ARCA MA60 Series Operating instructions

Operating and maintenance manual
Pneumatic diaphragm actuator
MA60 series
12.2020 / 1.0

Original instructions
© ARCA Regler GmbH. All rights reserved.
Cover picture background: Freepik.com

Table of contents
1 General data...........................................................................................................................5
1.1 Validity of the manual ..............................................................................................................5
1.2 Contact details.........................................................................................................................5
1.3 Other applicable documents....................................................................................................5
1.4 Place of storage of the manual................................................................................................5
1.5 ARCA ONSITE ........................................................................................................................5
2 Safety......................................................................................................................................7
2.1 General safety information ......................................................................................................7
2.2 Explanation of symbols and notices ........................................................................................7
2.3 Structure of the warning notices..............................................................................................7
2.4 Intended use............................................................................................................................8
2.5 Inappropriate use ....................................................................................................................9
2.6 Use in potentially explosive areas (optional) ........................................................................... 9
2.7 Residual risks ........................................................................................................................13
2.8 Qualification of the personnel................................................................................................13
2.9 Operator's duty of care..........................................................................................................14
2.10 Personal protective equipment..............................................................................................15
3 Transport, storage and packaging .................................................................................... 16
3.1 Transport ...............................................................................................................................16
3.2 Storage..................................................................................................................................16
3.3 Packaging..............................................................................................................................16
4 Nameplate ............................................................................................................................17
5 Type code.............................................................................................................................18
6 Sectional drawings..............................................................................................................19
6.1 Parts list.................................................................................................................................19
6.2 MA60 A/D6 ** O ....................................................................................................................21
6.3 MA60 A/D6 ** S.....................................................................................................................22
6.4 MA60 A/D6 ** O HB ..............................................................................................................23
6.5 MA60 A/D6 ** S HB...............................................................................................................24
6.6 MA60 C6 ** O........................................................................................................................25
6.7 MA60 C6 ** S ........................................................................................................................26
6.8 MA60 C6 ** O HVH ...............................................................................................................27
6.9 MA60 C6 ** S HVH................................................................................................................28
6.10 MA60 G6 ** O........................................................................................................................29
6.11 MA60 G6 ** S ........................................................................................................................30
7 Functional description........................................................................................................ 31
8 Installation ...........................................................................................................................32
9 Commissioning ...................................................................................................................33
ARCA Regler GmbH Table of contents
MA60 series 3 / 4612.2020 / 1.0

9.1 Adjustment ............................................................................................................................33
9.1.1 If stroke limitation is fitted ......................................................................................................33
9.1.2 If hydraulic emergency manual actuation is fitted ................................................................. 33
9.2 Actuating signal connection...................................................................................................34
9.3 Positioner installation ............................................................................................................35
10 Maintenance.........................................................................................................................36
10.1 Care.......................................................................................................................................36
10.2 Maintenance..........................................................................................................................36
11 Disassembly / assembly of the actuator ........................................................................... 37
11.1 Procedure..............................................................................................................................37
11.2 Hydraulic emergency manual actuation (if fitted) .................................................................. 37
11.3 Stroke limitation (if mounted).................................................................................................39
11.4 Guide and sealing element....................................................................................................39
11.5 Springs ..................................................................................................................................40
11.6 Diaphragm.............................................................................................................................41
12 Torque tables - bolted connections................................................................................... 42
12.1 Bolts conforming to DIN EN ISO 4017/4014/4762 ................................................................42
12.2 Hex nut (360, 364).................................................................................................................42
13 Fault removal .......................................................................................................................43
14 Disposal and recycling .......................................................................................................44
Table of contents ARCA Regler GmbH
4 / 46 MA60 series12.2020 / 1.0

ARCA Regler GmbH 1 General data
MA60 series 5 / 4612.2020 / 1.0
1 General data
This operating manual contains instructions that enable the product to
be safely and properly installed, put into operation and maintained.
The target group for this operating manual is exclusively specially
trained and authorised technical personnel.
Please contact the manufacturer if you encounter problems that cannot
be solved with the aid of this operating manual.
The product is subject to technical changes at any time.
1.1 Validity of the manual
This operating manual applies to the product in the version described in
the device pass.
1.2 Contact details
Further information about the product can be obtained from:
Manufacturer's address ARCA Regler GmbH
Kempener Str. 18
D-47918 Tönisvorst
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.arca-valve.com
1.3 Other applicable documents
The product can be delivered as part of an actuator and equipped with
additional components that are described in their own operating manu-
als. The instructions as well as the warning and safety information con-
tained therein must also be observed.
Furthermore, the following documents apply in addition to this operating
manual.
▪ Device pass
▪ Installation drawing
1.4 Place of storage of the manual
The operating manual and all other applicable documents are part of the
product.They must be kept in the immediate vicinity of the product and
must be accessible to the personnel at all times.
1.5 ARCA ONSITE
Acceptance documents (if ordered) and operating documentation for this
product can be downloaded from the ARCA ONSITE portal.
Two options are available here:
1. Scan the QR Code¹ on the product. Further entries are not required.

1 General data ARCA Regler GmbH
6 / 46 MA60 series12.2020 / 1.0
2. Visit the website https://onsite.arca-valve.com/search and enter
the ARCA order no. and ARCA serial no. The order no. and serial no.
can be found in the device pass and in our order confirmation.
Entry example
Illustration1: ARCA ONSITE
¹ QR Code is a registered trademark of DENSO WAVE INCORPOR-
ATED

ARCA Regler GmbH 2 Safety
MA60 series 7 / 4612.2020 / 1.0
2 Safety
2.1 General safety information
The operating manual contains detailed descriptions for the safe installa-
tion, commissioning and maintenance of the product.
▪ Read this operating manual attentively in its entirety in order to famili-
arise yourself with the product.
▪ Particular attention must be paid to the information in this chapter.
2.2 Explanation of symbols and notices
Safety and warning instructions are intended to avoid hazards to the life
or health of operating or maintenance personnel, and to avoid material
damage. It is emphasised through the use of the special terms defined
here. Additionally, their location is marked by warning symbols (picto-
grams). The signal terms used have the following meanings:
DANGER
means that death, serious injuries and/or considerable damage to
property will occur if the corresponding preventive measures are
not taken and maintained.
WARNING
means that death, serious injuries and/or considerable damage to
property can occur if the corresponding preventive measures are
not taken and maintained.
CAUTION
means that minor injuries and/or damage to property can occur if
the corresponding preventive measures are not taken and main-
tained.
NOTICE
indicates an important item of information about the product itself
or how the product should be handled, to which special attention
should be paid.
2.3 Structure of the warning notices
Section-related warning notice Section-related warning notices refer to the entire chapter, sections or
several paragraphs within this operating manual. Section-related warn-
ing notices are structured as follows:

2 Safety ARCA Regler GmbH
8 / 46 MA60 series12.2020 / 1.0
DANGER
Type and source of the danger
Possible consequences of disregard
► Measure to avoid the danger
► Further measures
Embedded warning notice Embedded warning notices refer to a certain area within a section. They
apply to smaller information units than the section-related warning no-
tices. Embedded warning notices are structured as follows:
DANGER!Instructions for avoiding a dangerous situation.
2.4 Intended use
The product complies with laws, regulations and standards valid at the
time of delivery.
The product does not pose a danger to people, property or environment
if it is used for its intended purpose and the warning notices contained in
this operating manual and attached to the product are observed. This
applies to the entire lifetime, from the delivery, assembly and operation
to the disassembly and disposal.
The following is deemed to be used for the intended purpose:
▪ Operate the product exclusively in accordance with this operating
manual and in accordance with the specification in the order confirm-
ation and the device pass.
▪ Use exclusively original ARCA spare parts for the maintenance of the
product.
DANGER
Risk of death and serious injuries as well as damage to property
and the environment!
Risk of death and serious injuries as well as damage to property and the
environment due to hazardous operating media, high temperatures and
pressures as well as moving parts.
► The following requirements and conditions must be complied with
without fail.
► Observe warning notices.
Maintenance Ensure or observe the following before performing any maintenance
work:
▪ Depressurise the actuator and the attached valve.
▪ If necessary, cool the actuator down or heat it up to ambient temper-
ature.
▪ Disconnect electrical connections, if any.
▪ The actuator springs are inserted with a high preload; it is imperative
to follow the disassembly instructions according to the chapter en-
titled [11.5] Springs.
▪ Ensure that the system cannot be started up by third parties.

ARCA Regler GmbH 2 Safety
MA60 series 9 / 4612.2020 / 1.0
▪ You are expressly directed to observe the regulations for potentially
explosive equipment where necessary. Refer also to the chapter [2.6]
Use in potentially explosive areas (optional).
Limits of use Operate the actuator only within the following limits of use.
Max. operating pres-
sure [bar]
Min. operating tem-
perature [°C]
Max. operating tem-
perature [°C]
6 -20 / Low temperature
version -40
+80
The actuator is designed for a maximum number of switching cycles of 1
million full strokes.
The max. permissible switching cycle frequency is 1 full stroke every 3
seconds.
2.5 Inappropriate use
Inappropriate use is use of the product other than as described is the
chapter entitled [2.4] Intended use.
In the addition, the following applies:
▪ Unauthorised modifications to the product can lead to injuries, dam-
age to property and malfunctions. The user alone bears this risk.
Warranty and liability claims are excluded.
2.6 Use in potentially explosive areas (optional)
The product can also be used in potentially explosive areas if fitted with
the optional additional "EX" equipment.
WARNING
Unsuitable product for potentially explosive areas
Risk of explosion!
► Use only products that are approved for use in Ex-zones and are
marked accordingly.
► Make sure that the product is suitable for the area of use.
WARNING
Impermissible accessories and impermissible spare parts
Risk of explosion or damage to the product!
► Use exclusively original accessories and original spare parts.
► Observe all relevant installation and safety instructions described in
the manuals for the product, accessories and spare parts.

2 Safety ARCA Regler GmbH
10 / 46 MA60 series12.2020 / 1.0
WARNING
Exceeding the maximum ambient or media temperature
Risk of explosion due to high surface temperature!
The temperature class of the product is no longer valid if the maximum
permissible ambient or media temperature is exceeded!
► Make sure that the maximum permissible ambient or media temper-
ature of the product is not exceeded.
WARNING
Contaminated operating medium
Risk of explosion and damage to the product due to clogging up with fine
dust or solid contents!
► Install a pre-filter or fine filter
► Clean the filter after 100,000 switching cycles or at least twice annu-
ally.
WARNING
Heat radiation
Risk of explosion due to high surface temperature as a result of heat ra-
diation from additionally attached products!
► Make sure that the maximum permissible surface temperature is not
exceeded.
► Insulate or decouple any attached products that radiate increased
heat.
WARNING
Dust deposits
Risk of explosion due to raised product temperature as a result of dust
deposits!
► Remove dust deposits that are thicker than 2 mm.
► Avoid electrostatic charging of the surface; remove dust deposits
properly without rubbing the surface.
WARNING
Damaged surface coating
Risk of explosion due to damage to the surface coating in conjunction
with corrosion and aluminium!
► Make sure that the surface coating is not damaged and that there is
no corrosion.

ARCA Regler GmbH 2 Safety
MA60 series 11 / 4612.2020 / 1.0
WARNING
Exceeding the layer thickness of the surface coating
Risk of explosion due to electrostatic charging of the electrically non-
conductive surface coating!
► Make sure in case of overpainting that the surface coating does not
exceed a total thickness of 0.2 mm.
WARNING
External impact effect
Risk of explosion due to generation of sparks caused by an impact!
► Avoid external impact effects on the product.
WARNING
Dismantling the product
Risk of explosion due to the ingress of an explosive atmosphere!
üThe product may only be opened after it has been proven that no ex-
plosive atmosphere exists in the area around the product
► Ensure through ventilation that there is no explosive atmosphere. If
this is not possible, take the product to an area where there is no risk
of explosion.
WARNING
Non-conductive materials with pipe-laying work
Risk of explosion due to potential differences when using non-conduct-
ive materials!
► When using non-conductive materials for piping or sealing, care must
be taken that they are bridged with conductors.
WARNING
Non-conductive lubricants
Risk of explosion due to potential differences when using non-conduct-
ive lubricants!
► Use only electrically conductive lubricants to lubricate the compon-
ents.
WARNING
Contaminated breathing air
Risk of explosion due to the ingress of dust and gas via the breathing
aperture and breathing line!
üThe product is equipped with exhaust air blanketing, which prevents
dust or gas entering the spring chamber via the breathing aperture.
► The exhaust air blanketing components must be inspected after
100,000 switching cycles or at least twice annually.

2 Safety ARCA Regler GmbH
12 / 46 MA60 series12.2020 / 1.0
WARNING
Exceeding the max. surface temperature at bearing points
Risk of explosion due to raised surface temperature in case of inad-
equate lubrication and dust deposits at the bearing points!
► Make sure that the maximum permissible surface temperature is not
exceeded.
► The lubrication and dust deposits at the bearing points must be in-
spected after 100000 operating cycles or at least twice annually.
ATEX nameplate
3 2
1
4
8
7
6
5
Illustration2: ATEX nameplate
1 Manufacturer
2 Type designation
3 ATEX marking
4 EAC marking
5 "X" marking – the actuator can be used for an ambient temperat-
ure of -40 °C up to a surface temperature of +80 °C.
6 "X" marking – the actuator can be used for an ambient temperat-
ure of -40 °C up to a surface temperature of +80 °C. - The actu-
ator exhaust (97) must be replaced by an exhaust line that leads
to a non-explosive atmosphere.
7 Part number
8 Serial number
Gas atmospheres When using the product in gas atmospheres of device category 2G, it
must be ensured that the spring chamber is ventilated with instrument
air. To this end the product is equipped with exhaust air ventilation (95)
from the positioner. If no positioner is mounted, the spring chamber must
be connected to the supply air pipe via a locking throttle on the factory
side.
Dust atmospheres For the use of the product in dust atmospheres of device category 2D,
the actuator exhaust (97) must be replaced by an exhaust line that leads
to a non-explosive atmosphere.

ARCA Regler GmbH 2 Safety
MA60 series 13 / 4612.2020 / 1.0
Illustration3: Additional equipment - EX
2.7 Residual risks
There may still be residual risks even if the product is used for its inten-
ded purpose.
▪ Danger of being crushed by unsecured actuators
In case of negligent use of personal protective equipment:
▪ Danger due to noise resulting in hearing loss
▪ Thermal hazards (burning, scalding, etc.)
▪ Danger due to escape of the operating medium
Furthermore, there may be unapparent residual risks despite all precau-
tions taken.
Residual risks can be minimised if the notes on safety and commission-
ing as well as the operating manual as a whole are observed.
2.8 Qualification of the personnel
The product is exclusively intended for use in plants and installations in
which trained technical personnel carry out the necessary work. Tech-
nical personnel are persons who are entrusted with the installation, com-
missioning and operation of this product and who have the appropriate
qualifications for their work activities, such as, for example:
▪ training or instruction in accordance with current technical safety
standards in the maintenance and usage of appropriate safety equip-
ment.
▪ Training in First Aid.
▪ In the case of systems with explosion protection: training or instruc-
tion and authorisation to carry out work on potentially explosive sys-
tems.
Repair work may be carried out only by trained and qualified technical
personnel.
Work on electrical equipment may be carried out only by trained electri-
cians or persons who have received electrotechnical instruction.

2 Safety ARCA Regler GmbH
14 / 46 MA60 series12.2020 / 1.0
Persons
Activity
Instructed
persons
Persons
with a recog-
nised tech-
nical educa-
tion
Persons
with a recog-
nised elec-
trotechnical
education
Superiors
with relevant
skills
ARCA ser-
vice person-
nel
Transport X X X X X
Installation X X X X X
Commissioning X X X X
Maintenance X X X X X
Fault finding X X X
Mechanical
troubleshooting
X X
Electrical
troubleshooting
X X
Repairs X X X X
Disposal X X X X X
2.9 Operator's duty of care
To avoid accidents, malfunctions and environmental impacts, the re-
spective person responsible for the transport, commissioning, operation,
maintenance and disposal of the product must ensure the following:
▪ Observation of all warning and danger notices.
▪ Regular instruction of personnel on all applicable questions of work
safety, the operating manual and in particular the safety instructions
that it contains.
▪ Regulations and work instructions for safe working as well as the cor-
responding instructions for the conduct of the personnel in case of
accidents and fire are to be kept at the ready at all times and hung
up in the plant if necessary.
▪ Operate the product only if it is in perfect working order.
▪ Use only spare parts, lubricants and operating resources approved
by the manufacturer.
▪ Observe the specified operating conditions and requirements at the
place of installation.
▪ Provide all necessary devices and the personal protective equipment
required for the respective task.
▪ Refer to the chapter entitled Maintenance for the prescribed mainten-
ance intervals and comply with the corresponding regulations.
▪ Allow installation, commissioning and maintenance of the product to
be carried out only by qualified and trained personnel in accordance
with this operating manual.
▪ The operator must ensure that the product is used for its intended
purpose.
▪ Before commissioning the product the operator must carry out a risk
assessment and define appropriate inspection and maintenance in-
tervals according to the operating conditions.

ARCA Regler GmbH 2 Safety
MA60 series 15 / 4612.2020 / 1.0
2.10 Personal protective equipment
Personal protective equipment must be worn during work in order to
minimise health risks.
▪ During work, always wear the protective equipment necessary for the
respective work
▪ Follow the notices about personal protective equipment displayed in
the working area.
Always wear
Protective clothing
Tight-fitting work clothes with a low tear
resistance, with narrow sleeves and
without protruding parts. They primarily
serve to protect against being caught up
by moving machine parts.
Do not wear rings, chains or other jew-
ellery.
Safety shoes
To protect against heavy falling parts and
slipping on smooth floors.
Wear in case of particular
environmental conditions
Special protective equipment is neces-
sary in particular environmental condi-
tions.
It is to be selected according to the
environment.
Safety glasses
To protect the eyes against flying parts
and splashes of liquids.
Helmet
To protect against falling and flying parts
and materials.
Hearing protection
To protect against hearing damage.

3 Transport, storage and packaging ARCA Regler GmbH
16 / 46 MA60 series12.2020 / 1.0
3 Transport, storage and packaging
3.1 Transport
WARNING
Tipping or falling load!
Danger of death and danger of damage to property due to load tipping
over or falling!
► Only suitable and approved means of transport and lifting equipment
may be used for transporting the product.
► Lifting equipment must generally be attached to the housing of the
product, not to attachments.
► Allow only instructed persons to select and attach the lifting equip-
ment.
► Do not stand under suspended loads.
Transport at a temperature lower than -40 °C or higher than +80 °C is
not permissible.
The attachment points on actuators (lifting eyes, ring bolts, etc.) are de-
signed solely for transporting the actuator. Under no circumstances may
these attachment points be used if the actuator is coupled to a valve.
3.2 Storage
NOTICE
Improper storage!
There is a danger of the product and in particular the attached electronic
accessories no longer functioning if stored improperly.
► Storage at a temperature lower than -40 °C or higher than +80 °C is
not permissible.
► It must be stored in roofed-over storage places and that are weather-
proof.
To protect against contamination and to protect the sealing surfaces,
openings such as nozzles, flanges, etc. must be sealed using suitable
means. These should be removed by technical personnel at the place of
installation.
3.3 Packaging
The product is packed in a PE film inside the outer packaging (card-
board box, wooden crate, pallet, lattice box).
If the packaging, in particular the PE film, has been opened, the product
must be stored immediately in a heated room.
The product must be packed in weatherproof or seaworthy packaging for
transport by ship, airplane, rail or truck.

ARCA Regler GmbH 4 Nameplate
MA60 series 17 / 4612.2020 / 1.0
4 Nameplate
1
2
3
5
4
8
6
9
7
10
11
12
13
16
14
15
Illustration4: Nameplate
1 Type designation valve
2 Nominal size
3 Nominal pressure
4 Valve stroke
5 Material of housing / trim
6 ARCA order number
7 Flow coefficient, characteristic curve
8 Seat diameter
9 Serial number
10 Actuator type code
11 Actuation pressure range
12 Max. actuation pressure
13 Valve safety position
14 Marking
15 Conformity mark
16 Year of manufacture
Place of installation The nameplate is attached to the actuator yoke or the actuator head.

5 Type code ARCA Regler GmbH
18 / 46 MA60 series12.2020 / 1.0
5 Type code
MA.. 60 A6 6G O HVH S0 T
[1] [2] [3] [4] [5] [6]
1. Series
MA
2. Actuator size
60 Diaphragm area 1500 - 2185 cm²
3. Actuator version (stroke)
G6 Stroke 60 mm
A6 Stroke 83 mm
D6 Stroke 125 mm
C6 Stroke 136 mm
4. Spring set
4B 6B 8B 12B 16B 4, 6, 8, 12, 16 blue springs (vers.
G6)
2G 4G 6G 8G 2, 4, 6, 8 green springs (vers. A6)
2S 4S 6S 8S 2, 4, 6, 8 silver springs (vers. D6)
2R 4R 6R 8R 2, 4, 6, 8 red springs (vers. C6)
5. Function
O Stem extended by spring (normally
closed)
S Stem retracted by spring (normally
open)
6. Additional equipment
EX Explosion-proof version
HB Stroke limiter
HVH Emergency manual operation, hy-
draulic
HVS prepared for emergency manual
actuation
S0 without yoke ring, without columns
S6 with yoke ring, without columns
S7 with yoke ring, with columns
SD Actuator stem 1.4462
T Low temperature version max. -40
°C
VA external screws VA
Example of type designation MA60 A6 6G O HVH S0 T
Diaphragm actuator MA ─ actuator size 60 ─ actuator version A6 (stroke
83 mm) ─ spring set 6G ─ normally closed function ─ additional equip-
ment hydraulic emergency manual actuation + without yoke ring, without
columns + low temperature version.

ARCA Regler GmbH 6 Sectional drawings
MA60 series 19 / 4612.2020 / 1.0
6 Sectional drawings
Some versions of the actuator are illustrated below. Further versions are
possible by combining the different components.
Connections Z1 see chapter [9.2] Actuation signal connection
6.1 Parts list
Item Name
1 Bottom cover
6 * Guide bush
9 * Sealing ring
10 * O-ring
13 Circlip
15 Hex screw
18 Stem
19 Split ring
21 * O-ring
22 * Diaphragm
24 Diaphragm plate
25 Diaphragm plate
29 Hex screw
31 Clamping ring
33 Anti-rotation device
34 Screw
35 Bearing
36 Spacer ring
37 Hex nut
38 Spring lock washer
39 Hex screw
40 Stroke limiter
41 Hex screw
43 Spring
51 Intermediate ring
52 Spring washer
53 Guide bush
54 Top cover
55 Hex screw
56 Sealing ring
57 Lifting eye
60 Hex screw
64 Hex screw
65 Hex nut
66 Spring lock washer
67 Bellows

6 Sectional drawings ARCA Regler GmbH
20 / 46 MA60 series12.2020 / 1.0
Item Name
70 Spring centring
84 Pipe elbow
85 Pipe elbow
86 Bushing
91 Hex nut
95 Exhaust air ventilation
96 Nameplate Ex
97 Actuator exhaust
115 Washer
116 Yoke
117 Stroke dial
118 Plug
311 Cylinder
314 Hex nut
315 Housing
317 Pump
327 * Sealing ring
328 * O-ring
329 Circlip
332 Hex screw
345 Holder compl.
346 Hex screw
347 Hex screw
348 Hex nut
349 Washer
350 * Guide bush
354 Hex screw
355 Hex nut
356 Locking plate
357 Locking plate
358 Intermediate piece
360 Hex nut
364 Hex nut
365 Threaded bushing
* Recommended spare part / wearing part