2-way control valves - insatech · 2.1 signiﬁcance of symbols warning of general danger 2.2...

Technical Manual

Instructions for installation, operation and maintenance

723 2-WAY CONTROL VALVES Fig. 440-446, with electric actuator Ari-Premio

Publication nr TIB-723-GB-0711 Supersedes TIB-723-GB-0508

0040000053 4000 englisch

1.0 General Information on Operating Instructions ..2

2.0 Notes on Possible Dangers ......................................22.1 Significance of Symbols ............................................... 2

2.2 Safety-Related Definitions ............................................ 2

2.3 Qualified Personnel ....................................................... 2

3.0 Handling ...................................................................33.1 Storage .......................................................................... 3

3.2 Transport ....................................................................... 3

3.3 Handling Before Installation......................................... 3

4.0 Description ...............................................................34.1 Scope of Applications ................................................... 3

4.2 Operating Principles...................................................... 3

4.3 Diagram / Plug Designs ................................................ 4

4.4 Marking......................................................................... 5

5.0 Installation ...............................................................55.1 General Notes on Installation........................................ 5

5.2 Requirements at the Place of Installation...................... 5

5.3 Installation Instructions Concerning Actuators .............6

6.0 Notes on Dangers During Installation, Operationand Maintenance .....................................................6

7.0 Putting the Valve into Operation............................6

8.0 Care and Maintenance ............................................78.1 Spindle Packings / Assembly.........................................7

8.2 Packings with PTFE V-ring unit ....................................7

8.3 Stuffing Box Packings....................................................8

8.4 Bellow Seal ....................................................................9

8.5 Replacing the Plug, Spindle and Seating .......................9

9.0 Troubleshooting .....................................................11

10.0 Troubleshooting Table .........................................12

11.0 Dismantling the Valve..........................................13

12.0 Warranty ..............................................................13

Operating and Installation InstructionsStraightway Control Valves Fig. 440-446

Contents

22.44023.44034.44035.440

Fig. 12.44122.44123.44134.441

55.44055.445

35.44155.44155.446

Fig. 12.440

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Operating and Installation InstructionsControl Valves Fig. 440-446

1.0 General Information on Operating Instructions

These operating instructions contain information necessary to install and operate the valve both safely andeffectively.If problems arise which cannot be solved with the aid of these operating instructions, please contact thesupplier/manufacturer for further information. These operating instructions comply with applicable ENsafety standards as well as regulations and codes of practice applicable in the Federal Republic ofGermany. If the valve is used outside the Federal Republic of Germany, the operator or the personresponsible for the system design must ensure that valid national codes of practice are complied with.The manufacturer reserves all rights to implement technical modifications and improvements at any time.The use of these operating instructions assumes the user is qualified as described under Section 2.3"Qualified Personnel".The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on Possible Dangers

2.1 Significance of Symbols

Warning of general danger

2.2 Safety-Related Definitions

The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operatinginstructions as indications for particular hazards or for important information requiring special signs.

DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / orconsiderable damage to property can occur.

WARNING means that if the relevant information is disregarded, there is a danger of serious injury and /or damage to property can occur.

CAUTION means that if the relevant information is disregarded, there is a danger of injury and / ordamage to property can occur.

NOTE means that particular attention must be paid to certain technical aspects.

All other information not specifically emphasised such as transport, installation, operating andmaintenance instructions as well as technical data (in the operating instructions, product documentationand on the device itself) must also be complied with to the fullest extent in order to avoid faults which inturn can cause serious injury to persons or damage to property.

2.3 Qualified Personnel

The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-up,operation and maintenance of the product and have the qualifications corresponding to theirresponsibilities such as:Instruction and obligation to comply with all operational, regional and in-company regulations andrequirements;Training or instruction in accordance with safety technology standards with regard to the upkeep and useof appropriate safety and work protection equipment; First aid training, etc.(see TRB 700).


0040000053 4000 page 3

3.0 Handling3.1 Storage- Storage temperature -20˚ to +65˚C dry, free of dirt

- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘tdamage the paintwork.

- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport- Transport temperature -20˚ to +65˚C.

- Protect against external force (impact, vibration etc.).

- Don‘t damage the paintwork.

3.3 Handling Before Installation- If flange covers are fitted, remove shortly before maintenance!

- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).

- Correct handling protects against damage.

4.0 Description4.1 Scope of ApplicationsThese control valves are suitable for controlling the flow of liquids, gases and vapours in chemical andother processing plants and for plant engineering.The materials have been selected and matched on the basis of current DIN, AD, TRD and UVV rules.The mechanical and flow characteristics conform to standard DIN EN 60534.The engineer planning a plant is responsible for selecting the correct valve for a given application. Thespecial features of the valve concerned must be taken into account.

- Valves for oxygen application (O2) have a fixed plate.

- Valves for Ammonia (NH3) acc. to TRD 451-452 must be free from nonferrous metalswith flanges DIN 2512 form N.

acc. to TRB 801 No.34 for ammonia storage tank systems, bodies withshoed ends must be stress-relief-annealed.

- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.

- Valves for inflammable, aggressive or toxic media, must be off tensile material.

- With applications for media that demand special criteria, please consult.

- -marking for applications acc. to Pressure Equipment Directive.

4.2 Operating PrinciplesARI control valves are especially suitable for actuation by pneumatic or electrical actuators.

Three plug types are available to suit the various applications:parabolic plug (standard pattern)perforated plugV-port plug

The flow through control valves with parabolic and V-port plugs is always against the closing direction. Inthe case of control valves with perforated plugs, gases and vapours flow against the closing directions, butliquids flow through in the closing direction.

If a pneumatic actuator is to be used on a straight-way valve with a perforated plug with the fluid movingin the closing direction, a higher closing force will be needed. This is to prevent vibration as the plugapproaches the closed position.

Pressure-balanced plugs can be provided if the actuator force is inadequate.

Oil and grease freefor oxygen application

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4.3 Diagram / Plug Designs

fig. 1: Fig. ...440 standard design fig. 2: Fig. ...441 standard design

fig. 3: Design with perforated plug fig. 4: Design with V-port plug

rotatedview

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4.4 MarkingDetails of the CE-marking on the name plate of the valve:

5.0 Installation5.1 General Notes on InstallationThe following points should be taken into account besides the general principles governing installationwork:- Remove flange covers if present.- There must be no foreign bodies inside the valve or piping.- Pay attention to the direction of flow: see markings on the valve and refer to the operation and installation

instructions (point 4.2).- Centre sealings between the flanges.- Connection flanges must mate exactly.- If the valve is handling steam, the piping must be laid with a gradient to prevent water from accumulating

in pockets. Condensation traps are needed to prevent water-hammer.- All parts must be free from stress after installation.- The valve must not serve as a fixed point. It must be carried by the piping.- Protect the valve from dirt, especially during construction work. Strainers or filters shoud be installed

before the valves.- Install compensators to compensate for thermal expansion of the piping.- Keep the thread and shaft of the spindle free from paint.5.2 Requirements at the Place of InstallationThe place of installation should be easily accessible and provide ample space for maintenance andremoving the actuator. Stopvalves shoud be installed before and after the controlvalve to enablemaintenance working without draining the piping system. The valve should preferably installed verticallywith the actuator at the top. Inclined or horizontal installation without supports is permissible only withlight actuators.For this installallation position, the two distance columns (or joke) have to be above each other in theverical plane.

Permissible servo weights for valves with unsupported horizontal spindles:20 kg for DN 15 - 3225 kg for DN 40 - 6535 kg for DN 80 - 100

The pipes must be lagged to protect the actuators from excessive heat. Sufficient space must be left for themaintenance of the spindle packing.To ensure that the control valves function correctly, the pipe run should be straight for at least2 x DN upstream and 6 x DN downstream of the valve.

CE-marking According to the Pressure Equipment Directivepart 3, valves without safety function are onlyallowed to bear the CE-marking DN32 onwards.

Valves with safety function are:Type 440 DP-G / 441 DP-G andType 440 / 440-D with FR2.1 and Ü-sign

0525 Notified body

Fig. ______ Figure-No. / Type-No.Serial-No.Year of manufacture (clear speech)(1. and 2. position of the serial-No.)

SN _ _ ____

Pipeline Pipelinevertically horizontally

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5.3 Installation Instructions Concerning ActuatorsNormally, control valves are supplied complete with actuator fitted.It is not permitted to mantle / dismantle actuators with valves operating and service conditions(temperature and pressure) (see 2.3). The actuators must be assemble as describe in the operatinginstructions during conversion and maintenance.During assembly work, the plug is not be turned on its seating at closing pressure.

Caution!Care must be taken with the bellow type valves when actuators are mounted or removed. Hold the valve-spindle against turning with an open-end wrench.When retrofitting actuators, the maximum permissible force for valve actuation must be taken intoaccount.The maximum permissible actuation forces are:

6.0 Notes on Dangers During Installation, Operation and MaintenanceDANGER !Operation can be completely safe only if the valve is properly installed, put into operation and maintainedby trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to the warnings in theseoperating instructions. In addition, the general installation and safety rules for piping and plant installationmust be observed, and appropriate tools and safety equipment are to be used. Strict attention must be paidto the operating instructions during all work on the valve and when handling it. Injury or damage can becaused by ignoring them.

When used as an end-blockage, a safety precaution is recommended by maintenance works.

7.0 Putting the Valve into Operation- Before putting the valve into operation, check that the material, pressure, temperature and direction of

flow are as specified with the plans of the piping system.

- Regard the TRB 700.

- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.

DANGER !Before putting a new plant into operation or restarting a plant after repairs or modification, always makesure that:- All installation and assembly work has been completed!- Only qualfied personnel (see point 2.3) are employed to start the plant!- The valve is in the correct position for its function!- Existing guards have been attached and in good order.

Fig. 440 / 445 Fig. 441 / 446

12 kN for DN 15 - 50 18 kN for DN 15 - 100

29 kN for DN 65 - 100


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8.0 Care and Maintenance

Maintenance and maintenanceintervals have to be defined by the operator according to the serviceconditions (see TRB 700).

8.1 Spindle Packings / Assembly

8.2 Packings with PTFE V-ring unit

See Fig. 5 and 8PTFE V-ring unit consisting of: 1 backing ring

4 sealing rings1 cover ring

Owing to the installed compression spring, this spindle packing is self-adjusting. Ifthe spindle starts leaking, the ring pack is worn out and must be replaced.

Replacing PTFE V-ring unit:

Warning! See point 11.0 before dismantling the valve.

- Remove the actuator (see operating instructions for actuator).

- When replacing PTFE V-ring unit (12), make sure that the parts are installed in thecorrect order and positions (see Fig. on right).

- Damaged spindles must also be replaced (see point 8.5 for instructions) since anew ring pack will soon start leaking again with a damaged spindle.

- Attention! Gasket (17) must be replaced.

fig. 8

fig. 5: PTFE V-ring unit fig. 6: Stuffing box sealing fig. 7: Bellow seal

rotatedview

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8.3 Stuffing Box PackingsSee Fig.6 and 10

- Stuffing box packings require maintenance.

- If leaks develop, immediately tighten the screw joint (25) gradually until thepacking stops leaking.

- The service life of stuffing box packings (23) can be increased by checkingregularly leakage.

- If leaks can no longer be stopped by tightening the nuts, a new packing ring must beinserted into the gland.

Replacing a stuffing box packing:


- Insert the new packing ring as shown in the Fig. on the right.

- If a split packing ring is used, cut with a chamfer as shown in Fig. 9

fig. 9: Split packing ring fig. 10

- Damaged spindles must also be replaced (see point 8.5 for instructions) since a new ring pack will soonstart leaking again with a damaged spindle.


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8.4 Bellow Seal

See Fig. 7 and 11If the spindle leaks, the bellow seal is defective. The leak can initially be stopped bytightening the screw joint (20.17).

Replacing the bellow seal:

Warning! See point 11.0 before dismantling the valve.- Remove the actuator (see operating instructions for actuator).

- Slacken the screw joint (20.17) by about one turn.

- Remove the bellows housing by unscrewing the nuts (11).

- Remove the plug as described in point 8.5b.

- Detach the mounting bonnet (20.2) after unscrewing the nuts (20.8).

- Extract the spindle from the bellows housing.

- Drill new spindle with plug.

- Replace 2 seals (20.6) and 1 seal (9).

- Assemble in the reverse order. Screw on the nuts (11, 20.8)and tighten them crosswise (See page 11 for tightening torque‘s).

(The spindle can only be replaced complete with bellows.)

8.5 Replacing the Plug, Spindle and Seating fig. 11Warning! See point 11.0 before dismantling the valve.- Remove the actuator (see operating instructions for actuator)

a) Control valves (cf. Fig. 1 and 12)

- Detach the mounting bonnet (7).

- Slacken screw joint (19) by about one turn.

- Extract and replace the plug with spindle.

- Replace the gasket (9).

- Set the mounting bonnet cover in place and secure it with nuts (11)tightened crosswise.(See page 11 for tightening torque‘s.)

(Plug and spindle can only be replaced completely.)

fig. 12

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b) Control Valves with Bellow Seal (cf. Fig. 2 and 11)

- Unscrew the nuts (11).

- Remove the bellows housing (20.1) with plug (3).

- Keep the spindle pressed down.

- Remove the clamping sleeve (4).

- Unscrew the plug (3).

- Fit the new plug in the reverse order.

- Drill the plug and insert new pin.

The spindle can only be replaced complete with bellows (see point 8.4)

c) Replacing the Seating Ring (only Fig. 55.445 and Fig. 55.446)

The seating ring is screwed into the valve body and can be unscrewed for replacement or remachining.

A special wrench is needed to remove the seating. It can be obtained from the manufacturer.

When fitting a new or reconditioned seating, clean thread and sealing taper in body and apply suitablelubricant.

See table below for seat ring tightening torque‘s.

Tightening torque‘s

DN 15/ 20 = 100 Nm

fig. 13

DN 25/ 32 = 150 Nm

DN 40/ 50 = 350 Nm

DN 65 = 480 Nm

DN 80 = 660 Nm

DN100 = 980 Nm

rotated view


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d) Pressure-balanced Plug - Replacing the Seals


- Detach valve top part and remove plug (replace ifnecessary) as described in point 8.5 a or b.

- Prise worn piston seal (32) out of groove in plug withsuitable tool (e.g. screwdriver).

- Insert new piston seal, taking care that it is in the correctposition (cf. Fig. 14).

- Replace guide ring (31).

fig. 14: Pressure-balanced plug- Clean sliding surface of guide bush (30); smooth with fine abrasive if necessary.

- Before assembly, remember that two seals (9) must be replaced.

- Set valve top part in place.

- Tighten the hexagon nuts of the cover gradually crosswise.

Tightening torque for hexagon nuts:

See operating instructions for actuator concerned for installing actuators!

9.0 Troubleshooting

In the event of failures or malfunctions, check that the valve was assembled and installed as described inthese instructions.Regard the TRB 700.

Compare the material, pressure, temperature and direction of flow with the information given in the plansof the piping system. Check also that the service conditions correspond to the data given on the data plateand the technical data.

DANGER !It is essential that the safety regulations are observed when identifying faults!

If malfunctions cannot be eliminate with the help of the following „troubleshooting table“, the supplier ormanufacturer should be consulted.

Bolts Torque

M 10 20 Nm

M 12 35 Nm

M 16 80 Nm

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10.0 Troubleshooting Table

Caution: - Read point 11.0 prior to dismantling and repair work!- Read point 7.0 before restarting the plant!

Fault Possible cause Corrective measuresNo flow Valve closed. Open valve (using actuator).

Flange covers not removed. Remove flange covers.

Little flow Valve not sufficiently open. Open valve (using actuator).

Dirt sieve clogged. Clean / replace sieve.

Relieve pressure first!

Piping system clogged. Check piping system.

Kvs value of valve unsuitable. Fit valve with higher Kvs value.

Valve spindle moves in jerks. Stuffing box sealing too tight (for valveswith graphite packings).

Slacken screw joint (25/20.17) slightly.

Valve must nor start leaking!

Valve plug slightly seized owing to solid dirtparticles.

Clean internals, smooth rough spots.See points 7.0 and 11.0!

Valve spindle or plug cannotbe moved.

Seating and plug clogged with dirt; especi-ally with V-port and perforated plugs.

Clean seating and plug with suitable sol-vent.See points 7.0 and 11.0!

Valve plug seized in seating or guide owingto deposits or dirt in medium.

Replace plug and seating; use parts madefrom different material if necessary.

Valve spindle leaking. PTFE V-ring unit damaged or worn. Replace ring pack - see point 8.2See points 7.0 and 11.0!

In valves with packed stuffing boxes, tightensleeve nut (25).

Tighten screw joint (25); replace packing ifnecessary. See point 8.3.See points 7.0 and 11.0!

Bellows defective in valves with bellow seal. Replace bellows unit - see point 8.4See points 7.0 and 11.0!

Leakage too high when valveis closed.

Sealing surfaces of plug eroded or worn. Replace plug - see point 8.5.See points 7.0 and 11.0!

Sealing edge of seating damages or worn. Replace seating (see point 8.5),(only Fig. ...445/446)See points 7.0 and 11.0!

Piston sealing ring worn (pressure-balancedvalves).

Replace sealing ring.See points 7.0 and 11.0!

Seating and/or plug dirty. Clean internals of valve.See points 7.0 and 11.0!

Pneumatic actuator not completely vented;spring force not fully effective.

Vent actuator air chamber completely.See points 7.0 and 11.0!

Actuator not powerful enough. Install more powerful actuator. Check ser-vice data.

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11.0 Dismantling the ValveThe following points must be observed beside the general principals rules and TRB 700 governing theassembly work:

- Pressureless pipe system.

- Medium must be cool.

- Plant must be drained.

- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.

- Have assembly work performed only by qualified personnel (see point 2.3).

12.0 Warranty

The extent and period of warranty cover are specified in the "Standard Terms and Conditions of AlbertRichter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of saleitself.

We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmedapplication.

No warranty claims can be made for any damage caused as the result of incorrect handling or disregard ofoperating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and otherapplicable codes of practice.

This warranty also does not cover any damage which occurs during operation under conditions deviatingfrom those laid down by specifications or other agreements.

Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.

No claims will be accepted beyond the scope of this warranty. The right to replacement delivery isexcluded.

The warranty shall not cover maintenance work, installation of external parts, design modifications ornatural wear.

Any damage incurred during transport should not be reported to us but rather to the competent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements fromthese companies will be invalidated.

Technology for the Future.GERMAN QUALITY VALVES

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-StukenbrockTelephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159

Internet: http://www.ari-armaturen.com E-mail: [email protected]

EC declaration of conformity / Manufacturers declaration

EC declaration of conformityas defined by

the Pressure Equipment Directive 97/23/EC and

Manufacturers declarationas defined by

the Machinery Directive 98/37/EC

Herewith we declare,

ARI-Armaturen Albert Richter GmbH & Co. KG,Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock

that according to the above mentioned Pressure Equipment Directive (PED) and Machinery Direc-tive the below listed products comply and have been approved according to Category III , Module Hor Category IV , Module H1 (with safety function) through Lloyd´s Register of Shipping (NB-No.0525), Mönckebergstr. 27, 20095 Hamburg

If the supplied model is intended to be incorporated into machinery or assembled with othermachinery to constitute machinery covered by this directive and must be put into service until themachinery into which it is be incorporated has been declared in conformity with the provisions of theEC-Machinery Directive as amended by 98/37/EC.

Schloß Holte Stukenbrock, 13.12.2001

Category III , Module H, Certificate-No: 50003/1

Straightway stop and control valvesType 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 480

Applied standards :DIN EN 60534 Part 1

VDI/VDE 3844 sheet 1DIN 3840

Category IV , Module H1, Certificate-No: 50003/2

Straightway control valves with safety functionType 440, 441

Applied standards :DIN EN 60534 Part 1

VDI/VDE 3844 sheet 1DIN 3840

(Brechmann, Managing director)...................................................

ARI-STEVI® 440 / 441with electric and pneumatic actuators

Fig. 440

Fig. 441

Features: �Compact�designPrecision�guided�stemBurnished�stemTapered�seat�ringRangeability�50�:�1Spring�loaded�PTFE-V�ring�packing�unitTwo-ply bellows seal as standardTravel�indicator

••••••••

Edition�12/07�-�Data�subject�to�alteration Data�sheet�440001�englisch�(english)

ARI-STEVI® 440 / 441 Electric actuator ARI-PREMIO

Enclosure�IP�652�torque�switchesHandwheelAdditional�devices�available,�e.g.�potentiometer

••••

�Page�2

ARI-STEVI® 440 Electric actuator FR1 with safety reset

�Operating�mode�for�safety�reset�CLOSEEnclosure�IP�66Operating�time�adjustableAdditional�devices�available,�e.g.�potentiometer

••••

�Page�6

ARI-STEVI® 440 / 441 Electric actuator FR2 with safety reset

Type�approval�acc.�to�DIN�32730��for�Fig.�440�with�FR�2.1��CE-marking�from�DN15�Optional�direction�for�safety�reset,�OPEN�or�CLOSE,�as�requiredEnclosure�IP�541�travel�switch�for�OPEN�and�CLOSEAdditional�devices�available,�e.g.�potentiometer

•

••

••• �Page�10

ARI-STEVI®� 440 / 441 Electric actuator AUMA SAR

Electric�multiturn�actuator�capable�of�high�closing�pressuresEnclosure�IP�672�torque�switches2�travel�switches�Handwheel�Overheating�protection�for�motor�as�standard�Additional�devices�available,�e.g.�potentiometerExplosion�proof�version�available

•

••••••• �Page�14

ARI-STEVI® 440 / 441 Pneumatic actuator ARI-DP

Reversible�pneumatic�actuatorActuator�with�rolling�diaphragmAir�supply�pressure�max.�6�barStem�protection�by�bellow�Maintenance-free�O-ring�sealingAssembly�of�additional�devices�acc.�to�DIN�IEC�60534-6

••••••

�Page�18

Control valve - straight through with flangesDN 15 - 150

2

ARI-STEVI® 440 / 441Electric actuator ARI-PREMIO

Control valve straight through with electric actuator ARI-PREMIO

Fig. 440

Fig. 441

Figure Nominal pressure Material Nominal diameter

12.440�/�12.441 PN16 EN-JL1040 DN15-150�22.440�/�22.441 PN16 EN-JS1049 DN15-15023.440�/�23.441 PN25 EN-JS1049 DN15-15034.440�/�34.441 PN25 1.0619+N DN15-15035.440�/�35.441 PN40 1.0619+N DN15-15055.440�/�55.441 PN40 1.4408 DN15-150Other�materials�and�versions�on�request.Stem sealing Fig.�440:�� •�PTFE-V-ring�unit�-10°C�up�to�+220°C�� •�PTFE-packing�-10°C�up�to�+250°C�� •�Pure�graphite-packing�-10°C�up�to�+450°C�Fig.�441:�� •��Stainless�steel�bellows�seal�with�safety�stuffing�box�-60°C�up�to�+450°C�Plug design standard:�� •�Parabolic�plug,�metal�seatoptional:� �� •�Parabolic�plug�with�PTFE�soft�seat�(max.�200°C)�� •�V-port�plug,�metal�seat�� •��Parabolic�pressure�balanced�plug,�metal�seat,��

Material�of�piston�seal:��PTFE�with�stainless�steel�spring�(max.�200°C)

Guiding� •�Parabolic�plug:�Stem�guiding� •�V-port�plug:�Stem�and�port�guidingFlow characteristic� •��Equal�percentage�or�linear�Rangeability�� •��50�:�1�on�parabolic�plug� •�30�:�1�on�V-port�plugShut off class�(seat / plug leackage classes)� •��Metal�seat�-�Leakage�class�IV�acc.�to�DIN�EN�1349�or�IEC�60534-4� •��Soft�seat�-�Leakage�class�VI�acc.�to�DIN�EN�1349�or�IEC�60534-4Closing�pressures�refer�to�page�4.

Technical�data�for�actuator�refer�to�data�sheet.

Selection of possible applications Industrial�installations,�processing�technology,�plant�manufacturing,�etc.��(other�applications�on�request)�Selection of possible flow media Fig.�440:��Cooling�water,�cooling�brine,�warm�water,�hot�water,�steam,�gas,�etc.��Fig.�441:��Refrigerant,�cooling�water,�warm�water,�hot�water,�thermal�oil,�steam,�gas,�etc.��(other�flow�media�on�request)�

Edition�12/07�-�Data�subject�to�alteration

3

Dimensions and weightsDN 15 20 25 32 40 50 65 80 100 125 150

L (mm) 130 150 160 180 200 230 290 310 350 400 480Fig. 440 H (mm) 556 556 564 564 571 577 590 605 624 685 745

ARI-PREMIO 2,2 kNPN16 (kg) 9 9,7 10,6 12,2 14,1 17 22,1 27,8 38 -- --PN25/40 (kg) 9,8 10,6 11,9 13,7 16,2 18,9 26,1 32,3 45 -- --

ARI-PREMIO 5 kNPN16 (kg) 10,1 10,8 11,7 13,3 15,2 18,1 23,2 28,9 39 66 88PN25/40 (kg) 10,9 11,7 13 14,8 17,3 20 27,2 33,4 46 78 110

H (mm) -- -- --- -- 721 727 740 755 774 833 893ARI-PREMIO 12 kN ARI-PREMIO 15 kN

PN16 (kg) -- -- -- -- 19,2 22,1 27,2 32,9 43 59 77PN25/40 (kg) -- -- -- -- 21,3 24 31,2 37,4 50 90 131

Fig. 441 H (mm) 741 741 749 749 740 742 826 838 854 1040 1071

ARI-PREMIO 2,2 kNPN16 (kg) 13,4 13,4 14,4 16,9 19,4 21,9 24,9 35,9 51 -- --PN25/40 (kg) 15,4 16,9 19,4 22,4 28,4 30,9 37,9 47,9 64 -- --

ARI-PREMIO 5 kNPN16 (kg) 14,5 14,5 15,5 18 20,5 23 26 37 53 73 105PN25/40 (kg) 16,5 18 20,5 23,5 29,5 32 39 49 66 85 130

H (mm) -- -- -- -- 890 892 976 988 1004 1188 1219ARI-PREMIO 12 kN ARI-PREMIO 15 kN

PN16 (kg) -- -- -- -- 24,5 27 30 41 57 77 109PN25/40 (kg) -- -- -- -- 33,5 36 43 53 70 89 134

Standard-flange�dimensions�refer�to�page�23.

Face-to-face�dimension�FTF�series�1�according�to�DIN�EN�558-1

Parts

Pos. Description Fig. 12.440 Fig. 12.441Fig. 22.440 / Fig. 23.440 Fig. 22.441 / Fig. 23.441

Fig. 34.440 / Fig. 35.440 Fig. 34.441 / Fig. 35.441

Fig. 55.440 Fig. 55.441

1 Body� EN-GJL-250�,�EN-JL1040 EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.4408

1.2 Seat�ring X20Cr13+QT,�1.4021+QT X20Cr13+QT,�1.4021+QT��>DN50:�G19�9�Nb�Si,�1.4551 --

3 Plug�* X20Cr13+QT,�1.4021+QT X6CrNiMoTi17-12-2,�1.45714 Straight�pin�* X10CrNi18-8,�1.4310 A4�-�705 Stem X20Cr13+QT,�1.4021+QT�(DN125-150) X6CrNiMoTi17-12-2,�1.45717 Mounting�bonnet EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.44088 Guide�bushing X20Cr13+QT,�1.4021+QT��(hardened) X6CrNiMoTi17-12-2,�1.45719 Gasket�* Pure�graphite�(CrNi�laminated�with�graphite)10 Studs 25CrMo4,�1.7218 A4�-�7011 Hexagon�nuts C35E,�1.1181 A412 V-ring�unit�* PTFE14 Washer�* X5CrNi18-10,�1.430115 Spring�* X10CrNi18-8,�1.431016 Bushing�* PTFE�(reinforced)17 Sealing�ring�* Cu�/�Soft�iron18 Scraper�* PTFE�(reinforced)19 Screw�joint�* X8CrNiS18-9,�1.430520.1 Bellows�housing EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.440820.2 Mounting�bonnet EN-GJS-400-18U-LT,�EN-JS1049 GP240GH+N,�1.0619+N GX5CrNiMo19-11-2,�1.440820.3 Stem-�/�Bellows�unit�* X20Cr13+QT,�1.4021+QT�/�X6CrNiTi18-10,�1.4541 X6CrNiMoTi17-12-2,�1.457120.4 Guide�bushing X20Cr13+QT,�1.4021+QT��(hardened) X6CrNiMoTi17-12-2,�1.457120.5 Guide�bushing X20Cr13+QT,�1.4021+QT��(hardened) X6CrNiMoTi17-12-2,�1.457120.6 Gasket�* Pure�graphite�(CrNi�laminated�with�graphite)20.7 Studs 25CrMo4,�1.7218 A4�-�7020.8 Hexagon�nuts C35E,�1.1181 A420.10 Packing�ring�* Pure�graphite20.12 Washer�* X5CrNi18-10,�1.430120.17 Screw�joint�* X8CrNiS18-9,�1.4305*�Spare�parts�

Information�/�restriction�of�technical�rules�need�to�be�observed!ARI-Valves�of�EN-JL1040�are�not�allowed�to�be�operated�in�systems�acc.�to�TRD�110.A�production�allowance�acc.�to�TRB�801�No.�45�exists�(acc.�to�TRB�801�No.�45�EN-JL1040�is�not�allowed.)The�engineer,�designing�a�system�or�a�plant,�is�responsible�for�the�selection�of�the�correct�valve.

ARI-STEVI® 440 / 441Electric actuator ARI-PREMIO


4

max. permissible closing pressures�on�flow-to-open�P2�=�0�(Observe�regulations,�refer�to�page�23.�Plug�design�acc.�to�„Selection�STEVI“,�refer�to�techn.�annex.)DN 15 20 25 32 40 50 65 80 100 125 150Seat-ø�(mm) 21 21 27 31 41 51 66 81 101 126 151Standard�Kvs-values 4 6,3 10 16 25 40 63 100 160 250 400Reduced�Kvs-values�3) 2,5 4;�2,5 6,3 10 16 25 40 63 100 160 250Travel�(mm) 20 30 50

Actuator�1)

ARI-PREMIO 2,2 kN

Closing�pressure�(bar)

I. 40 40 30,8 23,1 12,8 8 4,3 2,7 1,5II. 40 40 28,8 21,6 11,9 7,4 3,9 2,3 1,3III. 30,7 30,7 27,1 20,4 10,6 6,5 3,6 2,2 1,2

Operating�time�2)�(s)�(Op.�speed�0,38�mm/s) 53 79

Actuator�1)

ARI-PREMIO 5 kN


I. 40 40 33,3 21,3 12,3 8 4,9 3 2II. 40 40 32,3 20,7 11,9 7,6 4,7 2,9 1,9III. 40 40 40 40 31 19,8 11,6 7,5 4,6 2,7 1,8

Operating�time�2)�(s)�(Op.�speed�0,38�mm/s) 53 79 132

Actuator�1)

ARI-PREMIO 12 kN


I. 40 40 32,3 21,2 13,5 8,5 5,9II. 40 40 31,8 20,9 13,3 8,4 5,8III. 40 40 31,6 20,7 13,2 8,3 5,7

Operating�time�2)�(s)�(Op.�speed�0,79�mm/s) 25 38 63

Actuator�1)

ARI-PREMIO 15 kN


I. 40 26,9 17,2 10,9 7,5II. 40 26,6 17 10,8 7,4III. 40 26,4 16,9 10,6 7,3

Operating�time�2)�(s)�(Op.�speed�0,38�mm/s) 79 132

I. Fig. 440: PTFE-V-ring unit; II. Fig. 440: PTFE- / pure graphite-packing; III. Fig. 441: Bellows seal

1)��Motor�voltage:�230V�50Hz��Other�voltages:�24V�50/60Hz;�115V�50/60Hz;�230V�60Hz��Technical�data�for�actuator�refer�to�data�sheet�ARI-PREMIO.

2)�Indicated�operating�times�with�50Hz.3)��Other�Kvs-value-reductions�are�possible�with�Fig.�445�/�446�(Stainless�steel�body�with�screwed�seat�ring).��

For�max.�permissible�closing�pressures�refer�to�separate�data�sheet.

ARI-STEVI® 440 / 441Closing pressures: Electric actuator ARI-PREMIO


23

Standard-flange dimensions Flanges�acc.�to�DIN�EN�1092-1/-2�(Flange�holes�/�-thickness�tolerances�acc.�to�DIN�2533/2544/2545)

DN (mm) 15 20 25 32 40 50 65 80 100 125 150

PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285

PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240

PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22

PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300

PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250


PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300

PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250


Pressure-temperature-ratings acc. to DIN EN 1092-2

Material PN -60°C to

24

Technology for the Future. G E R M A N Q U A L I T Y V A L V E S

ARI-Armaturen�Albert�Richter�GmbH�&�Co.�KG,�D-33756�Schloß�Holte-Stukenbrock,��Tel.�+49�52�07�/�994-0,�Telefax�+49�52�07�/�994-158�or�159��Internet:�http://www.ari-armaturen.com��E-mail:�[email protected]

Stem sealing

Spring�loaded�PTFE-V�ring�packing�unit PTFE-/�Pure�graphite-packing

Bellows�seal�with�safety�stuffing�box

Body design

Body�with�pressed�seat�ring��(EN-JL1040,�EN-JS1049) Body�with�welded�seat�(1.0619+N) Body�with�machined�seat�(1.4408)

Plug design

Parabolic�plug�with�PTFE�soft�seat�and�stem�guiding V-port�plug�with�stem�and�port�guiding Parabolic�pressure�balanced�plug

ARI-STEVI® 440 / 441Constructions


Pos. Description23 Packing�ring�* PTFE�or�Pure�graphite25 Screw�joint�* X8CrNiS18-9,�1.4305*�Spare�part

0040000107 2402 englisch

Operating and Installation InstructionsThrust Actuator ARI-PREMIO

Contents1.0 General information on operating instructions ..................................................................................................32.0 Notes on possible dangers .....................................................................................................................................3

2.1 Significance of symbols ........................................................................................................................................................3

2.2 Safety-related definitions: .....................................................................................................................................................4

2.3 Qualified personnel ...............................................................................................................................................................4

3.0 Handling .................................................................................................................................................................43.1 Storage ..................................................................................................................................................................................4

3.2 Transport ...............................................................................................................................................................................4

3.3 Handling before installation..................................................................................................................................................4

4.0 Description .............................................................................................................................................................54.1 Field of application ...............................................................................................................................................................5

4.2 Method of functioning ..........................................................................................................................................................5

4.3 Technical data .......................................................................................................................................................................6

4.4 Diagram.................................................................................................................................................................................84.4.1 ARI-PREMIO 2,2 - 5 kN....................................................................................................................................................84.4.2 ARI-PREMIO 12 - 15 kN...................................................................................................................................................9

4.5 Parts list...............................................................................................................................................................................10

4.6 Dimensions .........................................................................................................................................................................11

5.0 Notes on dangers during installation, operation and maintenance ................................................................12

6.0 Installation ...........................................................................................................................................................126.1 General installation data .....................................................................................................................................................12

6.2 Manual operation ................................................................................................................................................................136.2.1 ARI-PREMIO 2.2 - 5 kN..................................................................................................................................................136.2.2 ARI-PREMIO 12 - 15 kN.................................................................................................................................................14

6.3 Installation instructions for mounting to valves..................................................................................................................156.3.1 Mounting for valve-lift up to 30 mm (yoke version) ........................................................................................................156.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version) ....................................................................................16

6.4 Electrical connection...........................................................................................................................................................186.4.1 Wiring diagram ARI-PREMIO 2,2 - 5 kN........................................................................................................................186.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN.......................................................................................................................19

6.4.2.1ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor............................................................................................. 196.4.2.2ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor.................................................................................................. 20

6.4.3 Connection ........................................................................................................................................................................21

6.5 Settings................................................................................................................................................................................226.5.1 Torque and travel switches - standard feature...................................................................................................................226.5.2 Connection boards PA or NA (only 2.2 - 5 kN)................................................................................................................226.5.3 Travel switch .....................................................................................................................................................................23

6.5.3.1Installation of additional travel switches.......................................................................................................................................... 236.5.3.2Setting of standard travel switch (S3): ............................................................................................................................................. 256.5.3.3Setting the additional travel switches (S4/S5 and S24/S25) ............................................................................................................ 26

6.5.4 Potentiometers...................................................................................................................................................................266.5.4.1Installing the potentiometer.............................................................................................................................................................. 276.5.4.2Setting the potentiometer ................................................................................................................................................................. 28

6.5.5 Heating..............................................................................................................................................................................296.5.5.1Installation of heating....................................................................................................................................................................... 29

6.5.6 Electronic position indicator RI21 ....................................................................................................................................306.5.7 Electronic position controller ES11 ..................................................................................................................................306.5.8 Electronic position indicator (RI21) and position controller (ES11) together in the actuator..........................................316.5.9 Integrated temperature controller dTRON 16.1 ................................................................................................................32

6.5.9.1Installation of the dTRON 16.1........................................................................................................................................................ 326.5.10 Integrated reversing contactor.........................................................................................................................................33

6.5.10.1Installing the reversing contactor ................................................................................................................................................... 336.5.10.2Electrical connection with ES11 or dTRON 16.1 .......................................................................................................................... 33

6.5.11 Phase control relay..........................................................................................................................................................346.5.11.1Installing the phase control relay ................................................................................................................................................... 34

7.0 Starting up............................................................................................................................................................358.0 Care and maintenance ........................................................................................................................................359.0 Troubleshooting ...................................................................................................................................................3510.0 Troubleshooting table........................................................................................................................................3611.0 Dismantlement of thrust actuator....................................................................................................................3612.0 Warranty ............................................................................................................................................................3713.0 EC declaration of conformity ...........................................................................................................................38

00400001072402 page 3

Operating and installation instructionsThrust actuator ARI-PREMIO

1.0 General information on operating instructions

These operating instructions contain information necessary to install and operate the thrust actuatorboth safely and effectively.If problems arise which cannot be solved with the aid of these operating instructions, please contactthe supplier/manufacturer for further information. These operating instructions comply withapplicable EN safety standards as well as regulations and codes of practice applicable in the FederalRepublic of Germany. If the electronic positioner is used outside the Federal Republic of Germany,the operator or the person responsible for the system design must ensure that valid national codes ofpractice are complied with.The manufacturer reserves all rights to implement technical modifications and improvements at anytime.The use of these operating instructions assumes the user is qualified as described under Section 2.3"Qualified Personnel".The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on possible dangers

2.1 Significance of symbols

Warning of general danger

Warning of dangerous voltage

Exposed to injury!Don’t touch the turning handwheel when the motor is running

Exposed to injury!Don’t put your hand into the up or downwards moving appliance

Danger when not observing the operating and installation instructions!Before installing, operating, maintenance or dismantling read and observe theinstructions

Danger though voltage!Before dismantling the hood, switch of the electrical source and secure againstturning on again

00400001072402


2.2 Safety-related definitions:The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operatinginstructions as indications for particular hazards or for important information requiring special signs.

DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and/ or considerable damage to property can occur.

WARNING means that if the relevant information is disregarded, there is a danger of serious injuryand / or damage to property can occur.

CAUTION means that if the relevant information is disregarded, there is a danger of injury and / ordamage to property can occur.

NOTE means that particular attention must be paid to certain technical aspects.

All other information not specifically emphasised such as transport, installation, operating andmaintenance instructions as well as technical data (in the operating instructions, productdocumentation and on the device itself) must also be complied with to the fullest extent in order toavoid faults which in turn can cause serious injury to persons or damage to property.

2.3 Qualified personnelThis refers to personnel possessing corresponding qualifications and familiar with the processes ofinstalling and assembling the product as well as with putting the product into service and operatingthe same, e.g.

- Training or instruction or authorisation to switch on and off electric circuits and equipment/systemsand to disconnect, ground and identify the same in accordance with VDE 0100, the regulationsstipulated by the local electricity generating boards as well as technical safety standards.

- Instruction and obligation to comply with all regulations and requirements pertaining to use as wellas regional and in-house regulations and requirements, especially TRB 700.

- Training or instruction in accordance with technical safety standards in the use and maintenance ofpertinent safety equipment including job-safety equipment.

- Training in first-aid, etc.

3.0 Handling3.1 Storage- Storage temperature -20˚ to +70˚C dry, free of dirt

- Do not damage packing

- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport- Transport temperature -20˚ to +70˚C

- Protect against external force (impact, vibration etc.).

- Do not damage packing.

3.3 Handling before installation- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).

- Correct handling protects against damage.

- Do not soil or damage type identification plate and wiring diagram on the controller.

00400001072402 page 5


4.0 Description

4.1 Field of application

ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves requiring anominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN. The thrust actuatorsare set to the thrust forces specified in the technical data. If supplied with the valve, the lift of thethrust actuator will be set to the stroke distance of the valve.Selection of the proper actuator version in alignment with the corresponding fitting as well as use ofthe thrust actuator in accordance with the specified technical data is the responsibility of the systemsengineer.Any use of the thrust actuator beyond the specified technical data or improper use of the actuator isdeemed to be not for the intended purpose.

The ambient conditions have to be conform to the actual electromagnetic compatibility directives.Additional the compatibility to this directives has to be maintained in case of expansion or otherchanging of the ambient conditions.

4.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve.Transfer of force is effected via a coupling safeguarded against torsion.The torsion safeguarding feature also serves as a lift indicator.The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear clampsmounted to the column.

The electrical components are accommodated separately from the gearbox underneath a sealed hood,thus being protected against operating and environmental effects.Following removal of the hood, easy access is provided to the switchgear and indicating feature.The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut and thusperforms a pull or push motion depending on the sense of rotation.In the final positions of the valve, the spindle nut is pressed against a set of springs so as to produceclosing force.The motor is switched off by means of two load-dependent switches and one stroke-dependentswitch. The load-dependent switches will also switch off the motor if foreign bodies have lodgedthemselves between the valve seat and cone.The load-dependent switches serve to protect the valve and thrust actuator against damage.

00400001072402


4.3 Technical dataType ARI-PREMIO

Thrust force kN 2.2 5.0 12.0 15.0

Stroke distance max. mm 50 80

Duty classification in accordancewith DIN VDE 0530

S1 - 100 % duty cycle; S4 - 80% duty cycle 1200 c/h S1 - 100% ED;S4 - 50% ED 1200 c/h

Control speed mm/sec. 0.25 0.38 0.38 1,0 0.79 0.38

Motor voltage 230V - 50Hz / 60Hz * 230V -50Hz 230V - 50Hz / 60Hz *

Power consumptionW 10.3 11.7 25.3 52.9 109 96

Torque switch 2 only, permanently wired,switching capacity 10A, 250V~

2 pcs., permanentlywired

switching capacity 16A,250V~

Travel switch 1 only, permanently wired,switching capacity 10A, 250V~

1 pcs.,permanently wired

switching capacity 16A,250V~

Enclosure IEC 60529 IP 65

Max. permissible ambienttemperature

-20 ˚ C ... +70 ˚ C

Handwheel Yes (rotating during operation) Yes (engageable)

Mounting position Any. Exception: motor must not be suspended downwards

Gear lubricant Klüber Unigear LA02 50/50-mixKlüber Isoflex NBU15

Ultra andKlüber Nontrop KR291

Weight kg 5.4 6 6.5 10,5

* Control speed and power consumption are 20% higher at frequency of 60 Hz

00400001072402 page 7


Accessories

Type ARI-PREMIO

Thrust force kN 2.2 5.0 12.0 15.0

Additional travel switches 2 additional travel switches, zero potential,Switching capacity 10A, 250V ~

Additional travel switches for low-voltage / electronic system

2 additional travel switches, zero potential, with gold contacts,switching capacity max. 0,1A, 4-30V DC

Potentiometer max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt

Electronic position indicator RI 21 0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possibleUsing the temperature controller, installation is only possible in the control cabinet

Electronic position controller ES 11 0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possibleNot compatible for use with the temperature controller.

Heating resistor (with automatic switching)230V-50Hz, 115V-50Hz, 24V-50Hz, 15 watt

Additional voltages / frequencies 24V - 50/60Hz115V - 50/60Hz

24V - 50Hz 24V - 60Hz115V - 50Hz115V - 60Hz230V - 60Hz

24V - 50/60Hz 115V - 50/60Hz

3~400V - 50Hz3~440V - 60Hz

Standard-voltage connection board,PA

2 torque switches and 1 travel switch, zero potential,for free wiring,

Switching capacity10A, 250V ~--

Low-voltage connection board(electronic system), NA

2 torque switches and 1 travel switch,for free wiring,

with gold contacts,Switching capacity max. 01A, 4-30 VDC

--

Integrated temperature-controllerdTRON 16.1

Three-step temperature-controller in microprocessor-technology.Control range: -200˚C to 850 C (resistance thermometer)

Voltage: 24V, 115V or 230V 50/60HzCompatible with resistance thermometers and thermocouples

(provided by customer), or standardized active current or voltage signals.

Integrated reversing contactor --

Actuator with 400V-50Hzand 440V-60Hz

Only 1 electronic modulepossible!

Phase control relay --Only in addition with

integrated reversing con-tactor!

00400001072402


4.4 Diagram4.4.1 ARI-PREMIO 2,2 - 5 kN

Fig. 1

Yoke Version Column Version

00400001072402 page 9


4.4.2 ARI-PREMIO 12 - 15 kN

Fig. 2

00400001072402


4.5 Parts listDesignation Designation

50.1 Gearbox 50.30 Driving spindle

50.1.1 Gearbox cover plate 50.31 Spindle safety feature

50.2Cable conduit fitting2,2 - 5kN: 2 x PG1112 - 15kN: 2 x PG13,5 / 1 x PG9

50.32 Torsion safety feature

50.34 Bellow

50.35 Grub screw M6

50.4 Sealing plug 1 x PG11 50.36 Set collar

50.5 Gasket 50.37 Grub screw DIN 913-M3x5

50.6 Hood 50.38 Guide spindle

50.7 Hood seal 50.39 Hexagon nut DIN EN 24034-M5

50.8 Counter-sunk screw DIN 7991-M5x20 50.40 Synchronous motor, complete

50.9 Sealing washer DIN 125-5,3 50.41 Head cap screw DIN 912-M4

50.10 Column 50.42 Board support

50.12 Handwheel 50.43 Standard board

50.12.1 Turning handle of handwheel 50.45 Shift lever

50.14 Yoke 50.46 Washer

50.15 Flange 50.47 Wiring diagram sticker, standard

50.16 Spring washer DIN 128-A10 50.48 Connector, 3-pole (standard)

50.17 Hexagon head screwDIN EN 24017-M10x30

50.50 Trip slide

50.51 Setting spindle for switch S3

50.18 Hexagon head screwDIN EN 24017-M10x45



50.19 T-head bolt DIN 261-M12x40 50.54 Trip cam

50.20 Washer DIN 125-13 50.55 Lock washer DIN 6799-2,3

50.21 Spring washer DIN 128-A12 50.56 Spring PREMIO for trip slide

50.22 Hexagon nut DIN EN 24032-M12 50.57 Head cap screwDIN 912-M4x10

50.23 Lift dial 50.58 Protective conductor terminal

50.24 Distance column 50.59 Head cap screw DIN 912-M4x6

50.25 Hexagon nut DIN 980-V-M16 50.87 Threaded bush

50.26 2-ear clamp (stroke indicator) 50.101 Connector, 8-pole

50.27 Coupling

00400001072402 page 11


4.6 Dimensions

Fig. 3

XL

h23

663

3m

ax. 3

0 m

m25

665

3m

ax. 5

0 m

m27

166

8m

ax. 6

5 m

m28

668

3m

ax. 8

0 m

m

Cle

aran

ce r

equi

red

for

rem

oval

of

hood

AR

I-P

RE

MIO

2,2

- 5

kN

Nom

inal

str

oke

> 3

0 m

m -

50

mm

AR

I-P

RE

MIO

2,2

- 5

kN

Nom

inal

str

oke

max

. 30

mm

AR

I-P

RE

MIO

12

- 15

kN

Nom

inal

str

oke

max

. 80

mm

Cle

aran

ce r

equi

red

for

rem

oval

of

hood

Cle

aran

ce r

equi

red

for

rem

oval

of

hood

00400001072402


5.0 Notes on dangers during installation, operation and maintenance

DANGER!

Safe operation of the positioner is only ensured if it is installed, put into operation and maintained byqualified personnel (refer to Point 2.3 "Qualified personnel"), while observing the warning notesprovided in these operating instructions. In addition, care must be taken to ensure that the generalequipment and safety regulations for electrical lines and installations are complied with and thattools and protection devices are used professionally. The operating instructions for the electronicpositioner must be observed when carrying out all work on and when handling the electronicpositioner. Disregard of these instructions can result in injury to persons or damage to property.

6.0 Installation

6.1 General installation data

In addition to general installation guidelines, the following points are required to be observed:

- Existing operating instructions for valve.

- Complete valve with crossarm.

- Valve cone approximately in mid lift position - on no account supported inside a seat!

- Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricitygenerating board.

- Conductor cross-section selected to correspond to the given drive power and existing line length.

- Mains fuse rating max. 6A.

- Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the actuator.

- Conformity of technical data on thrust actuator with field conditions.

- Mains voltage in accordance with data specified on rating plate of thrust actuator.

- Thrust actuator complete with yoke or distance columns and coupling parts intended for mountingto the corresponding valve.

- Qualified personnel possessing knowledge of the regulations pertaining to the erection of powerinstallations.

- Ease of access to installation site.

- Adequate clearance space above the thrust actuator for removing the hood(refer to point 4.6 Dimensions).

- Install where there is protection against high-energy heat radiation.

- The ambient temperature must not exceed +70 ˚C.

00400001072402 page 13


If installed outdoors, the thrust actuator must be provided with an additional cover to protect against- rain,- direct insulation,- powerful draughts and- dust.In case of widely fluctuating ambient temperatures and high atmospheric humidity, your arerecommended to install a heating resistor to minimise condensation buildup in the actuator.- Thrust actuator mountable in any position except in downward suspended position.If installed with a horizontal connecting rod, the thrust actuator must be mounted so both yoke legsor columns are on top of one another in the vertical plane (see fig. 4).

Fig. 4

6.2 Manual operation6.2.1 ARI-PREMIO 2.2 - 5 kN

With the motor in the stationary state, the thrust actuator can be run in the open and closed state withthe handwheel firmly meshed with the gear.

Proceed as follows:

- Swing out lever (50.12.1) from handwheel (50.12).

- Turning in clockwise direction--> closes valve.

- Turning in counter-clockwise direction--> opens valve.

CAUTION !In the manual operating mode pay careful attention in the final positions that the handwheel isonly turned to the point where the torque switch trips (audible click) as otherwise damage willbe caused to the thrust actuator! Since the handwheel always follows during motor-drivenoperation (running indication), never operate by hand while the motor is running - potentialinjury hazards!!!

Fig. 5

Correct Incorrect

Open Close

00400001072402


6.2.2 ARI-PREMIO 12 - 15 kN

With the motor in the stationary state, the thrust actuator can be run in the open and closed state withthe engageable handwheel.

Proceed as follows:

- Fold the turning handle out of the handwheel (A)

- Turn the handwheel slightly and push in the engaging button for manual mode (B) --> the buttonengages

- Turning in clockwise direction --> closes valve

- Turning in counter-clockwise direction--> opens valve

The motor is no longer in mesh when the handwheel is engaged. The handwheel is automaticallydisengaged when the motor starts and the handwheel is once more in mesh.

Fig. 6

CAUTION:In the manual operating mode pay careful attention in the final positions that the handwheel isonly turned to the point where the torque switch trips (audible click) as otherwise damage willbe caused to the thrust actuator!

Engaging buttonfor manual mode

OpenClose

00400001072402 page 15


6.3 Installation instructions for mounting to valves6.3.1 Mounting for valve-lift up to 30 mm (yoke version)

Fig. 7

To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed asfollows:

- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator(not illustrated).

- Position valve cone approximately in mid lift position.

Fig. A: - Turn flat hexagon nut if not present on valve spindle.

Fig. A-B: - Slip coupling (50.27) over valve spindle.

- Screw threaded bush (50.87) matching the valve onto the valve spindle in accordancewith setting dimension (Y) and lock with hexagon nut.

- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.

Fig. C: - Place thrust actuator (50) on valve.

- Mount thrust actuator (50) on fitting with two T-head bolts (50.19), two washers(50.20), two spring washers (50.21), two hexagon nuts (50.22).

Fig. D/E: - Swing out handwheel lever (50.12.1) and use it to move out the thrust actuator until thedriving spindle (50.30) comes to rest on the threaded bush (50.87).

Fig. F: - Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure inplace using grub screw M6 (50.35).

- Run valve to lowest position.

- Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is inalignment with tip of arrow mark on lift dial.

- Run valve to both final positions and check to ensure that these are safely reached

- Carry out electrical connection (refer to section 6.4.1).

- Set travel switch S3 (refer to section 6.5.3.2).

Hexagon nutValve spindle


turn

00400001072402


6.3.2 Mounting for valve lift over 30 mm to 80 mm, (column version)

Fig. 8

To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm, proceedas follows:

- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator(not illustrated).

- Position valve cone approximately in mid lift position.

Fig. A: - Turn flat hexagon nut if not present on valve spindle.

Fig. A-B: - Slip coupling (50.27) over valve spindle.

- Screw threaded bush (50.87) matching the valve onto the valve spindle in accordancewith setting dimension (Y) and lock with hexagon nut.

- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.

- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.

Fig. C: - Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly.

- Screw distance column with 2-ear clamps on opposite side of handwheel into the flangein such a way that one of the 2-ear clamps is situated above the torsion safety feature(50.32) and the other below.

- Screw the other distance column into the flange likewise.

- Place thrust actuator (50) with distance columns onto valve and fix into position withtwo self-locking hexagon nuts (50.25).

Fig. D/E: - Fold out turning handle of handwheel (50.12.1), slightly turn the handwheel and pressin the engaging button for manual mode (only 12 - 15 kN) (button engages). Havingdone this, move out the thrust actuator until driving spindle (50.30) comes into contactwith threaded bush (50.87).



turn

00400001072402 page 17


Fig. F: - Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure using grubscrew M6 (50.35).

- Move the valve to the lowest position.

- Press 2-ear clamps (50.26) into position according to the stroke so they cannot slip,with the bottom clamp in the lowest valve position located directly below torsion safetyfeature (50.32) and the top clamp in the highest valve position located directly abovethe torsion safety feature.

- Move the valve to both travel positions and check that it reaches them reliably.

- Fold turning handle of handwheel (50.12.1) back in.

- Make the electrical connection (see points 6.4.1 and 6.4.2). The engaging button formanual mode (only 12 - 15 kN) disengages when the motor starts up.

- Set standard travel switch S3 (see point 6.5.3.2).

00400001072402


6.4 Electrical connection6.4.1 Wiring diagram ARI-PREMIO 2,2 - 5 kN

Fig. 9

acce

ssoi

res

HZ

Hea

ting

resi

stor

DE

Torq

ue s

witc

h

WE

(S3)

Tra

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avel

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nce

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tion

RI

21E

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sitio

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11E

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sitio

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Low

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ero

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output 2

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alse

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pow

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ly

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open

open

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Opt

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00400001072402 page 19


6.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN6.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor

Fig. 10

Acc

esso

ries

HZ

Hea

ting

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stor

DE

Torq

ue s

witc

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WE

(S3)

Tra

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avel

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RI

21E

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output 1

output 2

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Opt

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Ext

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actu

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In a

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otor

.

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00400001072402


6.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor

Fig. 11

Acc

esso

ries

WS

+ P

R

3-st

ep in

put s

igna

l

Acc

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ries

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Con

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!

00400001072402 page 21


DANGER!!!The processes of mains connection and putting the thrust actuator into service call forspecialised knowledge of power installation erection (VDE 0100), knowledge of regulations forthe prevention of accidents and the specific conditions for putting this thrust actuator intoservice. Such work may only be carried out by suitably qualified personnel in accordance withsection 2.3 "Qualified Personnel". The supply line for connecting up the thrust actuator mustbe in the dead state i.e. disconnected from the mains while connection work is being carriedout. After being disconnected, the mains power must be prevented from being switched backon again accidentally.

Failure to observe these instructions may lead to death, grievous bodily injury or substantialproperty damage!

6.4.3 Connection

To connect the thrust actuator up to the electrical power supply, proceed as follows:

- Run the thrust actuator a few mm out of the lower final position applying the manual mode.

- Loosen countersunk screw in hood, carefully remove hood in upward direction.

- Screw out one of the two cable inlets and re-assemble in the same way without the supplied blankflange.

- Insert the connection line through this cable inlet until sufficient conductor length is available up tothe corresponding terminals; then tighten the cable inlet until the connecting cable is clamped inplace inside it.

- Strip connecting cable approx. 1-1.5cm above cable inlet.

- Strip the individual conductors approx. 5mm away from the end and fit with conductor end sleeves.

- Connect protective conductor of connecting cable up to protective conductor terminal of thrustactuator.

- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator terminalstrip.

- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator terminal strip.

- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal strip.

- Place hood on carefully from above and mount firmly onto thrust actuator with countersunk screwand rubber gasket.

- Connect supply line to mains and run thrust actuator to each of the final positions so as to checkwhether the final-position travel switches effect switching off, also checking to see whether thedirection of movement on the thrust actuator corresponds to the desired direction.

- If the directions of movement are contrary to those desired, the pulse lines governing the move-inand move-out connecting rod will need to be exchanged.

00400001072402


6.5 Settings

DANGER !!!The thrust actuator may only be operated for a short time without the hood for unavoidablesetting operations to the potentiometers, travel switches and the electrical options. While theseoperations are in progress, the thrust actuator has hazardous, live, uninsulated parts exposedas well as moving and rotating parts. Improper execution of the setting operations or lack ofcare may cause death, grievous bodily injury or substantial property damage. Only suitablyqualified personnel must be allowed to perform these operations (refer to section 2.3"Qualified Personnel") . Operation of the thrust actuator without the hood for any purposeother than that described above is strictly prohibited.

6.5.1 Torque and travel switches - standard feature

As standard, thrust actuators are equipped with a load-dependent travel switch for the closingdirection (S1), a load-dependent travel switch for the opening direction (S2) and a stroke-dependenttravel switch for the opening direction (S3).The load-dependent travel switches (S1, S2) switch off the motor as soon as the factory-set thrustforce is attained.NOTE: The settings of the load-dependent travel switches must on no account

whatsoever be changed!The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke isattained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent travel switchS3 is set in such a way that the motor of the thrust actuator is switched off as soon as the maximumvalve-lift is attained.If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel switch S3 isset in the opening direction in the trip slide to such a downward extent that the upper final position ofthe valve is attained prior to travel switch S3 being reached, thus causing the load-dependent travelswitch S2 to switch off the motor.For this function, all three switches reveal interlock-controlled circuitry on the board.If the standard travel switches are to be integrated directly into the facility control system, thestandard board can be replaced by optional boards PA or NA (only 2.2 - 5 kN).

6.5.2 Connection boards PA or NA (only 2.2 - 5 kN)

On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/S23 do notreveal interlock-controlled circuitry and can be integrated individually into the facility controlsystem.The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as double-throwcontacts, are - in the case of these boards - brought out on terminals 40-48 and can be freelyconnected.The switches on the PA optional board (standard-voltage connection board) are designed forswitching capacities of up to 10A, 250V AC.The switches on the NA optional board (low-voltage connection board) are designed for switchingcapacities of up to 0.1A, 4-30V (gold contacts).The optional boards may only be installed at the factory due to the switching points of the load-dependent switches having to be reset following installation of these boards!

00400001072402 page 23


CAUTION !When using optional boards PA or NA, it must be warranted - due to the operator’s individualcircuitry- that, when switching the load-dependent travel switches S11/21, S12/S22 and S13/S23 the motor of the thrust actuator comes to a standstill without delay.This function is not provided for on the optional boards PA and NA in the supplied state!

6.5.3 Travel switch

The thrust actuators can be equipped with an additional stroke-switch board containing two travelswitches (double-throw contact S4 and S5).These switches can be set on infinitely variable lines over the entire stroke distance in both liftdirections and integrated at will into the facility control system (no interlock-controlled circuitry).The maximum switching capacity of the switches (refer to section 4.3 Technical Data) must not beexceeded.For low voltage (refer to section 4.3 Technical Data), the additional travel switches are supplied withgold contacts (option: low-voltage travel switch).

6.5.3.1 Installation of additional travel switches

To install additional travel switches, proceed as follows.

- Switch off mains voltage and safeguard to prevent it from being switched back on againaccidentally.

- Loosen countersunk screw in hood, carefully remove hood.

- Disconnect motor plug and mains connection plug from board.

- Carefully ease open the lock washer (50.56) (open ends) with a screw driver while pulling the tripslide (50.50) upwards from the board support.

- Remove trip slide (50.50) from board support by pulling upwards.

- Loosen head cap screws (50.57) on board support and remove this from gearbox (only necessary on5kN thrust actuator).

- Insert stroke-switch board (50.61) in board support (50.42) and fix in place using the suppliedscrews (50.44).

- Mount board support loosely on gearbox cover plate with two head cap screws (50.57) (onlynecessary on 5kN).

- Push trip slide (50.50) back into board support (50.42) from above and onto the guide spindle(50.38).

- Align board support (50.42) on gearbox cover plate in such a way that the guide spindle (50.38) iscentrally situated in the borehole of the board support (50.42); then screw down tightly on gearboxcover plate

2-way control valves - insatech · 2.1 signiﬁcance of symbols warning of general danger 2.2...

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