Agromatic NEx Series User instructions

Revision: 2020-10-02
Assembly and Operating Manual
(Original)
Actuators Series
NEx, NEx-K, NEx-KA, and NEx-V
Keep for future use!

Legal Notice
© Agromatic Regelungstechnik GmbH
This operating manual and all illustrations contained therein are protected by copy-
right law. Any use outside the limitations of copyright law without our prior written
approval is prohibited and liable to prosecution. This applies especially to repro-
duction, translation, microfilming, saving, and editing in electronic systems.
We reserve the right to make technical changes as a result of improvements to the
performance characteristics and further developments without prior written notice.
Agromatic Regelungstechnik GmbH
Postfach 1162
D - 33804 Oerlinghausen
Germany
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Web: www.agromatic.de
Revision: 2020-10-02
Document: BA_NEx_EN_rev.03
Article no.: 23141.23 / PM-100071
Important information!
All dimensions in this manual are specified in metric units. The values
in millimeter can easily be converted into inches by multiplying the
values with the factor 1/25.4.

Actuators NEx, NEx-K, NEx-KA, NEx-V I
Note:
An index is provided on page 104 to help you navigate to specific subjects.
Contents
1  Introduction ................................................................................................ 1 
1.1  Notes and signs used in this document ....................................................... 2 
1.2  Symbols used in this manual ....................................................................... 3 
1.3  Warranty and liability.................................................................................... 3 
2  Safety .......................................................................................................... 5 
2.1  General safety information........................................................................... 5 
2.2  Intended use ................................................................................................ 6 
2.3  Symbols applied to the actuator................................................................... 7 
2.4  Residual risks............................................................................................... 7 
2.4.1  Hazards due to electricity ....................................................................... 8 
2.4.2  Hazards due to fire/explosion ................................................................. 9 
2.4.3  Danger from moving parts .................................................................... 10 
2.4.4  Protection classes IP66/IP67................................................................ 11 
2.5  Personal protective equipment .................................................................. 12 
2.6  Notes for emergencies............................................................................... 13 
2.7  Obligations of the plant operator................................................................ 13 
2.8  Requirements imposed on the personnel .................................................. 15 
2.8.1  Responsibilities..................................................................................... 15 
2.8.2  Qualifications required of the personnel ............................................... 16 
2.8.3  Obligations of the personnel................................................................. 16 
3  Product description ................................................................................. 17 
3.1  Product series............................................................................................ 17 
3.2  Overview .................................................................................................... 17 
3.2.1  Series NEx (rotary/part-turn actuator) .................................................. 17 
3.2.2  Series NEx-K, NEx-KA, NEx-V (linear actuators)................................. 18 
3.3  Functional description ................................................................................ 19 
3.4  Technical data............................................................................................ 20 
3.4.1  Dimensions........................................................................................... 20 
3.4.2  Weight .................................................................................................. 20 
3.4.3  Housing ................................................................................................ 20 
3.4.4  Drive motors ......................................................................................... 20 
3.4.5  Anti-condensate heater ........................................................................ 21 
3.4.6  Functional data ..................................................................................... 22 
3.4.7  Airborne noise emission ....................................................................... 23 
3.5  Nameplate.................................................................................................. 24 

Contents
II Actuators NEx, NEx-K, NEx-KA, NEx-V
4  Transport and storage..............................................................................25 
4.1  Acceptance inspection by the receiver .......................................................25 
4.2  Packaging, insulation..................................................................................25 
4.3  Transport instructions .................................................................................26 
4.4  Interim storage............................................................................................26 
5  Assembly...................................................................................................27 
5.1  General notes .............................................................................................28 
5.2  Installation...................................................................................................30 
5.2.1  Series NEx ............................................................................................30 
5.2.2  Series NEx-K, NEx-KA ..........................................................................34 
5.2.3  Series NEx-V.........................................................................................38 
5.2.4  Assembly of the handwheel ..................................................................40 
5.3  Electrical connection...................................................................................41 
5.3.1  Determining the direction of rotation .....................................................43 
5.3.2  Control using a BLDC motor .................................................................47 
5.3.3  Control using a synchronous motor.......................................................50 
5.3.4  Schematic diagram - DC (BLDC motor) ................................................51 
5.3.5  Schematic diagram AC (synchronous motor)........................................52 
5.3.6  Schematic diagram for direct current ....................................................53 
5.3.7  AC schematic diagram with service switch (option) ..............................53 
5.3.8  AC schematic diagram for parallel operation (option) ...........................53 
5.4  Setting the position switches ......................................................................54 
5.4.1  Control cam shapes and switches.........................................................55 
5.4.2  JNO: adjustable cam to be set from above ...........................................56 
5.4.3  JNS: sideways adjustable cam..............................................................58 
5.4.4  Brass control cam (option) ....................................................................60 
5.5  Connecting and adjusting the potentiometer (option).................................62 
5.6  2-wire current output 4 … 20mA (option)....................................................64 
5.7  Anti-condensate heater...............................................................................65 
5.8  Installing the hood.......................................................................................66 
6  Operation...................................................................................................69 
6.1  Auxiliary functions (optional).......................................................................71 
6.1.1  Handwheel ............................................................................................71 
6.1.2  Gearbox decoupling ..............................................................................73 
7  Maintenance and repair............................................................................75 
7.1  Safety instructions ......................................................................................75 
7.2  Maintenance work.......................................................................................77 
7.2.1  Maintenance intervals ...........................................................................77 
7.2.2  Cleaning the actuator (all series)...........................................................78 
7.2.3  Series NEx 1 to NEx 8...........................................................................78 

Contents
Actuators NEx, NEx-K, NEx-KA, NEx-V III
7.2.4  Series NEx-K ........................................................................................ 79 
7.2.5  Series NEx-KA...................................................................................... 80 
7.2.6  Series NEx-V ........................................................................................ 81 
7.2.7  Leak test ............................................................................................... 82 
7.2.8  Visual inspection................................................................................... 83 
7.2.9  Explosion protection test ...................................................................... 83 
7.2.10  Electrical inspection (all series) ............................................................ 84 
7.3  Spare parts ................................................................................................ 85 
8  Malfunctions............................................................................................. 87 
8.1  Safety information ...................................................................................... 87 
8.2  General notes ............................................................................................ 87 
8.3  Resetting the temperature switch .............................................................. 88 
8.4  Repairs....................................................................................................... 90 
9  Decommissioning, disassembly ............................................................ 91 
9.1  Putting the actuator out of operation.......................................................... 91 
9.2  Dismantling and disposing of the actuator ................................................. 92 
10  Appendix................................................................................................... 93 
10.1  Certificates................................................................................................. 93 
11  Index........................................................................................................ 104 


Actuators NEx, NEx-K, NEx-KA, NEx-V 1
1 Introduction
This operating manual applies to the series NEx, NEx-K, NEx-KA und NEx-V.
It provides all the information required for a safe and secure assembly and
trouble-free operation of the actuator.
This operating manual must be read, understood and applied by all persons
responsible for installing, operating, servicing, checking, troubleshooting,
dismantling or disposing of the actuator. This shall apply in particular to the
safety instructions provided.
After reading the operating manual you will be able to
−install the actuator in a safe and secure manner,
−operate the actuator in a safe and secure manner,
−service the actuator according to instructions,
−take the necessary action in the event of a fault.
Any general, legal or otherwise binding regulations for the prevention of acci-
dents and for the protection of the environment in force in the country of use
should be taken into account in addition to the operating manual.
This operating manual is an integral part of the actuator. It should be stored
in an easily accessible place close to the actuator during the entire service
life of the device.
The following documentation in its current version should also be taken into
account:
−the product catalog, and
−the General Terms and Conditions of Agromatic Regelungstechnik GmbH
−any additional operating/assembly instructions for optional accessories
where applicable (e.g. electronic position controller).

1.1 Notes and signs used in this document 1 Introduction
2 Actuators NEx, NEx-K, NEx-KA, NEx-V
1.1 Notes and signs used in this document
Passages of this operating manual that require special attention or are a di-
rect hazard warning are shown as follows:
DANGER
Warning of electrical hazard
This warning indicates an electrical hazard.
Only qualified and authorized electrical specialists are allowed to work on
electrical equipment.
DANGER
This warning note identifies an immediate hazard with a high risk, which
will lead to death or (serious) personal injury if it is not avoided.
WARNING
This warning indicates a potential hazard which, unless avoided, may
involve a medium risk of death or (serious) injury.
CAUTION
This warning note identifies a hazard with a low risk, which may lead to
minor or slight personal injury if it is not avoided.
NOTE
This warning indicates a hazard which, unless avoided, could involve a
low risk of material damage.
Important information
This sign draws attention to a function or setting of the actuator and in-
structs to exercise caution while working.
Instructions next to this sign must be completed before commencing other
activities.

1 Introduction 1.2 Symbols used in this manual
Actuators NEx, NEx-K, NEx-KA, NEx-V 3
The following means of representation are used in addition:
−Text following this mark represents an item in a list.
1. Text following this mark describes actions to be performed in the specified
order.
“ ” Text in quotes refers to other chapters, sections or documents.
1.2 Symbols used in this manual
In this operating manual, particular hazards are identified by the following
symbols:
Danger to life due to electric current
These symbols warn of danger to life due to electrical current.
Direct contact with live parts poses an immediate threat to life.
Risk of explosion
This symbol warns of dangers due to a potentially explosive atmos-
phere.
Risk of burns
This symbol warns of a burn hazard due to hot surfaces.
1.3 Warranty and liability
The obligations laid down in the supply contract, the General Terms and
Conditions, the delivery terms of Agromatic Regelungstechnik GmbH and the
legal regulations in force at the time of the signing of the contract shall apply.
All information and instructions in this operating manual were composed in
due consideration of the standards and regulations in force, state-of-the-art
technology as well as long-term knowledge and experience.
Each actuator will be subjected to tests before it leaves the factory. However,
the actuator should be subjected to final functional testing by qualified tech-
nical staff after assembly.

1.3 Warranty and liability 1 Introduction
4 Actuators NEx, NEx-K, NEx-KA, NEx-V
Agromatic Regelungstechnik GmbH shall not accept any liability for produc-
tion faults and resulting damages or consequential damages after the actua-
tor has been tested and installed at the provided location and declared func-
tional by the customer.
Warranty and liability claims shall be precluded in case of personal injury and
property damage if they can be attributed to one or more of the following
causes:
−improper use of the actuator or use other than intended,
−improper installation, start-up, operation, maintenance and cleaning of the
actuator,
−insufficient testing of the installed actuator within the complete system,
−continued operation of the actuator even though malfunctions were de-
tected during the initial or subsequent tests,
−failure to observe the operating manual and the notes in the operating
manual referring to assembly, start-up, operation and maintenance of the
actuator,
−employment of unskilled personnel,
−disaster situations, influence of foreign bodies and force majeure,
−improperly performed repairs,
−use of inadmissible spare parts and/or use of spare parts not in compli-
ance with the technical requirements as defined,
−physical alterations, i.e. conversions, add-ons or other modifications of the
actuator,
−technical modifications, i.e. changes to the actuator that lead to functional
changes or changes in the application or performance characteristics.
Important information regarding the EC conformity of the actuator
The declaration of conformity and/or declaration of incorporation issued by
Agromatic Regelungstechnik GmbH shall become void if the customer
performs structural or technical modifications to the actuator. In this case,
the owner/lessor of the system himself shall be obliged to prove compli-
ance with the relevant EC directives and issue an appropriate declaration
of conformity.
Exceptions:
– use of an original retrofit kit (e.g. auxiliary switch)
– prior written approval of the modification to the actuator provided by
Agromatic Regelungstechnik GmbH
We reserve the right to make technical changes as a result of improvements
to the performance characteristics and further developments without prior
written notice.

Actuators NEx, NEx-K, NEx-KA, NEx-V 5
2 Safety
WARNING
Failure to observe the safety instructions below may have serious
consequences:
– Danger to persons resulting from electrical or mechanical influences
– Failure of essential functions
Carefully read the safety instructions and hazard warnings in this section
before commissioning the actuator.
Observe the general safety instructions and regulations for the prevention
of accidents in addition to the instructions in this operating manual.
The owner/lessor and the user must observe the existing national work,
operating and safety instructions in addition to the instructions in this op-
erating manual. Any existing internal factory specifications must also be
followed.
2.1 General safety information
−The actuator is designed exclusively for industrial use.
−Be sure to always read this operating manual before installing, operating,
servicing, checking, troubleshooting, dismantling or disposing the actua-
tor.
−Always observe all applicable safety instructions and regulations for the
prevention of accidents such as the guidelines of professional associa-
tions for occupational safety and health when installing, operating, servic-
ing, checking, troubleshooting, dismantling or disposing the device.
−Always disconnect any machinery and installations that may be affected
before starting to work on the actuator.

2.2 Intended use 2 Safety
6 Actuators NEx, NEx-K, NEx-KA, NEx-V
2.2 Intended use
The operating safety of the actuator cannot be guaranteed unless it is used
as intended.
The actuator has been designed for the automation of industrial valves (e.g.
ball valves, dampers, other valves).
Important information!
The actuator can be used in potentially explosive areas of Zone 1 and
Zone 2.
Actuator marking:
II 2G Ex db IIC Tx Gb and
II 2G Ex h IIC Tx Gb
Tx = temperature class = T3 or T4 or T5 or T6
The intended use also includes
−Heeding all information from the operating manual
−adherence to the inspection and maintenance intervals,
−the use of resources and process materials in compliance with the safety
instructions in force,
−adherence to the operating and maintenance requirements.
The technical data mentioned in the section “3.4 Technical data” must be ad-
hered to without exception.
Any use of the actuator other than the intended use described in this docu-
ment shall not be permitted and will be regarded as misuse.
Agromatic Regelungstechnik GmbH shall not accept liability for any damage
resulting from such misuse. The owner/lessor shall bear the sole risk for pos-
sible damage due to improper use.
Foreseeable misuse
It is forbidden to use the actuator as an ascending aid!
It is forbidden to use the actuator in any other potentially explosive
area than the one described above!

2 Safety 2.3 Symbols applied to the actuator
Actuators NEx, NEx-K, NEx-KA, NEx-V 7
2.3 Symbols applied to the actuator
Explosion-proof equipment
This symbol identifies explosion-proof equipment.
Observe in conjunction with the actuator marking.
2.4 Residual risks
The actuator has been built according to the state of the art and recognized
safety regulations. Nevertheless, use of the device may still entail danger to
users' or third parties' life and limb and/or result in impairments of the actua-
tor itself or other material assets.
Only use the actuator
−for its intended use (see section “2.2 Intended use” ) and
−in perfect technical condition in accordance with the safety regulations.
Any faults that could impair safety must be rectified immediately.
WARNING
– Danger of electrostatic discharge
– Use a damp cloth for cleaning

2.4 Residual risks 2 Safety
8 Actuators NEx, NEx-K, NEx-KA, NEx-V
2.4.1 Hazards due to electricity
DANGER
Warning of electrical hazard
Direct contact with live parts or with parts that became energized due to
faults poses an immediate threat to life. Damage to the insulation or to
individual components may be life-threatening. Short-circuits and over-
loading pose the risk of being hit by ejected molten parts.
– Always ensure that the electrical supply units remain locked. Only au-
thorized persons with a key or special tool are permitted to access the
units.
– Work on the electrical actuator equipment may only be carried out by a
qualified electrician.
– Always operate the actuator with the hood in place.
– When working on live components or lines, a second person must al-
ways be present to interrupt the power supply in case of an emergency.
– Regularly inspect the electrical equipment of the actuator for defects
such as loose connections or damaged insulation.
– Immediately disconnect the power supply in case of defects, and have
the device repaired.
– Always switch off the power supply to the electrical actuator equipment
and verify its voltage-free condition before carrying out any work on it.
– Switch the power supply off before carrying out service and repair work,
and protect it from being switched on again.
– Do not bypass any fuses and do not put fuses out of operation.
– Ensure the correct tripping current when replacing fuses.
– Protect live parts from humidity as it may cause short circuits. Never
clean the electrical equipment with water or similar liquids.
– Have electrical machinery and stationary electrical equipment checked
by a qualified electrician at least every 4 years (also refer to the section
“7.2.1 Maintenance intervals”).
– Modifications made after the inspection must comply with the applicable
standard.

2 Safety 2.4 Residual risks
Actuators NEx, NEx-K, NEx-KA, NEx-V 9
2.4.2 Hazards due to fire/explosion
DANGER
Risk of injury due to fire/explosion when operating the actuator in a
potentially explosive atmosphere!
When operating the actuator, distribution of an explosion inside the actua-
tor is prevented by the flameproof enclosure of the housing.
– It is not permitted to replace screwed cable glands or connection ca-
bles!
If damaged screwed cable glands or connection cables need replacing,
please contact Agromatic Regelungstechnik GmbH.
When the hood is open, live parts may ignite an existing potentially explo-
sive atmosphere and cause a fire / an explosion.
– Only qualified personnel should carry out work at the actuator in ac-
cordance with explosion protection regulations.
– Always operate the actuator with the hood in place.
If the hood needs to be opened, observe the following instructions:
– Disconnect all sources of power to the actuator.
– Wait at least 60 min. before opening the hood.
– When installing the hood, make sure that no potentially explosive at-
mosphere is present in the area around the actuator.

2.4 Residual risks 2 Safety
10 Actuators NEx, NEx-K, NEx-KA, NEx-V
2.4.3 Danger from moving parts
WARNING
Moving components on the actuator and the valves connected to it
pose a risk of injury!
When the actuator is operated, the valves connected to it will also move.
The threaded spindle and the spindle nut of series K and V are freely ac-
cessible.
When couplings are used between the actuator (series NEx) and the
valve, there is a risk of injury due to moving parts.
The dangers include crushing, shearing off or drawing in of the upper
limbs.
– The assembly or start-up of a damaged actuator is not permitted.
– Attach covers over the exposed moving actuator parts and the valve
once the actuator is installed before putting the actuator into service.
Observe DIN EN ISO 13857 (“Safety of machinery – Safety distances to
prevent hazard zones being reached by upper and lower limbs” ) when
designing the protective covers.
– The heat dissipation of the actuator and, if present, of the stroke unit or
the additional gear box, must be ensured even if additional protective
covers are installed.
– Verify the proper function of all protective equipment on your ma-
chine/plant.
– Verify the correct operation of the actuator and of the valves moved by
the actuator after the assembly and the actuator setup are completed.
– Always operate the actuator with the hood in place.

2 Safety 2.4 Residual risks
Actuators NEx, NEx-K, NEx-KA, NEx-V 11
2.4.4 Protection classes IP66/IP67
The actuator may not be put into service unless
– the hood is properly installed, and
– the screwed cable glands are plugged and have been checked for
tightness.
NOTE
– To be able to ensure that protection class IP66/IP67 is permanently
complied with, the actuator must be protected against mechanical influ-
ences, e.g. by attaching safeguards or installing the actuator in a pro-
tected location.
– Outdoor assembly of the actuator is only permitted if approved by
Agromatic Regelungstechnik GmbH.
– Protect the actuator against environmental influences such as UV radia-
tion, humidity, formation of condensation, fluctuations of temperature,
and frost.
– The heat dissipation of the actuator and, if present, of the stroke unit or
the additional gear box, must be ensured even if additional protective
covers are installed.
The following items must always be observed for all actuators:
Screwed cable glands
−The actuator is equipped with explosion proof screwed cable glands and
connection cables according to Ex Zone 1 and Ex Zone 2.
The connection cables (max. three cables) are always guided out of the
actuator, either as a 1000 mm long unconnected cable end or to an Ex-e
terminal box installed directly at the actuator. The customer is not permit-
ted to carry out wiring and terminal work at the actuator.
Electrical connection work within the actuator is forbidden! Unau-
thorized intervention by the customer in the wiring of the actuator
will result in the loss of the ATEX and the IECEx certificate!
−Only use connection cables with an outer diameter suitable for the cable
glands of the Ex-e terminal box.
−If cable glands/filler plugs are to be replaced or retrofitted, the replace-
ment parts must be approved for the actuator's protection class as well as
for Ex-Zone 1 and Ex-Zone 2.
In order to permanently ensure explosion protection requirements,
only fully trained and qualified personnel from Agromatic Regelung-
stechnik GmbH should replace components!

2.5 Personal protective equipment 2 Safety
12 Actuators NEx, NEx-K, NEx-KA, NEx-V
Installing the hood
−See section “5.8 Installing the hood”.
Housing/Hood
−The housing (basic module and hood) is made of an aluminum alloy.
−The housing is a flameproof enclosure according to Ex-Zone 1 and Ex-
Zone 2.
−Swapping hoods of different actuators is not permitted.
−Do not drill any holes into the housing or the hood.
2.5 Personal protective equipment
Personal protective equipment must be worn when starting up and operating
the actuator to minimize exposure to a variety of hazards.
−When working, always wear protective equipment that is required for the
kind of work being carried out.
−In the work area, obey all signs relating to personal protective equipment.
The symbols have the following meaning:
Protective clothing
Industrial protective clothing is tightly fitting clothing with low tear strength,
tightly fitting sleeves and no protruding parts. Its main function is to protect
against being caught by moving components.
Do not wear rings, necklaces or other jewelry.
Safety shoes
Wear anti-
skid safety shoes to protect yourself from heavy, falling parts or
slipping on slick surfaces.
Protective gloves
Wear protective gloves to protect your hands ag
ainst contacting hot surfaces
or chemical substances.

2 Safety 2.6 Notes for emergencies
Actuators NEx, NEx-K, NEx-KA, NEx-V 13
2.6 Notes for emergencies
Preventive measures
−Always be prepared for accidents or fires.
−Keep first aid equipment (first aid box, blankets etc.) and fire extinguishers
at hand.
−Familiarize the personnel with accident reporting, first aid, fire-
extinguishing, and rescue equipment.
−Keep access routes for rescue vehicles clear.
Measures in the event of accidents
−Set off an emergency stop.
−Remove all persons from the danger zone.
−Immediately take first aid actions in case of a cardiac or respiratory arrest.
−Immediately inform the first aid officer and an emergency doctor or the
emergency medical service in case of personal injury.
−Clear the access routes for rescue vehicles. Assign a person to instruct
the rescue forces if required.
−Extinguish burning oil or grease with a CO
2
fire extinguisher or a
dry powder extinguisher.
−Extinguish a fire within the electrical control using a CO
2
fire extinguisher.
2.7 Obligations of the plant operator
The actuator is designed for industrial use. The owner/lessor of the actuator
is therefore legally obligated to maintain safety at work.
In addition to the safety instructions provided in this operating manual, the
safety instructions, instructions for the prevention of accidents and the envi-
ronmental legislation in effect at the area of use of the actuator must be com-
plied with. The following shall apply in particular:
−The owner/lessor must ensure that the actuator is operated according to
its intended use (see section “2.2 Intended use”).
−The owner/lessor must ensure that the actuator's operating manual is al-
ways available in complete and readable form in the area of use of the ac-
tuator.

2.7 Obligations of the plant operator 2 Safety
14 Actuators NEx, NEx-K, NEx-KA, NEx-V
−The owner/lessor must keep himself informed about the locally applicable
industrial safety regulations and carry out a hazard assessment to investi-
gate additional risks resulting from the specific work conditions in the area
of use of the actuator. The hazard assessment must then be implemented
in the form of operating instructions for the operation of the actuator.
−During the entire service life of the actuator, the owner/lessor must verify
that the operating instructions created by him comply with the current lev-
el of the technical standards and adjust the instructions where required.
−The owner/lessor must clearly define and control the responsibilities for
installing, starting up, operating and servicing the actuator.
−The owner/lessor must ensure that the maintenance intervals described in
this operating manual are adhered to.
−The owner/lessor may allow only sufficiently qualified and authorized per-
sonnel to work on the actuator.
−The owner/lessor must ensure that all employees handling the actuator
have thoroughly read and understood the operating manual.
In addition, he must at regular intervals verifiably train and inform the per-
sonnel about any risks involved.
−The owner/lessor must provide personal protective equipment to his em-
ployees and make sure that they use the equipment.
−The owner/lessor must ensure that employees under influence of drugs,
alcohol, medication or similar substances are not allowed to work on the
actuator.