TG 1 - Sistema de Limpeza Do Condensador - Manual de Instalação

Rev No Date Description Prepared Checked Approved
A 25-07-2022 FOR INFORMATION SANTHOSH.K SUDHARSAN.I RAVIKUMAR.N
Purchaser : SIEMENS ENERGY BRASIL LTDA
EQUIPMENT NAME : CONDENSER TUBE CLEANING SYSTEM
PROJECT: CERRADO (43150 &

43151)
GEA BGR ENERGY SYSTEM INDIA LIMITED
PREPARED CHECKED APPROVED DOCUMENT NO REV
KS IS NRK GI 5320 100 09 021 A

PROJECT REFERENCE DOCUMENT TITLE
Operation and Maintenance Manual -

GBX/5320/2022
Condenser Tube Cleaning System
OPERATION & MAINTENANCE MANUAL
FOR AUTOMATIC CONDENSER TUBE CLEANING SYSTEM
INDEX
PART 1
OPERATION & MAINTENANCE MANUAL FOR AUTOMATIC DES/OMM/TCS/DS

CONDENSER TUBE CLEANING SYSTEM
PART 2
CONTENTS OF PART 2
S. No. DESCRIPTION No of Sheets
1 MECHANICAL DATASHEET 8
2 DATASHEET FOR ACTUATOR 4
3 MOTOR DATASHEET 3
4 INSTRUMENT DATASHEET 4
5 STARTUP & COMMISSIONING SPARE PARTS LIST 2
6 LUBRICANT LIST 1
7 CONTROL PHILOSOPHY 15
8 P&I DIAGRAM (incl. Legend) 2
9 GENERAL ARRANGEMENT OF BALL STRAINER 1
10 GENERAL ARRANGEMENT OF BALL RECIRCULATING SKID
1
AND FOUNDATION DETAILS
11 GENERAL ARRANGEMENT OF BALL DISTRIBUTOR & BALL
6
INJECTION PIPE
12 HOOK UP DIAGRAM 1
PART 3
CONTENTS OF PART 3
1 WORM GEAR FOR BALL STRAINER 49
2 ACTUATOR FOR BALL STRAINER 62
3 ACTUATOR FOR BALL VALVE 66
4 MECHANICAL SEAL FOR PUMP 13
5 MOTOR FOR BALL RECIRCULATING PUMP 13
6 D.P. TRANSMITTER 20
7 CLEANING BALLS 6
8 BALL RECIRCULATING MONITOR 18
GI 5320 100 09 021

CONDENSER PERFORMANCE ENHANCING UNIT

PURPOSE OF THE MANUAL
This Manufacturer’s manual provides information regarding the Operation

& Maintenance of Automatic Condenser Tube Cleaning System
Failure to observe the information provided herein may result in

malfunction/damage of the unit
Contents of the manual are subject to change without notice
Wherever the term “Condenser” used in the manual is applicable to Heat

Exchanger also
This Technical Document is the property of GEA BGR and protected in

accordance with the prevailing law. Any unauthorized transfer or copying
of this document, in part or in whole, is prohibited
CONTENTS
PART 1
SECTION 1 INTRODUCTION .............................................................................................................. 4

1.1 CONDENSER TUBE CLEANING SYSTEM ............................................................................................ 4
1.1.1 DESCRIPTION ............................................................................................................................................................. 4
1.1.2 SERVICE ........................................................................................................................................................................ 5
SECTION 2 DESCRIPTION OF COMPONENTS ............................................................................. 6

2.1 BALL SEPARATOR (BALL STRAINER) .................................................................................................. 6
2.1.1 OPERATION POSITION............................................................................................................................................. 6
2.1.2 BACKWASH POSITION ............................................................................................................................................. 6
2.2 D.P. MEASURING SYSTEM ....................................................................................................................... 7
2.3 BALL RECIRCULATING SKID ................................................................................................................. 7
2.4 V-PIECE (BALL DISTRIBUTOR) ............................................................................................................... 7
2.5 MANUALLY OPERATED VALVES .......................................................................................................... 8
2.6 ACTUATOR OPERATED VALVES ......................................................................................................... 8
2.7 BALL TRANSPORT PIPING ...................................................................................................................... 8
2.8 CLEANING BALLS ....................................................................................................................................... 8
2.9 BALL GAUGE / BALL GAUGE TROLLEY .............................................................................................. 8
2.10 INJECTION PIPE ........................................................................................................................................... 9
2.11 OTHER OPTIONAL COMPONENTS ...................................................................................................... 9
2.11.1 BALL MONITORING SYSTEM (BALL OVERSIZE MONITOR) ...................................................................... 9
2.11.2 BALL RECIRCULATING MONITOR .................................................................................................................. 9
2.11.3 BROM (COMBINED BALL RECIRCULATING + OVERSIZE MONITOR) .................................................... 9
2.11.4 DP BALL SORTER .................................................................................................................................................. 9
2.11.5 CONTROL PANEL ................................................................................................................................................. 9
2.11.6 STARTER PANEL ................................................................................................................................................. 10
SECTION 3 PRECONDITION ............................................................................................................. 11

3.1 GENERAL INSTRUCTIONS .................................................................................................................... 11
3.2 PRESERVATION / STORAGE ................................................................................................................. 11
3.2.1 EQUIPMENT & ACCESSORIES .............................................................................................................................. 11
3.2.2 ELECTRICAL & ELECTRONIC ITEMS .................................................................................................................. 11
3.3 INSTRUCTIONS DURING SHUTDOWN DURING CW SYSTEM MAINTENANCE................ 11
3.4 SAFETY INSTRUCTIONS......................................................................................................................... 12
3.4.1 GENERAL ................................................................................................................................................................... 12
3.4.2 ELECTRICAL .............................................................................................................................................................. 13
3.4.3 PRESSURE ................................................................................................................................................................... 13
3.4.4 TEMPERATURE ......................................................................................................................................................... 13
DES/OMM/TCS/DS Sheet 1
SECTION 4 REQUIRED TOOLS & TACKLES ................................................................................ 14

SECTION 5 INSTALLATION INSTRUCTION ............................................................................... 15
5.1 PREPARATION FOR INSTALLATION ................................................................................................. 15
5.2 GENERAL INSTALLATION PROCEDURE .......................................................................................... 15
5.3 BALL SEPARATOR .................................................................................................................................... 15
5.4 COVERAGE OF DEAD SPOTS IN THE CONDENSER AND TAP-OFF PIPELINE ..................... 16
5.5 PUMP ARRANGEMENTS ........................................................................................................................ 16
5.5.1 GROUTING THE BASE PLATE ............................................................................................................................... 16
5.5.2 PRIOR TO INSTALLATION OF COUPLING ........................................................................................................ 16
5.5.3 MOUNTING PROCEDURE FOR COUPLING ...................................................................................................... 17
5.5.4 ALIGNMENT OF SPACER COUPLING ................................................................................................................ 17
5.5.5 ASSEMBLY PROCEDURE FOR COUPLING ......................................................................................................... 17
5.6 BALL RECIRCULATING PUMP AND MOTOR .................................................................................. 18
5.7 COUPLINGS - FIG.1 & 2 ............................................................................................................................ 18
5.8 COUPLINGS - FIG.3 & 4 ............................................................................................................................ 19
5.9 BALL COLLECTOR .................................................................................................................................... 20
5.10 V-PIECE ......................................................................................................................................................... 20
5.11 INJECTION PIPE ......................................................................................................................................... 21
5.12 ISOLATION VALVES ................................................................................................................................ 21
5.13 BALL CIRCULATION PIPES.................................................................................................................... 22
5.14 DIFFERENTIAL PRESSURE MEASURING SYSTEM ........................................................................ 22
5.15 CONTROL PANEL / STARTER PANEL ................................................................................................. 22
SECTION 6 SUPERVISION AND FINAL INSTALLATION ........................................................ 23
6.1 BALL SEPARATOR .................................................................................................................................... 23
6.2 BALL TRANSPORT, BALL INJECTION & BALL EXTRACTION PIPES ....................................... 23
6.3 MANUAL VALVES .................................................................................................................................... 23
6.4 ACTUATOR OPERATED VALVES ........................................................................................................ 24
6.5 BALL RECIRCULATING SKID ............................................................................................................... 24
6.5.1 PUMP & MOTOR ....................................................................................................................................................... 24
6.5.2 BALL MONITORING SYSTEM / BALL RECIRCULATING MONITOR ......................................................... 25
6.6 V-PIECE ......................................................................................................................................................... 25
6.7 INJECTION PIPE ......................................................................................................................................... 25
6.8 CONTROL PANEL / STARTER PANEL ................................................................................................. 26
6.9 D.P. TRANSMITTER .................................................................................................................................. 26
SECTION 7 COMMISSIONING ......................................................................................................... 27
7.1 FILLING THE SYSTEM WITH WATER (MANUALLY) ..................................................................... 27
7.2 CHECKING AND SETTING OF D.P. MEASURING SYSTEM ........................................................ 28
7.3 CHARGING OF CLEANING BALLS ...................................................................................................... 29
SECTION 8 SERVICE & MAINTENANCE ....................................................................................... 30

8.1 BALL SEPARATOR .................................................................................................................................... 30
8.2 BALL COLLECTOR .................................................................................................................................... 30
8.3 BALL RECIRCULATING PUMP AND MOTOR .................................................................................. 30
8.4 DIFFERENTIAL PRESSURE MEASURING SYSTEM ........................................................................ 30
8.5 ACTUATOR FOR SCREEN AND BALL VALVES ............................................................................... 31
8.6 VALVES ........................................................................................................................................................ 31
8.7 CONTROL PANEL / STARTER PANEL ................................................................................................ 31
8.8 WORM GEAR .............................................................................................................................................. 32
SECTION 9 TROUBLESHOOTING ................................................................................................... 33
9.1 BALL SEPARATOR .................................................................................................................................... 33
9.2 BALL RECIRCULATING PUMP.............................................................................................................. 35
9.3 MOTOR FOR BALL RECIRCULATING PUMP ................................................................................... 37
SECTION 1 INTRODUCTION
1.1 CONDENSER TUBE CLEANING SYSTEM
1.1.1 DESCRIPTION
Condensers/Heat Exchanges play a key role in Power, Desalination & Process Industries. A lower
back pressure of the turbine results in a higher generation of power and this largely depends on the
performance of the Condenser.
It is essential to maintain the heat transfer rate and co-efficient close to the design parameters for
improved steam condensation. Hence the cleanliness of the condenser tubes should be kept as close
as possible to the design values in order to increase the condenser efficiency which will result in an
optimum Power Generation. Similarly, highly efficient heat transfer rate of the heat exchangers can
lower energy cost of the Processing Industries.
Tube Cleaning System of the Condensers/Heat Exchangers by using Sponge Rubber Balls has been
in use all over the world, for more than a four decades now. This system is found to be an effective
solution for maintaining the cleanliness factor at the optimum level.
Sponge rubber balls with a special composition and size 1 to 3mm greater than the inner diameter
of the Condenser Tubes are injected into the Cooling Water stream at the inlet. These balls with
specific gravity close to the cooling water are carried into the Condenser by the velocity of the inlet
water. Cleaning balls are then pushed through the tubes by the differential pressure existing across
the Condenser. While passing through the Condenser tubes, the balls are pressed against the walls
of the tubes removing all deposits on the inner surface of the tubes. A specially designed screen
arrangement called the Ball Separator, separates the balls from the main Cooling Water system and
the balls are collected in the Ball Collector. The balls are injected into the Cooling Water through the
Ball Recirculating Pump.
The main advantages of a Tube Cleaning System are :
 Maintain the Heat Transfer Rate

 Optimum Turbine Back Pressure
 Maintain Generation Efficiency
 Avoidance of corrosion in Tubes
 Avoidance of Shutdown for Manual Cleaning
 Reduction of Chemical costs for Water Treatment
 Reduction in Fuel costs
 Avoidance of Tube Failure
1.1.2 SERVICE
 Erection, Commissioning work, modifications to the system(s), instructions to the operating

personnel, Checking and Inspection are as per scope of the Agreement.
 Operation of the GEA-BGR TUBE CLEANING SYSTEM is in accordance with the operating
instructions.
 Maintenance and repair work as specified in the Operation Manual.
 Repairs, if any, should always be carried out in co-operation with our FIELD ENGINEERING
DEPARTMENT
 GEA-BGR responsibility ceases if breakdowns and damages are caused by failure to comply
with the OPERATING INSTRUCTIONS
OUR PRODUCT WARRANTY WILL BE NULL AND VOID IN CASE OF
 Incorrect Installation, disregard or incorrect application of instructions provided in this manual

 Incorrect or defective electrical/hydraulic Power Supply
 Modification & Tampering
 Work done by unqualified or unsuitable persons
 Operation of the System beyond the Operating Limits
 Not observing the routine Maintenance Schedule
 Not using original Spare Parts
 Not using the recommended Lubricants
 Using the System and its components in a way not intended for
 Failure to comply with the Operating Instructions
For advice please contact :

GEA-BGR ENERGY SYSTEM INDIA LIMITED
443, 1st FLOOR, GUNA BUILDINGS,
ANNA SALAI, TEYNAMPET
CHENNAI - 600 018. INDIA.
TEL - 00 91 - 44 - 2430 1000
FAX - 00 91 - 44 - 2434 3374
E-Mail - [email protected]
SECTION 2 DESCRIPTION OF COMPONENTS

The description of various components which form part of Tube Cleaning System is given below :
2.1 BALL SEPARATOR (BALL STRAINER)
Ball Separator (Ball Strainer) is specially designed to facilitate the smooth passage of the Cleaning
Balls to the extraction point. The unique design of the Ball Separator ensures that the Cleaning Balls
will have to move through only a small angle, since larger angles may result in the balls sticking to
the screen in case of adverse conditions.
Ball Separator is of shell type construction with flanged ends. The Ball Separator consists of two
screens, which are mounted on two independent shafts. These shafts are fitted one end with bearing
and another end with a separate drive that facilitates independent operation of screens and easier
maintenance.
Screen separate the Cleaning Balls from the Ball Separator and guide them to Ball Extraction Pipes.
The screen can be set in either OPERATION POSITION or in BACKWASH POSITION. Actuator
with Worm Gear arrangement enables the movement of screen to the required position.
2.1.1 OPERATION POSITION
In this position, Cleaning Balls are separated from the cooling water and are guided to the Ball
Extraction Nozzle.
2.1.2 BACKWASH POSITION
Screens in the Ball Separator are in an inverted position. In this position, balls are not in circulation
and the screens are thoroughly backwashed, when the Differential Pressure across the Ball Separator
exceeds a preset value due to the fouling of screen.
OPERATION POSITION BACKWASH POSITION
2.2 D.P. MEASURING SYSTEM
Differential Pressure across the Ball Separator Screens is constantly monitored by a Differential
Pressure Measuring System, wherein the measured value is sensed by a Differential Pressure
Transmitter. This is to monitor the Differential Pressure across the Ball Separator Screen. When the
Differential Pressure exceeds the value, the screen automatically will move to Backwash Position.
The above system consists of
- D.P. Transmitter senses the Differential Pressure and transforms this into an electrical output.
- Isolation Valves isolate the D.P. Transmitter from the Cooling Water in case of Service
requirements.
2.3 BALL RECIRCULATING SKID
The Ball Recirculating Skid transport the Cleaning Balls to the Ball Injection Point at the Main
Cooling Water Pipe Line.
The Ball Recirculating Skid consists of
- Ball Recirculating Pump is a non-clog centrifugal pump with specially designed impeller,
capable of handling Cleaning Balls under suitable pressure for injection and collection of sponge
rubber balls in the inlet and outlet of the condenser respectively.
- Motor for the Ball Recirculating Pump is a totally enclosed fan Cooled squirrel cage induction
motor.
- Pressure Gauge measures the discharge pressure of the Ball Re-circulating Pump.
- Ball transport Piping is provided for the movement of the balls to the condenser.
- Ball Collector (Ball Vessel) is specially designed with no moving parts and hence it is
maintenance free. It is used for charging and collection of cleaning balls. The Ball Collector has
a perforated screen basket which traps the balls inside the Ball Collector during collection mode.
The Ball Collector acts as a reservoir for the sponge balls when the system is not in operation.
- Valves are given in the Ball Collector for charging, collecting and bypassing the water from the
Ball Collector.
- Valves are provided in the Ball Collector for venting and draining purpose whenever required.
2.4 V-PIECE (BALL DISTRIBUTOR)
V-Piece is provided in case of its requirement to branch off the Ball Transport Pipe into two separate
pipelines. Sight glass in the V-Piece to monitor the movement of Cleaning Balls.
2.5 MANUALLY OPERATED VALVES
Manually operated valves are provided in the Ball Extraction, Ball Injection and other isolation areas
for service requirements. These Valves are operated manually by a lever.
2.6 ACTUATOR OPERATED VALVES
Actuator operated valves are normally provided in the Ball Collector for Ball Collection and
Distribution purpose. They can be provided in other areas also depends upon the requirement.
2.7 BALL TRANSPORT PIPING
Ball Transport Pipes are installed between the Ball Separator Extraction Nozzle and the Injection
Nozzle. These pipes are used to transport the cleaning balls from the Ball Extraction Nozzle to
Injection Nozzle.
2.8 CLEANING BALLS
Cleaning Balls are used for preventing formation of deposits and scales inside the Condenser tubes.
The composition of balls is based on a natural rubber mixture containing fillers and chemicals.
To ensure uniform distribution of cleaning balls to all the Condenser tubes, the cleaning balls have
been designed to have a specific gravity close to that of the Cooling Water.
Ball life strongly depends on Water Quality, Cleaning frequency and surface condition of the
condenser tubes. Scaled and corroded surfaces are having a detrimental effect on ball life.
For every fresh charge of cleaning balls in the Ball Collector, squeezing in water is mandatory to
release the air to avoid floating of balls on top of the condenser and uniform ball circulation.
Used but effective balls should always be kept in the water.
2.9 BALL GAUGE / BALL GAUGE TROLLEY
Ball Gauge is made of polymer bin, fitted with Stainless Steel Gauge Plate. The Gauge Plate has
Sieves for separating the oversize balls. The sieve size is equal to the internal diameter of the tube
size.
The balls collected from the Ball collector, after the water is completely squeezed out, are to be spread
over the sieve plate. The undersize balls are passed through the sieve and collected in the Bin. The
oversize balls will stay over the sieve plate.
The operator has to collect the oversize balls and to add new balls to compensate the worn-out balls.
The same shall be charged in the Ball Collector for circulation.
Ball Gauge mounted on castor wheels for mobility is termed as Ball Gauge Trolley.
2.10 INJECTION PIPE
Injection Pipe facilitates transportation and even distribution of the balls in the branches. The balls
are injected towards counter-flow direction for homogeneous mixing and distribution over the tube
sheets.
The Injection Pipes are installed at the Cooling Water inlet pipe. Cleaning Balls are injected through
these pipes into the system. For a good ball distribution, the end of the injection pipe is directed
against the Flow.
2.11 OTHER OPTIONAL COMPONENTS
In addition to the above, following components are provided optionally to the equipment. They are:
2.11.1 BALL MONITORING SYSTEM (BALL OVERSIZE MONITOR)
The Ball Monitoring System (W01) continuously monitors the size & quantity and displays the status
of percentage of effective cleaning balls and the total number of balls in circulation.
2.11.2 BALL RECIRCULATING MONITOR
Ball Recirculating Monitor monitors the sufficient number of cleaning balls in circulation in the
condenser. BRM initiates an alarm when the number of circulating balls falls below the set value
while the preset measuring time elapses.
2.11.3 BROM (COMBINED BALL RECIRCULATING + OVERSIZE MONITOR)
BROM is the common panel where Ball Recirculating Monitor (BRM) and Ball Oversize Monitor
(Ball Monitoring System (BMS)) can be operated or monitored the status individually or
simultaneously.
2.11.4 DP BALL SORTER
DP Ball Sorter is for sorting out the undersize balls. Ball Sorter Valve and Draining Valve are
provided for collect the undersize balls and draining the water respectively.
2.11.5 CONTROL PANEL
Control Panel is provided to perform functional operations (ON/OFF; OPEN/CLOSE for the system
Field drives) of the Field equipments. This panel is having Electrical starters (Motor Protection
Circuit Breaker, Power Contactor etc.), PLC units, HMI, Control circuits for the system Field
equipments. Automatic operation for the system is performed and monitored in this panel through
Panel HMI. All the Functional requirements/Process conditions/Process monitoring/Alarms are
performed in this CONTROL PANEL. DCS interface signals shall be transmitted through this
control panel.
2.11.6 STARTER PANEL
Starter Panel (is provided to perform functional operations (ON/OFF for Ball Recirculating Pump
Motor) of Motors. This panel is having Electrical starters (Motor Protection Circuit Breaker, Power
Contactor, etc.) for the system Field equipments. Automatic operation for the system shall be
performed and monitored from plant DCS. DCS interface signals shall be transmitted from Field
through this Starter Panel.
SECTION 3 PRECONDITION
3.1 GENERAL INSTRUCTIONS
PRE-SCREENING
The prescreening must be good. There must be no coarse debris such as mussels, fish, wood,
twigs, stones, leaves, grass, deposits, etc. which can enter the condenser. Should the
prescreening be inadequate deposits can form on the tube sheet and partial blockage of the
tubes can occur thereby blocking the movement of cleaning balls. Moreover, the efficiency of
the condenser is lowered by
- a loss in heat transfer because of the lack of adequate cleaning by the balls.
- partial blockage of the tubes by coarse debris.
3.2 PRESERVATION / STORAGE
3.2.1 EQUIPMENT & ACCESSORIES
Equipments, pipes and rods are to be kept on wood plank without touching the mud.
All machined surfaces shall be preserved by rust preventive coating and covered by
Polythene Sheet. Machined surfaces shall not be kept in such a way that damages can occur.
Equipment should be kept away from the flammable items.
Cover the finished goods with Tarpaulin/Polythene sheet to keep away from dust and rain.
Then they should be packed in wooden box and stored in a group with tag nos. for easy
identification. Cannibalization should be avoided.
3.2.2 ELECTRICAL & ELECTRONIC ITEMS
All Motors and actuators shall be away from areas where water or water droplet are likely
to fall.
Electrical and Electronic goods are to be covered with 3 types of packing like thermo coal,
air bubbled sheet and polythene sheet, as applicable.
3.2.3 INSTRUCTIONS DURING SHUTDOWN DURING CW SYSTEM MAINTENANCE
A) BALL SEPARATOR
Drain out the Circulating Water outlet line up to the bottom level of Ball Separator.
Flush the Ball Separator Screen with Service water.
Ensure that the Ball Separator Screen is clean and dry.
B) BALL RECIRCULATING SKID
Drain out all the pipelines of Ball Recirculating Skid
Keep the Pump to dry
Drain the Ball Collector fully.
Flush the Ball Collector with Service water.
Ensure that the Ball Collector is clean and dry.
3.3 SAFETY INSTRUCTIONS
3.4.1 GENERAL
Purpose
To meet the accident free and also to achieve all the erection activities as per the guidance of
safety instructions.
Scope
This is applicable to staff, skilled and unskilled manpower deputed during execution of
erection & commissioning of Automatic Condenser Tube Cleaning System.
Responsibilities
It is every one responsibility to follow the safety instructions during erection work in order
to meet the accident free day.
Procedure
Obtain the line clearance (Permit) from the engineer incharge before starting up the erection
activities in case of retrofit.
During erection of heavy activities, isolate the area of erection before starting up the work.
Use the proper scaffolding and ladder whenever required to work in elevated locations.
Use the safety belts to the manpower deputed to carry out the work in elevated locations.
Follow the use if helmets, safety shoes in day-to-day activities inside the plant premises.
Ensure that all the flammables and wastages are kept away from the working area.
Ensure that the welders use appropriate shielding glass during welding activity.
Ensure that the grinders use the goggles and apron during the grinding works.
Ensure that the masks are worn during painting activity.
Ensure that the load is lifted within the safe working load of the crane, rope, chain, D-shackle
etc.
Lifting angle of the rope or chain shall be within the safety limit.
3.3.2 ELECTRICAL
Check all the wire connections to prevent from looseness
Always use proper Lockout/Tag out procedures while de-energizing electrical components
as per site procedures.
Power take up points of cables provided with proper socket pin arrangement.
Do not use appliance with defective parts
Always switch off the power supply after using electrical equipment.
Inspect for abnormal smell in the electrical items. And find the Root cause for the same.
Turn off and unplug any electrical device before attempting to service or repair it.
Do not overload electrical circuits.
3.3.3 PRESSURE
Our equipment is designed to the Design Pressure and hydrostatic test pressure as specified
in GA Drawing. Hence, the equipment is safe for the given operating pressure condition.
3.3.4 TEMPERATURE
Our equipment can be safely operated up to the maximum temperature as specified in GA

Drawing..
SECTION 4 REQUIRED TOOLS & TACKLES

Our Standard Tools & Tackles are sufficient for installation, operation and maintenance of the
equipment.
SECTION 5 INSTALLATION INSTRUCTION
5.1 PREPARATION FOR INSTALLATION
All the components have to be checked for physical verification with the packing list of the
consignments to make sure that the required items are totally available to take up the
Installation. This can also be crosschecked with the P&I Diagram.
Safety instructions as stipulated have to be followed strictly.
5.2 GENERAL INSTALLATION PROCEDURE
P&I Diagram for the entire system has to be studied thoroughly and the respective
components for installation are to be kept separately. Necessary tools & tackles have to be
made ready and the safety instructions have to be followed strictly. The major components
such as Ball Separator, Ball Recirculating Unit and DP Measuring System can be erected in
the sequence based on the site progress and the site front availability.
If any actuators used should only be attached after the general assembly shortly before
Commissioning, adjustment of the limit switch depends on momentum and path is to be
carried out according to the separate operating instructions for actuators.
5.3 BALL SEPARATOR
Installation is according to Plant layout / Installation Plan / P&I Diagram & GA Drawings.
Please observe the direction of flow.
PROCEDURE
1) Check matching flange fit up and welding of flange to the Cooling Water outlet pipe.
Welding is to be done by a qualified welder. Proper welding procedure should be
followed and the suitable welding rods should be used
2) Check the final dimension and install the Ball Separator as per Installation Plan.
3) Insert Gasket between both flanges and tighten the fasteners by applying uniform
torque.
4) Check the pipeline for any leakage. To avoid leakage in the pipeline the fasteners
should be tightened with uniform torque.
Note
After installation of the Ball Separator in the pipeline, at initial start up of the system the
screens shall be turned to the backwash position. In case the continuous operation of the
Condenser Tube Cleaning System is not maintained (e.g. incomplete control system) screens
shall be in operating position. Depending on debris load in the water frequent backwashing
of the Ball Separator screens has to be ensured to avoid damage to the screens.
5.4 COVERAGE OF DEAD SPOTS IN THE CONDENSER AND TAP-OFF PIPELINE
Dead Spots (Dead Zones) are areas that lie outside the free flowing water segment where the
water either stagnates or eddies. There is a danger that balls will get trapped in these areas
(in extreme cases, several thousand balls can also be lodged) and will no longer be available
for cleaning the tubes. Dead Spots therefore have to be screened off with perforated metal
sheets for equalizing the pressure differences. Holes in the metal sheet / or gap between the
sheet and the wall should not be larger than 6mm. Similarly, Vent, Drain, Tap-off pipelines
to Plate Heat Exchangers within the ball recirculating loop should also be screened. These
screening portions should have more free flow area considering the pipe cross section.
5.5 PUMP ARRANGEMENTS
The complete arrangement should be so installed that the foundations are capable of
absorbing all external forces and moments.
The bed plate, with the equipment mounted on it, should be carefully adjusted with a spirit
level. Metallic packing should be placed close to the bosses of the anchor bolts. To prevent
sagging of the base plate, metallic packing should be placed midway between the bosses
where necessary.
5.5.1 GROUTING THE BASE PLATE
The anchor bolts should be embedded in quick-setting cement. Following this treatment the
bolts should be tightened uniformly. The base plate can then be grouted.
5.5.2 PRIOR TO INSTALLATION OF COUPLING
 After removing the coupling from packing, thoroughly inspect to ensure that they is/are
as ordered & there no is transit damage or loss.
 Remove protective coating/lubricant from bores & keyways. Remove all the bolts & nuts
and dismantle the assembly.
5.5.3 MOUNTING PROCEDURE FOR COUPLING
Mount hubs/adapter on their respective shafts with keys such that the shaft ends are flush
with inner face of the adapter & tighten the set screw over the keys.
For spacer type of couplings, the spacer length is normally equal to the distance between
shaft ends (DBSE) of the equipment’s. Refer the following figure.
For normal applications the shaft ends should be flush with inner face of hub/adapter. They
can protrude beyond the inner face of hub or remain inside if required. But sufficient gap
should be allowed to take care of end float of both shafts. Ensure that the effective length of
key is sufficient to transmit the rated torque of the coupling.
For RRS coupling, mount the outer ring on one of the adapters and slide it towards the
nearest equipment.
DBSE is 100mm (inclusive of G Gap 94mm + 3mm (Drive Side) + 3mm (Driven Side) (G) Gap
= 100mm. Refer Installation manual attached herewith for more details.
5.5.4 ALIGNMENT OF SPACER COUPLING

(to be carried out after the bed plate has been cast and the pipework has been connected)
An alignment of the couplings is absolutely necessary in order to ensure that the pump is
mechanically free to rotate and additionally to avoid damage to the coupling. First, care
should be taken to maintain the prescribed separation (Fig. 1) between the two halves of the
coupling. Furthermore, the center axis of the shaft should join up smoothly with the coupling
(no kinks). Possible non-alignments either side-ways and / or vertical (Fig. 3) or at an angle
(Fig. 4) should be eliminated.
Alignment can be controlled using either a straight edge, or feeler gauge or calipers (Fig. 1 &
2). A coupling is judged to be aligned when a straight edge placed across both halves of the
coupling and parallel to the shaft, should have the same distance from the shaft over the
whole coupling.
5.5.5 ASSEMBLY PROCEDURE FOR COUPLING
After ensuring that the equipment’s are aligned properly, insert the spacer between RRS
hubs mounted earlier as explained in mounting procedure.
5.6 BALL RECIRCULATING PUMP AND MOTOR
Installation shall be done according to Plant layout / Installation Plan / P&I Diagram & GA
Drawings.
PROCEDURE
1) As per dimensions prepare foundation and install Ball Recirculating Skid.

2) Level the base frame and grout the foundation bolts using a spirit level.
3) Connecting pipes should not be under stress.
4) Adjust the couplings as per figures 1 - 4.
5) Install pump in such a way that a maximum NPSH (Net Positive Suction Head) is
assured.
6) Keep suction side pipe lengths as short as possible.
5.7 COUPLINGS - FIG.1 & 2
CHECKING PARALLEL ALIGNMENT
PARALLEL
MIS-ALIGNMENT
FIG. 1
Using Straight Edge: Align straight edge on OD of one half measure gap at 4 places 90° apart
without rotating shafts. Allowable initial parallel misalignment of the gap is 0.1mm. The maximum
permissible parallel misalignment is 0.4mm
CHECKING ANGULAR ALIGNMENT
ANGULAR
MIS-ALIGNMENT
FIG. 2
Using Feeler Gauge : Measure the gap using feeler gauge at 4 places 90° apart without rotating
shafts. The difference in maximum & minimum gap will be the Total Indicated Reading (TIR), which
will be the angular misalignment present. The permissible TIR of the coupling is 0.740mm, i.e., the
angular misalignment of 0.5º. The maximum permissible TIR is 1.4mm (1º angular misalignment).
5.8 COUPLINGS - FIG.3 & 4
CHECKING PARALLEL ALIGNMENT
MAGNETIC V BLOCK
FIG. 3
Using Dial Gauge : Fix the dial gauge on the hub of one of the half & set plunger on the OD of
another half. Rotate the coupling slowly to one complete revolution by taking dial gauge reading at
4 places 90° apart. The permissible parallel misalignment is half of the Total Indicated Reading (TIR)
of dial gauge, i.e., 0.1mm. The maximum permissible parallel misalignment is 0.4mm
CHECKING ANGULAR ALIGNMENT
MAGNETIC V BLOCK
FIG. 4
Using Dial Gauge : Fix the dial gauge on hub OD of one of the halves & set plunger on the
face of the another half. Rotate the coupling slowly to one complete revolution by taking dial
readings at 4 intervals 90° apart. The Total Indicated Readings (TIR) will be the angular
misalignment. The permissible TIR of the coupling is 0.740mm, i.e., the angular
misalignment of 0.5º. The maximum permissible TIR is 1.4mm (1º angular misalignment).
5.9 BALL COLLECTOR
Drawings.
PROCEDURE
1) Ball Collector is horizontally mounted on the base frame of the Ball Recirculating Skid.
2) Check the Ball Collector alignment with spirit level and Tighten Base Bolts
3) All the interconnecting valves are mounted on Ball Collectors in line with drawing
orientation.
4) Check for any leakage, and if required tighten the fasteners at the inter-connecting
flanges with uniform torque.
5.10 V-PIECE
Installation is according to Plant layout / Installation Plan / P&I Diagram & GA Drawings.
Installation of Ball Distributor should be done in an easily accessible place where it can be
freely observed.
Pipes branching out or coming together at Ball Distributor should be of equal length and
should join symmetrically and without stresses.
PROCEDURE
1) Measure the dimensions from the center line of the sight glass to the ball transport pipes.
2) Install the Ball Distributor in between the branching pipe lines so that the connecting
flanges are perfectly matching with the center.
3) Check the overall dimensions with respect to Ball Distributor centerline.
4) Provide Gaskets on all the three connecting flanges and tighten the fasteners uniformly.
5) Check for any leakage and if required tighten the fasteners with uniform torque.
5.11 INJECTION PIPE
Drawings.
Point of installation should be as far from the water box as possible.
Install such that the inlet bend (ball injection) faces against the cooling water flow.
PROCEDURE
1) As per installation plan mark and cut Nozzle opening in cooling water inlet pipe.
2) Fit-up and weld the injection nozzles.
3) Insert the Ball Injection Pipes into the flange nozzle along with gasket.
4) Fasten the flange and tighten uniformly.
5) Check for any leakage, if required tighten with uniform torque.
6) Care should be taken while positioning the injection nozzle in counter flow direction
5.12 ISOLATION VALVES
Drawings.
Locate in dry area protected from dripping water.
Locate wherever possible, close to the system.
PROCEDURE
1) Counter flanges must be parallel and concentric.

2) Clean the sealing surface of valves and counter flanges.
3) Check valve for easy running and install with flange gasket into pipeline.
4) Insert flanges, fasteners and tighten uniformly with equal torque.
5.13 BALL CIRCULATION PIPES
Drawings.
Bowed, symphonic and long piping arrangements should be avoided.
PROCEDURE
When the pipes are fabricated at site, the following points are to be ensured :
1) Ball circulation pipe lengths to be marked and cut as per Installation plan.
2) Pipe edges to be ground suitably to suit matching pipe joint and weld.
3) Connecting pipe should not be under stress
4) Make sure that there are sufficient pipe supports provided.
5) Ensure for no sharp edges and burr in the pipe to avoid severing of balls
After completion of the assembly, all isolation valves should be closed.
Leaks are possible during start-up.
Check for any leakage, if required tighten with uniform torque.
5.14 DIFFERENTIAL PRESSURE MEASURING SYSTEM
Assembly and arrangement are as per General Arrangement Drawing and the Operation
Manual of the DP Transmitter.
Arrangement of measuring unit is recommended in an easily accessible place.

Pipework to DP Transmitter should slope upwards.
Ensure positive and negative terminal before connection.
Note : Once the system has been assembled, the Isolation Valves should be closed.
5.15 CONTROL PANEL / STARTER PANEL
GENERAL
Arrangement as per Panel Wiring Diagram document.
Panel should be installed in such way that direct sunlight and water drippings to be avoided.
SECTION 6 SUPERVISION AND FINAL INSTALLATION
6.1 BALL SEPARATOR
TEST DESCRIPTION REQUIREMENT ACTIVITY RESULT

1 Arrangement Must be according to G.A. of Ball Check
Separator
2 Name Plate Must be complete Check
3 Operation of the screens Must function without using too Check
with manual operation much force
4 End Positions
- Operating Position Screen must fit perfectly in Check
Operation Position
- Backwash Position Must be turned to an angle set for Check

backwash position to the flow
direction of the cooling water
5 Wiring As per the Wiring Diagram of the Check
Actuator
6 Current Setting Must be adjusted to the rated Check
current according to nameplate
of the actuator
6.2 BALL TRANSPORT, BALL INJECTION & BALL EXTRACTION PIPES

1 Arrangement Installation plan shall be done Check
according to Installation plan /
Plant layout / General
Arrangement / P&I Diagram.
2 Suction Pipes Must slope down to the pump Check
6.3 MANUAL VALVES

2 Functioning Must function without an Check
excessive movement
6.4 ACTUATOR OPERATED VALVES

1 Arrangement Must be carried out according to Check
BR Skid Drawing
2 Functioning Must function within the torque Check
range of the valve
3 Wiring As per the Wiring Diagram of the Check
Actuator
4 Current Setting Must be adjusted to the rated Check
current according to name plate
of the actuator
5 OPEN, and CLOSE Blinking of indicating lamps at Visual
position (INTERMEDIATE the appropriate position Check
position if 3-Way Valve is
provided)
6.5 BALL RECIRCULATING SKID

2 Grouting of Skid Installation plan shall be done Check
according to plant layout or
General Arrangement.
6.5.1 PUMP & MOTOR

1 Arrangement Must be carried out according Check
to Ball Recirculating Skid
Drawing.
2 Coupling – Alignment Pump motor assembly should Check using a

be free to rotate feeler gauge
and hair ruler
3 Motor Motor must be connected Check
- Wiring according to the circuit
diagram
3.1 - Motor Overload Relay Must be adjusted to the rated Check -
current according to the adjustment
identification plate
3.2 Motor Overload Relay Motor stationary. Try to start Check

tripped motor (should not operate)
fault display (should show up).
3.3 Motor Overload relay (not Start motor (should operate) Check
tripped) fault display (no signal).
3.4 Direction of rotation Must be correct Check by

starting and
stopping
3.5 Indicating Lamp When the pump is in operation Check
the corresponding lamp ON
must light up
When the pump is not in Check

operation the corresponding
lamp OFF must light up
6.5.2 BALL MONITORING SYSTEM / BALL RECIRCULATING MONITOR
1 Arrangement As per flow diagram Check

2 Wiring As per flow diagram Check
6.6 V-PIECE

1 Arrangement Installation shall be done according to Check
Installation Plan / Plant Layout /
General Arrangement Drawings /
P&I Diagram.
6.7 INJECTION PIPE
1 Arrangement Installation shall be done according Check

to Plant layout / Installation Plan /
Plant layout / P&I Diagram & GA
Diagram.

1 Wiring Connection Must be according to Panel Wiring Check
Diagram Document
2 Wiring (Supply lines from Must be done according to the Check
field to panel and from Cable Schedule Document
panel to field)
3 Incoming Supply Switch Switch on Check
4 Overload Relays MPCB setting range to be ensured Check
as per Starter Panel Wiring
Diagram
6.9 D.P. TRANSMITTER

1 Installation
Perpendicular to the instrument
Avoid Zero shift

Lowest level possible in respect to
the Tube Cleaning System Check
2 Wiring Terminal & Loops for proper
wiring
3 Voltage & Polarity 24V at the Terminals of the
Transmitter & Indicator (loop-
wired)
SECTION 7 COMMISSIONING
7.1 FILLING THE SYSTEM WITH WATER (MANUALLY)
PRE REQUIREMENT
- Min./max. quantity of Cooling Water does not fall below or exceed that given in the specification
- Main CW system is to be filled by opening CW inlet/outlet Valve and vented after receiving line
clearance from the control room of the end user
- All the valves for Tube Cleaning System are closed
- the screen positions have been checked and the screens are in operation position
Refer P&I Diagram for KKS Nos.

DESCRIPTION ACTIVITY EFFECT
BALL COLLECTOR Close properly Ball Collector is correctly
Handhole Arrangement closed
Isolation Valves Open Filling the pipes, pump with
water
BALL SEPARATOR
Pressure Gauge Valves Open Pressure Gauge valves are

opened
BALL COLLECTOR
Vent Valve Open Vent Valve is opened
By-Pass Valve Open Crack Water level in the Ball
Collector raises. Water flows
out of the Vent Valve
Vent Valve Close Vent Valve is closed
By-Pass Valve Open Fully Bypass Valve is opened

completely
Drain Valve Open & Close Drain Valve is opened and

water flows out through the
Drain Valve and closed
Bypass Valve should be in OPEN position
DP Measuring System
DP Transmitter Isolation Valves Open DP Transmitter Isolation

valves are opened and the
water is getting filled in DP
Remote Seal line
NOW THE SYSTEM IS FILLED WITH WATER
7.2 CHECKING AND SETTING OF D.P. MEASURING SYSTEM
PRE REQUIREMENT
Tube Cleaning System is filled with water as mentioned in 6.1
Differential Pressure across the Ball Separator screens is measured and displayed by D.P. Measuring
System. When the screens are moved to Backwash Position, the DP display should show 0 mbar.
Turbulences caused by the operation can lead to different values. In this case resetting to relative
0 mbar is to be undertaken by our Service Department.
Ball Collector Inlet Valve Open Ball Collector Inlet Valve is opened
Ball Recirculating Pump ON Pump Starts
Ball Collector Outlet Valve Open Ball Collector Outlet valve is opened and
the system is in operation
Ball Separator Screen Turn the screens to Screens are turned to backwash position
backwash position
DP Measuring System
DP Transmitter DP Value is to be reset Must read 0 mbar in clean condition at
to 0 normal flow
Ball Separator Screen Turn the screens to Screens are turned to operation position
operation position
DP Measuring System
DP Transmitter Observe Must read the designed value in clean
condition at normal flow
Ball Collector Outlet Valve Close Ball Collector Outlet Valve is closed
Ball Recirculating Pump OFF Pump is Stopped
Ball Collector Inlet Valve Close Ball Collector Inlet Valve is Closed
After checking the D.P. Measuring System, Charging of Cleaning Balls is to be followed.
Note : Cleaning Balls should be squeezed well in the water before charging
7.3 CHARGING OF CLEANING BALLS

Bypass Valve Close Bypass Valve is Closed
Vent Valve is opened and air is vented

Vent Valve Open & Close
and closed
Drain Valve is opened and the water is
Drain Valve Open & Close getting drained and closed when the Ball
Collector is in half a portion of water
Handhole of Ball Collector Open Handhole of Ball Collector is Opened
Basic Charge Qty. of Cleaning Squeezed balls are charged in the Ball
Charging
Balls in the Ball Collector Collector
Handhole of Ball Collector Close Handhole of Ball Collector is Closed
Bypass Valve Open Bypass Valve is Opened
Note : Outlet/Bypass side is positioned accordingly if 3-Way Valve is provided
After charging the Cleaning Balls in the Tube Cleaning System, the system can be operated now as
described in Control Philosophy in PART 2. Position of valves is also to be checked according to
Control Philosophy before starting the operation.
SECTION 8 SERVICE & MAINTENANCE
8.1 BALL SEPARATOR
FREQUENCY
COMPONENTS / OPERATIONS
OF CHECK
Inspect general condition of the screens, screen shaft
Y
and funnel assembly.
Check smooth movement of the shafts. M
Check whether the indications on the screen shaft is
in line with marking on the shaft disc and worm gear
W
labelling at "Operating Position" & "Backwash
Position" respectively.
8.2 BALL COLLECTOR
FREQUENCY
OF CHECK
Check for Cleanliness W
Check “O” Ring and change if necessary W
Clean Sight Glass W
Check the Gasket and change if necessary W
8.3 BALL RECIRCULATING PUMP AND MOTOR
FREQUENCY
OF CHECK
Ball Recirculating Pump
Inspect shaft, impeller Y
Check Mechanical Seal condition and change if
W
necessary
Check oil level W
Refilling (If required) -
Check noise & temperature of bearing D
Inspect coupling tightness H
Motor
Check noise & temperature of bearing D
Check Motor terminal tightness H
8.4 DIFFERENTIAL PRESSURE MEASURING SYSTEM
FREQUENCY
OF CHECK
Check electrical function of DP Transmitter M
8.5 ACTUATOR FOR SCREEN AND BALL VALVES
FREQUENCY
OF CHECK
Actuator Motors
Inspect general condition M
Check movability, fastening tightness M
Actuator Limit & Torque Switches
Inspect switch operation M
8.6 VALVES
FREQUENCY
OF CHECK
Change : Ball Seat, Stem, Gasket, Sealing, if
Y
necessary due to leakage
Check Tightness, movability and fastening M
FREQUENCY
OF CHECK
Inspect Panel internal components Y&V
Check wiring for any loose connections
M&V
and clean the wires & Terminal Blocks if required.
Check all the panel components healthiness Y&V
Legend : D - Daily
W - Weekly
M - Month
Y - Yearly
2Y - Every 2 years
HY - Half Yearly
V - Verify
8.8 WORM GEAR
REMOVAL & FIXING OF THE POINTER COVER & O RING
Read the NOTE below, before starting the job.
Dismantling
1) Loosen all three hex nuts. Turn the bolts by 90 degree & pull towards you.
2) Now the pointer cover is free for removal from its seat. Check the condition of O-ring.
3) Clean the cavity below the pointer cover of any residual grease & water.
4) Clean the O-ring seat.
Fixing
5) Replace the O-ring if its condition is not good.

6) Place the pointer cover in its position & push the bolts in & turn 90 degree & tighten the hex nuts.
7) Shake & ensure there is no play in bolts & pointer cover.
Note: Measure the bolt length projecting out from the pointer cover surface in the beginning as
reference for comparison with the same after fixing the cover back in its location (slight
difference in measurement can be ignored).
This will enable you to conclude that the pointer cover is secured firmly.
SECTION 9 TROUBLESHOOTING
Following guidelines to identify and rectify minor faults that may occur in Equipment during
operation.
In case of major overhaul it may be referred to our service department.
9.1 BALL SEPARATOR
FAILURE CAUSE REMEDY

Indicating Lamps Screen has not reached the operating Check screen if it is
SCREEN FAIL : ON position and the running time has mechanically blocked.
exceeded.
SEQUENCE FAIL : ON Check whether the limit
setting in the Actuator is
correctly done.
Thermoswitch tripped Check reason for tripping
& correct.
Illuminating Differential Pressure > 1st Point Screens are to be

Lamp due to choking of screens. backwashed.
Ball losses Screens not in operating position Move screens to operating

position.
Dead spot in ball circulation. Dead spots to be covered
Balls are not satisfactorily deaerated. Check and deaerate
properly
Balls do not circulate Debris in the water box and on the Remove debris by
tube sheet. improving pre-screening
of the Cooling water.
In-adequate flow and Condenser DP Design flow and
Condenser DP to be
maintained.
Blockage in ball extraction Due to debris Eliminate blockage in ball
pipe extraction by repeatedly
closing and opening the
isolation valve and if
necessary, by careful
moving the screens
manually.
Balls stay in long, Circulating water rate is too low. Increase flow rate, use
horizontal pipes harder balls without
deaerating them, install
turbulence plate.

Balls are cut into pieces Worn out balls Replace with good balls.
Valves are not fully open. Check and correct
Welding burs Remove the welding burs
Ball distribution problems Water flow is not uniform. Modify hydraulic

across the tube sheet. condition if possible.
Install turbulence plate.
Asymmetrical inlet pipes. Check and rectify.

Deaerate balls. Increase the
number of inlet pipes. Re-
route inlet pipes.
Cleaning ball wear is Internal surfaces of Condenser tubes Increase number of ball
excessive are badly fouled. passes (use more balls or
reduce intervals between
cleaning cycle).
Wrong size and hardness of the ball. Use recommended balls.
9.2 BALL RECIRCULATING PUMP

Pump does not deliver Motor speed too low. Check motor speed and take
water corrective action.
/ Insufficient capacity Foreign material in impeller. Open Pump and check impeller.
delivered. Remove any foreign material
present
Impeller damaged Open pump and rectify
Pump requires Foreign material in impeller. Open Pump and check impeller.
excessive power Remove any foreign material
present.
Misalignment Check and correct
misalignment.
Shaft bent Straighten or change shaft
Packing / Mechanical Seal Check and correct

improperly installed.
Stuffing Box leaks Shaft bent Straighten or change shaft
excessively
Leakage in Mechanical Seal (if Check and correct
provided)
Shaft running off center because of Check and change bearings if
worn bearings or misalignment. necessary, correct
misalignment.
Shaft out of balance Dynamic Balance of the shaft
Mechanical Seal Excessive heat built-up, shaft Check and take preventive
vibration, shaft deflection & measure to avoid cavitation
bearing failure due to excessive
Cavitation.
Pump vibrates and Operation at very low capacity Check and take corrective action
noisy
Cavitation Check and take corrective action
Foreign material in impeller. Open pump and check impeller.

Remove any foreign material
present.
Misalignment Check and correct
misalignment.
Foundation not rigid Check and correct

Shaft bent Straighten or change shaft
Bearing Worn Check and change bearings.
Shaft out of balance Dynamic Balance of the shaft
Pump overheats Misalignment Check and correct

misalignment.
Rotating part rubbing on Open pump and correct
stationary part
Bearing Worn Check and change bearings
Shaft running off center because of Check and change bearings if

worn bearings or misalignment. necessary, correct
misalignment.
9.3 MOTOR FOR BALL RECIRCULATING PUMP

Motor vibrates Misalignment Check and correct misalignment.
Defective bearings. Replace bearings
Bearing overheats Insufficient grease Maintain proper quantity of

grease in bearings.
Bearing overloaded This may be due to
misalignment of the drive,
excessive end thrust imposed on
motor.
Take adequate steps to reduce
load on the bearings.
Bent shaft Straighten or change the shaft.
Motor fails to start Main supply switched off. Check and correct
Open circuit in one line (single Check fuse and switch contacts
phasing). May be due to blown and test lines for continuity.
fuse, faulty switch contact or
broken lead.
Motor may be overloaded Reduce starting load
Wrong connection Check with diagram and see that

connections are right.
Motor overheats Motor terminal Loose Connection Tightness to ensure.
Wrong rotation Wrong sequence of phases Reverse connections of any two

phase at motor or in the control
panel.
KEY BENEFITS OF GEA BGR
TUBE CLEANING SYSTEM & DEBRIS FILTER
 Increase in the Heat Transfer Rate
 Optimum Turbine Back Pressure
 Optimum Power Generation
 Avoidance of Corrosion/Erosion of Condenser Tubes
 Life Enhancement of Condenser Tubes
 No Shutdown for Manual Cleaning
 Economy in Fuel Cost
 Low Chemical cost for Water Treatment
 Typical payback period of 12-18 months on investment

CONTACT :

443, ANNA SALAI, TEYNAMPET, CHENNAI - 600 018. INDIA.
TEL: (+91 44) 2430 1000 FAX: (+91 44) 2434 3374
DES/OMM/TCS/DSA XXI
PART 2
CONTENTS OF PART 2
1 MECHANICAL DATASHEET 8
2 DATASHEET FOR ACTUATOR 4
3 MOTOR DATASHEET 3
4 INSTRUMENT DATASHEET 4
5 STARTUP & COMMISSIONING SPARE PARTS LIST 2
6 LUBRICANT LIST 1
7 CONTROL PHILOSOPHY 15
8 P&I DIAGRAM (incl. Legend) 2
9 GENERAL ARRANGEMENT OF BALL STRAINER 1
10 GENERAL ARRANGEMENT OF BALL RECIRCULATING SKID
1
AND FOUNDATION DETAILS
11 GENERAL ARRANGEMENT OF BALL DISTRIBUTOR & BALL
6
INJECTION PIPE
12 HOOK UP DIAGRAM 1
GI 5320 100 09 021

A 28-02-2022 FOR APPROVAL SANTHOSH.K SUDHARSAN.I RAVIKUMAR.N
B 15-03-2022 FOR APPROVAL SANTHOSH.K SUDHARSAN.I RAVIKUMAR.N
Eder 21/03/22

43151)
KS IS NRK GI 5320 100 09 007 B

Mechanical Data Sheet - Condenser

GBX/5320/2022
Tube Cleaning System
PURCHASER : SIEMENS ENERGY BRASIL LTDA

PROJECT : CERRADO (43150 & 43151)
Sl.No. Description Sheet No.
INDEX
1.0 General Information 03 of 08
2.0 Cleaning Balls 03 of 08
3.0 Worm Gear for Ball Strainer Screen 04 of 08
4.0 Ball Valves 07 of 08
5.0 Ball Recirculating Pump 08 of 08
GI 5320 100 09 007 Rev.B

Sheet 02 of 08

Sl.No. Description Unit Data / Parameters
1.0 General Information & Design Data
1.1 No. of Condenser tube cleaning system Nos 2
1.2 Liquid handled Cooling Tower Water
1.3 Operating pressure bar (g) < 6.0
1.4 Design pressure for ball strainer bar (g) 6.0
1.5 Hydro Test pressure bar (g) 8.58
1.6 Condenser Inlet Pipe Size DN 1400
1.7 Condenser Outlet Pipe Size DN 1400

o
1.8 Design Temperature C 65
Cooling water flow per strainer
1.9 a) Normal water flow m3/hr 11394
b) Maximum water flow (CTCS Operation) m3/hr 12514
Condenser Details
a) Tube outside diameter x Thickness mm 25.4 x 0.711
1.10 b) Total number of Condenser tubes Nos 6100 (Double Pass)
c) Length of tubes mm 10000
d) Tube material ASTM A249 TP 304
Pressure drop across screen in clean condition at

1.11 mbar 30
normal flow
Maximum Presure Drop across Ball Strainer for
1.12 mbar 40
Normal Backwash (Ist set point)
Power Supply 660 V / 3 Ph / 60Hz
1.13 - Voltage variation % + 10
- Frequency variation % +5
2.0 CLEANING BALL DETAILS
2.1 Cleaning ball make Schmitz
2.2 Cleaning ball Type / Size. RB / Dia 26 mm
2.3 Quantity per charge Nos 310
2.4 No. of charges Nos 4
2.5 Total No. of Quantity required Nos 1240
2.6 Design Temperature °C 65
GI 5320 100 09 007 Rev.B

Sheet 03 of 08

Sl.No. Description Unit Data/Parmeters
3.0 Worm Gear for Ball Strainer Screen
3.1 Make Auma (Germany)
3.2 Model GS 125.3
3.3 Quantity No. 4
3.4 Worm Gear Output torque Nm 8000

o
3.5 Design Ambient temperature C 50
3.6 Total reduction ratio 208 : 1
Angle of rotation
- Operation Deg 25
3.7
- Backwash Deg 5
- Total Angle of Travel Deg 30
3.8 Suitable Multi turn actuator SA 10.2 E54 AM 01.1
3.9 Mounting Flange for Multi turn actuator F10
3.10 Mounting Flange for the Ball Strainer F25
3.11 Protection Class IP 67
DES-TDS-AUMA WG-GS125.3 GI 5320 100 09 007 Rev.B

Sheet 04 of 08
GS 50.3 – GS 250.3
Technical data Part-turn gearboxes for open-close duty
Duty class 11)

Motor operation in accordance with EN 15714-2.
Valve Gearbox
Max. output Valve attachment Type Reduct. Factor3) Turns Input Input mounting Max. Weight4)
torque2) ratio for 90° shaft flange for mul- input
ti-turn actuator torques
Flange
according to Max.
to EN ISO shaft diameter
[Nm] 5211 [mm] [mm] [Nm] [kg]
F07 F07
500 38 GS 50.3 51:1 16.7 12.75 16 30 7.0
F10 F10
1,000 F10 51:1 16.7 12.75 F07 60
50 GS 63.3 20 12
7505) F12 82:1 17.0 20.5 F10 44
2,000 F12 53:1 18.2 13.25 F07 110
60 GS 80.3 20 16
1,5005) F14 82:1 17.0 20.5 F10 88
4,000 52:1 18.7 13 F14 (F10) 214
30/(20) 33
2,8005) 107:1 22.6 26.8 F14 (F10) 124
F14
80 GS 100.3 126:17) 42.8 31.5 F10 93
F16
4,000 160:17) 54.0 40 20 F10 74 39
208:17) 71.0 52 F10 57
52:1 19.2 13 30 F14 417 40
F16 126:17) 44.0 31.5 F14 (F10) 182
30/(20)
8,000 F25 90 GS 125.3 160:17) 56.0 40 F14 (F10) 143
46
F306)
208:17) 72.7 52 20/(30) F10 (F14) 110
54:1 21.0 13.5 30 F16 (F14) 667 80
F25
218:17) 76.0 54.5 30/(20) F14 (F10) 184
14,000 F30 100 GS 160.3
442:17) 155 110.5 90 91
F356) 20 F10
880:17) 276 220 51
53:1 21.0 13.25 40 F25 (F16) 1,333 140
F30 214:17) 75.0 53.5 30 F14 373
160
28,000 F35 125 GS 200.3 434:17) 152 108.5 30/(20) F14 (F10) 184
F406) 864:17) 268 216 20 F10 104
170
1,752:17) 552 438 20 F10 51
52:1 20.3 13 50 F30 (F25) 2 759 273
F35 210:17) 74.0 52.5 40/(30) F16 (F14) 757
296
56,000 F40 160 GS 250.3 411:17) 144 103 30 F14 389
F486) 848:17) 263 212 30/(20) F14 (F10) 213
308
1,718:17) 533 430 20/(30) F10 105
Duty class 21)

Motor operation for infrequently operated valves (max. 1,000 cycles)
Valve Gearbox
Max. output Valve attachment Type Reduct. Factor3) Turns Input shaft Input mounting Max. Weight4)
torque2) ratio for 90° flange for mul- input
ti-turn actuator torques
Flange
according to Max.
to EN ISO shaft diameter
[Nm] 5211 [mm] [mm] [Nm] [kg]
F07 F07
625 38 GS 50.3 51:1 16.7 12.75 16 37 7.0
F10 F10
F10 F07
1,250 50 GS 63.3 51:1 16.7 12.75 20 75 12
F12 F10
F12 F07
2,200 60 GS 80.3 53:1 18.2 13.25 20 120 16
F14 F10
52:1 18.7 13 30/(20) F14 (F10) 267 33
F14 126:17) 42.8 31.5 117
5,000 80 GS 100.3
F16 160:17) 54.0 40 20 F10 93 39
208:17) 71.0 52 71
52:1 19.2 13 30 F16 521 40
F16
126:17) 44.0 31.5 227
10,000 F25 90 GS 125.3 30/(20) F14 (F10)
160:17) 56.0 40 179 46
F306)
208:17) 72.7 52 20 F10 (F14) 138
54:1 21.0 13.5 30 F16 (F14) 833 80
F25
218:17) 76.0 54 30/(20) F14 (F10) 230
17,500 F30 100 GS 160.3
442:17) 155 110.5 91
F356) 20 F10 113
880:17) 276 220
1) – 7) Refer to notes on page 3.

We reserve the right to alter data according to improvements made. Previous documents become invalid with the issue of this document.
Y000.288/003/en Issue 1.16 Page 1/7

SHEET 05 OF 08
GS 50.3 – GS 125.3
Dimensions Part-turn gearboxes
Without primary reduction gearings With primary reduction gearings

Valve attachment d11
d11 d13
EN ISO 5211
d13 d12
a
d12 F07 – F16 F25 – F35
a
4
d10 For manual operation
d1
4
d1
h11
t1
z
s
h11
c
e
h2
b1
F
d4
R
Valve attachment
R
GS 125.3 – F30 h3
d1
d3
d5
B1
d1
d2
d3
h1 L max. a
E
1)
2)
c
e
E1
E2
Version N K
without spigot
d4
h2
J I
F
B A H H
Ø d6
Ø d2
C
1) Swing angle adjustable 10° – 100° Version Y

with spigot For manual operation
2) Swing angle adjustable 100° – 190°
h1
3) Equipped with primary reduction gearing or planetary gearing to reduce input torques
Dimensions GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
3)
51:1 53:1 52:1 126:1 126:1 3)
51:1 52:1 208:1 3)
82:1 82:1 107:1 160:1/208:1 3) 160:1 3)
EN ISO 5211 F05 F07 F10 F10 F12 F12 F14 F14 F16 F14 F16 F16 F25 F30 F16 F25 F30 F16 F25 F30
A 50 63 80 100 100 125 125 125
B 60 60 63 75 88 105 105 125 150 125 125 150 125 125 150 125
B1 108 108 125 150 175 210 210 250 300 250 250 300 250 250 300 250
C 77 94 111 148 148 173 173 173
E 98 128 133 189 189 194 194 194
E1 1) 101 135 140 213 213 218 218 218
E2 2) 114 150 155 225 225 230 230 230
F 132 165 170 230 250 299 255 324 304
H 85 80 80 91 94 97 107 142 142 145 184 145 184 145 184
I 3 3 4 5 5 5 5 5
J 45 40 40 42 45 47 57 75 75 75 114 75 114 75 114
K 12 13 16 17 17 18 18 18
R 100 125 130 190 259 195 264 264
Ø a f7 16 20 20 20 30 20 30 20 30 20 20
b1 5 6 6 6 8 6 8 6 8 6 6
c 31.5 42 42 43 60 43 60 43 60 43 42
Ø d1 65 90 125 125 150 150 175 175 210 175 210 210 300 348 210 300 348 210 300 348
Ø d2 f8 35 55 70 70 85 85 100 100 130 100 130 130 200 230 130 200 230 130 200 230
Ø d3 50 70 102 102 125 125 140 140 165 140 165 165 254 298 165 254 298 165 254 298
d4 M6 M8 M10 M10 M12 M12 M16 M16 M20 M16 M20 M20 M16 M20 M20 M16 M20 M20 M16 M20
Ø d5 40 60 85 85 105 105 115 115 140 115 140 140 225 – 140 225 – 140 225 –
Ø d6 32.5 49 64 64 79 79 92 92 121 92 121 121 190 – 121 190 – 121 190 –
d10 M5 M6 M6 M10 M6 M10 M10 M6
e 28 38 38 55 38 55 55 38
h1 2.5 2.5 2.5 3.5 3.5 4.5 3.5 4.5 4.5 4.5 5 4.5 4.5 5 4.5 4.5 5
h2 10 13 16 16 19 19 25 25 32 25 32 32 25 32 32 25 32 32 25 32
h3 3 3.5 4 4 4 5 5 5 5 5 – 5 5 – 5 5 –
L max. 68 63 63 75 78 80 90 125 125 128 128 167 128 128 167 128 128 167
t1 18 22.5 22.5 22.5 33 22.5 33 22.5 33 22.5 22.5
z 32 40 40 40 60 40 60 40 60 40 40
EN ISO 5210 4) F07/F10 F07/F10 F07/F10 F10/F14 F10 F14 F10/F14 F10
DIN 3210 4) G0 G0 G0 G0/G1/2 G0 G1/2 G0/G1/2 G0
4)
Flange for mounting multi-turn actuator
EN ISO 5210 F07 F10 F14
DIN 3210 G0 G1/2
Ø d11 90 125 125 175
Ø d12 55 70 60 100
Ø d13 70 102 102 140
Ø d14 9 11 11 18
h11 5 5 5 5
s 8 12 12 17
We reserve the right to alter data according to improvements made. Previous documents become invalid with the issue of this document.
Y000.265/003/en Issue 1.16 Page 1/2 SHEET 06 OF 08


4.0 Ball Valves
a. Size DN 25
4.1 b. Type Manually Operated - Full Bore
c. Quantity Nos. 8
a. Size DN 80
4.2 b. Type Manually Operated - Full Bore
c. Quantity Nos. 10
a. Size DN 80
4.3 b. Type Actuator Operated - Full Bore
c. Quantity Nos. 4
4.4 Fluid Handled Cooling Tower Water

o
4.5 Design temperature C 65
4.6 Design pressure bar (g) 6.0
4.7 Test pressure bar (g) 8.58
4.8 Face to Face dimension ASME B16.10
Material of construction
a) Body &Tail Piece ASTM A 216 Gr.WCB (Carbon Steel)

ASTM A 276 / ASTM A 479 Type 316 / A351 Gr.CF8M
4.9 b) Ball
(SS316)
c) Stem ASTM A 276 Type 316 / ASTM A 479 Type 316
d) Seat PTFE
4.10 Type of end connection Flanged RF
4.11 Manufacturing Standards EN-ISO-17292 / BS-5351 / ASME B 16.34 / API 608

4.12 Testing Standards BS-EN-12266 / BS 6755 Part-I / API 598
4.13 Flange / Drilling Standard Dimensions shall be as per ASME B16.5 Cl.150.SORF
DES-TDS-BV-ASME-CS-SS GI 5320 100 09 007 Rev.B

Sheet 07 of 08

Sl.No. Description Unit Data/Parmeters
5.0 Ball Recirculating Pump
5.1 Type Non Clog type Horizontal Centrifugal Pump
5.2 Quantity No. 2
5.3 Type of duty S1 (Continuous)
5.4 Operating capacity m3/Hr. 60
5.5 Operating head MWC 15*
5.6 Design Pressure bar (g) 6.0 B

5.7 Operating Pressure bar (g) < 6.0

o
5.10 Nominal speed rpm 1760 approx.
5.11 Motor rating kW 7.5*
- Casing ASTM A 216 Gr.WCB (Carbon Steel)
- Impeller ASTM A 744 CF8M (SS316)

1.12
- Shaft ASTM A 276 Type 316 (SS316)
- Shaft Sleeve ASTM A 276 Type 316 (SS316)
- Sealing Type Mechanical Seal
5.13 Suction Condition / Size / End Connection mm Flooded / DN 100 / Flanged
5.14 Discharge size / End Connection mm DN 80 / Flanged
5.15 Drilling standard / Flange standard ASME B16.5 Cl.150.RF
*Note: Subject to change based on finalisation of Installation plan

DES-TDS-PUMP-ASME-CS-SS GI 5320 100 09 007 Rev.B
Sheet 08 of 08
Eder 30/03/22

43151)
KS IS NRK GI 5320 100 09 008 A

Data Sheet for Actuator - Condenser

GBX/5320/2022

SL. NO CONTENTS SHEET
INDEX
1.0 Actuator for Ball Strainer 03 of 04
2.0 Actuator for Ball Valve 04 of 04
GI 5320 100 09 008 Rev.A

Sheet 02 of 04

1.0 Actuator for Ball Strainer AUMA GERMANY
1.1 Model SA 10.2 E 54 AUMA MATIC 01.1
1.2 Application Screen Operation / Backwash
1.3 Type Integral Starter (Intrusive type)
1.4 Type of Duty S2 -15 mins
1.5 Enclosure IP 68
o
1.6 Design ambient temperature C 40°
2 Nos. - 2 NO + 2NC contacts
1.7 Position Limit Switches
(1 each in open and close position)
2 Nos. - 2 NO + 2NC contacts
1.8 Torque Switches
1.9 Rating of switches 5V AC/DC – 0.004A to 50V AC/DC - 0.4A.
1.10 Maximum Torque Nm 120
1.11 Operating Time Sec. 24 approx.
1.12 Nominal Power kW 0.40
1.13 Rated voltage V 660
1.14 Rated frequency Hz 60
1.15 No of phases / wires 3 Ph / 3 wire
1.16 Admissible voltage variation % ± 10
1.17 Admissible frequency variation % ±5
1.18 Nominal current A 1.8 approx.
1.19 Motor Speed rpm 1680 approx.
1.20 Starting current A 6.2 approx.
1.21 Insulation class Class "F" with temp. rise limited to Class "B"
1.22 Power factor 0.42 approx.
1.23 Temperature rise over ambient temp 40°C 70°
24V-48V AC/DC self-regulating, 5 - 20W (Voltage

1.24 Space heater Voltage, Power
internally derived in Actuator)
1.25 Cable Entry M20 - 1 No, M25 - 1 No ; M32 - 1 No.
1.26 Actuator Lamp Color Open - Green ; Failure - Red ; Close - Yellow
DES-TDS-AUMA-BS-ACT-SA10.2 AM01.1-60HZ GI 5320 100 09 008 Rev.A
Sheet 03 of 04
2.0 Actuator for Ball Valve AUMA GERMANY
2.1 Model SQ 05.2 AUMA MATIC 01.1
2.2 Application Valve Operation
2.3 Type Integral Starter (Intrusive type)
2.4 Type of Duty S2 -15 mins
2.5 Enclosure IP 68
o
2.6 Design ambient temperature C 40
2 Nos. - 2 NO + 2 NC contacts
2.7 Position Limit Switches Nos.
2 Nos. - 2 NO + 2 NC contacts
2.8 Torque Switches Nos.
2.9 Rating of switches 5V AC/DC – 0.004A to 50V AC/DC - 0.4A
2.10 Maximum Torque Nm 150
2.11 Operating Time between Open & Close Sec. 12
2.12 Nominal Power kW 0.02
2.13 Rated voltage V 660
2.15 No of phases / wires 3 Ph / 3 wire
2.16 Admissible voltage variation % ± 10
2.17 Admissible frequency variation % ±5
2.18 Nominal current A 0.3 approx.
2.19 Motor Speed rpm 1680 approx.
2.20 Starting current A 0.7 approx.
2.21 Insulation class Class "F" with temp. rise limited to Class "B"
2.22 Power factor 0.40
2.23 Temperature rise over ambient temp 40°C °C 70
24V-48V AC/DC self-regulating, 5 - 20W (Voltage

2.24 Space heater Voltage, Power
internally derived in Actuator)
2.25 Cable Entry 1 x M20; 1 x M25;1 x M32.
2.26 Actuator Lamp Color Open - Green ; Failure - Red ; Close - Yellow
DES-TDS-AUMA-ACT-SQ05.2 AM01.1-60HZ GI 5320 100 09 008 Rev.A
Sheet 04 of 04
Eder 30/03/22

43151)
KS IS NRK GI 5320 100 09 006 A

Motor Data Sheet - Condenser Tube

GBX/5320/2022
Cleaning System
INDEX
1.0 Motor for Pump 03 of 03
GI 5320 100 09 006 Rev.A

Sheet 02 of 03

Sl. No. Item Description Unit Data / Parameters
1.0 Motor for Pump
1.1 Make Marathon Motors
1.2 Equipment driven by motor Pump
1.3 Motor type Squirrel cage induction motor, TEFC

o
1.4 Design Ambient temperature C 40
1.5 Quantity Nos 2
1.6 Type of duty S1, Continuous duty
1.7 Service factor 1.25
1.8 Type of enclosure and method of cooling TEFC / IC411
1.9 Degree of protection IP 55
1.10 Applicable standard IEC 60034
1.11 No. of Phases / No. of Poles 3 Ph / 4 Poles
1.12 Motor Rating KW 7.5*
1.13 Rated voltage V AC 660
Permissible variation
1.15 a) Voltage % + 10
b) Frequency % +5
1.16 Rated speed rpm 1766 Approx.
1.17 Full current at rated voltage & frequency A 8.9
1.18 Efficiency at rated voltage / frequency-100% load % 91.7
1.19 Power factor - 100% load 0.79
1.20 Class of insulation F (Temperature rise limited to class B)
1.21 Type of Starting Direct - on - line (DOL)
1.22 Drive Transmission Flexible Coupling
1.23 Frame Size 132S
1.24 Space heater Not Applicable
* Note: Subject to change based on finalisation of Installation plan

DES-TDS-MOTOR-7.5KW-60HZA GI 5320 100 09 006 Rev.A
Sheet 03 of 03
Eder 21/03/22

43151)
KS IS NRK GI 5320 100 09 009 A

Instrument Data Sheet - Condenser

GBX/5320/2022

INDEX
1.0 D.P Transmitter 03 of 04
2.0 Pressure Gauge 04 of 04
GI 5320 100 09 009 Rev.A

Sheet 02 of 04

1.0 D.P Transmitter
1.1 Type Remote Seal, HART Protocol Compatible
1.2 Quantity Nos 2
1.3 Liquid Handled Cooling Tower Water

o
1.5 Design Pressure 6 bar (g)
1.6 Power Supply V DC 24
1.7 Transmitter measurement Differential pressure across ball strainer
1.8 Measuring range mbar 0 to 100
1.9 Transmitter output 4 - 20 mA DC signal
1.10 No. of wire Nos. 2
1.11 Housing material Polyurethane - covered Aluminium
Material
- Upper Housing SS 316L

1.12
- Lower Housing SS 316L
- Diaphragm (Remote Seal) SS 316L
1.13 Mounting Surface Mounting
1.14 Meter Digital meter, 0 to 100mbar
1.15 Process connection 1" Flange as per ASME B16.5 Cl.150
1.16 Load limit (at 24 V DC) Ohms 500
Performance data
- Accuracy ± 0.1% of URL

1.17
- Stability ± 0.2% of URL for 5 Years
-Turn down ratio 100:1
1.18 Diagnostics Self indicating features provided
1.19 Capillary Length m 1.5 on each side
1.20 Electrical Connection Screw type terminals
1.21 Protection Class IP 67
1.22 Cable Gland / Size Provided / M20 x 1.5
DES-TDS-DPT-SS316L GI 5320 100 09 009 Rev.A

Sheet 03 of 04

2.0 Pressure Gauge
Range Quantity
2.1 0 to 4 bar (g) Nos 2
0 to 6 bar (g) Nos 2
2.2 Design Pressure 6 bar (g)

o
2.3 Design Temperature C 65
2.5 Type Bourdon
2.6 Accuracy class % + 1 of FSD
2.7 Over range protection % 130 of maximum range
- Bourdon SS 316
- Case Stock Finished Stainless Steel

2.8
- Movement Stainless Steel
- Filling fluid Glycerine
- Process connection 1/2" NPT (M)
2.9 Enclosure IP 65
Dial Linear
- Size mm 150 / 160

2.10
- Colour White
- Numerals Black lettering on white background
2.11 Entry Local direct bottom mounting
2.12 Blow Out Disc Provided
DES-TDS-PG-SS316L GI 5320 100 09 009 Rev.A

Sheet 04 of 04
A 14-03-2022 FOR INFORMATION SANTHOSH.K SUDHARSAN.I RAVIKUMAR.N
X
Eder 21/03/22

43151)
KS IS NRK GI 5320 100 09 020 A

Start up and Commissioning Spare

GBX/5320/2022 Parts - Condenser Tube Cleaning
System
S. No Description Quantity
1 Manhole Gaskets for Ball strainer 1 No.
2 Ball Collector Hand hole O Ring 1 No.
3 Oil Leveller for pump 1 No.
Push Buttons
4 1 Set.
(Normal - 1 No, Illuminated - 1 No)
5 Indicating lamps 1 No.
6 Power Contactors 1 No.
7 Cleaning Balls for Commissioning (RB / Dia 26 mm) 2480 Nos.
8 Cleaning Balls for One Year Operation (RB / Dia 26 mm) 8060 Nos.
GI 5320 100 09 020 Rev.A

Sheet 02 of 02
LUBRICANT LIST
Equipment Lubricant Quantity per unit & interval

Sl. Point of
Tag Numbers Replacement Charge Remarks
No. Lubrication
Description Model Initial Charge Brand Type
Q'ty (L/set) Interval
Worm Gear for Ball 3 Yrs (Frequently

Strainer Factory Filled Operated)
1 B11, B12 GS 125.3 Gear & Bearings AUMA Grease 1964 - - Grease 1.17 Kg
Make : Auma, (1.17 Kg ) 5 Yrs
Germany (Rarely Operated)
Actuator for Ball 5 Yrs (Frequently

Strainer Screen SA 10.2 E 54 AUMA Factory Filled SHELL - ALVANIA MOBIL - MOBILPLEX Operated)
2 T11, T12 Gear & Bearings CASTROL - OLIT 00 Grease 0.81 Kg
Make : Auma, MATIC 01.1 (0.81 Kg ) 1029 EP00 7 Yrs
Actuator for Ball 5 Yrs (Frequently

Valve SQ 05.2 AUMA Factory Filled SHELL - ALVANIA MOBIL - MOBILPLEX Operated)
3 T01, T02 Gear & Bearings CASTROL - OLIT 00 Grease 0.63 Kg
Make : Auma, MATIC 01.1 (0.63 Kg.) 1029 EP00 7 Yrs
Lubricant is
filled at site in
Ball Recirculating MOBIL - MOBIL
INDIAN OIL - SERVO 6 months (with every order to aviod
4 F01 Pump TPP - 80 / 210 Bearing Housing 0.60 Ltr SHELL - VITREA 33 VACTRA HEAVY Oil 0.60 ltr
SYSTEM 150 200 hrs.of checking) oil leakage in the
Make : Sam Turbo DUTY
bearing housing
during transit
This Bearing is
sealed type
6308ZZ C3,
6208ZZ C3. This
Motor for Ball Squirrel cage
Life lubricated, SHELL - GRADUS S2 GULF - HYPERBAR has to be
5 T91 Recirculating Pump induction motor, Bearings ESSO - UNIREX N3 Grease Not required Not required
sealed bearing V 220 LCM 3 replaced with
Make : Marathon TEFC
new after its
wornness.
Refilling is not
possible.
A 15-03-2022 FOR INFORMATION PRASANNA.C VIDYAKUMAR.P RAVIKUMAR.N
X
Eder 21/03/22
PROJECT: CERRADO
(43150 & 43151)
CPK PVK NRK GI 5320 106 09 014 A

Control Philosophy-Condenser Tube

GBX/5320/2022
Cleaning System
PROJECT CERRADO (43150 & 43151)
CLIENT SIEMENS ENERGY BRAZIL LTDA
SYSTEM CONDENSER TUBE CLEANING SYSTEM (DN 1400)
DOCUMENT CONTROL PHILOSOPHY- CONDENSER TUBE CLEANING SYSTEM SHEET 2 of 15
DOC. No. GI 5320 106 09 014 REV.A
INDEX
1. EQUIPMENT DESCRIPTION AND KKS NUMBERS …............................................................. Sheet 3 of 15

2. REFERENCE DOCUMENT……..…………………....................................................................... Sheet 4 of 15
3. SALIENT FEATURES………………………………...................................................................... Sheet 4 of 15
4. MANUAL MODE…………………………………………............................................................. Sheet 5 of 15
5. AUTO OPERATION (LOCAL MODE)……………………........................................................... Sheet 5 of 15
5.1 INITIAL CONDITIONS……………………..………………………….………….……. Sheet 5 of 15
5.2 SYSTEM OPERATION SEQUENCE….…………………………..……………………. Sheet 6 of 15
5.3 BACKWASH SEQUENCES……………………...………………….………………....... Sheet 7 of 15
5.3.A BACKWASH SEQUENCE – DURING AUTO MODE…………………………………. Sheet 7 of 15
5.3.A.1 BACKWASH-WHEN SYSTEM CYCLE TIMER ON……….……………… Sheet 7 of 15
5.3.A.2 BACKWASH- WHEN IDLE TIMER ON……………..…….……………...... Sheet 8 of 15
5.3.B BACKWASH SEQUENCE- DURING MANUAL MODE……………………….……... Sheet 9 of 15
5.4 AUTO STOP SEQUENCES……………………………………………………………… Sheet 9 of 15
5.4.A AUTO STOP SEQUENCE-WHEN WATERING TIMER ON………………..….……... Sheet 9 of 15

5.4.B AUTO STOP SEQUENCE-WHEN SYSTEM CYCLE TIMER ON………...………...... Sheet 10 of 15
5.4.C AUTO STOP SEQUENCE-WHEN BALL COLLECTION TIMER ON………......…...... Sheet 10 of 15
5.4.D AUTO STOP SEQUENCE- WHEN IDLE TIMER ON………………………………...... Sheet 10 of 15
6. REMOTE MODE……………... ……..…………………................................................................. Sheet 11 of 15
7. BRM SEQUENCE IN AUTO MODE ……..…………………......................................................... Sheet 11 of 15
8. SETTING OF TIMER VALUES ……..…………………................................................................ Sheet 11 of 15
CONTROL LOGIC OPERATION IN THE EVENT OF
9. Sheet 12 of 15
ELECTRICAL / SEQUENCE FAILURE DURING AUTO OPERATION………..………………
10 LOGIC INTERLOCKS AND FEATURES………………………………………………………... Sheet 12 of 15
11. CAUSES FOR FAIL INDICATIONS….......................................................……………….……... Sheet 13 of 15
12. EQUIPMENT STATUS FOR PROCESS OPERATION CYCLES…............................................ Sheet 15 of 15
DES/TCS/CONTROL PHILOSOPHY_1_A
DOC. No. GI 5320 106 09 014 REV.A
1.0 EQUIPMENT DESCRIPTION AND KKS NUMBERS
SL. No. EQUIPMENT DESCRIPTION TAG NUMBERS
1 BALL STRAINER A01
2 ACTUATOR FOR BALL STRAINERS T11,T12
3 BALL EXTRACTION VALVES N41,N42
4 ISOLATION VALVES N26,N27
5 BALL RECIRCULATING PUMP F01
6 MOTOR FOR PUMP T91
7 BALL COLLECTOR INLET VALVE N01
8 BALL COLLECTOR OUTLET VALVE N02
9 ACTUATOR FOR INLET VALVE T01
10 ACTUATOR FOR OUTLET VALVE T02
11 BALL COLLECTOR G01
12 BALL COLLECTOR BYPASS VALVE N05
13 BALL COLLECTOR VENT VALVE N91
14 BALL COLLECTOR DRAIN VALVE N92
15 BALL INJECTION VALVES N31,N32
16 D.P. VALVES N21,N22
17 D.P. TRANSMITTER D01
18 CONTROL PANEL S01
19 BALL RECIRCULATING MONITOR U01
DOC. No. GI 5320 106 09 014 REV.A
2.0 REFERENCE DOCUMENT
1. GI 5320 100 01 001 _P&ID (INCL. LEGEND) - CONDENSER TUBE CLEANING SYSTEM
2. GI 5320 106 07 013_GENERAL ARRANGEMENT & WIRING DIAGRAM FOR CONTROL
PANEL- CONDENSER TUBE CLEANING SYSTEM.
Note:
1. This document has to be reviewed along with the P&I diagram.
3.0 SALIENT FEATURES

1. The Control logic is set out to cater to the operational requirements of CONDENSER TUBE
CLEANING SYSTEM (CTCS) under all conditions.
2. CONDENSER TUBE CLEANING SYSTEM functions in three operational modes.
a. LOCAL AUTO MODE – Operation in LOCAL AUTO can be selected by

pressing LOCAL AUTO in HMI.
b. MANUAL MODE – Operation in MANUAL can be selected by pressing

MANUAL in HMI.
c. REMOTE AUTO MODE – Operation in REMOTE AUTO can be selected by

pressing REMOTE AUTO in HMI.
3. Electric Actuators for the Ball Strainer Screens and the Ball Valves are provided with end
travel limit switches.
4. Indication and audible alarm, in the form of feedback signal, has been provided in the panel
for all failure signals.
5. 4-20mA Analog signal from the Differential Pressure Transmitters are used for DP
measurement across Ball Strainer.
6. Ready to start indication will glow only when all the electrical drives are in "HEALTHY"
condition. The "HEALTHY" condition is defined as a condition when all "FAIL"
indications are in OFF, these conditions and the availability of the "CTCS Start Permissive
(CW PUMP running feedback)" signal from the DCS will lead to switch “ON" the "READY
TO START" indication. The Ready to start indication will be on only when the system is
selected in AUTO MODE.
7. The indications (OPEN/CLOSE or OPERATION/BACKWASH) will blink when the

electric actuator operated valves / screens move from one status to another status. The
corresponding indication will glow steadily when end travel limit switch is reached.
8. Summary failure indication is for failures in the power circuitry of individual drives.
Sequence failure indication is for run time failure of actuators during the operation of the
system.
9. When the system is in "AUTO" mode (either in LOCAL AUTO MODE OR REMOTE
AUTO MODE), it will not respond for any manual pressing of Individual buttons and
selection of mode selector in HMI. And will respond only after the system is stopped.
DOC. No. GI 5320 106 09 014 REV.A
10. If Power fails, in any stage of the logic sequence - all equipment will come to initial position
when power is restored excepts screens, and manual interference is required for restarting.
I.e. when the power fails all the drives will be in their current position either open or close
and operation or backwash. Upon resumption of power the valves will come to close
position if in open position
Note: Indication, selector mentioned in this section of document is referring to soft indication
available in the Touch screen HMI, which is located in the CTCS LOCAL CONTROL PANEL.
4.0 MANUAL MODE
For MANUAL mode of operation, Manual mode selection has to be selected in the Local Panel HMI.
The system can be operated through Local Panel HMI by activating function keys for individual
drives.
This Manual mode is used predominantly for testing & commissioning purposes.
Note: Please note there will be no interlocking of equipments in manual mode. Any equipment
can be operated without any interlock.
5.0 AUTO OPERATION (LOCAL MODE):
5.1. INITIAL CONDITIONS
a. Ball Collector Outlet Valve should be in CLOSE position.
b. Ball Collector Inlet Valve should be in CLOSE position.
c. Ball Recirculating Pump Motor should be in OFF position.
d. Ball Strainer Screens should be in OPERATION position.
e. Valves (BALL COLLECTOR VENT VALVE, BALL COLLECTOR DRAIN VALVE &
BALL COLLECTOR BYPASS VALVE) to be in closed position.
f. Valves (BALL EXTRACTION VALVES, ISOLATION VALVES, BALL INJECTION

VALVES & D.P. VALVES) should be in OPEN position.
Note: Before starting of auto operation all Valve positions (open/close)

should be ensured physically by the site operator.
g. All FAIL Indications and Summary/Sequence Failure Indications shall be in OFF position.
h. Start Permissive from DCS shall be available. (CW Pump running feedback shall be available).
This feedback signal is required to ensure the water flow inside the system. Based on this Auto
operation shall be started.
DOC. No. GI 5320 106 09 014 REV.A
i. If the INITIAL CONDITIONS are satisfied, the operation of the system can be executed in
the following sequence. In case the initial conditions are not met, then the relevant
equipment will be brought to the required state to meet the INITIAL CONDITIONS.
j. Select LOCAL AUTO/REMOTE AUTO function to “LOCAL AUTO” position.
k. READY TO START Indication will be ON.
l. "AUTO STOP" indication will be ON.
m. Press the "AUTO START” function key to start the system in "LOCAL AUTO" mode.
5.2. SYSTEM OPERATION SEQUENCE
When the System is Healthy, Initial conditions are fulfilled then on pressing the
AUTO START the following operations take place in sequence.
a. AUTO START indication will start to blink and the AUTO STOP indication will be
switched OFF.
b. Simultaneously Ball Collector Inlet Valve will move from close position to open position
and The Ball Recirculating Pump Motor is switched ON, as soon as the Ball Collector
Inlet Valve starts opening.
c. A time-gap of 5 minutes is given by the PLC (Watering Timer – PLC internal timer) for
the water to be absorbed by the sponge rubber balls. This cycle is known as the
WATERING CYCLE.
d. After the end of 5 minutes. The Ball Collector Outlet Valve is opened. The cleaning balls
are now being injected into the CW inlet pipeline. The AUTO START indication will
glow steadily
e. The SYSTEM CYCLE RUN TIMER (System Cycle Run Timer - PLC Internal Timer)
picks up for 4 hrs.
f. After 4 hrs. SYSTEM CYCLE RUN TIMER elapses and the following sequence of
operation takes place.
g. The Ball Collector Outlet Valve is closed.
h. There should be a time gap of 30 minutes to allow for ball collection in the Ball Collector
(Ball Collection Timer - PLC Internal Timer)
i. The Ball Collector Inlet Valve is closed.
j. Ball Recirculating Pump Motor is switched OFF, after the Ball Collector Inlet Valve is
fully closed.
k. The system will be in Idle Timer (PLC Internal Timer - 20 Hours) mode.
l. After Idle Timer the system will start again and cycles has been repeated. In the
Consequent cycles the watering Cycle is not carried out and skipped. As the balls are in
circulation, the needed watering of balls is met automatically. The watering cycle is
performed whenever a new cycle is started by pressing AUTO START.
DOC. No. GI 5320 106 09 014 REV.A
m. Hence after Idle Timer, system cycle operation shall be continued followed by the next
cycle of operations. This cycle of operation continuously running up to Auto
Stop/Sequence stop/Trip conditions.
5.3 BACKWASH SEQUENCES
If the Differential pressure across the Ball Strainer exceeds 40 mbar* (DP Value may vary
depending on the site condition) the BACKWASH SEQUENCE will be carried out.
The BACKWASH can occur in following modes of operation.
A. AUTO Mode of operation

B. MANUAL Mode of operation
* DP VALUE MAY VARY DEPENDING ON THE SITE CONDITIONS.
5.3.A. BACKWASH During AUTO Mode of operation
During the AUTO Mode of operation, BACKWASH sequence can occur in the following
conditions:
1. When SYSTEM CYCLE RUN TIMER is ON

2. When IDLE TIMER is ON
Note: Once the BACKWASH operation is started in any of the conditions said above, the
BACKWASH sequence will be completed even if the DP is reduced in the middle of the cycle.
5.3. A.1. BACKWASH OPERATION – WHEN SYSTEM CYCLE RUN TIMER ON
During AUTO Mode of operation, when the SYSTEM CYCLE RUN TIMER is
ON, if the differential pressure across the Ball Strainer exceeds 40 mbar*, the following
operations are carried out.
i. A time gap of 30 seconds (BACKWASH SEQUENCE LEAD TIMER - PLC internal
timer, 30seconds) is given to ensure that the increase in differential pressure is not due to
any momentary surge.
ii. If the differential pressure remains above 40 mbar* for more than 30 seconds, the
BACKWASH Indication will glow.
iii. The System Cycle Run Timer will hold its present value.
iv. The Ball Collector Outlet Valve is closed.
v. There will be a time gap of 30minutes (BALL COLLECTION TIMER – PLC internal
timer) to allow for ball collection in the Ball Collector.
vi. After the elapse of Ball Collection Timer, the Ball Collector Inlet Valve is closed.
vii. The Ball Recirculating Pump Motor is switched off, after the Ball Collector Inlet Valve is
fully closed.
DOC. No. GI 5320 106 09 014 REV.A
viii. The Ball Strainer Screens are moved from the "OPERATION" position to the
“BACKWASH" position.
ix. A time gap of 30minutes (BACKWASH TIME – PLC internal timer) is given for washing
the screens off the debris. The Ball Strainer Screens are moved from the "BACKWASH"
position to the "OPERATION" position.
x. A time gap of 2 Minutes is given for DP to stabilize after the screen comes to operation
position (DP stabilizing timer – (PLC Internal Timer).
xi. If the DP is less than 40 mbar*, the BACKWASH indication will be switched OFF. And
following steps will be carried out.
a) Ball Collector Inlet Valve will move from close position to open position.
b) The Ball Recirculating Pump Motor is switched ON, as soon as the Ball Collector Inlet
Valve starts opening.
c) The Ball Collector Outlet Valve is opened.
d) The System Cycle Run Timer will continue from the hold value.
xii. If there is no reduction still, then the Ball Strainer Screens will go to backwash again then
the BACKWASH indication will start to blink and the alarm is switched ON, System
Cycle Run Timer Will Reset and the screens will remain in BACKWASH POSITION.
Press FAULT ACKNOWLEDGE, the BACKWASH indication will glow steadily and the
alarm is switched OFF. Then Manual intervention is required to ascertain the cause of
continuous increase in DP. After rectification of DP, press FAULT RESET the
BACKWASH indication will go off. The system must be restarted by selecting the AUTO
MODE.
5.3. A.2 BACKWASH OPERATION –WHEN IDLE TIMER ON
During AUTO Mode of operation, when the IDLE TIMER is ON, if the differential
pressure across the Ball Strainer exceeds 40 mbar*, the following operations are carried
out.
i. A time gap of 30 seconds (BACKWASH SEQUENCE LEAD TIMER - PLC internal
timer, 30 seconds) will be given to ensure that the increase in differential pressure is not
due to any momentary surge. BACKWASH Indication ON. The IDLE Timer will hold
its present value.
ii. The Ball Strainer Screens will be moved from the "OPERATION" position to the
"BACKWASH" position.
iii. A time gap of 30 minutes (BACKWASH TIME – PLC internal timer) is given for
washing the screens off the debris. After 30 minutes of backwash, the Ball Strainer
Screens are moved from the "BACKWASH" position to the "OPERATION" position.
iv. A time gap of 2 Minutes is given for DP to stabilize after the screen comes to operation
position (DP stabilizing timer – PLC Internal Timer)
DOC. No. GI 5320 106 09 014 REV.A
v. If the DP is less than 40 mbar*, the BACKWASH indication will be switched OFF.
The system will be continuing idle timer from the hold value.
vi. If there is no reduction still, then the Ball Strainer Screens will go to backwash again
then the BACKWASH indication will start to blink and the alarm is switched ON, Idle
timer will reset and the screens will remain in Backwash Position. Press Fault
Acknowledge, the BACKWASH indication will glow steadily and the alarm is switched
OFF. Then Manual intervention is required to ascertain the cause of continuous increase
in DP. After rectification of DP, press Fault Reset the BACKWASH will go off. The
system must be restarted by selecting the AUTO MODE.
5.3. B. BACKWASH DURING MANUAL Mode
During Manual mode of operation, if the differential pressure across the Ball Strainer exceeds
40 mbar*, the following operations are to be carried out.
1. A time gap of 30 seconds (BACKWASH SEQUENCE LEAD TIMER - PLC internal
timer, 30 seconds) will be given to ensure that the increase in differential pressure is not
due to any momentary surge.
2. The Hooter is switched ON. And BACKWASH will start to blink.
3. Press Fault Acknowledge. The Hooter will be cut-off. And the BACKWASH indication
will glow steadily.
4. Move the Ball Strainer Screens to Backwash position by pressing the Backwash.
5. After 30 minutes of backwashing, bring the Ball Strainer Screens to operation position.
6. Check the DP across the screens. If the DP > 40 mbar* still, then repeat the procedure
from 4 to 6, as said above.
7. If the DP reduces i.e. DP < 40 mbar*. Press Fault Reset, then the BACKWASH
indication is turned OFF.
5.4. AUTO STOP SEQUENCES
When the AUTO STOP is pressed, AUTO STOP sequence is carried out. The AUTO STOP
can take place in following conditions.
1. When the WATERING TIMER is ON

2. When the SYSTEM CYCLE RUN TIMER is ON
3. When the BALL COLLECTION TIMER is ON
4. When the IDLE TIMER is ON
5.4.A AUTO STOP SEQUENCES -WHEN THE SYSTEM WATERING TIMER ON
During the AUTO operation, when the WATERING TIMER is ON, if AUTO STOP is
pressed, following sequence of operations will take place:
a. Ball Collector Inlet Valve will be closed.
DOC. No. GI 5320 106 09 014 REV.A
b. As soon as the feedback for Ball Collector Inlet Valve close is received, the Ball Recirculating
Pump Motor will be stopped.
c. AUTO STOP Indication will glow.
5.4.B AUTO STOP SEQUENCES - WHEN THE SYSTEM CYCLE RUN TIMER ON
During the AUTO operation, when the SYSTEM CYCLE RUN TIMER is ON, if AUTO
STOP is pressed, following sequence of operation will take place:
a. The Ball Collector Outlet Valve will be closed.
b. There will be a time gap of 30minutes (BALL COLLECTION TIMER –Adjustable PLC
internal timer) to allow for ball collection in the Ball Collector G01.
c. At the end of 30minutes, Ball Collector Inlet Valve will be closed.
d. As soon as the feedback for Ball Collector Inlet Valve close is received, the Ball Recirculating
Pump Motor will be switched off.
e. System cycle run timer de-energized.
f. AUTO STOP Indication will ON.
5.4.C AUTO STOP SEQUENCES -When the BALL COLLECTION TIMER ON
During the AUTO operation, when the BALL COLLECTION TIMER is ON, if AUTO
STOP is pressed, following sequence of operation will take place:
a. System continues the ball collection till the Ball Collection Timer elapses.
b. At the end of Ball Collection Timer elapses, Ball Collector Inlet Valve will be closed.
c. As soon as the feedback for Ball Collector Inlet Valve close is received, the Ball
Recirculating Pump Motor will be stopped.
d. AUTO STOP Indication will ON.
5.4.D AUTO STOP SEQUENCES - When the IDLE TIMER ON
During the AUTO operation, when the IDLE TIMER is ON, if AUTO STOP is pressed then
following sequence of operation will take place:
a. Auto sequence of operation will be stopped. Idle timer will be reset.

b. Auto Start indication will go off and Auto Stop indication will be ON.
DOC. No. GI 5320 106 09 014 REV.A
6.0. REMOTE MODE

REMOTE mode operation is same as Local mode except that the start and stop are initiated
from remote DCS. However, operation of individual drives can be done from local only.
"CTCS Start Permissive (CW PUMP running feedback)" signal from DCS shall enable the
permission for the CONDENSER TUBE CLEANING SYSTEM. When this signal comes from
DCS and initial condition are met, then we can start the CTCS by Local Auto/Remote Auto.
i.e. Auto start in Local panel/Remote Auto start from DCS. However, if this start permissive is
cut off during operation then Auto operation will be stopped.
7.0 BRM SEQUENCE IN AUTO MODE
a. Press the BRM ON function key manually in the PLC panel HMI, during system running
operation (Ball Injection cycle).
And the following operation takes place.
1. BRM Counting timer will be started (Adjustable timer – 10 Minutes, Present inside the
PLC panel).
b. 12 – 24 V DC supply is given to sensor. (12-24 V DC is generated by the BRM counter
provided in the PLC panel).
c. During this 10 Minutes of operation if counting input will be met set value* the system is
considered to be operating with sufficient number of balls.
During this 10 Minutes of operation if counting input will be not met set value* the system is
considered to be operating with insufficient number of balls. And BRM fail indication will be
generated. This BRM fail indication shall be monitored in the panel HMI.
d. Operator has to press reset function key (HMI). BRM fail indication shall be off.
Based on the balls output, system shall be allowed to continue for further system operation.
Note: * For setting value arriving procedure refer O&M Manual (Submitted during final
engineering).
8.0. SETTINGS OF TIMERS

1. Watering Timer : 05 Minutes (PLC Internal Timer -Adjustable)
2. System Cycle Run Timer : 4 hrs. (PLC Internal Timer- Adjustable)
3. Ball Collection Timer : 30 Minutes (PLC Internal Timer-Adjustable)
4. IDLE Timer : 20 Hours (PLC Internal Timer- Adjustable)
5. Backwash Timer : 30 Minutes (PLC Internal Timer-Adjustable)
6. BACKWASH Seq. Lead Timer : 30 Seconds (PLC Internal Timer- Adjustable)
7. DP Stabilizing Timer : 02 Minutes (PLC Internal Timer- Adjustable)
Notes:
1. Timer can be adjustable (0 to 999) from HMI in CTCS LOCAL CONTROL PANEL.
2. System Cycle timer shall be set/reduced further as per the site conditions.
DOC. No. GI 5320 106 09 014 REV.A
9.0 CONTROL LOGIC OPERATION IN THE EVENT OF ELECTRICAL /

SEQUENCE FAILURE DURING AUTO OPERATION
When the system is under auto operation if any of the following failures occur:
1. Failure of ball re-circulating pump motor
2. Failure of ball valve actuators
3. Failure of screen actuators
4. Run time error of screen and ball valve actuators.
5. Failure of feed back control signals to PLC.
The following sequence of operation takes place:
a. All the drives excepting the one under failure move to INITIAL position.
b. Audio alarm ON, Corresponding drive Fail Indication
Starts Blinking and Summary or Sequence Fail Indication Starts Blinking.
c. Press FAULT ACKNOWLEDGE to reset audio alarm.
The Corresponding Drive Fail Indication glows steadily and Summary or Sequence Fail Indication
glows steadily.
d. The operation sequence will reset to initial condition and AUTO START will be OFF and
AUTO STOP indication is ON.
e. Bring the system to Manual Mode.
f. AUTO STOP indication goes OFF. Rectify the fault.
g. RESET Fault by pressing the FAULT RESET.
h. Corresponding drive Fail Indication switch OFF and Summary or Sequence
Fail Indication switch OFF.
i. Bring the System to Auto Mode
j. READY TO START & AUTO STOP indications are ON and the system
is ready for auto operation as per normal automatic sequence.
10.0 LOGIC INTERLOCKS AND FEATURES
1. If Power Supply fails during Auto Operation, on resume of power, all the drives will be brought to
initial condition automatically.
2. If the START PERMISSIVE signal goes OFF during the auto operation, the system stops
immediately as per SEQUENCE STOP Logic.
3. The System can be operated in MANUAL mode to select MANUAL mode the selector (in LCP) to
be selected to MANUAL mode. This mode is predominately used for testing and commissioning
purposes. There is no interlock between the equipment’s in MANUAL mode.
2. The System can be operated in REMOTE AUTO mode to select REMOTE AUTO mode the
selector (in the LCP) to be selected to REMOTE AUTO mode. This mode of operation is same as
of LOCAL AUTO MODE except the start and stop are initiated from DCS instead from Local
panel.
DOC. No. GI 5320 106 09 014 REV.A
3. When the system is in "AUTO" mode (either in LOCAL AUTO MODE OR REMOTE AUTO
MODE), it will not respond for any manual pressing of Individual buttons and selector buttons in
the HMI.
4. However Manual override is possible by pressing the "Sequence stop" button in the Local panel.
Then system will come to initial condition immediately. Which means motors shall be switched Off
and Actuators shall move towards close position.
5. Ball Recirculating Pump Motor has to be switched off after completion of Ball Collector Inlet
Valve fully closed.
11.0. CAUSES FOR FAIL, INDICATIONS
11.1 BY MOTOR PROTECTION CIRCUIT BREAKER TRIP

If Motors/Valves are overloaded, the corresponding Motor Protection Circuit Breaker will trip
and FAIL Indication will glow. Press FAULT ACKNOWLEDGE so that fail indication will
glow steadily.
After the equipment is checked for the healthiness, reset the Motor Protection Circuit Breaker.
Press FAULT RESET, so that FAIL Indication goes OFF.
11.2 COLLECTIVE FAULT
If Collective Fault (Thermal Fail or torque fail) occurs in the actuator, corresponding actuator
FAIL will glow and the Corresponding command will de-energize, hooter is switched on. Press
FAULT ACKNOWLEDGE Key, Indication will glow steadily. And alarm is switched off.
After bringing the actuator to healthy condition, press FAULT RESET, FAIL Indication goes
OFF.
11.3 RUN TIME ERROR
During running period, if time taken by the Actuator is over headed, respective command will
be de-energized by PLC Internal Timer called runtime error timer and FAIL will blink.
ACTUAL SETTING
RUNNING PERIOD FOR FAIL
1. Screen Actuators 22 Sec. 26 Sec.
2. Valve Actuator 16 Sec. 20 Sec.
Press FAULT ACKNOWLEDGE, FAIL indication will glow steadily and after the End Travel
limit, press FAULT RESET, and FAIL indication will go OFF.
11.4 SUMMARY FAILURE INDICATION
During operation of the equipment, if problem in the Power Circuit i.e. problem in Over Load
Relay and Main Circuit Breaker, torque operation, and thermal switch open will cut off supply
to the particular equipment. The corresponding FAIL INDICATION will blink along with the
SUMMARY FAILURE Indication.
DOC. No. GI 5320 106 09 014 REV.A
11.5 SEQUENCE FAILURE INDICATION
During operation of the equipment, if problem in the Control Circuit i.e. runtime error, supply
to the particular equipment will cut off. The corresponding FAIL indication will blink along
with the SEQUENCE FAILURE indication.
11.6 FAULT ACKNOWLEDGE AND FAULT RESET
The SEQUENCE / SUMMARY FAILURE indication will blink along-with the corresponding
equipment FAIL indication for fault condition. The alarm will also be ON.
Press FAULT ACKNOWLEDGE, the SEQUENCE / SUMMARY FAILURE and
corresponding equipment FAIL indications will glow steadily. The alarm will be switched
OFF.
After rectification of the fault, Press FAULT RESET, SEQUENCE / SUMMARY FAILURE
indication and corresponding equipment FAIL indication will go OFF.
11.7 EMERGENCY STOP
If at any point during the operation of the CONDENSER TUBE CLEANING SYSTEM in the
“AUTO” mode, manual over-ride is possible by pressing the EMERGENCY STOP. The
CONDENSER TUBE CLEANING SYSTEM will be brought to the initial condition
immediately.
11.8 OPERATION DURING POWER FAILURE & ON
If power fails, in any of the logic sequence – manual interference is required for restarting.
a. On resume of Power Supply all the drives will be brought to initial position
(OFF/CLOSE/OPERATION) automatically.
b. Ensure the Bypass Valve in open condition.
c. Simultaneously Switch on the Ball Recirculating Pump Motor and Ball Collector Inlet
Valve manually by pressing Open.
d. Wait for 30 Minutes for Ball Collection.
e. After 30 Minutes all balls in the system will be collected in the Ball Collector.
f. Now close the Ball Collector Inlet Valve.
g. Switch off the Ball Recirculating Pump Motor
h. Bring the system to Auto mode.
i. Start the system in Auto mode using Auto start selection. Auto sequence will commence as
per normal operation sequence.
DOC. No. GI 5320 106 09 014 REV.A
12.0 EQUIPMENT STATUS FOR PROCESS OPERATION CYCLES
TIMER BRP OUTLET

INLET VALVE BALL SEPERATOR
SL.NO CYCLES / MOTOR VALVE
(N01) (T11,T12)
EQUIPMENTS (T91) (N02)
INITIAL
CONDITIONS/
1. OFF CLOSE CLOSE OPERATION
AUTO STOP
CONDITIONS
WATERING
2. ON OPEN CLOSE OPERATION
CYCLE
SYSTEM
3. ON OPEN OPEN OPERATION
CYCLE
BALL
4. COLLECTION ON OPEN CLOSE OPERATION
CYCLE
5. IDLE CYCLE OFF CLOSE CLOSE OPERATION
BACKWASH
6. OFF CLOSE CLOSE BACKWASH
CYCLE
X
Eder 20/04/22
X
Eder 30/03/22
X
Eder 27/06/22
Rev Date Description Prepared Checked Approved
No
A 14-03-2022 FOR APPROVAL K. SANTHOSH S. SHANTHI A.K. MANOHARAN
Eder 21/03/22

PROJECT :
CERRADO (43150 & 43151)
KS SS AKM GI 5320 104 02 004 A

General Arrangement of Ball

GBX/5320/2022 Distributor, Ball Injection Pipe –
Condenser Tube Cleaning System
INDEX
Sl.
DESCRIPTION
No.
1 BALL DISTRIBUTOR - DN 80 / 80 & DN 80 / 100
2 BALL INJECTION PIPE
GI 5320 104 02 004

SHEET 2 OF 6
1. BALL DISTRIBUTOR
TAG EMPTY Qty. / Total

KKS No. N1 N2 N3 A B C D E F
No. WEIGHT System Qty.
H11 -- 100 80 80 141.4 200 161 200 100 200 38 Kg. 1 No. 1 No.
H12 -- 80 80 80 141.4 200 161 200 100 200 36 Kg. 1 No. 1 No.
DESIGN DATA :
1. DESIGN TEMPERATURE 65°C

2. OPERATING PRESSURE < 6.0 bar (g)
3. DESIGN PRESSURE 6.0 bar (g)
4. HYDRO TEST PRESSURE 8.58 bar (g)
5. FLUID HANDLED COOLING TOWER WATER
DES-TDS-BD-ASME-RF-CS-106B GI 5320 104 02 004

SHEET 3 OF 6
NOTES :
1. All dimensions are in `mm’ unless specified

2. Refer P&I Diagram for the above Tag Numbers and KKS Numbers
3. All nozzle flange dimensions shall be as per ASME B16.5 Cl.150 lbs SORF
4. All bolt holes are straddle to center line unless specified.
BALL DISTRIBUTOR
PART MATERIAL QTY./
DESCRIPTION REMARKS
No. SPECIFICATION TAG No.
CARBON STEEL
1 SHELL 1
A 106 Gr.B
CARBON STEEL
2 COVERING PLATE 1
A 516 Gr.70
CARBON STEEL
3 PIPE (N1) 1
A 106 Gr.B
CARBON STEEL
4 FLANGE (N1) 1
A 105
CARBON STEEL
5 PIPE (N2 & N3) 2
A 106 Gr.B
CARBON STEEL
6 FLANGE (N2 & N3) 2
A 105
CARBON STEEL
7 SHELL FLANGE 1
A 516 Gr.70
8 GASKET EPDM (SH70°A±5) 2
CARBON STEEL
9 SPECIAL FLANGE 1
A 516 Gr.70
STUD, DOMED NUT STAINLESS STEEL
10 8 SET
AND WASHER SS 316 (A4)
11 SIGHT GLASS ACRYLIC 1
DES-TDS-BD-ASME-RF-CS-106B
GI 5320 104 02 004
SHEET 4 OF 6
2. BALL INJECTION PIPE
CW INLET PIPE SIZE DN 1400

TAG Installation Empty Qty. / Total
KKS No. A B C D
No. Type Weight System Qty.
L31 -- 890 787 280 NA 2 20.5 Kg. 1 No. 2 Nos.
L32 -- 890 787 280 NA 2 20.5 Kg. 1 No. 2 Nos.
DESIGN DATA :
1. DESIGN TEMPERATURE 65°C

2. OPERATING PRESSURE < 6.0 bar (g)
3. DESIGN PRESSURE 6.0 bar (g)
4. HYDRO TEST PRESSURE 8.58 bar (g)
5. FLUID HANDLED COOLING TOWER WATER
DES-TDS-BIP-ASME-RF-SS316 GI 5320 104 02 004

SHEET 5 OF 6
NOTES :
1. All dimensions are in `mm’ unless specified

2. All nozzle flange dimensions shall be as per ASME B16.5 Cl.150 lbs SORF (except Part No.2)
3. Refer P&I Diagram for the above Tag Numbers and KKS Numbers.
BALL INJECTION PIPE

MATERIAL QTY./
PART
DESCRIPTION TAG REMARKS
No. SPECIFICATION No.
STAINLESS STEEL ASME B16.5
1 FLANGE (DN 80) 1
A 182 F 316 CL.150 LBS SORF
STAINLESS STEEL DRILLING AS PER
2 SPECIAL FLANGE 1 ASME B16.5
A 240 TY 316 CL.150 LBS
STAINLESS STEEL
3 PIPE (DN 80) 1
A 312 TP 316
STAINLESS STEEL
4 PLATE 1
A 240 TY 316
CARBON STEEL ASME B16.5
5 FLANGE (DN 150) 1
A 106 Gr.B CL.150 LBS SORF
CARBON STEEL
6 PIPE (DN 150) 1
A 105
7 GASKET (DN 150) EPDM (SH70°A± 5) 1
BOLT, NUT & STAINLESS STEEL

8 8 SET
WASHER A4 (SS 316)
Sl. Nos. 5 – 8 are Purchaser’s (Siemens) Scope
DES-TDS-BIP-ASME-RF-SS316 GI 5320 104 02 004

SHEET 6 OF 6
PART 3
CONTENTS OF PART 3
1 WORM GEAR FOR BALL STRAINER 49
2 ACTUATOR FOR BALL STRAINER 62
3 ACTUATOR FOR BALL VALVE 66
4 MECHANICAL SEAL FOR PUMP 13
5 MOTOR FOR BALL RECIRCULATING PUMP 13
6 D.P. TRANSMITTER 20
7 CLEANING BALLS 6
8 BALL RECIRCULATING MONITOR 18
GI 5320 100 09 021

Part-turn gearboxes
GS 50.3 – GS 250.3
Operation instructions Assembly, commissioning

GS 50.3 – GS 250.3
Table of contents
Read operation instructions first.

●
Observe safety instructions.
●
These operation instructions are part of the product.
●
Retain operation instructions during product life.
●
Pass on instructions to any subsequent user or owner of the product.
Purpose of the document:

This document contains information for installation, commissioning, operation and maintenance staff. It is intended
to support device installation and commissioning.
Table of contents Page

1. Safety instructions................................................................................................................. 4
1.1. Basic information on safety 4
1.2. Range of application 4
1.3. Warnings and notes 5
1.4. References and symbols 5
2. Identification........................................................................................................................... 7
2.1. Name plate 7
2.2. Short description 9
3. Transport, storage and packaging........................................................................................ 10
3.1. Transport 10
3.2. Storage 12
3.3. Packaging 13
4. Assembly................................................................................................................................ 14
4.1. Mounting position 14
4.2. Handwheel fitting 14
4.3. Chainwheel: mount 14
4.3.1. Chainwheel for gearboxes GS 50.3 – GS 80.3: mount 15
4.3.2. Chainwheel for gearboxes GS 100.3 – GS 250.3: mount 16
4.4. Multi-turn actuators for motor operation 17
4.4.1. Mounting positions Multi-turn actuators with part-turn gearboxes 17
4.4.2. Input mounting flange: mount 18
4.5. Gearbox to valve: mount 19
4.5.1. Output drive for coupling 19
4.5.1.1. Gearbox with coupling: mount to valve 19
5. Indications.............................................................................................................................. 22
5.1. Mechanical position indicator/running indication 22
6. Commissioning...................................................................................................................... 23
6.1. End stops in gearbox 23
6.1.1. End stop CLOSED: set 23
6.1.2. End stop OPEN: set 24
6.2. Seating in end positions via multi-turn actuator 25
6.2.1. Seating in end position CLOSED: set 25
6.2.2. Seating in end position OPEN: set 26
6.3. Swing angle 26
6.3.1. Swing angle: modify at gearboxes up to size 125.3 26
6.3.2. Swing angle: modify at gearboxes from size 160.3 27
2
GS 50.3 – GS 250.3
Table of contents
6.4. Mechanical position indicator: set 28

7. Servicing and maintenance................................................................................................... 30
7.1. Preventive measures for servicing and safe operation 30
7.2. Maintenance intervals 30
7.3. Disposal and recycling 30
8. Technical data......................................................................................................................... 32
8.1. Technical data Part-turn gearboxes 32
9. Spare parts............................................................................................................................. 39
9.1. Part-turn gearboxes GS 50.3 – GS 125.3 39
9.2. Part-turn gearboxes GS 160.3 – GS 250.3 41
9.3. Primary reduction gearings for GS 100.3 – GS 125.3 (126:1/160:1/208:1) 43
9.4. Primary reduction gearings for GS 160.3 (218:1/442:1) GS 200.3 (214:1/434:1) GS 250.3 45
(210:1/411:1)
9.5. Primary reduction gearings for GS 200.3 (864:1) GS 250.3 (848:1) 47
10. Certificates.............................................................................................................................. 49
10.1. Declaration of Incorporation and EU Declaration of Conformity 49
Index........................................................................................................................................ 52
Addresses............................................................................................................................... 54
3
GS 50.3 – GS 250.3
Safety instructions
1. Safety instructions
1.1. Basic information on safety
Standards/directives Our products are designed and manufactured in compliance with recognised
standards and directives. This is certified in a Declaration of Incorporation and an
EU Declaration of Conformity.
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly,
electrical connection, commissioning and operation are met at the place of installation.
Safety instructions/warn- All personnel working with this device must be familiar with the safety and warning
ings instructions in this manual and observe the instructions given. Safety instructions
and warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must
be carried out exclusively by suitably qualified personnel having been authorised by
the end user or contractor of the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules
regarding occupational health and safety.
Work performed in potentially explosive atmospheres is subject to special regulations
which have to be observed. The end user or contractor of the plant are responsible
for respect and control of these regulations, standards, and laws.
Commissioning Prior to commissioning, it is important to check that all settings meet the requirements
of the application. Incorrect settings might present a danger to the application, e.g.
cause damage to the valve or the installation. The manufacturer will not be held
liable for any consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:

● Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
● Only operate the device if it is in perfect condition while observing these instruc-
tions.
● Immediately report any faults and damage and allow for corrective measures.
● Observe recognised rules for occupational health and safety.
● Observe the national regulations.
● During operation, the device warms up and increased surface temperature may
occur. To prevent possible burns, we recommend checking the surface temper-
ature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior consent of the manufacturer.
1.2. Range of application
AUMA part-turn gearboxes are designed for the operation of industrial valves, e.g.
butterfly valves, ball valves and dampers.
Other applications require explicit (written) confirmation by the manufacturer.
The following applications are not permitted, e.g.:

● Industrial trucks according to EN ISO 3691
4
GS 50.3 – GS 250.3
Safety instructions
● Lifting appliances according to EN 14502

● Passenger lifts according to DIN 15306 and 15309
● Service lifts according to EN 81-1/A1
● Escalators
● Continuous duty
● Potentially explosive atmospheres in combination with F21 lubricant type (refer
to name plate)
● Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's
designated use.
1.3. Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these

operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure

to observe this warning could result in death or serious injury.
Indicates a potentially hazardous situation with a medium level of risk. Failure

Indicates a potentially hazardous situation with a low level of risk. Failure to

observe this warning may result in minor or moderate injury. May also be used
with property damage.
Potentially hazardous situation. Failure to observe this warning may result in

property damage. Is not used for personal injury.
Arrangement and typographic structure of the warnings
Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)
→ Measures to avoid the danger
→ Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.

The signal word (here: DANGER) indicates the level of hazard.
1.4. References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)

Symbol for OPEN (valve open)
Important information before the next step. This symbol indicates what is required
for the next step or what has to be prepared or observed.
5
GS 50.3 – GS 250.3
Safety instructions
<> Reference to other sections

Terms in brackets shown above refer to other sections of the document which provide
further information on this topic. These terms are either listed in the index, a heading
or in the table of contents and may easily be located.
6
GS 50.3 – GS 250.3
Identification
2. Identification
2.1. Name plate
Figure 1: Arrangement of name plates
[1] Gearbox name plate

[2] Additional plate, e.g. KKS plate (Power Plant Classification System)
Description of gearbox name plate

Figure 2: Gearbox name plate (example GS 250.3)
[1] Name of manufacturer

[2] Address of manufacturer
[3] Type designation - valve attachment (flange)
[4] Order number
[5] Serial number
[6] Reduction ratio
[7] Factor
[8] Max. valve torque (output torque)
[9] Type of lubricant
[10] Permissible ambient temperature
[11] Explosion-proof version (option)
[12] Can be assigned as an option upon customer request
[13] Enclosure protection
[14] Duty class
[15] Version
[16] Swing angle
[17] Data Matrix code
Type designation Figure 3: Type designation (example)
1. Type and size of gearbox
7
GS 50.3 – GS 250.3
Identification
2. Flange size for valve attachment

Type and size
These instructions apply to the following device types and sizes:
Part-turn gearboxes of type GS, sizes 50.3 – 250.3
Order number The product can be identified using this number and the technical data as well as
order-related data pertaining to the device can be requested.
Please always state this number for any product inquiries.
On the Internet at http://www.auma.com, we offer a service allowing authorised
users to download order-related documents such as wiring diagrams and technical
data (both in German and English), inspection certificates and the operation
instructions when entering the order number.
Serial number
Description of the serial number (with the example of 0512CG12345)
05 15 CG12345
05 Positions 1 + 2 : Assembly in week = week 05
15 Positions 3 + 4 : Year of manufacture = 2015
CG12345 Internal number for unambiguous product identification
Reduction ratio The reduction ratio within gearing and primary reduction gearing reduces the required
input torques and increases the operating time.
Factor Mechanical conversion factor for actuator size determination:
Input torque = required valve torque (output torque)/factor
Type of lubricant AUMA abbreviation for type of lubricant used in the gear housing.
Danger of explosion when using inappropriate lubricant in potentially explosive

atmospheres!
→ Do not use gearboxes with F21 lubricant in potentially explosive atmospheres.
→ Do not mix different lubricants.
Duty class The duty class specifies the application range of a gearbox relating to the lifetime
requirements. The duty class is only specified for gearboxes in operation mode class
A (OPEN-CLOSE duty).
● Duty class 1: suitable for motor operation, meets the lifetime requirements of
EN 15714-2
● Duty class 2: suitable for motor operation of rarely or infrequently operated
valves which do not exceed 1,000 operations across their total lifetime.
● Duty class 3: suitable (exclusively) for manual operation with approximately
250 operations, in compliance with the specified lifetime requirements in EN
1074-2.
Please refer to separate Technical data for further information on duty classes.
Version The first letter of the version indicates the position of the worm shaft in relation to
the worm wheel (view on input shaft).
The second letter indicates the direction of rotation at the output drive (view on
housing cover) for clockwise rotation at the input shaft.
8
GS 50.3 – GS 250.3
Identification
Versions: Worm shaft position and direction of rotation of output drive GS 50.3 – GS 250.3
RR LL RL LR
Description of the four different versions (view on housing cover):
Initials Direction of rotation at input shaft Position of worm shaft Direction of rotation at output drive
RR Clockwise Right Clockwise
LL Clockwise Left Counterclockwise
RL Clockwise Right Counterclockwise
LR Clockwise Left Clockwise
Data Matrix code When registered as authorised user, you may use the AUMA Support App to scan
the Data Matrix code and directly access the order-related product documents without
having to enter order number or serial number.
Figure 4: Link to the App store:
2.2. Short description
AUMA worm gearboxes are part-turn gearboxes converting a rotary movement at

the input shaft into a part-turn movement at the output drive. The worm gearboxes
are driven either via electric motor (by means of a multi-turn actuator) or manually
(e.g. via a handwheel). The required input torques are reduced due to high reduction
ratios. In standard version, internal end stops limit the swing angle to 100°.
Worm gearboxes are available in different versions to implement various mounting
conditions and rotary directions.
9
GS 50.3 – GS 250.3
Transport, storage and packaging
3. Transport, storage and packaging

3.1. Transport
For transport to place of installation, use sturdy packaging.
The coupling is not secured within the gearbox. Risk of falling out!
Injury hazard.
→ Remove coupling from gearbox housing prior to transport.
Figure 5: Coupling
Hovering load!
Risk of death or serious injury.
→ Do NOT stand below hovering load.
→ Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT
to handwheel.
→ Check eyebolts for tight seat in housing (verify reach of the screws).
→ Observe manufacturer specifications for fixing lifting straps and round slings.
→ Respect total weight of combination (gearbox, primary reduction gearing, actu-
ator).
Information Up to size 125.3, gearboxes are not equipped with special transport threads. Sus-
pension is possible using lifting straps/round slings.
From size 160.3, transport threads are provided for fixing with eyebolts. Eyebolts
are not included in the scope of delivery.
Examples of transport without actuator
Figure 6: Example of GS 50.3 – GS 125.3
10
GS 50.3 – GS 250.3
Figure 7: Examples of GS 160.3 – GS 250.3
[1] Worm shaft placed horizontally, with 2 eyebolts

[2] Worm shaft placed vertically, with one eyebolt
Examples of transport with mounted actuator/actuator controls
Figure 8: Examples of GS 50.3 – GS 125.3, vertical suspension
[1] Sizes 50.3 – 80.3, as well as 100.3/125.3 with i = 52:1/107:1

[2] Sizes 100.3/125.3 with i = 126:1/160:1/208:1
Place lifting straps/slings around the flange!
11
GS 50.3 – GS 250.3
Figure 9: Example of GS 50.3 – GS 250.3, horizontal suspension
Strap/sling arrangement
[1] View on front
[2] View on rear
Table 1:
Weights including grease filling in gear housing
Type Standard version Version with base and lever
[kg]1) [kg]
GS 50.3 7 10
GS 63.3 12 23
GS 80.3 16 29
GS 100.3 (52:1/107:1) 33 58
GS 100.3 (126:1/160:1/208:1) 39 64
GS 125.3 (52:1) 40 89
GS 125.3 (126:1/160:1/208:1) 46 95
GS 160.3 (54:1) 80 139
GS 160.3 (218:1/442:1/880:1) 91 150
GS 200.3 (53:1) 140 258
GS 200.3 (214:1/434:1) 160 278
GS 200.3 (864:1/1 752:1) 170 288
GS 250.3 (52:1) 273 467
GS 250.3 (210:1/411:1) 296 490
GS 250.3 (848:1/1 718:1) 308 502
Additional weights when mounting extension flanges
F30 for GS 125.3 18
F35 for GS 160.3 33
F40 for GS 200.3 48
F48 for GS 250.3 75
1) Specified weight includes unmachined coupling
3.2. Storage
Danger of corrosion due to inappropriate storage!

→ Store in a well-ventilated, dry room (maximum humidity 70 %).
→ Protect against floor dampness by storage on a shelf or on a wooden pallet.
→ Cover to protect against dust and dirt.
→ Apply suitable corrosion protection agent to uncoated surfaces.
Long-term storage For long-term storage (more than 6 months), observe the following points:
12
GS 50.3 – GS 250.3
1. Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting
surface, with long-term corrosion protection agent.
2. At an interval of approx. 6 months:
Check for corrosion. If first signs of corrosion show, apply new corrosion protec-
tion.
3.3. Packaging
Our products are protected by special packaging for transport when leaving the
factory. The packaging consists of environmentally friendly materials which can easily
be separated and recycled. We use the following packaging materials: wood,
cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.
13
GS 50.3 – GS 250.3
Assembly
4. Assembly
4.1. Mounting position

The gearboxes described here can be operated without restriction in any mounting
position.
4.2. Handwheel fitting

Gearboxes designed for manual operation are supplied with a separate handwheel.
Fitting is performed on site according to the description below.
Figure 10: Handwheel
[1] Retaining ring for input shaft (partly required)

[2] Gear input shaft
[3] Spacer (partly required)
[4] Handwheel
[5] Spacer (partly required)
[6] Retaining ring
[7] Ball handle
1. For input shafts with keyway: Place retaining ring [1] onto input shaft [2].
2. If required, fit spacer [3].
3. Slip handwheel [4] onto input shaft.
4. If required, fit spacer [5].
5. Secure handwheel [4] using the retaining ring [6] supplied.
6. Fit ball handle [7] to handwheel.
4.3. Chainwheel: mount
For gearboxes to be operated via chainwheel, the chainwheel is supplied separately.
Fitting is performed on site according to the description below.
Information Use in explosion-proof atmospheres is not permitted!
Gearboxes supplied without chainwheel can be retrofitted with a chainwheel. For
sizes 50.3 – 80.3, a special bearing cover is to be mounted for retrofitting.
14
GS 50.3 – GS 250.3
Assembly
4.3.1. Chainwheel for gearboxes GS 50.3 – GS 80.3: mount
Figure 11: Mount chain guide and chainwheel
[1] Thrust washers

[2] Chain guide
[3] Retaining ring for chain guide
[4] Retaining rings for chainwheel
Chain guide 1. Fit thrust washer [1] on input shaft.

2. Fit chain guide [2].
3. Fit second thrust washer [2].
4. Secure chain guide with retaining ring [3].
Chainwheel 5. Fit retaining ring [4] on input shaft.
6. Place chainwheel onto input shaft.
7. Secure chainwheel with second retaining ring [4].
Chain Figure 12: Mount chain
8. Pull chain through chain guide and place across chainwheel.

9. Connect chain ends with spare chain link.
Information: Do not twist chain!
15
GS 50.3 – GS 250.3
Assembly
4.3.2. Chainwheel for gearboxes GS 100.3 – GS 250.3: mount
Figure 13: Mount chain guide and chainwheel
[1] Thrust washers

[2] Washer
[3] Chain guide
[4] Retaining rings for chainwheel
Chain guide 1. Fit thrust washer [1] on input shaft.

2. Also place washer [2].
3. Fit chain guide [3].
4. Fit second thrust washer [2].
5. Fasten chain guide with 4 screws.
Chainwheel 6. Fit retaining ring [4] on input shaft.
7. Place chainwheel onto input shaft.
8. Secure chainwheel with second retaining ring [4].
Chain Figure 14: Mount chain
9. Pull chain through chain guide and place across chainwheel.

10. Connect chain ends with spare chain link.
Information: Do not twist chain!
16
GS 50.3 – GS 250.3
Assembly
4.4. Multi-turn actuators for motor operation
Refer to the operation instructions pertaining to the multi-turn actuator for indications
on how to mount multi-turn actuators to gearboxes.
This chapter supplies basic information and instructions which should be considered
in addition to the operation instructions of the multi-turn actuator.
Screws to actuator
Screws are included in the scope of delivery of the gearbox for mounting AUMA
multi-turn actuators. When mounting other actuators, the screws might be either too
long or too short (insufficient reach of screws).
Risk of actuator falling off in case inappropriate screws used should shear.
Risk of death or serious injury!
→ Check length of screws.
→ Only use screws with strength class specified herein.
The reach of screws must be sufficient for the internal threads to ensure the
supporting strength of the device and to accept the lateral forces due to the applied
torque.
Screws which are too long could make contact with the housing parts, presenting
the risk that the device performs a radial shift with respect to the gearbox. This can
lead to shearing of the screws.
4.4.1. Mounting positions Multi-turn actuators with part-turn gearboxes
Mounting positions A – D for multi-turn actuators with part-turn gearboxes

GS versions RR and LL
A B C1) D
GS versions LL and LR
A1) B C D
1) Caution: For multi-turn actuators SA/SAR 14.2 and 14.6 with GS 125.3, mounting position C is not possible for RR and RL versions;
mounting position A is not possible for LL and LR versions.
Please consider possible space constraints on site when selecting the mounting
position.
Mounting positions may easily be changed at a later date.
17
GS 50.3 – GS 250.3
Assembly
Up to size GS 125.3, the multi-turn actuator-gearbox combination is delivered in the

ordered mounting position. For packing reasons, actuator and gearbox will be
delivered separately from size GS 160.3.
4.4.2. Input mounting flange: mount
An input mounting flange is required for mounting a multi-turn actuator. Depending
on the version, the flange for mounting the multi-turn actuator is already fitted in the
factory.
Table 2:
Suitable input mounting flanges
Gearboxes Reduction ratio Input shaft Input mounting flange for mounting multi-turn actuators
[mm] EN ISO 5210 DIN 3210
GS 50.3 51:1 16 F07, F10 G0
51:1 20
GS 63.3 F07, F10 G0
82:1 20
53:1 20
GS 80.3 F07, F10 G0
82:1 20
52:1 30/(20) F14 (F10) G1/2 (G0)
107:11) 30 F14 (F10) G1/2 (G0)
GS 100.3 126:11) 30 F10 G0
260:11) 30 F10 G0
208:11) 30 F10 G0
52:1 30 F14 G1/2
126:11) 30/(20) F14 (F10) (G0)
GS 125.3
160:11) 30/(20) F14 (F10) (G0)
208:11) 20 F10, F14 G0
54:1 30 F16 (F14) G3 (G1/2)
218:11) 30/(20) F14 (F10) G1/2 (G0)
GS 160.3
442:11) 20 F10 G0
880:11) 20 F10 G0
53:1 40 F25 (F16) (G3)
1) 30 F14 G1/2
GS 200.3 434:11) 30/(20) F14 (F10) G1/2 (G0)
864:11) 20 F14 G0
1,752:11) 20 F10 G0
52:1 50 F30 (F25) –
210:11) 40/(30) F16 (F14) G3 (G1/2)
GS 250.3 411:11) 30 F14 G1/2
848:11) 30/(20) F14 (F10) G1/2 (G0)
1 718:11) 20 F10 G0
1) Equipped with primary reduction gearing or planetary gearing to reduce input torques.
Assembly steps 1. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
Figure 15: Mounting example, input mounting flange fitted to gearbox with primary
reduction gearing
[1] Gearbox with primary reduction gearing

[2] Parallel pin
[3] Input mounting flange
2. Mount parallel pin [2].
18
GS 50.3 – GS 250.3
Assembly
3. Place input mounting flange [3] and fasten with screws.

4. Fasten screws crosswise to a torque according to table.
Table 3:
Tightening torques for screws (for mounting multi-turn actuator and input mounting flange)
Threads Tightening torque Nm]
Strength class A2-80
M8 24
M10 48
M12 82
M16 200
M20 392
5. Mount AUMA actuator in compliance with the operation instructions pertaining

to the multi-turn actuator.
4.5. Gearbox to valve: mount
The gearbox is mounted to the valve using a coupling (standard) or via lever. Separate
instructions are available for actuator mounting to the valve when equipped with
base and lever.
4.5.1. Output drive for coupling
Application ● For valve attachments according to EN ISO 5211

● For rotating, non-rising valve stem
Design Figure 16: Valve attachment via coupling
[1] Gearbox worm wheel with internal splines

[2] Splined plug-in coupling
[3] Valve shaft (example with key)
4.5.1.1. Gearbox with coupling: mount to valve

Unbored couplings or couplings with pilot bore must be machined to match the valve
shaft prior to mounting the gearbox to the valve (e.g. with bore and keyway, two-flat
or square bore).
Information Assemble valve and gearbox in the same end position. As a standard, the gearbox
is supplied in end position CLOSED.
● Recommended mounting position for butterfly valves: End position CLOSED.
● Recommended mounting position for ball valves: End position OPEN.
Assembly steps 1. If required, move gearbox in same end position as valve using the handwheel.
2. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
Information: To avoid contact corrosion, we recommend applying a surface
sealing agent on the uncoated contact surfaces for gearboxes without powder
coating.
19
GS 50.3 – GS 250.3
Assembly
3. Apply a small quantity of grease to the valve shaft [2].

4. Place coupling [1] onto valve shaft [2] and secure against axial slipping by using
a grub screw [3] or a clamping washer and a screw with curved spring lock
washer [4]. Thereby, ensure that dimensions X, Y or L are observed (refer to
figure and table <Mounting positions for coupling>).
Figure 17: Examples: Fit coupling
[1] Coupling
[2] Valve shaft
[3] Grub screw
[4] Clamping washer and screw with curved spring lock washer
Figure 18: Mounting positions for coupling
Table 4:
Dimensions [mm] GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
EN ISO 5211 F05 F10 F10 F12 F12 F14 F14 F16 F16 F25 F301)
X max. 6 14 7 10 13 23 22 22 17 17 35
Y max. 5 5 18 13 18 5 13 8 35 27 0
L max. 61 61 61 73 76 78 88 123 123 126 126
1) Extension flange, extended coupling required
Table 5:
Dimensions [mm] GS 160.3 GS 200.3 GS 250.3
EN ISO 5211 F25 F301) F35 F30 F35 F401) F35 F40 F481)
X max. 15 30 30 19 44 44 8 13 20
Y max. 11 0 0 19 0 0 8 0 5
L max. 130 140 130 160 190 160 220 230 220
1) Extension flange, extended coupling required
20
GS 50.3 – GS 250.3
Assembly
5. Apply non-acidic grease at splines of coupling (e.g. Gleitmo by Fuchs).

6. Experience showed that it is very difficult to fasten screws or nuts of size M30
or larger at defined torques. There is a risk that the worm gearbox might shift
radially with regard to the valve mounting flange. To improve adhesion between
valve and gearbox, we recommend applying Loctite 243 (or similar adhesive
products) to the mounting faces of screws and nuts from size M30.
7. Fit gearbox. If required, slightly turn gearbox until splines of coupling engage.
Figure 19:
Information Ensure that the spigot (if provided) fits uniformly in the recess and that the flanges
are in complete contact.
8. If flange bores do not match thread:

8.1 Slightly rotate handwheel until bores line up.
8.2 If required, shift gearbox position by one tooth on the coupling.
9. Fasten gearbox with screws.
Information: We recommend applying liquid thread sealing material to the
screws to avoid contact corrosion.
Table 6:
Tightening torques for screws
Threads Tightening torque Nm]
Strength class
A2-70/A4-70 A2-80/A4-80
M6 8 10
M8 18 24
M10 36 48
M12 61 82
M16 150 200
M20 294 392
M30 564 1,422
M36 2,098 2,481
21
GS 50.3 – GS 250.3
Indications
5. Indications
5.1. Mechanical position indicator/running indication
Mechanical position indicator:
● continuously indicates the valve position
(pointer cover [2] follows the valve movement)
● indicates whether the actuator is moving (running indication)
● indicates that end positions have been reached
(mark on pointer cover [3] points to symbols OPEN [4] or CLOSED [5])
Figure 20: Mechanical position indicator
[1] Housing cover

[2] Pointer cover
[3] Indicator mark
[4] Symbol for position OPEN
[5] Symbol for position CLOSED
22
GS 50.3 – GS 250.3
Commissioning
6. Commissioning
6.1. End stops in gearbox

The internal end stops limit the swing angle and protect the valve against overload.
End stop setting is generally performed by the valve manufacturer prior to installing
the valve into the pipework.
Exposed, rotating parts (discs/balls) at the valve!

Pinching and damage at the valve.
→ End stops should be set by suitably qualified personnel only.
→ Set end stops as to ensure that they are NOT reached during normal operation.
Information The setting sequence depends on the valve:

● Recommendation for butterfly valves: Set end stop CLOSED first.
● Recommendation for ball valves: Set end stop OPEN first.
Information ● In general, gearboxes with a swing angle > 190° are multi-turn (without end
stops). Consequently, end position setting is not possible. Therefore, no protect-
ive function is available for the valve.
● In general, only one end stop (either OPEN or CLOSED) must be set, due to
the fact that the swing angle was already set in the factory.
6.1.1. End stop CLOSED: set
Figure 21: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
1. Remove the four screws [1] at end stop [2].
No overload protection at valve for unfastened end stop!

→ In motor operation: Stop travel before reaching the valve end position (consider
overrun).
→ The last part of the travel must be completed in manual operation mode.
2. Turn valve via handwheel to position CLOSED. Check whether end stop [2]
rotates simultaneously.
→ Otherwise: Turn end stop [2] clockwise to the stop.
23
GS 50.3 – GS 250.3
Commissioning
3. With mounted multi-turn actuator (not required for manual operation): Turn end
stop [2] counterclockwise by 1/4 turn.
➥ This ensures that the gearbox end stop cannot be approached during motor
operation if a multi-turn actuator is mounted and that the valve can close tightly
for torque seating.
4. In case the four holes of the end stop [2] do not match the four threaded bores
within the housing [3]: Remove end stop [2] until it disengages from the toothing
and replace in correct position.
5. Fasten screws [1] crosswise with a torque according to table <Tightening torques
for screws at end stop> .
Table 7:
Tightening torques for screws at end stop
Gearbox Screws [1] Tightening torque TA [Nm]
GS 50.3 M6 10
GS 50.3 – GS 80.3 M8 24
GS 100.3 – GS 125.3 M12 82
GS 160.3 M10 48
GS 200.3 M12 82
GS 250.3 M16 200
Further settings hereafter:

● If the gearbox is equipped with a pointer cover: Check whether the mark aligns
with the symbol CLOSED. Refer to <Mechanical position indicator: set>.
● If the gearbox is mounted to a multi-turn actuator, set the seating in end position
CLOSED straight after completion of the current setting: <Seating in end posi-
tions via multi-turn actuator>.
6.1.2. End stop OPEN: set
Figure 22: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
1. Remove the four screws [1] at end stop [2].
No overload protection at valve for unfastened end stop!

→ In motor operation: Stop travel before reaching the valve end position (consider
overrun).
→ The last part of the travel must be in manual operation mode.
2. Turn valve via handwheel in position OPEN. Check whether end stop [2] rotates
simultaneously.
→ Otherwise: Turn end stop [2] counterclockwise to the stop.
24
GS 50.3 – GS 250.3
Commissioning
3. With mounted multi-turn actuator (not required for manual operation): Turn end
stop [2] clockwise by 1/4 turn.
➥ This ensures that the gearbox end stop cannot be approached during motor
operation if a multi-turn actuator is mounted and that the valve can close tightly
for torque seating.
4. In case the four holes of the end stop [2] do not match the four threaded bores
within the housing [3]: Remove end stop [2] until it disengages from the toothing
and replace in correct position.
5. Fasten screws [1] crosswise with a torque according to table <Tightening torques
for screws at end stop>.
Further settings hereafter:
● If the gearbox is equipped with a pointer cover: Check whether the mark aligns
with the symbol OPEN. Refer to <Mechanical position indicator: set>.
● If the gearbox is mounted to a multi-turn actuator, set the seating in end position
OPEN straight after completion of the current setting: <Seating in end positions
via multi-turn actuator>.
6.2. Seating in end positions via multi-turn actuator
This chapter supplies basic information and notes which should be considered in
addition to the operation instructions of the multi-turn actuator.
● The valve manufacturer has to determine whether the valve is limit or torque
seated.
● End position seating must be set in compliance with the operating instructions
pertaining to the multi-turn actuator.
● When setting the torque switching within the multi-turn actuator, make sure that
the tripping torque for both directions does not exceed the max. gearbox input
torque (refer to technical data or name plate).
● Set the torque switching within the multi-turn actuator to the following value to
prevent damage to the valve:
Tripping torque = valve torque/factor (refer to name plate)
● If the swing angle set in the factory for opening and closing the valve is not
sufficient: refer to <Swing angle>.
6.2.1. Seating in end position CLOSED: set
1. Move valve to end position CLOSED.

Information: The last part of the travel must be in manual operation mode!
2. For limit seating in end position CLOSED:
2.1 Turn back the valve from the valve end position by an amount equal to
the overrun.
2.2 Set limit switching for the end position CLOSED according to the operation
instructions for the multi-turn actuator.
3. For torque seating in end position CLOSED:
3.1 Gearbox without primary reduction gearing: Turn handwheel in the opposite
direction of the valve end position by approx. 4 – 6 turns.
3.2 Gearbox with primary reduction gearing: Turn handwheel in the opposite
3.3 Check torque switching for end position CLOSED according to operation
instructions for multi-turn actuator and, if necessary, set to required value.
3.4 Set limit switching for signalling end position CLOSED according to oper-
ation instructions for multi-turn actuator.
25
GS 50.3 – GS 250.3
Commissioning
6.2.2. Seating in end position OPEN: set
1. Move valve to end position OPEN.

Information: The last part of the travel must be in manual operation mode!
2. For limit seating in end position OPEN:
2.1 Turn back the valve from the valve end position by an amount equal to
the overrun.
2.2 Set limit switching for end position OPEN according to the operation in-
structions for the multi-turn actuator.
3. For torque seating in end position OPEN:
3.1 Gearbox without primary reduction gearing: Turn handwheel in the opposite
3.2 Gearbox with primary reduction gearing: Turn handwheel in the opposite
3.3 Check torque switching for end position OPEN according to operation in-
structions for multi-turn actuator and, if necessary, set to required value.
3.4 Set limit switching for signalling end position OPEN according to operation
instructions for multi-turn actuator.
6.3. Swing angle

The swing angle must only be changed if the swivel range for end stop setting is not
sufficient.
Figure 23: Name plate indicating the swing angle
Versions Sizes GS 50.3 – GS 125.3 = adjustable swing angle - option

Sizes GS 160.3 – GS 250.3 = adjustable swing angle - standard
Accuracy Sizes GS 50.3 – GS 125.3 = 0.6°
Sizes GS 160.3 – GS 250.3 = 0.11° up to 0.14°
6.3.1. Swing angle: modify at gearboxes up to size 125.3
The adjustment is made in end position OPEN.

Special tools: Pin driver for spring-type straight pin
● for GS 50.3 (AUMA art. no. V001.367-Pos.003)
● for GS 63.3 – GS 80.3 (AUMA art. no. V001.367-Pos.002)
● for GS 100.3 – GS 125.3 (AUMA art. no. V001.367-Pos.001)
26
GS 50.3 – GS 250.3
Commissioning
Figure 24: End stop (figure shows size 80.3)
[1] Protective cap

[2] End stop
[3] Spring-type straight pin
[4] End stop nut
[5] Pairs of safety wedge discs (for OPEN and CLOSE)
1. Unscrew protective cap [1] at end stop [2].

2. Remove spring-type straight pin [3] with suitable pin driver (special tool).
3. Swing angle increase:
3.1 Turn end stop nut [4] counterclockwise.
Information: When turning counterclockwise the end stop nut [4] make
sure that the spring-type straight pin [3] can still be tapped within the oblong
hole.
3.2 Move valve manually to the desired end position OPEN.
3.3 Turn end stop nut [4] clockwise until it is tight to the travelling nut.
4. Swing angle reduction:
4.2 Turn end stop nut [4] clockwise until it is tight to the travelling nut.
Information: Spring-type straight pin [3] must remain completely covered
by end nut [4].
5. Drive in the spring-type straight pin [3] using the appropriate tool.
→ If the slot provided in the end stop nut [4] does not align with the bore of
the worm shaft: Turn end stop nut [4] slighty counterclockwise until the
hole is aligned; then drive in spring-type straight pin [3].
6. Check whether O-ring at protective cap is in good condition, replace if damaged.
7. Fasten protective cap [1].
Information If the gearbox is mounted to a multi-turn actuator, the limit switching for the end po-
sition OPEN must be set first in compliance with the operation instructions of the
multi-turn actuator. Allow for overrun!
6.3.2. Swing angle: modify at gearboxes from size 160.3
Adjustments are generally made in end position OPEN.
27
GS 50.3 – GS 250.3
Commissioning
Figure 25: End stop (figure shows size 200.3)
[1] Screws
[2] Protective cap
[3] Screw with curved spring lock washer
[4] Clamping washer
[5] Setting ring
[6] End stop nut
[7] Travelling nut
[8] Pairs of safety wedge discs (for OPEN and CLOSE)
1. Remove all four screws [1] and pull off protective cap [2].
2. Remove the screw with the curved spring lock washer [3] and clamping washer
[4].
3. Pull off setting ring [5].
4. Swing angle increase:
4.1 Turn end stop nut [6] counterclockwise.
4.3 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
5. Swing angle reduction:
5.2 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
6. Fit setting ring [5], secure with clamping washer [4], as well as screw and curved
spring lock washer [3].
7. Check whether O-ring at protective cap is in good condition, replace if damaged.
8. Place protective cap [2] and fasten screws [1] crosswise with a torque according
to table <Tightening torques for screws at end stop>.
Information If the gearbox is mounted to a multi-turn actuator, the limit switching for the end po-
sition OPEN must be set first in compliance with the operation instructions of the
multi-turn actuator.
6.4. Mechanical position indicator: set
End position CLOSED 1. Move valve to end position CLOSED and check setting.
➥ The setting is correct if the mark aligns with the symbol CLOSED.
28
GS 50.3 – GS 250.3
Commissioning
2. If the mark position is not correct:

2.1 Slightly loosen screws [1] at pointer cover [two screws up to size 125.3,
four screws as from size 160.3).
2.2 Turn pointer cover to symbol for position CLOSED [5].
2.3 Fasten screws again.
End position OPEN 3. Move valve to end position OPEN and check setting.
➥ The setting is correct if the mark aligns with the symbol OPEN.
29
GS 50.3 – GS 250.3
Servicing and maintenance
7. Servicing and maintenance
Damage caused by inappropriate maintenance!

→ Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
Therefore, we recommend contacting our service.
→ Only perform servicing and maintenance tasks when the device is switched off.
AUMA
AUMA offers extensive service such as servicing and maintenance as well as
Service & Support customer product training. For the relevant contact addresses, please refer to
<Addresses> in this document or to the Internet (www.auma.com)
7.1. Preventive measures for servicing and safe operation

● Before commissioning, perform visual inspection for grease leakage and paint
damage (corrosion).
● Thoroughly touch up any possible damage to paint. Original paint in small
quantities can be supplied by AUMA.
7.2. Maintenance intervals
Recommendation for plants subject to strong vibration
● For plants subject to strong vibration, 6 months after commissioning and then
once a year: Check fastening screws between actuator and gearbox/valve for
tightness. If required, fasten screws while applying the tightening torques as
indicated in chapter <Assembly>. For screws sealed and secured with e.g.
thread sealing material, this action is not required.
Recommendation for grease change and seal replacement:
● If rarely operated (typically in buried service), the gearboxes are maintenance-
free. Grease change or re-lubrication is not necessary.
● If operated frequently (typically in modulating duty), we recommend changing
both grease and seals after 4 – 6 years.
Gearing damage due to using inappropriate grease!

→ Only use original lubricants supplied by AUMA.
→ Do not mix lubricants.
Instructions for use in potentially explosive atmospheres of categories M2,

2G, 3G, 2D and 3D
● Imperatively heed the technical data, as well as the ambient temperatures, type
of duty and running times indicated on the name plate are observed.
● In potentially explosive atmospheres, in particular where combustible dust is
present, perform visual inspection for deposit of dirt or dust on a regular basis.
Clean devices if required.
● The pointer cover with indicator glass is only approved for use in potentially
explosive atmospheres according to ATEX II2G c IIB T4 or T3.
● When using mechanical microswitches (option), additionally observe the
mounting and wiring instructions of the manufacturer.
7.3. Disposal and recycling
Our devices have a long lifetime. However, they have to be replaced at one point in
time. The devices have a modular design and may, therefore, easily be separated
and sorted according to materials used, i.e.:
● electronic scrap
● various metals
● plastics
30
GS 50.3 – GS 250.3
Servicing and maintenance
● greases and oils

The following generally applies:
● Greases and oils are hazardous to water and must not be released into the
environment.
● Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
● Observe the national regulations for waste disposal.
31
GS 50.3 – GS 250.3
Technical data
8. Technical data
Information The following tables include standard and optional features. For detailed information
on the customer-specific version, refer to the order-related data sheet. The technical
data sheet can be downloaded from the Internet in both German and English at ht-
tp://www.auma.com (please state the order number).
8.1. Technical data Part-turn gearboxes
General information
For motor or manual operation of valves (e.g. butterfly valves, ball and plug valves).
For special applications, e.g. dampers, gas diverters, flue gas dampers, toggle arm driven diverters and guillotine isolators, specific sizing
is required. Separate technical data apply for these applications.
Features and functions

Worm wheel material For open-close duty: Spheroidal cast iron
For modulating duty: Bronze
Version Standard: Clockwise rotation RR, counterclockwise rotation LL
Option: RL or LR
Housing material Standard: Cast iron (GJL-250)
Option: Spheroidal cast iron (GJS-400-15)
Self-locking The gearboxes are self-locking when at standstill under normal service conditions; strong vibration may
cancel the self-locking effect. While in motion, safe breaking is not guaranteed. If this is required, a
separate brake must be used.
End stops Positive for both end positions by travelling nut, sensitive adjustment
Strength of end stop Guaranteed strength of end stop (in Nm) for input side operation
Type GS 50.3 GS 63.3 GS 80.3 GS 100.3

Reduction ratio 51:1 51:1 53:1 52:1 126:1 160:1 208:1
[Nm] 250 450 450 1,350 625 500 250
Type GS 125.3 GS 160.3

Reduction ratio 52:1 126:1 160:1 208:1 54:1 218:1 442:1 880:1
[Nm] 1,350 625 500 250 3,200 900 450 250
Type GS 200.3
Reduction ratio 53:1 67:1 214:1 434:1 864:1 1752:1
[Nm] 8,000 250 2,000 1,000 500 250
Type GS 250.3
Reduction ratio 52:1 210:1 411:1 848:1 1718:1
[Nm] 8,000 2,000 1,000 500 250
Swing angle GS 50.3 – GS 125.3 Standard: Fixed swing angle between 10° and max. 100°; set in the factory to 92° unless ordered
otherwise.
Options: Adjustable in steps of:
10° – 35°, 35° – 60°, 60° – 80°, 80° – 100°, 100° – 125°, 125° – 150°, 150° – 170°,170°
– 190°
Swing angles > 190° are only possible with a worm wheel made of bronze and without
end stops. For swing angles > 100°, we recommend a worm wheel made of bronze.
Worm wheel made of bronze; Multi-turn version without end stop, up to max. 10 turns of
worm wheel permissible Heed special sizing!
Swing angle GS 160.3 – GS 250.3 Standard: Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise.
Options: Adjustable in steps of:
0° – 20°, 20° – 40°, 40° – 60°, 60° – 80°, 90° – 110°, 110° – 130°, 130° – 150°, 150° –
170°, 170° – 190°
Swing angles > 190° are only possible with a worm wheel made of bronze and without
end stops. For swing angles > 100°, we recommend a worm wheel made of bronze.
Worm wheel made of bronze; Multi-turn version without end stop, up to max. 10 turns of
worm wheel permissible. Heed special sizing!
Swing angle for special reduction Standard: Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise.
ratio Options: Swing angle range different from standard range available on request
(worm wheel made of bronze only) Multi-turn version without end stop, up to max. 10 turns of worm wheel permissible. Heed
special sizing!
32
GS 50.3 – GS 250.3
Technical data

Mechanical position indicator Standard: Pointer cover for continuous position indication
Options: ● Sealed pointer cover for horizontal outdoor installation (not available for GS 50.3)
● Protection cover for buried services instead of pointer cover (without mechanical pos-
ition indicator)
● Sealed pointer cover with air vent valve, not available for GS 50.3
Observe notes on Information sheet Enclosure protection IP68 for part-turn gearboxes
Input shaft Cylindrical with parallel key according to DIN 6885-1
Operation
Motor operation ● Via electric multi-turn actuator
● Input mounting flanges for multi-turn actuator
Type of duty Open-close duty Short-time duty S2 - 15 min

Class A according to EN 15714-2: OPEN-CLOSE
Class B according to EN 15714-2: Inching/positioning or positioning duty
Type of duty Modulating duty Intermittent duty S4 - 25 %
Class C according to EN 15714-2: Modulating duty
Maximum permissible input speeds In modulating duty: 215 rpm
and operating times In open-close duty:
Type GS GS 63.3 GS 80.3 GS 100.3

50.3
Reduction ratio 51:1 51:1 82:1 53:1 82:1 52:1 107:1 126:1 160:1 208:1
Max. permissible
108 108 108 108 216
input speed [rpm]
Fastest operating 7 7 11 7 11 7 15 9 11 19
time for 90° [s]
Type GS 125.3 GS 160.3

Reduction ratio 52:1 126:1 160:1 208:1 54:1 218:1 442:1 880:1
Max. permissible
108 216 108 216
input speed [rpm]
Fastest operating 7 9 11 19 8 15 31 61
time for 90° [s]
Type GS 200.3 GS 250.3

Reduction ratio 53:1 214:1 434:1 864:1 1752:1 52:1 210:1 411:1 848:1 1718:1
Max. permissible in-
108 216 108 216
put speed [rpm]
Fastest operating 7 15 30 60 122 7 15 29 59 119
time for 90° [s]
Shorter operating times can be achieved with worm wheels made of bronze, refer to Technical data GS
50.3 – GS 250.3 for modulating duty and shorter operating times.
Due to gear tooth geometry and the material characteristics of bronze, worm gearboxes with a worm
wheel made of bronze can transmit lower torques.
Calculation of operating time for a 90° swivel movement
Calculation of the operating time for a swivel movement [°]:
33
GS 50.3 – GS 250.3
Technical data
Operation
Manual operation Standard: ● Handwheel made of aluminium with electrophoretic coating
● Handwheel with ball handle
Option: ● Handwheel made of GJL-200 with electrophoretic coating and painting

● Handwheel lockable
● WSH for signalling position and end positions
● Chainwheel (only available for torques according to duty class 1)
Available handwheel diameters according to EN 12570, selection according to output torque:
Type GS GS GS GS 100.3 GS 125.3

50.3 63.3 80.3
Reduction ratio 51:1 51:1 53:1 52:1 126:1 160:1 208:1 52:1 126:1 160:1 208:1
Handwheel Ø [mm] 160 500
250 315 400 315 250 400 315
200 630
315 400 500 400 315 500 400
250 800
Type GS 160.3 GS 200.3

Reduction ratio 54:1 218:1 442:1 880:1 53:1 67:1 214:1 434:1 864:1 1752:1
Handwheel Ø [mm] 630 500
400 315 250 – 800 400 315 250
800 630
Type GS 250.3
Reduction ratio 52:1 210:1 411:1 848:1 1718:1
Handwheel Ø [mm] 500
– 800 400 315
630
Deflection of the input shaft

90° deflection of the input shaft
Combination with GK bevel gearbox directly mounted on GS or on planetary stage possible, refer to Mounting positions Part-turn gearboxes
with multi-turn actuators
Base and lever

Not suitable for load class 3.
Base Made of spheroidal cast iron; for mounting to base, 4 holes for fastening screws are available.
Lever Made of spheroidal cast iron; with 2 or 3 bores for fixing lever arrangement. Considering the environ-
mental conditions, the lever may be mounted to the output shaft in any desired position.
Ball joints Two ball joints matching the lever, as an option including lock nuts and 2 welding nuts; suitable for pipe
according to dimension sheet.
Mechanical position indicator Standard: No position indicator (protection cover)
Option: Pointer cover instead of protection cover for continuous position indication
34
GS 50.3 – GS 250.3
Technical data
Valve attachment
Valve attachment Dimensions according to EN ISO 5211: The maximum torques of mounting flanges according to EN
ISO 5211 are to be met.
Spigot Flanges with spigot. Up to GS 125.3, spigots are implemented by means of spigot rings (option). From
GS 160.3 to GS 250.3, spigots are directly integrated into the housing.
Plane flanges Up to GS 125.3, plane flanges are implemented by means of recesses. From GS 160.3 to GS 250.3,
the housing is plane machined (option).
Bore for parallel pins (option) Two bores for parallel pins shifted by 180°. The parallel pins are not included in the scope of delivery.
Type GS 80.3 GS 100.3 GS 125.3 GS 160.3

Flange according to
F12 F14 F14 F16 F16 F25 F30 F25 F30 F35
EN ISO 5211
Housing material GJS GJS GJS GJS GJL GJL GJL GJL GJL GJL
Type GS 200.3 GS 250.3

Flange according to
F30 F35 F40 F35 F40 F48
EN ISO 5211
Housing material GJL GJL GJL GJL GJL GJL
Refer to Dimensions Output mounting flange GS 50.3 – GS 125.3 (Y000.854) and Dimensions Output
mounting flange GS 160.3 – GS 250.3 (Y005.001). Further pitch circle diameters for locating pins on
request.
Splined coupling for connection to Standard: ● Without bore or pilot bore from GS 160.3
the valve shaft
● Worm gearbox can be mounted on coupling
Options: Finish machining with bore and keyway, square bore or two-flat with grub screw for secure
fixing to valve shaft.
Service conditions
Mounting position Any position
Ambient temperature Standard: –40 °C to +80 °C
Options: –60 °C to +60 °C
0 °C to +120 °C
Enclosure protection according to Standard: IP68, dust-tight and water-tight up to max. 8 m head of water
EN 60529 Options: IP68-20, dust-tight and water-tight up to max. 20 m head of water
Corrosion protection Standard: GS 50.3 – GS 80.3: KS
GS 100.3 – GS 250.3: KN
Options: GS 50.3 – GS 80.3: KX
GS 100.3 – GS 250.3: KS/KX
KN Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration
KS Suitable for use in areas with high salinity, almost permanent condensation, and high
pollution.
KX Suitable for use in areas with extremely high salinity, permanent condensation, and high
pollution.
Coating GS 50.3 – GS 80.3: Double layer powder coating
GS 100.3 – GS 250.3: Two-component iron-mica combination
Colour AUMA silver-grey (similar to RAL 7037)
Option: Available colours on request
35
GS 50.3 – GS 250.3
Technical data
Service conditions
AUMA load spectrum For open-close duty with worm wheel made of spheroidal cast iron:
For modulating duty with worm wheel made of bronze:

A start consists of one movement of minimum 1 % in both directions at a load of 35 % of the maximum
valve torque (modulating torque).
AUMA worm gearboxes meet or exceed the lifetime requirements of EN 15714-2.
Lifetime for motor operation in ac- For open-close duty with worm wheel made of spheroidal cast iron:
cordance with AUMA load spectrum Duty class 1: Lifetime for 90° swivel movement. Meets the lifetime requirement of EN 15714-2
Gearbox size GS 50.3/GS 63.3 GS 80.3/GS100.3 GS 125.3 – GS GS 250.3

200.3
Number of cycles
10,000 5,000 2,500 1,200
for max. torque
Duty class 2: Lifetime for 90° swivel movement for valves which are infrquently operated.
Gearbox size GS 50.3/GS 63.3 GS 80.3/GS100.3 GS 125.3 – GS GS 250.3

200.3
Number of cycles
1,000
for max. torque
Lifetime for larger swing angle on request

For modulating duty with worm wheel made of bronze:
1.2 million modulating steps
Lifetime for manual operation Duty class 3: Meets the lifetime requirement of EN 1074-2
36
GS 50.3 – GS 250.3
Technical data
Special features for use in potentially explosive atmospheres in accordance with ATEX 2014/34 EU
Explosion protection in accordance Standard: II2G c IIC T4
with ATEX 2014/34 EU II2D c T130 °C
Option II2G c IIC T3
II2D c T190 °C
IM2 c
Type of duty Maximum 3 cycles (OPEN - CLOSE - OPEN) in accordance with AUMA load spectrum (90° swivel
(open-close duty, with worm wheel movement) and maximum permissible input speeds, or with mean constant output torques according
made of spheroidal cast iron) to table:
Type GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS

125.3
Reduction ratio – 51:1 82:1 53:1 82:1 – 107:1 –
Average output
250 500 375 1,000 750 2,000 1,400 4,000
torque [Nm]
Type GS 160.3 GS 200.3 GS 250.3

Average output
8,000 16,000 32,000
torque [Nm]
Type of duty Standard: Intermittent duty S4 – 25 % with modulating torque and max. input speed
(modulating duty with worm wheel
made of bronze) Type GS 50.3 GS 63.3 GS 80.3 GS 100.3
Reduction ratio 51:1 51:1 53:1 52:1 126:1 160:1 208:1
Max. speed at GS
input with SA 45 45 45 45 90 125 180
[rpm]
Type GS 125.3 GS 160.3

Reduction ratio 52:1 126:1 160:1 209:1 54:1 218:1 442:1 880:1
Max. speed at GS
input with SA 45 90 125 180 45 180 180 180
[rpm]
Type GS 200.3
Reduction ratio 53:1 67:1 214:1 434:1 864:1 1,752:1
Max. speed at GS
input with SA 11 11 45 90 180 180
[rpm]
Type GS 250.3
Reduction ratio 52:1 210:1 441:1 848:1 1,718:1
Max. speed at GS
input with SA 11 45 90 180 180
[rpm]
Exception: GS 200.3 with modulating torque up to 4,800 Nm

Option: GSD multi-turn version, specific sizing required; please contact AUMA.
37
GS 50.3 – GS 250.3
Technical data
Special features for use in potentially explosive atmospheres in accordance with ATEX 2014/34 EU
Ambient temperature Duty classes 1 and 3
(open-close duty, with worm wheel Standard: –40 °C to +60 °C (II2G c IIC T4; II2D c T130 °C)
made of spheroidal cast iron)
Option –60 °C to +60 °C (II2G c IIC T4; II2D c T130 °C)
–40 °C to +40 °C (II2G c IIC T4; II2D c T130 °C)
0 °C to +120 °C (II2G c IIC T3; II2D c T190 °C)
–20 °C to +40 °C (IM2 c)
Duty class 2
Standard: –40 °C to +60 °C (II2G c IIC T3; II2D c T190 °C); T4 on request with individual test
Option –60 °C to +40 °C (II2G c IIC T4; II2D c T130 °C)
–60 °C to +60 °C (II2G c IIC T3; II2D c T190 °C); T4 on request with individual test
–20 °C to +40 °C (IM2 c)
Further temperature classes or loads exceeding the average torque of the AUMA load spectrum on re-
quest.
Ambient temperature Standard: –40 °C to +40 °C (II2G c IIC T4; II2D c T130 °C)
(modulating duty with worm wheel –40 °C to +60 °C (II2G c IIC T4; II2D c T130 °C)
made of bronze) –50 °C to +60 °C (II2G c IIC T4; II2D c T130 °C)
Options: –40 °C to +80 °C (II2G c IIC T3; II2D c T190 °C)
0 °C to +120 °C (II2G c IIC T3; II2D c T190 °C)
–20 °C to +40 °C (IM2 c)
Further information
EU Directives ATEX Directive: (2014/34/EU)
Machinery Directive: (2006/42/EC)
38
GS 50.3 – GS 250.3
Spare parts
9. Spare parts
9.1. Part-turn gearboxes GS 50.3 – GS 125.3
39
GS 50.3 – GS 250.3
Spare parts
Please state device type and our order number (see name plate) when ordering spare parts. Only original AUMA spare parts should be used.
Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the
representation in these instructions.
Ref. no. Designation Type

512.0 Input mounting flange Sub-assembly
517.0 Housing Sub-assembly
518.0 Housing cover Sub-assembly
519.1 Worm wheel
520.0 Worm shaft Sub-assembly
521.0 Travelling nut with two pairs of safety wedge discs Sub-assembly
521.1 Travelling nut
521.12 Pair of safety wedge discs
522.0 Bearing cover Sub-assembly
523.0 End stop Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
534.0 Drive shaft Sub-assembly
538.0 Bearing cover with drive shaft Sub-assembly
595.0 Screw kit for manual gearbox Sub-assembly
619.1 Extension flange Sub-assembly
S1 Seal kit Set
40
GS 50.3 – GS 250.3
Spare parts
9.2. Part-turn gearboxes GS 160.3 – GS 250.3
41
GS 50.3 – GS 250.3
Spare parts

513.1 Grub screw
519.1 Worm wheel
520.0 Worm shaft Sub-assembly
521.0 Travelling nut with two pairs of safety wedge discs
521.1 Travelling nut
521.2 Pair of safety wedge discs Sub-assembly
522.0 Bearing cover Sub-assembly
523.0 End stop Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
536.0 Protective cap Sub-assembly
537.0 Lock nut Sub-assembly
538.0 Bearing cover with drive shaft Sub-assembly
619.1 Extension flange Sub-assembly
S1 Seal kit Set
42
GS 50.3 – GS 250.3
Spare parts
9.3. Primary reduction gearings for GS 100.3 – GS 125.3 (126:1/160:1/208:1)
43
GS 50.3 – GS 250.3
Spare parts

003.0 Housing cover with drive shaft Sub-assembly
022.0 Planet carrier Sub-assembly
045.0 Internal geared wheel Sub-assembly
S1 Seal kit Set
44
GS 50.3 – GS 250.3
Spare parts
9.4. Primary reduction gearings for GS 160.3 (218:1/442:1) GS 200.3 (214:1/434:1) GS 250.3 (210:1/411:1)
45
GS 50.3 – GS 250.3
Spare parts

006.0 Planetary gearing first stage (GS 160.3) Sub-assembly
588.1 Blanking plug
S1 Seal kit Set
46
GS 50.3 – GS 250.3
Spare parts
9.5. Primary reduction gearings for GS 200.3 (864:1) GS 250.3 (848:1)
47
GS 50.3 – GS 250.3
Spare parts

006.0 Planetary gearing first stage Sub-assembly
007.0 Planetary gear second stage (GS 200.3) Sub-assembly
008.0 Planetary gear second stage (GS 250.3) Sub-assembly
010.0 Intermediate housing Sub-assembly
011.1 Pinion
588.1 Blanking plug
S1 Seal kit Set
48
Y003.822/003/en/2.17
For detailed information on AUMA products, refer to the Internet: www.auma.com

Multi-turn actuators
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
with actuator controls
AUMA MATIC AM 01.1/AM 02.1
Operation instructions Assembly, operation, commissioning

SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Table of contents AM 01.1/AM 02.1

● Observe safety instructions.
● These operation instructions are part of the product.
● Preserve operation instructions during product life.
● Pass on instructions to any subsequent user or owner of the product.

Reference documents:
Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(refer to <Addresses>).

1.3. Applications in Ex zone 22 (option) 6
2. Identification........................................................................................................................... 8
2.1. Name plate 8
3.1. Transport 10
3.2. Storage 10
3.3. Packaging 10
4. Assembly................................................................................................................................ 11
4.3. Multi-turn actuator: mount to valve/gearbox 11
4.3.1 Output drive types B, B1 – B4 and E 11
4.3.1.1 Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox 12
4.3.2 Output drive type A 12
4.3.2.1 Stem nut: finish machining 13
4.3.2.2 Multi-turn actuator (with output drive A): mount to valve 14
4.4. Accessories for assembly 15
4.4.1 Stem protection tube for rising valve stem 15
4.5. Mounting positions of local controls 15
4.5.1 Mounting positions: modify 16
5. Electrical connection............................................................................................................. 17
5.1. Basic information 17
5.2. Connection with AUMA plug/socket connector 18
5.2.1 Terminal compartment: open 19
5.2.2 Cable connection 19
5.2.3 Terminal compartment: close 21
5.3. Accessories for electrical connection 21
2
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Table of contents
5.3.1 Controls mounted to wall bracket 21

5.3.2 Parking frame 22
5.3.3 Protection cover 22
5.3.4 Earth connection, external 23
6. Operation................................................................................................................................ 24
6.1. Manual operation 24
6.1.1 Manual operation: engage 24
6.1.2 Manual operation: disengage 24
6.2. Motor operation 24
6.2.1 Local operation 24
6.2.2 Actuator operation from remote 25
7. Indications.............................................................................................................................. 27
7.1. Indication lights 27
8. Signals..................................................................................................................................... 29
8.1. Feedback signals via output contacts (binary) 29
8.2. Feedback signals (analogue) 29
9. Commissioning (basic settings)........................................................................................... 30
9.1. Heat-up time for low temperature version 30
9.2. Switch compartment: open 30
9.3. Torque switching: set 31
9.4. Limit switching: set 32
9.4.1 End position CLOSED (black section): set 32
9.4.2 End position OPEN (white section): set 33
9.5. Intermediate positions: set 33
9.5.1 Running direction CLOSE (black section): set 34
9.5.2 Running direction OPEN (white section): set 34
9.6. Test run 34
9.6.1 Direction of rotation: check 34
9.6.2 Limit switching: check 35
9.6.3 PTC tripping device (option): test 36
9.7. Potentiometer setting 36
9.8. Electronic position transmitter RWG: set 37
9.10. Switch compartment: close 38
10. Commissioning – controls settings..................................................................................... 40
10.1. Controls: open 40
10.2. Type of seating: set 40
10.3. Push-to-run operation or self-retaining: set 41
10.4. Running indication (blinker transmitter): activate/deactivate 42
10.5. Torque fault in collective fault signal: activate/deactivate 42
10.6. Positioner 42
10.6.1 Input ranges (signal type) for setpoint and actual value 43
10.6.2 Behaviour on loss of signal (actuator reaction) 43
10.6.3 Adjustment in end positions 45
10.6.4 Sensitivity setting 46
10.7. EMERGENCY command (EMERGENCY - OPEN/EMERGENCY - CLOSE) 47
10.8. Controls: close 48
3
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Table of contents AM 01.1/AM 02.1
11. Corrective action.................................................................................................................... 49

11.1. Faults during commissioning 49
11.2. Fuses 49
11.2.1 Fuses within the actuator controls 49
11.2.2 Motor protection (thermal monitoring) 51
12.2. Maintenance 52
13. Technical data......................................................................................................................... 54
13.1. Features and functions of actuator 54
13.2. Features and functions of actuator controls 56
13.3. Service conditions 57
13.4. Further information 58
14. Spare parts............................................................................................................................. 59
14.1. Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2 59
14.2. Actuator controls AUMA MATIC AM 01.1/AM 02.1 61
15. Certificates.............................................................................................................................. 63
15.1. Declaration of Incorporation and EC Declaration of Conformity 63
16. Index........................................................................................................................................ 64
Addresses............................................................................................................................... 66
4
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Safety instructions
1.1 Basic information on safety
Standards/directives AUMA products are designed and manufactured in compliance with recognised
EC Declaration of Conformity.
Safety instructions/war- All personnel working with this device must be familiar with the safety and warning
nings instructions in this manual and observe the instructions given. Safety instructions
damage.

commissioning.
tions.
● During operation, the housing warms up and surface temperatures > 60 °C may
occur. To prevent possible burns, we recommend checking the surface tempe-
rature using an appropriate thermometer and wearing protective gloves, if re-
for the staff.
must be observed.
1.2 Range of application
AUMA multi-turn actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves, and ball valves.

5
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Safety instructions AM 01.1/AM 02.1
● Escalators
● Continuous operation
● Buried service
● Permanent submersion (observe enclosure protection)
● Potentially explosive areas, with the exception of zone 22
designated use.
Information These operation instructions are only valid for the "clockwise closing" standard
version, i.e. driven shaft turns clockwise to close the valve.
1.3 Applications in Ex zone 22 (option)
Actuators of the indicated series basically meet the requirements for applications in
dust hazardous locations of ZONE 22 in compliance with the ATEX directive 94/9/EC.
The actuators are designed to meet enclosure protection IP 68 and fulfil the
requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for use in
presence of combustible dust, requirements for category 3 electrical equipment -
protected by enclosures.
To comply with all requirements of EN 50281-1-1:1998, it is imperative that the
following points are observed:
● In compliance with the ATEX directive 94/9/EC, the actuators must be equipped
with an additional identification – II3D IP6X T150 °C.
● The maximum surface temperature of the actuators, based on an ambient
temperature of +40 °C in accordance with EN 50281-1-1 section 10.4, is +150
°C. In accordance with section 10.4, an increased dust deposit on the equipment
was not considered for the determination of the maximum surface temperature.
● The correct connection of the thermoswitches or the PTC thermistors as well
as fulfilling the requirements of the duty type and the technical data are prere-
quisites for compliance with the maximum surface temperature of devices.
● The connection plug may only be plugged in or pulled out when device is dis-
connected from the mains.
● The cable glands used also have to meet the requirements of category II3 D
and must at least comply with enclosure protection IP 67.
● The actuators must be connected by means of an external ground connection
(accessory part) to the potential compensation or integrated into an earthed
piping system.
● The screw plug (part no. 511.0) or the stem protection tube with protective cap
(part nos. 568.1 and 568.2) for sealing the hollow shaft must imperatively be
mounted to guarantee tightness and therefore the combustible dust hazard
protection.
● As a general rule, the requirements of EN 50281-1-1 must be respected in dust
hazardous locations. During commissioning, service, and maintenance, special
care as well as qualified and trained personnel are required for the safe opera-
tion of actuators.
1.4 Warnings and notes


6
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Safety instructions





1.5 References and symbols

or in the table of contents and may quickly be found.
7
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Identification AM 01.1/AM 02.1
2. Identification
2.1 Name plate
Each device component (actuator, controls, motor) is equipped with a name plate.
[1] Actuator name plate

[2] Controls name plate
[3] Motor name plate
Data for identification Figure 2: Actuator name plate
[1] Type and size of actuator

[2] Commission number
Figure 3: Controls name plate
[1] Type and size of the controls

[2] Commission number
[3] Wiring diagram
[4] Control
Type and size
These instructions apply to the following devices:
Multi-turn actuators for open-close duty: SA 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
Multi-turn actuators for modulating duty: SAR 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
AM 01.1/02.1 = actuator controls AUMA MATIC
8
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Identification
Commission number An order-specific commission number is assigned to each device. This commission
number can be used to directly download the wiring diagram, inspection records and
further information regarding the device from the Internet: http://www.auma.com.
Control
24 V DC = Control via parallel interface at 24 V DC control voltage.
115 V AC = Control via parallel interface at 115 V AC control voltage.
0/4 – 20 mA = Control via parallel interface via analogue input 0/4 – 20 mA.
2.2 Short description
Multi-turn actuator Definition in compliance with EN ISO 5210:

A multi-turn actuator is an actuator which transmits to the valve a torque for at least
one full revolution. It is capable of withstanding thrust.
AUMA multi-turn actuators are driven by an electric motor and are capable of
withstanding thrust in combination with output drive type A. For manual operation,
a handwheel is provided. Switching off in end positions may be either by limit or
torque seating. Controls are required to operate or process the actuator signals.
Actuator controls The AUMA MATIC actuator controls are used to operate AUMA actuators and are
supplied ready for use. The controls can be mounted directly to the actuator but also
separately on a wall bracket. The functions of the AUMA MATIC controls include
standard valve control in OPEN - CLOSE duty, position indications and different
signals right through to position control.
Local controls Operation (via push buttons), setting and indication can be performed directly at the
controls (contents of these instructions).
9
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Transport, storage and packaging AM 01.1/AM 02.1

3.1 Transport
Hovering load!
to handwheel.
→ Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting
by hoist to valve and NOT to actuator.
→ Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
→ Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting
by hoist only to the actuator and NOT to the controls.
3.2 Storage

→ Store in a well-ventilated, dry room.
Long-term storage If the device must be stored for a long period (more than 6 months) the following
points must be observed in addition:
tion.
3.3 Packaging
10
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Assembly
4. Assembly
4.1 Mounting position
AUMA actuators and actuator controls can be operated without restriction in any
mounting position.
4.2 Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are supplied sepa-
rately.
Figure 4: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
1. If required, fit spacer [1] onto input shaft [2].

3. Secure handwheel [3] using the circlip [4] supplied.
4.3 Multi-turn actuator: mount to valve/gearbox
Danger of corrosion due to damage to paint finish and condensation!

→ Touch up damage to paint finish after work on the device.
→ After mounting, connect the device immediately to electrical mains to ensure
that heater minimises condensation.
4.3.1 Output drive types B, B1 – B4 and E

Application ● For rotating, non-rising valve stem
● Not capable of withstanding thrust
Design Output drive bore with keyway:
● Types B1 – B4 with bore according to ISO 5210
● Types B and E with bore according to DIN 3210
● Later change from B1 to B3, B4, or E is possible.
11
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly AM 01.1/AM 02.1
Figure 5: Output drive
[1] Output drive types B, B1 – B4, E and C

[2] Output drive sleeve/plug sleeve with bore and keyway
[3] Circlip
Information Spigot at flanges should be loose fit.
4.3.1.1 Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox
1. Check if mounting flanges fit together.

2. Check whether bore and keyway match the input shaft.
3. Apply a small quantity of grease to the input shaft.
4. Place multi-turn actuator.
Information: Ensure that the spigot fits uniformly in the recess and that the
mounting faces are in complete contact.
5. Fasten multi-turn actuator with screws according to table.
Table 1: Tightening torques for screws

Screws Tightening torque TA [Nm]
Threads Strength class 8.8
M8 25
M10 51
M12 87
M16 214
M20 431
4.3.2 Output drive type A

Application ● Output drive for rising, non-rotating valve stem
● Capable of withstanding thrust
Information To adapt the actuators to output drive types A available on site with flanges F10 and
F14 (year of manufacture: 2009 and earlier), an adapter is required. The adapter
can be ordered from AUMA.
12
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
4.3.2.1 Stem nut: finish machining
✔ This working step is only required if stem nut is supplied unbored or with pilot
bore.
Figure 6: Design of output drive type A
[1] Stem nut

[2] Bearing
[2.1] Bearing race
[2.2] Bearing rim
[3] Spigot ring
1. Remove spigot ring [3] from output drive.

2. Remove stem nut [1] together with bearings [2].
3. Remove bearing races [2.1] and bearing rims [2.2] from stem nut [1].
4. Drill and bore stem nut [1] and cut thread.
Information: When fixing in the chuck, make sure stem nut runs true!
5. Clean the machined stem nut [1].
6. Apply sufficient Lithium soap EP multi-purpose grease to bearing rims [2.2] and
bearing races [2.1], ensuring that all hollow spaces are filled with grease.
7. Place greased bearing rims [2.2] and bearing races [2.1] onto stem nut [1].
8. Re-insert stem nut [1] with bearings [2] into output drive.
Information: Ensure that dogs or splines are placed correctly in the keyway of
the hollow shaft.
9. Screw in spigot ring [3] until it is firm against the shoulder.
13
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
4.3.2.2 Multi-turn actuator (with output drive A): mount to valve
Figure 7: Assembly with output drive type A
[1] Valve stem

[2] Output drive type A
[3] Screws to actuator
[4] Valve flange
[5] Screws to output drive
1. If the output drive type A is already mounted to the multi-turn actuator: Loosen
screws [3] and remove output drive type A [2].
2. Check if the flange of output drive type A matches the valve flange [4].
3. Apply a small quantity of grease to the valve stem [1].
4. Place output drive type A on valve stem and turn until it is flush on the valve
flange.
5. Turn output drive type A until alignment of the fixing holes.
6. Screw in fastening screws [5], however do not completely tighten.
7. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into
the output drive sleeve.
➥ The flanges are flush with each other if properly engaged.
8. Adjust multi-turn actuator until alignment of the fixing holes.
9. Fasten multi-turn actuator with screws [3].
10. Fasten screws [3] crosswise with a torque according to table.

M6 11
M8 25
M10 51
M12 87
M16 214
M20 431
11. Turn multi-turn actuator with handwheel in direction OPEN until valve flange
and output drive A are firmly placed together.
12. Tighten fastening screws [5] between valve and output drive type A crosswise
applying a torque according to table.
14
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
4.4 Accessories for assembly
4.4.1 Stem protection tube for rising valve stem

— Option —
Figure 8: Assembly of the stem protection tube
[1] Cap for stem protection tube

[2] Stem protection tube
[3] Sealing ring
1. Seal thread with hemp, Teflon tape, or thread sealing material.

2. Screw stem protection tube [2] into thread and tighten it firmly.
3. Push down the sealing ring [3] onto the housing.
4. Check whether cap for stem protection tube [1] is available and in perfect con-
dition.
4.5 Mounting positions of local controls
The mounting position of the local controls is selected according to the order. If, after
mounting the actuator to the valve or the gearbox on site, the local controls are in
an unfavourable position, the mounting position can be changed at a later date. Four
mounting positions are possible.
Figure 9: Mounting positions A and B
15
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Figure 10: Mounting positions C and D
4.5.1 Mounting positions: modify
Hazardous voltage!
Risk of electric shock.
→ Disconnect device from the mains before opening.
1. Loosen screws and remove the local controls.

2. Loosen 3 screws of the board, turn board to the new position and fasten the
screws.
3. Check whether O-ring is in good condition, correctly insert O-ring.
4. Turn local controls into new position and re-place.
Cable damage due to twisting or pinching!

Risk of functional failures.
→ Turn local controls by a maximum of 180°.
→ Carefully assemble local controls to avoid pinching the cables.
5. Fasten screws evenly crosswise.
16
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Electrical connection
5. Electrical connection
5.1 Basic information
Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury, or property damage.
→ The electrical connection must be carried out exclusively by suitably qualified
personnel.
→ Prior to connection, observe basic information contained in this chapter.
→ After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
Wiring diagram/terminal
The pertaining wiring diagram/terminal plan is attached to the device in a
plan weather-proof bag, together with these operation instructions. It can also be obtained
from AUMA (state commission no., refer to name plate) or downloaded directly from
the Internet (www.auma.com).
Protection on site
For short-circuit protection and for disconnecting the actuator from the mains, fuses
and disconnect switches have to be provided by the customer.
The current values for respective sizing is derived from the current consumption of
the motor (refer to electrical data sheet) plus the current consumption of the controls.
Table 3: Current consumption controls

Mains voltage Max. current consumption
100 to 120 V AC (±10 %) 575 mA
208 to 240 V AC (±10 %) 275 mA
380 to 500 V AC (±10 %) 160 mA
24 V DC (+20 %/-15 %) and AC motor 500 mA
Table 4: Maximum permissible protection

Switchgear Rated power max. protection
Reversing contactor up to 1.5 kW 16 A (gL/gG)
Reversing contactor up to 7.5 kW 32 A (gL/gG)
Reversing contactor up to 11 kW 63 A (gL/gG)
Thyristor up to 1.5 kW 16 A (g/R) I²t<1,500A²s
Thyristor up to 3 kW 32 A (g/R) I²t<1,500A²s
Thyristor up to 5.5 kW 63 A (g/R) I²t<5,000A²s
If controls are mounted separately from actuator (controls on wall bracket): Consider
length and cross section of connecting cable when defining the protection required.
Power supply for the
If the controls (electronics) are supplied externally with 24 V DC, the power supply
controls (electronics) is smoothed via an internal 1,000 µF capacitor). When selecting a power supply,
care must be taken to consider the capacitor inrush current upon powering the unit
up.
Safety standards All externally connected devices shall comply with the relevant safety standards.
Cable installation in ac-
Signal and bus cables are susceptible to interference.
cordance with EMC
Motor cables are interference sources.
● Lay cables being susceptible to interference or sources of interference at the
highest possible distance from each other.
● The interference immunity of signal and bus cables increases if the cables are
laid close to the earth potential.
● If possible, avoid laying long cables and make sure that they are installed in
areas being subject to low interference.
17
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection AM 01.1/AM 02.1
● Avoid long parallel paths with cables being either susceptible to interference or
interference sources.
● For the connection of remote position transmitters, screened cables must be
used.
Type of current, mains Type of current, mains voltage and mains frequency must match the data on the
voltage and mains fre- motor name plate.
quency
Figure 11: Motor name plate (example)
[1] Type of current

[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ● For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
● Use connecting cable with appropriate minimum rated temperature.
● For connecting cables exposed to UV radiation (outdoor installation), use UV
resistant cables.
5.2 Connection with AUMA plug/socket connector
Cross sections AUMA plug/socket connector:
● Power terminals (U1, V1, W1, U2, V2, W2): max. 6 mm² flexible/10 mm² solid
●
PE connection : max. 6 mm² flexible/10 mm² solid
● Control contacts (1 to 50): max. 2.5 mm²
18
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
5.2.1 Terminal compartment: open
Figure 12: Connection AUMA plug/socket connector, version S
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Screws for socket carrier
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
[8] Cable gland (not included in delivery)
Hazardous voltage!
1. Loosen screws [2] and remove cover [1].

2. Loosen screws [4] and remove socket carrier [5] from cover [1].
3. Insert cable glands [8] suitable for connecting cables.
➥ The enclosure protection IP... stated on the name plate is only ensured if suitable
cable glands are used. Example: Name plate shows enclosure protection IP
68.
4. Seal unused cable entries [6] with suitable blanking plugs [7].
5. Insert the cables into the cable glands [8].
5.2.2 Cable connection
✔ Observe permissible cross sections.

1. Remove cable sheathing.
2. Strip wires.
3. For flexible cables: Use end sleeves according to DIN 46228.
4. Connect cables according to order-related wiring diagram.
19
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
In case of a fault: Hazardous voltage while protective earth conductor is NOT

connected!
→ Connect all protective earth conductors.
→ Connect PE connection to external protective earth conductor of connecting
cables.
→ Start running the device only after having connected the protective earth con-
ductor.
5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables)

or loops (rigid cables).
Figure 14: PE connection
[1] Socket carrier

[2] Screw
[3] Washer
[4] Lock washer
[5] Protective earth with ring lugs/loops
[6] PE connection, symbol:
Danger of corrosion: Damage due to condensation!

→ After mounting, commission the device immediately to ensure that heater mini-
mises condensation.
Information Some actuators are equipped with an additional motor heater. The motor heater
minimises condensation within the motor and improves the start-up behaviour for
extremely low temperatures.
20
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
5.2.3 Terminal compartment: close
Figure 15: Example: Version S
[1] Cover
[3] O-ring
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
Short-circuit due to pinching of cables!

Risk of electric shock and functional failures.
→ Carefully fit socket carrier to avoid pinching the cables.
1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4].
2. Clean sealing faces of cover [1] and housing.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and
insert it correctly.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
6. Fasten cable glands [8] applying the specified torque to ensure the required
enclosure protection.
5.3 Accessories for electrical connection
— Option —
5.3.1 Controls mounted to wall bracket
The wall bracket allows separate mounting of controls and actuator.
Application ● If the actuator cannot be accessed safely.
● If the actuator is subjected to high temperatures.
● In case of heavy vibration of the valve.
21
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Design Figure 16: Design principle with wall bracket
[1] Wall bracket

[2] Connecting cables
[3] Electrical connection of wall bracket (XM)
[4] Electrical connection of actuator (XA)
[5] Electrical connection of controls (XK) - customer plug
Observe prior to ● Permissible length of connecting cables: max. 100 m.
connection ● If the actuator is equipped with a position transmitter (RWG): Connecting cables
must be designed as shielded version.
● Versions with potentiometer in the actuator are not suitable.
● We recommend: AUMA cable set LSW1.
● If the AUMA cable set is not used: Use suitable flexible and screened connecting
cables.
● When using connecting cables, e.g. of the heater or switch, requiring direct wiring
from the actuator to the XK customer plug (XA-XM-XK, refer to wiring diagram),
these connecting cables must be subject to an insulation test in compliance
with EN 50178. Connecting cables of position transmitters (RWG, IWG, poten-
tiometer) do not belong to this group. They may not be subject to an insulation
test.
5.3.2 Parking frame
Application Parking frame for safe storage of a disconnected plug.
For protection against touching the bare contacts and against environmental
influences.
Figure 17: Parking frame
5.3.3 Protection cover

Protection cover for plug compartment when plug is removed.
22
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
The open terminal compartment can be closed using a protective cover (not
illustrated).
5.3.4 Earth connection, external
As an option, the housing is equipped with an external earth connection (U-bracket)
to connect the device to the equipotential earth bonding.
Figure 18: Earth connection
23
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Operation AM 01.1/AM 02.1
6. Operation
6.1 Manual operation

For purposes of setting and commissioning, in case of motor failure or power failure,
the actuator may be operated manually. Manual operation is engaged by an internal
change-over mechanism.
6.1.1 Manual operation: engage
Damage at the motor coupling due to faulty operation!

→ Engage manual operation only during motor standstill.
1. Press push button.
2. Turn handwheel in desired direction.

→ To close the valve, turn handwheel clockwise:
➥ Drive shaft (valve) turns clockwise in direction CLOSE.
6.1.2 Manual operation: disengage
Manual operation is automatically disengaged when motor is started again. The

handwheel does not rotate during motor operation.
6.2 Motor operation
✔ Perform all commissioning settings and the test run prior to motor operation.
6.2.1 Local operation

The local operation of the actuator is performed using the push buttons of the local
controls.
24
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Operation
Figure 21: Local controls
[1] Push button for operation command in direction OPEN

[2] Push button Stop
[3] Push button for operation command in direction CLOSE
[4] Selector switch
Hot surfaces, e.g. possibly caused by high ambient temperatures or strong

direct sunlight!
Danger of burns
→ Check surface temperature and wear protective gloves, if required.
→ Set selector switch [4] to position Local control (LOCAL).
➥ The actuator can now be operated using the push buttons [1 – 3]:
- Run actuator in direction OPEN: Press push button [1] .
- Stop actuator: Press push button [2] Stop.
- Run actuator in direction CLOSE: Press push button [3] .
Information The OPEN - CLOSE operation commands can be given either in push-to-run opera-
tion mode or in self-retaining mode. In self-retaining mode, the actuator runs to the
defined end position after pressing the button, unless another command has been
received beforehand.
6.2.2 Actuator operation from remote
→ Set selector switch to Remote control (REMOTE).
➥ Now, it is possible to operate the actuator via remote control, via operation
commands (OPEN, STOP, CLOSE) or analogue setpoints (e.g. 0 – 20 mA).
25
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Operation AM 01.1/AM 02.1
Information For actuators equipped with positioner, it is possible to optionally select between
open-close duty (REMOTE OPEN-CLOSE) and modulating duty (REMOTE
SETPOINT). Selection is made via REMOTE MANUAL input, e.g. based on a 24 V
DC signal (refer to wiring diagram).
Behaviour in modulating duty for version with positioner:

In case of signal loss of setpoint E1 or actual value E2, the actuator moves to a
preset position. The following reactions are possible:
● Fail as is: Actuator stops immediately and remains in this position.
● Fail close: Actuator moves the valve to end position CLOSED.
● Fail open: Actuator moves the valve to end position OPEN.
The behaviour on loss of signal can be set via a switch in the controls.
26
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Indications
7. Indications
7.1 Indication lights
The colours of the 3 indication lights on the local controls and the assignment of the
signals are specified in the order.
Figure 24: Local controls with indication lights (default signalling)
[1] illuminated (green): End position OPEN reached

[2] illuminated (red): Collective fault signal
[3] illuminated (yellow): End position CLOSED reached
Collective fault signal The collective fault signal (red indication light) will be activated if one of the following
events occurs (default configuration):
● Torque fault: The set torque was exceeded before reaching an end position.
(This signal can be activated/deactivated via a switch in the controls.)
● Thermal fault: Motor protection has tripped, i.e. the motor is overheated.
● Phase failure: One phase is missing (3-ph AC motors only).
● PTC tripping device: Test complete
Running indication If the actuator is equipped with a blinker transmitter (wiring diagram designation:
S5), indication lights [1] and [3] can be used as running indication. The running
indication can be activated/deactivated via a switch in the controls. If the running
indication is active, the respective indication light blinks during operation.
7.2 Mechanical position indicator/running indication
— Option —
● Continuously indicates the valve position
(For complete travel from OPEN to CLOSED or vice versa, the indicator disc
[2] rotates by approximately 180° to 230°.)
● Indicates whether the actuator is running (running indication)
● Indicates that the end positions are reached (via indicator mark [3])
27
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Indications AM 01.1/AM 02.1
[1] Cover
[2] Indicator disc
[3] Mark
28
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Signals
8. Signals
8.1 Feedback signals via output contacts (binary)
The output contacts can be used to indicate operation modes of the actuator or the
controls as binary signals.
The signals are assigned according to the order. Example:
Output contact open = end position CLOSED not reached
Output contact closed = end position CLOSED reached
Collective fault signal Switches: 1 NC and 1 NO (standard)

Designation in the wiring diagram: K9
The collective fault signal appears if one of the following events occurs (default
configuration):
4 output contacts: Switches: 1 NC (standard)
Designation in the wiring diagram: K5, K6, K7, K8
Default configuration:
● K5: Selector switch is in position Remote control (REMOTE).
● K6: Selector switch is in position Local control (LOCAL).
● K7: End position OPEN reached
● K8: End position CLOSED reached
S5), output contacts K7 and K8 can be used as running indications. The running
indication function can be activated/deactivated via a switch in the controls. If the
running indication is active, the contacts open and close (blink) during actuator
operation.
8.2 Feedback signals (analogue)
— (Option) —
If the actuator is equipped with a position transmitter (potentiometer or RWG), an
analogue position feedback signal is available.
Valve position Signal: E2 = 0/4 – 20 mA (galvanically isolated)
Designation in the wiring diagram: E2 (actual value)
29
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning (basic settings) AM 01.1/AM 02.1
9. Commissioning (basic settings)

1. Set selector switch to position 0 (OFF).
Information: The selector switch is not a mains switch. When positioned to 0

(OFF), the actuator cannot be operated. The controls' power supply is
maintained.
2. Switch on the power supply.
Information: Please consider the heat-up time for ambient temperatures below
–20 °C.
3. Perform basic settings.
9.1 Heat-up time for low temperature version
Please note that for low temperature versions, the controls require a heat-up time.
This heat-up time is applicable in case the actuator and the controls are not live and
have cooled down to ambient temperature. Under these conditions and after
connection to the voltage supply, the following heat-up times must be complied with
prior to commissioning:
For –50 °C = 60 min.
For –60 °C = 80 min.
Figure 27: Sketch illustrating the heat-up time
[t ] Heat-up time in minutes

[ϑ] Ambient temperature in °C
9.2 Switch compartment: open
The switch compartment must be opened to perform the following settings (options).
30
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Commissioning (basic settings)
1. Loosen screws [2] and remove cover [1] from the switch compartment.
Figure 28:
2. If indicator disc [3] is available:

Remove indicator disc [3] using a spanner (as lever).
Information: To avoid damage to paint finish, use spanner in combination with
soft object, e.g. fabric.
Figure 29:
9.3 Torque switching: set

Once the set torque is reached, the torque switches will be tripped (overload protection
of the valve).
Information The torque switches may also trip during manual operation.
Valve damage due to excessive tripping torque limit setting!

→ The tripping torque must suit the valve.
→ Only change the setting with the consent of the valve manufacturer.
31
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Figure 30: Torque switching heads
[1] Torque switching head black in direction CLOSE

[2] Torque switching head white in direction OPEN
[3] Lock screws
[4] Torque dials
1. Loosen both lock screws [3] at the indicator disc.

2. Turn torque dial [4] to set the required torque (1 da Nm = 10 Nm).
3. Fasten lock screws [3] again.
Information: Maximum tightening torque: 0.3 – 0.4 Nm
➥ The torque switch setting is complete.
Example: The figure above shows the following settings:
● 3.5 da Nm = 35 Nm for direction CLOSE
● 4.5 da Nm = 45 Nm for direction OPEN
9.4 Limit switching: set
The limit switching records the travel. When reaching the preset position, switches
are operated.
Figure 31: Setting elements for limit switching
Black section:
[1] Setting spindle: End position CLOSED
[2] Pointer: End position CLOSED
[3] Mark: End position CLOSED is set
White section:
[4] Setting spindle: End position OPEN
[5] Pointer: End position OPEN
[6] Mark: End position OPEN is set
9.4.1 End position CLOSED (black section): set
1. Engage manual operation.

2. Turn handwheel clockwise until valve is closed.
32
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
3. Turn handwheel by approximately half a turn (overrun) in the opposite direction.

4. Press down and turn setting spindle [1] with screw driver in direction of the
arrow and observe the pointer [2]: While a ratchet click is felt and heard, the
pointer [2] moves 90° every time.
5. If the pointer [2] is 90° from mark [3]: Continue turning slowly.
6. If the pointer [2] moves to mark [3]: Stop turning and release setting spindle.
➥ The end position CLOSED setting is complete.
7. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
9.4.2 End position OPEN (white section): set

2. Turn handwheel counterclockwise until valve is open.
3. Turn handwheel by approximately half a turn (overrun) in the opposite direction.
➥ The end position OPEN setting is complete.
9.5 Intermediate positions: set
— Option —
Actuators equipped with DUO limit switching contain two intermediate position
switches. One intermediate position may be set for each running direction.
Black section:
[1] Setting spindle: Running direction CLOSE
[2] Pointer: Running direction CLOSE
[3] Mark: Intermediate position CLOSED is set
White section:
[4] Setting spindle: Running direction OPEN
[5] Pointer: Running direction OPEN
[6] Mark: Intermediate position OPEN is set
33
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Information After 177 turns (control unit for 1 – 500 turns/stroke) or 1,769 turns (control unit for
1 – 5,000 turns/stroke), the intermediate switches release the contact.
9.5.1 Running direction CLOSE (black section): set
1. Move valve in direction CLOSE to desired intermediate position.

2. If you override the tripping point inadvertently: Turn valve in opposite direction
and approach intermediate position again in direction CLOSE.
Information: Always approach the intermediate position in the same direction
as in later electrical operation.
➥ The intermediate position setting in running direction CLOSE is complete.
9.5.2 Running direction OPEN (white section): set
1. Move valve in direction OPEN to desired intermediate position.

2. If you override the tripping point inadvertently: Move valve in opposite direction
and approach intermediate position again in direction OPEN (always approach
the intermediate position in the same direction as in later electrical operation).
➥ The intermediate position setting in running direction OPEN is complete.
9.6 Test run
Perform test run only once all settings previously described have been performed.
9.6.1 Direction of rotation: check
Valve damage due to incorrect direction of rotation!

→ If the direction of rotation is wrong, switch off immediately (press STOP).
→ Eliminate cause, i.e. correct phase sequence for cable set wall bracket.
→ Repeat test run.
1. Move actuator manually to intermediate position or to sufficient distance from

end position.
2. Set selector switch to position Local control (LOCAL).
34
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
3. Switch on actuator in running direction CLOSE and observe the direction of

rotation:
with indicator disc: step 4
without indicator disc: step 5 (hollow shaft)
→ Switch off before reaching the end position.
4. With indicator disc:
→ Observe direction of rotation.
➥ The direction of rotation is correct, if actuator runs in direction
CLOSE and indicator disc turns counterclockwise.
5. Without the indicator disc:

→ Unscrew screw plug [1] and seal [2] or cap for stem protection tube [4]
and observe direction of rotation at hollow shaft [3] or the stem [5].
➥ The direction of rotation is correct, if actuator runs in direction CLOSE and
hollow shaft or stem turn clockwise.
Figure 35: Hollow shaft/stem
[1] Screw plug

[2] Seal
[3] Hollow shaft
[4] Cap for stem protection tube
[5] Stem
[6] Stem protection tube
9.6.2 Limit switching: check
35
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
2. Operate actuator using push buttons OPEN - STOP - CLOSE.

➥ The limit switching is set correctly if (default indication):
- the yellow indication light is illuminated in end position CLOSED
- the green indication light is illuminated in end position OPEN
- the indication lights go out after travelling into the opposite direction.
➥ The limit switching is set incorrectly if:
- the actuator comes to a standstill before reaching the end position
- the red indication light is illuminated (torque fault).
3. If the end position setting is incorrect: Reset limit switching.
4. If the end position setting is correct and no options (e.g. potentiometer, position
transmitter) are available: Close switch compartment.
9.6.3 PTC tripping device (option): test
1. Turn selector switch to position Test (spring return).
➥ If the PTC tripping device is working properly, the tripping of the motor protection
is signalled via the red indication light "collective fault signal" on the local con-
trols.
2. Turn selector switch to position Reset.
➥ The fault signal is reset if the device is working properly.

3. If no fault signal is initiated: Request AUMA service to check both wiring and
selector switch.
9.7 Potentiometer setting
— Option —
The potentiometer as travel sensor records the valve position.
Information This setting is only required if the potentiometer is directly wired to the customer
connection XK (refer to wiring diagram).
Information Due to the ratio of the reduction gearing the complete resistance range/stroke is not
always passed. Therefore, external adjustment (setting potentiometer) must be pro-
vided.
Figure 39: View of control unit
[1] Potentiometer
36
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
2. Turn potentiometer [1] clockwise to the stop.

➥ End position CLOSED corresponds to 0 %
➥ End position OPEN corresponds to 100 %
3. Turn potentiometer [1] slightly in opposite direction.
4. Perform fine-tuning of the zero point at external setting potentiometer (for remote
indication).
9.8 Electronic position transmitter RWG: set
— Option —
The electronic position transmitter RWG records the valve position. On the basis of
the actual position value measured by the potentiometer (travel sensor), it generates
a current signal between 0 – 20 mA or 4 – 20 mA.
Table 5: Technical data RWG 4020

Wiring 3- or 4-wire system
Terminal plan KMS TP_ _4/ _ _ _
Output current IA 0 – 20 mA, 4 – 20 mA
Power supply UV 24 V DC, ±15 % smoothed
Max. current consump- I 24 mA at 20 mA output current
tion
Max. load RB 600 Ω
Figure 40: View of control unit
[1] Potentiometer (travel sensor)

[2] Potentiometer min. (0/4 mA)
[3] Potentiometer max. (20 mA)
[4] Measuring point (+) 0/4 – 20 mA
[5] Measuring point (–) 0/4 – 20 mA
1. Connect voltage to electronic position transmitter.

3. Connect ammeter for 0 – 20 mA to measuring points [4 and 5].
6. Turn potentiometer [2] clockwise until output current starts to increase.
7. Turn potentiometer [2] in opposite direction until the following value is reached:
- for 0 – 20 mA approx. 0.1 mA
➥ This ensures that the signal remains above the dead and live zero point.
9. Set potentiometer [3] to end value 20 mA.
10. Approach end position CLOSED again and check minimum value (0.1 mA or
4.1 mA). If necessary, correct the setting.
37
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Information If the maximum value cannot be reached, the selection of the reduction gearing must
be checked. (The max. possible turns/stroke are indicated on the order-related
technical data sheet for the actuator.)
9.9 Mechanical position indicator: set

— Option —
1. Place indicator disc on shaft.

3. Turn lower indicator disc until symbol (CLOSED) is in alignment with the
mark on the cover.
4. Move actuator to end position OPEN.

5. Hold lower indicator disc in position and turn upper disc with symbol (OPEN)
until it is in alignment with the mark on the cover.
6. Move valve to end position CLOSED again.

7. Check settings:
If the symbol (CLOSED) is no longer in alignment with mark on the cover:
7.1 Repeat setting procedure.
7.2 Check whether the appropriate reduction gearing has been selected, if
required.
9.10 Switch compartment: close
Danger of corrosion due to damage to paint finish!

1. Clean sealing faces of housing and cover.

38
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
4. Place cover [1] on switch compartment.

5. Fasten screws [2] evenly crosswise.
39
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning – controls settings AM 01.1/AM 02.1
10. Commissioning – controls settings

The controls are set in the factory according to the order. The settings only have to
be changed if the device is used for applications other than those specified in the
order. In case the device is equipped with a positioner (option), subsequent setting
may be required.
The following settings are described in these operation instructions:
● Type of seating (limit or torque seating): set
● Push-to-run operation or self-retaining: set
● Running indication (blinker transmitter) (option): activate/deactivate
● Torque fault in collective fault signal: activate/deactivate
● Positioner setting (option)
10.1 Controls: open
Hazardous voltage!
Electrostatic discharge ESD!

Risk of damage to electronic components.
→ Earth both operators and devices.
→ Loosen screws [2] and remove cover [1].
10.2 Type of seating: set
Valve damage due to incorrect setting!

→ The type of seating must suit the valve.
→ Only change the setting with prior consent of the valve manufacturer.
The type of seating can be set via two DIP switches on the logic board.
Limit seating
The limit switching is set in such a way that the actuator switches off at the desired
switching points. The torque switching acts as overload protection for the valve.
Torque seating
The torque switching is set to the desired tripping torque. After reaching the tripping
torque, the actuator is turned off.
40
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Commissioning – controls settings
The limit seating is used to signal that the limit switching will trip shortly before
reaching the set tripping torque. If this is not the case, either the indication light on
the local controls or the alarm contact K9 (collective fault signal) will signal a fault.
→ Set type of seating for end positions via DIP switches [S1] and [S3].
Figure 45: DIP switches on logic board
[S1] DIP switch for end position CLOSED

[S3] DIP switch for end position OPEN
[1] Position [1] = limit seating
[2] Position [2] = torque seating
10.3 Push-to-run operation or self-retaining: set

Push-to-run operation or self-retaining is set via a DIP switch on the logic board.
Push-to-run operation Actuator only runs in direction OPEN or CLOSE while an operation command is
being received. The actuator stops if the operation command is cancelled.
Self-retaining After receiving an operation command, the actuator continues to run in direction
OPEN or CLOSE, even if the operation command is cancelled (self-retaining). The
actuator is either stopped by the STOP command or if an end position or intermediate
position has been reached.
→ Set push-to-run operation or self-retaining via DIP switch [S2].

Figure 46: DIP switch on logic board
[S2] 6-way DIP, switches [1 – 4]:

1 for operation commands CLOSE from remote
2 for operation commands OPEN from remote
3 for operation commands CLOSE via push button at local controls
4 for operation commands OPEN via push button at local controls
➥ Switch in lower position (position ON): Self-retaining

➥ Switch in upper position (position OFF): Push-to-run operation
41
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Information If the controls are equipped with a positioner, switches 1 and 2 (operation commands
from remote) must be in position OFF (push-to-run operation).
10.4 Running indication (blinker transmitter): activate/deactivate

— (Option) —
If the actuator is equipped with a blinker transmitter (wiring diagram designation:
S5), output contacts K7 and K8 can be used as running indication. If the running
indication is active, the contacts open and close (blink) during actuator operation.
The running indication is activated/deactivated via a DIP switch on the logic board.
→ Set running indication (blinker) via DIP switch [S2].

[S2] 6-way DIP, switch 5
➥ Switch 5 in lower position (position ON): Running indication is deactivated.

➥ Switch 5 in upper position (position OFF): Running indication is activated.
10.5 Torque fault in collective fault signal: activate/deactivate

The torque fault signal is activated/deactivated via a DIP switch on the logic board.
→ Activate/deactivate signal via DIP switch [S2].

➥ Switch 6 in lower position (position ON): The signal "Torque fault in collective
fault signal" is activated.
➥ Switch 6 in upper position (position OFF): The signal "Torque fault in collective
fault signal" is deactivated.
10.6 Positioner
— (Option) —
42
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
→ Prior to positioner setting, set limit and torque switching as well as potentiometer
or electronic position transmitter.
10.6.1 Input ranges (signal type) for setpoint and actual value
The input range (signal type) for setpoint E1 and actuator value E2 is set in the
factory and marked with a label on the cover plate of the positioner.
The type of signal can be modified at a later date exclusively for versions with setpoint
E1 ≠ 0/4 – 20 mA and split-range version. For these versions, the positioner board
is equipped with an additional contact.
Figure 49: Version with additional switch on the positioner board
5. Label indicating the set input ranges

[S1-7] 5 contact DIP switch for setting
DIP1 Actual value E2 (current or voltage signal)
DIP3 Setpoint E1 (current or voltage signal)
DIP5 Setpoint E1 (double signal range e.g. for split range)
Table 6: Input range setting for setpoint E1

Setpoint E1 [S1–7]
DIP 3 and 5
0/4 – 20 mA
0–5V
0 – 10 V
Table 7: Input range setting for actual value E2

Actual value E2 [S1–7]
DIP 1
0/4 – 20 mA1)
0 – 5 V2)
1) for internal feedback of electronic position transmitter RWG

2) for internal feedback of precision potentiometer 5 kΩ
Information When changing the setting, a new label [5] indicating the set signal type must be
provided. Furthermore, the wiring diagram indicated on the name plate of the actuator
controls also changes.
10.6.2 Behaviour on loss of signal (actuator reaction)
In case of a loss of signal of setpoint E1 or actual value E2, the reaction of the actuator
can be programmed via switch [S2-7]. The complete selection range, however, is
only available for signals 4 – 20 mA.
43
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
The following reactions are possible:

Fail as is: Actuator stops immediately and remains in this position.
Fail close: Actuator moves the valve to end position CLOSED.
Fail open: Actuator moves the valve to end position OPEN.
Figure 50: DIP switch [S2-7] on positioner board
DIP1 = ON, actual value E2 is monitored

DIP2 = ON, setpoint E1 is monitored
Table 8: Recommended settings

Behaviour on loss of signal of Signal type [S2–7]
E1 and/or E2 Setpoint E1 Actual value E2 DIP 1 2 3 4
Fail as is 4 – 20 mA 4 – 20 mA
Fail close
Fail open
Table 9: Further possible settings

Behaviour on loss of signal of Signal type1) [S2–7]
E1 E2 Setpoint E1 Actual value E2 DIP 1 2 3 4
Fail as is Fail open 4 – 20 mA 0–5V
Fail close Fail open 4 – 20 mA 0–5V
0 – 20 mA 4 – 20 mA
0 – 20 mA 0 – 20 mA
0–5V 0–5V
0 – 10 V
Fail close 0 – 20 mA 4 – 20 mA
0–5V
0 – 10 V
Fail open 4 – 20 mA 0 – 20 mA
0–5V
1) in case of a signal loss, a misinterpretation might be made for 0 – 20 mA, 0 – 5 V or 0 – 10 V, due

to the fact that E1 or E2 could take the value 0 mA even without loss of signal (end position CLOSED
= 0 mA or 0 V).
44
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
10.6.3 Adjustment in end positions

The setting described below applies to the standard positioner version, i.e. maximum
setpoint E1 (20 mA) triggers a travel to end position OPEN, minimum setpoint (0/4
mA) triggers a travel to end position CLOSED.
Figure 51: Electronic positioner board
[MP1] Measuring point (–) for actual value E2

[MP2] Measuring point (+) for actual value E2
[MP3] Measuring point (+) for setpoint E1
[MP4] Measuring point (–) for setpoint E1
[5] Label with signal indication
[V10] Red LED: E1/E2 <4 mA
End position CLOSED 1. Set selector switch to position Local control (LOCAL).
3. Connect lower setpoint to customer connection XK (terminals 2/3). The lower
setpoint (0 V, 0 mA or 4 mA) is indicated on the label [5].
4. If the red LED [V10] E1/E2 <4 mA is illuminated:
4.1 Verify polarity of setpoint E1.
4.2 Check whether external load is connected to customer connection XK
(terminals 23/24) (observe max. load RB), or
4.3 Connect terminals 23/24 across customer connection XK (terminals 23/24).
5. Measure setpoint E1: Connect measuring device for 0 – 5 V to measuring points
[MP3/MP4].
➥ For a setpoint E1 of 0 V or 0 mA, the voltmeter shows 0 V.
➥ For a setpoint E1 of 4 mA, the voltmeter shows 1 V.
6. If measured value is not correct: Correct setpoint E1.
7. Measure actual value E2: Connect measuring device for 0 – 5 V to measuring
points [MP1/MP2].
➥ For an actual value E2 of 0 mA, the voltmeter shows 0 V.
8. If measured value is not correct: Re-set potentiometer or electronic position
transmitter and perform adjustment once again, starting from step 1.
45
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
9. Adjust positioner using potentiometer 0 [P3].

9.1 If both LEDs are OFF or the green LED [V28] is illuminated: Turn potentio-
meter 0 [P3] slightly clockwise until the yellow LED [V27] is illuminated.
9.2 If the yellow LED [V27] is illuminated: Turn potentiometer 0 [P3] counter-
clockwise until the yellow LED [V27] goes out. Then turn potentiometer 0
[P3] slightly clockwise until the yellow LED [V27] is illuminated again.
[P3] Potentiometer 0
[P4] Potentiometer max
[V27] Yellow LED: End position CLOSED reached
[V28] Green LED: End position OPEN reached
➥ The setting is correct if the yellow LED [V27] is switched on when reaching end
position CLOSED.
End position OPEN 10. Move valve to end position OPEN.
11. Measure actual value E2 (measuring points [MP1/MP2]):
13. Set maximum setpoint E1 (5 V or 20 mA, refer to label [5]).
14. Measure setpoint E1 (measuring points [MP3/MP4]):
15. If measured value is not correct: Verify setpoint E1.
16. Adjust positioner using potentiometer max [P4].
16.1 If both LEDs are OFF or the yellow LED [V27] is illuminated: Turn poten-
tiometer max [P4] slightly counterclockwise until the green LED [V28] is
illuminated.
16.2 If the green LED [V28] is illuminated: Turn potentiometer max [P4] clock-
wise until the green LED [V28] goes out. Then turn potentiometer 0 [P3]
slightly counterclockwise until the green LED [V28] is illuminated again.
➥ The setting is correct if the green LED [V28] is switched on when
reaching end position OPEN.
10.6.4 Sensitivity setting
Unnecessary wear at valve and actuator caused by an excessive number of

starts (sensitivity)!
→ Set maximum dead band acceptable for the process.
→ Observe maximum number of actuator starts (refer to technical data sheet for
modulating actuators).
Dead band The dead band determines the sensitivity between switch-on point and switch-off
point. The smaller the dead band, the higher the sensitivity of the positioner.
46
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Default value: 2.5 %

Setting range: 0.5 % to 2.5 % (of the maximum setpoint E1)
Dead time The dead time prevents the operation to a new setpoint within a pre-determined time
(0.5 to 10 seconds). The number of starts can be reduced by setting the dead time
to a sufficiently high value.
Figure 53: Sensitivity setting
[P7] Potentiometer sens (fine tuning)

[P9] Potentiometer Δ E (dead band)
[P10] Potentiometer t-off (dead time)
Dead band setting 1. Set selector switch to position Remote control (REMOTE).
2. Connect setpoint E1 to customer connection XK (terminals 2/3).
3. Set dead band using potentiometer Δ E [P9]:
→ Reduce dead band (increase sensitivity): Turn potentiometer counter-
clockwise.
→ Increase dead band (reduce sensitivity): Turn potentiometer clockwise.
Fine tuning Information: Fine tuning is only useful for output speeds <16 rpm. For 1-phase
AC motors, fine tuning is not possible.
4. Reduce dead band further by up to 0.25 % (increase sensitivity): Turn potentio-
meter sens [P7] counterclockwise.
Dead time setting 5. Set dead time using potentiometer t-off [P10]:
→ Reduce dead time: Turn potentiometer t-off [P10] counterclockwise.
→ Increase dead time: Turn potentiometer t-off [P10] clockwise.
10.7 EMERGENCY command (EMERGENCY - OPEN/EMERGENCY - CLOSE)
— (Option) —
The EMERGENCY input (refer to wiring diagram) has to be connected to the control
voltage using an NC contact (closed circuit principle). In the event of an EMERGENCY
command (removal of the signal = NC contact is operated), the actuator runs to the
preset end position:
● EMERGENCY - CLOSE input: Actuator runs to end position CLOSED.
● EMERGENCY - OPEN input: Actuator runs to end position OPEN.
The EMERGENCY command is effective in all three selector switch positions (LOCAL,
OFF, REMOTE).
The actuator can immediately start when switched on!

Risk of personal injuries or damage to the valve.
→ Ensure that EMERGENCY signal is present when switching on.
→ If the actuator starts to run unexpectedly: Immediately press push button Stop.
47
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Disable EMERGENCY Figure 54:Interface board for available option EMERGENCY - OPEN/EMERGENCY
command - CLOSE
[B1] Link available: EMERGENCY - CLOSE

[B2] Link available: EMERGENCY - OPEN
1. Remove face plate.
2. Disconnect links [B1] or [B2].
10.8 Controls: close



48
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Corrective action
11. Corrective action
11.1 Faults during commissioning
Table 10: Faults during commissioning

Fault description Possible causes Remedy
Mechanical position indicator Reduction gearing is not suitable for Exchange reduction gearing.
cannot be set. turns/stroke of the actuator.
Fault in end position The overrun was not considered when setting Determine overrun: Overrun = travel covered
Actuator runs to end stop alt- the limit switching. from switching off until complete standstill.
hough the limit switches work The overrun is generated by the inertia of Set limit switching again considering the
properly. both the actuator and the valve and the delay overrun (turn handwheel back by the amount
time of the controls. of the overrun).
Position transmitter RWG Reduction gearing is not suitable for Exchange reduction gearing.
Measurement range 4 – 20 mA turns/stroke of the actuator.
or maximum value 20 mA cannot
be set.
Limit and/or torque switches do Switch is defective or switch setting is incor- Check setting, if required, reset end positions.
not trip. rect. → Check switches and replace them, if requi-
red.
Switch check
The red test buttons [1] and [2] are used for manual operation of the switches:
1. Turn test button [1] in direction of the TSC arrow: Torque switch CLOSED trips.
The red indication light (fault) on the local controls is illuminated.
2. Press push button OPEN to reset the fault (indication light) by operating the
device in the opposite direction.
3. Turn test button [2] in direction of the TSO arrow: Torque switch OPEN trips.
4. Press push button CLOSE to reset the fault (indication light) by operating the
If the actuator is equipped with a DUO limit switching (option), the intermediate
position switches (LSA and LSB) will be operated at the same time as the torque
switches.
1. Turn test button [1] in direction of the LSC arrow: Limit switch CLOSED trips.
2. Turn test button [2] in direction of the LSO arrow: Limit switch OPEN trips.
11.2 Fuses
11.2.1 Fuses within the actuator controls
After removal of local controls, the fuses can be accessed.
Hazardous voltage!
49
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Corrective action AM 01.1/AM 02.1
Figure 57: Access to fuses
[1] Local controls

[2] Signal and control board
[3] Power supply unit
F1/F2 Primary fuses on power supply unit
G fuses F1/F2 AUMA Art. No.:

Size 6.3 x 32 mm
Reversing contactors 1 A T; 500 V K002.277
Power supply≤ 500 V
Reversing contactors 2 A FF; 690 V K002.665
Power supply > 500 V
Thyristor units for motor power up to 1,5 kW 16 A FF; 500 V K001.185
Thyristor units for motor power up to 3,0 kW 30 A FF; 500 V K006.965
Thyristor units for motor power up to 5,5 kW 1 A T; 500 V K002.277
F3 Internal 24 V DC supply
G fuse according to IEC 60127-2/III F3 AUMA Art.no.:

Size 5 x 20 mm
Voltage output (power supply unit) = 24 V 500 mA T; 250 V K001.183
F4 Internal 24 V AC supply (115 V AC) for:

● Heater, switch compartment, reversing contactors control
● PTC tripping device
● for 115 V AC also control inputs OPEN - STOP - CLOSE

Size 5 x 20 mm
Voltage output (power supply unit) = 24 V 1.0 A T; 250 V K004.831
1.6 A T; 250 V K003.131
Information Only replace fuses with fuses of the same type and value.
→ After replacing the fuses, screw local controls back on again.

50
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Corrective action
11.2.2 Motor protection (thermal monitoring)
In order to protect against overheating and impermissibly high surface temperatures

at the actuator, PTC thermistors or thermoswitches are embedded in the motor
winding. The thermoswitch is tripped as soon as the max. permissible winding
temperature has been reached.
The actuator is stopped and the red indication light on the local controls is illuminated.
The motor has to cool down before the operation can be resumed.
Version with thermoswitch (standard)
The actuator can be controlled again once the motor has cooled down (red indication
light goes out).
Version with thermoswitch and additional thermal overload relay within the
controls (option)
The operation may only be resumed once the fault signal (red indication light) has
been reset. The fault signal is reset via the overload relay integrated in the actuator
controls. Therefore the controls have to be opened at the cover and the relay held
down. The relay is located on the contactors.
Version with PTC thermistor (option)
The operation may only be resumed once the fault signal (red indication light) has
been reset. The fault signal is reset via selector switch position Reset of the local
controls.
Figure 58: Selector switch on local controls
51
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Servicing and maintenance AM 01.1/AM 02.1

Service
AUMA offers extensive service such as servicing and maintenance as well as
customer product training. For the relevant contact addresses, please refer to
<Addresses> in this document or to the Internet (www.auma.com) .
12.1 Preventive measures for servicing and safe operation
The following measures are required to ensure safe device operation:

6 months after commissioning and then every year
● Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing.
Respect torques according to manufacturer's details.
● Check fastening screws between actuator and gearbox/valve for tightness. If
required, fasten screws while applying the tightening torques as indicated in
chapter <Assembly>.
● When rarely operated: Perform test run.
● For devices with output drive A: Press in Lithium soap EP multi-purpose grease
on mineral oil base at the grease nipple with a grease gun.
● Lubrication of the valve stem must be done separately.
Figure 59: Output drive type A
[1] Output drive type A

[2] Grease nipple
Table 11: Grease quantities for bearing of output drive type A

Output drive A 07.2 A 10.2 A 14.2 A 16.2
Quantity [g] 1) 1.5 2 3 5
1) For grease at density r = 0.9 kg/dm³
For enclosure protection IP 68
After continuous immersion:

● Check actuator.
● In case of ingress of water, locate leaks and repair, dry device correctly and
check for proper function.
12.2 Maintenance
Lubrication ● In the factory, the gear housing is filled with grease.
52
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Servicing and maintenance
● Grease change is performed during maintenance

- Generally after 4 to 6 years for modulating duty.
- Generally after 6 to 8 years if operated frequently (open-close duty).
- Generally after 10 to 12 years if operated rarely (open-close duty).
● We recommend exchanging the seals when changing the grease.
● No additional lubrication of the gear housing is required during operation.
12.3 Disposal and recycling
● various metals
● plastics
environment.
● Arrange for controlled waste disposal of the disassembled material or for sepa-
rate recycling according to materials.
53
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data AM 01.1/AM 02.1
13. Technical data

Information The following technical data includes standard and optional features. For detailed
information on the customer-specific version, refer to the order-relevant data sheet.
This data sheet can be downloaded from the Internet at http://www.auma.com (in-
dication of commission number required).
13.1 Features and functions of actuator
Type of duty1) Standard:

● SA: Short-time duty S2 - 15 min
● SAR: Intermittent duty S4 - 25 %
Options:
● SA: Short-time duty S2 - 30 min
● SAR: Intermittent duty S4 - 50 %
● SAR: Intermittent duty S5 – 25 %
Torque range Refer to actuator name plate
Output speed Refer to actuator name plate
Motor Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 60034
Motor voltage and frequency Refer to motor name plate
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Self-locking Self-locking: Output speeds up to 90 rpm (50 Hz), 108 rpm (60 Hz)
NOT self-locking: Output speeds up to 125 rpm (50 Hz), 150 rpm (60 Hz)
Multi-turn actuators are self-locking, if the valve position cannot be changed from standstill
while torque acts upon the output drive.
Limit switching Counter gear mechanism for end positions CLOSED and OPEN
Turns per stroke: 2 to 500 (standard) or 2 to 5,000 (option)
Standard:
● Single switches (1 NC and 1 NO, not galvanically isolated) for each end position
Options:
● Tandem switches (2 NC and 2 NO) for each end position, switches galvanically isolated
● Triple switches (3 NC and 3 NO) for each end position, switches galvanically isolated
● Intermediate position switch (DUO limit switching), adjustable for any position
Torque switching Torque switching adjustable for directions OPEN and CLOSE
Standard:
Single switch (1 NC and 1 NO; not galvanically isolated) for each direction
Option:
Tandem switches (2 NC and 2 NO) for each direction, switches galvanically isolated
Position feedback signal, ana- Potentiometer or 0/4 – 20 mA (RWG)
logue (option)
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Running indication Blinker transmitter (standard for SA, option for SAR)
Heater in switch compartment Standard: Resistance type heater, 5 W, 24 V DC, (internal supply)
Motor heater (option) Voltages: 110 – 220 V AC, 220 – 240 V AC or 400 V AC (externally supplied)
Power depending on the size 12.5 – 25 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during electrical
operation.
Option: Handwheel lockable
Connection to controls AUMA plug/socket connector with screw-type connection
54
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Technical data
Valve attachment Standard: B1 according to EN ISO 5210

Options:
A, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drive types: AF, B3D, ED, DD, IB1, IB3
A prepared for stem lubrication
Sensor system
Indication for manual operation Indication whether manual operation is active/not active via switch (1 change-over contact)
(option)
1) For nominal voltage and 40 °C ambient temperature and an average load with running torque or modulating torque according to sepa-
rate technical data. The type of duty must not be exceeded.
Technical data for limit and torque switches

Mechanical lifetime 2 x 106 starts
Silver plated contacts:
U min. 30 V AC/DC
U max. 250 V AC/DC
I min. 20 mA
I max. AC current 5 A at 250 V (resistive load)
3 A at 250 V (inductive load, cos phi = 0.6)
I max. DC current 0.4 A at 250 V (resistive load)
0.03 A at 250 V (inductive load, L/R = 3 µs)
7 A at 30 V (resistive load)
5 A at 30 V (inductive load, L/R = 3 µs)
Gold plated contacts:
U min. 5V
U max. 30 V
I min. 4 mA
I max. 400 mA
Technical data for blinker transmitter

Mechanical lifetime 107 starts
U min. 10 V AC/DC
U max. 250 V AC/DC
2 A at 250 V (inductive load, cos phi ≈ 0.8)
Technical data for handwheel activation switches

U min. 12 V DC
U max. 250 V AC
I max. AC current 3 A at 250 V (inductive load, cos phi = 0.8)
I max. DC current 3 A at 12 V (resistive load)
55
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
13.2 Features and functions of actuator controls
Power supply, mains frequency For mains voltage and mains frequency, refer to name plates at the controls and the motor
Permissible variation of the mains voltage: ±10 %
Permissible variation of the mains frequency: ±5 %
Option: Permissible variation of the mains voltage: –10 %
Current consumption Motor current consumption: Refer to motor name plate
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 575 mA
208 to 240 V AC = max. 275 mA
380 to 500 V AC = max. 160 mA
External supply of the electro- 24 V DC +20 % / –15 %
nics (option) Current consumption: Basic version approx. 200 mA, with options up to 500 mA
Rated power The controls are conceived for the rated motor power, refer to motor name plate
Overvoltage category Category III according to IEC 60364-4–443
Switchgear 1) 2) Standard:
Reversing contactors (mechanically and electrically interlocked) for motor power up to power
class A1
Options:
● Reversing contactors (mechanically and electrically interlocked) for motor power up to
power classes A2 or A3
● Thyristor unit for mains voltage up to 500 V AC (recommended for modulating actuators)
for AUMA power classes B1, B2 and B3
Auxiliary voltage output Standard:
24 V DC ±5 %, max. 50 mA for supply of the control inputs, galvanically isolated from internal
voltage supply
Option:
115 V AC ±10 %, max. 30 mA for supply of the control inputs3), galvanically isolated from
internal voltage supply
Control Standard:
Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator, one common), current
consumption: approx. 10 mA per input, observe minimum pulse duration for modulating ac-
tuators
Option:
Control inputs 115 V AC, OPEN - STOP - CLOSE - EMERGENCY (via opto-isolator, one
common), current consumption: approx. 15 mA input
Additional enable inputs for directions OPEN and CLOSE
Status signals Standard:
5 output contacts with gold-plated contacts:
● 4 potential-free NO contacts with one common, max. 250 V AC, 0.5 A (resistive load)
- Default configuration: End position OPEN, end position CLOSED, selector switch
REMOTE, selector switch LOCAL
● 1 potential-free change-over contacts, max. 250 V AC, 0.5 A (resistive load)
- Default configuration: Collective fault signal (torque fault, phase failure, motor protec-
tion tripped)
Options:
● Signals in combination with positioner:
- End position OPEN, end position CLOSED (requires tandem switch within actuator),
selector switch REMOTE, selector switch REMOTE, selector switch LOCAL via 2nd
level selector switch
● 1 potential-free change-over contact, max. 250 V AC, 0.5 A (resistive load)
- Default configuration: Collective fault signal (torque fault, phase failure, motor protec-
tion tripped)
Position feedback signal (option) Galvanically isolated analogue output E2 = 0/4 – 20 mA (load max. 300 Ω)
Local controls Standard:
● Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
● Push buttons OPEN, STOP, CLOSE
● 3 indication lights:
- End position CLOSED (yellow), collective fault signal (red), end position OPEN (green)
Options:
● Special colours for the 3 indication lights
● Protection cover, lockable
● Protection cover with indicator glass, lockable
56
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Technical data
Functions Standard:
● Switch-off mode adjustable
- Limit or torque seating for end position OPEN and end position CLOSED
● Overload protection against excessive torques over the whole travel
● Excessive torque (torque fault) can be excluded from collective fault signal.
● Phase failure monitoring with automatic phase correction
● Push-to-run operation or self-retaining in REMOTE
● Push-to-run operation or self-retaining in LOCAL
● Running indication via blinker transmitter signal of actuator (option) can be activated or
deactivated
Options:
● Positioner
- Position setpoint via analogue input E1 = 0/4 – 20 mA
- Galvanic isolation for position setpoint (0/4 – 20 mA) and position feedback (0/4 – 20
mA)
- Adjustable behaviour on loss of signal
- Adjustable sensitivity (dead band) and pause time
● Positioner for Split Range operation
Motor protection evaluation Standard:
Monitoring of the motor temperature in combination with thermoswitches in the actuator
motor
Options:
● Additional thermal overload relay in the controls in combination with thermoswitches within
the actuator
● PTC tripping device in combination with PTC thermistors in the actuator motor
Electrical connection Standard:
AUMA plug/socket connector (S) with screw-type connection and M-threads
Options:
● Pg-threads, NPT-threads, G-threads, special threads
● Gold-plated control contacts (pins and sockets)
● Parking frame for wall mounting of the disconnected plug
● Protection cover for plug compartment (when plug is removed)
Wiring diagram Refer to name plate
1) The reversing contactors are designed for a lifetime of 2 million starts.
2) For the assignment of AUMA power classes, please refer to electrical data on actuator.
3) Not possible in combination with PTC tripping device
13.3 Service conditions

Use Indoor and outdoor use permissible
Enclosure protection according Standard: IP 68 with AUMA 3-ph AC motor/1-ph AC motor
to EN 60529 According to AUMA definition, enclosure protection IP 68 meets the following requirements:
● Depth of water: maximum 8 m head of water
● Duration of continuous immersion in water: max. 96 hours
● Up to 10 operations during flooding.
● Modulating duty is not possible during continuous immersion.
For actual version, refer to actuator/controls name plate.
Corrosion protection Standard:
● KS: Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration as well as for installation in occasionally or permanently aggressive atmo-
sphere with a moderate pollutant concentration (e.g. in wastewater treatment plants,
chemical industry)
Options:
● KX: Suitable for installation in extremely aggressive atmospheres with high humidity and
high pollutant concentration
● KX-G : same as KX, however aluminium-free version (outer parts)
57
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Installation altitude Standard: ≤ 2,000 m above sea level

Option: > 2,000 m above sea level, please contact AUMA
Finish coating Standard: Paint based on polyurethane (powder coating)
Colour Standard: AUMA silver-grey (similar to RAL 7037)
Ambient temperature Standard:
● Open-close duty: –25 °C to +70 °C
● Modulating duty: –25 °C to +60 °C
For actual version, refer to actuator/controls name plate.
Vibration resistance according 1 g, from 10 to 200 Hz
to IEC 60068-2-6 Resistant to vibration during start-up or for failures of the plant. However, a fatigue strength
may not be derived from this. Not valid in combination with gearboxes.
Lifetime Open-close duty (operating cycles (OPEN - CLOSE - OPEN):
SA 07.2/07.6 – SA 10.2: 25,000
SA 14.2/14.6 – SA 16.2: 20,000
Modulating duty:1)
SAR 07.2/07.6 – SAR 10.2: 7.5 million modulating steps
SAR 14.2/14.6 – SAR 16.2: 5.0 million modulating steps
Weight Refer to separate technical data
1) The lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To
reach the longest possible maintenance and fault-free operating time, the number of starts per hour chosen should be as low as possible
for the process.
13.4 Further information
EU Directives ● Electromagnetic Compatibility (EMC): (2004/108/EC)

● Low Voltage Directive: (2006/95/EC)
● Machinery Directive: (2006/42/EC)
58
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Spare parts
14. Spare parts

14.1 Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
59
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Spare parts AM 01.1/AM 02.1
Information: Please state type and commission no. of the device (see name plate) when ordering spare parts.
Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. Designation Type No. Designation Type
001.0 Housing Sub-assembly 553.0 Mechanical position indicator Sub-assembly
002.0 Bearing flange Sub-assembly 554.0 Socket carrier with motor cable har- Sub-assembly
ness
003.0 Hollow shaft with worm wheel Sub-assembly 556.0 Potentiometer for position transmitter Sub-assembly
005.0 Drive shaft Sub-assembly 556.1 Potentiometer without slip clutch Sub-assembly
005.1 Motor coupling on output drive shaft 557.0 Heater Sub-assembly
005.3 Manual drive coupling 558.0 Blinker transmitter including pins at Sub-assembly
wires (without impulse disc and insula-
tion plate)
009.0 Planetary gear for manual drive Sub-assembly 559.0–1 Control unit without torque switching Sub-assembly
heads and switches
017.0 Torque lever Sub-assembly 559.0–2 Control unit with magnetic limit and Sub-assembly
torque transmitter (MWG) for Non-
intrusive version in combination with
AUMATIC integral controls
018.0 Gear segment 560.0–1 Switch stack for direction OPEN Sub-assembly
019.0 Crown wheel 560.0–2 Switch stack for direction CLOSE Sub-assembly
022.0 Drive pinion II for torque switching Sub-assembly 560.1 Switch for limit/torque switching Sub-assembly
023.0 Output drive wheel for limit switching Sub-assembly 560.2 Switch case
024.0 Drive wheel for limit switching Sub-assembly 566.0 Position transmitter RWG Sub-assembly
025.0 Locking plate Sub-assembly 566.1 Potentiometer for RWG without slip Sub-assembly
clutch
058.0 Wire for protective earth (pin) Sub-assembly 566.2 Electronic board RWG Sub-assembly
070.0 Motor (VD motor incl. no. 079.0) Sub-assembly 566.3 Wire harness for RWG Sub-assembly
079.0 Planetary gear for motor drive Sub-assembly 567.1 Slip clutch for potentiometer/RWG Sub-assembly
(SA/SAR 07.2 — 16.2 for VD motor)
155.0 Reduction gearing Sub-assembly 568.1 Stem protection tube (without cap)
500.0 Cover for switch compartment Sub-assembly 568.2 Cap for stem protection tube
501.0 Socket carrier (complete with sockets) Sub-assembly 568.3 V-seal
502.0 Pin carrier without pins Sub-assembly 574.1 Radial seal output drive A for ISO
flange
503.0 Socket for controls Sub-assembly 575.1 Stem nut type A
504.0 Socket for motor Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly
505.0 Pin for controls Sub-assembly 583.1 Pin for motor coupling
506.0 Pin for motor Sub-assembly 584.0 Retaining spring for motor coupling Sub-assembly
507.0 Plug cover Sub-assembly S1 Seal kit, small Set
511.0 Screw plug Sub-assembly S2 Seal kit, large Set
514.0 Output drive form A (without stem nut) Sub-assembly
514.1 Axial needle roller bearing Sub-assembly
516.0 Output drive D Sub-assembly
535.1 Snap ring
539.0 Screw plug Sub-assembly
542.0 Handwheel with ball handle Sub-assembly
549.0 Output drive B1/B3/B4/C Sub-assembly
549.1 Output drive sleeve B1/B3/B4/C
551.1 Parallel key
60
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AM 01.1/AM 02.1 Spare parts
14.2 Actuator controls AUMA MATIC AM 01.1/AM 02.1
61
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Spare parts AM 01.1/AM 02.1
Information: Please state type and commission no. of the device (see name plate) when ordering spare parts.
Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. Designation Type
001.0 Housing
002.0 Local controls Sub-assembly
002.5 Selector switch Sub-assembly
003.0 Local controls board Sub-assembly
003.1 Primary fuse
003.2 Fuse cover
004.0 Carrier for contactors
006.0 Power supply including mounting plate Sub-assembly
006.1 Secondary fuse F3
008.0 Interface board Sub-assembly
008.1 Interface board
008.2 Cover plate for interface board
009.0 Logic board Sub-assembly
013.0 Adapter board
500.0 Cover Sub-assembly
501.0 Socket carrier (complete with sockets) Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
505.0 Pin for controls Sub-assembly
506.0 Pin for motor Sub-assembly
507.0 Plug cover Sub-assembly
508.0 Switchgear Sub-assembly
509.1 Padlock
S Seal kit Set
62
Part-turn actuators
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
with actuator controls
AUMA MATIC AM 01.1
Operation instructions Assembly, operation, commissioning

SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Table of contents AM 01.1

●
Observe safety instructions.
●
These operation instructions are part of the product.
●
Retain operation instructions during product life.
●
Pass on instructions to any subsequent user or owner of the product.

Reference documents:
Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(refer to <Addresses>).

1.3. Applications in Ex zone 22 (option) 6
2. Identification........................................................................................................................... 8
2.1. Name plate 8
3.1. Transport 11
3.2. Storage 11
3.3. Packaging 11
4. Assembly................................................................................................................................ 12
4.3. Actuator: mount to valve 12
4.3.1. Valve attachment via coupling 13
4.4. Mounting positions of local controls 14
4.4.1. Mounting positions: modify 14
5. Electrical connection............................................................................................................. 16
5.1. Basic information 16
5.2. Connection with AUMA plug/socket connector 17
5.2.1. Terminal compartment: open 17
5.2.2. Cable connection 18
5.2.3. Terminal compartment: close 20
5.3. Accessories for electrical connection 20
5.3.1. Controls mounted to wall bracket 20
5.3.2. Parking frame 21
5.3.3. Protection cover 21
5.3.4. Double sealed intermediate frame 22
5.3.5. Earth connection, external 22
2
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Table of contents
6. Operation................................................................................................................................ 23
6.1. Manual operation 23
6.1.1. Manual operation: engage 23
6.1.2. Manual operation: disengage 23
6.2. Motor operation 23
6.2.1. Local operation 23
6.2.2. Actuator operation from remote 24
7. Indications.............................................................................................................................. 26
7.1. Indication lights 26
8. Signals..................................................................................................................................... 28
8.1. Feedback signals via output contacts (binary) 28
8.2. Feedback signals (analogue) 28
9. Commissioning (basic settings)........................................................................................... 29
9.1. Heat-up time for low temperature version 29
9.2. End stops in part-turn actuator 29
9.2.1. End stop CLOSED: set 30
9.2.2. End stop OPEN: set 31
9.3. Switch compartment: open 31
9.4. Torque switching: set 32
9.5. Limit switching: set 33
9.5.1. End position CLOSED (black section): set 33
9.5.2. End position OPEN (white section): set 33
9.6. Intermediate positions: set 34
9.6.1. Running direction CLOSE (black section): set 34
9.6.2. Running direction OPEN (white section): set 35
9.7. Test run 35
9.7.1. Direction of rotation: check 35
9.7.2. Limit switching: check 36
9.7.3. PTC tripping device (option): test 36
9.8. Electronic position transmitter EWG 01.1 36
9.8.1. Measuring range: set 37
9.8.2. Current values: adjust 38
9.8.3. LED end position signalling: switch on/off 38
9.9. Potentiometer 39
9.9.1. Potentiometer setting 39
9.10. Electronic position transmitter RWG 39
9.10.1. Measuring range: set 40
9.12. Switch compartment: close 41
10. Commissioning – controls settings..................................................................................... 43
10.1. Controls: open 43
10.2. Type of seating: set 43
10.3. Push-to-run operation or self-retaining: set 44
10.4. Running indication (blinker transmitter): activate/deactivate 45
10.5. Torque fault in collective fault signal: activate/deactivate 45
10.6. Positioner 45
10.6.1. Input ranges (signal type) for setpoint and actual value 46
10.6.2. Behaviour on loss of signal (actuator reaction) 46
3
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Table of contents AM 01.1
10.6.3. Adjustment in end positions 48

10.6.4. Sensitivity setting 49
10.7. EMERGENCY command (EMERGENCY - OPEN/EMERGENCY - CLOSE) 50
10.8. Controls: close 51
11. Corrective action.................................................................................................................... 52
11.1. Faults during commissioning 52
11.2. Fuses 53
11.2.1. Fuses within the actuator controls 53
11.2.2. Motor protection (thermal monitoring) 54
12.2. Maintenance 55
13. Technical data......................................................................................................................... 57
13.1. Technical data Part-turn actuator 57
13.2. Technical data Actuator controls 60
14. Spare parts............................................................................................................................. 63
14.1. Part-turn actuators SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2 63
14.2. Actuator controls AUMA MATIC AM 01.1/AM 02.1 65
15. Certificates.............................................................................................................................. 67
15.1. Declaration of Incorporation and EC Declaration of Conformity 67
Index........................................................................................................................................ 68
Addresses............................................................................................................................... 70
4
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Safety instructions
1.1. Basic information on safety
Standards/directives AUMA products are designed and manufactured in compliance with recognised
EC Declaration of Conformity.
Safety instructions/warn- All personnel working with this device must be familiar with the safety and warning
ings instructions in this manual and observe the instructions given. Safety instructions
damage.

commissioning.
tions.
● During operation, the housing warms up and surface temperatures > 60 °C may
occur. To prevent possible burns, we recommend checking the surface temper-
ature using an appropriate thermometer and wearing protective gloves, if re-
for the staff.
must be observed.
1.2. Range of application
AUMA part-turn actuators are designed for the operation of industrial valves, e.g.
butterfly valves and ball valves.

5
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Safety instructions AM 01.1
● Escalators
● Continuous duty
● Buried service
● Permanent submersion (observe enclosure protection)
● Potentially explosive areas, with the exception of zone 22
designated use.
Information These operation instructions are only valid for the "clockwise closing" standard
version, i.e. driven shaft turns clockwise to close the valve.
1.3. Applications in Ex zone 22 (option)
Actuators of the indicated series basically meet the requirements for applications in
dust hazardous locations of ZONE 22 in compliance with the ATEX directive 94/9/EC.
The actuators are designed to meet enclosure protection IP68 and fulfil the
requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for use in
presence of combustible dust, requirements for category 3 electrical equipment -
protected by enclosures.
To comply with all requirements of EN 50281-1-1:1998, it is imperative that the
following points are observed:
● In compliance with the ATEX directive 94/9/EC, the actuators must be equipped
with an additional identification – II3D IP6X T150 °C.
● The maximum surface temperature of the actuators, based on an ambient
temperature of +40 °C in accordance with EN 50281-1-1 section 10.4, is +150
°C. In accordance with section 10.4, an increased dust deposit on the equipment
was not considered for the determination of the maximum surface temperature.
● The correct connection of the thermoswitches or the PTC thermistors as well
as fulfilling the requirements of the duty type and the technical data are pre-
requisites for compliance with the maximum surface temperature of devices.
● The connection plug may only be plugged in or pulled out when device is dis-
connected from the mains.
● The cable glands used also have to meet the requirements of category II3 D
and must at least comply with enclosure protection IP68.
● The actuators must be connected by means of an external ground connection
(accessory part) to the potential compensation or integrated into an earthed
piping system.
● As a general rule, the requirements of EN 50281-1-1 must be respected in dust
hazardous locations. During commissioning, service, and maintenance, special
care as well as qualified and trained personnel are required for the safe operation
of actuators.
1.4. Warnings and notes



6
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Safety instructions




1.5. References and symbols

or in the table of contents and may quickly be found.
7
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Identification AM 01.1
2. Identification
2.1. Name plate
Each device component (actuator, controls, motor) is equipped with a name plate.
[1] Actuator name plate

[2] Controls name plate
[3] Motor name plate
Description of actuator name plate

Figure 2: Actuator name plate (example)
[1] Name of manufacturer

[2] Address of manufacturer
[3] Type designation
[4] Order number
[5] Serial number
[6] Operating time in [s] for a part-turn movement of 90°
[7] Torque range in direction CLOSE
[8] Torque range in direction OPEN
[9] Type of lubricant
8
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Identification
Description of actuator controls name plate

Figure 3: Actuator controls name plate
[1] Type designation

[2] Order number
[3] Serial number
[4] Actuator terminal plan
[5] Actuator controls terminal plan
[6] Mains voltage
[7] AUMA power class for switchgear
[10] Control
Descriptions
Type designation Figure 4: Type designation (example)
1. Type and size of actuator

2. Flange size
Type and size
These instructions apply to the following devices types and sizes:
SQ 05.2, 07.2, 10.2, 12.2, 14.2 = part-turn actuators for open-close duty
SQR 052, 07.2, 10.2, 12.2, 14.2 = part-turn actuators for modulating duty
AM 01.1 = AUMA MATIC actuator controls
Order number The product can be identified using this number and the technical data as well as
order-related data pertaining to the device can be compiled.
Please always state this number for any product inquiries.
On the Internet at http://www.auma.com, we offer a service allowing authorised
users to download order-related documents such as wiring diagrams and technical
data (both in German and English), inspection certificates and the operation
instructions when entering the order number.
Actuator serial number

Table 1: Description of serial number (with example)
05 14 NS12345
st nd
1 + 2 position: Assembly in week
05 Week 05
rd th
3 + 4 position: Year of manufacture
14 Year of manufacture: 2014
All other positions
NS12345 Internal number for unambiguous product identification
9
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Identification AM 01.1
AUMA power class for The switchgear used in the actuator controls (reversing contactors/thyristors) are
switchgear classified according to AUMA power classes (e.g. A1, B1, ....). The power class
defines the max. permissible rated power (of the motor) the switchgear has been
designed for. The rated power (nominal power) of the actuator motor is indicated in
kW on the motor name plate. For the assignment of the AUMA power classes to the
nominal power of the motor types, refer to the separate electrical data sheets.
For switchgear without assignment to any power classes, the actuator controls name
plate does not indicate the power class but the max. rated power in kW.
Data Matrix code When registered as authorised user, you may use the AUMA Support App to scan
the Data Matrix code and directly access the order-related product documents without
having to enter order number of serial number.
Figure 5: Link to the App store:
Control
Table 2: Control example (data on actuator controls name plate)
Input signal Description
24 V DC Control voltage 24 V DC for OPEN-CLOSE control via digital inputs
(OPEN, STOP, CLOSE)
115 V AC Control voltage 115 V AC for OPEN-CLOSE control via digital inputs
(OPEN, STOP, CLOSE)
0/4 – 20 mA Input current for setpoint control via analog input
2.2. Short description
Part-turn actuator Definition in compliance with EN ISO 5211:

A part-turn actuator is an actuator which transmits a torque to the valve for less than
one full revolution. It need not be capable of withstanding thrust.
AUMA part-turn actuators are driven by an electric motor. A handwheel is provided
for manual operation. Switching off in end positions may be either by limit or torque
seating. Controls are required to operate or process the actuator signals.
Actuator controls The AUMA MATIC actuator controls are used to operate AUMA actuators and are
supplied ready for use. The controls can be mounted directly to the actuator but also
separately on a wall bracket. The functions of the AUMA MATIC controls include
standard valve control in OPEN - CLOSE duty, position indications and different
signals right through to position control.
Local controls Operation (via push buttons), setting and indication can be performed directly at the
controls (contents of these instructions).
10
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Transport, storage and packaging

3.1. Transport
Hovering load!
to handwheel.
→ Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting
by hoist to valve and NOT to actuator.
→ Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
→ Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting
by hoist only to the actuator and NOT to the controls.
3.2. Storage

→ Store in a well-ventilated, dry room.
Long-term storage If the device must be stored for a long period (more than 6 months) the following
points must be observed in addition:
tion.
3.3. Packaging
11
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Assembly AM 01.1
4. Assembly
4.1. Mounting position
AUMA actuators and actuator controls can be operated without restriction in any
mounting position.
4.2. Handwheel fitting

Figure 6: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
1. If required, fit spacer [1] onto input shaft [2].

3. Secure handwheel [3] using the circlip [4] supplied.
4.3. Actuator: mount to valve
Danger of corrosion due to damage to paint finish and condensation!

→ After mounting, connect the device immediately to electrical mains to ensure
that heater minimises condensation.
The actuator is mounted to the valve using a coupling (standard) or via lever. Separate
instructions are available for actuator mounting to the valve when equipped with
base and lever.
12
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Assembly
4.3.1. Valve attachment via coupling
Dimensions Figure 7: Coupling fitting dimensions
[1] Coupling
[2] Valve shaft
[3] Grub screw
[4] Screw
Table 3: Coupling fitting dimensions

Type, size - output mounting flange X max [mm] Y max [mm] Z max [mm]
SQ/SQR 05.2-F05/F07 3 2 40
SQ/SQR 07.2-F05/F07 3 2 40
SQ/SQR 07.2-F10 3 2 66
SQ/SQR 10.2-F10 4 5 50
SQ/SQR 10.2-F12 4 5 82
SQ/SQR 12.2-F12 5 10 61
SQ/SQR 12.2-F14 5 10 101
SQ/SQR 14.2-F14 8 10 75
SQ/SQR 14.2-F16 8 10 125
Assembly Information: Mount valve and actuator in the same end position.
- For butterfly valves: Recommended mounting position is end position
CLOSED.
- For ball valves: Recommended mounting position is end position OPEN.
1. Thoroughly degrease mounting faces of output mounting flanges.
2. Apply a small quantity of grease to the valve shaft [2].
3. Use handwheel to run actuator to mechanical end stop.
4. Place coupling [1] onto valve shaft [2] and secure against axial slipping by using
a grub screw, a circlip or a screw. Thereby, ensure that dimensions X, Y or Z
are observed (refer to figure and table <Coupling fitting dimensions>).
5. Apply non-acidic grease at splines of coupling.
6. Fit actuator.
Information: Ensure that the spigot (if provided) fits uniformly in the recess
and that the flanges are in complete contact.
7. If flange bores do not match thread:
7.1 Slightly rotate handwheel until bores line up.
7.2 If required, shift actuator position by one tooth on the coupling.
13
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Assembly AM 01.1
8. Fasten actuator with screws [4].

→ Fasten screws [4] crosswise with a torque according to table.

M6 11
M8 25
M10 51
M12 87
M16 214
4.4. Mounting positions of local controls
The mounting position of the local controls is selected according to the order. If, after
mounting the actuator to the valve or the gearbox on site, the local controls are in
an unfavourable position, the mounting position can be changed at a later date. Four
mounting positions are possible.
Figure 8: Mounting positions A and B
Figure 9: Mounting positions C and D
4.4.1. Mounting positions: modify
Hazardous voltage!
1. Loosen screws and remove the local controls.
14
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Assembly
2. Loosen 3 screws of the board, turn board to the new position and fasten the
screws.
3. Check whether O-ring is in good condition, correctly insert O-ring.
4. Turn local controls into new position and re-place.

5. Fasten screws evenly crosswise.
15
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Electrical connection AM 01.1
5. Electrical connection
5.1. Basic information
Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury, or property damage.
→ The electrical connection must be carried out exclusively by suitably qualified
personnel.
→ Prior to connection, observe basic information contained in this chapter.
→ After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
Wiring diagram/terminal
The pertaining wiring diagram/terminal plan (both in German and English) is attached
plan to the device in a weather-proof bag, together with these operation instructions. It
can also be requested from AUMA (state order number, refer to name plate) or
downloaded directly from the Internet (http://www.auma.com).
Protection on site
For short-circuit protection and for disconnecting the actuator from the mains, fuses
and disconnect switches have to be provided by the customer.
The current values for respective sizing is derived from the current consumption of
the motor (refer to electrical data sheet) plus the current consumption of the controls.
Table 5: Current consumption controls

Mains voltage Max. current consumption
100 to 120 V AC (±10 %) 575 mA
208 to 240 V AC (±10 %) 275 mA
380 to 500 V AC (±10 %) 160 mA
24 V DC (+20 %/–15 %) and AC motor 500 mA
Table 6: Maximum permissible protection

Switchgear Rated power Max. protection
Reversing contactor A1 up to 1.5 kW 16 A (gL/gG)
Thyristor B1 up to 1.5 kW 16 A (g/R) I²t<1,500A²s
If controls are mounted separately from actuator (controls on wall bracket): Consider
length and cross section of connecting cable when defining the protection required.
Power supply for the
If the controls (electronics) are supplied externally with 24 V DC, the power supply
controls (electronics) is smoothed via an internal 1,000 µF capacitor). When selecting a power supply,
care must be taken to consider the capacitor inrush current upon powering the unit
up.
Safety standards All externally connected devices shall comply with the relevant safety standards.
Cable installation in ac-
Signal and bus cables are susceptible to interference.
cordance with EMC
Motor cables are interference sources.
● Lay cables being susceptible to interference or sources of interference at the
highest possible distance from each other.
● The interference immunity of signal and bus cables increases if the cables are
laid close to the earth potential.
● If possible, avoid laying long cables and make sure that they are installed in
areas being subject to low interference.
● Avoid long parallel paths with cables being either susceptible to interference or
interference sources.
● For the connection of remote position transmitters, screened cables must be
used.
16
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Electrical connection
Type of current, mains Type of current, mains voltage and mains frequency must match the data on the
voltage and mains fre- motor name plate.
quency Figure 10: Motor name plate (example)
[1] Type of current

[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ● For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
● Use connecting cable with appropriate minimum rated temperature.
● For connecting cables exposed to UV radiation (outdoor installation), use UV
resistant cables.
5.2. Connection with AUMA plug/socket connector
Cross sections AUMA plug/socket connector:
● Power terminals (U1, V1, W1, U2, V2, W2): max. 6 mm² flexible/10 mm² solid
●
PE connection : max. 6 mm² flexible/10 mm² solid
● Control contacts (1 to 50): max. 2.5 mm²
5.2.1. Terminal compartment: open
Figure 11: Connection AUMA plug/socket connector, version S
[1] Cover
[3] O-ring
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
17
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Hazardous voltage!
1. Loosen screws [2] and remove cover [1].

2. Loosen screws [4] and remove socket carrier [5] from cover [1].
3. Insert cable glands [8] suitable for connecting cables.
➥ The enclosure protection IP... stated on the name plate is only ensured if suitable
cable glands are used.
Figure 12: Example: Name plate shows enclosure protection IP68
4. Seal unused cable entries [6] with suitable blanking plugs [7].
5. Insert the cables into the cable glands [8].
5.2.2. Cable connection
✔ Observe permissible cross sections.
Danger of corrosion: Damage due to condensation!

→ After mounting, commission the device immediately to ensure that heater min-
imises condensation.
1. Remove cable sheathing.

2. Strip wires.
3. For flexible cables: Use end sleeves according to DIN 46228.
4. Connect cables according to order-related wiring diagram.
18
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
In case of a fault: Hazardous voltage while protective earth conductor is NOT

connected!
→ Connect all protective earth conductors.
→ Connect PE connection to external protective earth conductor of connecting
cables.
→ Start running the device only after having connected the protective earth con-
ductor.
5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables)

or loops (rigid cables).
Figure 13: PE connection
[1] Socket carrier

[2] Screw
[3] Washer
[4] Lock washer
[5] Protective earth with ring lugs/loops
[6] PE connection, symbol:
Information Some actuators are equipped with an additional motor heater. The motor heater
minimises condensation within the motor.
19
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
5.2.3. Terminal compartment: close
Figure 14: Example: Version S
[1] Cover
[3] O-ring
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
Short-circuit due to pinching of cables!

Risk of electric shock and functional failures.
→ Carefully fit socket carrier to avoid pinching the cables.
1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4].
2. Clean sealing faces of cover [1] and housing.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
6. Fasten cable glands [8] applying the specified torque to ensure the required
enclosure protection.
5.3. Accessories for electrical connection
— Option —
5.3.1. Controls mounted to wall bracket
The wall bracket allows separate mounting of controls and actuator.
Application ● When mounted in confined spaces.
● If the actuator is subjected to high temperatures.
● In case of heavy vibration of the valve.
20
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Design Figure 15: Design principle with wall bracket
[1] Wall bracket

[2] Connecting cables
[3] Electrical connection of wall bracket (XM)
[4] Electrical connection of actuator (XA)
[5] Electrical connection of controls (XK) - customer plug
Observe prior to connec- ● Permissible length of connecting cables: max. 100 m.
tion ● If the actuator is equipped with a position transmitter (EWG/RWG): Connecting
cables must be available as shielded version.
● Versions with potentiometer in the actuator are not suitable.
● We recommend using an AUMA cable set "LSW".
● If the AUMA cable set is not used: Use suitable flexible and screened connecting
cables.
● When using connecting cables, e.g. of the heater or switch, requiring direct
wiring from the actuator to the XK customer plug (XA-XM-XK, refer to wiring
diagram), these connecting cables must be subject to an insulation test in
compliance with EN 50178. Connecting cables of position transmitters (EWG,
RWG, IWG, potentiometer) do not belong to this group.They may not be subject
to an insulation test.
5.3.2. Parking frame
Application Parking frame for safe storage of a disconnected plug.
For protection against touching the bare contacts and against environmental
influences.
Figure 16: Parking frame
5.3.3. Protection cover

Protection cover for plug compartment when plug is removed.
21
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
The open terminal compartment can be closed using a protective cover (not
illustrated).
5.3.4. Double sealed intermediate frame
When removing the electrical connection or due to leaky cable glands, ingress of
dust and water into the housing may occur. This is prevented effectively by inserting
the double sealed intermediate frame [2] between the plug/socket connector [1] and
the housing of the device. The enclosure protection of the device (IP68) will not be
affected, even if the electrical connection [1] is removed.
Figure 17: Electrical connection with double sealed intermediate frame
[1] Electrical connection

[2] Double sealed intermediate frame
5.3.5. Earth connection, external

As an option, the housing is equipped with an external earth connection (U-bracket)
to connect the device to the equipotential earth bonding.
Figure 18: Earth connection
22
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Operation
6. Operation
6.1. Manual operation

For purposes of setting and commissioning, in case of motor or power failure, the
actuator may be operated manually. Manual operation is engaged by an internal
change-over mechanism.
6.1.1. Manual operation: engage
Damage at the motor coupling due to faulty operation!

→ Engage manual operation only during motor standstill.
1. Press push button.
2. Turn handwheel in desired direction.

→ To close the valve, turn handwheel clockwise:
➥ Drive shaft (valve) turns clockwise in direction CLOSE.
6.1.2. Manual operation: disengage
Manual operation is automatically disengaged when motor is started again. The

handwheel does not rotate during motor operation.
6.2. Motor operation
✔ Perform all commissioning settings and the test run prior to motor operation.
6.2.1. Local operation

The local operation of the actuator is performed using the push buttons of the local
controls.
23
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Operation AM 01.1
Figure 19: Local controls
[1] Push button for operation command in direction OPEN

[2] Push button Stop
[3] Push button for operation command in direction CLOSE
[4] Selector switch
Hot surfaces, e.g. possibly caused by high ambient temperatures or strong

direct sunlight!
Danger of burns
→ Check surface temperature and wear protective gloves, if required.
→ Set selector switch [4] to position Local control (LOCAL).
➥ The actuator can now be operated using the push buttons [1 – 3]:
- Run actuator in direction OPEN: Press push button [1] .
- Stop actuator: Press push button [2] Stop.
- Run actuator in direction CLOSE: Press push button [3] .
Information The OPEN - CLOSE operation commands can be given either in push-to-run operation
mode or in self-retaining mode. In self-retaining mode, the actuator runs to the defined
end position after pressing the button, unless another command has been received
beforehand.
6.2.2. Actuator operation from remote
→ Set selector switch to Remote control (REMOTE).
➥ Now, it is possible to operate the actuator via remote control, via operation
commands (OPEN, STOP, CLOSE) or analogue setpoints (e.g. 0 – 20 mA).
24
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Operation
Information For actuators equipped with positioner, it is possible to optionally select between
open-close duty (REMOTE OPEN-CLOSE) and modulating duty (REMOTE
SETPOINT). Selection is made via REMOTE MANUAL input, e.g. based on a 24 V
DC signal (refer to wiring diagram).
Behaviour in modulating duty for version with positioner:

In case of signal loss of setpoint E1 or actual value E2, the actuator moves to a
preset position. The following reactions are possible:
● Fail as is: Actuator stops immediately and remains in this position.
● Fail close: Actuator moves the valve to end position CLOSED.
● Fail open: Actuator moves the valve to end position OPEN.
The behaviour on loss of signal can be set via a switch in the controls.
25
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Indications AM 01.1
7. Indications
7.1. Indication lights
Figure 20: Local controls with indication lights
[1] illuminated (default: green): End position OPEN reached

[2] illuminated (default: red): Collective fault signal
[3] illuminated (default: yellow): End position CLOSED reached
Information The three indication lights can be provided in different colours (deviating from the
standard).
Collective fault signal The collective fault signal [2] appears if one of the following events occurs (default
configuration):
S5), indication lights [1] and [3] can be used as running indication. The running
indication can be activated/deactivated via a switch in the controls. If the running
indication is active, the respective indication light blinks during operation.
7.2. Mechanical position indicator/running indication
● Continuously indicates the valve position
(For a swing angle of 90°, the indicator disc [2] rotates by approximately 180°.)
● Indicates whether the actuator is running (running indication)
● Indicates that the end positions are reached (via indicator mark [3])
26
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Indications
[1] Cover
[2] Indicator disc
[3] Mark
27
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Signals AM 01.1
8. Signals
8.1. Feedback signals via output contacts (binary)
The output contacts can be used to indicate operation modes of the actuator or the
controls as binary signals.
The signals are assigned according to the order. Example:
Output contact open = end position CLOSED not reached
Output contact closed = end position CLOSED reached
Collective fault signal Switches: 1 NC and 1 NO (standard)

Designation in the wiring diagram: K9
The collective fault signal appears if one of the following events occurs (default
configuration):
4 output contacts: Switches: 1 NC (standard)
Designation in the wiring diagram: K5, K6, K7, K8
Default configuration:
● K5: Selector switch is in position Remote control (REMOTE).
● K6: Selector switch is in position Local control (LOCAL).
● K7: End position OPEN reached
● K8: End position CLOSED reached
8.2. Feedback signals (analogue)
— (Option) —
If the actuator is equipped with a position transmitter (EWG, RWG or potentiometer),
an analogue position feedback signal is available.
Valve position Signal: E2 = 0/4 – 20 mA (galvanically isolated)
Designation in the wiring diagram: E2 (actual value)
28
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Commissioning (basic settings)
9. Commissioning (basic settings)

1. Set selector switch to position 0 (OFF).
Information: The selector switch is not a mains switch. When positioned to 0

(OFF), the actuator cannot be operated. The controls' power supply is
maintained.
2. Switch on the power supply.
Information: Please consider the heat-up time for ambient temperatures below
–20 °C.
3. Perform basic settings.
9.1. Heat-up time for low temperature version
Please note that for low temperature versions, the controls require a heat-up time.
This heat-up time is applicable in case the actuator and the controls are not live and
have cooled down to ambient temperature. Under these conditions and after
connection to the voltage supply, the following heat-up times must be complied with
prior to commissioning:
For –50 °C = 60 min.
For –60 °C = 80 min.
Figure 22: Sketch illustrating the heat-up time
[t ] Heat-up time in minutes

[ϑ] Ambient temperature in °C
9.2. End stops in part-turn actuator

The internal end stops limit the swing angle. They protect the valve in the event of
limit switching failure.
End stop setting is generally performed by the valve manufacturer prior to installing
the valve into the pipework.
29
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Commissioning (basic settings) AM 01.1
Exposed, rotating parts (discs/balls) at the valve!

Pinching and damage by valve or actuator.
→ End stops should be set by suitably qualified personnel only.
→ Never completely remove the setting screws [2] and [4] to avoid grease leakage.
→ Observe dimension Tmin.
Information ● The swing angle set in the factory is indicated on the name plate:
● The setting sequence depends on the valve:

- Recommendation for butterfly valves: Set end stop CLOSED first.
- Recommendation for ball valves: Set end stop OPEN first.
Figure 23: End stop
[1] Screw plug for end stop OPEN

[2] Setting screw for end stop OPEN
[3] Screw plug for end stop CLOSED
[4] Setting screw for end stop CLOSED
Dimensions/sizes 05.2 07.2 10.2 12.2 14.2

T (for 90°) 17 17 20 23 23
Tmin. 11 11 12 13 12
9.2.1. End stop CLOSED: set
1. Remove screw plug [3].

2. Move valve to end position CLOSED with handwheel.
30
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
3. If the valve end position is not reached:

→ Slightly turn setting screw [4] counterclockwise until valve end position
CLOSED can be safely set.
➥ Turning the setting screw [4] clockwise results in a smaller swing angle.
➥ Turning the setting screw [4] counterclockwise results in a larger swing
angle.
4. Turn setting screw [4] clockwise to the stop.

➥ This completes the setting of end stop CLOSED.
5. Check O-ring in screw plug and replace if damaged.
6. Fasten and tighten screw plug [3].
Having completed this procedure, the end position detection CLOSED can be set
immediately.
9.2.2. End stop OPEN: set
Information In general, the end stop OPEN does not have to be set.
1. Remove screw plug [1].
2. Move valve to end position OPEN with handwheel.
3. If the valve end position is not reached:
→ Slightly turn setting screw [2] counterclockwise until valve end position
OPEN can be safely set.
➥ Turning the setting screw [2] clockwise results in a smaller swing angle.
➥ Turning the setting screw [2] counterclockwise results in a larger swing
angle.
4. Turn setting screw [2] clockwise to the stop.

➥ This completes the setting of end stop OPEN.
5. Check O-ring in screw plug and replace if damaged.
6. Fasten and tighten screw plug [1].
Having completed this procedure, the end position detection OPEN can be set
immediately.
9.3. Switch compartment: open
The switch compartment must be opened to perform the following settings (options).
31
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
1. Loosen screws [2] and remove cover [1] from the switch compartment.
2. If indicator disc [3] is available:

Remove indicator disc [3] using a spanner (as lever).
Information: To avoid damage to paint finish, use spanner in combination with
soft object, e.g. fabric.
9.4. Torque switching: set

Once the set torque is reached, the torque switches will be tripped (overload protection
of the valve).
Information The torque switches may also trip during manual operation.
Valve damage due to excessive tripping torque limit setting!

→ The tripping torque must suit the valve.
Figure 24: Torque measuring heads
[1] Torque switching head black in direction CLOSE

[2] Torque switching head white in direction OPEN
[3] Lock screws
[4] Torque dials
1. Loosen both lock screws [3] at the indicator disc.
32
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
2. Turn torque dial [4] to set the required torque (1 da Nm = 10 Nm). Example:
- Black torque switching head set to approx. 25 da Nm ≙ 250 Nm for direction
CLOSE
- White torque switching head set to approx. 20 da Nm ≙ 200 Nm for direction
OPEN
3. Fasten lock screws [3] again.
Information: Maximum tightening torque: 0.3 – 0.4 Nm
➥ The torque switch setting is complete.
9.5. Limit switching: set

The limit switching records the travel. When reaching the preset position, switches
are operated.
Black section:
[1] Setting spindle: End position CLOSED
[2] Pointer: End position CLOSED
[3] Mark: End position CLOSED is set
White section:
[4] Setting spindle: End position OPEN
[5] Pointer: End position OPEN
[6] Mark: End position OPEN is set
9.5.1. End position CLOSED (black section): set

2. Turn handwheel clockwise until valve is closed.
➥ The end position CLOSED setting is complete.
9.5.2. End position OPEN (white section): set

2. Turn handwheel counterclockwise until valve is open.
33
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
➥ The end position OPEN setting is complete.
9.6. Intermediate positions: set
— Option —
Actuators equipped with DUO limit switching contain two intermediate position
switches. One intermediate position may be set for each running direction.
Black section:
[1] Setting spindle: Running direction CLOSE
[2] Pointer: Running direction CLOSE
[3] Mark: Intermediate position CLOSED is set
White section:
[4] Setting spindle: Running direction OPEN
[5] Pointer: Running direction OPEN
[6] Mark: Intermediate position OPEN is set
9.6.1. Running direction CLOSE (black section): set
1. Move valve in direction CLOSE to desired intermediate position.

2. If you override the tripping point inadvertently: Turn valve in opposite direction
and approach intermediate position again in direction CLOSE.
Information: Always approach the intermediate position in the same direction
as in later electrical operation.
➥ The intermediate position setting in running direction CLOSE is complete.
34
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
9.6.2. Running direction OPEN (white section): set
1. Move valve in direction OPEN to desired intermediate position.

2. If you override the tripping point inadvertently: Move valve in opposite direction
and approach intermediate position again in direction OPEN (always approach
the intermediate position in the same direction as in later electrical operation).
➥ The intermediate position setting in running direction OPEN is complete.
9.7. Test run
Perform test run only once all settings previously described have been performed.
9.7.1. Direction of rotation: check
Valve damage due to incorrect direction of rotation!

→ If the direction of rotation is wrong, switch off immediately (press STOP).
→ Eliminate cause, i.e. correct phase sequence for cable set wall bracket.
→ Repeat test run.
1. Move actuator manually to intermediate position or to sufficient distance from

end position.
3. Switch on actuator in direction CLOSE and observe the direction of rotation on

the indicator disc.
→ Switch off before reaching the end position.
➥ The direction of rotation is correct if actuator runs in direction CLOSE and
indicator disc turns counterclockwise.
35
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
9.7.2. Limit switching: check
2. Operate actuator using push buttons OPEN - STOP - CLOSE.

➥ The limit switching is set correctly if (default indication):
- the yellow indication light is illuminated in end position CLOSED
- the green indication light is illuminated in end position OPEN
- the indication lights go out after travelling into the opposite direction.
➥ The limit switching is set incorrectly if:
- the actuator comes to a standstill before reaching the end position
- the red indication light is illuminated (torque fault).
3. If the end position setting is incorrect: Reset limit switching.
4. If the end position setting is correct and no options (e.g. potentiometer, position
transmitter) are available: Close switch compartment.
9.7.3. PTC tripping device (option): test
1. Turn selector switch to position Test (spring return).
➥ If the PTC tripping device is working properly, the tripping of the motor protection
is signalled via the red indication light "collective fault signal" on the local con-
trols.
2. Turn selector switch to position Reset.
➥ The fault signal is reset if the device is working properly.

3. If no fault signal is initiated: Request AUMA service to check both wiring and
selector switch.
9.8. Electronic position transmitter EWG 01.1
— Option —
The electronic position transmitter EWG 01.1 signals the remote position or the valve
position. On the basis of the actual valve position sensed by hall sensor, a current
signal between 0 – 20 mA or 4 – 20 mA is generated.
Technical data
Table 7: EWG 01.1
Data 3-wire or 4-wire system 2-wire system
Output current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA
Power supply UV 1) 24 V DC (18 – 32 V) 24 V DC (18 – 32 V)
Max. current consumption LED off = 26 mA, LED on = 27 20 mA
mA
Max. load RB 600 Ω (UV – 12 V)/20 mA
Impact of power supply 0.1 %
36
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2

Load influence 0.1 %
Temperature impact < 0.1 ‰/K
Ambient temperature2) –60 °C to +80 °C
1) Power supply possible via: AC, AM controls or external power supply
2) Depending on temperature range of the actuator: Refer to name plate
Setting elements The EWG is housed in the actuator switch compartment. The switch compartment
must be opened to perform any settings. ➔ Refer to <Switch compartment: open>.
All settings are made via the two push buttons [S1] and [S2].
Figure 27: View on control unit when switch compartment is open
[S1] Push button: Set 0/4 mA

[S2] Push button: Set 20 mA
LED Optical aid for setting
The output current (measuring range 0 – 20 mA) can be checked at measuring points
[1] and [2].
Table 8: Short overview on push button functions

Push but- Function
tons
[S1] + [S2] → press simultaneously for 5 s: Activate setting mode
[S1] → press in setting mode for 3 s: Set 4 mA
→ press in setting mode for 6 s: Set 0 mA
→ press in operation for 3 s: Switch on/off LED end position signalling.
→ touch in end position: Reduce current value by 0.02 mA
[S2] → press in setting mode for 3 s: Set 20 mA
→ press in operation for 3 s: Switch on/off LED end position signalling.
→ touch in end position: Increase current value by 0.02 mA
9.8.1. Measuring range: set
For measuring range setting, voltage must be applied at the position transmitter.
Information ● Both measuring ranges 0/4 – 20 mA and 20 – 0/4 mA (inverse operation) can
be set.
During setting process, the measuring range (normal or inverse operation) is
assigned to the end positions by push button S1/S2 assignment.
● Setting mode activating clears the setting in both end positions and sets the
output current to a value of 3.5 mA. After activation, both end values (0/4 mA
and 20 mA) need to be reset.
● In case of inadvertent incorrect adjustment, the settings can always be reset
by renewed activation of the setting mode (simultaneous pressing of [S1] and
[S2]).
37
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Activate setting mode 1. Press both push buttons [S1] and [S2] and hold down for 5 seconds:
➥ By pulsing double flashes, the LED indicates that the setting mode is correctly
activated:
➥ For any other LED flash sequence (single/triple flashing): ➔ Refer to <Faults
during commissioning>.
Set measuring range 2. Operate valve in one of the end positions (OPEN/CLOSED).
3. Set desired output current (0/4 mA or 20 mA):
→ for 4 mA: Hold down push button [S1] for approx. 3 seconds,
until LED is slowly blinking .
until LED is blinking fast .
until LED is illuminated .
4. Operate valve into opposite end position.
➥ The value set in end position (0/4 mA or 20 mA) does not change during travel
in setting mode.
5. Perform setting in the second end position following the same steps.
6. Approach both end positions again to check the setting.
→ If the measuring range cannot be set:
Refer to <Faults during commissioning>.
→ If the current values (0/4/20 mA) are incorrect:
Refer to <Current values: adjust>.
→ If the current value fluctuates (e.g. between 4.0 – 4.2 mA):
<LED end position signalling: switch on/off>.
9.8.2. Current values: adjust
The current values (0/4/20 mA) set in end positions can be adjusted at any time.
Conventional values are e.g. 0.1 mA (instead of 0 mA) or 4.1 mA (instead 4 mA).
Information If the current value fluctuates (e.g. between 4.0 – 4.2 mA), the <LED end position
signalling> must be switched on for current adjustment.
→ Operate valve in desired end position (OPEN/CLOSED).
→ Reduce current value: Press push button [S1]
(the current is reduced by 0.02 mA every time the push button is
pressed)
→ Increase current value Press push button [S2]
(the current is increased by 0.02 mA every time the push button is
pressed)
9.8.3. LED end position signalling: switch on/off
The LED behaviour for end position reached can be set as follows: blinking/continuous
illumination or no illumination. During setting mode, end positions signalling is
switched on.
Switching on and off 1. Operate valve in one of the end positions (OPEN/CLOSED).
38
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
2. Hold down push buttons [S1] or [S2] for approx. 3 seconds.

➥ End position signalling is switched on or off.
Table 9: LED behaviour when end position signalling is switched on

Set output current LED behaviour in end position
4 mA
LED is blinking slowly
0 mA
LED is blinking fast
20 mA
LED is illuminated
9.9. Potentiometer
— Option —
The potentiometer is used as travel sensor and records the valve position.
Information This setting is only required if the potentiometer is directly wired to the customer
connection XK (refer to wiring diagram).
Setting elements The potentiometer is housed in the actuator switch compartment. The switch
compartment must be opened to perform any settings. ➔ Refer to <Switch
compartment: open>.
Setting is made via potentiometer [1].
Figure 28: View on control unit
[1] Potentiometer
9.9.1. Potentiometer setting
Information Due to the ratio of the reduction gearing, the complete resistance range/stroke is not
always covered. Therefore, external adjustment (setting potentiometer) must be
provided.
➥ End position CLOSED corresponds to 0 %
➥ End position OPEN corresponds to 100 %
4. Perform fine-tuning of the zero point at external setting potentiometer (for remote
indication).
9.10. Electronic position transmitter RWG
— Option —
The electronic position transmitter RWG records the valve position. On the basis of
the actual position value measured by the potentiometer (travel sensor), it generates
a current signal between 0 – 20 mA or 4 – 20 mA.
39
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Technical data
Table 10: RWG 4020
Output current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA
Power supply UV 1) 24 V DC (18 – 32 V) 14 V DC + (I x RB), max. 30 V
Max. current consumption 24 mA at 20 mA output current 20 mA
Max. load RB 600 Ω (UV – 14 V)/20 mA
Impact of power supply 0.1 %/V 0.1 %/V
Load influence 0.1 %/(0 – 600 Ω) 0.1 %/100 Ω
Temperature impact < 0.3 ‰/K
Ambient temperature2) –60 °C to +80 °C
Transmitter potentiometer 5 kΩ
1) Power supply possible via: AC, AM controls or external power supply
2) Depending on temperature range of the actuator: Refer to name plate
Setting elements The RWG is housed in the actuator switch compartment. The switch compartment
must be opened to perform any settings. Refer to <Switch compartment: open>.
Setting is made via three potentiometers [1], [2] and [3].
Figure 29: View on control unit when switch compartment is open
[1] Potentiometer (travel sensor)

[2] Potentiometer min. (0/4 mA)
[3] Potentiometer max. (20 mA)
The output current (measuring range 0 – 20 mA) can be checked at measuring points
[4] and [5].
9.10.1. Measuring range: set
For measuring range setting, voltage must be applied at the position transmitter.

2. Connect ammeter for 0 – 20 mA to measuring points [4 and 5].
5. Turn potentiometer [2] clockwise until output current starts to increase.
6. Turn potentiometer [2] in opposite direction until the following value is reached:
➥ This ensures that the signal remains above the dead and live zero point.
8. Set potentiometer [3] to end value 20 mA.
40
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
9. Approach end position CLOSED again and check minimum value (0.1 mA or
4.1 mA). If necessary, correct the setting.
9.11. Mechanical position indicator: set
1. Place indicator disc on shaft.

3. Turn lower indicator disc until symbol (CLOSED) is in alignment with the
mark on the cover.
4. Move actuator to end position OPEN.

5. Hold lower indicator disc in position and turn upper disc with symbol (OPEN)
until it is in alignment with the mark on the cover.
6. Move valve to end position CLOSED again.

7. Check settings:
If the symbol (CLOSED) is no longer in alignment with mark on the cover:
→ Repeat setting procedure.
9.12. Switch compartment: close


41
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
42
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Commissioning – controls settings
10. Commissioning – controls settings

The controls are set in the factory according to the order. The settings only have to
be changed if the device is used for applications other than those specified in the
order. In case the device is equipped with a positioner (option), subsequent setting
may be required.
The following settings are described in these operation instructions:
● Type of seating (limit or torque seating): set
● Push-to-run operation or self-retaining: set
● Running indication (blinker transmitter) (option): activate/deactivate
● Torque fault in collective fault signal: activate/deactivate
● Positioner setting (option)
10.1. Controls: open
Hazardous voltage!
Electrostatic discharge ESD!

Risk of damage to electronic components.
→ Earth both operators and devices.
→ Loosen screws [2] and remove cover [1].
10.2. Type of seating: set
Valve damage due to incorrect setting!

→ The type of seating must suit the valve.
The type of seating can be set via two DIP switches on the logic board.
Limit seating
The limit switching is set in such a way that the actuator switches off at the desired
switching points. The torque switching acts as overload protection for the valve.
Torque seating
The torque switching is set to the desired tripping torque. After reaching the tripping
torque, the actuator is turned off.
43
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Commissioning – controls settings AM 01.1
The limit seating is used to signal that the limit switching will trip shortly before
reaching the set tripping torque. If this is not the case, either the indication light on
the local controls or the alarm contact K9 (collective fault signal) will signal a fault.
→ Set type of seating for end positions via DIP switches [S1] and [S3].
Figure 30: DIP switches on logic board
[S1] DIP switch for end position CLOSED

[S3] DIP switch for end position OPEN
[1] Position [1] = limit seating
[2] Position [2] = torque seating
10.3. Push-to-run operation or self-retaining: set

Push-to-run operation or self-retaining is set via a DIP switch on the logic board.
Push-to-run operation Actuator only runs in direction OPEN or CLOSE while an operation command is
being received. The actuator stops if the operation command is cancelled.
Self-retaining After receiving an operation command, the actuator continues to run in direction
OPEN or CLOSE, even if the operation command is cancelled (self-retaining). The
actuator is either stopped by the STOP command or if an end position or intermediate
position has been reached.
→ Set push-to-run operation or self-retaining via DIP switch [S2].

[S2] 6-way DIP, switches [1 – 4]:

1 for operation commands CLOSE from remote
2 for operation commands OPEN from remote
3 for operation commands CLOSE via push button at local controls
4 for operation commands OPEN via push button at local controls
➥ Switch in lower position (position ON): Self-retaining

➥ Switch in upper position (position OFF): Push-to-run operation
44
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Information If the controls are equipped with a positioner, switches 1 and 2 (operation commands
from remote) must be in position OFF (push-to-run operation).
10.4. Running indication (blinker transmitter): activate/deactivate

— (Option) —
If the actuator is equipped with a blinker transmitter (wiring diagram designation:
S5), indication lights (OPEN/CLOSE) on the local controls can be used as running
indication. If the running indication is active, the respective indication light blinks
during actuator operation.
The running indication is activated/deactivated via a DIP switch on the logic board.
→ Set running indication (blinker) via DIP switch [S2].

➥ Switch 5 in lower position (position ON): Running indication is deactivated.

➥ Switch 5 in upper position (position OFF): Running indication is activated.
10.5. Torque fault in collective fault signal: activate/deactivate

The torque fault signal is activated/deactivated via a DIP switch on the logic board.
→ Activate/deactivate signal via DIP switch [S2].

➥ Switch 6 in lower position (position ON): The signal "Torque fault in collective
fault signal" is activated.
➥ Switch 6 in upper position (position OFF): The signal "Torque fault in collective
fault signal" is deactivated.
10.6. Positioner
— (Option) —
45
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
→ Prior to positioner setting, set limit and torque switching as well as potentiometer
or electronic position transmitter.
10.6.1. Input ranges (signal type) for setpoint and actual value
The input range (signal type) for setpoint E1 and actual value E2 is set in the factory
and marked with a label on the cover plate of the positioner.
The type of signal can be modified at a later date exclusively for versions with setpoint
E1 ≠ 0/4 – 20 mA and split-range version. For these versions, the positioner board
is equipped with an additional contact.
Figure 34: Version with additional switch on the positioner board
[5] Label indicating the set input ranges

[S1-7] 5-contact DIP switch for setting
DIP1 Actual value E2 (current or voltage signal)
DIP3 Setpoint E1 (current or voltage signal)
DIP5 Setpoint E1 (double signal range e.g. for split range)
Table 11: Input range setting for setpoint E1

Setpoint E1 [S1–7]
DIP 3 and 5
0/4 – 20 mA
0–5V
0 – 10 V
Table 12: Input range setting for actual value E2

Actual value E2 [S1–7]
DIP 1
0/4 – 20 mA1)
0 – 5 V2)
1) for internal feedback of electronic position transmitter RWG

2) for internal feedback of precision potentiometer 5 kΩ
Information When changing the setting, a new label [5] indicating the set signal type must be
provided. Furthermore, the wiring diagram indicated on the name plate of the actuator
controls also changes.
10.6.2. Behaviour on loss of signal (actuator reaction)
In case of a loss of signal of setpoint E1 or actual value E2, the reaction of the actuator
can be programmed via switch [S2-7]. The complete selection range, however, is
only available for signals 4 – 20 mA.
46
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
The following reactions are possible:

Fail as is: Actuator stops immediately and remains in this position.
Fail close: Actuator moves the valve to end position CLOSED.
Fail open: Actuator moves the valve to end position OPEN.
Figure 35: DIP switch [S2-7] on positioner board
DIP1 = ON, actual value E2 is monitored

DIP2 = ON, setpoint E1 is monitored
Table 13: Recommended settings

Behaviour on loss of signal of Signal type [S2–7]
E1 and/or E2 Setpoint E1 Actual value E2 DIP 1 2 3 4
Fail close
Fail open
Table 14: Further possible settings

Behaviour on loss of signal of Signal type1) [S2–7]
E1 E2 Setpoint E1 Actual value E2 DIP 1 2 3 4
Fail as is Fail open 4 – 20 mA 0–5V
Fail close Fail open 4 – 20 mA 0–5V
0 – 20 mA 4 – 20 mA
0 – 20 mA 0 – 20 mA
0–5V 0–5V
0 – 10 V
Fail close 0 – 20 mA 4 – 20 mA
0–5V
0 – 10 V
Fail open 4 – 20 mA 0 – 20 mA
0–5V
1) in case of a signal loss, a misinterpretation might be made for 0 – 20 mA, 0 – 5 V or 0 – 10 V, due

to the fact that E1 or E2 could take the value 0 mA even without loss of signal (end position CLOSED
= 0 mA or 0 V).
47
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
10.6.3. Adjustment in end positions

The setting described below applies to the standard positioner version, i.e. maximum
setpoint E1 (20 mA) triggers a travel to end position OPEN, minimum setpoint (0/4
mA) triggers a travel to end position CLOSED.
[MP1] Measuring point (–) for actual value E2

[MP2] Measuring point (+) for actual value E2
[MP3] Measuring point (+) for setpoint E1
[MP4] Measuring point (–) for setpoint E1
[5] Label with signal indication
[V10] Red LED: E1/E2 <4 mA
End position CLOSED 1. Set selector switch to position Local control (LOCAL).
3. Connect lower setpoint to customer connection XK (terminals 2/3). The lower
setpoint (0 V, 0 mA or 4 mA) is indicated on the label [5].
4. If the red LED [V10] E1/E2 <4 mA is illuminated:
4.1 Verify polarity of setpoint E1.
4.2 Check whether external load is connected to customer connection XK
(terminals 23/24) (observe max. load RB), or
4.3 Connect terminals 23/24 across customer connection XK (terminals 23/24).
5. Measure setpoint E1: Connect measuring device for 0 – 5 V to measuring points
[MP3/MP4].
➥ For a setpoint E1 of 4 mA, the voltmeter shows 1 V.
6. If measured value is not correct: Correct setpoint E1.
7. Measure actual value E2: Connect measuring device for 0 – 5 V to measuring
points [MP1/MP2].
48
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
9. Adjust positioner using potentiometer 0 [P3].

9.1 If both LEDs are OFF or the green LED [V28] is illuminated: Turn poten-
tiometer 0 [P3] slightly clockwise until the yellow LED [V27] is illuminated.
9.2 If the yellow LED [V27] is illuminated: Turn potentiometer 0 [P3] counter-
clockwise until the yellow LED [V27] goes out. Then turn potentiometer 0
[P3] slightly clockwise until the yellow LED [V27] is illuminated again.
[P3] Potentiometer 0
[P4] Potentiometer max
[V27] Yellow LED: End position CLOSED reached
[V28] Green LED: End position OPEN reached
➥ The setting is correct if the yellow LED [V27] is switched on when reaching end
position CLOSED.
End position OPEN 10. Move valve to end position OPEN.
11. Measure actual value E2 (measuring points [MP1/MP2]):
13. Set maximum setpoint E1 (5 V or 20 mA, refer to label [5]).
14. Measure setpoint E1 (measuring points [MP3/MP4]):
15. If measured value is not correct: Verify setpoint E1.
16. Adjust positioner using potentiometer max [P4].
16.1 If both LEDs are OFF or the yellow LED [V27] is illuminated: Turn poten-
tiometer max [P4] slightly counterclockwise until the green LED [V28] is
illuminated.
16.2 If the green LED [V28] is illuminated: Turn potentiometer max [P4] clock-
wise until the green LED [V28] goes out. Then turn potentiometer 0 [P3]
slightly counterclockwise until the green LED [V28] is illuminated again.
➥ The setting is correct if the green LED [V28] is switched on when reaching
end position OPEN.
10.6.4. Sensitivity setting
Unnecessary wear at valve and actuator caused by an excessive number of

starts (sensitivity)!
→ Set maximum dead band acceptable for the process.
→ Observe maximum number of actuator starts (refer to technical data sheet for
modulating actuators).
Dead band The dead band determines the sensitivity between switch-on point and switch-off
point. The smaller the dead band, the higher the sensitivity of the positioner.
49
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Default value: 2.5 %

Setting range: 0.5 % to 2.5 % (of the maximum setpoint E1)
Dead time The dead time prevents the operation to a new setpoint within a pre-determined time
(0.5 to 10 seconds). The number of starts can be reduced by setting the dead time
to a sufficiently high value.
Figure 38: Sensitivity setting
[P7] Potentiometer sens (fine tuning)

[P9] Potentiometer Δ E (dead band)
[P10] Potentiometer t-off (dead time)
Dead band setting 1. Set selector switch to position Remote control (REMOTE).
2. Connect setpoint E1 to customer connection XK (terminals 2/3).
3. Set dead band using potentiometer Δ E [P9]:
→ Reduce dead band (increase sensitivity): Turn potentiometer counter-
clockwise.
→ Increase dead band (reduce sensitivity): Turn potentiometer clockwise.
Fine tuning Information: Fine tuning is only useful for output speeds <16 rpm. For 1-phase
AC motors, fine tuning is not possible.
4. Reduce dead band further by up to 0.25 % (increase sensitivity): Turn poten-
tiometer sens [P7] counterclockwise.
Dead time setting 5. Set dead time using potentiometer t-off [P10]:
→ Reduce dead time: Turn potentiometer t-off [P10] counterclockwise.
→ Increase dead time: Turn potentiometer t-off [P10] clockwise.
10.7. EMERGENCY command (EMERGENCY - OPEN/EMERGENCY - CLOSE)
— (Option) —
The EMERGENCY input (refer to wiring diagram) has to be connected to the control
voltage using an NC contact (closed circuit principle). In the event of an EMERGENCY
command (removal of the signal = NC contact is operated), the actuator runs to the
preset end position:
● EMERGENCY - CLOSE input: Actuator runs to end position CLOSED.
● EMERGENCY - OPEN input: Actuator runs to end position OPEN.
The EMERGENCY command is effective in all three selector switch positions (LOCAL,
OFF, REMOTE).
The actuator can immediately start when switched on!

Risk of personal injuries or damage to the valve.
→ Ensure that EMERGENCY signal is present when switching on.
→ If the actuator starts to run unexpectedly: Immediately press push button Stop.
50
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Disable EMERGENCY Figure 39: Interface board for available option EMERGENCY - OPEN/EMERGENCY
command - CLOSE
[B1] Link available: EMERGENCY - CLOSE

[B2] Link available: EMERGENCY - OPEN
1. Remove face plate.
2. Disconnect links [B1] or [B2].
10.8. Controls: close



51
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Corrective action AM 01.1
11. Corrective action
11.1. Faults during commissioning
Table 15: Faults during commissioning

Fault Description/cause Remedy
Mechanical position indicator Reduction gearing is not suitable for Exchange reduction gearing.
cannot be set. turns/stroke of the actuator.
In spite of correct setting of limit The overrun was not considered when setting ● Determine overrun: Overrun = travel
switching, actuator operated into the limit switching. covered from switching off until complete
the valve end position. The overrun is generated by the inertia of standstill.
both the actuator and the valve and the delay
time of the controls. ● Set limit switching again considering the
overrun (turn handwheel back by the
amount of the overrun).
No value can be measured at Current loop across RWG is open. ● Connect link across RWG to XK (terminals
measuring points of the RWG. (Position feedback 0/4 – 20 mA is only pos- 23/24)
sible if the current loop is closed across the
RWG.)
● Connect external load to XK, e.g. remote
indication.
● Observe maximum load RB.
Measuring range 0/4 – 20 mA or Reduction gearing is not suitable for Exchange reduction gearing.
maximum value 20 mA at position turns/stroke of the actuator.
transmitter cannot be set or sup-
plies an incorrect value.
The measuring range 0/4 – 20 The LED on the EWG either flashes in setting Call AUMA service.
mA at EWG position transmitter mode a) single flash or b) triple flash:
cannot be set.
a) EWG is not calibrated.

b) Magnet positions of EWG are not aligned.
Limit and/or torque switches do Switch is defective or switch setting is incor- ● Check setting, if required, reset end posi-
not trip. rect. tions.
● Refer to <Check switches> and replace
the switches if required.
Switch check
The red test buttons [1] and [2] are used for manual operation of the switches:
1. Turn test button [1] in direction of the TSC arrow: Torque switch CLOSED trips.
The red indication light (fault) on the local controls is illuminated.
2. Press push button OPEN to reset the fault (indication light) by operating the
3. Turn test button [2] in direction of the TSO arrow: Torque switch OPEN trips.
4. Press push button CLOSE to reset the fault (indication light) by operating the
If the actuator is equipped with a DUO limit switching (option), the intermediate
position switches (LSA and LSB) will be operated at the same time as the torque
switches.
1. Turn test button [1] in direction of the LSC arrow: Limit switch CLOSED trips.
2. Turn test button [2] in direction of the LSO arrow: Limit switch OPEN trips.
52
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Corrective action
11.2. Fuses
11.2.1. Fuses within the actuator controls
After removal of local controls, the fuses can be accessed.
Hazardous voltage!
Figure 40: Access to fuses
[1] Local controls

[2] Signal and control board
[3] Power supply unit
F1/F2 Primary fuses on power supply unit
G fuses F1/F2 AUMA Art. no.:

Size 6.3 x 32 mm
Power supply≤ 500 V 1 A T; 500 V K002.277
Power supply > 500 V 2 A FF; 690 V K002.665
F3 Internal 24 V DC supply

Size 5 x 20 mm
F4 Internal 24 V AC supply (115 V AC) for:

● Heater, switch compartment, reversing contactors control
● PTC tripping device (24 V AC only)
● for 115 V AC also control inputs OPEN - STOP - CLOSE

Size 5 x 20 mm
1.6 A T; 250 V K003.131
Information Only replace fuses with fuses of the same type and value.
→ After replacing the fuses, screw local controls back on again.
53
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Corrective action AM 01.1

11.2.2. Motor protection (thermal monitoring)
In order to protect against overheating and impermissibly high surface temperatures

at the actuator, PTC thermistors or thermoswitches are embedded in the motor
winding. The thermoswitch is tripped as soon as the max. permissible winding
temperature has been reached.
The actuator is stopped and the "collective fault" indication light (option) on the local
controls is illuminated.
The motor has to cool down before the operation can be resumed.
Version with thermoswitch (standard)
The actuator can be controlled again once the motor has cooled down ("collective
fault" indication light goes out).
Version with thermoswitch and additional thermal overload relay within the
controls (option)
The operation may only be resumed once the fault signal ("collective fault" indication
light) has been reset. The fault signal is reset via the overload relay integrated in the
actuator controls. Therefore the controls have to be opened at the cover and the
relay held down. The relay is located on the contactors.
Version with PTC thermistor (option)
The operation may only be resumed once the fault signal ("collective fault" indication
light) has been reset. The fault signal is reset via selector switch position Reset of
the local controls.
Figure 41: Selector switch on local controls
54
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Servicing and maintenance

Therefore, we recommend contacting our service.
AUMA
AUMA offer extensive service such as servicing and maintenance as well as customer
Service & Support product training. For the relevant contact addresses, please refer to <Addresses>
in this document or to the Internet (www.auma.com).
12.1. Preventive measures for servicing and safe operation
The following measures are required to ensure safe device operation:

6 months after commissioning and then every year
● Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing.
Respect torques according to manufacturer's details.
● Check fastening screws between actuator and gearbox/valve for tightness. If
required, fasten screws while applying the tightening torques as indicated in
chapter <Assembly>.
● When rarely operated: Perform test run.
For enclosure protection IP68
After continuous immersion:

● Check actuator.
● In case of ingress of water, locate leaks and repair, dry device correctly and
check for proper function.
12.2. Maintenance
Lubrication ● In the factory, the gear housing is filled with grease.

● Grease change is performed during maintenance
- Generally after 4 to 6 years for modulating duty.
- Generally after 6 to 8 years if operated frequently (open-close duty).
- Generally after 10 to 12 years if operated rarely (open-close duty).
● We recommend exchanging the seals when changing the grease.
● No additional lubrication of the gear housing is required during operation.
12.3. Disposal and recycling
● various metals
● plastics
environment.
● Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
55
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Servicing and maintenance AM 01.1
56
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Technical data
13. Technical data

Information The following technical data includes standard and optional features. For detailed
information on the customer-specific version, refer to the order-related data sheet.
The technical data sheet can be downloaded from the Internet at www.auma.com
in both German and English (please state the order number).
13.1. Technical data Part-turn actuator

Type of duty Short-time duty S2 - 15 min (part-turn actuators for open-close duty with 3-phase AC motors)
Short-time duty S2 - 10 min (part-turn actuators for open-close duty with 1-phase AC motors)
Intermittent duty S4 - 25 % (part-turn actuators for modulating duty with 3-phase AC motors)
Intermittent duty S4 - 20 % (part-turn actuators for modulating duty with 1-phase AC motors)
For nominal voltage and 40 °C ambient temperature and at average load with 35 % of the
max. torque
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 60034
Option: 1-phase AC motor, type IM B9 according to IEC 60034
Mains voltage, mains frequency Refer to motor name plate
Permissible variation of mains voltage: ±10 %
Permissible variation of mains frequency: ±5 %
Overvoltage category Category III according to IEC 60364-4-443
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Motor heater (option) Voltages: 110 – 120 V AC, 220 – 240 V AC or 400 V AC (externally supplied)
Power: 12.5 W
Swing angle Standard: Adjustable between 75° and < 105°
Option: 15° to < 45°, 45° to < 75°, 105° to < 135°
Self-locking Yes (Part-turn actuators are self-locking if the valve position cannot be changed from
standstill while torque acts upon the output drive.)
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during elec-
trical operation.
Option: Handwheel lockable
Handwheel stem extension
Indication for manual operation Indication whether manual operation is active/not active via single switch (1 change-over
(option) contact)
Splined coupling for connection Standard: Coupling without bore
to the valve shaft Option: Machined coupling with bore and keyway, square bore or bore with two-flats
according to EN ISO 5211
Valve attachment Dimensions according to EN ISO 5211 without spigot
With base and lever (option)

Swing lever Made of spheroidal cast iron with two or three bores for fixing a lever arrangement. Consid-
ering the installation conditions, the lever may be mounted to the output shaft in any desired
position.
Ball joints (option) Two ball joints matching the lever, including lock nuts and two welding nuts, suitable for pipe
according to dimension sheet
Fixing Base with four holes for fastening screws
57
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Technical data AM 01.1
Electromechanical control unit

Limit switching Counter gear mechanism for end positions OPEN and CLOSED
Standard: Single switches (1 NC and 1 NO) for each end position, not galvanically isolated
Options: Tandem switches (2 NC and 2 NO) for each end position, switches galvanically
isolated
Triple switches (3 NC and 3 NO) for each end position, switches galvanically
isolated
Intermediate position switch (DUO limit switching), adjustable for any position
Torque switching Torque switching adjustable for directions OPEN and CLOSE
Standard: Single switches (1 NC and 1 NO) for each direction, not galvanically isolated
Options: Tandem switches (2 NC and 2 NO) for each direction, switches galvanically
isolated
Position feedback signal, ana- Potentiometer or 0/4 – 20 mA (EWG/RWG)
logue (option)
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Running indication Blinker transmitter (option for modulating actuators)
Heater in switch compartment Standard: Self-regulating PTC heater, 5 – 20 W, 110 – 250 V AC/DC
Options: 24 – 48 V AC/DC or 380 – 400 V AC
A resistance type heater of 5 W, 24 V AC is installed in the actuator in combination with AM
or AC actuator controls.
Technical data for limit and torque switches

6
Mechanical lifetime 2 x 10 starts
U min. 24 V AC/DC
U max. 250 V AC/DC
I min. 20 mA
3 A at 250 V (inductive load, cos phi = 0.6)
0.03 A at 250 V (inductive load, L/R = 3 µs)
7 A at 30 V (resistive load)
5 A at 30 V (inductive load, L/R = 3 µs)
Gold plated contacts
U min. 5V
U max. 30 V
I min. 4 mA
I max. 400 mA
Technical data for blinker transmitter

7
U min. 10 V AC/DC
U max. 250 V AC/DC
2 A at 250 V (inductive load, cos phi ≈ 0.8)
Technical data for handwheel activation switches

6
U min. 12 V DC
U max. 250 V AC
I max. AC current 3 A at 250 V (inductive load, cos phi = 0.8)
I max. DC current 3 A at 12 V (resistive load)
58
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Service conditions
Installation altitude ≤ 2,000 m above sea level
> 2,000 m above sea level, please contact AUMA
Ambient temperature Standard: –40 °C to +80 °C (part-turn actuators for open-close duty with 3-phase AC mo-
tors)
–40 °C to +70 °C (part-turn actuators for open-close duty with 1-phase AC mo-
tors)
–40 °C to +60 °C (part-turn actuators for modulating duty)
Options: –60 °C to +60 °C
0 °C to +120 °C (part-turn actuators for open-close duty with 3-phase AC motors)
For actual version, refer to actuator name plate.
Enclosure protection according Standard: IP68 with AUMA 3-phase AC motor/1-phase AC motor
to EN 60529 For special motors differing enclosure protection: refer to name plate.
Option: DS Terminal compartment additionally sealed against interior (double sealed)
According to AUMA definition, enclosure protection IP68 meets the following requirements:
● Duration of continuous immersion in water: Max. 96 hours
● Up to 10 operations during continuous immersion
Modulating duty is not possible during continuous immersion.
For actual version, refer to actuator name plate.
Pollution degree Pollution degree 4 (when closed) according to EN 50178
may not be derived from this. Valid for part-turn actuators in version AUMA NORM (with
AUMA plug/socket connector, without actuator controls). Not valid in combination with
gearboxes.
Corrosion protection Standard: KS: Suitable for installation in industrial units, in water or power plants with a
low pollutant concentration as well as for installation in occasionally or perman-
ently aggressive atmosphere with a moderate pollutant concentration (e.g.
wastewater treatments plants, chemical industry)
Option: KX: Suitable for installation in extremely aggressive atmospheres with high hu-
midity and high pollutant concentration
KX-G : same as KX, however aluminium-free version (outer parts)
Finish coating Powder coating
Option: Other colours are possible on request.
Lifetime AUMA part-turn actuators meet or even exceed the lifetime requirements of EN 15714-2.
Detailed information can be provided on request.
Further information
EU Directives Electromagnetic Compatibility (EMC): (2004/108/EC)
Low Voltage Directive: (2006/95/EC)
59
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
13.2. Technical data Actuator controls

Mains voltage, mains frequency Refer to name plates at the controls and the motor
Permissible variation of the mains voltage: ±10 %
Further permissible fluctuations of mains voltage and frequency (option): (–20 %/+15 %),
(–20 %/+10 %), (–30 %/+30 %), , (–30 %/+10 %)
Permissible variation of the mains frequency: ±5 %
Current consumption of controls depending on mains voltage:
100 to 120 V AC = max. 575 mA
208 to 240 V AC = max. 275 mA
380 to 690 V AC = max. 160 mA
External supply of the electron- 24 V DC +20 % / –15 %
ics (option) Current consumption: Basic version approx. 200 mA, with options up to 500 mA
Overvoltage category Category III according to IEC 60364-4-443
Rated power The controls are conceived for the rated motor power, refer to motor name plate
Switchgear Standard: Reversing contactors (mechanically and electrically interlocked) for AUMA power
classes A1/A2
Options: Reversing contactors (mechanically and electrically interlocked) for AUMA power
classes A1/A2 with additional contacts, 1 NC + 1 NO each
Reversing contactors (mechanically and electrically interlocked) for AUMA power
class A3
Thyristor unit for mains voltage up to 600 V AC (recommended for modulating
actuators) for AUMA power classes B1, B2 and B3
Reversing contactors are designed for a lifetime of 2 million starts. For applications requiring
a high number of starts, we recommend using thyristor units.
For the assignment of AUMA power classes, refer to the Electric data pertaining to the actu-
ator.
Control Standard: Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator, one common),
current consumption: approx. 10 mA per input
Respect min. pulse duration for modulating actuators
Option: Control inputs 115 V AC, OPEN - STOP - CLOSE - EMERGENCY (via opto-
isolator, one common), current consumption: approx. 15 mA per input
Status signals Standard: 5 output contacts with gold-plated contacts:
● 4 potential-free NO contacts with one common, max. 250 V AC, 0.5 A (res-
istive load)
- Default configuration: End position CLOSED, end position OPEN, selector
switch REMOTE, selector switch LOCAL
- Default configuration: Collective fault signal (torque fault, phase failure,
motor protection tripped)
Options: ● Signals in combination with positioner:
- End position OPEN, end position CLOSED (requires tandem switch
within actuator), selector switch REMOTE, selector switch REMOTE,
selector switch LOCAL via 2nd level selector switch
- Default configuration: Collective fault signal (torque fault, phase failure,
motor protection tripped)
Voltage output Standard: Auxiliary voltage 24 V DC ±5 %, max. 50 mA for supply of control inputs, galvan-
ically isolated from internal voltage supply
Option: 115 V AC ±10 %, max. 30 mA for supply of the control inputs.1), galvanically
isolated from internal voltage supply
Local controls Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
Push buttons OPEN, STOP, CLOSE
3 indication lights: End position CLOSED (yellow), collective fault signal (red),
end position OPEN (green)
Options: Special colours for the 3 indication lights
Protection cover, lockable
60
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2

Functions Standard: Selectable type of seating, limit or torque seating for end position OPEN and
end position CLOSED
Overload protection against excessive torques over the whole travel
Excessive torque (torque fault) can be excluded from collective fault signal.
Phase failure monitoring with automatic phase correction
Push-to-run operation or self-retaining in REMOTE
Push-to-run operation or self-retaining in LOCAL
Blinker signal from actuator (option) for running indication via indication lights
of local controls can be activated/deactivated.
Options: Positioner (requires position transmitter in actuator)
● Position setpoint via analogue input E1 = 0/4 – 20 mA
● Galvanic isolation for position setpoint (0/4 – 20 mA) and position feedback
(0/4 – 20 mA)
● Adjustable behaviour on loss of signal
● Adjustable sensitivity (dead zone and dead time)
Positioner for Split Range operation (requires position transmitter in actuator)
Motor protection evaluation Standard: Monitoring the motor temperature in combination with thermoswitches within
actuator motor
Options: Additional thermal overload relay in the controls in combination with ther-
moswitches within the actuator
PTC tripping device in combination with PTC thermistors within actuator motor
Electrical connection Standard: AUMA plug/socket connector with screw-type connection
Options: Terminals or crimp connection
Gold-plated control plug (sockets and plugs)
Threads for cable entries Standard: Metric threads
Options: Pg-threads, NPT-threads, G-threads
Wiring diagram Refer to name plate
1) Not possible in combination with PTC tripping device
Service conditions
Installation altitude ≤ 2 000 m above sea level
> 2,000 m above sea level, please contact AUMA
Ambient temperature Standard: –40 °C to +70 °C
Options: -60 °C to +60 °C, extreme low temperature version incl. heating system
Low temperature versions incl. heating system for connection to external power
supply 230 V AC or 115 V AC.
For actual version, refer to actuator controls name plate.
Enclosure protection according Standard: IP68 with AUMA 3-phase AC motor/1-phase AC motor
to EN 60529 For special motors differing enclosure protection: refer to name plate.
Option: DS Terminal compartment additionally sealed against interior (double sealed)
According to AUMA definition, enclosure protection IP68 meets the following requirements:
● Duration of continuous immersion in water: Max. 96 hours
● Up to 10 operations during continuous immersion
Modulating duty is not possible during continuous immersion.
For actual version, refer to actuator controls name plate.
Pollution degree Pollution degree 4 (when closed) according to EN 50178
may not be derived from this. Valid for multi-turn actuators in version AUMA NORM (with
AUMA plug/socket connector, without actuator controls). Not valid in combination with
gearboxes.
61
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Service conditions
Corrosion protection Standard: KS: Suitable for installation in industrial units, in water or power plants with a
low pollutant concentration as well as for installation in occasionally or perman-
ently aggressive atmosphere with a moderate pollutant concentration (e.g.
wastewater treatments plants, chemical industry)
Option: KX: Suitable for installation in extremely aggressive atmospheres with high hu-
midity and high pollutant concentration
Finish coating Powder coating
Two-component iron-mica combination
Option: Other colours are possible on request.
Wall bracket AM mounted separately from the actuator, including plug/socket connector. Connecting cable
on request. Recommended for high ambient temperatures, difficult access, or in case of
heavy vibration during service.
Cable length between actuator and AM max. 100 m. Not suitable for version with potentiometer
in the actuator. Instead of the potentiometer, the actuator has to be provided with EWG.
Further information
Weight Approx. 7 kg (with AUMA plug/socket connector)
EU Directives Electromagnetic Compatibility (EMC): (2004/108/EC)
Low Voltage Directive: (2006/95/EC)
62
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Spare parts
14. Spare parts

14.1. Part-turn actuators SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
63
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Spare parts AM 01.1
Information: Please state device type and our order number (see name plate) when ordering spare parts. Only
original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation in these instructions.
Ref. Designation Type Ref. Designation Type
no. no.
001.0 Housing Sub-assembly 539.0 Screw plug Sub-assembly
005.0 Drive shaft Sub-assembly 542.0 Handwheel with ball handle
005.1 Motor coupling Sub-assembly 553.0 Mechanical position indicator Sub-assembly
005.3 Manual drive coupling 554.0 Socket carrier for motor plug/socket Sub-assembly
connector with cable harness
006.0 Worm wheel Sub-assembly 556.0 Potentiometer for position transmitter Sub-assembly
009.0 Planetary gearing for manual drive Sub-assembly 556.1 Potentiometer without slip clutch Sub-assembly
017.0 Torque lever 557.0 Heater Sub-assembly
018.0 Gear segment Sub-assembly 558.0 Blinker transmitter including pins at Sub-assembly
wires (without impulse disc and insula-
tion plate)
019.0 Crown wheel 559.0 Control unit with torque switching Sub-assembly
heads and switches
022.0 Drive pinion II for torque switching Sub-assembly 559.0 Control unit with magnetic limit and Sub-assembly
torque transmitter (MWG) for Non-in-
trusive version in combination with
AUMATIC integral controls
023.0 Output drive wheel for limit switching Sub-assembly 560.0–1 Switch stack for direction OPEN Sub-assembly
024.0 Drive wheel for limit switching Sub-assembly 560.0–2 Switch stack for direction CLOSE Sub-assembly
025.0 Locking plate Sub-assembly 560.1 Switch for limit/torque Sub-assembly
058.0 Wire for protective earth Sub-assembly 560.2 Switch case
070.0 Motor (VD motor incl. ref. no. 079.0) Sub-assembly 566.0 Position transmitter EWG/RWG Sub-assembly
079.0 Planetary gearing for motor drive Sub-assembly 566.1 Potentiometer for RWG without slip Sub-assembly
(SQ/SQR 05.2 – SQ SQR 14.2 for VD clutch
motor)
155.0 Reduction gearing Sub-assembly 566.2 Position transmitter board for RWG Sub-assembly
500.0 Cover Sub-assembly 566.3 Wire harness for RWG Sub-assembly
501.0 Socket carrier (complete with sockets) Sub-assembly 567.1 Slip clutch for potentiometer Sub-assembly
502.0 Pin carrier without pins Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly
503.0 Socket for control Sub-assembly 583.1 Pin for motor coupling Sub-assembly
504.0 Socket for motor 584.0 Retaining spring for motor coupling
505.0 Pin for controls Sub-assembly 596.0 Output drive flange with end stop Sub-assembly
506.0 Pin for motor Sub-assembly 612.0 Screw plug for end stop Sub-assembly
507.0 Cover for electrical connection Sub-assembly S1 Seal kit, small Set
525.0 Coupling Sub-assembly S2 Seal kit, large Set
64
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
AM 01.1 Spare parts
14.2. Actuator controls AUMA MATIC AM 01.1/AM 02.1
65
SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2
Spare parts AM 01.1
Information: Please state device type and our order number (see name plate) when ordering spare parts. Only
original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation in these instructions.
Ref. Designation Type
no.
001.0 Housing
002.0 Local controls Sub-assembly
002.5 Selector switch Sub-assembly
003.0 Signal and control board Sub-assembly
003.1 Primary fuse F1/F2
003.2 Fuse cover
004.0 Carrier for contactors
006.0 Power supply unit Sub-assembly
008.0 Interface board Sub-assembly
008.1 Interface board
008.2 Cover plate for interface board
009.0 Logic board Sub-assembly
013.0 Adapter board Sub-assembly
500.0 Cover Sub-assembly
501.0 Socket carrier (complete with sockets) Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
505.0 Pin for controls Sub-assembly
506.0 Pin for motor Sub-assembly
507.0 Cover for electrical connection Sub-assembly
508.0 Switchgear Sub-assembly
509.1 Padlock
S Seal kit Set
66
OPERATING MANUAL
This document was drawn up observing the EC directives

"Machinery" 98/37/EG, DIN EN ISO 12100-2 and the German Standard VDI 4500
In case of this mechanical seal is operated in explosion area an appropriate additional

operating manual, following EC directives 94/9/EC (ATEX 95), has to be observed by all
means! If required this could be ordered at BURGMANN.
BURGMANN MECHANICAL SEAL (M.S.)
Cartex®
applies to all mechanical seals of the same series
These instructions are intended for the assembly,

operating and control personnel and should be
kept at hand on site.
PLEASE READ this manual carefully and OBSERVE the information contained as to:
Safety Start up Removal

Storage Maintenance Repair
Installation
If there are any unclear points please contact BURGMANN by all means.
en Cartex® / September 2004 Rev. 5

Operating manual
Cartex® page 2 / 17
TABLE OF CONTENTS KEYWORDS AND SYMBOLS

KEYWORDS AND SYMBOLS ............................ 2 Following symbols for particularly important information are
GENERAL SAFETY NOTES............................. 3 used:
WORKERS PROTECTION ................................ 3
TRANSPORT...................................................... 3
STORAGE .......................................................... 4
PRODUCT INFORMATION ............................... 4 "Attention, please pay special attention to
MANUFACTURER.............................................. 4 these sections of text"
DECLARATION .................................................. 4
DESIGNATION ................................................... 4
OPERATING LIMITS ......................................... 5
DESIGNATED USE ........................................... 5 DANGER! Draws attention to a direct hazard that will
MATERIALS........................................................ 5 lead to injury or death
DESCRIPTION ................................................... 6
SUPPLY OF M.S. ............................................. 6
EMISSIONS ........................................................ 7 WARNING! Draws attention to the risk that a hazard
UTILITIES & TOOLS......................................... 7 could lead to serious injury or death
PRELIMINARIES ................................................ 8
INSTALLATION .................................................. 8
SUPPLY CONNECTIONS ................................. 9 CAUTION! Draws attention to a hazard or unsafe
PROCESS AGENTS.......................................... 9 method of working that could lead to
SAFE OPERATION ......................................... 10 personal injury or damage to equipment
TEST RUN ........................................................ 10
START UP ....................................................... 11
MAINTENANCE................................................ 12 ATTENTION! Identifies a potentially dangerous situation.
TROUBLES....................................................... 12 If it is not avoided the product or
AFTER-SALES ................................................. 12 something in its vicinity could be damaged
RECONDITIONING .......................................... 12
REMOVAL ........................................................ 12
SPARE PARTS................................................ 13
HOW TO ORDER ........................................... 13 IMPORTANT! Identifies tips for use and other
DISPOSAL ........................................................ 13 particularly useful information.
COPYRIGHT..................................................... 13
DIMENSION TABLES....................................... 14
Rev. 5 Cartex® / enklein.dot

Operating manual
GENERAL SAFETY NOTES WORKERS PROTECTION
Any person being involved in assembly, Mechanical seals are often used for sealing
disassembly, start up, operation and maintenance hazardous substances. The valid regulations
of the BURGMANN Mechanical Seal must have for handling hazardous substances have to be
read and understood this Operating Manual and observed by all means.
in particular the safety notes. We recommend the
user to have this confirmed. Medium and/or supply medium may splash out
if the seal fails. Personal injury may be
BURGMANN Mechanical Seals are prevented by the user providing for splash
manufactured on a high quality level (quality protection and wearing safety goggles. Care has
management EN ISO 9001: 2000) and they keep to be taken by the user for proper disposal of the
a high working reliability. Yet, if they are not leakage.
operated within their intended purpose or
handled inexpertly by untrained personnel they The user has to check what effects a failure of
may cause risks. the mechanical seal might have and what safety
measures have to be taken to prevent personal
The machine has to be put up in such a way that injury or damage to the environment.
seal leakage can be led off and disposed properly
and that any personal injury caused by spurting
product in the event of a seal failure is avoided.
TRANSPORT
Any operation mode that affects the operational
safety of the mechanical seal is not permitted. If not specified differently by contract the BURGMANN
standard packing is used which is suitable for dry transport
Unauthorised modifications or alterations which by truck, train or plane. The warning signs and notes on the
affect the operational safety of the mechanical packing must be observed.
seal are not permitted.
Notes for income inspection:
BURGMANN mechanical seals must be operated, • Check packaging for visible damages.
maintained or repaired by authorised, trained • Open packaging carefully. Do not damage or lose parts
supplied separately.
and instructed personnel only.
• Check if consignment is complete (delivery note). Inform
the supplier immediately in writing if parts are damaged
The responsibilities for the respective jobs to be or missing.
done have to be determined clearly and observed
in order to prevent unclear competencies from the Especially inboard side of the mechanical seal has to be
point of safety. protected from damage during transport and storage. The
transport case in which the seal is supplied is well suited for
Any work to be done on the mechanical seal is this purpose and should be kept for a possible return
only permitted when the seal is neither transport.
operating nor pressurised.
Seals that have been used with hazardous

substances must be properly cleaned so that
there is no possible danger to personnel or to the
environment.
Apart from the notes given in this manual the

general regulations for worker's protection and
those for the prevention of accidents have to
be observed.

Operating manual
STORAGE A preservation of the BURGMANN mechanical seals is not

necessary.
BURGMANN mechanical seals are super finished and tested • Do not use any anticorrosives!
machine elements for which special conditions before and Risk of deposits and possibly chemical attack of the
during the storage period have to be followed. elastomer secondary sealing elements.
For the stock keeping of elastomers special conditions are Check in case of a preservation of complete plants with
required. For all rubber-elastic parts the rules of ISO 2230- mechanical seals installed:
1973 (E) are valid. For reasons of safety BURGMANN • the compatibility of the chosen preservation agent with
recommend to replace the stock in store after 3 years at the the seal materials and with the elastomers
latest. • no impairment of the seal’s axial movability by
conglutination or by gumming
Sliding materials and elastomers are subject to material-
specific and time-based alterations (distortion, ageing) which
might reduce the full efficiency of the seals. Yet, this may be
avoided by observing the storage instructions. PRODUCT INFORMATION
IMPORTANT! Store the seal in the original packing The CARTEX® mechanical seal concept has been specially
lying on a flat surface. developed for machines and applications in refineries and
petrochemicals plants. At the heart of the CARTEX® are tried
Conveniences for storing of mechanical seals and tested elements, such as the rotating seat, which have
• dustfree been in successful service for years. Be it for retrofits, initial
• moderately ventilated equipping or the conversion of machines previously equipped
• constantly tempered with stuffing box packings, the CARTEX® is ideal for
relative air humidity below 65 %, standardisation projects due to the wide range of applications
temperature between 15 °C and 25 °C. for which it can be used.
Protect the seal from

• direct exposure to heat (sun, heating)
• ultraviolet light (arc welding, halogen or fluorescent
MANUFACTURER
lamps, sunlight)
• presence or development of ozone (arc welding, mercury
Burgmann Industries GmbH & Co. KG
vapour lamps, high-voltage devices, electric motors)
Äußere Sauerlacher Str. 6-10
risk of embrittlement of elastomeric materials 82515 Wolfratshausen
• Check the packaging periodically for damages. Germany

• Plastic sheet packagings with humidity indicators have to
be checked every 8 weeks. The check has to be recorded.
Packings exceeding 50 % rel. humidity values have to
be sent to the manufacturer or the nearest service centre DECLARATION
for inspection and new packaging. within the meaning of the EC-directive "MACHINERY"
98/37/EG
After a storage period of approx. 2 to 3 years of mechanical
seals: A mechanical seal does not function independently. It is
• Check for operational tightness by the user intended to be incorporated into or assembled with
In case of high leakage due to natural distortion: machinery.
• refinishing of the sliding faces in professional procedure
at a BURGMANN-Service centre or a well equipped
workshop at the user's.
• replacing of all elastomeric parts for reasons of safety
DESIGNATION
Damages caused by improper storage may not be claimed
BURGMANN-Mechanical Seal:
on the BURGMANN company with reference to their
warranty.
Cartex®-SNO
Cartex®-SN
These instructions apply to all BURGMANN mechanical
Cartex®-QN
seals which have been supplied and stored in their
Cartex®-DN
undamaged original packing , as well as to seals which have
been installed in a component of a plant (e.g. machine,
Cartex®-ASPN / ABPN
compressor, agitator etc.) but have not yet been put into
Cartex®-ASTN / ABTN
operation.
Cartex®-ASDN / ABDN

Operating manual
OPERATING LIMITS Notes

Shaft diameter d1 (dw) : 25 - 100 mm and 1" ... 4" All technical information given in this manual is based on the
Operating pressure, max. : 25 bar results of extensive testing and on BURGMANN's many
Operating temperature : -40 ... +220 °C years of practical experience. However, in view of the great
Sliding speed, max. : 16 m/s diversity of possible applications the technical data can only
limit values depending on the materials be taken as being of approximate nature.
Operation under several limit values simultaneously should We can only guarantee the safe and efficient functioning of
be avoided as higher loads (pressure, temperature, speed) can mechanical seals in individual cases if we have been
increase wear or lead to damage of sliding faces or comprehensively informed of the operating conditions to
elastomers. This could result in a shorter service life and in which they will be subject, and if this has been confirmed in a
the risk of a sudden seal failure endangering men and separate agreement. In case of doubt BURGMANN has to be
environment. consulted before start up.
Product pressure and sliding speed We reserve the right to carry out modifications, even if
they have not yet been considered in this manual.
Cartex®-SNO /-SN /-QN Cartex®-DN
Cartex®-ASPN+ABPN Cartex®-ASDN+ABDN
Cartex®-ASTN+ABTN
DESIGNATED USE
This mechanical seal is exclusively designed for the use in
the specified application. A different utilisation or a
utilisation going beyond the specification is considered
contrary to its designated use and excludes a liability by the
manufacturer.
Operation under conditions lying outside those limits stated

in paragraph "operating limits" is considered contrary to
its designated use.
Should the seal be operated under different conditions or

at a different application BURGMANN has to be asked for
recognition as safe in advance.
Changes of the operating conditions have to be
recorded.
The data given are for the seal. The machine data have to be
observed in addition by all means. MATERIALS
The operating data for the respective application, such as Designation acc. to EN 12756
medium to be sealed, operating pressure, operating
temperature, speed, etc. can be taken from the corresponding seal face, Q1 silicon carbide
machine data sheets. stationary B1 carbon graphite
seat, rotating Q1 silicon carbide
Connections construction G CrNiMo- steel, 1.4571
elements
Connections springs M Hastelloy®-C4, 2.4610
d1 < 38 mm (< 1.500") 1/4 NPT- thread o-rings V FPM
d1 ≥ 38 mm (≥ 1.500") 3/8 NPT- thread E EPDM
K perfluorocarbon rubber
Cartex®-SN / ASPN / ABPN U1 perfluorocarbon
Circulation (flushing) "IN" at connection » A « rubber/PTFE
rotary shaft seal P NBR
Cartex®-QN / ASTN / ABTN T3 PTFE, carbon reinforced
Circulation (flushing) "IN" at connection » A « gasket Buratherm® Buratherm
Supply medium (quench) "IN/OUT" at connections T2 PTFE, glass fibre reinforced
»B« throttle ring T12 PTFE, carbon-graphite
reinforced
Cartex®-DN /ASDN / ABDN
Supply medium "IN/OUT" at connections » C «

Operating manual
DESCRIPTION Cartex®-ASTN / ABTN

As Cartex®- ASPN / ABPN, but
Installing dimensions acc. to dimension tables throttle ring at the atmosphere side
cover with supply connections for flushing (A), quench
Cartex®-SN and drain
Cartex®-ASPN / ABPN
cartridge design with shaft sleeve, cover, item designation
assembly fixtures 16 throttle ring
single seal
balanced
bi-directional Cartex®-DN / ASDN / ABDN
rotating seat cartridge design with shaft sleeve, cover,
stationary seal face assembly fixtures
encapsulated multiple springs installation horizontal / vertical
axial movability dual seal
d1 < 75 mm ±1 mm / d1 ≥ 75 mm ±1.5 mm double pressure balanced
d1 ≤ 2.750 " ±0.039 / d1 >2.750" ±0.059" ! connections uni-directional !
assembly fixtures for optimum adjustment at works rotating seats
torque transmission to the shaft by means of cup- stationary seal faces
pointed set screws encapsulated multiple springs
cover with supply connection for flushing (A) axial movability
d1 < 75 mm ±1 mm / d1 ≥ 75 mm ±1.5 mm
item designation d1 ≤ 2.750 " ±0.039 / d1 >2.750" ±0.059"
1 seal face integrated pumping device
2; 5; 7 o-ring supply connections (C) in the cover
3 spring assembly fixtures for optimum adjustment at works
4 seat torque transmission to the shaft by means of cup-
6 shaft sleeve pointed set screws
8 driver
9 set screw item designation
10 retaining ring 1; 9 seal face
11 cover 2; 5; 7; 10; 13; 15 o-ring
12 assembly fixture 3; 11 spring
13 hsh cap screw 4; 12 seat
14 gasket 6 shaft sleeve
15 head screw plug 8 cover
14 driver
16 set screw
Cartex®-SNO 17 retaining ring
As Cartex®-SN, but item 15 is not necessary 18 assembly fixture
cover without supply connections ("dead-end") 19 hsh cap screw
20; 22 gasket
21 head screw plug
Cartex®-QN
As Cartex®-SN, but
rotary shaft seal at the atmosphere side
cover with supply connections for flushing (A) and SUPPLY OF M.S.
quench (B)
fitting length acc. to dimension tables (l15; l16; l17) The medium to be sealed must circulate around the
mechanical seal during all stages of operation.
item designation
1 seal face
2; 5; 7 o-ring Cartex®-SNO
3 spring External accessories (quench, flushing, circulation) are not
4 seat required if the seal is operated duly.
6 shaft sleeve
8 driver
9 set screw Cartex®-SN
10 retaining ring Cartex®-QN
11 cover Cartex®-ASPN / ABPN
12 assembly fixture Cartex®-ASTN / ABTN
13 hsh cap screw For a safe operation of the mechanical seal we recommend to
14 gasket apply at inboard the most suitable type of circulation
15 head screw plug described in API 610 / 682. This protects the seal cavity from
16 rotary shaft seal deposition of solids.

Operating manual
Cartex®-DN If this is not the case or if there are other malfunctions the
Cartex®-ASDN / ABDN mechanical seal has to be shut down, removed and checked
Operation with barrier pressure (pressurised supply for reasons of safety.
fluid)
When operating as a double seal a barrier fluid system Leakage of mechanical seal at outboard side has to be
(API, Plan 53 / 54) is required (where both seals are drained and disposed properly.
pressurised).
Forced fluid circulation by means of a pumping device IMPORTANT! Components which may get in contact with
in the seal when the shaft rotates. the leakage have to be corrosion-resistant or have to be
adequately protected.
External fluid reservoir,
pressurised. Thermosiphon or WARNING If the medium to be sealed and/or the
forced circulation, if required. barrier/buffer/quench liquid is subject to the Hazardous
1 if specified Substances Regulation (GefStoffV), the instructions for
(PS = pressure switch) handling dangerous substances (safety data sheets to EU
(PI = pressure indicator) Directive 91/155/EEC) and the accident prevention
(FI = flow indicator) regulations must be observed.
external pressure source
normally open
fill port Cartex®-DN
level indicator Cartex®-ASDN / ABDN
reservoir Operation with barrier pressure (pressurised supply
if specified fluid)
drain valve
ATTENTION! If the barrier pressure falls below the
Operation with pressureless supply fluid pressure in the machine the medium to be sealed may
penetrate through the seal gap, contaminating the barrier
When working in tandem, the reservoir liquid is used as a fluid. A regular control of the barrier pressure and change of
"dead-end quench" (API, Plan 51) or a circulating buffer the barrier fluid is recommended.
fluid (API, Plan 52) (with the seal on the production side
pressurised externally) depending on operating conditions. Operation with pressureless supply fluid
Forced fluid circulation by means of a pumping device
in the seal when the shaft rotates. ATTENTION! Due to the overpressure in the stuffing box
the medium to be sealed will penetrate through the sealing
External fluid reservoir, gap of the inboard seal into the buffer fluid which will
pressure less. Thermosiphon consequently be contaminated. For plan 52 BURGMANN
or forced circulation, if recommend a regular control and exchange of the buffer
required. fluid.
1 if specified
(PS = pressure switch)
(PI = pressure indicator)
(FI = flow indicator) UTILITIES & TOOLS
normally open
fill port ethyl alcohol
level indicator cellulose-tissue (no rag, no cloth!)
reservoir suitable lubricant for elastomer-sealing rings: e.g.
if specified "TURMOPOLGREASE SH 2 D", make Lubricant
drain valve Consult (LUBCON)
Elastomers made of EP-rubber must never come
into contact with lubricants on the base of mineral oil
(swelling, decomposition).
EMISSIONS liquid screw retention, e.g. "LOCTITE® No. 243" ,
make LOCTITE Corporation
A mechanical seal is a dynamic seal that cannot be free of set of hexagon keys (Allen keys)
leakage due to physical and technical reasons. Seal design, set of open end or ring spanners
manufacture tolerances, operating conditions, running quality torque wrench
of the machine, etc. mainly define the leakage value. In fact,
compared to other sealing systems (e.g. packings) there is
few leakage.
A possibly increased leakage during start-up will decrease to

a normal quantity after the running-in period of the sliding
faces.

Operating manual
PRELIMINARIES INSTALLATION
ATTENTION! To prevent damage to the seal, do not The mechanical seal is supplied as a precisely set cartridge
remove it from its packaging until all the work described unit, premounted at works, and does not require any
below has been completed. adjustment during installation.
Check the parts of the machine for: For installation the assembly drawing of mechanical seal has
to be on hand.
For installation the table of dimension has to be on hand.
IMPORTANT! The mechanical seal has to be installed

under the cleanest conditions and very carefully.
O-rings in sliding contact with other parts when mounting the

mechanical seal may be lubricated very thinly, if not
described otherwise.
The order of assembly to install the mechanical seal into the

• chamfered edges (sliding cones i.e. 30° / 2 mm or in
machine depends on the design of the machine and should
accordance with EN 12756)
advisably be determined by the machine manufacturer.
• radiused transitions
• mating fits and o-ring surfaces:
ATTENTION! Avoid unnecessary rotation of the shaft
fine finished Rz 10 µm (= N7 = CLA 63)
(sliding faces damage possible).
• shaft surface in the area of the mech. seal finished:
Ra 0.8 µm (=N6 = CLA 32).
ATTENTION! Do never force during installation.
Check at the machine:
Possible installation order:
• damage of connecting surfaces to the M.S.
• mating dimensions, rectangularity and concentricity to
• Make sure that all sealing elements are installed which
the shaft axis.
contact the surrounding machine parts.
Run-out accuracy of the shaft (acc. to DIN ISO 5199):
• Unpack the seal.
• Shaft diameters up to 50mm: max. 0.05 mm
• Shaft diameters 50mm - 100 mm: max. 0.08 mm
• Check, if the o-ring is installed in the shaft sleeve.
• Shaft diameters exceeding 100mm: max. 0.10 mm
• Insert the gasket into the cover.
particularly for:
Cartex®-DN If necessary, glue it with grease.
Cartex®-ASDN / ABDN
• Determine the direction of shaft rotation. Select the • Feed the complete seal cartridge onto the shaft.
correct supply connections.
ATTENTION! Avoid knocking the seal. Damage to
• If necessary moisten the shaft slightly with suitable mechanical seals has an adverse effect on their safe
lubricant in the area of the seal. operation.
Elastomers made of EP-rubber must never come into
• Pay close attention to supply connections and make sure
contact with lubricants on the base of mineral oil
they are oriented as per the drawing.
(swelling, decomposition).
Lubricant for elastomers (o-rings etc.) recommended particularly for:
by BURGMANN: "TURMOPOLGREASE SH 2 D"; Cartex®-DN
make Lubricant Consult (LUBCON) Cartex®-ASDN / ABDN
• When attaching the seal cartridge to the machine housing
• Prepare the place of assembly, take away any not care has to be taken that the supply connections at the
required tool, cuttings, dirty cleaning wool etc. M.S. are positioned in accordance with the instruction
"Integrated pump device" on the drawing.
• Cover the work bench with clean, non-fibrous cardboard.
• Bolt the cover of the M.S. to the machine housing.
Installation dimensions shown in the drawing must be
adhered to.
• Firmly screw the set screws crosswise to the shaft.

Degrease the set screws and secure with 1 drop each of
liquid screw retention, e.g. LOCTITE® 243.

Operating manual
ATTENTION! Set screws with cup point must be used Cartex®-DN

only once. Repeated fastening endangers the safety of force Cartex®-ASDN / ABDN
transmission.
Assignment of the connections for vertical arrangement of the
• Check the prescribed torque (marked on the seal connections:
drawing) with a torque wrench.
Determine the direction of shaft
IMPORTANT! Remove the assembly fixtures and keep rotation. Select the correct supply
them for a later removal of the seal. connections.
• Further assembly of the machine in accordance with the » IN « has to be positioned at

instructions of the machine manufacturer. the bottom
» OUT « has to be positioned
• Remove protective plastic caps at the open connections of at the top.
mechanical seal after installation.
Connection » VENT «
• Close unused supply connections pressure-tight with
(plugged) is of no importance
threaded plugs.
here.
Supply fluid "IN" at lower

connection » IN «
SUPPLY CONNECTIONS Supply fluid "OUT" at
upper connection » OUT «
The supply connections are designed as female threaded NPT
connections in accordance with ANSI B1.20.1.
The connections are marked on the mechanical seal and
Assignment of the connections for horizontal arrangement of
must not be interchanged during installation. the connections:
ATTENTION! Sealing agents for threads (PTFE-tape, etc.)

endanger the safe function of the seal if they enter the seal Connection » VENT «
chamber. When screwed connections are opened take care by (plugged) has to be positioned
all means that sealing agents cannot enter the seal. on the top.
Supply piping: Vent at upper connection

• Use pipes of stainless steel with a big cross-section. » VENT «
• Clean the piping thoroughly before connecting to the For this purpose open plug.
seal.
• Fasten all pipe connections pressure-sealed.
Use the fluid connections depending on the direction of
Additionally note for the supply fluid circuit: rotation:
• Install the pipes continuously rising, as short and as
convenient as possible for the flow to ensure self- Direction of rotation: CCW, seen from the drive
venting.
• Avoid air inclusions and provide for venting Supply fluid "IN" at left connection » IN «
connections, if necessary. Supply fluid "OUT" at right connection » OUT «
• For turns use pipe bends
• For shut off use ball valves Direction of rotation: CW, seen from the drive
• Fasten the pipes after approx. 2 m distance with elastic
pipe clips Supply fluid "IN" at right connection » IN «
• Follow the operating manual of the supply system Supply fluid "OUT" at left connection » OUT «
• Close unused supply connections pressure-tight with
threaded plugs.
PROCESS AGENTS
Supply fluid according to operating requirements.
For supply fluid preferably such media should be used
only which are compatible with the product medium and
may leak out to atmosphere at outboard side of seal
without risk for staff and environment.

Operating manual
ATTENTION! Supply fluids may not form residues on For reasons of safety the temperature of buffer fluid should
the seal faces. not exceed 60 ºC (at higher temperatures consultation
with BURGMANN) and should be at least 40 ºC below the
Supply fluids e. g.: boiling point at normal pressure measured at the outlet line
light oil without high pressure additives from the mechanical seal. Regulation of the temperature by
water/ethylene glycol mixture without anti-corrosion cooling the barrier fluid inside the barrier system.
additives
steam-condensate; demineralised water Operation with barrier pressure (pressurised supply
fluid)
The efficiency of the integrated pumping device depends on
different parameters e.g.: The barrier pressure must exceed the pressure to be sealed
the viscosity of supply medium during every state of operation.
the shaft speed
ATTENTION! If the barrier pressure falls below the
A clarification with BURGMANN is recommended. pressure in the machine the medium to be sealed may
penetrate through the seal gap, contaminating the barrier
fluid. A regular control of the barrier pressure and change of
the barrier fluid is recommended.
SAFE OPERATION
Operation with pressureless supply fluid
The mechanical seal at inboard has to be constantly wetted
by the product in its liquid form, in particular when the ATTENTION! Due to the overpressure in the stuffing box
machine is started or stopped. The machine design has to be the medium to be sealed will penetrate through the sealing
such as to take this necessity into consideration. gap of the inboard seal into the buffer fluid which will
consequently be contaminated. For plan 52 BURGMANN
Damages due to dry-running are excluded from the warranty. recommend a regular control and exchange of the buffer
fluid.
If the medium to be pumped builds deposits or tends to
solidify during cooling down or standstill of the machine the
stuffing box has to be flushed with suitable clean liquid. Flow
and liquid to be determined by the user. TEST RUN
If the operation limit values and the instructions given in this Safety checks before start up
manual are observed a trouble-free operation of the • Seal assembly fixtures removed
mechanical seal can be expected. • Torque transmission (set screws) between mechanical
seal and shaft duly installed
particularly for: • Supply connections tightened pressure-sealed
Cartex®-SNO • Disposal connections installed environmentally safe
Cartex®-SN
Cartex®-ASPN / ABPN The mechanical seal must never turn dry. The seal cartridge
For a single mechanical seal the pressure in the seal must be filled with liquid to avoid the risk of a dry-run and
chamber (stuffing box pressure) should always be higher consequently a damage of the sliding faces.
than the ambient pressure at the machine. Otherwise the When the shaft turns the filled-in liquid warms up due to
machine will suck in air via the sliding faces, which will frictional heat produced by the sliding faces. An
result in dry-running and consequent failure of the unpermitted pressure increase due to this temperature rise
mechanical seal. must be avoided.
particularly for: Damages due to dry-running are excluded from the warranty.
Cartex®-QN
Cartex®-ASTN / ABTN particularly for:
As for Cartex®-SNO / SN, Cartex®-ASPN / ABPN: but in Cartex®-DN
addition: Cartex®-ASDN / ABDN
Quench medium should flow through the mechanical • Connections must be assigned according to direction of
seal. shaft rotation (see instruction
"INTEGRAL CIRCULATION DEVICE" on the
particularly for: drawing)
Cartex®-DN
Cartex®-ASDN / ABDN ATTENTION! Circulation of the buffer fluid is only
ATTENTION! Circulation of the buffer fluid is only assured when the shaft rotates. At standstill the seal cannot
assured when the shaft rotates. At standstill the seal cannot be cooled because the fluid does not circulate. This can result
be cooled because the fluid does not circulate. This can result in damages caused by excessive heating!
in damages caused by excessive heating!
ATTENTION! Set screws with cup point must be used
only once. Repeated fastening endangers the safety of force
transmission.

Operating manual
Therefore: IMPORTANT! First the barrier pressure has to be set,

• Replace set screws by new set screws. then the mechanical seal can be put into operation.
• Adjust the barrier pressure:

2 -3 bar g above the highest pressure to be sealed at
START UP the inboard seal
at pressures >20 bar g: approx. 10 % of the pressure
Cartex®-SNO /-SN /-QN are sensible (accuracy of indication)
Cartex®-ASPN+ABPN at a constant level (appropriate for the outboard seal
Cartex®-ASTN+ABTN faces)
Observe the max. pressure difference (p3-p1).
Safety checks before start up Observe the max. barrier pressure (p3).
• Seal assembly fixtures removed
• Torque transmission (set screws) between mechanical • Flood machine and seal area with medium.
seal and shaft duly installed • Thoroughly vent seal and circulation system.
• Supply connections tightened pressure-sealed • After a short start up period repeat the venting procedure
• Disposal connections installed environmentally safe several times with the machine being at standstill.
• Flood machine and seal area with medium. Cartex®-DN

• Thoroughly vent seal and circulation system. Cartex®-ASDN / ABDN
• After a short start up period repeat the venting procedure
several times with the machine being at standstill. Operation with pressureless supply fluid
particularly for: Safety checks before start up

Cartex®-QN • Seal assembly fixtures removed
Cartex®-ASTN / ABTN • Torque transmission (set screws) between mechanical
• Start the quench circulation. seal and shaft duly installed
• Supply connections tightened pressure-sealed
Cartex®-DN • Disposal connections installed environmentally safe
Cartex®-ASDN / ABDN • Connections must be assigned according to direction of
shaft rotation (see instruction
Operation with barrier pressure (pressurised supply "INTEGRAL CIRCULATION DEVICE" on the
fluid) drawing)
Safety checks before start up When working in tandem, the reservoir liquid is used as a
• Seal assembly fixtures removed "dead-end quench" (API, Plan 51) or a circulating buffer
• Torque transmission (set screws) between mechanical fluid (API, Plan 52) (with the seal on the production side
seal and shaft duly installed pressurised externally) depending on operating conditions.
• Supply connections tightened pressure-sealed
• Disposal connections installed environmentally safe API, Plan 52:
• Connections must be assigned according to direction of
shaft rotation (see instruction • Fill supply circuit and mechanical seal with fluid and
"INTEGRAL CIRCULATION DEVICE" on the vent thoroughly.
drawing)
IMPORTANT! To avoid dry run at the sliding faces the
When operating as a double seal a barrier fluid system supply circuit has to be thoroughly vented a few times before
(API, Plan 53 / 54) is required (where both seals are start up.
pressurised).
In case of vertical arrangement:
• Flood mechanical seal and barrier circuit with clean • To ensure a complete venting of the M.S. carefully push
liquid (particles size ≤ 50 µm) and vent thoroughly. down the outboard seal face with a suitable tool through
the hole in cover.
IMPORTANT! To avoid dry run at the sliding faces the
barrier circuit has to be thoroughly vented a few times before • Make sure that the buffer fluid may circulate unimpeded.
start up. Forced fluid circulation by means of a pumping device
in the seal when the shaft rotates.
In case of vertical arrangement:
• To ensure a complete venting of the M.S. carefully push • Flood machine and seal area with medium.
down the outboard seal face with a suitable tool through • Thoroughly vent seal and circulation system.
the hole in cover. • After a short start up period repeat the venting procedure
several times with the machine being at standstill.
• Make sure that the barrier fluid may circulate unimpeded.
Forced fluid circulation by means of a pumping device
in the seal when the shaft rotates.

Operating manual
MAINTENANCE During the warranty period the BURGMANN mechanical

seal must not be removed and dismantled without the
The correctly operated mechanical seal needs low manufacturer’s agreement or unless a representative is
maintenance. Wear parts, however, have to be replaced, if present.
necessary.
An inspection of the mechanical seal should be carried out

during a revision of the complete plant. We recommend to AFTER-SALES
have this inspection be performed by authorised
BURGMANN personnel. BURGMANN's customer service department offers a
comprehensive service package covering consultancy,
If the mechanical seal is disassembled during a revision of engineering, installation, standardisation, commissioning as
the plant seal faces, seats, o-rings and springs may be well as damage analysis right through to seminars on sealing
replaced by original spares. Refinishing should be done at the technology.
manufacturer only.
Addresses are listed in the known BURGMANN Design
A duly operation includes a regular check of the following Manuals as well as in various other BURGMANN brochures.
parameters:
• Temperature
• Leakage (drainage) rate of mechanical seal
RECONDITIONING
particularly for:
Cartex®-DN; Cartex®-ASDN / ABDN If reconditioning is necessary, the complete seal should be
sent to the manufacturer, as this is the best way to find out
Operation with barrier pressure (pressurised supply which components can be reconditioned or which parts must
fluid) be replaced.
A duly operation includes a regular check of the following If, for compelling reasons, a repair has to be carried out
parameters: on site (e.g. no. spare seal on stock, long transport, problems
• Barrier pressure
with customs) the seal may be repaired in a clean room by
• Barrier fluid temperature
trained personnel of the operating company under the
• Barrier fluid quantity
instruction of BURGMANN maintenance personnel.
• Tightness of the supply circuit
• Leakage of mechanical seal
Operation with pressureless supply fluid

REMOVAL
A duly operation includes a regular check of the following
• Stop the machine as instructed, allow to cool,
parameters:
• Temperature of supply fluid
depressurise and ensure that pressure cannot
• Quantity of supply fluid
build up again.
• Work on the M.S. is only permitted when the
• Leakage (drainage) rate of mechanical seal
machine is at a standstill and depressurised.
• There must be no product on the M.S. ⇒ if
necessary drain the machine and rinse it out.
• Isolate the machine to prevent it starting up
TROUBLES unexpectedly.
• Comply with the safety notes (safety data
Try to define the kind of failure and record it. sheets).
In the event of excessive leakage, note changes in the IMPORTANT! When removing, please observe:
amount and switch the machine off if necessary. current accident prevention regulations
If a constant amount is leaking in a steady flow, the
regulations for handling hazardous substances
mechanical seal is damaged.
In the event of a prohibited temperature rise, the WARNING! Seals that have been used with hazardous
machine must be stopped for safety reasons. substances must be properly cleaned so that there is no
possible danger to people or to the environment.
If there is a malfunction which you cannot correct on your
own, or if the cause of malfunction is not clearly recognisable IMPORTANT! The packaging used to transport the seal
please immediately contact the nearest BURGMANN must
agency, a BURGMANN service centre or the BURGMANN be identified with the relevant hazard symbol and
headquarters. include the safety data sheet for the product and/or
barrier/buffer/quench medium

Operating manual
If the medium to be pumped builds deposits or tends to Address of headquarters:

solidify during cooling down or standstill of the machine the
stuffing box has to be flushed with suitable clean liquid. Flow Burgmann Industries GmbH & Co. KG
and liquid to be determined by the user. Postfach 1240
D - 82502 Wolfratshausen
The order of disassembly to remove the mechanical seal out
of the machine depends on the design of the machine and has Germany
to be determined by the machine manufacturer.
+49 (0) 81 71-23 0
• Depressurise and shut off (or drain) the supply system. Fax +49 (0) 81 71-23 12 14
www.burgmann.com
• Remove the supply piping from the mechanical seal.
Collect drained liquid and dispose it properly.
• Drain the mechanical seal. Collect the drained liquid and DISPOSAL
dispose it properly.
Usually, the BURGMANN mechanical seals can be easily
IMPORTANT! Insert all assembly fixtures into the groove disposed after a thorough cleaning.
in the cover and fix them. Metal parts (steels, stainless steels, non-ferrous heavy
metals) divided into the different groups belong to scrap
• Screw out the cup pointed set screws and dispose. metal waste.
Ceramic materials (synthetic carbons, ceramics, carbides)
ATTENTION! Set screws with cup point must be used belong to waste products. They can be separated from
only once. Repeated fastening endangers the safety of force their housing materials, as are physiologically recognised
transmission. as safe.
Synthetic materials/plastics (elastomers, PTFE) belong to
• Loosen all screw connections between seal cartridge and special waste.
the respective machine parts. CAUTION! Material containing fluorine must not be
burnt.
• Remove the seal in the reverse sequence as described for IMPORTANT! Some of the synthetic materials, divided
assembly (set up). into the different groups can be recycled.
SPARE PARTS COPYRIGHT

• Only BURGMANN original parts must be used. The Burgmann Industries GmbH & Co. KG (Germany)
Otherwise holds the copyright to this document. Customers and
• risks of a seal failure with danger for persons and operators are free to use this document in the preparation of
environment. their own documentation. No claims of any type or form can
The BURGMANN guarantee lapses. be derived in such instance.
• Store a complete spare seal for a quick replacement.
We reserve the right to carry out modifications, even if

they have not yet been considered in this manual.
HOW TO ORDER
For enquiries and orders the following details are required:
BURGMANN commission no.
Drawing no. of mechanical seal 23 September 2004
: Cartex®-SNO/dw-00 Department Technical Documentation
and/or : Cartex®-SN/dw-00
and/or : Cartex®-QN/dw-00
and/or : Cartex®-DN/dw-00
and/or : Cartex®-ASPN/dw-00
and/or : Cartex®-ABPN/dw-00
and/or : Cartex®-ASTN/dw-00
and/or : Cartex®-ABTN/dw-00
and/or : Cartex®-ASDN/dw-00
and/or : Cartex®-ABDN/dw-00
Part item no., designation, material, number of pieces
with reference to the drawing.
(dw = specified shaft diameter)

Marathon Motors INSTALLATION, OPERATION &
GES 4.0
TerraMAX Series MAINTENANCE INSTRUCTIONS
For Industrial AC Induction Motors

80 – 355 Frames (IEC)
www.regalbeloit.com
GES 4.0 / R10
TerraMAX Motor Installation, Operation and Maintenance
Product line: SCA / TCA / QCA / TCN / TCT / TCE
The TerraMAX series motors are designed • Shaft locking clamps, where supplied,
and manufactured to be robust and reliable are fitted securely
with minimal maintenance. The following • Remove shaft locking clamps and turn
items should be taken into consideration to rotor by one full rotation at least once
ensure a trouble free installation and a fortnight and replace shaft locking
reliable operation throughout the motor clamps
life. • Anti-condensation heaters, where fitted,
should be energized if the environment
Inspection is likely to be damp
TerraMAX motors are delivered through
safe and reliable transport in appropriate Installation
packing to avoid damage during transit. The following items should be considered
On receipt of the motor thoroughly inspect on installation to ensure reliable operation
the unit for any transit damage, if needed of the motor:
be in the presence of an insurance agent.
Any equipment damage or shortfall should Surroundings
be immediately advised to the nearest • Ensure that the motor is properly
Regal regional office. protected against ingress of oil, water or
dust especially if construction work is in
Check the following: progress around the motor,
• Rating plate details and enclosure are as • Ensure air intake is not obstructed. Refer
ordered to dimension BL in the catalogue,
• Shaft turns freely (in absence of shaft • When installing hazardous location
locking clamp) motors, make sure that the zone and
• Condensation drain holes are in the gas group or dust and temperature
correct position for the motor mounting classification on motor nameplate are
application (they should be located at complied with.
the lowest point of the motor when it is in
Mounting
its operating position)
• Bed plates or slide rails should be
• If the winding is Insulation Resistance
firmly fixed to a solid, level foundation
(IR) tested to earth, ensure that the
to ensure the motor remains rigid and
thermal protectors are not inadvertently
vibration free
damaged. (The thermistor leads should
• Shims or packers (if required) must be
be shorted together whilst IR testing
of adequate size and placed adjacent to
takes place)
and between base fixing screws
• Protective transport coatings on shafts
Storage and/or flanges must be removed prior to
When the motor is not for immediate use connection to the driven load
store as follows: • A light coating of grease to shafts and/
• Clean and dry location or flanges will inhibit corrosion during
• Free from vibration (vibration can service and assist removal of pulleys or
damage bearings) couplings
GES 4.0 / R10

Pulleys and couplings rechecked as bed plates could move
and/or distort during machine mounting,
• Pulleys or couplings should be
• No end thrust should be applied without
independently balanced with a half key
express approval
as the motor rotor is balanced with a half
• When slide rails are used in conjunction
key during manufacture
with pulley drives, the adjusting screw
• In fitting pulleys or couplings to the
ends should be positioned between
motor shaft care must be taken to
the motor and load at drive shaft end
ensure the roller/ball bearings are not
and the other diagonally opposite. This
damaged. Both shaft and coupling bore
helps speedy and accurate belt aligning,
should be cleaned and lubricated. If the
tensioning and replacement.
fit is still too tight, the pulley or coupling
should be pre-heated in air or oil to
The correct alignment of the motor pulley
enable easy assembly
with the load pulley is imperative. Both these
• Shock methods must not be used in
pulley’s must have matched centre distances
fitting or removing pulleys or couplings.
between grooves and alignment must be
Proper wheel or pulley removers should
carried out using a suitable metal straight
be used to prevent shaft and bearing
edge or other recommended tools to ensure
damage. Tapped holes are provided in
parallel offset or angular displacement of the
shaft extensions to assist in the fitment
pulley’s with respect to each other is inside
of couplings and/or pulleys
permissible limits as recommended by the
Pulley and belts transmission supplier. Correct alignment
• If the motor is to be coupled to the load will result in a uniform distribution of belt
using pulleys and belts it is important tension across the width of the pulley (and
to ensure that the belt tension does not the motor shaft) and ensure design life of
exceed the safe working radial load of both the belts and bearings is achieved.
the motor. Excessive radial load will
lead to reduced bearing life with the Note: The pulley should always be mounted
potential of breaking the motor shaft. firmly against the shaft shoulder and should
Because of this care must be taken to be a firm fit onto the shaft. Impact force
ensure the correct selection of pulley must not be used.
size and type (toothed, vee or flat) and
this is best done in consultation with the Driven
transmission supplier Load
Slide rails
• The belt manufacturer’s Mid
point
recommendations for installation, force
alignment and tensioning must be
strictly adhered to when fitting belt Straight
drives edge û ü û
û
Jack
Alignment bolts
• Great care must be taken in aligning the

complete machine, since misalignment
can cause rapid deterioration of
bearings and lead to other mechanical
failures due to the stress produced,
• After final tightening of foundation
bolts, machine alignment should be
`
As a general rule the midpoint of the applied Where higher than recommended axial loads
force should be at the midpoint of the shaft are necessary different bearing types will be
and it is good engineering practice to mount required. (Refer to Regal regional location).
the motor pulley with hub and locking screw
at the shaft end.
Axial load Radial load
There are various cooling formats for

Midpoint Yes No
Tension electric motors with IC411 (totally enclosed
fan cooled) as the most common type that is
Direct coupled used on our TerraMAX motors. This type of
cooling of motor is achieved by a fan
Where direct coupling of the motor is
mounted at the non-drive end, inside a fan
required, proper alignment must be achieved
cowl, which has an air inlet grill at the rear.
to prevent bearing damage to both motor
Air is drawn in through the grill and the fan
and load.
distributes the airflow along the fins of the
motor body. The fan is designed for either
For parallel offset, use a straight edge or
direction of rotation (unless otherwise
other recommended tools, as shown below.
indicated on the fan cowl).
No Yes
With TEFC motors it is important that the

cooling fins remain clear of debris to allow
Straight Straight
edge edge
the airflow to be fully effective in maintaining
motor winding temperature within the design
Excessive angular displacement must also limits.
be prevented. The recommended method to
achieve correct angular alignment is shown It is equally important to ensure the
below. installation provides good unrestricted
access to normal ambient air at the fan
entry point at all times and that inlet grill is
clear of contaminants. Refer to dimension
BL below.
No Yes Vernier caliper or Wall
Micrometer
Axial load BL
Where motors with standard bearings are

required to be mounted in either vertical
shaft up or vertical shaft down orientation, Free Air Intake Restricted Air Intake
there are limits on the axial forces that
must not be exceeded. This also applies to
Motor frame Dimensions BL
horizontal mounted motors with certain [ mm ]
loads that produce axial thrust. Axial loads 80 - 100 50
exceeding those listed in the catalogue will 112 – 132 75
reduce bearing life and may lead to internal 160 – 180 125
motor damage. 200 – 280 175
315 - 355 225
`
Hazardous location motors
Product line: TCN / TCT / TCE
Standard motors in the range of frame sizes 80 to 355 with appropriate modifications are
certified for use in hazardous areas as below.
Non-sparking motors / Dust ignition-proof motors
Ex nA, Zone 2, Group II, Temperature class T3, TAmb -20°C TO +50°C,
Ex tc, Zone 22, Group II, Temperature class T135, TAmb -20°C TO +50°C,
Ex ec, Zone 2, Group II, Temperature class T3, TAmb -20°C TO +50°C,
Brand Marking Code Certification # Contact Details

II 3 G Ex nA IIC T3 Gc IP55 IECEx UL
17.0014X Regal Beloit America, Inc.
II 3 D Ex tc IIIC T135 Dc IP66 100 E. Randolph St.
DEMKO 17 Wausau, WI 54401 USA
II 3 G Ex ec IIC T3 Gc IP55 ATEX 1836X
II 3 G Ex nA IIC T3 Gc IP55 IECEx UL

17.0104X CEMP S.r.l.
II 3 D Ex tc IIIC T135 Dc IP66 Via Piemonte 16-20030
DEMKO 17 SENAGO (Milan) - ITALY
IECEx UL Regal Beloit Wuxi Co.,
II 3 G Ex nA IIC T3 Gc IP55
17.0111X Ltd.
II 3 D Ex tc IIIC T135 Dc IP66 6 Xiangge Road, Hudai
DEMKO 17 Town, Wuxi City, Jiangsu,
II 3 G Ex ec IIC T3 Gc IP55 ATEX 1963X China
IECEx UL Regal Beloit Australia Pty

17.0112X Ltd
II 3 D Ex tc IIIC T135 Dc IP66 19 Corporate Avenue,
DEMKO 17 Rowville, VIC 3178
II 3 G Ex ec IIC T3 Gc IP55 ATEX 1964X Australia

17.0113X Ltd
II 3 D Ex tc IIIC T135 Dc IP66 7 Mahogany Court,
DEMKO 17 Willawong, QLD 4110
II 3 G Ex ec IIC T3 Gc IP55 ATEX 1965X Australia
IECEx UL Regal Beloit New Zealand

17.0114X Ltd
II 3 D Ex tc IIIC T135 Dc IP66 18 Jomac Place,
DEMKO 17 Avondale Aukland,
II 3 G Ex ec IIC T3 Gc IP55 ATEX 1966X New Zealand
II 3 G Ex nA IIC T3 Gc IP55 IECEx UL Regal Beloit South East

17.0115X Asia Pte Ltd,
II 3 D Ex tc IIIC T135 Dc IP66 12 Tuas Loop,
DEMKO 17
Singapore 637346
II 3 G Ex nA IIC T3 Gc IP55 IECEx UL Rotor BV

17.0129X Mors 1-5, 7151 MX,
II 3 D Ex tc IIIC T135 Dc IP66 Eibergen, The
DEMKO 17
Netherlands
GES 4.0 / R10

Dust Ignition Proof Motors / Increased Safety Motors
Ex tb, Zone 21, Group II, Temperature class T135, TAmb -20°C TO +50°C,
Ex eb, Zone 1, Group II, Temperature Class T3, TAmb -20°C TO +50°C,
Brand Marking Code Certification # Contact Details

IECEx UL
17.0014X Regal Beloit America, Inc.
II 2 D Ex tb IIIC T135 Db IP66
100 E. Randolph St.
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18 Wausau, WI 54401 USA
ATEX 1982X
IECEx UL
17.0104X CEMP S.r.l.
Via Piemonte 16-20030
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18 SENAGO (Milan) - ITALY
ATEX 2068X
IECEx UL Regal Beloit Wuxi Co.,
17.0111X Ltd.
6 Xiangge Road, Hudai
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18 Town, Wuxi City, Jiangsu,
ATEX 2073X China

17.0112X Ltd
19 Corporate Avenue,
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18 Rowville, VIC 3178
ATEX 2069X Australia

17.0113X Ltd
7 Mahogany Court,
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18 Willawong, QLD 4110
ATEX 2070X Australia
IECEx UL Regal Beloit New Zealand

17.0114X Ltd
18 Jomac Place,
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18 Avondale Aukland,
ATEX 2071X New Zealand
IECEx UL Regal Beloit South East

II 2 D Ex tb IIIC T135 Db IP66 17.0115X Asia Pte Ltd,
12 Tuas Loop,
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18
Singapore 637346
ATEX 2072X
IECEx UL Rotor BV
II 2 D Ex tb IIIC T135 Db IP66 17.0129X Mors 1-5, 7151 MX,
Eibergen, The
II 2 G Ex eb IIC T3 Gb IP55 DEMKO 18
Netherlands
ATEX 2074X
GES 4.0 / R10

Classification of zone, group and
temperature category are in accordance
with the standards applied in the
certificates. A detail explanation of these
is available in the product catalogue.
The hazardous location motor

nameplates also carry the certification
number in addition to the marking codes
for the specific protection levels. Details of
the standards to which these are certified
are available on the actual certificates,
copies of which can be accessed from
the website or obtained from the nearest
Regal regional office.
NOTE: Only motors that carry

nameplates indicating Ex nA / Ex t / Ex e
can be used in hazardous locations.
Check nameplate before installing motors
in hazardous locations.
GES 4.0 / R10

Cable entries Supply terminals
Cable entries are via appropriate cable Supply terminals are located in terminal
glands or conduits fitted to the threaded box. They are suitable for receiving
entries in the wall of the terminal box or the crimped lugs on the supply cables. In
gland plate attached to it. Cable entries for addition the terminal box also houses an
various frame sizes are as per the following earthing t erminal.
table
Motor Terminal *Tightening *Tightening
frame size torque- Steel torque-
Motor No. of Entry size Reference Zn Plated Brass
frame entries x pitch drawing for Ex Nm Nm
motors
80 - 132 M5 4 3.2
80 - 132 2 M20x1.5-6H TCA0811TB1
(or) 160 - 180 M6 6 5
TCA13TB1
M25 x 1.5-6H 200 - 225 M8 12 10
160 - 180 2 M25 x 1.5-6H TCA1618TB1 250 - 280 M10 20 16
(or) 315 M12 31 25
M32 x 1.5-6H 355 M16
(or) Above mentioned Tightening Torque is nominal Torque
M40 x 1.5-6H
200 - 280 2 M32 x 1.5-6H TCA2022TB1
(or)
M40 x 1.5-6H
TCA2528TB1 Electrical connection
(or)
M50 x 1.5-6H TerraMAX motors are provided with two
315 2 M63x1.5-6H TCA31TB1 earthing bolt, one inside the terminal box
355 4 M63x1.5-6H TCA35TB1 and other on the motor frame. Depending
on the cross-section of the line conductor,
the earthing conductor cross-section must
Cable glands used by installer on hazardous be:
location motors must be of IEC Ex certified
type as appropriate to the installation LINE CONDUCTOR EARTH CONDUCTOR
CROSS-SECTION CROSS-SECTION
requirements. Unused cable entries must be
blanked off by installer using IEC Ex
certified conduit stops as appropriate. ≤ to 25mm2 Same Section
Cable glands and conduit stops must be of Between

25mm2
25mm2 and 50mm2
an IP Rating equal to or better than that of
main motor as marked on the nameplate. > 50mm2 ≥ 50% of the section
Vibration sensors and shaft encoders when

fitted by the installer are to be appropriately
certified by IECEx or ATEX for the same zone
protection method(s) and temperature code.
GES 4.0 / R10

• Ensure all electrical connections are Initial start up
solid and continuous
Prior to initial start-up check the following-
• Check motor starter and overloads for
• Insulation resistance of motor winding
correct rating and trip setting
to earth to be over 1 MΩ for motors up
• All circuit breakers, HRC fuses/
to 600V and over 10 MΩ for over 600V
protective devices associated with the
• Thermistors or RTDs if fitted, should be
motor must be rated to suit motor
checked for continuity with a multimeter
running current & starting
• Ensure thermistors are wired up to
characteristics
the motor protection relay as to trip
• Supply cables must be appropriately
the supply to the motor in the event
selected considering the voltage drop,
of an over temperature
• When using long supply cables with
• Do not megger test thermal protective
Adjustable Speed Drive, check with
devices across their terminals. Short
Regal regional for proper
the entire protector leads together and
recommendations to avoid
apply the test voltage between the
high voltage transients occurring at
motor terminals shorted leads and earth and/or phases
• Check the connection diagram on the • Hazardous location motors supplied by
motor terminal box and make sure the an Adjustable Speed Drive must have
supply leads are properly connected the thermal protection devices
considering the supply phase connected into the motor control
sequence circuit in such a manner as to
• Ensure that the supply cable disconnect the source of supply in the
termination on to the motor terminal event of an over temperature thus
board is firm without loss of strands preventing the nominated temperature
while using crimped lugs and all class being exceeded
washers are used in the correct order • Anti-condensation heaters if provided
as provided must be so connected as to switch on
• Ensure enough clearances are when the motor supply is disconnected
provided between supply cable lugs & and switch off when the motor supply
gets connected
to earth especially so in case of
• Ensure that the supply voltage
hazardous location motors
and frequency correspond to the
• Ensure that proper earth connection motor nameplate ratings
is made with all washers as provided, • Ensure shaft turns freely before initial
• If using conduit for the supply leads,
start
ensure the conduit is completely
• Measure winding resistance between
threaded in and seal the threads
supply terminals and record in the log
appropriately
book
• If RTDs of hazardous location motors
are connected to monitor the winding
temperature, the maximum voltage to
the RTDs must be kept to 90V(peak) or
below
• The stator RTDs and thermistors can
be connected via a standard industrial
controller provided that the controller is
located in a safe area
GES 4.0 / R10

Operation of repeat stops to 20 per hour
• Before energizing the motor make

sure that the terminal box lid is
Maintenance
closed and secured with appropriate Reliable, trouble free operation of a
clearance to live parts. Make sure motor needs regular maintenance. Exact
maintenance needs are based on the site
that appropriate earthing is done
conditions. To obtain reliable service
• If an earthing ring and earth brush are
from the motor, the following
provided, make sure that the earthing
maintenance schedule may be used as a
ring is clean and the earth brush
guide. An authorized service agent must
makes a good contact with the
carry out maintenance of hazardous
earthing ring. This applies for the Safe
location motors. Clean the surface of the
Area motors
motor with a damp cloth to minimize the
• Make sure that the coupling and/or
risk of electrostatic discharge
transmission is adequately guarded
for safety A. Ensure air intake space is unobstructed
• Check the mounting bolts and/or
flanges are firmly secured B. On a weekly basis use an air hose to
ensure all air ways are clear and free of
• Make sure of no loose objects dust
around that may be sucked by the
cooling fan on the motor C. Once every month, check motor for
condensation. Replace drain plugs
• Make sure that the load applied is before starting if they are blocked or
within the nameplate specification, found missing
• Make sure that the ambient
D. Do not wash the motor unless it is IP66
temperature is inside 40ºC or rated
nameplate specification
E. On a quarterly basis-
• Avoid frequent starting of motor.
(i) Check the motor terminals for tightness
Refer to motor catalogue or nearest and proper contact
Regal regional office for (ii) If terminal lug/s are discolored, re-terminate
with fresh lugs
recommendation on frequency and
(iii) Check operation of starting
duration of starts equipment, ensuring all terminations
• If an Adjustable Speed Drive is used are tight
(iv) Check mechanical operation of
on Ex nA motor, f o llo w the
thermal overload if any.
instructions on additional nameplate for (v) Check mechanical operation of
converter supply in respect to applied thermistor relays, if fitted
(vi) Check operation of anti-condensation
load and frequency
heaters, if fitted
• Check that the running current on no (vii) Check the earth ring and earth brush
load and full load are reasonably Length, if fitted. (For Safe Area Motors)
balanced within 10% of the average
F. On a six monthly basis, in addition to the
and record the figures in the log book items in ‘E’ -
for future reference. Note that the
(i) Check winding resistance between supply
current imbalance can be higher,
terminals and compare to original value and
typically 10 times the voltage enter in log book.
imbalance if there is an imbalance in (ii) Check supply voltage at motor terminals and
record in log book.
supply voltage
(iii) Check bearing for abnormal noise/
• Brake motors used in hazardous overheating
locations must have a limited number
GES 4.0 / R10
Open (re-greaseable) bearings
G. On an annual basis, in addition to the items in
‘E’ and ‘F’ - It should be noted that for motors fitted
(i) Re-grease the bearings as recommended with Ball and Roller bearings, the
under Lubrication & Bearings .
(ii) Completely disassemble stator, rotor apart
lubrication intervals for both bearings
and clean thoroughly. should be based on the roller bearing
(iii) Check bearings for wear/damage – replace data.
as necessary.
(iv) Check all bolts and nuts for cracks or The re-lubrication intervals
damage – replace as necessary. recommended are calculated on the
(v) Check all holding down bolts for signs of
fatigue or damage – replace as necessary. basis of normal working conditions.
(vi) After re-assembly, check and record in the Note: Under hazardous conditions
log book- Insulation resistance by megger No please contact Regal regional or the
load current and voltages Full load current
and voltages Ensure that these figures bearing manufacturers catalogue. Air
compare well with the records in the log operated grease guns should not be
book. used.
(vii) Check and ensure that the cooling fan is
operational. Replenishment of grease media should
be by means of a hand held grease gun
while motor is running with relief plate
removed.
Lubrication & Bearings The lubricating ability of grease (over
Sealed bearings time) depends primarily on the type of
grease, the size of the bearing, the
The required replacement interval for
speed at which the bearing operates
sealed bearings is generally determined
and the severity of the operating
by the grease life which is dependent on
conditions. Longer bearing life can be
operating temperature, operating speed,
obtained of the listed recommendations
the limiting speed of the bearing and the
are followed:
type of grease. Under normal operating
conditions the following relationship
NOTE: If lubrication instructions are
applies for sealed bearings:
provided on the motor nameplate, the
n n nameplate instructions will superseded
logt = 6.54−2.6 −(0.025−0.012 )T
N N these instructions. Motors marked
“Permanently Lubricated” do not require
where, additional service.
t = Average grease life(hours)
N = Bearing limiting speed with grease CAUTION:BEARING/MOTOR
lubrication (RPM) DAMAGE WARNING
T= Operating temperature (°C) Lubricant should be added at a steady,
moderate pressure. If added under
heavy pressure, bearing shield(s) may
For further information, please contact your collapse. Over greasing bearings
nearest Regal regional office for advice.
greatly increases bearing friction and
can cause premature bearing and/or
motor failure.
GES 4.0 / R10

GREASE TYPE (unless nameplate Step 1: Clean the grease inlet and
states otherwise): drain plugs prior to re-greasing.
Use lithium based grease such as Mobil Step 2: Remove grease inlet and drain
Polyrex-EM or equivalent unless plugs
otherwise specified. Motors requiring Step 3: Add grease per below Table.
extra high temperature for use in Step 4: Re-install grease inlet and drain
ambient temperatures above 40°C, use plugs and ensure plugs have at least 5
grease such as Magnalube G or full threads of engagement with motor.
equivalent.
When re-greasing bearings ensure that
the correct type of grease is used. If in CAUTION: GREASE DRAIN
doubt about the existing grease type, PLUGGED
clean out the old grease thoroughly Old grease may completely block the
from bearings and bearing housing, drain opening and must be
prior to re-greasing mechanically removed prior to re-
greasing. Forcing a blocked drain open
WARING: by increased greasing pressure may
NEVER MIX GREASE OF DIFFERENT collapse bearing shields and/or force
TYPES excess grease through the bearings and
into the motor.
LUBRICATION PROCEDURE:
NOTE: Frames 80 through 180 use
sealed bearings and are not
re-greaseable.
Frames 200 through 355 use open
re-greaseable bearings.
CAUTION: BEARING DAMAGE

WARNING
Added grease must be compatible with
the original equipment’s grease. If a
grease other than those stated herein is
to be used, contact the motor
manufacturer. Nameplate information
supersedes grease type referenced in
this section. New grease must be free
of dirt. Failure to follow these
instructions and procedures may result
in bearing and/or motor damage. For
an extremely dirty environment, contact
the motor manufacturer for additional
information.
GES 4.0 / R10

Recommended Grease Replenishment Intervals (Hours) 1)
Bearing Grease
Bearing 3000 r/min 1500 r/min 1000 r/min 750 r/min
bore Qty
number (2)
[mm] [g] Ball Roller Ball Roller Ball Roller Ball Roller
6312/NU312 60 22 3000 1500 9000 4500 12000 6000 12000 6000
6313/NU313 65 24 2000 1000 8000 4000 10000 5000 10000 5000
6314/NU314 70 26 1500 750 4000 2000 7000 3500 7000 3500
6316/NU316 80 38 1000 500 - - - - - -
6317/NU317 85 38 1000 500 4000 2000 7000 3500 7000 3500
6319/NU319 90 45 - - 3000 1500 5000 2500 5000 2500
6322/NU322 95 60 - - 3000 1500 5000 2500 5000 2500
1) 2)
Based on maximum grease service life of 20,000 hours Refer to Nameplate / Motor to confirm bearing size.
Motors – PWM Drives

The TerraMAX motor performs excellently without cogging at the low speed when operating in conjunction with a
PWM (Pulse-Width Modulated) drive.
The graph below shows the TerraMAX motor’s loadability with a frequency converter.
GES 4.0 / R10

User’s
Manual Differential Pressure and
Pressure Transmitters
EJ 110 , EJ 120 ,
EJ 130 , EJ 310 ,
EJ 430 , and EJ 440
IM 01C25B01-01E
IM 01C25B01-01E
15th Edition
<7. Operation> 7-1
7. Operation
7.1 Preparation for Starting Venting Gas from the Transmitter Pressure-
detector Section
Operation
This section describes the operation procedure for
is constructed to be self-venting, no venting
the EJ 110 , EJ 120 and EJ 130 as shown
make the piping self-venting, refer to subsection
pressure connection: right side) when measuring
430 , EJ 440 and
open even after venting gas.
EJ 310
(b) Turn ON power and connect the communicator.
pressure.
Open the terminal box cover, and connect
the communicator to the SUPPLY + and
NOTE – terminals.
Check that the process pressure tap valves,
drain valves, and 3-valve manifold stop valves transmitter is operating properly. Check
on both the low pressure and high pressure parameter values or change the setpoints as
sides are closed, and that the 3-valve manifold necessary.
See IM 01C25T03-01E (BRAIN
communication) or IM 01C25T01-06EN (HART
(a) Follow the procedures below to introduce communication) for communicator operation.
process pressure into the impulse piping and
transmitter.
that the transmitter is operating properly.
Orifice
1) Open the low pressure and high pressure tap Tap valve
(high pressure)
Tap valve
(low pressure)
the transmitter pressure-detector section with
3) Close the high pressure stop valve.

4) Gradually open the low pressure stop valve and
Stop valve
5) Close the low pressure stop valve. (low pressure)
3-valve manifold
6) Gradually open the high pressure stop valve. At
Equalizing valve
and high pressure sides of the transmitter.
Stop valve
(high pressure)
impulse piping, 3-valve manifold, transmitter, or
other components. Drain valve
(high pressure)
F0701.ai
Figure 7.1a Liquid Flow Measurement
2) Gradually open the stop valve to introduce
detector section.
the impulse piping, transmitter, or other

components.
IM 01C25B01-01E
<7. Operation> 7-2
PARAM
C60:SELF CHECK
ERROR
Vent plug (Fill plug)
communication error
Tap valve DATA DIAG PRNT ESC
Communication error Self-diagnostic error

(Faulty wiring) (Faulty transmitter)
Stop valve F0703.ai
Figure 7.2 BT200 Display
Using the integral indicator
blank.
Drain valve displayed.

F0702.ai
Properly
Self-diagnostic error on the integral indicator
Using the BT200 (Faulty transmitter) F0704.ai
Figure 7.3 Integral Indicator with Error Code

IMPORTANT
NOTE
connecting with BRAIN terminal due to
If any of the above errors are indicated on
communication signal affecting the upper the display of the integral indicator or the
system, it is recommended to install a low- communicator, refer to subsection 8.5.3 for the
corrective action.
analog output signal. It is recommended

Verify and Change Transmitter Parameter
Setting and Values
0.1s) to the receiver in order to reduce the
output effect from communication signal. The parameters related to the following items are
communication signal does not give effect on

the upper system.
error’ appears on the display. Other parameters like following are shipped with the
default setting.
ERROR’ appears on the display.
06EN or 01C25T03-01E.
IM 01C25B01-01E
<7. Operation> 7-3
7.2 Zero Point Adjustment The zero-adjustment screw is located inside the
cover.
After completing preparations for operating the Use a slotted screwdriver to turn the zero-
transmitter, adjust the zero point.
Zero point adjustment can be done by turning the turn the screw clockwise to increase the output or
transmitter’s zero-adjustment screw or by using counterclockwise to decrease the output. The zero
the communicator. This section describes the point adjustment can be made with a resolution
procedure for the zero-adjustment screw. For the of 0.01% of the setting range. The degree of zero
communicator procedure, see the communication adjustments varies with the screw turning speed;
manual.
IMPORTANT When using differential pressure transmitters for

Do not turn off the power to the transmitter level measurement and if you cannot obtain the
immediately after performing a zero point lower range value from the actual measurement
adjustment. Powering off within 30 seconds of value of 0%, refer to subsection 7.2.2(2).
performing this procedure will return the zero
7.2.2 Adjusting Zero Point for Gauge/
point to its previous setting.
NOTE from the actual measured value of 0% (0

Before performing this adjustment, make sure
that the external zero adjustment function has For pressure measurement using gauge pressure
NOT been disabled by a parameter setting. transmitters, follow the steps below before
performing zero point adjustment.
To check the output signal, use a digital multimeter,
1) Close the tap valve (main valve).
calibrator, or communicator.
7.2.1 Adjusting Zero Point for Differential to the transmitter is only the head of the seal
Pressure Transmitters
3) Adjust the zero point at this status.
Before adjusting zero point, make sure that the
gradually open the tap valve.
Use a slotted screwdriver to turn the zero-
adjustment screw. Turn the screw clockwise
to increase the output or counterclockwise to
decrease the output. The zero point adjustment can
be made with a resolution of 0.01% of the setting
Zero-adjustment range. Since the degree of the zero adjustment
screw cover
F0705.ai
varies with the screw turning speed, turn the screw
Figure 7.4 External Zero Adjustment Screw make a rough adjustment.
IM 01C25B01-01E
<7. Operation> 7-4
Value from the actual measured value of IMPORTANT
Adjust the transmitter output to the actual measured

value obtained by a digital manometer or a glass screws are loose.
gauge.
[Example]
until it will not turn further.
The measuring range of 50 to 250 kPa; the actual
measured value of 130 kPa. on the ATEX Flameproof type transmitters.
130–50 An Allen head bolt (shrouding bolt) under
Actual measured value= x100=40.0% the edge of each cover is used to lock the
250–50
(=10.4mA) cover. When the shrouding bolt is driven
counterclockwise with an Allen wrench, the
Turn the screw to match the output signal to the
bolt rotates upward and locks the cover. (See
actual measured value.
that they are secure and cannot be opened
7.3 Starting Operation by hand.
Tighten the zero-adjustment cover mounting
After completing the zero point adjustment, follow screw to secure the cover.
the procedures below to start operation. Steps
screw to secure the cover.
transmitters.
2) Gradually open the low pressure stop valve. 7.4 Shutting Down the
This places the transmitter in an operational
condition. Transmitter
Shut down the transmitter as follows.
periodic variation in the process pressure, use pressure transmitters.

the communicator to dampen the transmitter
1) Turn off the power.
2) Close the low pressure stop valve.
receiving instrument or the integral indicator,
and set the optimum damping time constant.
4) Close the high pressure stop valve.
5) Close the high pressure and low pressure tap
the following.
valves.
NOTE
in the transmitter pressure-detector section.
IM 01C25B01-01E
<7. Operation> 7-5
7.5 Venting or Draining 7.5.2 Venting Gas
Transmitter Pressure- 1) Gradually open the vent screw to vent gas from
the transmitter pressure-detector section. (See
detector Section
Since this transmitter is designed to be self- 2) When the transmitter is completely vented,
draining and self-venting with vertical impulse close the vent screw.
piping connections, neither draining nor venting
appropriately for self-draining or self-venting

Vent screw
operation.
If condensate (or gas) collects in the transmitter
pressure-detector section, the measured pressure
piping for self-draining (or self-venting) operation,

you will need to loosen the drain (vent) screw on the
Vent screw
transmitter to completely drain (vent) any stagnated
When you loosen the vent screw, the gas
escpes in the direction of the arrow.
However, since draining condensate or bleeding off F0707.ai
gas disturbs the pressure measurement, this should Figure 7.6 Venting the Transmitter
not be done when the loop is in operation.
WARNING 7.6 Local Parameter Setting
toxic or otherwise harmful, take appropriate care

WARNING
to avoid contact with the body, or inhalation of The local push button on the integral indicator
vapors. must not be used in a hazardous area. When it is
necessary to use the push button, operate it in a
7.5.1 Draining Condensate non- hazardous location.
1) Gradually open the drain screw or drain plug

and drain the transmitter pressure-detector IMPORTANT
removed, close the drain screw or drain plug. immediately after performing parameter
setting. Powering off within 30 seconds of
performing this procedure will return the
parameter to its previous setting.
manual IM 01C25T (HART/BRAIN) for the

setting procedure.
is available with HART or BRAIN

Drain plug communication type.
LCD update will be slower at low ambient
Drain screw temperature, and it is recommended to use
When you loosen the drain screw or drain LPS function at temperatures above -10
plug, the accumulated liquid will be expelled degrees C.
in the direction of the arrow.
F0706.ai
Figure 7.5 Draining the Transmitter
IM 01C25B01-01E
<7. Operation> 7-6
7.6.1 Local Parameter Setting (LPS)
Overview
screw and push button (integral indicator code E)
number, Unit, LRV, URV, Damping,Output mode
by applying actual pressure (LRV/URV). There is

no effect on measurement signal (analog output
or communication signal) when Local Parameter
Setting is carried out.
Integral indicator
External adjustment
screw cover
Push-button
F0708.ai F0709.ai
Figure 7.7 External Adjustment Screw
screw
Process
Measurement Zero adjustment
Display push
Activate LPS mode
push
*
1. Tag Number Edit Tag number Save/Cancel the value
*
2. Press Unit Select Press unit Save/Cancel the value
push *
3. Press LRV Edit Press LRV Save/Cancel the value
*
4. Press URV Edit Press URV Save/Cancel the value
push *
5. Damping Time Edit Damping time Save/Cancel the value
*
6. Output Mode Select Output mode Save/Cancel the value
push *
7. Display Out1 Edit Display Out1 Save/Cancel the value
8. LRV-Apply Press Set LRV Save/Cancel the value
push
9. URV-Apply Press Set URV Save/Cancel the value
8, 9 : Re-range by applying actual pressure
10. Device Information Displayed when output signal code is Q.
Process
Measurement
Display F0710.ai
“Software rev” and IM 01C25T03 for BRAIN “SOFT REV”.

Figure 7.9
IM 01C25B01-01E
<7. Operation> 7-7
7.6.2 Activating Local Parameter Setting
Press the push button on the integral indicator to
activate the Local Parameter Setting mode. The
transmitter will exit automatically from the Local
Parameter Setting mode if no operation is carried
out for 10 minutes.
7.6.3 Parameter Setting Review

Current setting value for the below parameters
button.
Tag number, Unit, LRV, URV, Damping,Output
Process
Measurement
Display
push
push
push
push
push
push
push
push
push Process
Measurement
Display
F0711.ai
*: Up to 6 characters are shown in the bottom line. To review

after the 7th character, turn the external adjustment screw and
press the push button six times or more.
external adjustment screw on each parameter

screen after activating the Local Parameter Setting
mode.
To cancel the Local Parameter Setting
IM 01C25B01-01E
<7. Operation> 7-8
Tag Number is edited by turning the external

adjustment screw. Up to 8 alphanumeric characters
for HART or 16 alphanumeric characters for BRAIN
can be set.
Save ?/
Cancel ?
Blinking Blinking
Set all other
characters in the
Go to the next Character same way
Change the first Character
screw
push
F0712.ai
Pressure unit for the below table can be changed

as below. By turning the external adjustment screw,
user can scroll between the various available
pressure units.
Save ?/
Cancel ?
Blinking Blinking
[Available pressure units]
Select by the push button
kPa bar inH2O@4degC(39.2degF)
Torr mbar inH2O@20degC(68degF)
atm g/cm2 inHg
MPa kg/cm2 ftH2O@4degC(39.2degF)
screw hPa Pa ftH2O@20degC(68degF)
push mmHg mmH2O@4degC(39.2degF)
psi mmH2O@20degC(68degF)
In addition to the above units, mmAq@4degC,
mmAq@20degC, mmWG@4degC and mmWG@20degC
are available for BRAIN communication type.
F0713.ai
Pressure LRV and URV can be set. The number

for each digit is changed by turning the external
adjustment screw and set by pressing the push
button. Please refer to 7.6.7 Damping Time
numerical value.
When the setting is out of the limit, an alarm will be
generated.
IM 01C25B01-01E
<7. Operation> 7-9
7.6.7 Damping Time Constant
assembly can be set. Quick Response Parameter

is automatically set to ON when the damping time
constant is set to less than 0.5 seconds. Damping
time constant is rounded off to two decimal places.
Save ?/
Cancel ?
Blinking Blinking Blinking

Set all other
characters in the
same way
Change the first digit Go to the next
Character
screw Setting range: 0.00 to 100.00 (seconds)
push
F0714.ai
2) Press the push-button. The integral indicator

then displays “LRV.SET.”
selected by turning the external adjustment screw. 3) Apply a pressure of 0 kPa (atmospheric
pressure) to the transmitter. (Note 1)
how to select and set the enumerated value. 4) Turn the external adjustment screw in the
desired direction. The integral indicator displays
the output signal in %. (Note 2)
5) Adjust the output signal to 0% (1 V DC) by
Display Out1 can be selected by turning the
rotating the external adjustment screw. Press
external adjustment screw. Please refer to 7.6.5
the push button to save the value. Doing so
completes the LRV setting. (Note 3)
set the enumerated value.
6) Press the push-button. The integral indicator
then displays “URV.SET.”
7) Apply a pressure of 3 MPa to the transmitter.
pressure (LRV/URV). (Note 1)
This feature allows the lower and upper range 8) Turn the external adjustment screw in the
values to be setup with the actual input applied. desired direction. The integral indicator displays
the output signal in %. (Note 2)
9) Adjust the output signal to 100% (5 V DC)
by rotating the external adjustment screw.
Press the button to save the value.Doing so
completes the URV setting.
10) Press the push-button. The transmitter then
F0715.ai
switches back to the normal operation mode
Follow the procedure below to change the LRV and with the measurement range of 0 to 3 MPa.
URV settings. Note 1: Wait until the pressure inside the pressure-detector
[Example] section has stabilized before proceeding to the next
step.
Rerange LRV to 0 and URV to 3 MPa. Note 2: If the pressure applied to the transmitter exceeds the
previous LRV (or URV), the integral indicator may
1) Connect the transmitter and apparatus as display error number “AL.30” (In this case, the output
signal percent and “AL.30” are displayed alternately
shown in Figure 8.1 and warm it up for at least every two seconds). Although “AL.30” is displayed,
you may proceed to the next step. However, should
any other error number be displayed, take the
IM 01C25B01-01E
<7. Operation> 7-10
appropriate measure in reference to , “Errors and
Countermeasures” in each communication manual.
Note 3 : Changing the lower range value (LRV) also
automatically changes the upper range value (URV),
keeping the span constant. New URV=previous hold down the button for over 2 seconds and select
URV+(new LRV–previous LRV) “Save” or “Cancel”.
7.6.11 Save or Cancel
At the end of each parameter setting, select “Save”
or “Cancel” by the external adjustment screw
and press the push button to save or cancel the
Tag editing Return to
(3rd Character) parameter review window
Save or Cancel Push for Save or Cancel?

Over 2 seconds
F0718.ai
Save? Saved To disable parameter changes by the Local

After push Parameter Setting there are three different ways.
parameter screw
setting
Communication Parameter
Ext SW =disable Adjustment
(EXT ZERO ADJ = disable)
Communication Parameter
Write Protect = On
(WRT PROTECT = Yes) Parameters *
Cancel? Canceled
Hardware write protection
push switch on CPU assembly =
D (Disable) Parameters *
F0716.ai
*External Zero Adjustment is unlocked.
The above parameter setting is carried out by
manual IM 01C25T (HART/BRAIN) for the setting

Hold down the push button for over 2 seconds to procedure.
exit the Local Parameter Setting mode. Reviewing local parameter setting by push button
on the integral indicator is available at any time
Process Measurement Display
even when the Local Parameter Setting is locked.
1. Tag Number 7.6.14 Others
2. Press Unit
HART BRAIN
3. Press LRV Up to 8 Up to 16
Tag Number characters can characters can
be set be set
4. Press URV
Hold down the button “TRNS.FC” “OUT.MOD”
Output Mode
for over 2 seconds shown on the shown on the
Jump to the normal mode
5. Damping Time integral indicator integral indicator
6. Output Mode
speed of turning the adjustment screw. Turn the
7. Display Out1
8. LRV-Apply Press
9. URV-Apply Press
Process Measurement Display
Proccess Value
F0717.ai
IM 01C25B01-01E
<8. Maintenance> 8-1
8. Maintenance
8.1 Overview
Use the procedure below to check instrument
WARNING operation and accuracy during periodic
maintenance or troubleshooting.
toxic or otherwise harmful, take appropriate care

to avoid contact with the body or inhalation of
vapors when draining condensate or venting gas minutes (ten minutes for EJ 310 .)
from the transmitter pressure-detector section
and even after dismounting the instrument from IMPORTANT
the process line for maintenance.
accuracy, make adjustments with the
Maintenance of the transmitter is easy due to its power supply voltage and load resistance
modular construction. This chapter describes the including leadwire resistances set close to
procedures for calibration, adjustment, and the the conditions under which the transmitter is
installed.
for component replacement.
Transmitters are precision instruments. Please 0 kPa or shifted in the positive direction
carefully and thoroughly read the following sections (suppressed zero), the reference pressure
for information on how to properly handle them
while performing maintenance. If the measurement range 0% point is shifted
in the negative direction (elevated zero), the
IMPORTANT reference pressure should be applied using
a vacuum pump.
should be done in a shop that has all the 2) Apply reference pressures of 0%, 50%,
necessary tools. and 100% of the measurement range to the
transmitter. Calculate the errors (differences
that can be damaged by static electricity. between digital voltmeter readings and
Take precautions such as using a grounded reference pressures) as the pressure is
wrist strap when handling electronic parts or increased from 0% to 100% and is decreased
touching the board circuit patterns. Also be
sure to place the removed CPU assembly
into a bag with an antistatic coating.
Selection
Table 8.1 lists the instruments that can be used
to calibrate a transmitter. When selecting an
Exercise care when handling these instruments to
IM 01C25B01-01E
Name
Power supply Model SDBT or SDBS distributor 4 to 20 mA DC signal
Load resistor
Voltmeter Model 2501 A digital multimeter
Digital Model MT220 precision digital manometer Select a manometer having

manometer 1) For 10 kPa class a pressure range close to
. . . . for 0 to 10 kPa that of the transmitter.
. . . . . . . . for -10 to 0 kPa
2) For 130 kPa class
. . . . . . . . . . . . . . . . . . . . for 25 to 130 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . for 0 to 25 kPa
. . . . . . . . for -80 to 0 kPa
. . . . . . . . . . . for 100 to 700 kPa
. . . . . . . . . . . . . . . . . . . . . . . . for 0 to 100 kPa
. . . . . . . . for -80 to 0 kPa
. . . . . . . . . . for 0 to 3000 kPa
. . . . . . . . for -80 to 0 kPa
5) For 130 kPa abs class
. . . . . . . . . . . for 0 to 130 kPa abs
Pressure 2
generator 2 supply.
2 Select the one having a

pressure range close to that
of the transmitter.
Pressure Model 6919 pressure regulator (pressure pump) Prepare the vacuum pump
source for negative pressure
ranges.
Note: The above table contains the instruments capable of performing calibration to the 0.2% level. Since special maintenance and
Supply pressure Pressure source

Using pressure Using pressure
generator source with
manometer Model MT220
P Pressure generator P precision digital manometer
Low pressure side Reference pressure Low pressure side Reference pressure
open to atmosphere open to atmosphere
High pressure side High pressure side
Load resistance, Power Load resistance, Power

supply supply
E E
Rc R Load Rc R
Load
adjusting
adjusting V V
resistance,
resistance,
Digital voltmeter Digital voltmeter
F0801.ai
Figure 8.1 Instrument Connections (EJX110A, 4 to 20mA output)
IM 01C25B01-01E
8.4.1 Replacing the Integral Indicator
CAUTION
This section describes procedures for disassembly
and reassembly for maintenance and component Cautions for Flameproof Type Transmitters
replacement. Users are prohibited by law from modifying the
Always turn OFF power and shut off and release
pressures before disassembly. Use proper tools for This would invalidate the agency approval for the
use of the transmitter in a rated area.
It follows that the user is prohibited from using
Tool Quantity indicator removed, or from adding an integral

Phillips 1 JIS B4633, No. 2
screwdriver
Slotted 1
screwdriver
This subsection describes the procedure for
Allen wrenches 3 JIS B4648
One each, nominal 3, 4 and
2.5 mm Allen wrenches
Wrench 1 Removing the Integral Indicator
1
1) Remove the cover.
Adjustable 1
wrench 2) While supporting the integral indicator with one
Socket wrench 1 hand, loosen its two mounting screws.
Socket driver 1 3) Dismount the LCD board assembly from the
Tweezers 1 CPU assembly.
When doing this, carefully pull the LCD board
assembly straight forward so as not to damage
CAUTION the connector pins between it and the CPU
assembly.
Precautions for ATEX Flameproof Type
Attaching the Integral Indicator
Transmitters
1) Align both the LCD board assembly and CPU
a rule, removed to a non-hazardous area assembly connectors and engage them.
for maintenance and be disassembled and 2) Insert and tighten the two mounting screws.
reassembled to the original state. 3) Replace the cover.
Output terminal cable
covers are locked, each by an Allen head
bolt (shrouding bolt). When a shrouding bolt
is driven clockwise by an Allen wrench, it is
going in and cover lock is released, and then Press
the cover can be opened. forward
When a cover is closed it should be locked Slide

by a shrouding bolt without fail. Tighten the switch
Integral Zero-
Boss
indicator adjustment
CPU assembly screw
Bracket
(for zero-adjustment
screw pin)
Zero-adjustment
LCD board assembly screw pin
Mounting screw
Amplifier Cover
Shrouding Bolt
F0803.ai
Shrouding Bolt F0802.ai Figure 8.3 Removing and Attaching LCD Board
Figure 8.2 Shrouding Bolts
IM 01C25B01-01E
NOTE
This subsection describes the procedure for
placed properly in the groove on the bracket prior

to tightening the two bosses. If it is not, the zero-
1) Remove the cover. If an integral indicator is adjustment mechanism will be damaged.
mounted, refer to subsection 8.4.1 and remove
the indicator. 5) Replace the cover.
2) Turn the zero-adjustment screw to the position
(where the screw head slot is horizontal) as 8.4.3 Cleaning and Replacing the Capsule
3) Disconnect the output terminal cable (cable

This subsection describes the procedures for
with brown connector at the end). When doing
cleaning and replacing the capsule assembly. (See
this, lightly press the side of the CPU assembly
connector and pull the cable connector to
disengage.
CAUTION
to loosen the two bosses.
Cautions for Flameproof Type Transmitters
5) Carefully pull the CPU assembly straight
Users are prohibited by law from modifying the
forward to remove it.
you wish to replace the capsule assembly with

connector at the end) that connects the CPU
one of a different measurement range, contact
assembly and the capsule.
Yokogawa.
The user is permitted, however, to replace a
NOTE capsule assembly with another of the same
Be careful not to apply excessive force to the measurement range. When doing so, be sure to
CPU assembly when removing it. observe the following.
have the same part number as the one being

replaced.
between the CPU assembly and the capsule. capsule assembly is a critical element in
2) Connect the output terminal cable (with brown
connector). must be checked to verify that it is free of
dents, scratches, and other defects.
NOTE
securely tighten the setscrews that fasten
Make certain that the cables do not get pinched the transmitter section and pressure-detector
between the case and the edge of the CPU section together.
assembly.
3) Align and engage the zero-adjustment screw

pin with the groove on the bracket on the CPU
assembly. Then insert the CPU board assembly
4) Tighten the two bosses. If the transmitter is
subsection 8.4.1 to mount the indicator.
IM 01C25B01-01E
3) After the pressure-detector section has been
reassembled, a leak test must be performed to
IMPORTANT verify that there are no pressure leaks.
4) Reattach the transmitter section to the
Exercise care as follows when cleaning the pressure-detector section.
capsule assembly. Reattach the stopper with the hexagon-head
screw.
be especially careful not to damage or distort 5) Tighten the two setscrews. (Tighten the screws
the diaphragms that contact the process
6) Install the CPU assembly according to
subsection 8.4.2.
cleaning. 7) After completing reassembly, adjust the zero
point and recheck the parameters.
cleaning.
Transmitter section
1) Remove the CPU assembly as shown in
subsection 8.4.2.
2) Remove the two setscrews that connect the
transmitter section and pressure-detector
section.
Setscrew
3) Remove the hexagon-head screw and the
stopper.
4) Separate the transmitter section and pressure- Nut
detector section.
Capsule gasket
6) While supporting the capsule assembly with
Flange bolt
7) Remove the capsule assembly.

8) Clean the capsule assembly or replace with a
new one.
Pressure-detector section
bolts, paying close attention to the relative Cover flange
F0804.ai
positions of the H (high pressure side) and
Figure 8.4 Removing and Mounting the Pressure-
L (low pressure side) marks on the capsule detector Section
assembly.
Replace the two capsule gaskets with new
gaskets. IMPORTANT
If you remove the vent/drain plugs when
disassembling EJ 130 and EJ 440
transmitters, install the plugs again before
EJ 110 , EJ 310 , EJ 430
Model Wetted parts material code EJ 120 assmbly.
S H,M,T,A,D,B
17* 40 40
*: 40 for measurement span code F.
EJ 130 EJ 440
Model Bolts & nuts material code
G, C J G, C J
90 110 70 100
IM 01C25B01-01E
8.4.4 Replacing the Process Connector
First determine whether the process variable
This subsection describes process connector is actually abnormal or a problem exists in the
measurement system.
(a) Loosen the two bolts, and remove the process If the problem is in the measurement system,
connectors. isolate the problem and decide what corrective
(b) Replace the process connector gaskets. action to take.
(c) Remount the process connectors. Tighten the
function which will be useful in troubleshooting,
below, and verify that there are no pressure
leaks.
indicator will show an alarm code as a result of self-
EJ 110 EJ 440 diagnosis.
EJ 120 See subsection 8.5.3 for the list of alarms.
Model EJ 130
EJ 310 C capsule D capsule See also each communication manual.
EJ 430
: Areas where self-diagnostic offers support
39 to 49 49 to 59
Abnormalities appear in measurement.
Bolt
Process connector YES Is process variable

itself abnormal?
Process connector gasket

Inspect the NO
Measurement system problem
process system.
Isolate problem in
measurement system.
F0805.ai
YES Does problem exist in
Figure 8.5 Removing and Mounting the Process receiving instrument?
Connector
NO
Inspect receiver.
If any abnormality appears in the measured values, Environmental conditions Transmitter itself
and remedy the problem. Since some problems Check/correct

Check transmitter.
environmental conditions.
Operating conditions
correcting a problem, contact Yokogawa service
personnel. Check/correct operating
conditions.
F0806.ai
Figure 8.6 Basic Flow and Self-Diagnostics
IM 01C25B01-01E
Output travels beyond 0% or 100%.
The following sorts of symptoms indicate that transmitter

may not be operating properly.
Connect a communicator and check self-diagnostics.
process variable is known to be varying.
inferred for process variable.

Does the self- YES
diagnostic indicate problem
location?
Connect communicator and check self-diagnostics.
NO Refer to error message summary in
each communication manual to take
actions.
Does the self-diagnostic YES

indicate problem location?
Is power supply NO
polarity correct?
Refer to error message summary in
Subsection 8.5.3 or in each
communication manual to take actions. YES Refer to Section 6.3 to check/correct
polarity at each terminal from power
supply to the terminal box.
Is power supply
polarity correct?
Are valves opened or NO
closed correctly?
YES Refer to Section 6.3 to check/correct
polarity at each terminal from power
supply to the terminal box. YES Fully close equalizing valve, and fully
open high pressure and low pressure
valves.
Are power
supply voltage and load
resistance correct?
YES
Is there any pressure leak?
YES Refer to Section 6.6 for rated voltage
and load resistance.
NO
Fix pressure leaks, paying particular
attention to connections for impulse
piping, pressure-detector section, etc.
Are valves opened or

closed correctly?
Is impulse piping NO
to high pressure and low
pressure side correct?
YES Fully close equalizing valve, and fully
valves. YES Refer to individual model user manuals
and connect piping as appropriate for
the measurement purpose.
YES
Is there any pressure leak?
Is zero point NO
adjusted correctly?
Fix pressure leaks, paying particular
attention to connections for impulse
piping,pressure-detector section, etc. YES Adjust the zero point.
Is there
continuity through the Contact Yokogawa service personnel.
transmitter loop wiring? F0808.ai
Do the loop numbers
match?
Find/correct broken conductor or

YES
wiring error.
Contact Yokogawa service personnel.

F0807.ai
IM 01C25B01-01E
Large output error.
Connect a communicator and check self-diagnostics.
Does the self- YES

diagnostic indicate problem
location?
NO Refer to error message summary in

each communication manual to take
actions.
Are valves opened or NO

closed correctly?
YES Fully close equalizing valve, and fully

valves.
Is impulse piping NO
connected correctly?
YES Refer to individual model user manuals

and connect piping as appropriate for
the measurement purpose.
Are power supply NO

voltage and load resistance
correct?
YES Refer to Section 6.6 for rated voltage

and load resistance.
Is transmitter
installed where there is YES
marked variation in
temperature?
Provide lagging and/or cooling, or allow

NO adequate ventilation.
Were appropriate NO
instruments used for
calibration?
YES Refer to Section 8.2 when selecting

instruments for calibration.
NO
Is output adjusted correctly?
YES Adjust the output.
Contact Yokogawa service personnel.

F0809.ai
IM 01C25B01-01E
8.5.3 Alarms and Countermeasures
Output Operation
Indicator Cause Countermeasure
during Error
None
AL. 01 Sensor problem. Outputs the signal (Hold, High, or Replace capsule when error
CAP. ERR Capsule temperature sensor Low) set with parameter. keeps appearing even after
problem. restart.
Capsule EEPROM problem.
AL. 02 Outputs the signal (Hold, High, or
AMP. ERR problem. Low) set with parameter.
AL. 10 Input is outside measurement Outputs high range limit value or Check input or replace capsule
PRESS range limit of capsule. low range limit value. when necessary.
AL. 11 Static pressure exceeds limit. Continues to operate and output.
ST. PRSS
AL. 12 Capsule temperature is outside Use heat insulation or make
CAP. TMP range (–50 to 130°C). lagging to keep temperature
AL. 13 within range.
AMP. TMP range (–50 to 95°C)
AL. 30 Output is outside upper or lower Outputs high range limit value or Check input and range setting,
RANGE range limit value. low range limit value. and change them as needed.
AL. 31 Continues to operate and
SP. RNG range. output.
AL. 35 *1 Check input.
P. HI threshold.
AL. 36 *1
P. LO
AL. 37 *1 Input static pressure exceeds
SP. HI
AL. 38 *1
SP. LO
AL. 39 *1 Detected temperature exceeds
TMP. HI
AL. 40 *1
TMP. LO
AL. 50 Holds output immediately before Check setting and change them
P. LRV range. error occurred. as needed.
AL. 51
P. URV
AL. 52
P. SPN
AL. 53 Continues to operate and output. Check input.
P. ADJ
AL. 54 Continues to operate and output Check setting and change them
SP. RNG holding static pressure in %. as needed.
AL. 55 Continues to operate and output. Check input.
SP. ADJ
AL. 60 Check setting and change
SC. CFG them as needed.
do not satisfy the condition.
AL. 79 Displayed value exceeds limit.
OV. DISP
*1: These alarms may appear only when process alarm function is activated.
IM 01C25B01-01E
CLEANING BALLS
Cleaning Balls are used for preventing formation of deposits and scales inside the Condenser tubes.
The composition of balls is based on a natural rubber mixture containing fillers and chemicals.
APPLICATIONS
RB Cleaning Balls are used for Stainless Steel and Titanium Tubes to remove biofouled layers. Though
the titanium and high-performance stainless steels are having excellent corrosion resistance, they are
more susceptible to biofouled layers than copper-base alloys. In copper-base alloys, toxic effect of
copper-ions hampers the formation of biofouled layers. Generally, RB Scouring balls with 10 to 12
balls passes per tube per hour are recommended for continuous cleaning.
BRIEF DESCRIPTION
The bio fouled layers are soft in nature and readily removed by normal sponge balls. However, in Sea
Water applications, a gradual build-up of inorganic layer, resistant to normal sponge balls can occur.
It can be identified in any one of the following indications :
• Heat Transfer Rate (ΔT) is likely to dipped

• Abnormal Wear and Tear of normal Cleaning Balls due to rough surface of condenser tubes
In such case, a basic charge of ring coated with fine granulated balls (Type RG) may be circulated for
removing the inorganic layers because RG Balls are having more aggressive scouring effect. RG Balls
are effective only till the coating is prevailed but uncoated balls are effective as long as they are in
oversize. Extensive depreciation of Ring Coating of RG Balls after 30 minutes of operation with one
basic charge is the indication of rough surface or fouling of the condenser tubes. In such case, one or
more basic charge can be circulated. One basic charge of RG Balls is recommended at least once a
year for this project. However, the frequency may be increased depends upon any one of the above
indications is likely to appear. Usage of RG Balls can be stopped immediately once the system is free
from the above indications.
BALL HARDNESS / SPECIFIC GRAVITY
The choice of optimum ball hardness is dictated by the need to be able to collect the balls on screens,
recirculate them and good ball life (the soft balls with the optimum permitted oversize for a given
pressure drop are longer life).
The most commonly used cleaning ball is the "medium" grade.
From a practical point of view, ball hardness does not affect the cleaning properties of the ball.
DES/OMM/CB Sheet 1
LIFE
Ball life strongly depends on Water Quality, Cleaning frequency and surface condition of the condenser
tubes. Scaled and corroded surfaces are having a detrimental effect on ball life.
STORAGE
Storage temperature is to be maintained at 24 ± 3 ºC. Store the cleaning balls in packed cartons to
prevent deformation. Do not store the cleaning balls near the ozone releasing equipment. Do not stack
more than two cartons in a row. Use cleaning balls on first in first out basis. If the balls are removed
from the carton, they should be stored loosely. Cleaning balls should be stored in a place free from oil
and grease. Used but effective balls should always be kept in the water.
WATERING NEW BALLS
For every fresh charge of cleaning balls in the Ball Collector, squeezing in water is mandatory to
release the air to avoid floating of balls on top of the condenser and uniform ball circulation.
BALL OVERSIZE
Ball oversize is the difference between the actual ball diameter and the internal diameter of the tube.
Basically, a cleaning ball has to be larger than the internal diameter of the tube to be cleaned. The
cleaning ball gets squeezed when it enters the tube, thereby pressing itself against the surface of the
tube. The pressure drop between the inlet and outlet ends of the tube transport the ball through the
tube. Cleaning is only fully effective so long as the ball is oversize.
ORDERING
When ordering Cleaning Balls, please specify ball type (e.g. Type RB), nominal ball diameter in mm
and grade of hardness. Refer Catalogue Section for more details.
DES/OMM/CB Sheet 2
CLEANING BALLS
www.website.com
Schmitz Cleaning Balls
Schmitz (An Affiliate Company of GEA BGR) cleaning balls plays a crucial
role in maintaining the condenser and Heat Exchanger Tubes clean and
free from Fouling & Scaling.
Schmitz Cleaning balls are manufactured with high-quality standards CLEANING BALLS
and are eco-friendly in nature. The Cleaning balls we provide are proven
and accepted by several reputed customers across the world.
Soft Deposits
In all cooling water applications, fouled layers, such as slime, mud or silt,
from on the inner surfaces of condenser tubes even at velocities of
2m/s.These deposits are typically soft and easily removed by SCHMITZ
Cleaning Balls without an abrasive layer.
SCHMITZ recommend Type RS open pore structure sponge ball for
continuous cleaning with 8 to 12 ball passes per tube per hour.
Hard Deposits
In cooling towers and other open evaporative cooling water systems the
water becomes highly concentrated with certain chemicals. The solubility
limit is thereby exceeeded and hard crystalline deposits, such as calcium
carbonate, form on the tube surface.
SCHMITZ ring coated Abrasive Balls Type RA are first used to clean the
fouled tubes,typically for a period of a few weeks. Continuous cleaning
with Schmitz Balls without an abrasive layer then hinders growth of
nuclei. In very hard waters, regualr use of abrasive ball is recommended,
i.e. 1 or more ball charges every 1 to 3 months.
Artificial Protective Film
Copper base alloys have marginal corrosive resistance in seawater

applications. Although artificial protective film can be formed by using
ferrous sulphate, excessive sponge ball cleaning produces lacquer-like
films which easily flake away on drying of condenseer.
SCHMITZ recommends the use of cleaning balls without an abrasive layer
TYPE RS for 1 hour per day before ferrous sulphate dosing. This produces
compact, matt brown films, giving an optimum combination of heat
transfer and corrosion resistance. Abrasive balls fully coated TYPE RAT is
very effective for removing the peeled films.
Corrosion Resistant Materials
Although titanium and high performance stainless steels have excellent

resistance to corrosion they are more susceptible to fouling than
copper-base alloys. This can be attributed to the absence of copper-ions,
which are toxic and tend to hinder the formation of bio-fouled layers.
SCHMITZ recommends continuous cleaning type RB scouring balls with 8
to 10 balls passes per tuber per hour. Additionally, a basic charge of
granulated balls Type RG should be circulated every few months to avoid a
possible build-up of a strong adherent fouled layers.
For Sea Water And Fresh Water For Sea Water And Brine Fluid
Upto 80°C (176°F) Surface Condenser Upto 140°C (284°F) Desallinaton system
Lower
Sinking
Velocity
RS 15 RSL 10 RT 35
Removal of Soft Deposits Removal of Soft Deposits Removal of Soft Deposits

Copper & Brass Tubes Copper & Brass Tubes Cupronickel & SS Tubes
RA 15 RAT 15 RTAT 35
Removal of Hard Scales Ca Co, Removal of Soft Scales Removal of Soft Scales Mg (OH)2
Copper and Brass Tubes Mg (OH)2 Fe SO4 Cupronickel & SS Tubes
Welded Copper and Brass Tubes
Lower
Sinking
Velocity
RB 20 RG 20 RTL 30
RB Scouring balls for removal of RG Scouring balls for removal of Removal of Soft Deposits
Biofoulded layers Aderent Biofoulded layers Cupronickel & SS Tubes
Stainless Steel, Titanium Tubes Stainless Steel, Titanium Tubes
RBR 20 RSR 15
(LONG LIFE) (LONG LIFE) RTA 35
Removal of Soft Deposits Removal of Soft Deposits Removal of Hard Scales Ca Co,
Stainless Steel, Titanium Tubes Copper & Brass Tubes Cupronickel & SS Tubes
Ordering Data Example

Nominal Ball Ball Mixture Ball Ball Diameter
25 Diameter (mm) RS Type RS 15 Colour 15 M Texture 0 Tolerence Range 0
25 Standard Red Medium Dia + 1 mm, -0
Nominal Dia : Ball size from 8 - 51 mm dia in 1 mm steps. For Ring Coated Balls Coating of 1- 2 mm will be additional to nominal dia
Ball Type Mixture (colour) Ball Texture Tolerence Range

Temperature upto 800 C
Copper &
RS, RSR - Standard Ball 15 - Red S Soft 0 + 1.0 (std)

RSL - Low Sinking Velocity 10 - Yellow - 0
Brass
RA - Ring Coated Abrasive MS Medium Soft

RAT - Fully Coated Abrasive
M Medium 1 + 0.5
RB, RBR - Scouring Ball
Titanium &
20 - Blue - 0
SS Tubes
RG - Ring Coated with fine 15 - Red

granulated plastic MH Medium Hard
High Temperature upto 1400 C
H Hard
RT - Standard Ball 35 - Dark Blue 2 + 1.5
RTA - Ring Coated Abrasive 30 - Fleider SH Super Hard - 0
RTAT - Fully Coated Abrasive
RTL - Low Sinking Velocity
Basic Charge
Basic charge or the number of balls per system is calculated from the number of tubes per pass and the estimated time
interval taken by a ball between two passes of a tube.It is recommended that each tube is cleaned by a sponge ball at an
interval of 5 minutes. For general guidelines,the number of balls to be charged per system is usually around 10% of the total
number of condenser tubes per pass. For batch cleaning system as applicable to Multi Stage Flash distillers,the basic charge
is normally between 30 to 50% of the number of tube per evaporator.
Selection of Ball Size Ball Texture

The normal diameter of the cleaning ball selected is usually The choice of optimum ball hardness is dictated by the need
1 to 3mm oversize in diameter to the inner diameter of the to be able to catch the balls on the screens, recirculate them
tube. However, the oversize of the ball selected depends on and good ball life ( the softer the balls , the greater the
the available pressure drop across the condenser/ Heat permitted ball oversize for a given pressure drop, and thus
exchanger tube. the longer the ball life).The most commonly used cleaning
ball is the “medium” grade.
Storage
Ball Distribution
It is important that cleaning balls be stored in a cool, dry
place,away from direct sunlight. Do not stack more than 2 Distribution of balls in the condenser / heat exchanger is
boxes and the balls are to be used in First in First out basis. influenced by factors such as ball injection in c.w. inlet, the
With proper storage, the shelf life of cleaning balls can be c.w. flow conditions in the waterbox Schmitz cleaning balls
two years from manufacturing. are chosen also for optimising the ball distribution by
mixing ball types of different sinking velocities.
Ball Life
Advisory Service
Ball life is strongly dependent on the cleaning frequency
and the surface condition of the tubes to be cleaned. It is Our Specialists will gladly answer your queries regarding the
typically about 4 weeks, but can be much longer selection and use of schmitz clenaing balls. Contact us
depending on local conditions and frequency of cleaning. directly or via your local agent.
Scaled and corroded surface have a particularly detrimental
effect on ball life. The use of other types of balls e.g., abrasive
balls, to polish roughened surfaces should be considered in
case of excessive ball wear.
GEA BGR Energy System India Limited

Office No. 443, Anna Salai, Teynampet,
Chennai - 600018, Tamil Nadu, India.
For Enquiry : [email protected]
For Service : [email protected]
For Spares : [email protected]
BALL RECIRCULATING MONITOR
Monitoring Unit for sufficient Cleaning Balls

FOR BALL RECIRCULATING MONITOR
CONTENTS
1 PURPOSE ................................................................................................................................................. 3
2 DESIGN ................................................................................................................................................... 3
3 PARTS & FUNCTIONS ........................................................................................................................ 3
4 PRINCIPLE OF OPERATION ............................................................................................................. 4
5 INSTALLATION .................................................................................................................................... 4
6 PRE-COMMISSIONING CONDITIONS ......................................................................................... 5
7 PRE-REQUEST........................................................................................................................................ 5
8 START-UP ............................................................................................................................................... 5
9 CALIBRATION ...................................................................................................................................... 6
9.1 SETTINGS ...................................................................................................................................................... 6
10 OPERATION ....................................................................................................................................... 7
11 BRM MEASURING COUNTER...................................................................................................... 8
11.1 SALIENT FEATURES ................................................................................................................................... 8
11.2 DIP SWITCH SETTING ............................................................................................................................... 9
12 PHOTO ELECTRIC SENSOR ........................................................................................................ 10
12.1 SALIENT FEATURES ................................................................................................................................. 10
12.2 SENSOR PARTS & FUNCTIONS ............................................................................................................ 11
12.3 GUIDE LINES FOR SENSOR ALIGNMENT ........................................................................................ 11
12.4 GUIDELINE FOR SENSITIVITY ADJUSTMENT PROCEDURE ..................................................... 12
13 SAFETY AND GENERAL NOTES................................................................................................ 13
13.1 SENSORS ...................................................................................................................................................... 13
13.2 BRM FIELD UNIT ....................................................................................................................................... 13
13.3 MEASURING COUNTER ......................................................................................................................... 13
14 STORAGE .......................................................................................................................................... 14
15 PREVENTIVE MAINTENANCE SCHEDULE ........................................................................... 14
16 SHUTDOWN PROCEDURES ....................................................................................................... 14
17 TROUBLESHOOTING ................................................................................................................... 15
18 SPARE PARTS .................................................................................................................................. 16
19 BRM GENERAL ARRANGEMENT ............................................................................................. 17
20 BRM – 2K WIRING DIAGRAM ................................................................................................... 18
DES/OMM/BRM Sheet 2
1 PURPOSE
The GEA-BGR Condenser On Load Tube Cleaning System (COLTCS) maintains the condenser tube
cleanliness and constant heat transfer & corrosion-free operation by engaging sufficient number of
oversize sponge cleaning balls in the system.
GEA-BGR ball recirculating monitor (BRM2K) is stand-alone in operation and a user friendly
instrument. This continuously monitors the sufficient number of cleaning balls in circulation in the
condenser. BRM initiates an alarm when the number of circulating balls falls below the set value
while the preset measuring time elapses.
2 DESIGN
 BRM comprises a compact non-metallic field assembly unit with internal configuration
corresponding to the nominal diameter of the ball transport pipe.
 Ball counting is made free from any mechanical contact with use of light barrier sensor. These
sensors are mounted diametrically opposite in the housing. BRM is an easy and maintenance-free
instrument as no moving parts are involved.
 Ball monitor counter is mounted on the control panel mimic facial for easy operation, which
receives the signals from the field sensor unit and displays the status.
3 PARTS & FUNCTIONS
The sensor emits strong infrared light beam from its light-emitting transmitter, which is received at
the receiver end. Thrubeam type photo sensor is used to measure the change in light quantity caused
by the ball crossing the optical axis.
The photoelectric sensor employs the pulse light emission method, which ensures stable operation
even in strong external light and measures in extremely turbid cooling water flow.
Objects, which are bigger than Dia 10mm are identified as a cleaning object.
DES/OMM/BRM Sheet 3
Salient feature of BRM2K is capable of handling both Sponge and Abrasive Balls without affecting
the Sensor Assembly, which is protected by toughened glasses. Hence, the sensor need not be
removed while Abrasive balls are in use.
4 PRINCIPLE OF OPERATION
After sponge cleaning balls are circulated in the condenser tubes, balls are retrieved from the main
cooling water outlet stream through Ball Strainer. And this will be recirculated in the ball transport
line using Ball recirculation Pump. Ball recirculating monitor is fixed in the ball transport pipe line.
The balls will be passing through Ball recirculation monitor.
As the sensor is mounted at the middle of housing, all the balls passing through BRM will not be
counted. The balls which interrupts the sensor only will be counted. As the BRM is working on
statistical analysis principle, this sample counting is adequate for satisfactory results.
During commissioning stage GEA BGR engineer will establish the set value by counting the number
of cleaning balls passing the sensor for a duration of 10 minutes. And the set value will be arrived
by various trials and averaging the counts. And this value will be set in the Ball Counter which is
mounted in the control panel.
Ball recirculation Monitor is designed such that whenever the operator switches ‘ON’ the BRM
sensor will ON and continue to count the balls for the duration of 10 minutes and comes to OFF
condition after 10 minutes automatically.
At any point of time during the ball circulation, if the operator wants to ensure the availability of
sufficient quantity of balls in the system, he has to switch ON the BRM MANUALLY. Now BRM
continues to count the balls for the duration of 10 minutes and comes to OFF condition. If the actual
count in the Ball counter meets the set value, it is considered that there is sufficient quantity of
cleaning balls in the system. If it is not met there will be alarm which indicates there is no sufficient
number of balls in the system. Then operator has to intervene and find the root cause for less number
of balls and to replenish with good balls.
5 INSTALLATION
Installation Instructions
 Check for damage free condition of the equipment during storage

 Careful handling and transportation of equipment to the installation spot without any damage
 No special tools are required for assembly and installation
General Precautions
 Avoid the contact of ferrite material or tools with stainless steel to prevent corrosion
 Lubricate the O-rings with silicon-based grease
 Apply thin layer of grease/molly coat to all external bolts and nuts before assembly
 Apply Loctite 2701 to all the internal bolts and nuts for assembly
 Strictly observe required tightening torque of different bolts/nuts
DES/OMM/BRM Sheet 4
Mechanical
 Generally, BRM will be a part of the Ball Recirculating Skid. Otherwise, BRM field unit to be
installed as per installation drawing.
 BRM field unit is normally installed before Ball Vessel.
 BRM field unit counter flanges to be uniformly tightened crosswise to avoid leak and damage.
Electrical
 Measuring counter installed in the Control Panel.

 BRM connections to be made as per wiring diagram. Be sure to limit the length of shield cable
extension within 100mtrs between sensor and counter for best results.
 Check and record the supply voltage for measuring counter and sensor respectively
 Supply
Counter – 240 V AC, 50 – 60 Hz (9.2VA MAX)
Sensor – 12 V DC + 10% (100 mA MAX)
6 PRE-COMMISSIONING CONDITIONS
 COLCTS should be commissioned along with the commissioning of power plant

 In case of retrofit, the condenser should be jet cleaned thoroughly and remove loosen scales and
debris
 C.W. system should be free from debris without any choking, which enables effective circulation
of balls
 Check the Cooling Water Flow as specified in the Technical Data Sheet, to ensure required DP
across the condenser for ball movement.
7 PRE-REQUEST
 Check the Isolation Valves in open position
 Check the System watered and vented
 Check the Control Panel is energized
 Check the screen in operating position
 Check measuring time in HMI as 10 mins
 Check for basic charge fill-in
8 START-UP
 Recirculating pipes should be watered and vented.

 Fill the ball vessel with one full basic charge as specified in the Technical Data Sheet.
 Press push button lamp test, check all lamp glows on the mimic facial for healthy condition.
 Switch ON push button BRM “ON”, monitor counter LCD display and sensor LED’s lights.
 Enter the required set value in the ball monitoring counter.
 Start B.R. Pump in Manual/Auto mode
DES/OMM/BRM Sheet 5
 Balls are injected into the system as the ball vessel outlet valve is fully opened
 Start BRM manually after 10 minutes of interval to ensure good ball distribution on the tube
sheets and uniform ball circulation in the system.
9 CALIBRATION
BRM has to be calibrated during initial start-up. Further calibration can be made whenever the new
operating condition changes.
9.1 SETTINGS
 Fill the ball vessel with required basic charge of cleaning balls.
 Put the system in AUTO ON condition.
 Wait for 30 minutes to have the uniform ball circulation in the condenser.
 Switch ON the BRM. Now, the counter will start counting the cleaning balls.
 BRM will come to OFF condition automatically after 10 minutes (BRM is preprogrammed to
switch off after 10 minutes of operation).
 Note down the counter reading and enter in the table.
 Repeat this exercise ten times and enter the counter readings.
 Arrive the average of 10 readings.
 Set the counter value to 80% of the average value arrived by calibration.
SAMPLE MEASURING TABLE

No. of Counting Count Value
Test Time(Min.) (Nos)* Notes
Cycles
1 10 1500
2 10 1450
3 10 1550  Cleaning Balls travel with same velocity of cooling water flow
4 10 1600  Cleaning Balls take approximately 30-40 seconds to complete
5 10 1500 one cycle
 Cycle time always marginally varies as the bunch of ball travel
6 10 1500
at a time (or)
7 10 1450
 Possibility for prolonged stay of some balls in the circuit (or)
8 10 1550
 Fluctuation in the C.W. Pump that causes the change in flow
9 10 1600 velocity.
10 10 1500
Total Count Value 15200
Average Count Value 1520
Say Set Count Value in the BRM Counter - 1520x 80% = 1216 Nos.
* Counter reading shown above is only illustrative for understanding purpose.
DES/OMM/BRM Sheet 6
10 OPERATION
After setting the counter value, BRM can be operated during Normal Operation. Whenever we want
to count the number of balls following sequences has to be followed.
a) Press the BRM ON push button in the Mimic on the panel manually during Normal
operation of the system. BRM on indication will be illuminated in the panel.
b) Previous set value in the counter will be rested on by pressing the BRM ON pushbutton.
c) BRM Counting timer will be started (Adjustable internal PLC timer – 10 Minutes).
d) BRM Counter will start receiving the count input from the field sensor and counting of balls
started which can be viewed on the BRM counter.
e) After the elapse of counting time, BRM ON indication will go off and BRM OFF indication
will be ON.
f) Counting of balls will be stopped since 12-24V DC supply to sensor is stopped.
g) During 10 Minutes of operation, if healthy feedback is received from counter (i.e., the set
value in the counter is met), the system is considered to be operating with sufficient number
of balls.
h) During 10 Minutes of operation, if healthy feedback is not received from counter (i.e., the set
value in counter is not met), the system is considered to be operating with insufficient
number of balls. Then, BRM fail indication will glow. Operator has to press reset pushbutton
in the panel to switch off the BRM fail indication. The operator has to stop the system to
replenish the required no. of balls and start the system again.
Note : The BRM can be operated and monitored only from BRM Local Panel.
DES/OMM/BRM Sheet 7
11 BRM MEASURING COUNTER
 Bright backlight negative LCD display enables higher visibility under both dark & bright lighting
conditions.
 Programmable PV color indication change in output status are visually indicated by switching
the PV display color from red to green or vice versa, enable to check the output status from a
distance.
 Ergonomic up-down rocker keys enable to change setting values. (6-digits) & DIP switch.
 NPN switchable input.
 Six – language programme instruction.
 Weather protection IP66 / NEMA4 for front panel.
DES/OMM/BRM Sheet 8
11.2 DIP SWITCH SETTING
Setting Functions can be either in DIP switch mode or internal function settings. If the internal
function setting is opted, the DIP Switch Pin 1 should be in disabled (OFF) mode. It is
generally recommended to perform the settings with the operation keys.
DIP Switch Setting

Ensure that the power is turned OFF before changing DIP switch settings. Change DIP switch settings with the power
turned ON may result in electric shock due to contact with terminals subject to high voltages.
DES/OMM/BRM Sheet 9
How to Mount

1. Insert the controller through the panel cutout.
2. Insert the mounting bracket into the mounting groove at the top and bottom of the controller
and push the mounting bracket forward until the bracket stops at panel wall.
3. Insert and tighten screws on bracket to secure the controller in place.
Parameters Setting
12 PHOTO ELECTRIC SENSOR
A photoelectric sensor emits a light beam either visible or infrared from its light-emitting
transmitter. These photoelectric sensors employ the pulse light beam emission method with use of
infra red LED. Thrubeam type is used to measure the change in light quantity caused by the ball
crossing the optical axis.
 Compact in size
 Long-detecting distance
 Stable detecting position
 Powerful beam
 Opaque objects detectable regardless of shape, color or material.
DES/OMM/BRM Sheet 10
12.2 SENSOR PARTS & FUNCTIONS
Caution ! Do not hit the Sensor with hard materials such as hammer.
This may downgrade the degree of protection.
The sensors are waterproof (IP 67). However this does not mean the
detection is possible under water or in rain.
12.3 GUIDE LINES FOR SENSOR ALIGNMENT
The photoelectric sensors employ the pulse light emission method, which ensures stable operation
even when external light is strong and also harsh environment. The sensor emits infrared light beam
from its light-emitting transmitter, through beam type photo sensor is used to measure the change
in light quantity cause by the target crossing the optical axis.
 Set the operation mode switch to the Light-ON mode position (L side).
 Placing the emitter and the receiver face to face along a straight line. Move the emitter up, down,
left and right to determine where light is received with the help of the receiver’s operation
indicator (orange). Set the emitter in the middle of this area.
 Adjust the angle of the emitter by twisting it up, down, left and right.
 In a similar manner, adjust the angle of the receiver.
 Check that the stability indicator (green) lights up.
 Choose the desired operation mode, Light-ON or Dark-ON, with the operation mode switch.
12.4 GUIDELINE FOR SENSITIVITY ADJUSTMENT PROCEDURE
This procedure assumes that “Light-ON” is set for the operation mode.
If “Dark-ON” is the operation mode, the output will behave the other way around!
Sensitivity
Step Description
adjuster
Turn the sensitivity adjuster fully counterclockwise to the minimum

1 sensitivity position, MIN.
In the “light received” condition, turn the sensitivity adjuster slowly

clockwise to find point A where the sensor output turns ON.*1
2
In the “dark” condition, turn the sensitivity adjuster clockwise until the
sensor output turns ON.*1
3 Turn it back slowly to confirm point B, where the sensor output just turns
OFF.*1 If the sensor output does not turn ON even when the sensitivity
adjuster is turned fully clockwise, point B is the position at MAX.
The position exactly between points A and B is the optimum sensing

position.
4
1 Remember, this only applies if the operation mode is Light-ON.

*
Caution : Do not turn the receiver sensitivity adjuster beyond the specified range (0-
240º). If may so it cause mal function in sensitive adjustment. Do not use
metallic screwdrivers for adjusting the trimmer. Use only plastic
screwdrivers.
13 SAFETY AND GENERAL NOTES
13.1 SENSORS
 Handle the sensor carefully when mounting. Strong impact to the sensor head may damage the
sensor’s waterproof capability.
 The sensors enclosure are weatherproof, this does not mean the detection is possible under water
or in moist condition.
 Do not use voltage in excess of the operation voltage range (24V DC). It may result in internal
elements fail or burn of the sensors.
 Isolate the sensor wiring from power lines and high voltage lines; otherwise, the sensor may
malfunction due to noise interference.
13.2 BRM FIELD UNIT
 Use the attached mounting bracket to install and fix the sensor.
 Mount the sensor and fasten the screws at a tightening torque of 0.5nm (Max.)
 To ensure safety, be sure to observe the following :
 Avoid installing the BRM field unit in locations where there is a possibility of direct contact
with water, oil, corrosive gas or chemical splash
 Avoid exposure to strong magnetic or electric fields
 Avoid location with high humidity and a possibility of condensation
 Avoid location subject to vibration or shock
13.3 MEASURING COUNTER

 Do not use the counter in locations subject to dust, corrosive gases, or direct sunlight.
 Separate the input signal devices, input signal cables, and the counter from the source of noise or
high-tension cables producing noise.
 Organic solvents (such as paint thinner), as well as very acidic or basic solutions might damage
the counter front panel.
 Use the counter within the ratings specified for temperature and humidity.
 Do not use the counter in locations where condensation may occur due to high humidity or where
temperature changes are severe.
 Store at the specified temperature. If the counter has been stored at a temperature of less
than -10ºC, allow it to stand at room temperature for at least 3 hours before use.
Caution ! Be sure to turn OFF the BRM power before replacing any component.
It is recommended to take substantial safety measures to avoid any damage
in the event a problem occurs.
14 STORAGE
 Keep the BRM in a cool and dry place

 Wrap the equipment air tightly in a polythene sheet and place it in a wooden box
 Provide Silica gel bags to avoid any moisture content
 Keep the BRM away from the heat and direct sunlight
15 PREVENTIVE MAINTENANCE SCHEDULE
FREQUENCY PERSONS
S.NO. COMPONENTS INSPECTION
OF CHECK RESPONSIBLE
Check LCD Visible Display and
Weekly Electrician
confirm the correct set value
01 Counter Overall visual inspection Weekly Electrician
Check counter cable connection
Yearly Electrician
& TB
Overall visual inspection Weekly Electrician
Housing external damage, sign
Yearly Mechanic
of corrosion
Check wear and Tear of Inlet,
outlet spool piece ‘O’ Rings, bolt
Yearly Mechanic
BRM Field sensor & nut check and replace if
02
assembly unit require.
Inspect general condition of
Yearly Mechanic
polymer block & fasteners.
Check proper cable connection Monthly Electrician

Instrument
Check sensor alignment & clean Monthly
Technician
03 Cleaning Balls No. of Cleaning Balls Weekly Mechanic
16 SHUTDOWN PROCEDURES
 Switch off BRM

 Shutdown TCS operation
 Shut off isolation ball valves at Ball Strainer and injection
 Open vent and drain valves at ball collector and ball recirculating pump to drain out the water
 Follow the start-up procedure to resume the BRM operation
Precautions to prevent corrosion during prolonged shut-down
 The resistance of Stainless steel may be affected in corrosive water

 During prolonged shut-down, stagnated water causes pitting corrosion
 Drain the water in the system, viz., I.C. pipes, pumps, ball vessel and BRM, etc.
 Flush it with the clean water and keep the equipment dry
17 TROUBLESHOOTING
S.NO. FAULT PROBABLE CAUSE REMEDY

 No power supply  Check incoming supply at
BRM counter.
BRM Counter no  Cabling Fault  Check cable and connections
01
Indication or dead repair if necessary.
 Fuse blown  Check and replace fuse.
 No power supply  Check 12V DC supply from
counter
BRM Field sensor  Check 12VDC supply in sensor
02 no Indication or PCB.
dead
 Cabling Fault  Check shielded cable and
connection, repair if necessary.
 Are the wiring & connection  Check wiring polarity and
correct. correct supply voltage.
 Is any of the Mounting screw  Check and tightened the
Sensor Does not loose? mounting bracket screws.
03
operate  Are the optical axis and the  Realign sensor and adjust the
sensitivity adjusted sensitivity.
correctly?
 Sensor fail.  Check & Replace the sensor.
 Set value too low.  Check & adjust set value to
required ball quantity.
 Check measuring time, adjust
to the required average set
time.
 Total Basic ball quantity low.  Check and replace ball qty.
 Ball circulation discontinued.  Sudden ball loss due to CW
BRM Fail Alarm pump trip.
04 appears  Check screen in perfect
continuously operating position.
 Check dead spot in condenser.
 Check for tap off points and
screen it suitably.
 Balls are not in circulation.  Balls not charged.
 B.R.Pump / Outlet valve are
not in service.
 Screen in back wash position.
S.NO. FAULT PROBABLE CAUSE REMEDY

 Sensor cables are not  Check sensor cable and
connected. connect properly.
Measuring value  Sensor dirt & dust  Clean sensor lens.
05
zero  Check & Realign sensor.
 Sensor Misalignment.  Check counter count input
from sensor.
18 SPARE PARTS
Quantity
S. No. Description
per BRM
1 Sensor 1 Set
2 Counting Monitor 1 No.
3 Sensor PCB 1 No.
4 ON/OFF Push Button 2 Sets
19 BRM GENERAL ARRANGEMENT
20 BRM – 2K WIRING DIAGRAM
DES/OMM/BRM XXI

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Rev No Date Description Prepared Checked Approved

A 25-07-2022 FOR INFORMATION SANTHOSH.K SUDHARSAN.I RAVIKUMAR.N

Purchaser : SIEMENS ENERGY BRASIL LTDA

EQUIPMENT NAME : CONDENSER TUBE CLEANING SYSTEM

PROJECT: CERRADO (43150 &

PREPARED CHECKED APPROVED DOCUMENT NO REV

KS IS NRK GI 5320 100 09 021 A

Operation and Maintenance Manual -

OPERATION & MAINTENANCE MANUAL FOR AUTOMATIC DES/OMM/TCS/DS

GI 5320 100 09 021

OPERATION & MAINTENANCE MANUAL

This Manufacturer’s manual provides information regarding the Operation

Failure to observe the information provided herein may result in

Contents of the manual are subject to change without notice

Wherever the term “Condenser” used in the manual is applicable to Heat

This Technical Document is the property of GEA BGR and protected in

SECTION 1 INTRODUCTION .............................................................................................................. 4

SECTION 2 DESCRIPTION OF COMPONENTS ............................................................................. 6

SECTION 3 PRECONDITION ............................................................................................................. 11

SECTION 4 REQUIRED TOOLS & TACKLES ................................................................................ 14

SECTION 8 SERVICE & MAINTENANCE ....................................................................................... 30

1.1 CONDENSER TUBE CLEANING SYSTEM

The main advantages of a Tube Cleaning System are :

 Maintain the Heat Transfer Rate

 Erection, Commissioning work, modifications to the system(s), instructions to the operating

OUR PRODUCT WARRANTY WILL BE NULL AND VOID IN CASE OF

 Incorrect Installation, disregard or incorrect application of instructions provided in this manual

For advice please contact :

SECTION 2 DESCRIPTION OF COMPONENTS

2.1 BALL SEPARATOR (BALL STRAINER)

2.1.1 OPERATION POSITION

2.1.2 BACKWASH POSITION

OPERATION POSITION BACKWASH POSITION

2.2 D.P. MEASURING SYSTEM

2.3 BALL RECIRCULATING SKID

The Ball Recirculating Skid consists of

2.4 V-PIECE (BALL DISTRIBUTOR)

2.5 MANUALLY OPERATED VALVES

2.6 ACTUATOR OPERATED VALVES

2.7 BALL TRANSPORT PIPING

2.8 CLEANING BALLS

Used but effective balls should always be kept in the water.

2.9 BALL GAUGE / BALL GAUGE TROLLEY

2.10 INJECTION PIPE

2.11 OTHER OPTIONAL COMPONENTS

2.11.1 BALL MONITORING SYSTEM (BALL OVERSIZE MONITOR)

2.11.2 BALL RECIRCULATING MONITOR

2.11.3 BROM (COMBINED BALL RECIRCULATING + OVERSIZE MONITOR)

2.11.4 DP BALL SORTER

2.11.5 CONTROL PANEL

2.11.6 STARTER PANEL

3.1 GENERAL INSTRUCTIONS

3.2 PRESERVATION / STORAGE

3.2.1 EQUIPMENT & ACCESSORIES

Equipment should be kept away from the flammable items.

3.2.2 ELECTRICAL & ELECTRONIC ITEMS

3.2.3 INSTRUCTIONS DURING SHUTDOWN DURING CW SYSTEM MAINTENANCE

Flush the Ball Separator Screen with Service water.

Ensure that the Ball Separator Screen is clean and dry.