Controlli MVE522 User manual

Controlli S.p.A.
16010 Sant’Olcese (GE)
Tel. [phone]
Fax. [phone]
www.controlli.eu
1st Issue rev. a 04/2016 DBL483e Page 1
MVE522
Globe Valves Actuators
APPLICATION AND USE
MVE is a exible electro mechanical actuator for the control of two
and three-way globe valves in:
• heating and cooling systems;
• Air Handling Units;
• district heating plants;
• industrial temperature control systems.
The actuator can be controlled either by a proportional (modulat-
ing) signal or by an increase/decrease (Floating) signal.
It is easy to mount and connect the actuator. Direct mounting is pos-
sible to any CONTROLLI anged valve. Linkage kits are available for
CONTROLLI threaded valves as well as for valves of other manufac-
turers (table p. 3). The actuator has a ne resolution (500 steps on the
full stroke range) for exacting uid control and it is able to self-cali-
brate on a different stroke without the need of any user action (this
function is DIP switch selectable on the eld).
MVE has intelligent behaviour and alarm functionality in case of un-
expected operation, feedback of alarms to the user is provided by
LEDs (GREEN and RED) on the control board.
N.B.: Do not use the actuator if not coupled with its relating valve.
OPERATION
The actuator translates the control signal (modulating or 3 point
oating) from the controller into a valve position. A modern brushless
DC motor in the actuator drive a gear train and a worm gear – screw
jack mechanism convert the motor revolutions into accurate and
repeatable linear movements.
Control Signal
MVE can be controlled by one of 2 main control types:
• 3 point oating ;
• Modulating (or proportional) signal with led selectable
range (e.g., 0-10Vdc, 2-10Vdc, 0-5/2-6Vdc, 5-10/6-10Vdc and
4-20mA).
Manual Override
There is a manual operation handle on the actuator. When it is low-
ered (manual override ON), the power supply to the motor power
stage circuitry is cut and the motor stops. The actuator can be oper-
ated manually and the valve positioned accordingly.
The manual override lever stays in position until it is raised again, then
board and motor will be powered again. At the end of this operation
the actuator moves to initial position (on the basis of DIP n. 1 setting)
then it follows the control signal. When the manual override is en-
gaged the GREEN and the RED LED are ON.
Manual operation handle can also be used to modify any DIP switch
setting or as re-set function after any alarm occurrence.
The actuator is supplied with the manual override lowered (ON). It
is not necessary to remove power supply to modify DIP switches set-
ting.
Position Feedback
The actuator utilizes a 2-10Vdc position feedback (look at DIP n. 1
setting).
Calibration
The actuator has both auto and manual stroke calibration, DIP n. 7.
In factory delivery the auto stroke calibration is enabled – manual
calibration is not necessary unless maintenance is required on the
valve or certain alarm functions are desired.
Model Force [N] Power supply Description
MVE522 2200 24Vac/dc long yoke, modulating/
oating control
MVE522S 2200 24Vac/dc short yoke, modulating/
oating control

End Point Auxiliary Switches (with accessory DMVE)
End point switches change over when the valve is fully open or
closed. They are free contacts with 24V AC/DC, 4A max voltage on
terminals. End point switches can be utilized to indicate valve stroke
end positions and for relay control of additional plant equipment.
When the actuators are controlled individually or in sequence, it is
possible to use the end switches to toggle when the valve is fully
open or fully closed. The auxiliary switch position according to con-
trol signal (Y) is shown in the picture below.
K1 K2 KC1
K1 K2 KC1
End point
position
End point position
DMVE
RELE' DI CHIUSURA
RELE' DI APERTURA
K3 K4 KC2
Posizione
di fine corsa
Posizione
di fine corsa
K3 K4 KC2
OPENING RELAY
CLOSING RELAY
DMVE
Diagnostic
The actuator is provided with a self diagnostic algorithm able to de-
tect faulty conditions:
• stroke calibration out of range 5-60mm;
• unexpected stall condition (e.g. valve stuck or extra stroke due
to actuator link loose);
• voltage supply out of range.
These faulty conditions are signalled through the GREEN and RED LED
on the electronic board blinking accordingly (see Diagnostic – Alarm
Function Table).
Control signal (Y) Relay
KC1
Relay
KC2
0-0,5Vdc KC1 to K2 KC2 to K3
0,5-9,5Vdc KC1 to K1 KC2 to K3
9,5-10Vdc KC1 to K1 KC2 to K4
TECHNICAL FEATURES
MVE522
MVE522S
Supply voltage L1 Ln AC: 24Vac ±20% 50-60Hz
DC:22-30Vdc (Reference Ln)
Power consumption
(running) 25VA / 10W
Power consumption
(holding) 10VA / 4W
Running time
Modulating 5-15mm
60s
Modulating 15-25mm
Modulating 25-60mm
Floating
Transformer Size [VA] 50
Stroke 5-60mm (limited to 30mm for MVE.S)
Force [N] 2200
Duty cycle max 50%/60 minutes
Analogue input Y M
voltage 0-10Vdc - impedance > 100kΩ (range:
0-10Vdc, 2-10Vdc, 0-5/2-6Vdc, 5-10/6-10Vdc)
500Ω (range 4-20mA)
Digital inputs Y1 Y2 connection to L1 or Ln when powered in AC
connection to Ln only when powered in DC
Output V+
voltage 16Vdc ± 0,5Vdc
max load 25mA,
Output U
voltage 2-10Vdc (0-100%)
max load 2mA
Number of cycles of
manual action 6.000
Number of cycles of
automatic action 100.000
Type of action type 1
Type of movement linear
Room temperature operation -10T50°C; storage -20T50°C
Room Humidity max 90% R.H.
Protection degree Nema 2 (*) / IP54 (**)
Insulation class
Printed Circuit Board
FR4 (material)
PLC (Performance Level Categories) = 3
PTI (Proof Tracking Index) = 175 - 249V
CTI (Comparative Tracking Index) = PTI
Pollution Degree = 2
Standard Emission/Immunity EMC 2004/108/CE according
to EN 61326-1:2006 standard
Material housing: aluminium - cover: ABS plastic
Colour aluminium / white
Weight [kg] 1,7 (MVE5xx); 1,6 (MVE5xxS)
Dimensions [mm] refer to the picture on the page 7
Date code yy/ww
*To guarantee IP54 protection
• Insert the actuator cable in the PG13,5 cable gland (not sup-
plied)
1st Issue rev. a 04/2016 DBL483e Page 2

ELECTRIC CONNECTIONS
Remove the cover screw with a screwdriver and then remove the
cover as shown in the picture beside.
The actuator is equipped with a 8 poles removable terminal block;
the each pole of the plug is clearly marked and the same label are
reported on the electronic board. Before powering up the actuator
make sure the plug is properly connected to the board and the label
on the plugs and on the board match.
Use PG13,5 cable gland (not supplied).
Linkage MVE MVES
Current Controlli valves
(except for 2TGB.F/3TGB.F PN16) (not required) /
2TGB.F/3TGB.F PN16 /(not required)
Controlli valves with threaded M40
connections
(except for VSB/VMB/VSBF/VMBF
PN16)
AG51 /
VSB/VMB/ VSBF/VMBF PN16 AG52 AG63
Other manufacturers
Landis * AG70-10
AG70-14 /
Danfoss (VR/VF (S) models) AG60-07 /
TAC DN15-V298 AG 60-08 /
TAC DN15-V2XX/V3XX AG 60-09 /
Honeywell** AG 60-10 /
Airtek AG 60-11/
AG60-12 /
Johnson Controls code VB7816-
2111 AG 66 /
Johnson Controls code BM-3018-
3300 AG 67 /
Tac Venta (not required) /
(/) this model can not be assembled
(*) AG70-10 for valves having stem Ø 10mm
AG70-14 for valves having stem Ø 14mm
(**) valid for the following models: M6: V176A. B, V538C
1/4”: V5011A
ASSEMBLING
The actuator can be mounted with any orientation but never up-side
down. When the uid temperature exceed 120°C the actuator shall
be mounted leaning 45°.
N4170-17
T fluid ≥ 120°C
T fluid MAX 120°C
T fluid ≥ 120°C
To mount the actuator on to a valve, position the valve stem to the
bottom of its travel, slide the actuator onto the valve neck, adjusting
with the manual override the screw jack position so the square nut
on the valve spindle ts into the groove on the cross bar. Then slide
the brace into the groove on the valve neck and secure the nuts.
See mounting instructions for full details (MVE_DIM223).
MAINTENANCE
The actuator is free of maintenance.
ACCESSORIES
DMVE End point auxiliary switches (electrical rate 24V AC/DC,
4A max)
248 Yoke heater (suggested when the uid temperature is be-
low 0°C)
GMVE Thermal insulation for MVE actuators
GMVE.S Thermal insulation for MVE.S actuators
1st Issue rev. a 04/2016 DBL483e Page 3

Matching between MVE terminal block and others Controlli
actuators
Label Description Function Cable type Max wire
length
L1 24Vac/dc
Power
supply
AWG 16 ( min
1mm2 - max
1,5mm2)
75m
Ln 0V
Y 0-10Vdc Modulating
control
input
AWG 20 ( min
0,5mm2 - max
1,5mm2)
200m
M0V
(common)
Y1 Open Floating
control
input
AWG 20 ( min
0,5mm2 - max
1,5mm2)
200m
Y2 Close
V+ 16Vdc Voltage
output max
25mA
AWG 20 ( min
0,5mm2 - max
1,5mm2)
200m
M0V
(common)
U 2-10Vdc Feedback
output
signal
AWG 20 ( min
0,5mm2 - max
1,5mm2)
200m
M0V
(common)
Controller(*)
3-point floating control
(sink connection)
0V
Y2
Ln
MVE
Y1 OPEN
24Vac/24Vdc
L1
CLOSE
3-point floating control
(source connection)
24Vac
0V
Controller(*)
OPEN
CLOSE
MVE
L1
Ln
Y1
Y2
COMMAND +
COMMAND -
Controller (*)
MVE
24Vac/24Vdc
0V
Modulating control (0-10Vcc)
L1
Ln
Y
M
N.B.: M and Ln signals are internally connected.
(*) MVE contain a single half-wave rectier power supply. They must
not be powered with transformers that are used to power other
devices using not isolated double half-wave rectier power sup-
ply.
TERMINAL BLOCK
L1 / Ln
0 V
24Vac/dc
N4170-04
U Y M Y1 Y2
Note: To avoid damages to electronic components caused by the
PCB bending, do not press too much while xing the terminal
block.
WIRING DIAGRAMS
1st Issue rev. a 04/2016 DBL483e Page 4

DIP SWITCHES SETTINGS
Set the DIP switches according to the tables here below. Power
down and power up again the actuator or act on the manual over-
ride to be sure that settings will be recognized.
DIP
switch OFF ON
1
Direct Action Reverse Action
2
Modulating Control (MOD) (Input between Y [+] and M [-]) 3 point oating (INC) ( Y1 open-extend , Y2 close-retract
connected L1 or Ln if powered in Vac; if powered in Vdc
connected necessarily to Ln )
3- Selection of sequence mode, control range dened by DIP n. 5
4Modulating Control 0-10Vdc
(DIP n. 2 OFF only)
Modulating Control 2-10Vdc
(DIP n. 2 OFF only)
5
Sequence Control 0-5Vdc with DIP n. 4 OFF only
Sequence Control 2-6Vdc with DIP n. 4 ON only
(DIP n. 3 ON only)
Sequence Control 5-10Vdc with DIP n. 4 OFF only
Sequence Control 6-10Vdc with DIP n. 4 ON only
(DIP n. 3 ON only)
6Voltage Input Signal
(input between Y [+] and M [-])
Current Input Signal 4-20mA
(input between Y [+] and M [-]). In this case DIP n. 4 must be set
to ON.
7
Automatic Calibration: the actuator updates the stroke
range every time an unexpected mechanical stop is
detected for at least 10s
Manual Calibration: the actuator calibration is started moving
the DIP from OFF to ON or vice versa. With DIP in ON in case
of extra stroke or if an unexpected endpoint is detected, the
actuator will never update the stroke
U=10V
Y1 Y2
U = 10V U = 2V
U= feedback
U= feedback
U = 2V
Factory settings
1st Issue rev. a 04/2016 DBL483e Page 5

DIAGNOSTIC - ALARM FUNCTIONS
N° LEDs
behaviour Error Actuator use Actuator behaviour Typical trouble shooting condition
Reset
procedure
Automatic calibration
(DIP N. 7 OFF)
Manual calibration
(DIP N. 7 ON)
1RED ON Valve stroke
less than 5mm
Calibration/rst
installation
The actuator pushes/pulls 2
times (unexpected stall) trying
to remove the possible obstacle.
After 2 tries an alarm is signalled
and the actuator moves to initial
position and does not respond to
control signal. Stroke value is not
updated because out of range
The actuator pushes/pulls 2
times against endpoint during
calibration and the actuator
moves to the initial position and
then it does not respond to the
control signal. The actuator keeps
the previous stroke
Valve with a stroke
length lower than
5mm
Remove
power and
power up
again
2
RED quick
blinking +
GREEN ON
Stroke longer
than 60mm
Calibration/rst
installation
The actuator exits the 60mm
stroke range and it moves toward
the new stroke limit signalling an
anomaly. The actuator pushes/
pulls 2 times against the new
stroke limit, then it goes back to
the initial position still signalling
the anomaly until it is not within
60mm. The actuator does not
calibrate the stroke after 10s
(wrong range)
The actuator exits the 60mm
stroke range and it moves toward
the new stroke limit signalling an
anomaly. The actuator pushes/
pulls 2 times against the new
stroke limit, then it goes back to
the initial position still signalling the
anomaly until it is not within 60mm.
The actuator does not calibrate
the stroke after 10s (wrong range)
Valve with a stroke
length longer than
60mm
Remove
power and
power up
again
3RED Quick
Blinking
Unexpected
stall within the
calibrated
stroke range
normal
operation
The actuator tries 5 times against
the new stall condition and then
after 10s the actuator updates
the new stroke length
The actuator tries 5 times against
the new stall condition. At the end
of the attempts the fault will be
signalled. The actuator does not
update the new stroke length, but
after 60s makes other attempts to
verify the stall condition
Valve stuck Inverted
control signal
4RED Quick
Blinking
Stroke longer
than expected
Normal
operation
The actuator moves toward the
new stall condition with a lower
speed; after 10s the actuator
updates the new stroke value
The actuator moves toward the
new stall condition with a lower
speed; after 10s the actuator does
not update the new stroke value
Stem connection
loose or valve
damaged
Inverted
control signal
5RED slow
Blinking
Low Power
Voltage
Normal
operation
The actuator is still working
but performance cannot be
guaranteed
The actuator is still working
but performance cannot be
guaranteed
1. Wrong transformer
size Correct
Voltage Power
2. Unstable power
6RED slow
Blinking
High Power
Voltage
Normal
operation
The actuator is still working
but performance cannot be
guaranteed
The actuator is still working
but performance cannot be
guaranteed
1. Wrong transformer
size Correct
Voltage Power
2. Unstable power
1st Issue rev. a 04/2016 DBL483e Page 6

The performances stated in this sheet can be modifi ed without any prior notice
STANDARD LEDs BEHAVIOUR
DIMENSIONS [mm]
177
194 122
234
194
86
122
N° LED behaviour Actuator status
1GREEN ON The actuator arrived at the extreme point of the stroke read
2GREEN BLINKING The actuator arrived at the intermediate point of the stroke read
3RED GREEN BLINKING The actuator is reading the stroke or it is going to initial position
4RED GREEN ON Manual control ON, the actuators ignores the control signal.
ATTENTION! The electronic board is electrically supplied
1st Issue rev. a 04/2016 DBL483e Page 7