TIB-723-GB-0613_AP_2way_valves_with_electric_actuator_English.pdf

Technical Manual

Instructions for installation, operation and maintenance

723 2-WAY CONTROL VALVES Fig. 440-446, with electric actuator Ari-Premio

Publication nr TIB-723-GB-0613 Supersedes TIB-723-GB-0711

0040000053 4000 englisch

1.0 General Information on Operating Instructions ..2

2.0 Notes on Possible Dangers ......................................22.1 Significance of Symbols ............................................... 2

2.2 Safety-Related Definitions ............................................ 2

2.3 Qualified Personnel ....................................................... 2

3.0 Handling ...................................................................33.1 Storage .......................................................................... 3

3.2 Transport ....................................................................... 3

3.3 Handling Before Installation......................................... 3

4.0 Description ...............................................................34.1 Scope of Applications ................................................... 3

4.2 Operating Principles...................................................... 3

4.3 Diagram / Plug Designs ................................................ 4

4.4 Marking......................................................................... 5

5.0 Installation ...............................................................55.1 General Notes on Installation........................................ 5

5.2 Requirements at the Place of Installation...................... 5

5.3 Installation Instructions Concerning Actuators .............6

6.0 Notes on Dangers During Installation, Operationand Maintenance .....................................................6

7.0 Putting the Valve into Operation............................6

8.0 Care and Maintenance ............................................78.1 Spindle Packings / Assembly.........................................7

8.2 Packings with PTFE V-ring unit ....................................7

8.3 Stuffing Box Packings....................................................8

8.4 Bellow Seal ....................................................................9

8.5 Replacing the Plug, Spindle and Seating .......................9

9.0 Troubleshooting .....................................................11

10.0 Troubleshooting Table .........................................12

11.0 Dismantling the Valve..........................................13

12.0 Warranty ..............................................................13

Operating and Installation InstructionsStraightway Control Valves Fig. 440-446

Contents

22.44023.44034.44035.440

Fig. 12.44122.44123.44134.441

55.44055.445

35.44155.44155.446

Fig. 12.440

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Operating and Installation InstructionsControl Valves Fig. 440-446

1.0 General Information on Operating Instructions

These operating instructions contain information necessary to install and operate the valve both safely andeffectively.If problems arise which cannot be solved with the aid of these operating instructions, please contact thesupplier/manufacturer for further information. These operating instructions comply with applicable ENsafety standards as well as regulations and codes of practice applicable in the Federal Republic ofGermany. If the valve is used outside the Federal Republic of Germany, the operator or the personresponsible for the system design must ensure that valid national codes of practice are complied with.The manufacturer reserves all rights to implement technical modifications and improvements at any time.The use of these operating instructions assumes the user is qualified as described under Section 2.3"Qualified Personnel".The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on Possible Dangers

2.1 Significance of Symbols

Warning of general danger

2.2 Safety-Related Definitions

The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operatinginstructions as indications for particular hazards or for important information requiring special signs.

DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / orconsiderable damage to property can occur.

WARNING means that if the relevant information is disregarded, there is a danger of serious injury and /or damage to property can occur.

CAUTION means that if the relevant information is disregarded, there is a danger of injury and / ordamage to property can occur.

NOTE means that particular attention must be paid to certain technical aspects.

All other information not specifically emphasised such as transport, installation, operating andmaintenance instructions as well as technical data (in the operating instructions, product documentationand on the device itself) must also be complied with to the fullest extent in order to avoid faults which inturn can cause serious injury to persons or damage to property.

2.3 Qualified Personnel

The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-up,operation and maintenance of the product and have the qualifications corresponding to theirresponsibilities such as:Instruction and obligation to comply with all operational, regional and in-company regulations andrequirements;Training or instruction in accordance with safety technology standards with regard to the upkeep and useof appropriate safety and work protection equipment; First aid training, etc.(see TRB 700).


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3.0 Handling3.1 Storage- Storage temperature -20˚ to +65˚C dry, free of dirt

- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘tdamage the paintwork.

- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport- Transport temperature -20˚ to +65˚C.

- Protect against external force (impact, vibration etc.).

- Don‘t damage the paintwork.

3.3 Handling Before Installation- If flange covers are fitted, remove shortly before maintenance!

- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).

- Correct handling protects against damage.

4.0 Description4.1 Scope of ApplicationsThese control valves are suitable for controlling the flow of liquids, gases and vapours in chemical andother processing plants and for plant engineering.The materials have been selected and matched on the basis of current DIN, AD, TRD and UVV rules.The mechanical and flow characteristics conform to standard DIN EN 60534.The engineer planning a plant is responsible for selecting the correct valve for a given application. Thespecial features of the valve concerned must be taken into account.

- Valves for oxygen application (O2) have a fixed plate.

- Valves for Ammonia (NH3) acc. to TRD 451-452 must be free from nonferrous metalswith flanges DIN 2512 form N.

acc. to TRB 801 No.34 for ammonia storage tank systems, bodies withshoed ends must be stress-relief-annealed.

- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.

- Valves for inflammable, aggressive or toxic media, must be off tensile material.

- With applications for media that demand special criteria, please consult.

- -marking for applications acc. to Pressure Equipment Directive.

4.2 Operating PrinciplesARI control valves are especially suitable for actuation by pneumatic or electrical actuators.

Three plug types are available to suit the various applications:parabolic plug (standard pattern)perforated plugV-port plug

The flow through control valves with parabolic and V-port plugs is always against the closing direction. Inthe case of control valves with perforated plugs, gases and vapours flow against the closing directions, butliquids flow through in the closing direction.

If a pneumatic actuator is to be used on a straight-way valve with a perforated plug with the fluid movingin the closing direction, a higher closing force will be needed. This is to prevent vibration as the plugapproaches the closed position.

Pressure-balanced plugs can be provided if the actuator force is inadequate.

Oil and grease freefor oxygen application

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4.3 Diagram / Plug Designs

fig. 1: Fig. ...440 standard design fig. 2: Fig. ...441 standard design

fig. 3: Design with perforated plug fig. 4: Design with V-port plug

rotatedview

rotatedview

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4.4 MarkingDetails of the CE-marking on the name plate of the valve:

5.0 Installation5.1 General Notes on InstallationThe following points should be taken into account besides the general principles governing installationwork:- Remove flange covers if present.- There must be no foreign bodies inside the valve or piping.- Pay attention to the direction of flow: see markings on the valve and refer to the operation and installation

instructions (point 4.2).- Centre sealings between the flanges.- Connection flanges must mate exactly.- If the valve is handling steam, the piping must be laid with a gradient to prevent water from accumulating

in pockets. Condensation traps are needed to prevent water-hammer.- All parts must be free from stress after installation.- The valve must not serve as a fixed point. It must be carried by the piping.- Protect the valve from dirt, especially during construction work. Strainers or filters shoud be installed

before the valves.- Install compensators to compensate for thermal expansion of the piping.- Keep the thread and shaft of the spindle free from paint.5.2 Requirements at the Place of InstallationThe place of installation should be easily accessible and provide ample space for maintenance andremoving the actuator. Stopvalves shoud be installed before and after the controlvalve to enablemaintenance working without draining the piping system. The valve should preferably installed verticallywith the actuator at the top. Inclined or horizontal installation without supports is permissible only withlight actuators.For this installallation position, the two distance columns (or joke) have to be above each other in theverical plane.

Permissible servo weights for valves with unsupported horizontal spindles:20 kg for DN 15 - 3225 kg for DN 40 - 6535 kg for DN 80 - 100

The pipes must be lagged to protect the actuators from excessive heat. Sufficient space must be left for themaintenance of the spindle packing.To ensure that the control valves function correctly, the pipe run should be straight for at least2 x DN upstream and 6 x DN downstream of the valve.

CE-marking According to the Pressure Equipment Directivepart 3, valves without safety function are onlyallowed to bear the CE-marking DN32 onwards.

Valves with safety function are:Type 440 DP-G / 441 DP-G andType 440 / 440-D with FR2.1 and Ü-sign

0525 Notified body

Fig. ______ Figure-No. / Type-No.Serial-No.Year of manufacture (clear speech)(1. and 2. position of the serial-No.)

SN _ _ ____

Pipeline Pipelinevertically horizontally

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5.3 Installation Instructions Concerning ActuatorsNormally, control valves are supplied complete with actuator fitted.It is not permitted to mantle / dismantle actuators with valves operating and service conditions(temperature and pressure) (see 2.3). The actuators must be assemble as describe in the operatinginstructions during conversion and maintenance.During assembly work, the plug is not be turned on its seating at closing pressure.

Caution!Care must be taken with the bellow type valves when actuators are mounted or removed. Hold the valve-spindle against turning with an open-end wrench.When retrofitting actuators, the maximum permissible force for valve actuation must be taken intoaccount.The maximum permissible actuation forces are:

6.0 Notes on Dangers During Installation, Operation and MaintenanceDANGER !Operation can be completely safe only if the valve is properly installed, put into operation and maintainedby trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to the warnings in theseoperating instructions. In addition, the general installation and safety rules for piping and plant installationmust be observed, and appropriate tools and safety equipment are to be used. Strict attention must be paidto the operating instructions during all work on the valve and when handling it. Injury or damage can becaused by ignoring them.

When used as an end-blockage, a safety precaution is recommended by maintenance works.

7.0 Putting the Valve into Operation- Before putting the valve into operation, check that the material, pressure, temperature and direction of

flow are as specified with the plans of the piping system.

- Regard the TRB 700.

- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.

DANGER !Before putting a new plant into operation or restarting a plant after repairs or modification, always makesure that:- All installation and assembly work has been completed!- Only qualfied personnel (see point 2.3) are employed to start the plant!- The valve is in the correct position for its function!- Existing guards have been attached and in good order.

Fig. 440 / 445 Fig. 441 / 446

12 kN for DN 15 - 50 18 kN for DN 15 - 100

29 kN for DN 65 - 100


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8.0 Care and Maintenance

Maintenance and maintenanceintervals have to be defined by the operator according to the serviceconditions (see TRB 700).

8.1 Spindle Packings / Assembly

8.2 Packings with PTFE V-ring unit

See Fig. 5 and 8PTFE V-ring unit consisting of: 1 backing ring

4 sealing rings1 cover ring

Owing to the installed compression spring, this spindle packing is self-adjusting. Ifthe spindle starts leaking, the ring pack is worn out and must be replaced.

Replacing PTFE V-ring unit:

Warning! See point 11.0 before dismantling the valve.

- Remove the actuator (see operating instructions for actuator).

- When replacing PTFE V-ring unit (12), make sure that the parts are installed in thecorrect order and positions (see Fig. on right).

- Damaged spindles must also be replaced (see point 8.5 for instructions) since anew ring pack will soon start leaking again with a damaged spindle.

- Attention! Gasket (17) must be replaced.

fig. 8

fig. 5: PTFE V-ring unit fig. 6: Stuffing box sealing fig. 7: Bellow seal

rotatedview

rotatedview

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8.3 Stuffing Box PackingsSee Fig.6 and 10

- Stuffing box packings require maintenance.

- If leaks develop, immediately tighten the screw joint (25) gradually until thepacking stops leaking.

- The service life of stuffing box packings (23) can be increased by checkingregularly leakage.

- If leaks can no longer be stopped by tightening the nuts, a new packing ring must beinserted into the gland.

Replacing a stuffing box packing:


- Insert the new packing ring as shown in the Fig. on the right.

- If a split packing ring is used, cut with a chamfer as shown in Fig. 9

fig. 9: Split packing ring fig. 10

- Damaged spindles must also be replaced (see point 8.5 for instructions) since a new ring pack will soonstart leaking again with a damaged spindle.


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8.4 Bellow Seal

See Fig. 7 and 11If the spindle leaks, the bellow seal is defective. The leak can initially be stopped bytightening the screw joint (20.17).

Replacing the bellow seal:


- Remove the actuator (see operating instructions for actuator).

- Slacken the screw joint (20.17) by about one turn.

- Remove the bellows housing by unscrewing the nuts (11).

- Remove the plug as described in point 8.5b.

- Detach the mounting bonnet (20.2) after unscrewing the nuts (20.8).

- Extract the spindle from the bellows housing.

- Drill new spindle with plug.

- Replace 2 seals (20.6) and 1 seal (9).

- Assemble in the reverse order. Screw on the nuts (11, 20.8)and tighten them crosswise (See page 11 for tightening torque‘s).

(The spindle can only be replaced complete with bellows.)

8.5 Replacing the Plug, Spindle and Seating fig. 11


- Remove the actuator (see operating instructions for actuator)

a) Control valves (cf. Fig. 1 and 12)

- Detach the mounting bonnet (7).

- Slacken screw joint (19) by about one turn.

- Extract and replace the plug with spindle.

- Replace the gasket (9).

- Set the mounting bonnet cover in place and secure it with nuts (11)tightened crosswise.(See page 11 for tightening torque‘s.)

(Plug and spindle can only be replaced completely.)

fig. 12

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b) Control Valves with Bellow Seal (cf. Fig. 2 and 11)

- Unscrew the nuts (11).

- Remove the bellows housing (20.1) with plug (3).

- Keep the spindle pressed down.

- Remove the clamping sleeve (4).

- Unscrew the plug (3).

- Fit the new plug in the reverse order.

- Drill the plug and insert new pin.

The spindle can only be replaced complete with bellows (see point 8.4)

c) Replacing the Seating Ring (only Fig. 55.445 and Fig. 55.446)

The seating ring is screwed into the valve body and can be unscrewed for replacement or remachining.

A special wrench is needed to remove the seating. It can be obtained from the manufacturer.

When fitting a new or reconditioned seating, clean thread and sealing taper in body and apply suitablelubricant.

See table below for seat ring tightening torque‘s.

Tightening torque‘s

DN 15/ 20 = 100 Nm

fig. 13

DN 25/ 32 = 150 Nm

DN 40/ 50 = 350 Nm

DN 65 = 480 Nm

DN 80 = 660 Nm

DN100 = 980 Nm

rotated view


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d) Pressure-balanced Plug - Replacing the Seals


- Detach valve top part and remove plug (replace ifnecessary) as described in point 8.5 a or b.

- Prise worn piston seal (32) out of groove in plug withsuitable tool (e.g. screwdriver).

- Insert new piston seal, taking care that it is in the correctposition (cf. Fig. 14).

- Replace guide ring (31).

fig. 14: Pressure-balanced plug- Clean sliding surface of guide bush (30); smooth with fine abrasive if necessary.

- Before assembly, remember that two seals (9) must be replaced.

- Set valve top part in place.

- Tighten the hexagon nuts of the cover gradually crosswise.

Tightening torque for hexagon nuts:

See operating instructions for actuator concerned for installing actuators!

9.0 Troubleshooting

In the event of failures or malfunctions, check that the valve was assembled and installed as described inthese instructions.Regard the TRB 700.

Compare the material, pressure, temperature and direction of flow with the information given in the plansof the piping system. Check also that the service conditions correspond to the data given on the data plateand the technical data.

DANGER !It is essential that the safety regulations are observed when identifying faults!

If malfunctions cannot be eliminate with the help of the following „troubleshooting table“, the supplier ormanufacturer should be consulted.

Bolts Torque

M 10 20 Nm

M 12 35 Nm

M 16 80 Nm

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10.0 Troubleshooting Table

Caution: - Read point 11.0 prior to dismantling and repair work!- Read point 7.0 before restarting the plant!

Fault Possible cause Corrective measuresNo flow Valve closed. Open valve (using actuator).

Flange covers not removed. Remove flange covers.

Little flow Valve not sufficiently open. Open valve (using actuator).

Dirt sieve clogged. Clean / replace sieve.

Relieve pressure first!

Piping system clogged. Check piping system.

Kvs value of valve unsuitable. Fit valve with higher Kvs value.

Valve spindle moves in jerks. Stuffing box sealing too tight (for valveswith graphite packings).

Slacken screw joint (25/20.17) slightly.

Valve must nor start leaking!

Valve plug slightly seized owing to solid dirtparticles.

Clean internals, smooth rough spots.See points 7.0 and 11.0!

Valve spindle or plug cannotbe moved.

Seating and plug clogged with dirt; especi-ally with V-port and perforated plugs.

Clean seating and plug with suitable sol-vent.See points 7.0 and 11.0!

Valve plug seized in seating or guide owingto deposits or dirt in medium.

Replace plug and seating; use parts madefrom different material if necessary.

Valve spindle leaking. PTFE V-ring unit damaged or worn. Replace ring pack - see point 8.2See points 7.0 and 11.0!

In valves with packed stuffing boxes, tightensleeve nut (25).

Tighten screw joint (25); replace packing ifnecessary. See point 8.3.See points 7.0 and 11.0!

Bellows defective in valves with bellow seal. Replace bellows unit - see point 8.4See points 7.0 and 11.0!

Leakage too high when valveis closed.

Sealing surfaces of plug eroded or worn. Replace plug - see point 8.5.See points 7.0 and 11.0!

Sealing edge of seating damages or worn. Replace seating (see point 8.5),(only Fig. ...445/446)See points 7.0 and 11.0!

Piston sealing ring worn (pressure-balancedvalves).

Replace sealing ring.See points 7.0 and 11.0!

Seating and/or plug dirty. Clean internals of valve.See points 7.0 and 11.0!

Pneumatic actuator not completely vented;spring force not fully effective.

Vent actuator air chamber completely.See points 7.0 and 11.0!

Actuator not powerful enough. Install more powerful actuator. Check ser-vice data.

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11.0 Dismantling the ValveThe following points must be observed beside the general principals rules and TRB 700 governing theassembly work:

- Pressureless pipe system.

- Medium must be cool.

- Plant must be drained.

- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.

- Have assembly work performed only by qualified personnel (see point 2.3).

12.0 Warranty

The extent and period of warranty cover are specified in the "Standard Terms and Conditions of AlbertRichter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of saleitself.

We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmedapplication.

No warranty claims can be made for any damage caused as the result of incorrect handling or disregard ofoperating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and otherapplicable codes of practice.

This warranty also does not cover any damage which occurs during operation under conditions deviatingfrom those laid down by specifications or other agreements.

Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.

No claims will be accepted beyond the scope of this warranty. The right to replacement delivery isexcluded.

The warranty shall not cover maintenance work, installation of external parts, design modifications ornatural wear.

Any damage incurred during transport should not be reported to us but rather to the competent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements fromthese companies will be invalidated.

Technology for the Future.GERMAN QUALITY VALVES

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-StukenbrockTelephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159

Internet: http://www.ari-armaturen.com E-mail: [email protected]

EC declaration of conformity / Manufacturers declaration

EC declaration of conformityas defined by

the Pressure Equipment Directive 97/23/EC and

Manufacturers declarationas defined by

the Machinery Directive 98/37/EC

Herewith we declare,

ARI-Armaturen Albert Richter GmbH & Co. KG,Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock

that according to the above mentioned Pressure Equipment Directive (PED) and Machinery Direc-tive the below listed products comply and have been approved according to Category III , Module Hor Category IV , Module H1 (with safety function) through Lloyd´s Register of Shipping (NB-No.0525), Mönckebergstr. 27, 20095 Hamburg

If the supplied model is intended to be incorporated into machinery or assembled with othermachinery to constitute machinery covered by this directive and must be put into service until themachinery into which it is be incorporated has been declared in conformity with the provisions of theEC-Machinery Directive as amended by 98/37/EC.

Schloß Holte Stukenbrock, 13.12.2001

Category III , Module H, Certificate-No: 50003/1

Straightway stop and control valvesType 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 480

Applied standards :DIN EN 60534 Part 1

VDI/VDE 3844 sheet 1DIN 3840

Category IV , Module H1, Certificate-No: 50003/2

Straightway control valves with safety functionType 440, 441

Applied standards :DIN EN 60534 Part 1

VDI/VDE 3844 sheet 1DIN 3840

(Brechmann, Managing director)...................................................

ARI-STEVI® 440 / 441with electric and pneumatic actuators

Fig. 440

Fig. 441

Features: �Compact�designPrecision�guided�stemBurnished�stemTapered�seat�ringRangeability�50�:�1Spring�loaded�PTFE-V�ring�packing�unitTwo-ply bellows seal as standardTravel�indicator

••••••••

Edition�12/07�-�Data�subject�to�alteration Data�sheet�440001�englisch�(english)

ARI-STEVI® 440 / 441 Electric actuator ARI-PREMIO

Enclosure�IP�652�torque�switchesHandwheelAdditional�devices�available,�e.g.�potentiometer

••••

�Page�2

ARI-STEVI® 440 Electric actuator FR1 with safety reset

�Operating�mode�for�safety�reset�CLOSEEnclosure�IP�66Operating�time�adjustableAdditional�devices�available,�e.g.�potentiometer

••••

�Page�6

ARI-STEVI® 440 / 441 Electric actuator FR2 with safety reset

Type�approval�acc.�to�DIN�32730��for�Fig.�440�with�FR�2.1��CE-marking�from�DN15�Optional�direction�for�safety�reset,�OPEN�or�CLOSE,�as�requiredEnclosure�IP�541�travel�switch�for�OPEN�and�CLOSEAdditional�devices�available,�e.g.�potentiometer

•

••

••• �Page�10

ARI-STEVI®� 440 / 441 Electric actuator AUMA SAR

Electric�multiturn�actuator�capable�of�high�closing�pressuresEnclosure�IP�672�torque�switches2�travel�switches�Handwheel�Overheating�protection�for�motor�as�standard�Additional�devices�available,�e.g.�potentiometerExplosion�proof�version�available

•

••••••• �Page�14

ARI-STEVI® 440 / 441 Pneumatic actuator ARI-DP

Reversible�pneumatic�actuatorActuator�with�rolling�diaphragmAir�supply�pressure�max.�6�barStem�protection�by�bellow�Maintenance-free�O-ring�sealingAssembly�of�additional�devices�acc.�to�DIN�IEC�60534-6

••••••

�Page�18

Control valve - straight through with flangesDN 15 - 150

2

ARI-STEVI® 440 / 441Electric actuator ARI-PREMIO

Control valve straight through with electric actuator ARI-PREMIO

Fig. 440

Fig. 441

Figure Nominal pressure Material Nominal diameter

12.440�/�12.441 PN16 EN-JL1040 DN15-150�22.440�/�22.441 PN16 EN-JS1049 DN15-15023.440�/�23.441 PN25 EN-JS1049 DN15-15034.440�/�34.441 PN25 1.0619+N DN15-15035.440�/�35.441 PN40 1.0619+N DN15-15055.440�/�55.441 PN40 1.4408 DN15-150Other�materials�and�versions�on�request.Stem sealing Fig.�440:�� •�PTFE-V-ring�unit�-10°C�up�to�+220°C�� •�PTFE-packing�-10°C�up�to�+250°C�� •�Pure�graphite-packing�-10°C�up�to�+450°C�Fig.�441:�� •��Stainless�steel�bellows�seal�with�safety�stuffing�box�-60°C�up�to�+450°C�Plug design standard:�� •�Parabolic�plug,�metal�seatoptional:� �� •�Parabolic�plug�with�PTFE�soft�seat�(max.�200°C)�� •�V-port�plug,�metal�seat�� •��Parabolic�pressure�balanced�plug,�metal�seat,��

Material�of�piston�seal:��PTFE�with�stainless�steel�spring�(max.�200°C)

Guiding� •�Parabolic�plug:�Stem�guiding� •�V-port�plug:�Stem�and�port�guidingFlow characteristic� •��Equal�percentage�or�linear�Rangeability�� •��50�:�1�on�parabolic�plug� •�30�:�1�on�V-port�plugShut off class�(seat / plug leackage classes)� •��Metal�seat�-�Leakage�class�IV�acc.�to�DIN�EN�1349�or�IEC�60534-4� •��Soft�seat�-�Leakage�class�VI�acc.�to�DIN�EN�1349�or�IEC�60534-4Closing�pressures�refer�to�page�4.

Technical�data�for�actuator�refer�to�data�sheet.

Selection of possible applications Industrial�installations,�processing�technology,�plant�manufacturing,�etc.��(other�applications�on�request)�Selection of possible flow media Fig.�440:��Cooling�water,�cooling�brine,�warm�water,�hot�water,�steam,�gas,�etc.��Fig.�441:��Refrigerant,�cooling�water,�warm�water,�hot�water,�thermal�oil,�steam,�gas,�etc.��(other�flow�media�on�request)�

Edition�12/07�-�Data�subject�to�alteration

3

Dimensions and weightsDN 15 20 25 32 40 50 65 80 100 125 150

L (mm) 130 150 160 180 200 230 290 310 350 400 480Fig. 440 H (mm) 556 556 564 564 571 577 590 605 624 685 745

ARI-PREMIO 2,2 kNPN16 (kg) 9 9,7 10,6 12,2 14,1 17 22,1 27,8 38 -- --PN25/40 (kg) 9,8 10,6 11,9 13,7 16,2 18,9 26,1 32,3 45 -- --

ARI-PREMIO 5 kNPN16 (kg) 10,1 10,8 11,7 13,3 15,2 18,1 23,2 28,9 39 66 88PN25/40 (kg) 10,9 11,7 13 14,8 17,3 20 27,2 33,4 46 78 110

H (mm) -- -- --- -- 721 727 740 755 774 833 893ARI-PREMIO 12 kN ARI-PREMIO 15 kN

PN16 (kg) -- -- -- -- 19,2 22,1 27,2 32,9 43 59 77PN25/40 (kg) -- -- -- -- 21,3 24 31,2 37,4 50 90 131

Fig. 441 H (mm) 741 741 749 749 740 742 826 838 854 1040 1071

ARI-PREMIO 2,2 kNPN16 (kg) 13,4 13,4 14,4 16,9 19,4 21,9 24,9 35,9 51 -- --PN25/40 (kg) 15,4 16,9 19,4 22,4 28,4 30,9 37,9 47,9 64 -- --

ARI-PREMIO 5 kNPN16 (kg) 14,5 14,5 15,5 18 20,5 23 26 37 53 73 105PN25/40 (kg) 16,5 18 20,5 23,5 29,5 32 39 49 66 85 130

H (mm) -- -- -- -- 890 892 976 988 1004 1188 1219ARI-PREMIO 12 kN ARI-PREMIO 15 kN

PN16 (kg) -- -- -- -- 24,5 27 30 41 57 77 109PN25/40 (kg) -- -- -- -- 33,5 36 43 53 70 89 134

Standard-flange�dimensions�refer�to�page�23.

Face-to-face�dimension�FTF�series�1�according�to�DIN�EN�558-1

Parts

Pos. Description Fig. 12.440 Fig. 12.441

Fig. 22.440 / Fig. 23.440 Fig. 22.441 / Fig. 23.441

Fig. 34.440 / Fig. 35.440 Fig. 34.441 / Fig. 35.441

Fig. 55.440 Fig. 55.441

1 Body� EN-GJL-250�,�EN-JL1040 EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.4408

1.2 Seat�ring X20Cr13+QT,�1.4021+QT X20Cr13+QT,�1.4021+QT��>DN50:�G19�9�Nb�Si,�1.4551 --

3 Plug�* X20Cr13+QT,�1.4021+QT X6CrNiMoTi17-12-2,�1.45714 Straight�pin�* X10CrNi18-8,�1.4310 A4�-�705 Stem X20Cr13+QT,�1.4021+QT�(DN125-150) X6CrNiMoTi17-12-2,�1.45717 Mounting�bonnet EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.44088 Guide�bushing X20Cr13+QT,�1.4021+QT��(hardened) X6CrNiMoTi17-12-2,�1.45719 Gasket�* Pure�graphite�(CrNi�laminated�with�graphite)10 Studs 25CrMo4,�1.7218 A4�-�7011 Hexagon�nuts C35E,�1.1181 A412 V-ring�unit�* PTFE14 Washer�* X5CrNi18-10,�1.430115 Spring�* X10CrNi18-8,�1.431016 Bushing�* PTFE�(reinforced)17 Sealing�ring�* Cu�/�Soft�iron18 Scraper�* PTFE�(reinforced)19 Screw�joint�* X8CrNiS18-9,�1.430520.1 Bellows�housing EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.440820.2 Mounting�bonnet EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.440820.3 Stem-�/�Bellows�unit�* X20Cr13+QT,�1.4021+QT�/�X6CrNiTi18-10,�1.4541 X6CrNiMoTi17-12-2,�1.457120.4 Guide�bushing X20Cr13+QT,�1.4021+QT��(hardened) X6CrNiMoTi17-12-2,�1.457120.5 Guide�bushing X20Cr13+QT,�1.4021+QT��(hardened) X6CrNiMoTi17-12-2,�1.457120.6 Gasket�* Pure�graphite�(CrNi�laminated�with�graphite)20.7 Studs 25CrMo4,�1.7218 A4�-�7020.8 Hexagon�nuts C35E,�1.1181 A420.10 Packing�ring�* Pure�graphite20.12 Washer�* X5CrNi18-10,�1.430120.17 Screw�joint�* X8CrNiS18-9,�1.4305*�Spare�parts�

Information�/�restriction�of�technical�rules�need�to�be�observed!ARI-Valves�of�EN-JL1040�are�not�allowed�to�be�operated�in�systems�acc.�to�TRD�110.A�production�allowance�acc.�to�TRB�801�No.�45�exists�(acc.�to�TRB�801�No.�45�EN-JL1040�is�not�allowed.)The�engineer,�designing�a�system�or�a�plant,�is�responsible�for�the�selection�of�the�correct�valve.

ARI-STEVI® 440 / 441Electric actuator ARI-PREMIO


4

max. permissible closing pressures�on�flow-to-open�P2�=�0�(Observe�regulations,�refer�to�page�23.�Plug�design�acc.�to�„Selection�STEVI“,�refer�to�techn.�annex.)DN 15 20 25 32 40 50 65 80 100 125 150Seat-ø�(mm) 21 21 27 31 41 51 66 81 101 126 151Standard�Kvs-values 4 6,3 10 16 25 40 63 100 160 250 400Reduced�Kvs-values�3) 2,5 4;�2,5 6,3 10 16 25 40 63 100 160 250Travel�(mm) 20 30 50

Actuator�1)

ARI-PREMIO 2,2 kN

Closing�pressure�(bar)

I. 40 40 30,8 23,1 12,8 8 4,3 2,7 1,5II. 40 40 28,8 21,6 11,9 7,4 3,9 2,3 1,3III. 30,7 30,7 27,1 20,4 10,6 6,5 3,6 2,2 1,2

Operating�time�2)�(s)�(Op.�speed�0,38�mm/s) 53 79

Actuator�1)

ARI-PREMIO 5 kN


I. 40 40 33,3 21,3 12,3 8 4,9 3 2II. 40 40 32,3 20,7 11,9 7,6 4,7 2,9 1,9III. 40 40 40 40 31 19,8 11,6 7,5 4,6 2,7 1,8

Operating�time�2)�(s)�(Op.�speed�0,38�mm/s) 53 79 132

Actuator�1)

ARI-PREMIO 12 kN


I. 40 40 32,3 21,2 13,5 8,5 5,9II. 40 40 31,8 20,9 13,3 8,4 5,8III. 40 40 31,6 20,7 13,2 8,3 5,7

Operating�time�2)�(s)�(Op.�speed�0,79�mm/s) 25 38 63

Actuator�1)

ARI-PREMIO 15 kN


I. 40 26,9 17,2 10,9 7,5II. 40 26,6 17 10,8 7,4III. 40 26,4 16,9 10,6 7,3

Operating�time�2)�(s)�(Op.�speed�0,38�mm/s) 79 132

I. Fig. 440: PTFE-V-ring unit; II. Fig. 440: PTFE- / pure graphite-packing; III. Fig. 441: Bellows seal

1)��Motor�voltage:�230V�50Hz��Other�voltages:�24V�50/60Hz;�115V�50/60Hz;�230V�60Hz��Technical�data�for�actuator�refer�to�data�sheet�ARI-PREMIO.

2)�Indicated�operating�times�with�50Hz.3)��Other�Kvs-value-reductions�are�possible�with�Fig.�445�/�446�(Stainless�steel�body�with�screwed�seat�ring).��

For�max.�permissible�closing�pressures�refer�to�separate�data�sheet.

ARI-STEVI® 440 / 441Closing pressures: Electric actuator ARI-PREMIO


23

Standard-flange dimensions Flanges�acc.�to�DIN�EN�1092-1/-2�(Flange�holes�/�-thickness�tolerances�acc.�to�DIN�2533/2544/2545)

DN (mm) 15 20 25 32 40 50 65 80 100 125 150

PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285

PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240

PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22

PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300

PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250


PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300

PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250


Pressure-temperature-ratings acc. to DIN EN 1092-2

Material PN -60°C to <-10°C* -10°C to 120°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C

EN-JL1040 16 bar -- 16 14,4 12,8 11,2 9,6 -- -- --

EN-JS1049 16 bar on�request 16 15,5 14,7 13,9 12,8 11,2 -- --

EN-JS1049 25 bar on�request 25 24,3 23 21,8 20 17,5 -- --

Pressure-temperature-ratings acc. to DIN EN 1092-1

Material PN -60°C to <-10°C* -10°C to 50°C 100°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C

1.0619+N 25 bar 18,7 25 23,3 21,7 19,4 17,8 16,1 15 14,4 13,9

1.0619+N 40 bar 30 40 37,3 34,7 30,2 28,4 25,8 24 23,1 22,2

1.4408 40 bar 40 40 37,3 33,8 31,1 29,3 27,6 26,7 25,6 --

Intermediate values for max. permissible operational pressures can be determined by linear interpolation of the given temperature / pressure chart.*�Valve�with�extended�bonnet,�studs�and�nuts�made�of�A4-70�(at�temperatures�below�-10°C)

Please indicate when ordering-�Figure-No.�-�Nominal�diameter-�Nominal�pressure-�Body�material-�Plug�design-�Kvs-value-�Flow�characteristic-�Stem�sealing-�Actuator-�Special�design�/�accessoriesExample:Figure�35.440;�Nominal�diameter�DN100;�Nominal�pressure�PN40;�Body�material�1.0619+N;�Parabolic�plug;�Kvs�160;�GLP;��Stem�sealing�PTFE-V-ring�unit;�Actuator�ARI-PREMIO�5�kN.

Dimensions�in�mmWeights�in�kgPressures�in�barg�(gauge)�1�bar�=̂ �105�Pa�=̂ �0,1�MPa�Kvs�in�m3/h�


ARI-STEVI® 440 / 441Flange dimensions / Pressure-temperature-ratings

24

Technology for the Future. G E R M A N Q U A L I T Y V A L V E S

ARI-Armaturen�Albert�Richter�GmbH�&�Co.�KG,�D-33756�Schloß�Holte-Stukenbrock,��Tel.�+49�52�07�/�994-0,�Telefax�+49�52�07�/�994-158�or�159��Internet:�http://www.ari-armaturen.com��E-mail:�[email protected]

Stem sealing

Spring�loaded�PTFE-V�ring�packing�unit PTFE-/�Pure�graphite-packing

Bellows�seal�with�safety�stuffing�box

Body design

Body�with�pressed�seat�ring��(EN-JL1040,�EN-JS1049) Body�with�welded�seat�(1.0619+N) Body�with�machined�seat�(1.4408)

Plug design

Parabolic�plug�with�PTFE�soft�seat�and�stem�guiding V-port�plug�with�stem�and�port�guiding Parabolic�pressure�balanced�plug

ARI-STEVI® 440 / 441Constructions


Pos. Description23 Packing�ring�* PTFE�or�Pure�graphite25 Screw�joint�* X8CrNiS18-9,�1.4305*�Spare�part

0040000107 2402 englisch

Operating and Installation InstructionsThrust Actuator ARI-PREMIO

Contents1.0 General information on operating instructions ..................................................................................................32.0 Notes on possible dangers .....................................................................................................................................3

2.1 Significance of symbols ........................................................................................................................................................3

2.2 Safety-related definitions: .....................................................................................................................................................4

2.3 Qualified personnel ...............................................................................................................................................................4

3.0 Handling .................................................................................................................................................................43.1 Storage ..................................................................................................................................................................................4

3.2 Transport ...............................................................................................................................................................................4

3.3 Handling before installation..................................................................................................................................................4

4.0 Description .............................................................................................................................................................54.1 Field of application ...............................................................................................................................................................5

4.2 Method of functioning ..........................................................................................................................................................5

4.3 Technical data .......................................................................................................................................................................6

4.4 Diagram.................................................................................................................................................................................84.4.1 ARI-PREMIO 2,2 - 5 kN....................................................................................................................................................84.4.2 ARI-PREMIO 12 - 15 kN...................................................................................................................................................9

4.5 Parts list...............................................................................................................................................................................10

4.6 Dimensions .........................................................................................................................................................................11

5.0 Notes on dangers during installation, operation and maintenance ................................................................12

6.0 Installation ...........................................................................................................................................................126.1 General installation data .....................................................................................................................................................12

6.2 Manual operation ................................................................................................................................................................136.2.1 ARI-PREMIO 2.2 - 5 kN..................................................................................................................................................136.2.2 ARI-PREMIO 12 - 15 kN.................................................................................................................................................14

6.3 Installation instructions for mounting to valves..................................................................................................................156.3.1 Mounting for valve-lift up to 30 mm (yoke version) ........................................................................................................156.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version) ....................................................................................16

6.4 Electrical connection...........................................................................................................................................................186.4.1 Wiring diagram ARI-PREMIO 2,2 - 5 kN........................................................................................................................186.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN.......................................................................................................................19

6.4.2.1ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor............................................................................................. 196.4.2.2ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor.................................................................................................. 20

6.4.3 Connection ........................................................................................................................................................................21

6.5 Settings................................................................................................................................................................................226.5.1 Torque and travel switches - standard feature...................................................................................................................226.5.2 Connection boards PA or NA (only 2.2 - 5 kN)................................................................................................................226.5.3 Travel switch .....................................................................................................................................................................23

6.5.3.1Installation of additional travel switches.......................................................................................................................................... 236.5.3.2Setting of standard travel switch (S3): ............................................................................................................................................. 256.5.3.3Setting the additional travel switches (S4/S5 and S24/S25) ............................................................................................................ 26

6.5.4 Potentiometers...................................................................................................................................................................266.5.4.1Installing the potentiometer.............................................................................................................................................................. 276.5.4.2Setting the potentiometer ................................................................................................................................................................. 28

6.5.5 Heating..............................................................................................................................................................................296.5.5.1Installation of heating....................................................................................................................................................................... 29

6.5.6 Electronic position indicator RI21 ....................................................................................................................................306.5.7 Electronic position controller ES11 ..................................................................................................................................306.5.8 Electronic position indicator (RI21) and position controller (ES11) together in the actuator..........................................316.5.9 Integrated temperature controller dTRON 16.1 ................................................................................................................32

6.5.9.1Installation of the dTRON 16.1........................................................................................................................................................ 326.5.10 Integrated reversing contactor.........................................................................................................................................33

6.5.10.1Installing the reversing contactor ................................................................................................................................................... 336.5.10.2Electrical connection with ES11 or dTRON 16.1 .......................................................................................................................... 33

6.5.11 Phase control relay..........................................................................................................................................................346.5.11.1Installing the phase control relay ................................................................................................................................................... 34

7.0 Starting up............................................................................................................................................................358.0 Care and maintenance ........................................................................................................................................359.0 Troubleshooting ...................................................................................................................................................3510.0 Troubleshooting table........................................................................................................................................3611.0 Dismantlement of thrust actuator....................................................................................................................3612.0 Warranty ............................................................................................................................................................3713.0 EC declaration of conformity ...........................................................................................................................38

00400001072402 page 3

Operating and installation instructionsThrust actuator ARI-PREMIO

1.0 General information on operating instructions

These operating instructions contain information necessary to install and operate the thrust actuatorboth safely and effectively.If problems arise which cannot be solved with the aid of these operating instructions, please contactthe supplier/manufacturer for further information. These operating instructions comply withapplicable EN safety standards as well as regulations and codes of practice applicable in the FederalRepublic of Germany. If the electronic positioner is used outside the Federal Republic of Germany,the operator or the person responsible for the system design must ensure that valid national codes ofpractice are complied with.The manufacturer reserves all rights to implement technical modifications and improvements at anytime.The use of these operating instructions assumes the user is qualified as described under Section 2.3"Qualified Personnel".The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on possible dangers

2.1 Significance of symbols

Warning of general danger

Warning of dangerous voltage

Exposed to injury!Don’t touch the turning handwheel when the motor is running

Exposed to injury!Don’t put your hand into the up or downwards moving appliance

Danger when not observing the operating and installation instructions!Before installing, operating, maintenance or dismantling read and observe theinstructions

Danger though voltage!Before dismantling the hood, switch of the electrical source and secure againstturning on again

00400001072402


2.2 Safety-related definitions:The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operatinginstructions as indications for particular hazards or for important information requiring special signs.

DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and/ or considerable damage to property can occur.

WARNING means that if the relevant information is disregarded, there is a danger of serious injuryand / or damage to property can occur.

CAUTION means that if the relevant information is disregarded, there is a danger of injury and / ordamage to property can occur.

NOTE means that particular attention must be paid to certain technical aspects.

All other information not specifically emphasised such as transport, installation, operating andmaintenance instructions as well as technical data (in the operating instructions, productdocumentation and on the device itself) must also be complied with to the fullest extent in order toavoid faults which in turn can cause serious injury to persons or damage to property.

2.3 Qualified personnelThis refers to personnel possessing corresponding qualifications and familiar with the processes ofinstalling and assembling the product as well as with putting the product into service and operatingthe same, e.g.

- Training or instruction or authorisation to switch on and off electric circuits and equipment/systemsand to disconnect, ground and identify the same in accordance with VDE 0100, the regulationsstipulated by the local electricity generating boards as well as technical safety standards.

- Instruction and obligation to comply with all regulations and requirements pertaining to use as wellas regional and in-house regulations and requirements, especially TRB 700.

- Training or instruction in accordance with technical safety standards in the use and maintenance ofpertinent safety equipment including job-safety equipment.

- Training in first-aid, etc.

3.0 Handling3.1 Storage- Storage temperature -20˚ to +70˚C dry, free of dirt

- Do not damage packing

- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport- Transport temperature -20˚ to +70˚C

- Protect against external force (impact, vibration etc.).

- Do not damage packing.

3.3 Handling before installation- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).

- Correct handling protects against damage.

- Do not soil or damage type identification plate and wiring diagram on the controller.

00400001072402 page 5


4.0 Description

4.1 Field of application

ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves requiring anominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN. The thrust actuatorsare set to the thrust forces specified in the technical data. If supplied with the valve, the lift of thethrust actuator will be set to the stroke distance of the valve.Selection of the proper actuator version in alignment with the corresponding fitting as well as use ofthe thrust actuator in accordance with the specified technical data is the responsibility of the systemsengineer.Any use of the thrust actuator beyond the specified technical data or improper use of the actuator isdeemed to be not for the intended purpose.

The ambient conditions have to be conform to the actual electromagnetic compatibility directives.Additional the compatibility to this directives has to be maintained in case of expansion or otherchanging of the ambient conditions.

4.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve.Transfer of force is effected via a coupling safeguarded against torsion.The torsion safeguarding feature also serves as a lift indicator.The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear clampsmounted to the column.

The electrical components are accommodated separately from the gearbox underneath a sealed hood,thus being protected against operating and environmental effects.Following removal of the hood, easy access is provided to the switchgear and indicating feature.The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut and thusperforms a pull or push motion depending on the sense of rotation.In the final positions of the valve, the spindle nut is pressed against a set of springs so as to produceclosing force.The motor is switched off by means of two load-dependent switches and one stroke-dependentswitch. The load-dependent switches will also switch off the motor if foreign bodies have lodgedthemselves between the valve seat and cone.The load-dependent switches serve to protect the valve and thrust actuator against damage.

00400001072402


4.3 Technical dataType ARI-PREMIO

Thrust force kN 2.2 5.0 12.0 15.0

Stroke distance max. mm 50 80

Duty classification in accordancewith DIN VDE 0530

S1 - 100 % duty cycle; S4 - 80% duty cycle 1200 c/h S1 - 100% ED;S4 - 50% ED 1200 c/h

Control speed mm/sec. 0.25 0.38 0.38 1,0 0.79 0.38

Motor voltage 230V - 50Hz / 60Hz * 230V -50Hz 230V - 50Hz / 60Hz *

Power consumptionW 10.3 11.7 25.3 52.9 109 96

Torque switch 2 only, permanently wired,switching capacity 10A, 250V~

2 pcs., permanentlywired

switching capacity 16A,250V~

Travel switch 1 only, permanently wired,switching capacity 10A, 250V~

1 pcs.,permanently wired

switching capacity 16A,250V~

Enclosure IEC 60529 IP 65

Max. permissible ambienttemperature

-20 ˚ C ... +70 ˚ C

Handwheel Yes (rotating during operation) Yes (engageable)

Mounting position Any. Exception: motor must not be suspended downwards

Gear lubricant Klüber Unigear LA02 50/50-mixKlüber Isoflex NBU15

Ultra andKlüber Nontrop KR291

Weight kg 5.4 6 6.5 10,5

* Control speed and power consumption are 20% higher at frequency of 60 Hz

00400001072402 page 7


Accessories

Type ARI-PREMIO

Thrust force kN 2.2 5.0 12.0 15.0

Additional travel switches 2 additional travel switches, zero potential,Switching capacity 10A, 250V ~

Additional travel switches for low-voltage / electronic system

2 additional travel switches, zero potential, with gold contacts,switching capacity max. 0,1A, 4-30V DC

Potentiometer max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt

Electronic position indicator RI 21 0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possibleUsing the temperature controller, installation is only possible in the control cabinet

Electronic position controller ES 11 0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possibleNot compatible for use with the temperature controller.

Heating resistor (with automatic switching)230V-50Hz, 115V-50Hz, 24V-50Hz, 15 watt

Additional voltages / frequencies 24V - 50/60Hz115V - 50/60Hz

24V - 50Hz 24V - 60Hz115V - 50Hz115V - 60Hz230V - 60Hz

24V - 50/60Hz 115V - 50/60Hz

3~400V - 50Hz3~440V - 60Hz

Standard-voltage connection board,PA

2 torque switches and 1 travel switch, zero potential,for free wiring,

Switching capacity10A, 250V ~--

Low-voltage connection board(electronic system), NA

2 torque switches and 1 travel switch,for free wiring,

with gold contacts,Switching capacity max. 01A, 4-30 VDC

--

Integrated temperature-controllerdTRON 16.1

Three-step temperature-controller in microprocessor-technology.Control range: -200˚C to 850 C (resistance thermometer)

Voltage: 24V, 115V or 230V 50/60HzCompatible with resistance thermometers and thermocouples

(provided by customer), or standardized active current or voltage signals.

Integrated reversing contactor --

Actuator with 400V-50Hzand 440V-60Hz

Only 1 electronic modulepossible!

Phase control relay --Only in addition with

integrated reversing con-tactor!

00400001072402


4.4 Diagram4.4.1 ARI-PREMIO 2,2 - 5 kN

Fig. 1

Yoke Version Column Version

00400001072402 page 9


4.4.2 ARI-PREMIO 12 - 15 kN

Fig. 2

00400001072402


4.5 Parts listDesignation Designation

50.1 Gearbox 50.30 Driving spindle

50.1.1 Gearbox cover plate 50.31 Spindle safety feature

50.2Cable conduit fitting2,2 - 5kN: 2 x PG1112 - 15kN: 2 x PG13,5 / 1 x PG9

50.32 Torsion safety feature

50.34 Bellow

50.35 Grub screw M6

50.4 Sealing plug 1 x PG11 50.36 Set collar

50.5 Gasket 50.37 Grub screw DIN 913-M3x5

50.6 Hood 50.38 Guide spindle

50.7 Hood seal 50.39 Hexagon nut DIN EN 24034-M5

50.8 Counter-sunk screw DIN 7991-M5x20 50.40 Synchronous motor, complete

50.9 Sealing washer DIN 125-5,3 50.41 Head cap screw DIN 912-M4

50.10 Column 50.42 Board support

50.12 Handwheel 50.43 Standard board

50.12.1 Turning handle of handwheel 50.45 Shift lever

50.14 Yoke 50.46 Washer

50.15 Flange 50.47 Wiring diagram sticker, standard

50.16 Spring washer DIN 128-A10 50.48 Connector, 3-pole (standard)

50.17 Hexagon head screwDIN EN 24017-M10x30

50.50 Trip slide

50.51 Setting spindle for switch S3

50.18 Hexagon head screwDIN EN 24017-M10x45



50.19 T-head bolt DIN 261-M12x40 50.54 Trip cam

50.20 Washer DIN 125-13 50.55 Lock washer DIN 6799-2,3

50.21 Spring washer DIN 128-A12 50.56 Spring PREMIO for trip slide

50.22 Hexagon nut DIN EN 24032-M12 50.57 Head cap screwDIN 912-M4x10

50.23 Lift dial 50.58 Protective conductor terminal

50.24 Distance column 50.59 Head cap screw DIN 912-M4x6

50.25 Hexagon nut DIN 980-V-M16 50.87 Threaded bush

50.26 2-ear clamp (stroke indicator) 50.101 Connector, 8-pole

50.27 Coupling

00400001072402 page 11


4.6 Dimensions

Fig. 3

XL

h23

663

3m

ax. 3

0 m

m25

665

3m

ax. 5

0 m

m27

166

8m

ax. 6

5 m

m28

668

3m

ax. 8

0 m

m

Cle

aran

ce r

equi

red

for

rem

oval

of

hood

AR

I-P

RE

MIO

2,2

- 5

kN

Nom

inal

str

oke

> 3

0 m

m -

50

mm

AR

I-P

RE

MIO

2,2

- 5

kN

Nom

inal

str

oke

max

. 30

mm

AR

I-P

RE

MIO

12

- 15

kN

Nom

inal

str

oke

max

. 80

mm

Cle

aran

ce r

equi

red

for

rem

oval

of

hood

Cle

aran

ce r

equi

red

for

rem

oval

of

hood

00400001072402


5.0 Notes on dangers during installation, operation and maintenance

DANGER!

Safe operation of the positioner is only ensured if it is installed, put into operation and maintained byqualified personnel (refer to Point 2.3 "Qualified personnel"), while observing the warning notesprovided in these operating instructions. In addition, care must be taken to ensure that the generalequipment and safety regulations for electrical lines and installations are complied with and thattools and protection devices are used professionally. The operating instructions for the electronicpositioner must be observed when carrying out all work on and when handling the electronicpositioner. Disregard of these instructions can result in injury to persons or damage to property.

6.0 Installation

6.1 General installation data

In addition to general installation guidelines, the following points are required to be observed:

- Existing operating instructions for valve.

- Complete valve with crossarm.

- Valve cone approximately in mid lift position - on no account supported inside a seat!

- Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricitygenerating board.

- Conductor cross-section selected to correspond to the given drive power and existing line length.

- Mains fuse rating max. 6A.

- Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the actuator.

- Conformity of technical data on thrust actuator with field conditions.

- Mains voltage in accordance with data specified on rating plate of thrust actuator.

- Thrust actuator complete with yoke or distance columns and coupling parts intended for mountingto the corresponding valve.

- Qualified personnel possessing knowledge of the regulations pertaining to the erection of powerinstallations.

- Ease of access to installation site.

- Adequate clearance space above the thrust actuator for removing the hood(refer to point 4.6 Dimensions).

- Install where there is protection against high-energy heat radiation.

- The ambient temperature must not exceed +70 ˚C.

00400001072402 page 13


If installed outdoors, the thrust actuator must be provided with an additional cover to protect against- rain,- direct insulation,- powerful draughts and- dust.In case of widely fluctuating ambient temperatures and high atmospheric humidity, your arerecommended to install a heating resistor to minimise condensation buildup in the actuator.- Thrust actuator mountable in any position except in downward suspended position.If installed with a horizontal connecting rod, the thrust actuator must be mounted so both yoke legsor columns are on top of one another in the vertical plane (see fig. 4).

Fig. 4

6.2 Manual operation6.2.1 ARI-PREMIO 2.2 - 5 kN

With the motor in the stationary state, the thrust actuator can be run in the open and closed state withthe handwheel firmly meshed with the gear.

Proceed as follows:

- Swing out lever (50.12.1) from handwheel (50.12).

- Turning in clockwise direction--> closes valve.

- Turning in counter-clockwise direction--> opens valve.

CAUTION !In the manual operating mode pay careful attention in the final positions that the handwheel isonly turned to the point where the torque switch trips (audible click) as otherwise damage willbe caused to the thrust actuator! Since the handwheel always follows during motor-drivenoperation (running indication), never operate by hand while the motor is running - potentialinjury hazards!!!

Fig. 5

Correct Incorrect

Open Close

00400001072402


6.2.2 ARI-PREMIO 12 - 15 kN

With the motor in the stationary state, the thrust actuator can be run in the open and closed state withthe engageable handwheel.

Proceed as follows:

- Fold the turning handle out of the handwheel (A)

- Turn the handwheel slightly and push in the engaging button for manual mode (B) --> the buttonengages

- Turning in clockwise direction --> closes valve

- Turning in counter-clockwise direction--> opens valve

The motor is no longer in mesh when the handwheel is engaged. The handwheel is automaticallydisengaged when the motor starts and the handwheel is once more in mesh.

Fig. 6

CAUTION:In the manual operating mode pay careful attention in the final positions that the handwheel isonly turned to the point where the torque switch trips (audible click) as otherwise damage willbe caused to the thrust actuator!

Engaging buttonfor manual mode

OpenClose

00400001072402 page 15


6.3 Installation instructions for mounting to valves6.3.1 Mounting for valve-lift up to 30 mm (yoke version)

Fig. 7

To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed asfollows:

- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator(not illustrated).

- Position valve cone approximately in mid lift position.

Fig. A: - Turn flat hexagon nut if not present on valve spindle.

Fig. A-B: - Slip coupling (50.27) over valve spindle.

- Screw threaded bush (50.87) matching the valve onto the valve spindle in accordancewith setting dimension (Y) and lock with hexagon nut.

- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.

Fig. C: - Place thrust actuator (50) on valve.

- Mount thrust actuator (50) on fitting with two T-head bolts (50.19), two washers(50.20), two spring washers (50.21), two hexagon nuts (50.22).

Fig. D/E: - Swing out handwheel lever (50.12.1) and use it to move out the thrust actuator until thedriving spindle (50.30) comes to rest on the threaded bush (50.87).

Fig. F: - Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure inplace using grub screw M6 (50.35).

- Run valve to lowest position.

- Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is inalignment with tip of arrow mark on lift dial.

- Run valve to both final positions and check to ensure that these are safely reached

- Carry out electrical connection (refer to section 6.4.1).

- Set travel switch S3 (refer to section 6.5.3.2).

Hexagon nutValve spindle


turn

00400001072402


6.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version)

Fig. 8

To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm, proceedas follows:

- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator(not illustrated).

- Position valve cone approximately in mid lift position.

Fig. A: - Turn flat hexagon nut if not present on valve spindle.

Fig. A-B: - Slip coupling (50.27) over valve spindle.

- Screw threaded bush (50.87) matching the valve onto the valve spindle in accordancewith setting dimension (Y) and lock with hexagon nut.

- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.

- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.

Fig. C: - Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly.

- Screw distance column with 2-ear clamps on opposite side of handwheel into the flangein such a way that one of the 2-ear clamps is situated above the torsion safety feature(50.32) and the other below.

- Screw the other distance column into the flange likewise.

- Place thrust actuator (50) with distance columns onto valve and fix into position withtwo self-locking hexagon nuts (50.25).

Fig. D/E: - Fold out turning handle of handwheel (50.12.1), slightly turn the handwheel and pressin the engaging button for manual mode (only 12 - 15 kN) (button engages). Havingdone this, move out the thrust actuator until driving spindle (50.30) comes into contactwith threaded bush (50.87).



turn

00400001072402 page 17


Fig. F: - Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure using grubscrew M6 (50.35).

- Move the valve to the lowest position.

- Press 2-ear clamps (50.26) into position according to the stroke so they cannot slip,with the bottom clamp in the lowest valve position located directly below torsion safetyfeature (50.32) and the top clamp in the highest valve position located directly abovethe torsion safety feature.

- Move the valve to both travel positions and check that it reaches them reliably.

- Fold turning handle of handwheel (50.12.1) back in.

- Make the electrical connection (see points 6.4.1 and 6.4.2). The engaging button formanual mode (only 12 - 15 kN) disengages when the motor starts up.

- Set standard travel switch S3 (see point 6.5.3.2).

00400001072402


6.4 Electrical connection6.4.1 Wiring diagram ARI-PREMIO 2,2 - 5 kN

Fig. 9

acce

ssoi

res

HZ

Hea

ting

resi

stor

DE

Torq

ue s

witc

h

WE

(S3)

Tra

vel s

witc

h fo

r tr

avel

ing

the

stro

ke d

ista

nce

in o

peni

ng d

irec

tion

RI

21E

lect

roni

c po

sitio

n in

dica

tor

ES

11E

lect

roni

c po

sitio

n co

ntro

ller

NA

Low

-vol

tage

con

nect

ion

boar

d, z

ero

pote

ntia

l

PASt

anda

rd-v

olta

ge c

onne

ctio

n bo

ard,

zero

pot

entia

l

PO

TPo

tent

iom

eter

WE

Tra

vel s

witc

h, z

ero

pote

ntia

l

TT

RE

lect

roni

c te

mpe

ratu

re-c

ontr

olle

r dT

RO

N 1

6.1

output 1

output 2

actu

alex

tern

alse

t poi

nt in

put

binary input 2/output 5

pow

erin

terf

ace

valu

e in

put

supp

ly

(K1)

(K2)

clos

ed

open

open

open

open

open

Opt

ion

NA

:sa

me

desi

gn b

ut n

o R

C c

ircu

itan

d sw

itche

s w

ith g

old

cont

acts

(Sw

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ng c

apac

ity 0

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Stra

ight

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ve

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alve

with

div

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ug

3-w

ay v

alve

with

mix

ing

plug

00400001072402 page 19


6.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN6.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor

Fig. 10

Acc

esso

ries

HZ

Hea

ting

resi

stor

DE

Torq

ue s

witc

h

WE

(S3)

Tra

vel s

witc

h fo

r tr

avel

ing

the

stro

kedi

stan

ce in

ope

ning

dir

ectio

n

RI

21E

lect

roni

c po

sitio

n in

dica

tor

ES

11E

lect

roni

c po

sitio

n co

ntro

ller

NA

Low

-vol

tage

con

nect

ion

boar

d,ze

ro p

oten

tial

PASt

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onne

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ial

PO

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iom

eter

WE

Tra

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ero

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l

TT

RTe

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r

WS

Rev

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ng c

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ctor

PR

Phas

e co

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l rel

ay

output 1

output 2

actu

al v

alue

inpu

tex

tern

al s

etpo

int i

nput

pow

erin

terf

ace

binary input 2/output 5

Opt

ion

Ext

erna

l rev

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ng c

onta

ctor

:L

1, L

2, L

3 -

actu

ator

spi

ndle

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ves

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3, L

2, L

1 -

actu

ator

spi

ndle

dri

ves

out

In a

ll ex

tern

al r

ever

sing

cir

cuits

the

torq

uesw

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s S1

and

S2

have

to b

e us

ed to

switc

h of

f th

e ac

tuat

or m

otor

.

(K1)

(K2)

supp

ly

clos

ed

open

A-A

B o

pen

B-A

B o

pen

AB

-B o

pen

AB

-A o

pen

Stra

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way

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vew

ith d

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plug

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Ple

ase

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n

Wir

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exte

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rsin

gco

ntac

tor

00400001072402


6.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor

Fig. 11

Acc

esso

ries

WS

+ P

R

3-st

ep in

put s

igna

l

Acc

esso

ries

WS

Con

nect

3 p

hase

s L

1, L

2, L

3 on

ly h

ere

3-st

ep in

put s

igna

lC

onne

ct 3

pha

ses

L1,

L2,

L3

only

her

e

clos

ed

open

A-A

B o

pen

B-A

B o

pen

AB

-B o

pen

AB

-A o

pen

Stra

ight

way

val

ve3-

way

val

vew

ith d

iver

ting

plug

3-w

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alve

with

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plug

Ple

ase

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k th

e op

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ing

dire

ctio

n

Wir

e co

nnec

tion

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the

dif

fere

nt v

alve

typ

es

of t

he a

ctua

tor

!

00400001072402 page 21


DANGER!!!The processes of mains connection and putting the thrust actuator into service call forspecialised knowledge of power installation erection (VDE 0100), knowledge of regulations forthe prevention of accidents and the specific conditions for putting this thrust actuator intoservice. Such work may only be carried out by suitably qualified personnel in accordance withsection 2.3 "Qualified Personnel". The supply line for connecting up the thrust actuator mustbe in the dead state i.e. disconnected from the mains while connection work is being carriedout. After being disconnected, the mains power must be prevented from being switched backon again accidentally.

Failure to observe these instructions may lead to death, grievous bodily injury or substantialproperty damage!

6.4.3 Connection

To connect the thrust actuator up to the electrical power supply, proceed as follows:

- Run the thrust actuator a few mm out of the lower final position applying the manual mode.

- Loosen countersunk screw in hood, carefully remove hood in upward direction.

- Screw out one of the two cable inlets and re-assemble in the same way without the supplied blankflange.

- Insert the connection line through this cable inlet until sufficient conductor length is available up tothe corresponding terminals; then tighten the cable inlet until the connecting cable is clamped inplace inside it.

- Strip connecting cable approx. 1-1.5cm above cable inlet.

- Strip the individual conductors approx. 5mm away from the end and fit with conductor end sleeves.

- Connect protective conductor of connecting cable up to protective conductor terminal of thrustactuator.

- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator terminalstrip.

- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator terminal strip.

- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal strip.

- Place hood on carefully from above and mount firmly onto thrust actuator with countersunk screwand rubber gasket.

- Connect supply line to mains and run thrust actuator to each of the final positions so as to checkwhether the final-position travel switches effect switching off, also checking to see whether thedirection of movement on the thrust actuator corresponds to the desired direction.

- If the directions of movement are contrary to those desired, the pulse lines governing the move-inand move-out connecting rod will need to be exchanged.

00400001072402


6.5 Settings

DANGER !!!The thrust actuator may only be operated for a short time without the hood for unavoidablesetting operations to the potentiometers, travel switches and the electrical options. While theseoperations are in progress, the thrust actuator has hazardous, live, uninsulated parts exposedas well as moving and rotating parts. Improper execution of the setting operations or lack ofcare may cause death, grievous bodily injury or substantial property damage. Only suitablyqualified personnel must be allowed to perform these operations (refer to section 2.3"Qualified Personnel") . Operation of the thrust actuator without the hood for any purposeother than that described above is strictly prohibited.

6.5.1 Torque and travel switches - standard feature

As standard, thrust actuators are equipped with a load-dependent travel switch for the closingdirection (S1), a load-dependent travel switch for the opening direction (S2) and a stroke-dependenttravel switch for the opening direction (S3).The load-dependent travel switches (S1, S2) switch off the motor as soon as the factory-set thrustforce is attained.NOTE: The settings of the load-dependent travel switches must on no account

whatsoever be changed!The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke isattained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent travel switchS3 is set in such a way that the motor of the thrust actuator is switched off as soon as the maximumvalve-lift is attained.If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel switch S3 isset in the opening direction in the trip slide to such a downward extent that the upper final position ofthe valve is attained prior to travel switch S3 being reached, thus causing the load-dependent travelswitch S2 to switch off the motor.For this function, all three switches reveal interlock-controlled circuitry on the board.If the standard travel switches are to be integrated directly into the facility control system, thestandard board can be replaced by optional boards PA or NA (only 2.2 - 5 kN).

6.5.2 Connection boards PA or NA (only 2.2 - 5 kN)

On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/S23 do notreveal interlock-controlled circuitry and can be integrated individually into the facility controlsystem.The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as double-throwcontacts, are - in the case of these boards - brought out on terminals 40-48 and can be freelyconnected.The switches on the PA optional board (standard-voltage connection board) are designed forswitching capacities of up to 10A, 250V AC.The switches on the NA optional board (low-voltage connection board) are designed for switchingcapacities of up to 0.1A, 4-30V (gold contacts).The optional boards may only be installed at the factory due to the switching points of the load-dependent switches having to be reset following installation of these boards!

00400001072402 page 23


CAUTION !When using optional boards PA or NA, it must be warranted - due to the operator’s individualcircuitry- that, when switching the load-dependent travel switches S11/21, S12/S22 and S13/S23 the motor of the thrust actuator comes to a standstill without delay.This function is not provided for on the optional boards PA and NA in the supplied state!

6.5.3 Travel switch

The thrust actuators can be equipped with an additional stroke-switch board containing two travelswitches (double-throw contact S4 and S5).These switches can be set on infinitely variable lines over the entire stroke distance in both liftdirections and integrated at will into the facility control system (no interlock-controlled circuitry).The maximum switching capacity of the switches (refer to section 4.3 Technical Data) must not beexceeded.For low voltage (refer to section 4.3 Technical Data), the additional travel switches are supplied withgold contacts (option: low-voltage travel switch).

6.5.3.1 Installation of additional travel switches

To install additional travel switches, proceed as follows.

- Switch off mains voltage and safeguard to prevent it from being switched back on againaccidentally.

- Loosen countersunk screw in hood, carefully remove hood.

- Disconnect motor plug and mains connection plug from board.

- Carefully ease open the lock washer (50.56) (open ends) with a screw driver while pulling the tripslide (50.50) upwards from the board support.

- Remove trip slide (50.50) from board support by pulling upwards.

- Loosen head cap screws (50.57) on board support and remove this from gearbox (only necessary on5kN thrust actuator).

- Insert stroke-switch board (50.61) in board support (50.42) and fix in place using the suppliedscrews (50.44).

- Mount board support loosely on gearbox cover plate with two head cap screws (50.57) (onlynecessary on 5kN).

- Push trip slide (50.50) back into board support (50.42) from above and onto the guide spindle(50.38).

- Align board support (50.42) on gearbox cover plate in such a way that the guide spindle (50.38) iscentrally situated in the borehole of the board support (50.42); then screw down tightly on gearboxcover plate (only necessary on 5kN).

- Mount the trip slide (50.50) so that the spring (50.56) clips into the groove of the guide spindle(50.38).

- Insert 6-pole connector (50.62) in jack strip of stroke-switch board.

- Proceed to strip the connecting cable that has been led in through the cable inlet and fastened, andconnect the individual conductors to the terminal strip in accordance with the desired circuitry andthe wiring diagram.

00400001072402


- Set switch points on travel switches in accordance with section 6.3.2. Setting the travel switches

- Insert motor connection plug in jack strip (50.43.4) provided for the purpose.

- Insert mains connection plug in jack strip (50.43.3) provided for the purpose.

- Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket andcountersunk screw.

Fig. 12 Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

Designation Designation

50.38 Guide spindle 50.52 Setting spindle for switch S4

50.42 Board support 50.53 Setting spindle for switch S5

50.43.3 Jack strip for mains connection 50.54 Trip cam

50.43.4 Jack strip for motor connection 50.56 Spring

50.44 Self-tapping screw 50.57 Head cap screws DIN 912-M4x10

50.50 Trip slide 50.61 Stroke-switch board

50.51 Setting spindle for switch S3 50.62 Connector, 6-pole(option: travel switch)

00400001072402 page 25


6.5.3.2 Setting of standard travel switch (S3):

On delivery of the thrust actuator, the standard travel switch (S3) is already set to the existing valve-lift and the setting spindle for the travel switch S3 (50.51) is sealed with screw glyptal.This setting needs no changing for normal operation.

If reinstalling the thrust actuator on a straight-way valve, the travel switch S3 needs to be setas follows:

Move valve out of the lowest position so as to run valve-lift to up position.

Using a screw driver, proceed to turn setting spindle for switch S3 (50.51) until the trip cam (50.54)arriving from below trips the switch (audible click).

Run thrust actuator briefly in closing direction and then in opening direction once more, checking tosee whether the thrust actuator is switched off at the desired point (nominal lift).

If need be, correct the setting as described.

If reinstalling the thrust actuator on a three-way valve, the travel switch S3 needs to be set asfollows:

- Run valve in both final positions and check in each final position whether the valve switches off viathe load-dependent switch.

- Carry out a check in the top final position the see whether, after switching off the thrust actuator,the trip cam (50.54) of the travel switch S3 is situated below switch S3 and has not tripped thelatter. If the trip cam (50.54) is situated above the travel switch S3 or trips the same, the settingspindle governing the travel switch S3 (50.51) needs to be turned until the trip cam is situatedbelow travel switch S3 without tripping it.

- Run the thrust actuator in both final positions once more and check whether thrust actuator switchesoff in both final positions via the load-dependent switches.

- If need be, correct the setting as described above.

00400001072402


6.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)

The two additional travel switches can be freely set in both lift directions for indicating certain valvepositions.

To do this, proceed as follows:

- Run valve to desired position due to be indicated by the corresponding switch.

- Proceed to turn the setting spindle belonging to the appurtenant switch until the switch is tripped(audible click).

- Run thrust actuator briefly in both directions, checking and, if need be, correcting the setting.

The actuating feature on the travel switches is designed in such a way that both travel switches canbe overrun in both directions.

Standard design:For that reason, care should be taken on additional travel switches to see that the actuating state ofthe switches remains active only for a short time while the thrust actuator continues to run and thatswitching back takes place afterwards.The actuating state of the travel switches remains in force over a lift of 4 mm.

Special design:At additional travel switches with extended switch levers, the actuating state of the travel switchesremains in force over a lift of 49 mm.

6.5.4 Potentiometers

The potentiometers are used for electrical position acknowledgement on the facility control systemor for the options - electronic position controller ES11 or electronic position indicator RI21

A maximum of 2 potentiometers can be installed (= 1 double potentiometer).The potentiometers can be supplied with different resistance values (refer to section 4.3 TechnicalData).

For the electronic position controller ES11 and the electronic position indicator RI21 use must bemade solely of 1000 ohm potentiometers.

Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by means oftransmission determined in respect of each valve-lift between the toothed rack on the trip slide andthe pinion on the potentiometer shaft.Use must only be made of the pinion specified for the valve-lift.

If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer isassembled and set ready for operation.

To achieve optimal electromagnetic compatibility it is recommended to use shielded cables forconnecting potentiometers or standardized active current or voltage signals.

00400001072402 page 27


6.5.4.1 Installing the potentiometer

If retrofitting the potentiometer, proceed as follows:


- Loosen countersunk screw in hood, carefully remove hood.- Plug in the flat connectors on grey potentiometer cables onto the middle connector pins, those of

the red cables onto the upper connector pins and those of the yellow cables onto the lowerconnector pins of the potentiometer (Fig 12).

- Insert the potentiometer into the guide in the way that the pinion (50.73) of the potentiometermeshes with the gear stick of the trip slide.

- With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand window of boardsupport (50.42) above the potentiometer guide, insert into the guide between the slide block andthe potentiometer guide and hook into the cut-out below the potentiometer.With a valve lift between 30 mm and 50mm, hook spiral spring (50.70) into the right-hand window(for 12 - 15kN middle window) above the potentiometer guide, insert into the guide between theslide block and the potentiometer guide and hook into the cut-out below the potentiometer.With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70) into the middle window inboard support (50.42) above the potentiometer guide, insert into the guide between the slide blockand the potentiometer guide and hook into the cut-out below the potentiometer.

- Check to see whether pinion (50.73) is pressed into toothed rack by spiral spring (50.70) and ispositioned free from backlash.

- If this is not the case, remove spiral spring (50.70), readjust by bending a little, and place back inposition again.

- Screw jack strip of connecting cable (50.68) to board support (50.42) with two self-tapping screws(50.69) (single potentiometer connectors 25-27).

- Insert additional 3-pole connector (50.74) in jack strip of connecting cable (50.68).- Set potentiometer (refer to section 6.5.4.2).- Place hood carefully onto thrust actuator and fasten it on the actuator with rubber gasket and

countersunk screw.

Fig. 13

yellow

red grey

red

grey

yellow

00400001072402


Fig. 14: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

6.5.4.2 Setting the potentiometerTo set the potentiometer, proceed as follows:- Move thrust actuator to closing position.- Switch off mains voltage and safeguard to prevent it from being switched back on again

accidentally.- Using a screw driver, turn slotted potentiometer shaft in counter-clockwise direction until reaching

the travel stop. This places the potentiometer in the initial position (approx. 0 ohm).- For checking purposes, the resistance of the potentiometer needs to be measured using an

ohmmeter.- Measure resistance on potentiometer 1 between terminals 25 and 26.- Measure resistance on potentiometer 2 between terminals 28 and 29.- In this position of the actuator, the measured value should be approx. 0 ohm.- Run thrust actuator to upper final position and read off corresponding resistance value on

ohmmeter.- The resistance values thus measured need to be taken into account for the settings to the facility

control system.

Designation Designation50.42 Board support 50.69 Self-tapping screw50.47 Circuit-diagram sticker 50.70 Spiral spring (option: potentiometer)50.67.1 Hexagon nut 50.71 Slide block (option: potentiometer)50.67.2 Tooth lock washer 50.72 Set collar50.67.3 Potentiometer 50.73 Pinion (selection depends on valve-

lift 20, 30, 50, 65 or 80 mm)50.67.4 Washer from PA 50.74 Connector, 3-pole

(option: potentiometer)50.68 Connecting cable for option:

potentiometer50.95 Spring washer

00400001072402 page 29


6.5.5 Heating

A heating resistor can be fitted as a means of protection against the formation of condensation waterin cases involving widely varying ambient temperatures and high atmospheric humidity (outdooruse). The heating resistor is self-regulating so that a continuous supply of current merely needs to beconnected up.

6.5.5.1 Installation of heating

On principle, the heating can be combined with all options. It is completely mounted on a holdingbracket.If electronic system ES11 or RI21 is already installed, unscrew the electronic system from theholding bracket, remove it, install the heating and attach the electronic system to the holding bracketfor the heating.

To install the heating proceed as follows:


- Loosen countersunk screw in hood, carefully remove hood.

- Using the supplied screws, mount complete heating (on holding bracket) at the point on the gearboxcover plate provided for the purpose. (Fig. 16).

- Lead continuous-current cable (mains voltage = rated voltage of heating) through cable inlet intothrust actuator and fix in place with inlet.

- Strip continuous-current cable approx. 1-1.5cm above cable inlet.

- Strip individual conductors approx. 5mm away from the end and provide with conductor endsleeves.

- Lay the individual conductors in such a way that they do not come into contact with moving parts.

- Connect the individual conductors up to the connection terminal block in accordance with thewiring diagram.

Fig. 15

Designation Designation 50.83.1 Holding bracket (Option:

heating) 50.83.4 Jack strip

50.83.2 Head cap screw DIN 84-M3x8 50.83.6 Connector, 2-pole 50.83.3 Thermal circuit breaker 50.83.10 Heating resistor

Mounting thread M3for heating reisistor

Mounting thread M3for jack strip

Mounting thread M3for thermal circuit breaker

Mounting thread M4for options ES11 and RI21

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6.5.6 Electronic position indicator RI21

The electronic position indicator RI21 converts the resistance of the 1000 ohm potentiometercorresponding to the lift into an optional output control signal 0 (2) ...10V DCor 0 (4) ...20mA DC. For installing and setting the electronic position indicator RI21 the operatinginstructions applicable to this unit must be observed in the appropriate valid version. Thecorresponding operating instructions are supplied with each unit.

6.5.7 Electronic position controller ES11

The electronic position controller ES11 converts continuous input control signals 0 (2) ...10V DC or0 (4) ...20mA into a 3-point output signal for the motor, in which case interrogation of the valveposition takes place via a 1000 ohm potentiometer. For installing and setting the electronic positioncontroller ES11 the operating instructions applicable to this unit must be observed in the appropriatevalid version. The corresponding operating instructions are supplied with each unit.

Designation Designation50.67 Potentiometer 50.81 Head cap screw

DIN912 - M4x850.78/79 Option ES11 or RI21 50.82 Head cap screw

DIN912 - M4x1250.80 Holding bracket 50.83 Heating

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6.5.8 Electronic position indicator (RI21) and position controller (ES11) together in theactuator

Except or the 5 kN, 12 kN and 15 kN type in 24V version, the electronic position indicator RI21 andthe electronic position controller ES11 can be build-in together in the ARI-PREMIO.

It must be used a double potentiometer with 1000/1000 Ohm.

To install the RI21 and ES11 proceed as follows:


- Loosen counter-sunk screw in hood, carefully remove hood.

- Mount the electronic units by using the specific installation kit’s (Fig. 17).

Bild 17: Switchgear and indicating feature ARI-PREMIO 2,2 - 5 kN

Designation Designation

50.67 Potentiometer 50.82 Head cap screw DIN912 - M4x12

50.78/79 Option ES11 or RI21 50.106 Metal sheet ES11 and RI21

50.81 Head cap screw DIN912 - M4x8 50.108 Distance bold

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6.5.9 Integrated temperature controller dTRON 16.1

The integrated temperature controller controls temperatures, which are measured by input-connectedtemperature sensors, to a manual given setpoint by means of a three-step output connected with theactuator.

6.5.9.1 Installation of the dTRON 16.1The dTRON 16.1 can be mounted in the ARI-PREMIO as a complete unit with a mounting kit.It cannot be combined with ES11.

To install the dTRON 16.1 proceed as follows:In addition to 6.4.2 Connection, the electrical connection of the dTRON 16.1 has to be done in thefollowing way:

- Mount the temperature controller on the gear plate by using the specific installation kit (Fig. 18).

- Plug in the connector X2 of the dTRON 16.1 to the plug-in connector X1 (1/N, 11, 14) of theactuator terminal (Fig. 6).

- Connect the signal input and the individual wanted additional functions according the wiringdiagram (Fig. 6) to the dTRON 16.1.

- Connect the power supply to the dTRON 16.1 according to the wiring diagram (Fig. 6).

- For changing the working direction to heating signal = extending driving spindle, just change thewires on the connectors 11 and 14.


Designation

50.81 Head cap screw DIN912 - M4x8

50.97 Temperature controller dTRON 16.1

50.98 Fixing bracket (option dTRON)

50.99 Holding bracket (option dTRON)

50.100 Self-locking nut (option dTRON)

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6.5.10 Integrated reversing contactorThe integrated reversing contactor is actuated using a 3-step input signal.The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction of rotationof the three-phase motor.6.5.10.1 Installing the reversing contactorThe reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a mountingkit.The reversing contactor can only be combined with one of the ES11, RI21 or temperature controlleroptions. It is also possible to install the heating and the phase control relay.Proceed as follows to install the reversing contactor:Switch off the mains voltage and take measures to prevent it being switched back on inadvertently.The electrical connection procedure as described in 6.4.3 Connection is supplemented by thefollowing steps:- Use the mounting kit to attach the reversing contactor to the gear plate (fig. 19).- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in fig. 11.- Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor without a

phase control relay.- Refer to 6.5.11 Phase Control Relay regarding connecting with a phase control relay.

6.5.10.2 Electrical connection with ES11 or dTRON 16.1Modify the 3P output cable of the ES11 or the dTRON 16.1 as follows:- Remove plug X25.- Strip off the outer cable insulation down to about 18 cm.- Connect the individual conductors as follows:

CAUTION:The thrust actuator may be damaged if phases L1, L2 and L3 are not connected correctly andno phase control relay is fitted!

Black (L↑ ) - S2/14

Brown (L↓ ) - S1/11

Blue (1/N) - K1/A2, K2/A2

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Fig. 19: Switchgear and indicating feature ARI-PREMIO 12 - 15 kN

6.5.11 Phase control relay

The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The reversingcontactor is only activated by the phase control relay providing phases L1, L2 and L3 are connectedcorrectly. This protects the thrust actuator.

6.5.11.1 Installing the phase control relay

The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is onlypossible to use the phase control relay in conjunction with the reversing contactor. It cannot becombined with the dTRON 16.1 temperature controller in the actuator.

Proceed as follows to install the phase control relay:

Switch off the mains voltage and take measures to prevent it being switched back on inadvertently.

The electrical connection procedure as described in 6.4.3 Connection and 6.5.10 IntegratedReversing Contactor is supplemented by the following steps:

- Attach the phase control relay next to the reversing contactor (fig. 19).

- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in fig. 10.

Designation

50.57 Head cap screw DIN 912 - M4 x 10



50.102 Reversing contactor

50.103 Fixing plate (option reversing contactor)

50.105 Phase control relay

50.107 Bracket (option phase control relay)

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7.0 Starting upDANGER!Check the following before starting up a new system or restarting a system after repairs orconversion:- Correct completion of all installation/assembly work!- Circuits of the system in accordance with DIN VDE regulations and regulations of the

relevant power supply company as well as compliance with all safety regulations, especiallyTRB 700.

- hood of thrust actuator assembled.- Start up only by qualified personnel (see 2.3).While in operation, the thrust actuator has moving and rotating parts as well as beingintegrated in an electrical network system. Improper handling or failure to observe theoperating instructions or the valid regulations may lead to death, grievous bodily injury orsubstantial property damage!When placing into service proceed as follows:- Using the handwheel, run the thrust actuator to approximately mid lift position.- Apply brief pulses to the thrust actuator for each direction of movement and check whether the

directions of movement correspond to those desired. If this is not the case, the pulse linesgoverning the opening and closing action must be exchanged on the thrust actuator.

- Run thrust actuator to the final position in each direction of movement and check whether itswitches off automatically and whether all externally moving parts are able to move freely.

- If failing to function properly, check all installation and setting work previously carried out,correcting if necessary, and afterwards place into service once again.

8.0 Care and maintenanceThe thrust actuator requires very little maintenance. Accordingly maintenance in specified intervalsis not necessary.Depending on the conditions governing use, the maintenance and maintenance-intervals have to bedefined by the operator (see TRB 700).The thrust actuator must not be cleaned with high-pressure equipment or aggressive solvents ordetergents injurious to health or highly inflammable.During and after cleaning, an inspection should be carried out of the sealing points on the thrustactuator.If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements must berepaired.

9.0 TroubleshootingIn the event of malfunctions or disturbances in operation, first check whether the installation andadjustment work has been carried out and concluded in accordance with these operating instructions.Compare the data referring to operating voltage, actuating signal and temperature to the dataspecified on the layout drawing of the control system. Also check whether the given operatingconditions correspond to those specified in the data sheet or to the technical data specified on thetype identification plate.DANGER!All relevant safety regulations must be observed when carrying out the troubleshooting procedure,especially TRB 700.Contact the supplier/manufacturer if faults cannot be rectified on the basis of the following„troubleshooting table“.

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10.0 Troubleshooting tableDuring the process of trouble shooting, all safety regulations previously mentioned andcorresponding to the various operations must definitely be observed!!

11.0 Dismantlement of thrust actuatorIn addition to general installation guidelines, the following points are required to be observed:- Dismantlement of the thrust actuator from the fitting must only to be carried out by suitably

qualified personnel (refer to section 2.3).- Regard TRB 700.- The supply line for connecting up the thrust actuator must be in the dead state i.e. disconnected

while dismantlement work is being carried out. After being disconnected, the mains power must beprevented from being switched back on again accidentally.

- The system must be run down (depressurised state) as the valve cone is not held without the thrustactuator and would thus be conducted by the system pressure.

- Valve cone approximately in mid lift position - on no account supported inside a seat!

Fault Possible Causes RemedyThrust actuator fails to move Power failure Ascertain and eliminate cause

Fuse has blown Replace fuse

Thrust actuator not properlyconnected

Rectify connection on thrust actuatorin accordance with wiring diagram

Short circuit due to:

- moisture

Ascertain exact cause,

- Dry the thrust actuator and eliminateleakage

- wrong connection - Rectify connection on thrust actuatorin accordance with wiring diagram

- motor has burned out - Check whether the mains voltageagrees with the voltage specified onthe rating plate. Have motorchanged.

Connector contacts not plugged in/not properly plugged into jack strip

Insert connector firmly in jack stripthus affected

(Only for 12 - 15 kN)Handwheel is still engaged anddoes not disengage when the motorstarts up

Unscrew the motor mountingscrew closest to the cable feed-through. (Manual release of thehandwheel disengagementmechanism.)

Thrust actuator alternates betweenclockwise and counter-clockwiserotation

Motor operating capacitor defective Have motor operating capacitorreplaced

Thrust actuator fails to run to finalpositions and also produces chatter

Load-dependent travel switches out ofadjustment / defective

Remove thrust actuator and send tofactory for repair

Voltage drop due to excessively longconnecting cables or inadequateconductor cross-section

Lay connecting cables in accordancewith requisite output

Mains fluctuations beyondpermissible tolerance travels

Arrange for "clean" mains systemwithin requisite tolerances

System pressure too high Reduce system pressure

Periodic failure on thrust actuator Loose connection on feedline Tighten connections on terminal strips

Thrust actuator is switched off inopening direction prior to load-dependent switch (three-wayvalve)

Travel switch S3 not setcorresponding to use

Set travel switch S3 in accordancewith operating instructions

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To dismantle the thrust actuator proceed as follows:

- Loosen counter-sunk screw in hood, carefully remove hood.

- Disconnect all cables led into thrust actuator from outside and remove from thrust actuator.

- Place hood on carefully from above and fix in place with counter-sunk screw and rubber gasket.

- Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety feature.

- Loosen clamping bolts connecting the thrust actuator to the fitting.

- Remove thrust actuator from valve.

12.0 Warranty

The extent and period of warranty cover are specified in the "Standard Terms and Conditions ofAlbert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contractof sale itself.

We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmedapplication.

No warranty claims can be made for any damage caused as the result of incorrect handling ordisregard of operating and installation instructions, accident prevention regulations, EN, DIN, VDEstandards and other applicable codes of practice.

This warranty also does not cover any damage which occurs during operation under conditionsdeviating from those laid down by specifications or other agreements.

Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.

No claims will be accepted beyond the scope of this warranty. The right to replacement delivery isexcluded.

The warranty shall not cover maintenance work, installation of external parts, design modificationsor natural wear.

Any damage incurred during transport should not be reported to us but rather to the competentcargo-handling depot, the railway company or carrier company immediately or else claims forreplacements from these companies will be invalidated.

Technology for the Future.GERMAN QUALITY VALVES

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-StukenbrockTelephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159

Internet: http://www.ari-armaturen.com E-mail: [email protected]

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13.0 EC declaration of conformity

EC declaration of conformityas defined by

Directive about electromagnetic compatibility 89/336/EEC and theEG-Low voltage directive 73/23/EEC

Declaration of the manufactureras defined by

the Machinery Directive 98/37/EC

Herewith we declare,

ARI-Armaturen Albert Richter GmbH & Co. KG,Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock

that the supplied model of

electric thrust actuator ARI-PREMIO

in the delivered version complies with the following regulations:

- Directive about electromagnetic compatibility 89/336/EEC(amended by 92/31/EEC and 93/68/EEC)

Applied harmonized standards:EN 55011; EN 50081-1; EN 50082-2

- EG-Low voltage directive 73/23/EEC(amended by 93/68/EEC)

Applied harmonized standards:EN 60204-1, EN 60335-1, EN 60730-1

- EG-Machinery Directive 98/37/EC

Applied harmonized standards:EN 292-1; EN 292-2; EN 294; EN 349; EN 60204-1

The supplied model is intended to be incorporated into machinery or assembled with other machin-ery to constitute machinery covered by this directive and must be put into service until the machineryinto which it is be incorporated has been declared in conformity with theprovisions of the directive as amended by 98/37/EC.

Schloß Holte-Stukenbrock, 15.04.1999

........................................................(Brechmann, Managing director)

For 3504 controller

For CM30 controller

Revision 0508: Parts list Control Valve added Revision 0711: House style change Revision 0613: Connection diagram new controller added

VAF Instruments B.V.

Vierlinghstraat 24, 3316 EL Dordrecht, The Netherlands

P.O. Box 40, 3300 AA Dordrecht, The Netherlands

T +31 (0) 78 618 3100, F +31 (0) 78 617 7068

[email protected], www.vaf.nl

Specifications subject to change without notice.

Agents and distributors in more than 50 countries.

Represented by

TIB-723-GB-0613_AP_2way_valves_with_electric_actuator_English.pdf

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