Warren Controls ILEA-Ax User manual

Installation Instructions for ILEA electric actuators
ILEA-Ax
ILEA-Bx
ILEA-Px
ILEA-Qx
ILEA_IOM
ILEA_IOM_RevDc_0721
9250 013 6 R e v C
TABLE OF CONTENTS
Designations .................................................... 2
Symbols and Safety ....................................... 2
Actuator Mounting........................................ 3
General Safety ................................................. 4
Wiring & Commissioning............................. 5
Symbols and Safety ....................................... 5
Tracing Faults Charts................................. 6-7

22600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.com
SYMBOLS AND SAFETY
Pillar
Clamping Screws
for Spring Pack
Valve Stem
Locking Nut
Yoke Lock Nut
Coupling
Coupling Nut
Bracket
Pillar Nut
ACTUATOR PART DESIGNATIONS
Please ensure that the detailed operating instructions and the chapter on “Safety” in particular have been read and
understood by all personnel involved in the installation, start-up, operation, maintenance and repair of the actuators.
Beware of mechanical hazards due to electrically powered actuator components! With the actuator powered
electrically, operating the unit holds the danger of crushing your finger!
Caution! During the installation of the actuator on the valve, the unit must not be powered electrically. Disconnect
voltage from the actuator before maintenance and adjustment work.
During adjustment work, the actuator must be operated by means of the handwheel only. Do not operate electrically!
DO NOT FULLY EXTEND.

3
ILEA_IOM_RevDc_0721
ACTUATOR MOUNTING
BEFORE START WORKING:
SAFETY REGULATIONS: - Disconnect mains!
- Prevent reconnection!
- Test for absence of harmful voltages!
- Cover or close nearby live parts!
Mounting
1: Drive coupling
upwards by hand
6:
Use the commission function
to complete the actuator
mounting, detailed on the
bottom of Page 5.
2: Position Jam nuts as per reference
drawing and lock nuts together.
3: Drop Actuator onto
Valve assembly and
tighten lock nut.
4: Extend
Actuator by
hand and lift
valve stem to
meet Actuator
coupling.
5: Thread the valve stem
into the coupling until
the jam nuts meet the
coupling. Lock the
upper jam nut against
the coupling. Lock the
second jam nut against
the upper nut.
When mounting an actuator on a valve, always
use the hand wheel! Motor operation during
mounting may cause injuries and damage to
actuator and valve!
FOR MOUNTING THE ACTUATOR, THE VALVE
MUST BE IN FULLY CLOSED POSITION!
Valve
Height
*(H)
Number
of Jam
Nuts
18L 3.55 2
18M 3.35 1
18N 3.91 1
28E, 28M 3.46 2
29E 3.46 2
29S 3.03 1
58E 3.46 2
58T 3.35 1
NS, PICV (Pxx) 2.67 2
GENERAL SAFETY
ILEA actuators are built with state of the art technology and
are safe to operate with commonly accepted electrical safety
precautions. ILEA Actuators can also produce significant
linear forces and should only be operated when connected
to a control valve unless otherwise instructed. Fingers should
not be anywhere near the moving parts of the valve and
actuator assembly while power is connected.
Operators should be trained, read the user manual and have
a good understand of the actuator’s function and operating
capabilities.
The wiring termination should be verified before
commissioning commences.
If the actuator was purchased together with a control valve
the actuator will be precalibrated to the valve’s stroke and
there will be no other requirement than applying the correct
power supply and control signal.
The standard control signal is 4 – 20 mA where a 2-way valve
is closed at 4mA and fully open at 20 mA. This standard
configuration would be depicted on the product label for
*(H)
Proceed ONLY AFTER
following set-up and
wiring on Pages 4 & 5.

42600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.com
SET UP & GENERAL SAFETY
With power applied, preferably, use a signal calibrator to
verify that the valve is fully stroking from one end to the
other as depicted by the travel indicator on the side of
the actuator mounting Pillar and with the proper control
action. Alternately the process controller could be directly
connected to test if it has a ‘Manual-Mode’ of operation
where the controllers output can be manually adjusted from
0% - 100%.
IF THE ACTUATOR IS ONE WITH A DEFINED ‘FAIL-SAFE’
DIRECTION ,THAT CAN BE VERIFIED BY:
1. Using the signal calibrator to move the
actuator position to mid-stroke.
2. Safely disconnecting power at the power
breaker switch and observing the actuator
going to its fail-safe position.
Once these steps are verified you may proceed to
commissioning the control valve. If either of these tests did
not perform as expected, then contact the Warren Controls
factory for further troubleshooting steps.
BASIC SAFETY NOTES:
• Before opening the actuator cover, ensure that the electrical
mains supply voltage is disconnected.
• If operating the actuator with the cover removed for
troubleshooting reasons make sure the wiring terminations
are clearly understood. Contract the Warren Controls factory
for further troubleshooting steps as may be necessary.
• Do NOT attempt to auto-stroke the actuator when the
actuator is not connected to a control valve as it will not
function.
• Do NOT adjust the Manual Override completely downward
when the actuator is not connected to a control valve as this
could permanently damage the actuator.
•If the actuator is removed from the control valve, upon
reinstallation the auto-calibration procedure must be
performed.
CONTROL SIGNAL AND POSITION FEEDBACK CHOICES AND LABEL DESIGNATIONS.
SIGNAL 2-WAY VALVE CLOSED LABEL
DESIGNATION
3-WAY VALVE
LOWER PORT CLOSED
LABEL
DESIGNATION
4 – 20 mA @ 4 mA 20 – 4 mA CL @ 4 mA 20 – 4 mA DN
4 – 20 mA @ 20 mA 4 – 20 mA CL @ 20 mA 4 – 20 mA DN
0 – 20 mA @ 0 mA 20 – 0 mA CL @ 0 mA 20 – 0 mA DN
0 – 20 mA @ 20 mA 0 – 20 mA CL @ 20 mA 0 – 20 mA DN
2 – 10 Vdc @ 2 Vdc 10 – 2 Vdc CL @ 2 Vdc 10 – 2 Vdc DN
2 – 10 Vdc @ 10 Vdc 2 – 10 Vdc CL @ 10 Vdc 2 – 10 Vdc DN
0 – 10 Vdc @ 0 Vdc 10 – 0 Vdc CL @ 0 Vdc 10 – 0 Vdc DN
0 – 10 Vdc @ 10 Vdc 0 – 10 Vdc CL @ 10 Vdc 0 – 10 Vdc DN
‘Signal’ as 20-4 CL, to indicate it is a 4 – 20 mA signal and CLOSED at 4 ma. The actuator should be preprogrammed for control
action and which signal is designated. Switching from a milliamp signal to a voltage signal is simply a matter of wiring termination.
Switching whether the control signal is ZERO based or not, or the control action must be done in the software set up. This can
be done on the job site as necessary with the programming umbilical cord option along with a laptop computer that has a USB
connection. If this is required, contact the Warren Controls factory.
Electric installation as well as over-current and over-voltage protection devices must be conform to the standard
DIN IEC 60364-4-41, protection class I resp. protection class III (24VAC/24VDC) and also to the standard DIN IEC
60364-4-44 according to the applied over-voltage category of the actuator.
Please protect all of the power supply and control cables in front of the terminals mechanically by
using suitable measures against unintentional loosening.
Remove
connection
terminal cover
Never install the power supply and the control cables
together in one conduit but instead please always use
two different conduit.

5
ILEA_IOM_RevDc_0721
WIRING TERMINATION (A/B ONLY)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 TTL Button
+0(2) - 10 V + 0(4) - 20 mA GND + 0(2) - 10 V + 0(4) - 20 mA GND max. Last/max. Load 100 mA/at 24 VD (Option) L/ + Open N/- L/ + Close N/- (24V AC/DC) (Option) L/+ (24V AC/DC) 21-40 VDC/ 100 mA + 0(2) - 10 V + 0(4) - 20 mA GND (Option) (Option) (Option) (Option) L/+(see tag plate) N/-(see tag plate) PE (Option)
24 V
AC/DC (OPTION)
115V- 230V
AC
Control
Signal
Input
Position
Feedback
Output
Monitor relay
potential-free
Binary
Input
signals
Fail
safe
signal
Supply
Actual
value Closed Open Supply Voltage
Fieldbus
Interface
PC
Communication
Commissioning
Galvanically isolated 1 kV Process-Sensor
(Option)
Position switch
potential-free
contact
Electric supply for 1-phase AC/DC
COMMISSIONING
CAUTION! ELECTRICAL OPERATION OF THE ACTUATOR IS ALLOWED ONLY AFTER
MOUNTING TO A VALVE!
AUTOMATIC COMMISSIONING
(Only available if at least one of the cut-offs is set to be “by force/torque” or
“by position automatically”.)
1 Press the commissioning button for 3 sec
2 Commissioning in progress
(Green LED is flashing, actuator
drives in both positions).
3 Green LED lights – Actuator successfully
commissioned and ready to be used.
OPERATING DISPLAY
– CONTROLS
ILEA actuators are commissioned at the factory when
mounted to a control Valve.
It must be commissioned if provided separately from a valve
or has been dismounted.
The actuator can only be commissioned when correctly
mounted to a valve and with at least one cut off set to “force/
torque.

62600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.com
TRACING FAULTS CHARTS (A/B ONLY)

 
21
18.Tracingfaults

RedLEDGreenLED
Glowing
permanently
Flashingquickly
Flashingslowly
Off
Glowing
permanently
Flashingquickly
Flashingslowly
Off

        StatusProbablereasonsPossibleremedy
   x   xActuatordoesnotrespond,both
LEDsareoff
1)Nosupplyvoltageapplied
2)Theappliedvoltagedoes
notmatchtheactuator
voltageonthetagplate
1)Checkmainssupply
2)Applycorrectsupply
voltage
   xx   Actuatordoesnotdrivethefull
stroke
1)Actuatornotcorrectly
commissioned
2)Toosmallstroke
programmed(inmode“one
position‐dependentcut‐
off”)
1)Repeatcommissioning
2)Checkvalvestroke
parameters‐>see
instructionsAMS‐PSCS
   xx   Actuatordoesnotclosethevalve
properly
1)Actuatornotcorrectly
commissioned
2)Actuatorclosingforce/
torquetoolow
1)Repeatcommissioning
2)Checkactuatorselection
   xx   Actuatorisinnormaloperating
condition,butdoesnotrespondto
set‐valuechanges
1)Fixeddigitalset‐valueis
activated
2)Actuatorisconfiguredto
workwithprocess
controller
1)Checkset‐value
parameters‐>see
instrucionsAMS‐PSCS
2)Connectprocesssensor
   xx   Actuatorpositiondoesnot
correspondtoset‐valueinput
Anon‐linearvalvecurvehas
beenparameterised
Verifyparameterised
characteristic‐>see
instructionsAMS‐PSCS
        OperatingconditionsProbablereasonsPossibleremedy
   xx   Normaloperatingcondition 
   x x

  Actuatorincommissioningmode Commissioningmodewillbe
leftautomaticallyafter
completion
   x  x Actuatornotcommissioned Dependingonthetypeof
cut‐offs,theactuatorhasto
becommissionedeither
automaticallyormanually
        Faultswithintheactuator’s
environment
ProbablereasonsPossibleremedy
  x x   Toohightorquehasbeen
encounteredwithinthevalvestroke
1)Actuatornotcorrectly
commissionedtothevalve
2)Mechanicalblockwithin
thestrokepath
3)Improperselectionofthe
actuator
1)Repeatcommissioning
2)Checkvalveandactuator
forunobstructedrunning
3)Checkactuatorselection
  x  x

  1)Noproperprocessfeedback(only
incombinationwithPSIC)
2+3)Maximumcontrolrange
exceeds(onlyincombinationwith
PSIC)
1)Processfeedbackwrongly
ornotatallconnected
2)Processfeedbackoutside
odadjustedrange
3)Noprocesssensorsignal
available
1)Applythecorrectprocess
feedbacksignalandcheck
polarity
2)Ensurethecorrectprocess
feedbackrange
3)Checktheprocesssensor
anditssupplyvoltage

7
ILEA_IOM_RevDc_0721

22
RedLEDGreenLED
Glowing
permanently
Flashingquickly
Flashingslowly
Off
Glowing
permanently
Flashingquickly
Flashingslowly
Off

        Faultswithintheactuator’s
environment
ProbablereasonsPossibleremedy
  x   x  Actuatordrivesintoapreset
position
1)Signalisappliedtothe
binaryfail‐safeinput
2)Supplyvoltagefailureon
actuatorswithoptional
PSCP
1)Disconnectthesignal
2)Checksupplyvoltage
  x    xSet‐valuedisconnectedoroutside
theparameterizedrange
1)Set‐valuenotconnected
2)Wrongpolarityofset‐
value
3)set‐valuesignaloutside
parameterrange,please
check
1)Applyset‐value
2)Checktheset‐value
polarity
3)Checktheset‐valuerange
 x  x    Storedendpositioncouldnotbe
reached
LooseordirtyvalveseatCheckthevalveseat
 x   x

  Storedendpositionhasbeen
passedover
ValveseatwornordefectiveCheckthevalveseat
 x    x  Actuatorsupplyvoltagetoolow1)Improperwiringofthe
mainssupply
2)Jitterinsupplyvoltage
3)Toolowsupplyvoltage
fromPSEP(withoptional
PSEP)
1)Checkmainswiring
2)Checksupplyvoltage‐>
seedatasheet
3)ContactPSserviceteam
        Faultswithintheactuator ProbablereasonsPossibleremedy
x   x    ActuatorhasreachedlifetimelimitWearand/orrunningtime ContactPSserviceteam
x    x

  Faultyelectronicsorinvalid
parameters
1)Supplyvoltage
interruptedduring
commissioning
2)Defectiveelectronic
component
1)Reloadparameters(‐>see
manualAMS‐PSCS),then
repeatcommissioning
2)ContactPSserviceteam
x     x  Criticalormaximumtemperature
reached
1)Toohighnumbersof
starts
2)Ambienttemperaturetoo
high
1)Checkapplicationandits
adjustment
2)Checkambient
temperatureandtryto
reduceit‐>seerelevantdata
sheet
x      xMechanicalfaultintheactuator DefectivemechanicalpartContactPSserviceteam


TRACING FAULTS CHARTS (A/B ONLY)

2600 EMRICK BLVD • BETHLEHEM, PA 18020 • USA •8009220085 • WWW.WARRENCONTROLS.COM
DEPENDABLE, RUGGED, PRECISION CONTROL VALVES AND ACCESSORIES
ILEA_IOM_RevDc_0721
9250 013 6 R e v C