Burkert Type 3003 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 3003
Electrical rotary
Open/ClOse
actuator
Elektromotorischer Drehantrieb
Auf/Zu
Actionneurs électriques
Ouvert/fermé

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2011 - 2013 Bürkert Werke GmbH
Operating Instructions 1307/01_EU-ML_00809466 / Original DE

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1. OPERATING INSTRUCTIONS ...................................................................4
1.1. Symbols ..............................................................................................4
1.2. Definition of the term “device” .......................................................4
2. INTENDED USE ................................................................................................5
2.1. Restrictions ........................................................................................5
3. GENERAL SAFETY INFORMATION ........................................................5
4. GENERAL INFORMATION ...........................................................................7
4.1. Contact address ............................................................................... 7
4.2. Warranty ............................................................................................. 7
4.3. Informations in the Internet .............................................................7
5. SYSTEM DESCRIPTION ...............................................................................7
5.1. Intended area of application .......................................................... 7
5.2. General description .........................................................................7
5.3. Options ............................................................................................... 8
5.4. Marking ...............................................................................................8
5.5. Type label ...........................................................................................8
6. TECHNICAL DATA ...........................................................................................9
6.1. Conformity .........................................................................................9
6.2. Standards ...........................................................................................9
6.3. Operating conditions ....................................................................... 9
6.4. General technical data .................................................................... 9
7. INSTALLATION ...............................................................................................13
7.1. Safety information ..........................................................................13
7.2. Power and control connections ..................................................13
7.3. Connecting the additional limit switches (optional) ...............13
7.4. Circuit board for actuator with standard signal input ............15
8. ROTARY ACTUATORS WITH INTEGRATED EMERGENCY
RESET ................................................................................................................18
8.1. Safety block for emergency power version ..............................18
8.2. Technical data .................................................................................18
8.3. Electric wiring ..................................................................................19
8.4. Circuit board ...................................................................................19
9. OPERATING .....................................................................................................20
9.1. Safety information ..........................................................................20
9.2. Manual operation of the rotary actuator ....................................21
9.3. Returning from manual to automatic operation .......................21
10. MAINTENANCE AND REPAIR ..............................................................22
10.1. Safety information ........................................................................22
10.2. Maintenance ..................................................................................22
10.3. Malfunctions ..................................................................................22
11. ACCESSORIES ...........................................................................................23
12. TRANSPORT, STORAGE, DISPOSAL ..............................................23
Contents
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Operating Instructions
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device.
Keep these instructions in a location which is easily accessible to
every user and make these instructions available to every new owner
of the device.
The operating instructions contain important safety information!
Failure to observe these instructions may result in hazardous
situations.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning may result in a fatal or serious
injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderately
severe or minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the
device or the equipment.
Designates additional significant information, tips and
recommendations.
Refers to information in these operating instructions or in
other documentation.
→designates a procedure which you must carry out.
1.2. Definition of the term “device”
In these instructions, the term device always refers to the electrical
rotary actuator Type 3003.
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Intended use
2. INTENDED USE
Non-authorized use of the electrical rotary actuator Type
3003 may be dangerous to people, nearby equipment and the
environment.
• The device may be used outside.
• During use observe the authorized data, the operating conditions
and conditions of use specified in the contract documents and
in the operating instructions. These are described in the chapter
entitled “Technical Data”.
• The device may only be used in connection with third-party devices
and components recommended or approved by Bürkert.
• Requirements for safe and proper operation are proper trans-
port, storage and installation as well as careful operation and
maintenance.
• Only use the device as intended.
2.1. Restrictions
Observe any existing restrictions that apply to the device to be exported.
3. GENERAL SAFETY
INFORMATION
This safety information does not cover:
• Haphazard situations that can arise during installation, operation and
maintenance of the use.
• Locally applicable safety regulations which the operator and instal-
lation personnel are obligated to follow.
Hazard due to electrical voltage!
Intervention in the device poses an acute risk of injury.
• Before starting work, be sure to switch off the supply voltage
and secure it to prevent restarting!
• Always connect multiple electrical rotary OPEN/CLOSED
actuators with phase isolation via a switch.
• Observe all applicable accident protection and safety guidelines
for electrical equipment!
Unintentional operation or impermissible damage can lead to
generally dangerous situations as well as physical injury!
• Take appropriate measures to prevent the possibility of uninten-
tional activation of the device!
The general rules of technology apply to the planning and
operation of the device!
• Observe the general rules of technology!
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General safety information
General hazardous situations.
To prevent injury, ensure:
• The electrical rotary actuator Type 3003 may not be used in poten-
tially explosive atmospheres (in this case please use type 3004).
• Do not put any loads on the body (e.g. by placing objects on it
or standing on it).
• Do not make any external modifications to the device body. Do
not paint the body parts or screws.
• Do not install the actuator with the cover facing down (head first).
• When installing the actuator, observe a minimum distance of
30 cm to electromagnetic sources of interference.
• Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
• After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
• The device may be operated only when in perfect condition and
in consideration of the operating instructions.
• The general rules of technology apply to application planning
and operation of the device.
NOTE!
Electrostatically sensitive components / modules!
The device contains electronic components that react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects will endanger these components. In
the worst case, they will be immediately destroyed or will fail after
commissioning.
• Observe the requirements according to EN 61340-5-1 in order
to minimise or avoid the possibility of damage through sudden
electrostatic discharge.
• You should also ensure that the electronic components do not
come into contact with nearby operating voltage.
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General information
4. GENERAL INFORMATION
4.1. Contact address
Germany
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
E-mail: [email protected]
International
Contact addresses are found on the final pages of this operating
manual.
And also on the Internet under: www.burkert.com
4.2. Warranty
The warranty is only valid if the electromotive rotary actuator type
3003 is used as intended in accordance with the specified application
conditions.
4.3. Informations in the Internet
The operating manual and the data sheets on Type 3003 can be found
on the Internet under: www.burkert.com
5. SYSTEM DESCRIPTION
5.1. Intended area of application
The electrical rotary OPEN/CLOSED actuator type 3003 (referred to
as rotary actuator in the following) is designed for ball or flap valves.
5.2. General description
Due to its modular construction, the basic device can be extended
with many options.
Options for expanding the basis device are found in chapter
“5.3. Options”.
The rotary actuator is designed for direct or alternating current with a
varied rating and available for torques of 20, 35, 60 or 100 Nm. The
materials used guarantee maintenance-free operation and ensure a
low thermal load.
All rotary actuators are equipped with a standard emergency manual
control and two additional limit switches and are tested by the manu-
facturer. The limit switches are set for a 0 ... 90° operating range.
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System description
5.3. Options
• Additional limit switches
• Rotary actuator with feedback potentiometer:
- Potentiometer with resistance values of 100 W, 1 kW, 5 kW,
10 kW
- Analogue feedback via 4 ... 20 mA signal
• 3rd position (180°)
• Actuators with integrated fail safe function (see chapter “8. Rotary
actuators with integrated emergency reset”)
5.4. Marking
The rotary actuator is fitted with a type label which enables clear iden-
tification and provides the most important technical data.
Do not remove the type label from the rotary actuator!
It is extremely important for identification during installation
and maintenance.
The warranty is void without the type label.
5.5. Type label
3003 / 225431
~ 24 V 50/60 Hz
Fluid Control Systems
IP66 OF N°460050/79
24 V
90° 20 Nm 15W
10/11 S46
Protection class, Serial number (internal)
Type, Identification number
Operating voltage
Torque, Rating
Operating voltage
Fig. 1: Location and description of the type label
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Technical Data
6. TECHNICAL DATA
6.1. Conformity
In accordance with the EC Declaration of conformity, the electromotive
rotary actuator type 3003 is compliant with the EC Directives.
6.2. Standards
The applied standards, which verify conformity with the EC Directives,
can be found on the EC Type Examination Certificate and/or the EC
Declaration of Conformity.
6.3. Operating conditions
Ambient temperature: -10 °C ... +55 °C
-10 °C ... +40 °C (Emergency
reset)
Permissible areas of application: 0 ... 2000 m altitude
Permissible humidity: < 81 % to 31 °C (88 °F) with
linear decrease as far as 50 % at
40 °C (according to EN 61010-1)
Protection class: IP66 with cable bushing
6.4. General technical data
6.4.1. Mechanical data
Dimensions: See data sheet
Weight: 1.3 kg (20 Nm)
2.8 - 3.1 kg (35-100 Nm)
Materials
Cover: Nylon
Body: PA (Nylon with glass fibre)
Axis / screws: Stainless steel
Gears: Stainless steel and PC (Polycarbonate)
Actuating angle: 90° ± 5° (optional 180°, 270°)
Duty cycle: 50 % at max. torque
6.4.2. Electrical data
Electrical connections: Cable bushing according to
EN 175301-803
Cable gland ISO M20
Limit switches: 4 adjustable (2 for the motor and 2 addi-
tional ones for feedback signal) -
max. 250 V AC / 5 A
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Technical Data
Electrical data for version without analog input signal:
Torque
90° Posi-
tioning time1)
(Specifica-
tions under
load)
Power
consumption Voltage / Frequency
20 12 s 15 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
35 7 s 45 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
60 12 s 45 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
100 23 s 45 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
1) Other positioning times on request
2) The operating voltage must not drop below 11.5 V
We recommend an actuator designed with 1.5 times the
maximum torque of the fitting (On/Off).
Electrical data for version with analog input signal:
Torque
90° Posi-
tioning time1)
(Specifica-
tions under
load)
Power
consumption Voltage / Frequency
20 25 s 15 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
35 40 s 45 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
60 79 s 45 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
100 119 s 45 W 15-30 V AC, 50-60 Hz /
12-48 V DC 2)
100-240 V AC, 50-60 Hz /
100-350 V DC
1) Other positioning times on request
2) The operating voltage must not drop below 11.5 V
We recommend an actuator designed with 2 times the
maximum torque of the fitting (analog input signal).
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Technical Data
6.4.3. Electrical circuit diagrams
Symbol Description
FCO Limit switch ON
FCF Limit switch OFF
FC1 Additional limit switch 1
FC2 Additional limit switch 2
4 5 6 7 8 9
1
3
2
TP/PE
N
-
Ph
+
1
3
2
TP/PE
N
-
Ph
+
Open Close
Open Close
FC1
FC2
3-Point mode On-Off-Mode Feedback
Fig. 2: Open/Closed Version
If voltage is applied simultaneously to terminals 2 and 3, terminal 2 is the leading one and the actuator moves to the OPEN position.
NOTE!
Make certain in 3-point mode that the pulse duration of a controller lasts for at least 1 second. A pause time of at least 500 ms is required
before controller activation is repeated. Observe the duty cycle specified on the type label!
Please note the circuit board must remain power supplied to allow heating resistances working.
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Technical Data
1
3
2
TP/PE
N
-
Ph
+
FC2
Feedback
1
3
2
12 3
17
17 18
18
13 14 15 16
B
A
A B
Motor
=
FCO
FCF
~
~+
-
FC1
P6 POSI
+ +- -
Output
signal
Input
signal
0-20 mA / 4-20 mA /0-10 V
TP/PE
The resolution of the control mode is 1°
The input resistance for control 0-10 V is 10 kW
The input resistance for control 0-20 mA / 4-20 mA is 100 W
4 5 6 7 8 9
15V-30V 50/60 Hz (12V-48V DC)
100V-240V 50/60 Hz
(100V-350V DC)
D1
D2
Error feedback (24V DC/3A max)
Fig. 3: Version with analog input signal
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Installation
7. INSTALLATION
7.1. Safety information
DANGER!
Hazard due to electrical voltage!
• Always switch off the power and secure it to prevent restarting
before removing the cover, or using the lever.
• Always connect multiple rotary actuators with phase isolation via
a switch!
• Protect electrical rotary actuators by using a mains-dependent
safety!
• Observe all applicable accident protection and safety guidelines
for electrical equipment!
WARNING!
Hazard due to improper installation!
• Installation may only be carried out by authorised technicians
using appropriate tools!
• Before installation, ensure that the manual lever can move freely.
Danger due to unintentional activation of the device!
Unintended actuation of the device during installation can lead to
injury and damage to property.
• Take appropriate measures to prevent the possibility of uninten-
tional activation of the device.
7.2. Power and control connections
Procedure:
→Disconnect the rotary actuator from the power supply.
→Remove the position indicator from the axis.
→Loosen the cover screws with a screwdriver and lift the cover off.
→Disconnect the cable connector ISO20 and insert the cable.
→Wire the connections according to the circuit diagram figures (see
“6.4.3. Electrical circuit diagrams”).
Use cables with a diameter of 7 ... 12 mm for the ISO20
cable fitting.
→Set the cover in place and screw it tight.
→Reinstall the position indicator.
7.3. Connecting the additional limit
switches (optional)
In the standard variant, the rotary actuator has 2 additional limit switches
(for 90º range of motion). Connect these as follows.
Procedure:
→Disconnect the rotary actuator from the power supply.
→Remove the position indicator from the axis.
→Use a screwdriver to loosen the cover screws.
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Installation
→Lift the cover off.
→Wire the connections of the additional limit switches (FC1 and FC2)
according to the circuit diagram figures (see “Fig. 2” and “Fig. 3” ).
→Tighten the cable gland after connecting the terminals.
→Set the cover in place and screw it tight.
→Reinstall the position indicator.
Only use 4 or 6 conductor cable with a diameter of 7 ... 12
mm for the ISO20 cable fitting.
Ensure that the cable in the ISO20 cable fitting is com-
pletely sealed when tightening the union nut.
7.3.1. Setting the limit switches
The rotary actuator is supplied with the following factory
settings:
• The CLOSED limit switches are activated with the cams 2
and 4 (closed position).
• The OPEN limit switches are preset at a 90° rotation
angle.
The procedure for setting the limit switches is shown in “Fig. 4” and
“Fig. 5” .
Electronic card
Shaft
Motor
Body
Wrench (00679946)
Cam No. 4
Additional limit
switch CLOSED
CLOSED
black
Cam No. 3
Additional limit
switch OPEN
OPEN
white
Cam No. 2
Motor limit switch
CLOSED
CLOSED
black
Cam No. 1
Motor limit switch
OPEN
OPEN
white
Fig. 4: Setting the limit switches. Limit switches max. 250 V / 5 A
Setting in
clockwise direction
or setting in
counter clockwise
direction
Cams
Wrench
Adjustment
direction
Fig. 5: Setting limit switches in counter clockwise and clockwise
directions
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Installation
7.4. Circuit board for actuator with
standard signal input
A
D
F
E
B
G
C
M
I
K
L
HJ
N
Fig. 6: Circuit board
A Electrical power supply
24 V AC/DC
H K2 plug-in jumper
B Connection terminals of
the input signal
I K3 plug-in jumper
C Connection terminals of
the feedback
J Green and red LED
D MEM pushbutton K LED yellow: Indicates the
power supply
E CLOSE pushbutton L Potentiometer
F OPEN pushbutton M Motor connection
G K1 plug-in jumper N Heat resistor connection
To prevent electromagnetic interference, shielded cables
must be used.
Procedure:
→Loosen the cable gland and feed the cable through.
→Wire the signal transducer between terminals 15 and 16. Terminal
15 is the negative pole (-) and terminal 16 the positive pole (+).
→Wire the position feedback sensor between terminals 13 and 14.
Terminal 13 is the positive pole (+) and terminal 14 the negative
pole (-).
→Re-attach the cable gland.
If the connection voltage is 100 V to 240 V, a fuse must be
provided in the power supply.
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Installation
7.4.1. Specify position of the plug-in
jumpers
ONOFF
Fig. 7: Plug-in
jumper K1
/ K2
Fig. 8: Plug-in
jumper
K3 OFF
Fig. 9: Plug-in
jumper
K3 ON
Signal
trans-
ducer
Feed-
back
Plug-in jumper
K1
Plug-in jumper
K2
Plug-in
jumper
K3
A B A B
0-10 V 0-10 V ON OFF ON OFF OFF
0-10 V 0-20 mA ON OFF OFF ON OFF
0-10 V 4-20 mA ON OFF OFF ON ON
0-20 mA 0-10 V OFF ON ON OFF OFF
0-20 mA 0-20 mA OFF ON OFF ON OFF
0-20 mA 4-20 mA OFF ON OFF ON ON
4-20 mA 0-10 V OFF ON ON OFF OFF
4-20 mA 0-20 mA OFF ON OFF ON OFF
4-20 mA 4-20 mA OFF ON OFF ON ON
7.4.2. Parameterization steps
Specify direction of rotation of the shut-off valve
Normal direction of rotation (preset)
G
→Press <OPEN> pushbutton and switch on
the card (hold down pushbutton).
The GREEN LED lights up.
→Release <OPEN> pushbutton and disconnect
the card from the power supply.
Reverse direction of rotation
R
→Press <CLOSE> pushbutton and switch on
the card (hold down pushbutton).
The RED LED lights up.
→Release <CLOSE> pushbutton and disconnect
the card from the power supply.
Specify control signal type
Control signal when voltage 0 – 10 V
R
→Press <MEM> pushbutton and switch on the
card (hold down pushbutton).
The RED LED lights up 3x.
→Release <MEM> pushbutton and disconnect
the card from the power supply.
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Installation
Control signal when current 0 – 20 mA
R
→Press <MEM> and <OPEN> push-
button and switch on the card (hold
down pushbutton).
The RED LED lights up 3x.
→Release <MEM> and <OPEN> push-
button and disconnect the card from
the power supply.
Control signal when current 4 – 20 mA (preset)
R
→Press <MEM> and <CLOSE> push-
button and switch on the card (hold
down pushbutton).
The RED LED lights up 3x.
→Release <MEM> and <CLOSE>
pushbutton and disconnect the card
from the power supply.
Learning mode
Specify end positions
GR
→Press <OPEN> and <CLOSE>
pushbutton and switch on the card
(hold down pushbutton).
The RED and the GREEN LEDs light up.
→Release <OPEN> and <CLOSE>
pushbutton.
Both LEDs go out.
Learning mode is selected.
R
→Press <CLOSE> pushbutton to move
the shut-off valve into the closed
position.
The RED LED lights up.
R
→Press <MEM> and <CLOSE> push-
button to save the closed position.
The RED LED lights up 2x.
G
→Press <OPEN> pushbutton to move
the shut-off valve into the open
position.
The GREEN LED lights up.
R
→Press <MEM> and <OPEN> push-
button to save the open position.
The GREEN LED lights up 2x.
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Rotary actuators with integrated emergency reset
Specify end positions
All positions are now saved.
→Disconnect the card from the power
supply.
7.4.3. Normal operation
Display normal operation
G
→Switch on card.
The GREEN LED lights up 3x to indicate that the
start process has been implemented correctly.
GIn normal operation the GREEN LED lights up
when the rotary actuator opens the shut-off valve.
RThe RED LED lights up when the rotary actuator
closes the shut-off valve.
GRIf neither of the LEDs is lit, the actuator is not
actuated.
GR
The RED and the GREEN LEDs light up if the
torque is too high and the rotary actuator stops.
→Change direction of rotation of the rotary
actuator or switch over the voltage OPEN/
CLOSED to restart the rotary actuator!
8. ROTARY ACTUATORS WITH
INTEGRATED EMERGENCY
RESET
8.1. Safety block for emergency
power version
Circuit board
Battery
Fig. 10: Safety block for emergency power version
8.2. Technical data
Voltage: 18 V DC
Currant nominal: 0.8 A
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Rotary actuators with integrated emergency reset
Max. current 2.4 A
Charging time 14 h max
Feedback relay for charge state 24 V DC - 1 A max
Permitted ambient temperature -10 °C - +40 °C
8.3. Electric wiring
65
F+
E-
66
17
18
17
18
Battery block
Control and power
supply card
F+ Wire colour
red
E- Wire colour
black
Load state
feedback
Loaded battery: closed
contact 123 123
D1
D2
Open
NPh
A
A
Ph
Open
KM1
N
A1
A2
N
24 V
AC/DC
B
B
100V-240V 50/60 Hz
(100V-350V DC)
15V-30V 50/60 Hz
(12V-48V DC)
On / Off Mode
KM1 - Customer
contactor switch
Suggestet customer
wiring
Actuator
wiring
Total security mode
Safety block
Fig. 11: Electric wiring
Configuration A or B
A-standard mode: If the actuator is controlled with a programmable
controller, the feedback of the charge state can be connected to it.
B-mode - increased safety (if the feedback relay is used, terminals
65 and 66): The actuator does not actuate the valve unless the safety
block is loaded.
8.4. Circuit board
A
DE
B
C
Fig. 12: Diagram: Circuit board
A 18 V DC connection D Green LED*
B Battery block connection E Red LED **
C Connection for feedback
(charge state)
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Operating
Description of the LED:
Green LED Red LED Description
Off Blinks / Off /
Blinks
Battery off or out of service
On Blinks Battery loading cycle in progress
(max. 14 h)
On Off Battery loading cycle finished
Blinks
rapidly
Off Actuator electrical supply during
3 min. (failure mode)
Off Blinks
rapidly
Microcontroller failure
9. OPERATING
9.1. Safety information
DANGER!
Hazard due to electrical voltage!
Intervention in the device poses an acute risk of injury.
• Turn off the power before manually servicing the rotary actuator.
WARNING!
Hazard due to improper servicing!
Improper servicing can result in personal injury and in damage to
the device and its surroundings.
• The operating personnel must be aware of and fully understand
the operating instructions.
• Pay attention in particular to the safety information and the
intended use.
• The device may only be serviced by properly trained personnel.
Hazardous situation due to manual intervention!
During manual intervention the process can change into an unde-
fined state which can lead to hazardous situations.
• Ensure a defined and controlled restarting of the process fol-
lowing manual intervention!
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