KSB EA-C Series Installation instructions

Control Valve Actuators
EA-C / EA-B
For the Type Series BOA-CVE C/CS/W/IMS/EKB/IMSEKB
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual EA-C / EA-B
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 09/09/2020

Contents
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Contents
1 General.................................................................................................................................................... 5
1.1 Principles ...........................................................................................................................................................5
1.2 Target group.....................................................................................................................................................5
1.3 Symbols .............................................................................................................................................................5
2 Safety...................................................................................................................................................... 6
2.1 Key to safety symbols/markings.......................................................................................................................6
2.2 General..............................................................................................................................................................6
2.3 Intended use .....................................................................................................................................................7
2.3.1 Prevention of foreseeable misuse.......................................................................................................7
2.4 Personnel qualification and training...............................................................................................................7
2.5 Consequences and risks caused by non-compliance with this operating manual........................................7
2.6 Safety awareness ..............................................................................................................................................7
2.7 Safety information for the user/operator.......................................................................................................8
2.8 Safety information for maintenance, inspection and installation ................................................................8
2.9 Unauthorised modes of operation..................................................................................................................8
3 Transport/Storage/Disposal .................................................................................................................. 9
3.1 Checking the condition upon delivery............................................................................................................9
3.2 Transport...........................................................................................................................................................9
3.3 Storage/preservation........................................................................................................................................9
3.4 Disposal/recycling .............................................................................................................................................9
4 Description............................................................................................................................................ 10
4.1 General description ........................................................................................................................................10
4.2 Designation.....................................................................................................................................................10
4.3 Name plate......................................................................................................................................................10
4.4 Design details..................................................................................................................................................11
4.5 Function ..........................................................................................................................................................12
4.6 Noise characteristics .......................................................................................................................................13
5 Installation............................................................................................................................................ 14
5.1 General information/Safety regulations .......................................................................................................14
5.2 Checking prior to installation........................................................................................................................15
5.3 Installation position........................................................................................................................................15
5.4 Manual override .............................................................................................................................................16
5.5 Mounting actuator type EA-B12...................................................................................................................17
5.5.1 Mounting type EA-B12 .....................................................................................................................17
5.5.2 Electrical connection..........................................................................................................................18
5.6 Mounting actuator type EA-C20 to 140.......................................................................................................20
5.6.1 Fitting the actuator............................................................................................................................20
5.6.2 Electrical connection..........................................................................................................................21
5.6.3 Mains connection...............................................................................................................................23
5.6.4 Interfaces ............................................................................................................................................23
5.6.5 Heating resistor (optional) ................................................................................................................24
5.6.6 Limit switching ...................................................................................................................................25
5.6.6.1 Continuous-action actuators.........................................................................................................25
5.6.6.2 230V, 3-point actuators................................................................................................................25
5.6.7 Operation ...........................................................................................................................................26
6 Commissioning/Start-up/Shutdown................................................................................................... 27
6.1 Prerequisites for commissioning/start-up......................................................................................................27
6.2 Commissioning/Start-up.................................................................................................................................27
6.2.1 Automatic commissioning of EA-B actuators...................................................................................27
6.2.2 Automatic commissioning of EA-C actuators (continuous-action and 24VAC/DC 3-point
actuators)............................................................................................................................................27
6.2.3 Mechanical commissioning of 3-point actuators .............................................................................28
6.3 Operating limits..............................................................................................................................................28

Contents
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6.3.1 Ambient temperature........................................................................................................................28
6.4 Shutdown........................................................................................................................................................29
6.4.1 Measures to be taken for shutdown ................................................................................................29
6.5 Returning to service .......................................................................................................................................29
7 Servicing/Maintenance........................................................................................................................ 30
7.1 Safety regulations...........................................................................................................................................30
7.2 Removing the actuator ..................................................................................................................................30
7.2.1 Removing type EA-B12 ......................................................................................................................30
7.2.2 Removing type EA-C 20 to 140..........................................................................................................31
7.3 Maintenance/inspection.................................................................................................................................32
7.4 Lubrication......................................................................................................................................................32
7.5 Cleaning ..........................................................................................................................................................32
7.6 Mounting the actuator ..................................................................................................................................32
7.7 Spare parts stock.............................................................................................................................................32
8 Trouble-shooting.................................................................................................................................. 33
8.1 Display of EA-B actuators...............................................................................................................................33
8.2 Display of EA-C actuators...............................................................................................................................33
9 Related Documents.............................................................................................................................. 36
9.1 General assembly drawing, manual override EA-B 12 .................................................................................36
9.2 General assembly drawing, handwheel on top (EA-C 20 to 140)................................................................37
9.3 Wiring diagrams .............................................................................................................................................38
9.3.1 Terminal configuration EA-B10/24...................................................................................................38
9.3.2 Terminal configuration EA-C 20 to 140 ............................................................................................38
9.3.3 Terminal configuration EA-C 20 to 140, 230V AC...........................................................................39
9.4 Technical data.................................................................................................................................................41
9.4.1 Operating data: EA-B 12 actuator ....................................................................................................41
9.4.2 Operating data: EA-C 20 to 140 actuators, 24 V AC/DC ..................................................................41
9.4.3 Operating data: EA-C 20 to 140 actuators, 230 V AC ......................................................................42
10 EU Declaration of Conformity............................................................................................................. 44
11 Declaration of Incorporation of Partly Completed Machinery ......................................................... 45
Index ..................................................................................................................................................... 46

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the valve and actuator and serve as identification for all further
business processes.
In the event of damage, immediately contact your nearest KSB service facility to
maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Symbols
Table1: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 Key to safety symbols/markings
Table2: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and kept in a perfectly legible condition at all times. This applies
to, for example:
– Markings for connections
– Name plate

2 Safety
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▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
▪The motor has been designed and constructed in accordance with the
requirements of Directive 2014/35/EU (“Low-voltage Directive”). The motor is
intended for use in industrial plants.
▪If the motor is used in countries outside the European Community, adhere to the
regulations applicable to the relevant country. Also observe any local and
industry-specific regulations governing installation and safety.
2.3 Intended use
▪Only operate actuators which are in perfect technical condition.
▪Do not operate partially assembled actuators.
▪Generally observe the operating limits given.
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
2.3.1 Prevention of foreseeable misuse
▪Never exceed the permissible operating limits (temperature, etc.) specified in the
data sheet or product literature.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
▪ All personnel involved must be fully qualified to install, operate, maintain and
inspect the product this manual refers to.
▪The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
▪Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
▪ Training on the product must always be supervised by specialist technical
personnel.
2.5 Consequences and risks caused by non-compliance with this operating
manual
▪Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
2.6 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws

2 Safety
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2.7 Safety information for the user/operator
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the actuator are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Any work on the product shall only be performed when it has been disconnected
from the power supply (de-energised).
▪Carry out work on the product during standstill only.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.2,Page27)
2.9 Unauthorised modes of operation
Never operate the product outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.

3 Transport/Storage/Disposal
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3 Transport/Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
CAUTION
Impacts against the coupling when placing it in a horizontal or vertical position
Damage to the coupling!
▷Place a suitable support underneath the coupling half when placing it in a
horizontal or vertical position.
Transport the actuator carefully and in its original packaging. Avoid damaging the
coating.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken :
Table3: Ambient conditions for storage
Ambient condition Value
Storage temperature EA-B -40°C to +80°C
Storage temperature EA-C -20°C to +80°C
Humidity 5 % to 95 % rH
▪Well-ventilated
▪Dry
▪Dust-free
▪Shock-free
▪Vibration-free
3.4 Disposal/recycling
Due to some components, the product is classified as special waste.
1. Dismantle the product.
2. Separate and sort the materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner. PCBs, power electronics, capacitors and electronic
components are all hazardous waste.

4 Description
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4 Description
4.1 General description
▪Electric actuator for the automation of a control valve
The electric actuators are installed in industrial plants and power plants for actuating
control valves and shut-off valves. They provide high actuating forces at short
actuating times.
Versions
Continuous-action actuator versions 24VAC/DC, 230VAC including actuator
version 24VAC 3-point
Variable speed actuator
control
▪24VDC motor, controlled by pulse-width modulation (PWM)
▪Absolute-coded feedback via precision potentiometer
▪Positioning function
▪Active feedback function
▪Automatic commissioning
▪Comprehensive diagnosis options
Parameterisation by
software
▪Actuator functions can be adapted to a wide variety of process conditions by
means of current and voltage monitoring.
▪Setting of valve-specific details
▪Setting of actuating force and actuating moment
▪Setting of stroke and actuating speed
▪Configuration of messages
▪Freely programmable characteristic curve corrections
3-point actuators 230VAC
▪The actuator can be set by limit switches in opening direction and closing
direction.
▪Torque transmission via soft-seated valve disc/plug in closing direction.
▪2 limit switches for visualising the limit positions included as standard
4.2 Designation
Example: EA-C 80
Table4: Designation key
Code Description
EA-C Product name
80 Actuator size and maximum actuating force of 8kN
4.3 Name plate
The main control valve data is given on the name plate fitted on the actuator
housing.

4 Description
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BOA-CVE CS
Auftrag / Pos.:
order No. / pos.: 2120000000 / 0000
DN
PN
40
6/10/16
Kvs
Cv
Kennlinie:
characteristic: lin. Stellkraft: act. force: 1200 N
Laufzeit:
run time: 150 s Signal: signal: 2 -- 10 V
Hub:
stroke: 23 mm
Antrieb:
actuator: EA--B12/2451
IP54
Stromversorgung:
power supply: 24V
1 2 3 45 6
7 8 9 10 11 12 13 14
Fig.1: Name plate example for BOA-CVE CS
1 Order number 2 Order item number
3 Product name 4 Actuating force [N]
5 Actuator stroke 6 Enclosure
7 Kvs value 8 Nominal pressure class
9 Nominal size (DN) 10 Power supply
11 Characteristic curve 12 Runtime
13 Actuating signal 14 Actuator size
4.4 Design details
Operating modes
▪IEC 34-1, 8: S2 for short-time duty
▪IEC 34-1, 8: S4 for control duty
Actuating force
1.2kN to 140kN
Actuating speed1)
▪Continuous-action actuation: 0.2mm/s to 1.3mm/s
▪3-point actuation: 0.45mm/s to 1.4mm/s
Enclosure
▪EA-B 12: IP54 to EN 60529
▪EA-C 20: IP65 to EN 60529
▪EA-C 40: IP65 to EN 60529
▪EA-C 80: IP65 to EN 60529
▪EA-C 140: IP67 to EN 60529
1Depending on the actuator type

4 Description
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Design
1
2
Type EA-B Type EA-C
▪Configurable, microprocessor-controlled actuators
– Supply voltage: 24VAC/DC, 230VAC
– Position setpoint: 4 - 20mA, 0/2 - 10V
– Actual-position feedback: 4 - 20mA, 0/2 - 10V
– Limit switching is torque-dependent in closing direction and stroke-
dependent in opening direction.
▪3-point actuators
– Supply voltage: 230VAC
– Actual-position feedback value: 2 limit switches
– Stopping via limit switches in closing direction and opening direction
▪Actuating time between 23 and 150seconds, depending on the stroke
▪Operating data stored in permanent memory
▪After a power failure, operation is resumed in accordance with the operating
data.
Variants for type EA-C
▪Actuator configured to match the order specification
▪Integrated process controller
▪Power back-up unit
▪Heating of the motor space
▪Local control unit
▪Additional limit switch for continuous-action actuator
▪Optional potentiometer for 3-point actuators
▪PSPT2) for 3-point actuators
4.5 Function
Function The actuator pillars serve to mount the actuator on the valve. The motor torque is
transmitted via a multistage spur gear to a spindle with trapezoidal thread. The
spindle translates the torque received into axial thrust via a self-locking spindle nut.
The resulting linear movement of the spindle nut is transferred to the valve stem via
a coupling.
2Optional potentiometer with printed circuit board for converting the resistance into a 4-20mA output current
signal (additional 24V DC power supply required)

4 Description
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4.6 Noise characteristics
The sound pressure level depends on the local conditions and the duty point. The
value is ≤35dB(A) for EA-B and ≤70dB(A) for EA-C.

5 Installation
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5 Installation
5.1 General information/Safety regulations
DANGER
Electrical connection work by unqualified personnel
Danger of death from electric shock!
▷Always have the electrical connections installed by a trained and qualified
electrician.
▷Observe regulations IEC60364.
DANGER
Work performed on an energised terminal box
Danger of death from electric shock!
▷Switch off the power supply at least 5minutes prior to commencing work and
ensure that it cannot be switched on again unintentionally.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷Observe the technical specifications of the local energy supply companies.
▷Inspect the power cable for visible damage.
▷Never connect damaged power cables.
NOTE
The power cables must be designed for the maximum power input of the
equipment and comply with the IEC227 and IEC245 standards.
NOTE
Yellow/green conductors must be connected to earth terminals only.
NOTE
When running the cables through the actuator cable glands make sure to observe
the minimum bending radius for the cables.
NOTE
The building circuitry and the overcurrent protection devices must comply with
standard IEC364-4-41, Safety Class I.
NOTE
The actuators are not provided with an internal means of electrical isolation. The
building circuitry must therefore be equipped with a switch or circuit breaker. This
switch must be fitted close to the equipment and must be readily accessible to
users. The switch must be clearly marked as being the isolating switch for the
equipment.

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5.2 Checking prior to installation
Before beginning with the installation check the following:
▪The actuator and valve are compatible.
▪The valve has been prepared for the actuator to be mounted.
▪The actuator cover has been removed if necessary.
– The actuator cover has to be removed on sizes 200 to 250 and 3-point
actuators. (ðSection5.6.2,Page21)
– The minimum wall clearance for removing the actuator cover has been
ensured.
A
X
X
Ø 180 Ø 180
A
50
52
EA-B 12 EA-C 20, 40, 80 EA-C 140
Fig.2: Actuator with minimum wall clearance X
Table5: Dimensions [mm]
Type A Minimum wall clearance X
EA-B 12 205 100
EA-C 20 478,2 100
EA-C 40 481 100
EA-C 80 510,3 100
EA-C 140 579 120
5.3 Installation position
CAUTION
Incorrect installation position
Valve function impaired!
▷Always observe the valve's operating manual and the permissible installation
position.

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1) 2)
Fig.3: Installation position depending on actuator type
1) Actuator type EA-B123)
2) Actuator types EA-C20 to EA-C140 and EA-C3-point3)
Install the actuator with sufficient clearance for removal. (ðSection5.2,Page15)
5.4 Manual override
A handwheel (actuator type EA-C) or hexagon socket (actuator type EA-B) is provided
for operating the actuator in the event of a power failure or for making settings
when mounting the actuator on the valve. Optionally available power back-up units,
if fitted, must be disconnected to allow manual operation via the handwheel.
Proceed as follows:
1. Open the terminal box cover (ðSection9.3.1,Page38) .
2. Disconnect the cable from the minus terminal (ðSection5.5.2,Page18) .
3. The actuator is supplied with 230VAC or 24VAC/DC.
1
2
Fig.4: Manual override for types EA-B and EA-C
3Installation of BOA-CVE IMS and BOA-CVE IMS EKB with the valve stem in a horizontal position is not allowed.

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CAUTION
Manual operation of actuator
Damage to the actuator and the valve!
▷Do not operate the actuator manually when the motor is in the electric
actuation mode. The actuator will try to compensate for the deviation in
position, depending on the actuation mode.
CAUTION
Incorrect manual operation
Damage to the actuator!
▷Do not exceed the valve travel set at the limit switches when operating the
actuator manually.
5.5 Mounting actuator type EA-B12
5.5.1 Mounting type EA-B12
1
8
4
6
5
10
11
7
9
3
2
1 Actuator spindle 2 Spacer ring
3 Actuating bush 4 Fastening nut
5 Bracket 6 Clamping hoop
7 Coupling 8 Position indicator
9 Valve stem 10 Locking device
11 Latches
Mount actuator type EA-B12 as follows:
üThe actuator has been de-energised.
üRetract the actuator spindle (1) sufficiently.
üVerify that the spacer ring (2) has been placed over the actuating bush (3).
1. Undo the fastening nut (4) at the bracket (5) and slide the clamping hoop (6)
with the bracket over the clean actuating bush (3) until the bracket is firmly
seated.
2. The actuator can be rotated on the actuating bush (3) and fastened in any
position.
3. Tighten both fastening nuts (4) evenly to a torque of 10Nm.
4. Slide the locking device (10) upwards until it will not go any further, unlocking
the coupling (7).
5. Using the manual override, run the actuator spindle (1) in closing direction until
the valve stem (9) engages in the coupling (7).

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6. Slide the locking device (10) down again until it will not go any further, locking
the connection between the coupling (7) and the valve stem (9).
7. Position the tabs of the position indicator (8) such that they abut the coupling
(7). The position indicator (8) tabs will be moved automatically to the
programmed stroke limits during the commissioning procedure.
ðThe actuator mounting procedure is now complete.
5.5.2 Electrical connection
1. Use a suitable Phillips screwdriver to remove the actuator cover.
2. Below the actuator cover you will find the terminals for connecting the cables as
well as the control elements S1, S2, S3 and the LED displayH1.
3. By means of the S3 slide switches or the S1 and S2 pushbuttons the actuator can
easily be adjusted to the requirements at the site. (S3.1 Direction of valve travel
S3.2 Closing point of the valve)
4. The terminals have to be connected as shown in the connection diagram.
(ðSection5.6.2,Page21)
Table6: Control elements for connection
Control
elements
Status Description
H1 LED Steady green Actuator is working properly
Flashing green Test or adjustment with
synchronisation in progress
Steady red Fault, adjustment must be
repeated
Flashing red Voltage interruption
(>2seconds). The next time the
valve closes synchronisation will
automatically be effected for the
closing point found and the LED
will change from flashing red to
steady green.
T1 pushbutton The control valve covers its
programmed travel; it is checked
whether both travel limits
(H=0% and H=100%) are
reached.
T2 pushbutton The programmed valve travel is
recorded as 100% travel and
stored in the microcontroller.
The actuating signal and the
runtime are matched to this
100% travel.
S3.1 switch Position OFF (factory setting) 0% actuating signal means 0%
travel.
Position ON 100% actuating signal means
0% travel.
S3.2 switch Position OFF (factory setting) Linear characteristic
Position ON Equal-percentage characteristic

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5.6 Mounting actuator type EA-C20 to 140
5.6.1 Fitting the actuator
üThe actuator has been de-energised.
üThe actuator is in the middle position.
1. Unscrew the four hexagon head bolts (7) from the actuator coupling.
2. Slide the coupling disc (5) over the end of the stem (6).
3. Screw the torque-transmitting element (3) onto the stem (6) and secure with the
grub screw (4).
4. Place the spacer (2) onto the torque-transmitting element (3).
5. Insert the actuator into the flange (8) holes in such a way that the pre-
assembled stem (6) components are guided into the actuator coupling (1).
6. Tighten the four hexagon head bolts (7) and the hexagon nuts (9) of the
actuator.
1
2
3
4
5
6
7
8
9
CAUTION
Incorrect installation of actuator pillars
Damage to the actuator!
▷Before tightening the hexagon head bolts (7) and the hexagon nuts (9) make
sure that both actuator pillars are fully engaged in the holes of the valve's top
flange (8).
▷If required, correct the actuator position using the handwheel.