angle has been set
.
in the factory.
Move gearbox to the end stop in position CLOSED.
The last part of the travel has to be made manually.
. To turn the valve back manually from the end position by an amount equal
to the overrun, proceed as follows:
For actuators mounted directly:
by approx. 4 to 6 turns at the handwheel.
With mounted primary reduction gearing VZ/ GZ:
by approx. 10 to 15 turns at the handwheel, according to the reduction
. ratio of the primary reduction gearing.

Set limit switching in actuator for the end position CLOSED according to
the operation instructions SA/ SAR.
15
10. Changing the swing angle The adjustment is made in end position OPEN.
Optional for size GS 50.3 GS 125.3
Standard for size GS 160.3 GS 250.3
Accuracy:
GS 50.3 GS 125.3: 0.6
GS 160.3 GS 250.3: 0.11 to 0.14
..
10.1 Changing the swing angle for sizes GS 50.3 GS 125.3 (option)
Unscrew protective cap (16) at limit stop housing (10) (figure 8).
Remove roll pin (020) with appropriate tool (available from AUMA).
.
Increasing the swing angle
Turn end stop nut (15) back counterclockwise.
When turning back the end stop nut (015), make sure the roll
pin (020) can still be tapped in within the oblong hole.
.. Move valve into the desired end position.

Turn end stop nut (15) clockwise until it is tight up to the stop nut (7).
..
Reducing the swing angle
Move valve into the desired end position.
The end stop nut (15) must entirely cover the roll pin (020).
082/083 03/04
058
16 34 15 054 056 10 7
16 020 15 08 10 7 055
. Tap in roll pin (020) with tool. If slot in end stop nut (15) does not align with
..
the hole in the worm shaft, turn end stop nut (15) slightly counterclockwise
until it is in alignment, then tap in roll pin.
.
Check O-ring (08) and replace, if damaged.
If gearbox is mounted to a multi-turn actuator, set limit switching again for
the end position OPEN according to the operation instructions SA/ SAR.
Allow for overrun.
16
.
10.2 Changing the swing angle for sizes GS 160.3 GS 250.3
.
Remove all bolts (054) and pull off protective cap (16)
(figure 9).
Remove screw (082) with washer (058) and setting ring (34).
..
Increasing the swing angle
.
Turn end stop nut (15) back counterclockwise.
..
Reducing the swing angle
..
..
Place setting ring (34), secure with washer (058) and screw (082).
Check O-ring (056) and replace, if damaged.
.
Place protective cap (16), fasten bolts (054) with lock washers (055).
Fasten bolts (see table 3) crosswise with a torque according to table 2.
If gearbox is mounted to a multi-turn actuator, set limit switching again for
the end position OPEN according to the operation instructions SA/ SAR.
Allow for overrun.
17
11. Enclosure protection IP 68

Definition According to EN 60 529, the conditions for meeting the requirements of
enclosure protection IP 68 (requirements exceed those of IP 67) are to be
agreed between manufacturer and user. AUMA worm gearboxes and
primary reduction gearings in enclosure protection IP 68 meet the following
..
requirements according to AUMA:
..
IP 68-3, submersible in water up to 3 m head of water
For size GS 50.3, only enclosure protection IP 68-3 is available.
If submersed in other media, additional measures for corrosion protection

may be necessary; please consult AUMA. Submersion in aggressive media,
e.g. acids or alkaline solutions, is not permitted.
Review Gearboxes in enclosure protection IP 68-3 were type tested in the factory.
Gearboxes in enclosure protection IP 68-6, IP 68-10 and IP 68-20 undergo
a routine testing for tightness in the factory.
.
.
Note: The enclosure protection IP 68 refers to the interior of the gearboxes, but
not to the coupling compartment.
.
If the gearboxes are likely to be repeatedly submersed, a higher corrosion
protection KS or KX is required.
.
For gearboxes intended for buried service we strongly recommend to use
the higher corrosion protection KS or KX.
For horizontal outdoor installation of the gearboxes, a sealed pointer cover
should be used.
.
For gas applications with sealed pointer cover, an air vent in the pointer
cover or venting grooves in the valve mounting flange must be provided.
In case of permanent submersion of the gearboxes or for buried service, a
protection cover must be fitted instead of a pointer cover. This will be taken
..
into account in the factory if indicated on the purchase order. Subsequent
exchange of the pointer cover for the protection cover is possible.
Use suitable sealing material between valve flange and gearbox.
Water can enter into the coupling compartment along the valve shaft. This
would lead to corrosion of hub and coupling. Therefore a suitable
.
anticorrosive (or sticky grease) must be applied to the hub and coupling of
the gearbox before mounting.
With corrosion protection KX, the hub and coupling are provided with a
high quality corrosion protection as standard.
18
12. Maintenance
12.1 General notes After commissioning, check worm gearbox for damage to paint finish.
Do a thorough touch-up to prevent corrosion.
Original paint in small quantities can be supplied by AUMA.
AUMA worm gearboxes require only very little maintenance.

To ensure that the worm gearbox is always ready to operate, we recom-
mend for gearboxes operated less than 10 times per year, the following
.
measures:
Approximately six months after commissioning and every year after, check
..
bolts between multi-turn actuator, worm gearbox, and valve for tightness.
If required, tighten applying the torques given in table 2 (page 11).
Perform a test run every six months.
.
Perform a visual inspection for grease leakage on each gearbox every
2 years.
.
Carry out a detailed functional test for each gearbox every 5 years.
Record the results for future reference.
For gearboxes permanently exposed to ambient temperatures above
40 C, maintenance must be performed at shorter intervals.
Seals:
Seals made of elastomeric materials are subject to ageing. The theoretical
usable lifetime of the seals made of NBR is 13.5 years from the date of
manufacture. These figures are based on an average ambient temperature
of 40 C. Seal kits may be obtained from AUMA.
Grease:
..
A grease and seal change is recommended after the following operation
time:
.
if operated seldom after 10 12 years
if operated frequently, after 6 8 years
..
in modulating duty after 4 6 years
Only original AUMA grease must be used.
. For the grease type, refer to the name plate.

Lubricants should not be mixed.
Table 4: Grease quantities for worm gearboxes and primary reduction gearings
GS 50.3 63.3 80.3 100.3 125.3 160.3 200.3 250.3
Qty dm 0.1 0.3 0.4 1.0 1.3 3.3 6.6 12.2
Weight1) kg 0.09 0.27 0.36 0.9 1.17 3.0 6.0 11.0
Primary VZ GZ
reduction 2.3 3.3 4.3 160.3 200.3 250.3
gearing
4:1/8:1 16:1 4:1/8:1 16:1
Quantity dm 0.35 0.35 0.35 1.0 1.5 2.0 2.2 2.8
Weight1) kg 0.32 0.32 0.32 0.9 1.4 1.8 2.0 2.25
1) for = approx. 0.9 kg / dm3
The removed lubricant and the cleaning agent used must be

disposed of according to the relevant regulations.
19
..
12.2 Grease change for worm gearboxes GS 50.3 GS 125.3 and primary reduction gearing VZ 2.3 VZ 4.3
For gearboxes with multi-turn actuator: Remove multi-turn actuator.

Remove gearbox from the valve:
During this time, the valve/ pipeline must not be under pres-
sure!
12.2.1 Worm gearboxes Refer to spare parts list GS 50.3 GS 125.3, page 24.
.
Grease type, see name plate; grease quantities, see page 19, table 4.
.
Mark position of the gearbox on the valve, loosen connecting bolts to the
valve and remove the worm gearbox.
.
Remove fastening bolts with lock washers from the housing cover (518.0)
and take off housing cover.
Remove bolts with lock washers from the bearing cover (522.0). Lift worm
.
wheel carefully from the housing. For this, the worm shaft must be pulled
from the bearings and tilted slightly in the worm channel.
Remove old grease completely from the housing and the individual parts
.
and clean gear housing. For this purpose, kerosene or a similar cleaning
agent may be used.
.
Clean mounting faces at housing and housing cover (518.0). Replace
O-rings at the worm wheel (010, 011) by new ones.
..
Re-insert worm wheel carefully and bring worm shaft into correct position,
fasten bearing cover (522.0) at housing with bolts and lock washers.
Fill with new grease.
Place housing cover (518.0) on housing, while ensuring the proper posi-
tion of the O-rings (010, 011) at the worm wheel. Place bolts with lock
washers and fasten them evenly crosswise.
Thoroughly degrease mounting faces at mounting flange.
Apply non-acidic grease at splines of coupling
Mount worm gearbox to valve, ensure correct position,
observe mark
.
Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts
crosswise to the appropriate torque according to table 2, page 11.
.
Gearbox without primary reduction gearing: Continue with clause After
maintenance.
Gearbox with reduction gearings VZ 2.3 VZ 4.3: Perform grease change
at the reduction gearing according to the following subclause.
12.2.2 Primary reduction gearing Refer to spare parts list VZ 2.3 VZ 4.3., page 24.
.
.
Remove bolts with lock washers from housing cover (020.0) and pull off
housing cover (020.0) with the complete input drive shaft (021.0).
.
Take off plate with internal teeth (045.0) and planet carrier (022.0) with the
planet wheels.
.
and clean them. For this purpose, kerosene or a similar cleaning agent
may be used.
..
Clean mounting faces at housing (019.0), housing cover (020.0) and plate
with internal teeth (045.0). Replace O-rings by new ones.
.
Insert planet carrier (022.0) with planet wheels.
Place plate with internal teeth (045.0) and insert the input drive shaft
.
(021.0) completely. Screw in bolts with lock washers and fasten them
evenly crosswise to the appropriate torque according to table 2, page 11.
Continue with clause After maintenance, page 22.
20
..
VZ 160.3 VZ 250.3
For gearboxes with multi-turn actuator: Remove multi-turn actuator.

Remove gearbox from the valve:
During this time, the valve/ pipeline must not be under pres-
sure!
12.3.1 Worm gearboxes Refer to spare parts list GS 160.3 GS 250.3, page 26.
.
Tools: Lock nut tool, can be obtained from AUMA.
.
Mark position of the gearbox on the valve, loosen connecting bolts to the
valve and remove the worm gearbox.
.
Remove bolts with lock washers from the housing cover (518.0) and take
off housing cover.
Remove bolts with lock washers from the bearing cover (522.0). Take off
bearing lock nut (537.0) by loosening the grub screw. Remove protective
cap (536.0), pull off snap ring from end nut (526.0). Remove end stop
(523.0). Lift worm wheel carefully from the housing. For this, the worm
shaft must be pulled from the bearings and tilted slightly in the worm
.
channel.
Pull out worm shaft from housing in direction of the housing input.
.
and clean gear-housing. For this purpose, kerosene or a similar cleaning
agent may be used.
.
Clean mounting faces at housing and housing cover (518.0). Replace
O-rings at the worm wheel (010, 011) by new ones.
Re-insert worm wheel carefully and bring worm shaft into correct position.
..
Screw in bearing lock nut (537.0) and secure with grub screw. Fasten
bearing cover (522.0) at the housing with bolts and lock nuts.
Place housing cover (518.0) on housing, while ensuring the proper posi-
tion of the O-rings (010, 011) at the worm wheel. Place bolts with lock
washers and fasten them evenly crosswise.
Thoroughly degrease mounting faces at mounting flange and valve.
Mount worm gearbox to valve, ensure correct position, observe mark.
.
Fasten with bolts of minimum quality 8.8 using lock washers, fasten
bolts crosswise to the appropriate torque according to table 2, page 11.
.
Gearbox without primary reduction gearing: Continue with clause After
maintenance.
Gearbox with reduction gearings GZ 160.3 GZ 250.3: Perform grease
change at the reduction gearing according to the following clauses.
12.3.2 Single-stage reductions gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1 and 8:1)
Refer to spare parts list GZ 160.3 GZ 250.3, page 28.
.
Remove bolts with lock washers at housing cover (002.0) and pull off
.
housing cover (002.0) with the input drive shaft (003.0) and the plate with
internal teeth).
.
Remove screws from the plate with internal teeth and separate the plate
with internal teeth from the input drive shaft.
..
and clean them.
For this purpose, kerosene or a similar cleaning agent may be used.
.
Clean mounting faces at housing (001.0), housing cover (002.0) and plate
with internal teeth. Replace O-rings by new ones.
Fill housing cover (002) with new grease.
21
.. Fix plate with internal teeth (006.0) with screws at housing cover.
Fill housing (001.0) with remaining grease and fit the complete housing
cover with input drive shaft (003.0). Screw in bolts with lock washers and
.
fasten them evenly crosswise to the appropriate torque according to table
2, page 11.
Continue with clause After maintenance, page 22.
12.3.3 Double-stage primary reduction gearing GZ 200.3 GZ 250.3 (reduction ratio 16:1)
Refer to spare parts list GZ 160.3 GZ 250.3, page 28.
.
.
Remove bolts with lock washers from housing cover (002.0) and pull off
housing cover with the complete input drive shaft (003.0).
.
Take off screws with lock washers from housing frame (010.0) and remove
housing frame with planet carrier and hollow wheel.
.
Remove screws from the plate with internal teeth and separate the plate
with internal teeth from the input drive shaft (003.0).
.
Remove screws (021) from the second stage of the plate with internal
teeth and separate it from the pinion (011.1).
.
and clean them. For this purpose, kerosene or a similar cleaning agent
may be used.
..
Clean mounting faces at housing (001.0), housing frame, housing cover
(002.0) and hollow wheels. Replace O-rings by new ones.
.
Fill housing (001.0) with new grease.
Fix second stage of the plate with internal teeth on housing frame (010.0).
Replace complete housing frame. Screw in bolts with lock washers and
.
fasten them evenly crosswise to the appropriate torque according to table
2, page 11.
..
Fill housing frame (010.0) and housing cover (002.0) with the remaining
grease.
Fix first stage of the plate with internal teeth on the housing cover (002.0).
Place complete housing cover with input drive shaft onto housing frame.
Screw in bolts with lock washers and fasten them evenly crosswise to the
appropriate torque according to table 2, page 11.
..
.
12.4 After maintenance If applicable, mount multi-turn actuator.
Reset the end stops.
For gearboxes with multi-turn actuator, check the setting of the limit
..
switching according to the operation instructions for multi-turn actuators; if
required, reset.
Perform test run to ensure the proper function.
Check worm gearbox for damage to paint finish. Do a thorough touch-up
to prevent corrosion. Original paint in small quantities can be supplied by
AUMA.
22

AUMA gearboxes have an extremely long lifetime. However, they have to be
Our gearboxes have a modular design and may therefore easily be disas-
..
sembled, separated and sorted according to materials, i.e.:
.
various metals
plastics
greases and oils
.
.
are hazardous to water and must not be released into the environment.
.
See disassembled material to a sound disposal or to separate recycling
according to materials.
14. Service AUMA offers extensive services such as maintenance and inspection for
gearboxes. Addresses of AUMA offices and representatives can be found on
page 32 and on the Internet (www.auma.com).
23
24
524.0
527.0 S1(011)
S1(073) 522.0
S1(009)
S1(017)
VZ 2.3 VZ 4.3
518.0 S1(012)
521.1
526.0
512.0
Worm gearboxes GS 50.3 GS 250.3
S1(009) S1(017)
520.0
512.0
522.0
517.0 S1(009)
S1(010) S1(017)
523.0 520.0
519.1 512.0
S1(009)
S1(010)
534.0
520.0 021.0
525.0
S1(034)
045.0
022.0
019.0
020.0
S1(076)
15. Spare parts list worm gearboxes GS 50.3 GS 125.3 and reduction gearing
S1(033)
S1(033)
S1(009)
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original
AUMA spare parts should be used. Delivered spare parts may slightly vary from the representation
in these instructions.
No. Designation Type

019.0 Housing VZ Sub-assembly
020.0 Housing cover VZ Sub-assembly
021.0 Input drive shaft VZ Sub-assembly
022.0 Planet carrier VZ Sub-assembly
045.0 Plate with internal teeth VZ Sub-assembly
512.0 Flange for actuator Sub-assembly
517.0 Housing Sub-assembly
518.0 Housing cover Sub-assembly
519.1 Worm wheel Component
520.0 Worm shaft Sub-assembly
521.1 Travelling nut Component
522.0 Bearing cover Sub-assembly
523.0 Limit stop housing Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
534.0 Input shaft Sub-assembly
536.0 Cap Sub-assembly
S1 Seal kit
25
26
524.0
527.0
S1(011)
S1(073)
Worm gearboxes GS 50.3 GS 250.3
518.0 520.0
S1(012)
537.0
S1(009)
513.1 521.1
S1(056)
526.0
522.0
517.0
16. Spare parts list worm gearboxes GS 160.3 GS 250.3
538.1
S1(009)
S1(010)
523.0
536.0
519.1
512.0
S1(017)
S1(010)
538.0
525.0
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original
AUMA spare parts should be used.
Delivered spare parts may slightly vary from the representation in these instructions.
No. Designation Type

513.0 Grub screw Component
519.1 Worm wheel Component
520.0 Worm shaft Sub-assembly
521.1 Travelling nut Component
522.0 Bearing cover Sub-assembly
523.0 Limit stop housing Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
536.0 Cap Sub-assembly
S1 Seal kit
27
17. Spare parts list reduction gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1)
S1(003)
006.0
S1(003)
GZ 160.1 GZ 250.1
4:1 / 8:1
S1(004)
S1(009)
001.0
003.0
003.3
512.0
S1(014)
002.0
006.0 S1(003)
GZ 200.1 GZ 250.1
S1(003)
16:1
003.0
S1(004)
S1(009)
S1(029)
001.0 003.3
S1(029)
S1(014)
512.0
002.0
011.1
013.0
010.0
28
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used. Delivered spare parts may slightly vary from the representation in these instructions.
No. Designation
003.3 Input drive shaft Sub-assembly
006.0 Planetary gear Sub-assembly
010.0 Housing frame Sub-assembly
011.1 Pinion Sub-assembly
013.0 Planetary gear 1st stage Sub-assembly
S1 Seal kit Set
29
30
Index
B L S
Bolts for mounting actuators 10 Lubricant 20 Safety instructions 3
Service 23
C M
Setting the end stop
Changing the swing angle 16 Maintenance 3,19
with mounted
Corrosion protection 7 Manual operation 12
multi-turn actuator 13
Motor operation 13
D Setting the end stops
Mounting positions 8
Declaration of Conformity 30 for manual operation 12
Mounting the multi-turn actuators 9
Declaration of Incorporation 30 Spare parts list
Mounting to valve 11
Disposal and recycling 23 GS 160.3 - GS 250.3 26
P GS 50.3 - GS 125.3 24
E
Packaging 7 GZ 160.3 - GZ 250.3
Enclosure protection IP 68 18 (4:1/8:1/16:1) 28
R
F Storage 7
Range of application 3
Fitting the handwheel 7 T
H Technical data 4
Handwheel 7 Transport 7
Information also available Inspection records and further gearbox information can be downloaded
on the Internet: directly from the Internet by entering the order no. or comm. no.
(refer to name plate).
Visit us at: http://www.auma.com
31
IBEROPLAN S.A.
Europe ES-28027 Madrid
Suplibarca
VE- Maracaibo Estado, Zulia
AUMA Riester GmbH & Co. KG Tel +34 91 3717130 Tel +58 261 7 555 667
Factory Mllheim iberoplan@iberoplan.com suplibarca@intercable.net.ve
DE-79373 Mllheim D. G. Bellos & Co. O.E.
Tel +49 7631 809 - 0 GR-13671 Acharnai Athens Asia
riester@auma.com Tel +30 210 2409485 AUMA Actuators (Tianjin) Co., Ltd.
www.auma.com info@dgbellos.gr CN-300457 Tianjin Teda District
Factory Ostfildern-Nellingen SIGURD SRUM A. S. Tel +86 22 6625 1310
DE-73747 Ostfildern NO-1301 Sandvika mailbox@auma-china.com
Tel +49 711 34803 - 3000 Tel +47 67572600 www.auma-china.com
riester@wof.auma.com post@sigurd-sorum.no AUMA (INDIA) PRIVATE LIMITED
Service Centre Cologne INDUSTRA IN-560 058 Bangalore
DE-50858 Kln PT-2710-297 Sintra Tel +91 80 2839 4655
Tel +49 2234 20379 - 00 Tel +351 2 1910 95 00 info@auma.co.in
Service@sck.auma.com jpalhares@tyco-valves.com www.auma.co.in
Service Centre Magdeburg MEGA Endstri Kontrol Sistemieri Tic. Ltd. Sti. AUMA JAPAN Co., Ltd.
DE-39167 Niederndodeleben TR-06460 vecler Ankara JP-210-0848 Kawasaki-ku, Kawasaki-shi
Tel +49 39204 759 - 0 Tel +90 312 472 62 70 Kanagawa
Service@scm.auma.com megaendustri@megaendustri.com.tr Tel +81 44 329 1061
AUMA Armaturenantriebe GmbH CTS Control Limited Liability Company mailbox@auma.co.jp
AT-2512 Tribuswinkel UA-02099 Kiyiv AUMA ACTUATORS (Singapore) Pte Ltd.
Tel +43 2252 82540 Tel +38 044 566-9971, -8427 SG-569551 Singapore
office@auma.at v_polyakov@cts.com.ua Tel +65 6 4818750
www.auma.at sales@auma.com.sg
AUMA (Schweiz) AG Africa www.auma.com.sg
CH-8965 Berikon AUMA South Africa (Pty) Ltd. AUMA Middle East Rep. Office
Tel +41 566 400945 ZA-1560 Springs AE- Dubai
RettichP.ch@auma.com Tel +27 11 3632880 Tel +971 4 3682720
AUMA Servopohony spol. s.r.o. aumasa@mweb.co.za auma@emirates.net.ae
CZ-10200 Praha 10 A.T.E.C. PERFECT CONTROLS Ltd.
Tel +420 272 700056 EG- Cairo HK- Tsuen Wan, Kowloon
auma-s@auma.cz Tel +20 2 3599680 - 3590861 Tel +852 2493 7726
www.auma.cz atec@intouch.com joeip@perfectcontrols.com.hk
OY AUMATOR AB DW Controls Co., Ltd.
FI-02270 Espoo America KR-153-803 Seoul Korea
Tel +35 895 84022 AUMA ACTUATORS INC. Tel +82 2 2113 1100
auma@aumator.fi US-PA 15317 Canonsburg sichoi@actuatorbank.com
AUMA France Tel +1 724-743-AUMA (2862) www.actuatorbank.com
FR-95157 Taverny Cdex mailbox@auma-usa.com AL-ARFAJ Eng. Company W. L. L.
Tel +33 1 39327272 www.auma-usa.com KW-22004 Salmiyah
stephanie.vatin@auma.fr AUMA Chile Respresentative Office Tel +965 4817448
www.auma.fr CL- Buin arfaj@qualitynet.net
AUMA ACTUATORS Ltd. Tel +56 2 821 4108 BEHZAD Trading Enterprises
GB- Clevedon North Somerset BS21 6QH aumachile@adsl.tie.cl QA- Doha
Tel +44 1275 871141 LOOP S. A. Tel +974 4433 236
mail@auma.co.uk AR-C1140ABP Buenos Aires behzad@qatar.net.qa
www.auma.co.uk Tel +54 11 4307 2141 Sunny Valves and Intertrade Corp. Ltd.
AUMA ITALIANA S.R.L. contacto@loopsa.com.ar TH-10120 Yannawa Bangkok
IT-20023 Cerro Maggiore Milano Asvotec Termoindustrial Ltda. Tel +66 2 2400656
Tel +39 0331-51351 BR-13190-000 Monte Mor/ SP. sunnyvalves@inet.co.th
info@auma.it Tel +55 19 3879 8735 www.sunnyvalves.co.th/
www.auma.it atuador.auma@asvotec.com.br Top Advance Enterprises Ltd.
AUMA BENELUX B.V. TROY-ONTOR Inc. TW- Jhonghe City Taipei Hsien (235)
NL-2314 XT Leiden CA-L4N 5E9 Barrie Ontario Tel +886 2 2225 1718
Tel +31 71 581 40 40 Tel +1 705 721-8246 support@auma-taiwan.com.tw
office@benelux.auma.com troy-ontor@troy-ontor.ca www.auma-taiwan.com.tw
www.auma.nl
MAN Ferrostaal de Colombia Ltda.
AUMA Polska Sp. z o.o. CO- Bogot D.C.
Australia
PL-41-310 Dabrowa Grnicza Tel +57 1 401 1300 BARRON GJM Pty. Ltd.
Tel +48 32 26156 68 dorian.hernandez@manferrostaal.com AU-NSW 1570 Artarmon
R.Ludzien@auma.com.pl www.manferrostaal.com Tel +61 294361088
www.auma.com.pl info@barron.com.au
PROCONTIC Procesos y Control Automtico
OOO Priwody AUMA EC- Quito www.barron.com.au
RU-141400 Moscow region for mail: Tel +593 2 292 0431
124365 Moscow a/ya 11 info@procontic.com.ec
Tel +7 495 221 64 28
aumarussia@auma.ru IESS DE MEXICO S. A. de C. V.
www.auma.ru MX-C.P. 02900 Mexico D.F.
Tel +52 55 55 561 701
ERICHS ARMATUR AB informes@iess.com.mx
SE-20039 Malm
Tel +46 40 311550 Corsusa S.A.C.
info@erichsarmatur.se PE- Miralflores - Lima
Tel 00511444-1200 / 0044 / 2321
www.erichsarmatur.se
corsusa@corsusa.com
GRNBECH & SNNER A/S www.corsusa.com
DK-2450 Kbenhavn SV
Tel +45 33 26 63 00 PASSCO Inc.
GS@g-s.dk PR-00936-4153 San Juan
Tel +18 09 78 77 20 87 85
www.g-s.dk
Passco@prtc.net
2006-04-20
P. O. Box 1362 P. O. Box 1151
D - 79373 Mllheim D - 73747 Ostfildern
Tel +49 (0)7631/809-0 Tel +49 (0)711 / 34803 0
Fax +49 (0)7631/809 1250 Fax +49 (0)711 / 34803 34
riester@auma.com riester@wof.auma.com Certificate Registration No.
12 100/104 4269
For detailed information on AUMA products, refer to the Internet

www.auma.com Y003.822/003/en /1.06
INDEX
1. FORWARD
2. STORAGE
3. INSTALLATION INSTRUCTIONS
4. CORRECT INSTALLATION
5. THE PROCEDURE OF CONCENTRIC BUTTERFLY VALVE DISASSEMBLY
6. THE PROCEDURE OF CONCENTRIC BUTTERFLY VALVE ASSEMBLY
7. TROUBLE SHOOTING
8. CONCENTRIC BUTTERFLY VALVE CONSTRUCTION
2/8
FORWARD (For AV-C Series)
Design principles of ACE VALVE have concentrated in reliability and safety being of principle
importance to all modern process industries.
ACE VALVE type 'AV-C Series' concentric butterfly valve shall be capable of bi-directional flow and
provide bubble tight shut-off at full rated pressure.
Long life durability is achieved with the ball shape seat and flat edge disc which minimises seat
compression and wear.
In addition, the valve is designed with following technical features
1. The face to face dimensions are provided in accordance with ISO5752, KS V7490, JIS B2032
JIS F7480 and API 609 standard.
2. Provisions to connect with actuator are provided in accordance with ISO standard.
3. Spherical shape is adopted in disc with seat ring design for easy concurrence.
4. Three point groove is provided in the body for good fastening of seat ring.
5. Sealing in way of shaft is provided in three places.
6. Taper pin is adopted to fix the disc at the shaft.
7. The shaft is provided through the disc as a strengthening of disc.
8. The parts are interchangeable each other for easy maintenance.
These excellent design features are complemented by ACE VALVE established quality assurance
system which is approved by major end users.
Although it is possible to carry out on-site maintenance of this type of valve, it is recommended
that the valves are serviced at : -
ACE VALVE COMPANY LIMITED.

278-4, MangDeok-Ri, JuChon-Myeon, KimHae-City, KyeongNam, Korea
Tel : +82-55-329-0651~6, Fax. : +82-55-329-0657
E-mail : ace-valve@ace-valve.co.kr
STORAGE (For AV-C Series)

Be careful not to get a scratch on Disc edge and Seat ring.
The flange must be protected by plywood or other things
when carrying valve.
Valve must not be shocked and shaken too much.
(It may cause the cracking neck, lever, handle and body)
It is recommended to be kept and carried under the condition of opening.
The suitable temperature is from -10 to 70 and humidity is between
10%~60% while keeping valve.
In keeping valve, must check the opration once per months.
3/8
INSTALLATION INSTRUCTIONS (For AV-C Series)
General
Valves can be installed in the pipeline in any position.
Before installing valves, the pipeline must be cleaned from dirt and welding residues,
otherwise seat may be damaged.
Also the pipeline must be free from tension and electric current.
When handling valves, be careful to avoid contact with or impact by other equipment, vault walls
or trench walls.
Check carefully to see if valve seat/disc surface as well as mating flange are all clean.
Tighten again, if any, all bolts loosened during transport and/or handling.
Open and close valves to check for proper operation.
Do not use valve as a substitute for jack when putting pipes alignment.
The span of pipeline having connection between valve and pipe should be free from such
excessive loading as may cause serious bending.
Do not weld the piping around the valve area under the condition that the valve is installed.
Installation of butterfly valve in the existing pipe

Verify the distance between two flanges to be equal to face to face valve dimension.
In order to facilitate installation of the valve, allow with adequate tools a sufficient room
in between flanges.
Insert at least two flange-bolts in the lower part of flanges.
Close valve disc partially so that disc edge is at least 10mm within the body.
Inset valve in between flanges. Valve will be held by the two flange-bolts previously fitted
in the lower part of flanges.
Insert the flange-bolt through centering lugs of valve.
Insert the remaining flange-bolts aligning the valve with the flanges and tightening bolts
partially.
Maintain the valve aligned, remove flange spreaders gradually and tighten bolts partially.
Adjust open and close operation of valve to be easy and smooth.
Open the valve complete and closs tight the bolts adequate torque.
Installation of lug type butterfly valves has same procedure of wafer type using
studs instead of bolts and nuts.
Installation of butterfly valve in the new pipeline

Shut valve disc partially until disc profile is at least 10mm within the body.
Align the two flanges with the valve body.
Span the body with some flange-bolts and tighten the bolts partially.
Finish tightening by uniform cross bolting.
Use the flange-valve-flange unit for pipe centering.
Install the valve following the installation instruction on exsting pipeline.
4/8
CORRECT INSTALLATION
Correct Installation Incorrect Installation
1. Spread flange enough to allow

the valves with disc in semi-
closed position.
This prevents the damage of
disc and seat during installation
and reduces initial torque.
2. It is recommended flange
gaskets are not be provided.
3. Insert bolts through the two bottom

pipe flange holes to rest valves on
during installation.
4. Tighten the flange bolts evenly to

prevent the leakage between flange
and valve.
5/8
The procedure of concentric butterfly valve disassembly (For AV-C Series)
Caution
Do not attempt to remove an actuator from the valve that is under pressure. Doing so may cause
the actuator to swing violently. Isolate the valve by closing the valves that are just upstream
and then downstream(in that order) of the valve before attempting to remove the actuator.
Turn the disc to the nearly closed position. Loosen and remove all flange bolting.
Spread the flange if necessary and remove the valve from the pipeline.
Turn the disc to the almost open position. Remove the actuator if still mounted.
Remove the taper pins in the disc.
Remove the packing gland.
Remove the stem by pulling it out through the valve top plate.
Remove the disc from the valve body by pulling or "rolling" the disc out of the seat bore.
Remove the seat by prying under both seat edges at one point. Collapse the seat into the
shape of a round bottom heart and pull the seat out of the body bore.
If needed, remove the o-ring and inspect for damage. Replace it if necessary.
The procedure of concentric butterfly valve assembly (For AV-C Series)
Clean all reusable parts. If possible use silicone base oil or lubricant to facilitate assembly.
Install bearing bush into the valve body. (1pc for upper part and 1pc lower part.)
Collapse the valve seat into the shape of a round bottom heart configuration. Firmly place the
"bottom" part of the seat into position taking care to align the lower stem holes. Snap the seat
into position within the body and check all stem holes for proper alignment.
Install disc into the valve seat with taper pin holes toward the valve top plate and align
stem holes.
Install the stem by using a downward rotary motion taking care not to cut or tear the seat
due to misalignment of the stem holes.
Install packing o-ring.
Install packing gland and tighten securely by using screws.
Install bottom cover (for ND 400A and over size)
Align taper pin holes in the disc with the holes in the stem and install taper and tighten
securely.
6/8
TROUBLE SHOOTING (For AV-C Series)
SYMPTOM PROBABLE CAUSE SOLUTION
Valve opens only a few Loosen the flange bolts. Realign

Improper installation.
degrees and stops the valve with flanges. And retighten
The valve is improperly
(It will not open to the the flange bolts to correct torque per
aligned.
full angle desired.) ANSI requirements.
1. Flange bolts are not 1. Loosen the flange bolts and

evenly tighten. tighten the flange bolts to correct
torque per ANSI requirements.
Leakage past the flange face
2. Improper flanges. 2. Refer to "Flange requirements"
on page 1.
The disc is not closing fully

1. Actuator is not properly 1. Refer to actuator adjustment
adjusted. procedures.
Leakage in the closed 2. Damaged seat. 2. Replace seat.

position
(Leakage in the pipeline) 3. Line pressure exceeds 3. Reduce line pressure to valve
valve's working pressure working pressure.
4. Damaged valve disc. 4. Replace disc.
Leakage at the valve stem Packing/bushing failure Refer to valve disassembly procedure
The valve is closing or

Water hammer Adjust the actuator.
opening too quickly
1. Obstruction in the pipeline 1. Remove valve from pipeline and

remove obstruction.
2. Valve stem or disc bent. 2. Return valve to factory for

disc / stem replacement.
(Check for water hammer or
Excessively high torque
freezing of line material)
3. Scale build-up on stem or 3. Open and close the valve several

seat. times. Operate the valve at least
once a month. Check the valve
seat for deterioration.
7/8
CONCENTRIC BUTTERFLY VALVE CONSTRUCTION (For AV-C Series)
P.NO. PART NAME REMARK
1 BODY
2 DISC
3 SEAT
4 STEM
5 DISC PIN
6 O-RING
7 PACKING GLAND
8 GLAND BOLT
9 BEARING BUSH
10 O-RING 400A & OVER
11 BOTTOM COVER 400A & OVER
12 BOLT & WASHER 400A & OVER
8/8

MOV O&M - Butterfly - Actuator

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

MOV O&M - Butterfly - Actuator

Transféré par

Droits d'auteur :

Formats disponibles

INSTALLATION & MAINTENANCE MANUAL

CONCENTRIC BUTTERFLY VALVE

ACE VALVE CO., LTD.

Certificate Registration No.

Table of contents Page

1.2 Electrical connection

1.4 Warnings and notes

This pictograph means: Note!

This pictograph means: Electrostatically endangered parts!

This pictograph means: Warning!

Switchgear Standard: Reversing contactors2) (mechanically and electrically interlocked)

Further options for version with RWG in the actuator

4. Additional information to the wiring diagram legend

5. Transport, storage and packaging

. the change-over mechanism.

.. force may damage the change-over mechanism.

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

. and mounting surface, with long-term corrosion protection agent.

After mounting, connect actuator immediately to electrical

. Check if mounting flange fits the valve/ gearbox.

Spigot at flanges should be loose fit!

Finish machining of stem nut (output drive type A):

.. Remove spigot ring (80.2, figure 5) from mounting flange.

.. bearing races (80.02).

. then place them on stem nut.

Table 2: Grease quantities for output drive type A

7. Mounting positions of the local controls

Four mounting positions are possible:

Figure 9: Mounting position C Figure 10: Mounting position D

Changing the mounting position

.. Disconnect actuator from the mains before opening.

. Turn local controls by a maximum of 180!

.. Loosen 4 bolts and remove the local controls.

. Check whether O-ring is in good condition.

Cable installation in accordance with EMC

.the highest possible distance from each other.

.are laid close to the ground potential.

.in areas being subject to low interference.

.ence or interference sources.

Actuator controls on wall bracket (accessory)

For version on wall bracket, please observe the following:

. potentiometer, an RWG has to be used in the actuator

Subsequent mounting of the actuator controls on the actuator

Figure12: Version S (standard) Figure 13: Version SH Figure 14: Version SE

Before mains connection

IP67 Enclosure protection

Each time the PE connection has been disconnected, it has

Figure 17: PE connection

Protective earth with ring lugs/ lugs

Parking frame, protection cover (accessories)

Manual force is sufficient for operating the change-over

Operating the change-over lever while the motor is running

. Turn handwheel into desired direction (figure 21).

Disengaging manual operation

10. Operation and indications of the local controls

Figure 22: Local controls

Push buttons Indication lights

Position Test (III):

Red indication light (fault) is illuminated.

Position Reset (III):

OPEN: Actuator runs in direction OPEN

STOP: Actuator stops

CLOSE: Actuator runs in direction CLOSE