GF EA21 User manual

37
Index of content
English
1. Introduction ..................................................................36
General Information ...................................................................... 36
2. EC Manufacturer’s Declaration .................................. 36
3. Intended use ................................................................. 37
4. Safety Information ....................................................... 37
4.1 Due care required by the operator ......................................... 37
4.2 Special hazards ........................................................................ 37
4.3 Transport and Storage ............................................................ 38
5. Actuator Design ............................................................38
5.1 Wiring Diagram for Standard Version .................................... 39
5.2 Error message ......................................................................... 39
5.3 DIP switch in case of error ...................................................... 40
6. Setting Up the Actuator ...............................................40
6.1 Emergency Manual Override ...................................................41
6.2 Dimensional drawings of the
Electrical Actuator Type EA 21/31 ............................................. 42
6.3 Technical Specications .......................................................... 43
7. Mounting and Connecting Supplementary Kits ...........44
7.1 Heating Element ....................................................................... 44
7.2 Fail-safe return ........................................................................ 45
7.3 Additional Limit Switches ........................................................ 47
7.3.1 Additional 4 Limit Switches ........................................... 48
7.4 Middle Positioning .................................................................... 49
7.5 Monitoring print ........................................................................ 52
7.6 Position Signalization .............................................................. 58
7.7 Positioner .................................................................................. 60
8. TROUBLESHOOTING .................................................... 66
Ordering Information ....................................................... 67
Notizen/Notice/Note ............................................................................ 68

38
1. Introduction
This instruction manual contains all the pertinent information on the de-
sign, installation and operation of the electrical actuator type EA 21/31/42.
General Information
Hazard notices
Hazard notices are used in this manual to warn you of possible injuries or
damages to property. Please read and follow these hazard notices at all
times!
Meaning
Imminent acute danger!
Failure to comply could result in death or extremely serious injury.
Possible acute danger!
Failure to comply could result in serious injury.
Dangerous situation!
Failure to comply could lead to injury or damage to property.
2. EC Manufacturer’s Declaration
The manufacturer, Georg Fischer Piping Systems Ltd., CH 8201 Schaffhau-
sen, declares that the electrical actuator EA 21 / 31 / 42 is not a ready-to-
use machine in the sense of the EC Machine Directive and therefore cannot
meet all the requirements of this directive.
Operation of these actuators is prohibited until conformity of the entire
system into which the valve and the actuator have been installed is estab-
lished according to the EC Directives listed below.
Applied EC Directives:
72/23 EEC EC Low Voltage Directive
89/336 EEC EC Directive on Electromagnetic
Compatibility
Warning
symbols
Danger
Hazard
Caution
Beantragt/pending

39
Modications to the actuator which have an effect on the technical data
given in this instruction manual and its intended use, i.e. signicantly alter
the actuator, render this manufacturer’s declaration null and void.
3. Intended use
When mounted on a valve and connected to a system control, the purpose of
this actuator is to
• actuate valves with up to 180° pivoting (ball valves and buttery valves),
• indicate the previously calibrated end positions of the valve via electrical
signal to the system control (accessory), and
• provided that the actuator data correspond to the electrical control and
the valve and
• in case of interruption in the supply voltage, warrant that the actuator/
valve remains in the current position. Please use emergency manual
override or install fail-safe return.
The actuator is not intended for uses other than those listed above. If the
instructions contained in this manual are not observed, the manufacturer is
excluded from all liability for the above mentioned products.
4. Safety Information
4.1 Due care required by the operator
The actuator described herein was designed and manufactured with consi-
deration to the respective harmonized European standards. It corresponds
to the latest technology and the technical specications contained under
section 6.3.
Safety on the job can, however, only be realized if the operator warrants that
• the actuator is only used as indicated under section 3,
• he is familiar with this instruction manual and the manual of the corres-
ponding valve and adheres to the instructions contained therein and
• he has taken the necessary measures against electrostatic inuence.
4.2 Special hazards
Under normal conditions, the actuator may only be operated with the
cover closed.
If work is performed on the actuator with the cover removed, the supply
and control voltage must rst be disconnected. Adjustments, which need
to be done in the energized state, should be carried out with special insu-
lated tools.

40
In addition, the operating instructions of the manual valve
must be observed. They are an integral component of this
manual.
4.3 Transport and Storage
The actuators must be handled, transported
and stored with care. Please note the following
points:
• The actuators should be transported and/or stored in
their original unopened packaging.
• The actuators must be protected from harmful physical
inuences such as dust, heat (humidity).
• It is important that the connections are neither dama-
ged by mechanical nor by thermal inuences.
• Prior to installation, the actuators should be inspected
for transport damages. Damaged actuators must not be
installed.
5. Actuator Design
The standard version of the EA 21/31/42 electrical actuator
consists of the following elements: gear unit, direct current
motor, electrical board and components for end position
limiting.
For special applications, the actuator can be equipped addi-
tionally with various supplementary kits (see section 7).
1
2
3
5
6
8
7
1. Limit switches S1 and S2
2. Direct current motor
3. Optical position indicator
4. Plug X1 for accessories
5. Terminal strip for external
connections max. 1.5 mm2
6. Wide range power supply,
without protection against
accidental contact
7. Shaft for emergency manual
override
8. Connections for DIN plug or
cable gland
9. Assembly bolts for accesso-
ries
4
9

41
5.1 Wiring Diagram for Standard Version
Position indicator
Installation note
If the actuator is directly connected to the power supply, it
is necessary to install a disconnector between the actuator
and the power supply (do not disconnect the earth cable).
Cross-section of the external cables max. 1,5 mm2.
To avoid water owing into the actuator, make sure the cable
entry point is not upturned.
The EA 21/31/42 has a temperature control (ready-to-
operate monitoring).
Due to the loading of the power supply capacitor
when rst time switching on the actuator current
peaks can occur for a few micro seconds. The-
refore we recommend to connect the actuator in
accordance with accompanying wiring diagram.
5.2 Error message
If an error occurs, the red LED (8) on the base board will
light up.
If the monitoring print is installed, the LED (7) on the BCD
switch (10) which selected value has been exceeded will also
light up red.
With all occurring error messages the ready-to-operate
signal will be off (terminals 5,6 no passage).
Eliminating the error message
Check the error cause, if necessary carry out the appropri-
ate maintenance.
To eliminate the message, activate the reset switch (9) on
the base board while the supply voltage is still connected
or briey disconnect the actuator from the mains voltage.
(Not effective with cycle counter)
3/2-way
horizontal
A
C
B
B−C
A−C
vertical
A
C
B
B−C
A−C
2/2-way/BV
A
C
B
C
A−B
closed
open
10
8
9
Releaiscontact
max. 24V

42
The two LEDs will go out and the actuator is ready to ope-
rate again.
5.3 DIP switch in case of error
In case of an error the actuator can be set to the CLOSED or
the OPEN position with the help of the DIP switch. The DIP
switches need to be set as follows:
DIP 1 DIP 2
ON Position of DIP 2 effec-
tive
Actuator turns to the
OPEN position
OFF Actuator remains in the
current position (DIP 2
not effective)
Actuator turns to the
CLOSED position
(refer to explanation on the left)
6. Setting Up the Actuator
Attention
Check the following before connecting the actuator to the
mains:
• Does the main voltage correspond to the spe-
cications given on the type plate
• Has the actuator been connected correctly
(see Section 5.1)
Adjustments
If a complete valve is supplied by Georg Fischer, no further
adjustments are required. After installation by the customer
or after repair, the end positions should be checked and
adjusted if necessary.
Limit switch allocation
Switch S1 (bottom) opens at “open” position
Switch S2 (top) opens at “closed” position
Procedure
• Set both switching cams (1) to S1 and S2 so that the
rotating angle is less than 90°.
• Let the actuator turn until a limit switch is activated.
• By adjusting the respective switching cam, the end
position can be set since the actuator follows the cam.
1
In case of malfunc-
tion the actuator
remains on the
current position
(delivery state)
In case of malfunc-
tion the actuator
turns to the OPEN
position
In case of
malfunction the
actuator turns
to the CLOSED
position
ON
OFF
1 2
ON
OFF
1 2
ON
OFF
1 2
S2: «Closed», top
S1: «Open», bottom

43
6.1 Emergency Manual Override
Assembly
1. Pull the crank (1) out of the bracket
2. Remove cover screw (2) with the provided crank (1)
3. Insert the crank in the hexagon shaft in the opening
Function
Push the crank down to the stop. This activates a micro
switch that disconnects the actuator from the current. When
letting go the crank, the actuator is energized again.
With 9 revolutions, the actuator EA21 turns by 90°
With 27 revolutions the actuator EA31 turns by 90°
With 41 revolutions the actuator EA42 turns by 90°
Direction of rotation
Clockwise = CW = close
Counterclockwise = CCW = open
Note the “open” and “closed” position on
the optical indicator
Disconnect the connector plug.
If that is not possible, after usage pull the
crank rapidly out of the opening. (Actuator
might start turning)
1
2

44
6.2 Dimensional drawings of the Electrical Actuator Type EA 21/31/42
L1 L2 L3 L4 L5 L6 L7 L8 L9 H1 H2 H3
EA21 150 82.5 108 64.3 122 16 49 33 33 167 20 188.5
EA31 150 82.5 108 64.3 122 16 49 33 33 190 25 211.5
EA42 150 82.5 108 64.3 122 16 49 33 33 208 25 229.5
EA21/F05 EA31/F07
EA42/F07

45
EA21 EA31 EA42
Rated voltage 100 – 230V, 50/60 Hz
24V = /24V, 50/60 Hz
Rated voltage tolerance +/- 10%
Rated output @ 24V AC/DC
@ 100 – 230V AC
22 VA
40 VA
32 VA
40 VA
40 VA
60 VA
Electric impedance 230V, 100kΩ
24V, 4.7kΩ
Altitude over NN (UL/CSA) < 2000m
Protection class IP 65 per EN 60529 *(3) UL/CSA: indoors use
Duty cycle 100% 50% 35%
Overload protection current/time-dependent (resetting) *(1)
temperature dependent
Electrical connections Connector plug 3 P+E per DIN EN 175301-03 (formerly
DIN 43650) Cable gland M20 x 1,5 according to ISO 724
Nominal torque Mdn 10 Nm 60 Nm 100 Nm
Actuating angle max. 180°, set to 90°
Control time 5 s / 90° at Mdn 15 s / 90° at Mdn 25 s / 90° at Mdn
Peak torque 20Nm 120 Nm 250 Nm
Ambient temperature -10° to + 50°C (2) -10° to + 50°C (2)
Allowable humidity max. 90% relative humidity, non condensing
Pollution grade (4) 2
Overvoltage category (4) II
Housing material PP breglass reinforced, ame retardant,external stainless
steel screws, non-losable
Position indication optical, integrated
Emergency manual override integrated
Flange pattern (5) F05 F07 F07
(1) Overload protection of the motor is dimensio-
ned so that the motor and the power supply board
are protected. As soon as the load is in the torque
range, the actuator runs again.
(2) For temperatures below -10°C as well as
condensation, the heating element no. 198 190
086 should be built in.
(3) Protection rating IP 67 for use of cable glands
and vertical installation
(4) Per EN 61010-1
(5) Per ISO 5211
6.3 Technical Specications

46
Wiring diagram
Heating element kit
7. Mounting and Connecting
Supplementary Kits
7.1 Heating Element
Description Technical data Code
Heating element 24 V= 199 190 086
The heating element is mounted on the base board and is
connected electrically via a at cable (X1). The temperature
is measured with a temperature sensor, which is mounted
on this element, and between approx. 0 - 5°C the heating
element is switched on.
Mounting the heating element (board)
1. Disconnect the actuator from the supply voltage.
2. Remove actuator cover.
3. Take the board out of its packaging and check for damages.
Do not touch the board itself. Electrostatic
discharge can damage the components.
4. Screw the three distance bolts (1) into the assembly
bolts. Screw hand-tight.
5. Fasten the board (3) on the distance bolts with the sup-
plied screws (2).
6. Plug the at cable into the X1 (4) connector.
7. Put the cover back onto the actuator.
8. Reconnect to supply voltage.
The heating element may not heat at temperatures over
+ 5 °C, but in case it is switched on it might heat up to
10-15 °C.
1
2
3
4
LED on =
heating operation

47
7.2 Fail-safe return
Description Technical data Code
Fail-safe return 24 V= 199 190 085
The fail-safe return unit is mounted on the base board and
is connected electrically via a at cable.
The fail-safe return unit is connected to the battery via
a two-core wire. If the supply voltage is interrupted, the
electronics will switch to the storage battery automatically
after 5 sec. With the DIP switches (5), the functions “move
to the CLOSED position” or “move to the OPEN position” can
be selected.
Both switches ON: Actuator moves to OPEN
Both switches OFF: Actuator moves to CLOSED
The storage battery is charged continuously. Full charging
takes approximately 15 hours.
Wiring diagram
DIP switch

48
Mounting the fail-safe return (board)
1. Disconnect the actuator from the supply voltage.
2. Take the board out of its packaging and check for damages.
Do not touch the board itself. Electrostatic discharge can
damage the components.
3. Screw the three distance bolts (1) into the assembly bolts. Screw hand-
tight.
4. Fasten the board (3) on the distance bolts with the supplied screws (2)
and washers.
5. Plug the at cable into the X1 connector.
6. Reconnect to supply voltage.
Rechargeable battery
Connect the battery via the second plug or cable gland to the terminals 16
and 17 (4). (we recommend 2x1.5mm2)
Attention must be given to the polarity. Charge the battery
for at least 15 hours.
In case the fail-safe return and the monitoring print are
installed both together, make sure that the adjustments will
not interfere one another.
1
2
3
LED on
= normal operation / blinks with battery operation
4
5
6
LED on = battery operation
Battery

49
7.3 Additional Limit Switches
Description Technical
data
Code
Kit with 2 additional*
limit switches Ag-Ni
250 V ~, 6 A 199 190 092
Kit with 2 additional*
limit switches Au
30 V =, 100 mA 199 190 093
Kit with 2 additional
limit switches NPN
10-30 V=,
100 mA
199 190 096
Kit with 2 additional
limit switches PNP
10-30 V=,
100 mA
199 190 095
Mounting set for 4 limit
switches
199 190 097
* The switches are wired as openers according to the dia-
gram. It is possible for the customer to convert to closer by
rewiring.
(Terminal 8 > 7 and terminal 10 > 9).
Mounting the limit switches
1. Disconnect the actuator from the supply voltage.
2. Remove the screws from the limit switches S1 and S2.
3. Mount the limit switch kit (1) on S1 and S2 as shown.
4. Tighten with the new, longer screws.
5. Mount the additional switching cams (2) as well as the
spacer rings (3).
Wiring diagram
1
2
3
B)
B)

50
Setting the limit switch position
1. Reconnect the actuator to the supply voltage.
The switch position may only be set with an
extra-low voltage under 50 V.
2. Move the actuator to the two end positions and set the
respective switching points.
The switching cams can be adjusted with a screwdriver
size 2.
3. Disconnect the actuator from the supply voltage.
4. Connect limit switches.
5. Close the actuator with the housing cover and connect to
the supply voltage.
7.3.1 Additional 4 Limit Switches
Analog to the mounting instructions for the 2 additional limit
switches the EA 21/31/42 can be expanded to include 4 limit
switches.
The mounting sequence for the individual parts is equal to
the 2 additional limit switches.
For stability purposes additionally the
mounting set for 4 limit switches must also
be used. The fully assembled unit can be
seen in the picture below.

51
7.4 Middle Positioning
Description Technical data Code
Middle positioning 199 190 094
The kit is mounted on the limit switches S1, S2 and serves to
move the actuator to a third position ( e.g. 3-way ball valve
into the middle position).
Wiring diagram

52
Mounting the middle positioning kit
1. Disconnect the actuator from the supply voltage.
2. Remove the screws of the limit switches S1 and S2
3. Connect the plug of the kit to the four-pole slot (1).
Make sure that the multipoint socket connector of the plug
ts into the socket board of the four-pole plug.
4. Attach the two switches S3 and S4 of the kit to S1 and S2. When doing
this, switch S3 (assigned to PIN1, 2) must be down and switch S4 (PIN 3,
4) on top. (see wiring diagram).
5. Fasten the two switches S3 and S4 with the longer screws supplied.
Overview on activation
Actuator moves
in position
Terminal
under current
Activated
switch
Direction of rota-
tion of the actuator
OPEN 1 S1 CCW*
CLOSED 2 S2 CW**
MIDDLE 3 S3 CCW
S4 CW
* CCW – Counter Clock Wise – Gegen Uhrzeigersinn
** CW – Clock Wise – Im Uhrzeigersin
> Move actuator to position “OPEN” (CCW): Put terminal 1 under current
> Switch S1 is activated.
> Move actuator to position “CLOSED” (CW): Put terminal 2 under current
> Switch S2 is activated.
> Move actuator to middle position (CCW / CW): Put terminal 3 under
current > Switch S3/S4 is activated.
S4
S3
(1)

53
Setting the end positions
Setting the opening angle from 90° to 180°
• Turn switching cam 2 of switch S2 counter clockwise (top view) by 90°.
• Reconnect the actuator to the supply voltage
• Move the actuator into position “CLOSED” (terminal 2 under current)
• Turn cam 2 until reaching the desired position. (see position of the ball)
• Replace the standard position indicator by the new 3-way position indi-
cator
Standard position indicator 3-way position indicator
Setting the middle position
• Move the actuator to the OPEN position (terminal 1 under current)
• Place the additional switching cam on the shaft. For this, rst remove
the position indicator again and put it back on again in the same position
afterwards
• Place cam 3 upon cam 2 (cam 4 still stays on top of the switches)
• Put cam 3 into the same position as cam 2 and turn it clockwise by 90°
• Move actuator to the “middle” position (terminal 3 under current)
• Readjust cam 3 until reaching the desired middle position (see position
of the valve)
• Now Place cam 4 upon cam 3 in the same position as cam 3. Adjust cam
4 afterwards. Its corner ank should activate switch S4 (S3 and S4 are
activated, the two nocks of the cams indicate to the opposite direction).
• Close the actuator with the housing cover. The middle position is now
set.
OPEN MIDDLE CLOSED

54
7.5 Monitoring print
Description Technical data Code
Monitoring print 199 190 099
The monitoring print is mounted on the base board and is
connected electrically with a at cable. The monitoring print
enables ve functions:
1. Cycle time extension
2. Cycle time monitoring
3. Monitoring a selected maximum number of cycles
4. Monitoring a selected maximum of motor current
5. Position feedback signal 4-20mA (see page 26)
These monitor settings are made via the BCD switches 1 to
4. They are described in the following pages. The switches
must be plugged in order for the function to be active. The
functions work independently of one another. BCD switches
(1 to 4) can be connected individually.
Wiring diagram
BCD switch DIP switch
1. Cycle time extention (Vario)
2. Cycle time monitoring
3. Cycle counter
4. Current monitoring
5. Position feedback
1 5 2 3 4

55
Mounting the monitoring print
1. Disconnect the actuator from the supply voltage.
2. Take the board out of the packaging and check for dama-
ges.
Do not touch the board itself. Electrostatic
discharge can damage the components.
3. Screw the three distance bolts (1) into the assembly bolts.
Hand-tighten.
4. Fasten the board (3) to the distance bolts (1) with the
screws (2).
5. Insert the BCD switch (4) for the desired function. Secure
it with the help of the nipple supplied.
6. Select the desired switch setting with a screwdriver.
7. Plug the at cable into the X1 (7) connector.
8. Reconnect to supply voltage.
The board has been connected correctly, when:
1. The LED (9) above the BCD switches blinks green.
2. The LED (6) lights up green.
Monitoring print kit
1. Cycle time extention (Vario)
2. Cycle time monitoring
3. Cycle counter
4. Current monitoring
5. Position feedback
9 6
1
2
3
4
3
2
1
4
7
4
3
2
1
8 5

56
Error message
If an error occurs, the red LED (8) on the base board lights
up.
In case the monitoring print is installed, the LED (10) on the
BCD switch which selected value has been exceeded will
also light up red.
With all occurring error messages the ready-to-operate
signal will be off.
Eliminating the error message
Check the error cause, if necessary carry out the appropri-
ate maintenance.
To eliminate the message, activate the reset switch (9) on
the base board while the supply voltage is still connected
or briey disconnect the actuator from the mains voltage.
The two LEDs will go out and the actuator is ready to opera-
te again.
The ready-to-operate module can react the
fail-safe mode as well. Resetting the error
message does not reset the cycle counter!
DIP switch in case of error
With the help of the DIP switch, the actuator can be moved
to the CLOSED or OPEN position in case of an error. For this,
the DIP switches need to be adjusted as follows:
DIP 1 DIP 2
ON Position of DIP 2
effective
Actuator moves to the
OPEN position
OFF Actuator remains in its
position
(DIP 2 not effective)
Actuator moves to the
CLOSED position
(please refer to example on the left)
ON
OFF
1 2
ON
OFF
1 2
ON
OFF
1 2
In case of malfunc-
tion the actuator
remains in its
position (delivery
state)
In case of malfunc-
tion the actuator
moves to the OPEN
position
In case of malfunc-
tion the actuator
moves to the
CLOSED position
10
8
9