Econex AB1 Series User manual

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ELECTRIC ROTARY GEAR MOTOR
SERIES AB1
INSTALLATION AND
OPERATING INSTRUCTIONS
1. GENERAL FEATURES 2
2. TECHNICAL DATA 2
3. INSTALLATION 3
4. WIRING 4
5. CABLE CONNECTIONS 5
6. AUXILIARY MICROSWITCHES 7
7. FEEDBACK POTENTIOMETER/S7
8. CONTROL STATION 7
9. ADJUSTMENTS 8
10. OPERATING 10
11. MAINTENANCE 10
12. REPLACEMENT 10

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1. GENERAL FEATURES
Electric rotary gear motors of series AB1 have been newly conceived and specially
designed to be installed on residential and industrial combustion systems.
They are particularly suitable for control and regulation of modulating disc valves,
butterfly valves, dampers and other fluid regulation systems requiring control of
position angle within 90° or 180°.
Electric rotary gear motors are unipolar and bidirectional with high static and they
maintain torque for 3-position-control.
WARNING
Installation, wiring, adjustment and maintenance of gear motors must be carried
out exclusively by skilled and authorized service technicians.
Non-proper installation, adjustment, modifications, use and maintenance may
cause injuries to the staff or material damages.
It is therefore necessary to respect strictly the following instructions and local
prescriptions for the installation of electric devices.
2. TECHNICAL DATA
Body and cover die-cast aluminium
Nominal torque 5 Nm
Maintaining torque 2,5 ÷ 3 Nm
Rotation time 7,5 ÷ 60 seconds for 90° at 50 Hz
Output shaft 10 mm diameter
Adjustable rotation angle 20° ÷ 180° [standard 90°]
Installation in any position
Fastening bore DIN ISO 5211 – F05 and F07
Ambient temperature - 10° ÷ + 60° C
Weight 1,7 Kg
Standard supply voltage 230 Vac / 50 - 60 Hz
110 Vac / 50 - 60 Hz
24 Vac / 50 - 60 Hz
Nominal load 4 VA
Rating of electric contacts of
Endswitches and auxiliary switches 5 [1] A/250 V c.a.
Enclosure IP 54 and IP 65 according to IEC 529
Duty cycle continuous 100%
Available potentiometers 150, 1000, 2500 Ohm
Cable entry 2 x Pg 13.5

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3. INSTALLATION
3.1 Make sure that all operating data indicated on gear motor plate correspond
to the ones of the systems.
3.2 When installing the gear motor make sure that there is sufficient clearance
above the gear cover and that it is easily accessible in order to perform
wiring and endswitches' adjustment.
3.3 If not otherwise specified, AB1 rotary gear motor is always supplied by the
factory with standard endswitches adjustment suitable for 90° rotation
angle.
3.4 From a frontal view the motor shaft
- rotates clockwise 3[closes] supplying terminals 1 -2
- rotates counter clockwise 4[opens] supplying terminals 1 -3
3.5 AB1 gear motor must be free to be stopped by its electric endswitches; the
installation of mechanical locks or the presence of other obstacles could
damage it.
3.6 AB1 gear motor can be installed in any environment included in the range of
electrical protection IP 54 except where acid fumes or other deteriorating
vapours might attack its metal parts or where gas leaks or explosive vapours
are present in the atmosphere. In environments with high salt percentage,
fastening screws should be zinc or cadmium plated and should not be made
of brass or stainless steel.

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4. WIRING
4.1 After having installed AB1 gear motor and before fastening it mechanically to
the device it has to operate, proceed with wiring and earthing.
4.2 Wiring diagrams are reported in the attached technical bulletin and on the
plate inside the cover.
4.3 WARNING!
Before servicing make sure, that power supply is disconnected by means of
the two-pole-switch [phase and neutral]; in case of non-observance,
damages to people and equipments may occur.
4.4 In order to accede to the internal wiring terminal board, remove the cover
by loosening the 4 fastening screws.
4.5 Two threaded holes for the fitting of the conduit plugs PG 13.5 are present
on the frame of the AB1 gear motor.
4.6 All wires must comply with local prescriptions and, in any case, their section
must be ranging between 1 and 1.5 mm2. Connection piping recommended
H07V-U…G1.5 mm2.
4.7 Connection wiring diagrams show AB1 gear motor at end position closed
[0°].
4.8 Auxiliary microswitches are single-pole double through and voltage-free.
4.9 The rating of auxiliary microswitches is 5[1]A/250V a.c.
4.10 If a potentiometer is installed, its resistance value is indicated on the
nameplate.
4.11 Make sure that power supply and system frequency correspond to the values
indicated on the gear motor plate.
4.12 Low-tension signalling cable [tension lower than 48V] must be laid
separately from the higher-tension conduits [tension higher than 48V]. In
case they are laid in a single channel, screened cables must be used.

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5. CABLE CONNECTIONS
The wiring schemes refer to the gear motor in position “closed” [0°].
5.1 Without manual/automatic control station.
TERMINAL BOARD
Terminal earthing
Terminal 1 N = neutral
Terminal 2 by tension the gear motor shaft rotates clockwise 3[closes]
Terminal 3 by tension the gear motor shaft rotates counter clockwise 4
[opens]
Terminal 16 answer signal when the gear motor reaches the position “open”
Terminal 17 answer signal when the gear motor reaches the position “closed”

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5.2 With manual/automatic control station
TERMINAL BOARD
Terminal earthing
Terminal 1 N = neutral
Terminal 2 by tension the gear motor shaft rotates clockwise 3[closes]
Terminal 3 by tension the gear motor shaft rotates counter clockwise 4
[opens]
Terminal 4 for manual electric control
Terminal 16 answer signal when the gear motor reaches the position “open”
Terminal 17 answer signal when the gear motor reaches the position “closed”
5.3 Auxiliary microswitches
TERMINAL BOARD
Terminal 20 common contact of the auxiliary microswitch S3
Terminal 21 normally open contact of the auxiliary microswitch S3
Terminal 22 normally closed contact of the auxiliary microswitch S3
Terminal 23 common contact of the auxiliary microswitch S4
Terminal 24 normally open contact of the auxiliary microswitch S4
Terminal 25 normally closed contact of the auxiliary microswitch S4
5.4 Potentiometer/s for answer signal of Pot. A and/or B position
TERMINAL BOARD
Terminal 30 max. value
Terminal 31 slider
Terminal 32 min. value
Terminal 33 max. value
Terminal 34 slider
Terminal 35 min. value

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6. AUXILIARY MICROSWITCHES
On request, AB1 gear motor can be supplied with 2 auxiliary microswitches, which
can be adjusted in any position.
Microswitches are voltage-free.
Contact rating is about 5 A/250 with Ohm load and about 1 A/250 with inductive
load.
For adjusting the cams of auxiliary microswitches, proceed as for cams of
endswitches as indicated in paragraph 9.1 chapter 9 “SETTINGS”.
7. FEEDBACK POTENTIOMETER/S
On request, the AB1 gear motor can be supplied with 1 or 2 independent
potentiometers [pot. A and/or pot. B] for answer signal of the position of the gear
motor.
Resistance value of the potentiometer is indicated on the identification plate.
If resistance value does not correspond to the one wished, proceed as indicated in
paragraph 9.2 of chapter 9 “ADJUSTMENTS”.
Power consumption is 2 W.
8. CONTROL STATION
8.1 The control station allows the manual electric control of the gear motor.
8.2 Phase L1 must be connected to Terminal no. 4.
8.3 The switch AUTO/MAN is supplied on position AUTO .
8.4 Position the switch AUTO/MAN on manual position indicated by a stylized
hand .
8.5 Switch-ON / Switch-OFF as follows:
8.5.1 By pushing the switch towards the symbol Tthe gear motor rotates
counter-clockwise 4[cam S2 regulates the wished end position “OPEN”].
8.5.2 By pushing the switch towards the symbol Sthe gear motor rotates
clockwise 3[cam S1 regulates the wished end position “CLOSED”].
8.5.3 By positioning the switch in the middle, the motor does not run.
8.5.4 IMPORTANT: once the operations for the manual electric control of the gear
motor are over, reset the switch AUTO/MAN /C] on position AUTO .

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9. ADJUSTMENTS
9.1 Endswitches
As already reported in chapter 4 paragraph 4.3 the AB1 electric rotary gear
motor is supplied by the factory with adjustment foreseen for a 90° rotation
angle. If higher or lower than 90° rotation angles are requested, proceed as
follows:
9.1.1 Disconnect the operating lever system of the gear motor shaft and remove the cover.
9.1.2 For “CLOSED” position adjustment it is necessary to operate on cam “S1”.
For “OPEN” position adjustment, it is necessary to operate on cam “S2”.
9.1.3 For cam adjustment, use the proper “half-moon” key, supplied with the AB1
gear motor equipment and installed inside.
9.1.4 Use the key from the right side, introducing the pin into one of the holes on
the sides of the blue cam of the cam involved and lever it to desired position.
9.1.5 If the blue cam is in a behind position, use at first the lever on its curved
side to move the blue cam to a more suitable position to perform adjustment.
Picture 1
9.1.6 Cam adjustment is possible in both directions and along the whole rotation
angle of the cam shaft.
9.1.7 Remove the key before servicing.
9.1.8 Run the AB1 gear motor for a few cycles making sure that the right cam
adjustment has been achieved.

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9.1.9 Once all adjustments have been carried out return the key inside the AB1
gear motor and reinstall the cover by fastening the 4 screws.
9.1.10 Reinstall the control lever system of the AB1 gear motor and test
functioning of the whole system.
9.2 Potentiometer/s
9.2.1 The potentiometer shaft is frictioned and is accessible from the upper side
inside the gear motor.
9.2.2 Disconnect the cables connected with the regulation system from the
respective terminals n. 30, 31 and 32 [Pot. A] and, if necessary, n. 33, 34
and 35 [Pot. B].
9.2.3 By means of a suitable screwdriver with 5 mm cut rotate the potentiometer
shaft and measure the resistance value of 0 Ohm between terminals n. 31
and 32 and, if necessary, also between terminals n. 34 and 35 when the
gear motor is closed [picture 2].
Picture 2
By rotating the potentiometer:
●clockwise 3the resistance value increases
●counter dock wise 4the resistance value decreases
9.2.5 The gearbox between the gear motor shaft and the potentiometer shaft is
foreseen for a 90° rotation angle. Hence should the gear motor opening be
reduced with a rotation angle lower than 90°, the variation of the
potentiometer resistance value will be proportionally reduced.
If, on the contrary, the rotation angle has been wrongly adjusted over 90°
there will be no increase in the resistance value beyond the plate maximum
value.

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10. OPERATING
After installation and adjustment of the control lever system check that switch and
wiring of the circuit are correct.
Check that the AB1 rotary gear motor duly controls the device it is meant for.
Check that the AB1 rotary gear motor runs in accordance with the given manual input.
Check that the AB1 gear motor, the lever system and the controlled device are
mechanically connected in a correct and safe way.
Check that the levers' movements occur smoothly without jamming or blocking due
to other objects.
11. MAINTENANCE
The AB1 rotary gear motor does not require any particular current maintenance.
The AB1 gear motor does not require any lubrication because the gear mechanism
is immersed in a grease bath.
Do not disassemble any internal part of the AB1 gear motor. In case of non-
functioning, after having performed all possible checks on field, it must be returned
to the factory for any possible repair.
It is not advisable to perform any repair on field.
Any replacement must be carried out by qualified technicians only.
12. REPLACEMENT
In case replacement of the AB1 gear motor is necessary, proceed as follows:
- disconnect power supply from the gear motor.
- remove the gear motor's cover.
- disconnect electric wiring taking note of the cables' numeration.
- remove all levers between the AB1 gear motor and the controlled device.
- install the new AB1 gear motor proceeding as per the instructions given in the
foregoing chapters