AUMA SA 25.1 User manual

Operation instructions
Assembly and commissioning
Multi-turn actuators
SA 25.1 – SA 48.1
SAR 25.1 – SAR 30.1
AUMA NORM actuator (without controls)

Table of contents
2
Read operation instructions first.
• Heed safety instructions.
• These operation instructions are part of the product.
• Store operation instructions during product life.
• Pass on instructions to any subsequent user or owner of the product.
Target group:
This document contains information for assembly, commissioning and maintenance staff.
Table of contents
1 Safety instructions ........................................................................................................................................... 4
1.1 Prerequisites for the safe handling of the product..................................................................................... 4
1.2 Range of application ................................................................................................................................. 4
1.3 Warnings and notes .................................................................................................................................. 5
1.4 References and symbols........................................................................................................................... 5
2 Short description.............................................................................................................................................. 7
3 Name plate ........................................................................................................................................................ 8
4 Transport and storage ..................................................................................................................................... 10
4.1 Transport................................................................................................................................................... 10
4.2 Storage...................................................................................................................................................... 11
5 Assembly .......................................................................................................................................................... 12
5.1 Mounting position ...................................................................................................................................... 12
5.2 Fit handwheel............................................................................................................................................ 12
5.3 Mount actuator to valve............................................................................................................................. 13
5.3.1 Overview of output drive types...................................................................................................... 13
5.3.2 Output drive type A ....................................................................................................................... 14
5.3.3 Output drive types B/C/D/E........................................................................................................... 18
5.4 Accessories for assembly ......................................................................................................................... 19
5.4.1 Stem protection tube for rising valve stem.................................................................................... 19
6 Electrical connection ....................................................................................................................................... 21
6.1 Basic information....................................................................................................................................... 21
6.2 Motor connection....................................................................................................................................... 22
6.2.1 Open motor connection compartment........................................................................................... 23
6.2.2 Connect motor cables................................................................................................................... 24
6.2.3 Close motor connection compartment .......................................................................................... 25
6.3 S/SH electrical connection (AUMA plug/socket connector) ...................................................................... 25
6.3.1 Open terminal compartment ......................................................................................................... 26
6.3.2 Cable connection .......................................................................................................................... 27
6.3.3 Close terminal compartment......................................................................................................... 28
6.4 Accessories for electrical connection (option)........................................................................................... 29
6.4.1 Parking frame................................................................................................................................ 29
6.4.2 DS intermediate frame for double sealing..................................................................................... 29
6.4.3 External earth connection ............................................................................................................. 30
7 Operation .......................................................................................................................................................... 31
7.1 Manual operation ...................................................................................................................................... 31
7.1.1 Manual valve operation................................................................................................................. 31
7.2 Motor operation ......................................................................................................................................... 32
8 Indications (option) .......................................................................................................................................... 33

Table of contents
3
8.1 Mechanical position indication via indicator mark ..................................................................................... 33
9 Signals (output signals)................................................................................................................................... 34
9.1 Feedback signals from actuator ................................................................................................................ 34
10 Commissioning (basic settings) ..................................................................................................................... 35
10.1 Open switch compartment ........................................................................................................................ 35
10.2 Set torque switching.................................................................................................................................. 35
10.3 Set limit switching...................................................................................................................................... 36
10.3.1 Set end position CLOSED (black section) .................................................................................... 36
10.3.2 Set end position OPEN (white section)......................................................................................... 37
10.4 Test run ..................................................................................................................................................... 37
10.4.1 Check direction of rotation at mechanical position indicator......................................................... 37
10.4.2 Check direction of rotation at hollow shaft/stem ........................................................................... 38
10.4.3 Check limit switching..................................................................................................................... 39
10.5 Close switch compartment ........................................................................................................................ 39
11 Commissioning (optional equipment settings) ............................................................................................. 40
11.1 Potentiometer............................................................................................................................................ 40
11.1.1 Potentiometer setting.................................................................................................................... 40
11.2 RWG electronic position transmitter.......................................................................................................... 40
11.2.1 Set measuring range..................................................................................................................... 41
11.3 EWG 01.1 electronic position transmitter.................................................................................................. 41
11.3.1 Set measuring range..................................................................................................................... 42
11.3.2 Adjust current values .................................................................................................................... 43
11.3.3 Switch on/off LED end position signalling..................................................................................... 44
11.4 Set intermediate positions......................................................................................................................... 44
11.4.1 Set running direction CLOSE (black section)................................................................................ 45
11.4.2 Set running direction OPEN (white section).................................................................................. 45
11.5 Set mechanical position indicator.............................................................................................................. 45
12 Corrective actions ............................................................................................................................................ 47
12.1 Faults during operation/commissioning..................................................................................................... 47
12.2 Motor protection (thermal monitoring) ....................................................................................................... 48
13 Servicing and maintenance............................................................................................................................. 49
13.1 Preventive measures for servicing and safe operation ............................................................................. 49
13.2 Maintenance.............................................................................................................................................. 50
13.3 Disposal and recycling .............................................................................................................................. 50
14 Technical data .................................................................................................................................................. 51
14.1 Technical data Multi-turn actuators ........................................................................................................... 51
14.2 Tightening torques for screws ................................................................................................................... 53
15 Spare parts list ................................................................................................................................................. 54
15.1 Multi-turn actuators SA 25.1 – SA 48.1 S / SAR 25.1 – SAR 30.1 S ........................................................ 54
Index .................................................................................................................................................................. 56

Safety instructions
4
1Safety instructions
1.1 Prerequisites for the safe handling of the product
Standards/directives The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly, elec-
trical connection, commissioning and operation are met at the place of installation.
Depending on the device version, this includes:
• Configuration guidelines for the respective fieldbus or network applications.
Safety instructions/warn-
ings
All personnel working with this device must be familiar with the safety and warning in-
structions in this manual and heed the instructions given. Safety instructions and
warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must be
carried out by suitably qualified personnel authorised by the end user or contractor of
the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules re-
garding occupational health and safety.
Commissioning Prior to commissioning, imperatively check that all settings meet the requirements of
the application. Incorrect settings might present a danger to the application, e.g. cause
damage to the valve or the installation. The manufacturer will not be held liable for any
consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:
• Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
• Only operate the device if it is in perfect condition while observing these instruc-
tions.
• Immediately report any faults and damage and allow for corrective measures.
• Heed recognised rules for occupational health and safety.
• Heed national regulations.
• During operation, the housing warms up and surface temperatures > 60°C may
occur. To prevent possible burns, we recommend checking the surface temperat-
ure using an appropriate thermometer and wearing protective gloves, prior to
working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment for
the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior written consent of the manufacturer.
1.2 Range of application
AUMA SA/SAR multi-turn actuators are designed for the operation of industrial valves,
e.g. globe valves, gate valves, butterfly valves, and ball valves.
Other applications require explicit (written) confirmation by the manufacturer.
The following applications are not permitted, e.g.:
• Industrial trucks according to EN ISO 3691
• Lifting appliances according to EN 14502
• Passenger lifts according to DIN 15306 and 15309
• Service lifts according to EN 81-1/A1
• Escalators

Safety instructions
5
• Continuous duty
• Buried service
• Continuous underwater use (observe enclosure protection)
• Potentially explosive atmospheres
• Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's desig-
nated use.
These operation instructions are only valid for the “clockwise closing” standard ver-
sion, i.e. driven shaft turns clockwise to close the valve. For “counterclockwise closing”
version, a supplement must be observed in addition to these operation instructions.
1.3 Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these
operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
DANGER Indicates an imminently hazardous situation with a high level of risk.
Failure to observe this warning results in death or serious injury.
WARNING Indicates a potentially hazardous situation with a medium level of risk.
Failure to observe this warning could result in death or serious injury.
CAUTION Indicates a potentially hazardous situation with a low level of risk. Fail-
ure to observe this warning could result in minor or moderate injury. May
also be used with property damage.
NOTICE Potentially hazardous situation. Failure to observe this warning could
result in property damage. Is not used for personal injury.
The safety symbol warns of a potential personal injury hazard.
The signal word (here: DANGER) indicates the level of hazard.
1.4 References and symbols
The following references and symbols are used in these instructions:
The symbol stands for the Information concept. This text provides important
notes and information.
Information: If the Information term is part of instruction, the text will give important
notes and information to this action step.
Symbol for CLOSED (valve closed)
Symbol for OPEN (valve open)
Result of a process step
Describes the result of a preceding process step.
Action step
Describes one single action step.
Reference to the page number

Safety instructions
6
Refers to the page number for further information. To return from the target to the pre-
vious view, it is possible to jump back to the previous view within PDF documents:
When using Adobe Acrobat via Menu > Previous view, or using the key combination
Alt + left.

Short description
7
2Short description
Multi-turn actuator Definition according to ISO 22153:
A multi-turn actuator is an actuator which transmits torque to the valve or the valve
gearbox for at least one revolution and can be capable of withstanding thrust.
AUMA multi-turn actuator Figure1: Example of AUMA multi-turn actuator SA 25.1 – SA 40.1 and SA 48.1
[1]
[2]
[5]
[4]
[3]
SA 48.1SA 25.1 – SA 40.1
[4]
[1] Motor [2] Electrical connection, e.g. S (AUMA
plug/socket connector)
[3] Mechanical position indicator [4] Valve attachment, e.g. output drive
type A
[5] Handwheel
AUMA SA/SAR multi-turn actuators are driven by an electric motor. A handwheel is
available for setting and emergency operation.
Actuator controls are required to operate or process the actuator signals.
Actuators without controls can be equipped with AUMA actuator controls at a later
date. For any queries, please state our order number. The order number is available
on the name plate. (Refer to Actuator name plate [}8].)
Switching off in end positions may be either by limit or torque seating.
In combination with output drive type A, the actuator is capable of withstanding thrust.

Name plate
8
3Name plate
Figure2: Arrangement of name plates
[1]
[2]
[1] Actuator name plate [2] Motor name plate
Actuator name plate
Figure3: Actuator name plate (example)
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[1] Name of manufacturer [2] Address of manufacturer
[3] Type designation [4] Order number
[5] Serial number [6] Speed
[7] Torque range in direction CLOSE [8] Torque range in direction OPEN
[9] Type of lubricant [10] Permissible ambient temperature
[11] Can be assigned as an option upon
customer request
[12] Data Matrix code
[13] Enclosure protection
Motor name plate
Figure4: Motor name plate (example)
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[14]
[13]
[12]
[11]
[1] Motor type [2] Motor article number
[3] Serial number [4] Current type, mains voltage

Name plate
9
[5] Nominal power [6] Nominal current
[7] Type of duty [8] Enclosure protection
[9] Motor protection (thermal protection) [10] Insulation class
[11] Speed [12] Power factor cos phi
[13] Mains frequency [14] Data Matrix code
Descriptions referring to name plate indications
Type designation Table1: Description of type designation with the example of SA 25.1-F25
SA 25.1 -F25
SA Type SA = Multi-turn actuators for open-close duty
Type SAR = Multi-turn actuators for modulating duty
25.1 Size
The operation instructions apply to sizes 25.1, 30.1, 35.1, 40.1
F25 Flange size
Order number The product can be identified using this number and the technical data as well as or-
der-related data pertaining to the device can be requested.
Please always state this number for any product inquiries.
On our website at http://www.auma.com, via Service & Support| myAUMA, we of-
fer a service allowing authorised users to download order-related documents such as
wiring diagrams and technical data (both in German and English), inspection certific-
ate and the operation instructions when entering the order number.
Actuator serial number Table2: Serial number until 2023, description with the example of 0523MD12345
05 23 MD12345
05 Positions 1+2: Assembly in week = week 05
23 Positions 3+4: Year of manufacture = 2023
MD12345 Internal number for unambiguous product identification
Table3: Serial number as from 2024, description with the example 0000-00101-2024
00000-00101 – 2024
00000-00101 Serial number of sales article
11-digit, internal number for unambiguous product identification
2024 Year of manufacture = 2024
Data Matrix code When registered as authorised user, you may use our AUMA Assistant App to scan
the Data Matrix code and directly access the order-related product documents without
having to enter order number or serial number.
Figure5: Link to AUMA Assistant App
For further Service & Support, Software/Apps/..., refer to www.auma.com.

Transport and storage
10
4Transport and storage
4.1 Transport
Actuator For transport to place of installation, use sturdy packaging.
DANGER Suspended load!
Death or serious injury.
àDo NOT stand below suspended load.
àAttach ropes or hooks for the purpose of lifting by hoist only to housing and NOT
to handwheel.
àActuators mounted on valves: Attach ropes or hooks for the purpose of lifting by
hoist to valve and NOT to actuator.
àActuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
àRespect total weight of combination (actuator, gearbox, valve)
àSecure load against falling down, sliding or tilting.
àPerform lift trial at low height to eliminate any potential danger e.g. by tilting.
Figure6: Example: Lifting the actuator
Valve attachment
DANGER Suspended load!
Death or serious injury!
àDo NOT stand below suspended load.
àUse appropriate lifting accessories.
àSelect screws in appropriate lengths.
àSelect eye nuts suitable for screws.
àCompletely fasten eye nuts and avoid lateral pull.
àHeed plane position and seat on the mounting surface of eye nuts.

Transport and storage
11
Figure7: Example: Lifting output drive type
Weights Table4: Weights for SA/SAR multi-turn actuators with 3-phase motors
Type designation
Actuator
Motor type
1) Weight 2)
approx. [kg]
SA 25.1/
SAR 25.1
AD... 90-... 150
AD... 132-... 160
SA 30.1/
SAR 30.1
AD... 112-... 190
AD... 160-... 260
SA 35.1 AD... 132-... 410
AD... 160-... 425
SA 40.1 AD... 160-... 510
SA 48.1 AD... 180-... 750
1) Refer to motor name plate
2) Indicated weight includes AUMA NORM multi-turn actuator with 3-phase AC motor, electrical connec-
tion in standard version, output drive type B1 and handwheel. For other output drive types, consider
additional weights.
Table5: Weights of output drive types A
Type designation Flange size [kg]
A 25.2 F25 42
A 30.2 F30 69
A 35.2 F35 126
A 40.2 F40 202
A 48.2 F48 271
4.2 Storage
NOTICE Danger of corrosion due to inappropriate storage!
àStore in a well-ventilated, dry room.
àProtect against floor dampness by storage on a shelf or on a wooden pallet.
àCover to protect against dust and dirt.
àApply suitable corrosion protection agent to uncoated surfaces.
Long-term storage For long-term storage (more than 6 months), observe the following points:
1. Prior to storage: Protect uncoated surfaces, in particular output drive parts and
mounting surfaces using long-term corrosion protection agents.
2. At an interval of approx. 6 months: Check uncoated surfaces for corrosion. Should
traces of corrosion be detected, renew the corrosion protection.

Assembly
12
5Assembly
5.1 Mounting position
5.2 Fit handwheel
To avoid transport damage, handwheels are supplied separately as appropriate. In
this instance, the handwheel must be mounted prior to commissioning.
NOTICE Damage at the change-over mechanism due to incorrect assembly!
àOnly pivot change-over lever manually.
àDo NOT use extensions as lever for operation.
àFirst engage manual operation correctly, then mount handwheel.
How to proceed 1. Manually lift the red change-over lever while slightly turning the shaft back and
forth until manual operation engages.
ðManual operation is properly engaged if the change-over lever can be shifted
by approx. 85°.
Figure8: Shift change-over lever
85°
2. Push handwheel over the red change-over lever then onto the shaft.
Figure9: Place handwheel.
3. Release change-over lever (should snap back into initial position by spring action,
if necessary, push it back manually).
4. Secure handwheel using the retaining ring supplied.

Assembly
13
Figure10: Secure with retaining ring.
5.3 Mount actuator to valve
NOTICE Corrosion due to damage to paint finish and condensation!
àTouch up damage to paint finish after work on the device.
àAfter mounting, connect the device immediately to electrical mains to ensure that
heater minimises condensation.
5.3.1 Overview of output drive types
Table6: Overview on output drive types
Valve attach-
ment
Application Further information
Output drive type
A
Threads
• For rising, non-rotating valve stem
• For transmission of torques and thrusts
• Not appropriate for withstanding radial forces
Output drive type A
[}14]
Bore with keyway, square bore, hexagon bore
• For rotating, non-rising valve stem
• For transmission of torques and thrusts
• Not appropriate for withstanding radial forces
Output drive
types
B, B1 – B4
C, D, E
Valve shaft, gearbox shaft
• Only for transmission of torques
• Not appropriate for withstanding thrust
Output drive types B/
C/D/E [}18]

Assembly
14
5.3.2 Output drive type A
Figure11: Design of output drive type A
[1]
[2]
[3]
[1] Output mounting flange [2] Stem nut with dog coupling
[3] Valve stem
Short description Output drive type A consisting of output mounting flange [1] with axial bearing stem
nut [2]. The stem nut transmits the torque from the actuator hollow shaft to the valve
stem [3]. Output drive type A can withstand thrusts.
5.3.2.1 Mount multi-turn actuator with output drive type A
1. If output drive type A is already mounted to the multi-turn actuator: Loosen screws
[3] towards multi-turn actuator and remove output drive type A [2].
Figure12: Multi-turn actuator with output drive type A
[1]
[2]
[3]
(2a)
(2b)
(2c)
[1] Multi-turn actuator [2] Output drive type A, from left to right
(2a) Finish machined with thread (2b) Unbored
(2c) Pilot bore [3] Screws to multi-turn actuator
For an unbored or pilot bore stem nut, the stem nut must be finish-machined prior
to mounting valve stem and prior to performing the following steps: Finish machin-
ing of stem nut for output drive type A [}16]
2. Apply a small quantity of grease to the valve stem.

Assembly
15
3. Place output drive type A [2] on valve stem and turn until output drive type A [2] is
flush on the valve flange [4].
4. Turn output drive type A [2] until alignment of the fixing holes.
5. Fasten screws [5] between valve and output drive type A [2] without completely
tightening them.
Figure13: Output drive type A on stem
[2]
[5]
[5]
[4]
6. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into the
output drive sleeve.
Figure14: Fit unit onto stem
[3]
ðThe flanges are flush with each other if properly engaged.
7. Adjust multi-turn actuator until alignment of the fixing holes.
8. Fasten multi-turn actuator with screws [3].
9. Fasten screws [3] crosswise with a torque according to table Tightening torques
for screws [}53].
10. Turn multi-turn actuator with handwheel in direction OPEN until valve flange [4]
and output drive type A [2] are firmly placed together.

Assembly
16
Figure15: Tighten flange
[2]
[4]
[5]
11. Tighten screws [5] between valve and output drive type A crosswise applying a
torque according to table Tightening torques for screws [}53].
5.3.2.2 Finish machining of stem nut for output drive type A
This working step is only required if stem nut is supplied unbored or with pilot bore.
For exact product version, please refer to the order-related technical data sheet or
the AUMA Assistant App.

Assembly
17
Figure16: Output drive type A
[1]
[2]
[3]
[2]
[2.1]
[2.2]
[2.1]
[2.1]
[2.1]
[2.2]
[1] Stem nut [2] Axial needle roller bearing
[2.1] Axial bearing washer [2.2] Axial needle roller and cage assembly
[3] Spigot ring
How to proceed 1. Remove spigot ring [3] from output drive.
2. Remove stem nut [1] together with axial needle roller bearing [2].
3. Remove axial bearing washers [2.1] and axial needle roller and cage assemblies
[2.2] from stem nut [1].
ðRecord the order of axial bearing washers [2.1].
4. Drill and bore stem nut [1] and cut thread.
5. Clean the machined stem nut [1].
6. Apply sufficient Lithium soap EP multi-purpose grease to axial needle roller and
cage assemblies [2.2] and axial bearing washers [2.1], ensuring that all hollow
spaces are filled with grease.
7. Place greased axial needle roller and cage assemblies [2.2] and axial bearing
washers [2.1] onto stem nut [1].
ðHeed the correct order of the axial bearing washers [2.1].
8. Re-insert stem nut [1] with axial needle roller bearings [2] into output drive.
9. Screw in spigot ring [3] until firm seat against the shoulder.

Assembly
18
5.3.3 Output drive types B/C/D/E
Figure17: Example of output drive type B
[1]
[2]
[3]
[2*]
[1] Multi-turn actuator flange [2] For output drive types B/B1/B2 hollow
shaft with keyway
[2*] For output drive types B3/B4/E, an out-
put drive sleeve is fitted into the hollow
shaft
[3] Gearbox/valve shaft with parallel key
Spigot at valve flanges should be loose fit.
5.3.3.1 Mount multi-turn actuator with output drive type B
Figure18: Mounting output drive types B
[1]
[2]
[3]
[4]
[1] Multi-turn actuator [2] Valve/gearbox
[3] Valve/gearbox shaft [4] Screw
How to proceed 1. Check if mounting flanges fit together.
2. Check, if output drive of multi-turn actuator [1] matches the output drive of valve/
gearbox or valve/gearbox valve shaft [2/3].
3. Apply a small quantity of grease to the valve or gearbox stem [3].
4. Place multi-turn actuator [1] and ensure that the spigot fits uniformly in the recess
and that the mounting faces are in complete contact.
5. Fasten multi-turn actuator with screws [4].
Information:We recommend applying liquid thread sealing material to the screws
to avoid contact corrosion.

Assembly
19
6. Fasten screws [4] crosswise with a torque according to table Tightening torques
for screws [}53].
5.4 Accessories for assembly
5.4.1 Stem protection tube for rising valve stem
Figure19: Assembly of the stem protection tube
[1] [1]*
[1]**
[2]
[3]
[1] Protective cap for stem protection tube
(fitted)
[1]* Option for size 25.1: Protective cap
made of steel (screwed)
[1]** Option for sizes 30.1, 35.1, 40.1, 48.1:
Protective cap made of steel (welded)
[2] Stem protection tube
[3] V-seal
NOTICE Risk of bending or oscillation of protection tubes exceeding a length of 2
m!
Risk of damage at stem and/or protection tube.
àSecure protection tubes exceeding 2 m by an appropriate support.
How to proceed 1. Seal all threads with hemp, Teflon tape, sealing agent or thread sealing material.
2. Screw stem protection tube [2] into thread and tighten it firmly.
Information:For stem protection tubes made of two or more segments, all parts
have to be thoroughly screwed together.
Figure20: Protection tube made of segments with threaded sleeves (> 900 mm) (only applic-
able for sizes 25.1 and 30.1)
[2]
[3] [4]
[2] [2]
[3] [3][4]
[2] Segment of stem protection tube [3] V-seal
[4] Threaded sleeve
3. Push down the sealing ring [3] onto the housing.
Information:For mounting segments, push down seals of segments down to the
sleeve (connecting pieces).

Assembly
20
4. Check whether protective cap [1] for stem protection tube is available, in perfect
condition and tightly placed on or screwed to the tube.