Vag ROTOP User manual

KAT-B 5551 Edition 1 - 01/2018
VAG ROTOP®Portable Electric Drive
Installation and Operation Instructions

Content
VAG reserves the right to make technical changes and use
materials of similar or better quality without express noti-
ce. The pictures are non-binding.
1 General 3
1.1 Safety 3
1.2 Proper use 3
2 Transport and Storage 3
2.1 Transport 3
2.2 Storage 3
3 Product features 3
3.1 Features and function description 3
3.2 Fields of application 3
3.3 Performance limits 3
3.4 Proper and improper mode of operation 4
4 Set-up and operation 5
4.1 Visual inspection and preparation 5
4.2 Set-up and operation 6
4.3 Adjusting the speed 6
4.4 Adjusting the torque 6
4.5 Important note about torque shut-o! 6
4.6 Adjusting the direction of rotation 6
4.7 The counter 6
4.8 Starting the VAG ROTOP®6
4.9 Operation 6
5 Maintenance and repair 7
5.1 General safety instructions 7
5.2 Inspection and operation intervals 7
6 Trouble-shooting 7
7 How to contact us 7

VAG Installation and Operation Instructions
Any deviating operating conditions and applications require the
manufacturer‘s prior written consent!
These Installation and Operation Instructions contain important
information on the safe and reliable operation of the VAG ROTOP®.
Observing these Operation and Maintenance Instructions helps
you to:
•Prevent hazards
•Reduce repair costs and down-times of the drive and/or the
complete system
•Improve the operational safety and useful life of the equipment
2 Transport and Storage
2.1 Transport
The VAG ROTOP®should be transported in such a way that it is
protected from external influences such as cold and damp, soiling
and mechanical influences. The carrying case available from the
accessories programme reliably protects the drive.
2.2 Storage
The VAG ROTOP®should be stored in such a way that sufficient
protection against damage from improper storage is ensured. Fur-
thermore, the VAG ROTOP®should be stored in such a way that
avoids condensation forming in the machine. The VAG ROTOP®
may not be subjected to great heat for an extended period of time.
The fitting can be stored in ambient temperatures ranging from -20
°C to + 50 °C (protected by adequate covers).
3 Product features
3.1 Features and function description
The VAG ROTOP®is a portable electric drive for the easy and er-
gonomic operation of valves with and without housing. The high-
torque drive with up to 230 Nm enables the comfortable operation
of gate valves, butterfly valves and underground hydrants. The
application options offered by the different coupling sleeves make
the VAG ROTOP®compatible with any valve. An integrated torque
control prevents unintentional damage to the valves.
The VAG ROTOP®is available in a version with infinitely variable
speed or in a version with two pre-adjusted speeds.
3.2 Fields of application
The standard version of the VAG ROTOP®is suitable for all valve
types via the use of different coupling sleeves.
For technical data concerning temperature operating limits please
refer to document KAT-A 5551.
Contact the manufacturer in the event of divergent operating con-
ditions and areas of application.
3.3 Performance limits
Overload protection is triggered should the VAG ROTOP®become
overloaded. The trigger point of overload protection depends on
the period of operation and the specified torque.
The overload protector is located next to the motor on the right.
A safety pin integrated into the overload protector pops out and
the VAG ROTOP®can no longer be operated. Only after a cooling
1 General
1.1 Safety
These Operation and Maintenance Instructions must
be observed and applied at all times along with the ge-
neral „VAG Installation and Operation Instructions for
Valves“ (see www.vag-group.com / Category: Installa-
tion and Operation Instructions).
Arbitrary alterations of this product and of the parts and acces-
sories supplied with it are not allowed. VAG does not assume any
warranty or liability for consequential damage arising from non-
compliance with these instructions. When using this drive, the
generally acknowledged rules of technology have to be observed
(e.g. DIN standards, DVGW data sheets, VDI directives, etc.). The
installation may only be carried out by qualified staff (see also
Section 7.1 General safety instructions). For further technical in-
formation such as dimensions, materials or applications, please
refer to the respective documentation (KAT-A 5551).
The VAG ROTOP®is designed and manufactured to the state of
the art and its safety of operation is ensured in general. However,
the VAG ROTOP®may be potentially dangerous if it is operated
improperly or is not applied for the intended use.
Everyone dealing with the assembly, disassembly, operation,
maintenance and repair of the valves must have read and under-
stood the complete Operating and Maintenance Instructions (Ac-
cident Prevention Regulations, VBG 1 §14 ff and following).
The operator must have a strong foothold when operating the val-
ve with the VAG ROTOP®.
When using the VAG ROTOP®great care must be taken that the
end positions of the valve are approached slowly. Make sure to
watch the display. Any sudden stop would otherwise threaten to
turn the drive as well.
Make sure to observe when in operation:
•For reasons of safety only adjust the torque and direction of
rotation switch when shut down.
•To prolong the service life of the valve and the drive, always
operate at the lowest possible torque.
•To avoid overloads to the valve and the drive, moving to end
position must not be dependent on the torque, but the path,
while watching the counter.
•Even with power switched off the drive will continue to turn until
operating power has been completely dissipated.
•Use the supplied actuator column to give the operator a firm
foothold, especially for stiff valves.
For equipment for which monitoring is mandatory, the relevant
laws and regulations such as the Industrial Code, Accident Pre-
vention Regulations, VDE Guidelines, AD Data Sheets (AD = Boiler
Study Group), etc. must be complied with. In addition to this, local
accident prevention regulations must be complied with.
1.2 Proper use
The VAG ROTOP®is a portable electric drive.
It is suitable for easily and ergonomically operating valves.
For technical data concerning the operating limits such as medi-
um or temperature, please refer to document KAT 5551-A.

VAG Installation and Operation Instructions
off period of several minutes can the safety pin be pushed back in
and operation continued.
3.4 Proper and improper mode of operation
At torque of up to 100 Nm one-man operation is possible when
the actuator column is used. At higher torques the VAG ROTOP®
must be operated by two people.
Use on valves with handwheels is not permitted. For operation
with the VAG ROTOP®the handwheel must first be disassembled
from the valve.
The maximum operating conditions specified in the technical do-
cumentation (KAT 5551-A) may not be exceeded.
Figure 1: Torque duty cycle dependence
Torque
Duty cycle

VAG Installation and Operation Instructions
4 Set-up and operation
4.1 Visual inspection and preparation
Before putting the VAG ROTOP®into operation, per-
form a visual inspection of all working parts.
While doing so, make sure to check the integrity of the power
cable including protective switch. Damaged power cables from
both the VAG ROTOP®and the supplied DI protective switches
can pose a hazard to the user.
Figure 2: Detailed view of the VAG ROTOP®
Protector
Indicator plate, rear side
The electrical connection in ac-
cordance with prevailing regulations. In
addition, DI, Fi or RCD protective
switches can be used.
Only change the direction of rotation
when shut down. Watch the counter
when approaching metallic end stops.
(3) Torque control via
step switch- adjustable
in 4 steps
(1) On/off switch with
speed control
Name plate
(5) Temperature
protection switch
(8) LED – The machine is
connected to mains power
(4) Direction of rotation
switch
(6) Digital counter
(forward-backward)
Inlet for power cable
(2) On/off switch
(7) Counter reset button
Rotations of standard
valves on the front-rear side
DN 40 50 65 80 100 125 150 200 250 300
Rot/stroke 11 13,5 14 17 21 26 31 34,5 43 51
Tolerance +/- 2
rotations/stroke

VAG Installation and Operation Instructions
4.2 Set-up and operation
•Connect the supplied DI protective switch to the ROTOP con-
nection cable.
•Connect the plug to the power source (generator or mains).
•Push in the function button in the middle of the DI protective
switch until it locks into place (hold for up to 2 seconds).
•Any generators or cable reels used must be suitable for operati-
on outdoors and comply with VDE regulations.
•The possible power output of the generator must be at least
2000 watts in order to guarantee the required current of 230V
when under load.
•The generator must be earthed (an earthing device must be in
the generator’s scope of supply).
•The ROTOP and the protective switch are now ready for opera-
tion. The green power indicator (item 8) goes on.
•If the power circuit is interrupted or an operating failure occurs
the protective switch pops out and must be locked back into
position for continued operation.
•The DI protective switch is for personal protection and must be
used in accordance with VDE regulations.
4.3 Adjusting the speed
•In order to operate the VAG ROTOP®both switches (items 1 and
2) must be pushed simultaneously.
•After the VAG ROTOP®starts up in soft start the speed can be
varied, depending on the amount of pressure applied, between
10 rpm and 70 rpm on the right handle (item 1) of the VAG RO-
TOP®.
•Even mains fluctuations which may cause the speed to change
can be compensated by the operator.
•Speed should be lowered in the end positions in particular, in
order to gently move to the seat and thus avoid impacts.
4.4 Adjusting the torque
The maximum torque required can be adjusted in 4 steps by me-
ans of a step switch (item 3).
•Step 1: 50 Nm
•Step 2: 70 Nm
•Step 3: 150 Nm
•Step 4: 230 Nm -> maximum torque
Please note!
•Only adjust the torque and direction of rotation switch when
shut down.
•To prolong the service life of the valve and the drive, always
operate at the lowest possible torque.
•For valves with metallic limit stops (e.g. butterfly valves) over-
loads to valves and the drive should be avoided by moving to
end position not dependent on the torque, but the path, by wat-
ching the counter. Pay attention to the overrun of the drive.
4.5 Important note about torque
shut-off!
After being switched on the motor starts up in soft start. In this
brief time (approx. two seconds) the machine starts up to maxi-
mum torque. This phase can also be used as a breakaway func-
tion. Only afterwards is the value set for automatic torque shut-off
activated.
If the valve is already in end position and it should be turned
closed even more, only switch on the machine for a brief moment.
4.6 Adjusting the direction of rotation
The direction of rotation can be both clockwise and anti-clock-
wise.
A change in the direction of rotation is done by using the switch
(item 4).
Caution: Only change the direction of rotation when
shut down.
4.7 The counter
The counter (item 6) displays the number of revolutions digitally.
When rotating clockwise counting goes from „0“ upwards (0, 1,
2, 3,...).
When rotating anti-clockwise counting goes backwards from the
current counter reading (3, 2, 1, 0, -1, -2, -3,…). The reset button
(item 7) can be used to reset the counter to “0”.
4.8 Starting the VAG ROTOP®
The VAG ROTOP®is started by simultaneously pushing the on/
off switch on the left handle (item 2) along with the switch of the
speed control on the right handle (item 1).
The integrated “soft start” causes a delay of approx. two seconds
until full operating speed is attained, even when the speed control
is pushed in all the way.
4.9 Operation
One man operation without any other equipment is possible up
to approx. 100 Nm. If an “actuator column” permanently affixed
to the device is used higher loads are also possible during one
man operation. For higher loads two people should operate the
machine.
Make sure that the VAG ROTOP®is not overloaded. Refer to the
diagram for duty cycle.
In two man operation the duty cycle falls off sharply and falls to
approx. 1 minute at 230 Nm.
Failure to observe these instructions will trigger the overload pro-
tector (item 5) integrated in the ROTOP. It is located next to the
motor on the right. A safety pin integrated into the overload pro-
tector pops out and the VAG ROTOP®can no longer be operated.
Only after a cooling off period of several minutes can the safety
pin be pushed back in and operation continued.

VAG Installation and Operation Instructions
5 Maintenance and repair
5.1 General safety instructions
Prior to the performance of inspection and maintenance work on
the valve or its assemblies, shut-off the pressurised
pipeline, depressurise it and secure it against inadver-
tent activation. Depending on the kind and dangerous-
ness of the fluid conveyed, comply with all required
safety regulations.
After completing maintenance work and before resuming ope-
ration, check all connections for proper fastening and tightness.
Perform the steps described for initial set-up as described under
Section 5 “Set-up and operation”.
Statutory and local provisions as well as the safety and accident
prevention regulations must be observed and complied with at all
times.
Any damage that may be caused by electric current and current
flow must be prevented. Couplings and connections must never
be disassembled when they are under pressure or current-bea-
ring.
Servicing, maintenance and inspection work as well as the repla-
cement of spare parts must only be done qualified staff. The plant
operator is responsible for determining the suitability of the staff or
for ensuring the relevant qualifications.
In case the operator’s employees do not have the qualifications re-
quired, they need to attend a training course. This training course
can e.g. be held by VAG Service employees.
In addition to this, the plant operator needs to ensure that all em-
ployees have understood these Operation and Maintenance In-
structions as well as all further instructions referred to in them.
Protective equipment such as safety boots, safety helmets, safety
clothing, goggles, protective gloves, etc. must be worn during all
work requiring such protective equipment or for which such pro-
tective equipment is prescribed.
Improper or wrong use of the valve should be avoided. Prior to the
performance of any work on the valve and equipment it must be
ensured that the relevant pipeline section has been depressurised
and/or de-energised.
5.2 Inspection and operation intervals
The VAG ROTOP®requires only minimal maintenance. The gear
housing is filled with lubricant at the factory. No topping off is
necessary.
Prior to each use of the VAG ROTOP®we recommend checking
whether the power cable, plug and operating controls meet regu-
lations.
Half-yearly: If the VAG ROTOP®is used only rarely, a test run
must be carried out approximately every 6 months. Failure to do
so may result in the loss of warranty. Check cables and plug for
any defects prior to the test run.
Yearly: Check that are retaining bolts are secure and tighten if
necessary.
According to statutory regulations (Accident Prevention Regulati-
ons, VGB 4m §5) all portable machines, in particular those being
used outdoors, must be inspected at least once per year by the
manufacturer or by an authorised qualified person. Failure to do
so may result in the loss of warranty.
6 Trouble-shooting
For all repair and maintenance work, please observe the general
safety instructions described in Section 7.1.
7 How to contact us
Headquarters
VAG GmbH
Carl-Reuther-Str. 1
68305 Mannheim
Germany
Telephone: [phone]
Fax: [phone]
[email protected]
http://www.vag-group.com
Service
Our service hotline can be reached 24/7 world-wide. In case of
emergency, please contact us by phone.
Service hotline: +49 621 - 749 2222
Service by e-mail: [email protected]
Problem Possible causes Solutions
VAG ROTOP®won’t start up
Power supply not connected Connect to power
Generator doesn’t work Ensure proper working order of the generator
Cable defective Have cable repaired professionally
Protection switches not switched on Switch on DI protection switches
Overload protector triggered Switch overload protector back on af-
ter a cooling off period
Counter skips Unsuitable generator Replace or repair generator
Power indicator LED won’t go on LED defective Exchange indicator light at the factory

Edition 1- 01/2018
www.vag-group.com
[email protected]