AUMA SAEx 07.2 User manual

Multi-turn actuators
SAEx 07.2 –SAEx 16.2
SAREx 07.2 –SAREx 16.2
AUMA NORM (without controls)
Version FM/CSAEX (Class/Division system)
Assembly, operation, commissioningOperation manual

Read operation manual first.
●Observe safety instructions.
●This operation manual is part of the product.
●Preserve operation manual during product life.
●Pass on manual to any subsequent user or owner of the product.
●Proposition 65:This product may contain one or more substances or chemicals known to the state of California
to cause cancer.
Purpose of the document:
This document contains information for the installation, commissioning, operation and maintenance staff.It is intended
to support device installation and commissioning.
Table of contents Page
51. Safety instructions................................................................................................................. 51.1. Basic information on safety 51.2. Range of application 61.3. Warnings and notes 71.4. References and symbols
82. Identification........................................................................................................................... 82.1. Name tag 102.2. Short description
113. Transport, storage and packaging........................................................................................ 113.1. Transport 113.2. Storage 113.3. Packaging
124. Assembly................................................................................................................................ 124.1. Mounting position 124.2. Handwheel fitting 124.3. Multi-turn actuator: mount to valve/gearbox 124.3.1. Output drive type A 134.3.1.1. Stem nut: finish machining 144.3.1.2. Multi-turn actuator (with output drive type A): mount to valve 154.3.2. Output drive types B 164.3.2.1. Multi-turn actuator with output drive types B: mount to valve/gearbox 174.4. Accessories for assembly 174.4.1. Stem protection tube for rising valve stem
195. Electrical connection............................................................................................................. 195.1. Basic information 205.2. Connecting via Ex plug & socket connector with terminal blocks (KES) 205.2.1. Terminal compartment: open 215.2.2. Cable connection 235.2.3. Terminal compartment: close 235.3. Accessories for electrical connection
2
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Table of contents

235.3.1. Parking frame 245.3.2. Protection cover 245.3.3. External PE connection
256. Operation................................................................................................................................ 256.1. Manual operation 256.1.1. Manual operation: engage 256.1.2. Manual operation: disengage 256.2. Motor operation
267. Indications.............................................................................................................................. 267.1. Mechanical position indicator/running indication on indicator mark on cover
278. Signals..................................................................................................................................... 278.1. Feedback signals from actuator
289. Commissioning...................................................................................................................... 289.1. Switch compartment: open 289.2. Torque switch setting 299.3. Limit switch setting 309.3.1. End position CLOSED (black section): set 309.3.2. End position OPEN (white section): set 319.4. Intermediate positions: set 319.4.1. Running direction CLOSE (black section): set 329.4.2. Running direction OPEN (white section): set 329.5. Test run 329.5.1. Direction of rotation: check 349.5.2. Limit switch checking 349.6. EWG 01.1 electronic position transmitter 359.6.1. Measuring range: set 369.6.2. Current values: adjust 369.6.3. LED end position signaling: switch on/off 369.7. Potentiometer 379.7.1. Potentiometer setting 379.8. RWG electronic position transmitter 389.8.1. Measuring range: set 389.9. Mechanical position indicator: set 399.10. Switch compartment: close
4110. Corrective action.................................................................................................................... 4110.1. Faults during commissioning 4110.2. Motor protection (thermal monitoring)
4311. Servicing and maintenance................................................................................................... 4311.1. Preventive measures for servicing and safe operation 4411.2. Disconnection from the mains 4511.3. Maintenance 4511.4. Disposal and recycling
4612. Technical data......................................................................................................................... 4612.1. Technical data Multi-turn actuators
3
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Table of contents

4913. Spare parts............................................................................................................................. 4913.1. Multi-turn actuators SAEx 07.2 –SAEx 16.2/SAREx 07.2 –SAREx 16.2 KES Exd
5114. Certificates.............................................................................................................................. 5114.1. Certificate of compliance, FM Approval
55Index........................................................................................................................................
57Addresses...............................................................................................................................
4
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Table of contents

1. Safety instructions
1.1. Basic information on safety
Standards/directives AUMA productsaredesignedandmanufacturedin compliance with recognizedstandards
and directives.
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly, electrical
connection, commissioning and operation are met at the place of installation.
Safetyinstructions/warn-
ings All personnel working with this device must be familiar with the safety and warning
instructions in this manual and observe 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 exclusively by suitably qualified personnel having been authorized by the
end user or contractor of the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
theseinstructionsand, furthermore,knowand observeofficially recognizedrules regarding
occupational health and safety.
Work performed in potentially explosive atmospheres is subject to special regulations
which have to be observed.The end user or contractor of the plant is responsible for
respect and conformance to these regulations, standards, and laws.
Commissioning Prior to commissioning, it is important to check that all settings meet the requirements
ofthe application.Incorrect settingsmight present adanger 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 instructions.
●Immediately report any faults and damage and allow for corrective measures.
●Observe recognized rules for occupational health and safety.
●Observe the national regulations.
●During operation,the housingwarmsup andsurfacetemperatures> 140 °F (60 °C)
may occur.To prevent possible burns, we recommend checking the surface tem-
perature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor is 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 consent of the manufacturer.
1.2. Range of application
AUMA multi-turn actuators are designed for the operation of industrial valves, e.g.globe
valves, gate valves, butterfly valves, and ball valves.
The devices described below are approved for use in hazardous classified locations
according to Class I, Division 1; Class II/III, Division 1 and Class I, Zone 1.
5
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Safety instructions

Other applications require explicit (written) confirmation by the manufacturer.
The following applications are not permitted, e.g.:
●Industrial trucks
●Lifting appliances
●Passenger lifts
●Service lifts
●Escalators
●Continuous duty
●Buried service
●Continuous submersion (observe enclosure protection)
●Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of this operation manual is considered as part of the device's designated
use.
Information This operation manual is only valid for the "clockwise closing" standard version, i.e.
driven shaft turns clockwise to close the valve.
1.3. Warnings and notes
The following warnings draw special attention to safety-relevant procedures in this
operation manual, each marked by the appropriate signal word (DANGER, WARNING,
CAUTION, NOTICE).
Indicates a hazardous situation that, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation that,if not avoided,could result in death or serious
injury.
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
Indicates information considered important,but not hazard related (e.g.messages
related to property damage).
Arrangement and typographic structure of the warnings
Type of hazard and respective source!
Possible consequence(s) in case of non-observance (option)
→Measures to avoid the danger
→Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.
The signal word (here: DANGER) indicates the level of hazard.
6
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Safety instructions

1.4. References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)
Symbol for OPEN (valve open)
Important information before the next step.This symbol indicates what is required for
the next step or what has to be prepared or observed.
< > Reference to other sections
Terms in the brackets shown above refer to other sections of the document which provide
further information on this topic.These terms are either listed in the index, a heading or
in the table of contents and may easily be located.
7
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Safety instructions

2. Identification
2.1. Name tag
Each device component (actuator, motor) is equipped with a name tag.
Figure 1: Arrangement of name tags
[1] Motor name tag
[2] Actuator name tag
[3] Additional plate, e.g. KKS plate (Power Plant Classification System)
[4] Explosion protection approval plate
Actuator name tag
Figure 2: Actuator name tag (example)
[1] Name of manufacturer
[2] Address of manufacturer
[3] Type designation
[4] Order number (commission number)
[5] Actuator serial number
[6] Speed
[7] Torque range in direction OPEN
[8] Torque range in direction CLOSE
[9] Type of lubricant
[10] Permissible ambient temperature
[11] Can be assigned as an option upon customer request
[12] Enclosure protection
8
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Identification

Approval plate in explosion-proof version
Figure 3: Approval plates in explosion-proof version (examples)
[1] Ex symbol
[2] Number of test authority
[3] Classification:
Division 1 (frequency or duration of occurrence of hazardous substances)
Class I = Gasses, vapors or liquids (groups B, C, D)
Class II = Combustible dusts (groups E, F, G)
Class II = Fibers and Flyings
[4] Protection type of housing
[5] Temperature class / max.surface temperature
[6] Permissible ambient temperature
[7] Number of certificate (for CSA only)
Description referring to name tag indications
Type designation Figure 4:Type designation (example)
1. Type and size of actuator
2. Flange size
3. Ex marking
Type and size
This manual applies to the following device types and sizes:
Multi-turn actuators for open-close duty: SAEx 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
Multi-turn actuators for modulating duty: SAREx 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
9
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Identification

Ex marking
Table 1:
Motor for explosion protection (with example /13B1111-)
-1111B31/
Version (actuator with/without actuator controls)
1 = NORM (without actuator controls)
1
Electrical connection
3 = Terminal connection type: KES-Exd
(terminal compartment Ex dflameproof enclosure)
3
Control unit cover
B = Without indicator glas
W = With indicator glas
B
Motor heater
1 = Without motor heater
2 = With motor heater
1
Motor insulation class
1 = Insulation class F
2 = insulation class H
1
Not applicable
Not appliccable
1
Motor type
1 = ADX or VDX: 3-phase AC motor
2 = AEX, ACX,VEX, VCX: 1-phase AC motor
1
Order number The product can be identified using this number and the technical data as well as
order-specific data pertaining to the device can be determined.
Please always state this number for any product inquiries.
Actuator serial number Table 2:
Description of serial number (example of 0516UD12345)
UD123451605 Positions 1+2: Assembly in week = week 0505 Positions 3+4:Year of manufacture = 201616 Internal number for unambiguous product identificationUD12345
2.2. Short description
Multi-turn actuator Definition in compliance with MSS SP-102 [EN ISO 5210]:
A multi-turn actuator is an actuator which transmits to the valve a torque for at least one
full revolution.It is capable of withstanding thrust.
AUMA multi-turn actuators are driven by an electric motor and are capable of withstanding
thrust in combination with output drive type A. For manual operation, a handwheel is
provided.Switching off in end positions may be either by limit or torque seating.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 more information, please state our order number (refer to actuator name tag).
10
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Identification

3. Transport, storage and packaging
3.1. Transport
For transport to place of installation, use sturdy packaging.
Hovering load!
Death or serious injury possible.
→Do NOT stand below hovering load.
→Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT
to handwheel.
→Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting by
hoist to valve and NOT to actuator.
→Actuators 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.
→Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting by
hoist only to the actuator and NOT to the controls.
3.2. Storage
Danger of corrosion due to inappropriate storage!
→Store in a well-ventilated, dry room.
→Protect against floor dampness by storage on a shelf or on a wooden pallet.
→Cover to protect against dust and dirt.
→Apply suitable corrosion protection agent to uncoated surfaces.
Long-term storage If the device must be stored for a long period (more than 6 months) the following points
must be observed in addition:
1. Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting surface,
with long-term corrosion protection agent.
2. At an interval of approx.6 months:
Check for corrosion.If first signs of corrosion show, apply new corrosion protection.
3.3. Packaging
Our products are protected by special packaging for the transport ex works.The
packaging consists of environmentally friendly materials which can easily be separated
and recycled.We use the following packaging materials: wood, cardboard, paper, and
PE foil.For the disposal of the packaging material, we recommend recycling and collection
centers.
11
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Transport, storage and packaging

4. Assembly
4.1. Mounting position
The product described in this document can be operated without restriction in any
mounting position.
4.2. Handwheel fitting
Information For transport reason, handwheels with a diameter 15.7 inches (400 mm) and larger are
supplied separately within the scope of delivery.
Figure 5: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Retaining ring
1. If required, fit spacer [1] onto input shaft [2].
2. Slip handwheel [3] onto input shaft.
3. Secure handwheel [3] using the retaining ring [4] supplied.
4.3. Multi-turn actuator: mount to valve/gearbox
Danger of corrosion due to damage to paint finish and condensation!
→Touch up damage to paint finish after work on the device.
→After mounting, connect the device immediately to electrical mains to ensure that
heater minimizes condensation.
4.3.1. Output drive type A
Application ●Output drive for rising, non-rotating valve stem
●Capable of withstanding thrust
Design Output mounting flange [1] with axial bearing stem nut [2] form one unit.Torque is
transmitted to valve stem [3] via stem nut [2].
12
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Assembly

Figure 6: Design of output drive type A
[1] Output mounting flange
[2] Stem nut with dog coupling
[3] Valve stem
Information To adapt the actuators to available output drive types A with flanges FA10 and FA14
(year of manufacture:2009 and earlier), an adapter is required.The adapter can be or-
dered from AUMA.
4.3.1.1. Stem nut: finish machining
✔This working step is only required if stem nut is supplied unbored or with pilot bore.
Figure 7: Output drive type A
[1] Stem nut
[2] Axial needle roller bearing
[2.1] Axial bearing washer
[2.2] Axial needle roller and cage assembly
[3] Spigot ring
1. Remove spigot ring [3] from output drive.
13
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Assembly

2. Remove stem nut [1] together with axial needle roller bearings [2].
3. Remove axial bearing washers [2.1] and axial needle roller and cage assemblies
[2.2] from stem nut [1].
4. Drill and bore stem nut [1] and cut thread.
Information: When fixing in the chuck, make sure stem nut runs true!
5. Clean the machined stem nut [1].
6. Apply sufficient suitable 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].
8. Re-insert stem nut [1] with bearings [2] into output drive.
Information: Ensure that dogs or splines are placed correctly in the keyway of the
hollow shaft.
9. Screw in spigot ring [3] until it is firm against the shoulder.
4.3.1.2. Multi-turn actuator (with output drive type A): mount to valve
Figure 8: Assembly of output drive type A
[1] Valve stem
[2] Output drive type A
[3] Screws to actuator
[4] Valve flange
[5] Screws to output drive
1. If the output drive type A is already mounted to the multi-turn actuator: Remove
screws [3] and remove output drive type A [2].
2. Check if the flange of output drive type A matches the valve flange [4].
3. Apply a small quantity of grease to the valve stem [1].
4. Place output drive type A on valve stem and turn until it is flush on the valve flange.
5. Turn output drive type A until alignment of the mounting holes.
6. Screw in fastening screws [5], however do not completely tighten.
7. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into the
output drive sleeve.
➥The flanges are flush with each other if properly engaged.
14
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Assembly

8. Rotate multi-turn actuator until alignment of the mounting holes.
9. Reinstall multi-turn actuator with screws [3].
10. Reinstall screws [3] crosswise with a torque according to table.
Table 3:
Tightening torques for screws Tightening torque ft-lb [Nm]M threadsUNC threads Strength class A2-808.8 7 [10]8 [11]M61/4" 18 [24]18 [25]M85/16" 35 [48]38 [51]M103/8”60 [82]64 [87]M121/2" 148 [200]158 [214]M165/8”289 [392]318 [431]M203/4”
11. Turn multi-turn actuator with handwheel in direction OPEN until valve flange and
output drive A are firmly placed together.
12. Tighten fastening screws [5] between valve and output drive type A crosswise ap-
plying a torque according to table.
4.3.2. Output drive types B
Application ●For rotating, non-rising valve stem
●Not capable of withstanding thrust
Design Connection between hollow shaft and valve or gearbox via output drive sleeve fixed to
the hollow shaft of the multi-turn actuator via retaining ring.
Changing output drive sleeve allows later retrofitting to a different output drive type.
●Output drive type B: Output drive sleeve with bore according to DIN 3210
●Output drive types B1 –B4: Output drive sleeve with bore according to EN ISO
5210
15
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Assembly

Figure 9: Output drive type B
[1] Multi-turn actuator flange (e.g. FA07)
[2] Hollow shaft
[3] Output drive sleeve (illustration examples)
[3] B/B1/B2 and [3]* B3/B4, respectively with bore and keyway
[4] Gearbox/valve shaft
Information Spigot at valve flanges should be loose fit.
4.3.2.1. Multi-turn actuator with output drive types B: mount to valve/gearbox
Figure 10: Mounting output drive types B
[1] Multi-turn actuator
[2] Valve/gearbox
[3] Valve/gearbox shaft
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].
16
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Assembly

3. Apply a small quantity of grease to the valve or gearbox stem [3].
4. Fit multi-turn actuator [1].
Information: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 according to table.
Information: We recommend applying liquid thread sealing material to the screws
to avoid contact corrosion.
6. Fasten screws crosswise to a torque according to table.
Table 4:
Tightening torques for screws Tightening torque ft-lb [Nm]M threadsUNC threads Strength class A2-808.8 7 [10]8 [11]M61/4" 18 [24]18 [25]M85/16" 35 [48]38 [51]M103/8”60 [82]64 [87]M121/2" 148 [200]158 [214]M165/8”289 [392]318 [431]M203/4”
4.4. Accessories for assembly
4.4.1. Stem protection tube for rising valve stem
—Option —
Figure 11: Assembly of the stem protection tube
[1] Protective cap for stem protection tube (fitted)
[1]* Protective cap made of steel (screwed)
[2] Stem protection tube
[3] V-seal
1. Seal thread with Teflon tape 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.
17
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Assembly

3. Push down the sealing ring [3] onto the housing.
Information: For mounting segments, push down seals of segments down to the
sleeve (connecting piece).
4. Check whether protective cap for stem protection tube [2] is available, in perfect
condition and tightly placed on or screwed to the tube.
18
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Assembly

5. Electrical connection
5.1. Basic information
Danger due to incorrect electrical connection
Failure to observe this warning can result in death, serious injury, or property damage.
→The electrical connection must be carried out exclusively by suitably qualified per-
sonnel.
→Prior to connection, observe basic information contained in this chapter.
→After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
Wiring diagram/terminal
plan The pertaining wiring diagram/terminal plan is in the cover of the electrical connection.
The operation manual is attached to the device in a weather-proof bag.
Valve damage for connection without controls!
→NORM actuators require controls: Connect motor via controls only (reversing con-
tactor circuit).
→Observe the type of seating specified by the valve manufacturer.
→Observe wiring diagram.
Delay time The delay time is the time from the tripping of the limit or torque switches to the motor
power being switched off.To protect the valve and the actuator, we recommend a delay
time < 50 ms.Longer delay times are possible provided the operating time, output drive
type, valve type, and the type of installation are considered.We require switching off the
corresponding contactor directly by limit or torque switch.
Protection on site For short-circuit protection and for disconnecting the actuator from the mains, fuses and
disconnect switches have to be provided by the customer.
The current value for respective sizing is derived from the current consumption of the
motor (refer to electrical data sheet).
Protection via thermal
motor protection According to FM approvals, thermal switches for thermal motor protection must be
connected to external controls for explosion-proof actuators.
Limit and torque switch-
es Limit and torque switches can be provided as single, tandem, or triple switches.Only
the same potential can be switched on the two circuits (NC/NO contact) of each single
switch.If different potentials are to be switched simultaneously, tandem switches or triple
switches are required.When using tandem/triple switches:
●For signaling use the leading contacts TSC1, TSO1, LSC1, LSO1.
●For switching off use the lagging contactsTSC, TSO, LSC, LSO.
Type of current, mains
voltage and mains fre-
quency
Type of current, mains voltage and mains frequency must match the data on the motor
name tag.
19
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2 Electrical connection

Figure 12: Motor name tag (example)
[1] Type of current
[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ●Use suitable (voltage-proof) cables.Specify cables for the highest occurring rated
voltage.
●Use connecting cables with a minimum temperature range of 165 °F (+80 °C).
●For connecting cables exposed to UV radiation (outdoor installation), use UV resis-
tant cables.
5.2. Connecting via Ex plug & socket connector with terminal blocks (KES)
5.2.1. Terminal compartment: open
Figure 13:Terminal compartment: open
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Blanking plugs
[5] Cable gland
[6] Frame
20
SAEx 07.2 –SAEx 16.2 / SAREx 07.2 –SAREx 16.2
Electrical connection