valve position indicator - auma

Valve position indicatorWSG 90.1

for part-turn gearboxes

GS 50.3 – GS 250.3

GS 315 – GS 500

and lever gearboxes

GF 50.3 – GF 250.3

Operation instructions

Table of contents Page

1.Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1. Range of application 31.2. Commissioning (electrical connection) 31.3. Maintenance 31.4. Warnings and notes 3

2.Short description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.1. Transport 54.2. Storage 54.3. Packaging 5

5.Mounting to gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.1. Removing the protection cover or pointer cover 65.2. Part-turn gearboxes GS 50.3 – GS 125.3 and lever gearboxes GF 50.3 – GF 125.3 75.3. Part-turn gearboxes GS 160.3 – GS 250.3 and GS 315 – GS 500 and lever gearboxes GF 160.3 – GF 250.3 85.4. Foreign gearboxes 8

6.Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1. Connection with AUMA plug/socket connector in crimp version 96.2. Heater 9

7.Switch compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.1. Opening the switch compartment 107.2. Closing the switch compartment 10

8.Changing the settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.1. Power supply of output contacts 118.2. Clockwise and counterclockwise closing 12

9.Checking and setting the end position detection . . . . . . . . . . . . . . . . . . . . . . . . 139.1. Standard swing angle (82° to 98°) 139.2. Special swing angle (option) 159.3. Re-adjust control disc 16

10.Setting of mechanical position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

11.Setting the potentiometer (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

12.Setting the electronic position transmitter RWG (option) . . . . . . . . . . . . . . . . . . . . 1912.1. Setting 2-wire system 4 – 20 mA and 3- or 4-wire system 0 – 20 mA 2012.2. Setting 3- or 4- wire system 4 – 20 mA 21

13.Enclosure protection IP 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

14.Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

15.Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

16.Disposal and recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

17.Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

18.Declaration of Conformity and Declaration of Incorporation . . . . . . . . . . . . . . . . . . 24

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Valve position indicator WSG 90.1 Operation instructions

Scope of these instructions: These instructions are valid for the valve position indicator WSG 90.1 formounting to an AUMA part-turn gearbox of type ranges:GS 50.3 – GS 250.3, GS 315 – GS 500,and AUMA lever gearboxes of type ranges:GF 50.3 – GF 250.3.It is furthermore possible to mount the unit to foreign gearboxes.

1. Safety instructions1.1. Range of application AUMA valve position indicators are designed for indicating the position and the

final position of AUMA part-turn gearboxes of type ranges GS 50.3 – GS 250.3,GS 315 – GS 500 and AUMA lever gearboxes GF 50.3 – GF 250.3.For other applications, please consult us. The manufacturer is not liable forany possible damage resulting from use in other than the designated appli-cations. Such risk lies entirely with the user.Observance of these operation instructions is considered as part of thegearboxes’ designated use.

1.2. Commissioning(electrical connection)

During electrical operation, certain parts inevitably carry lethal voltages.Work on the electrical system or equipment must only be carried out by askilled electrician himself or by specially instructed personnel under thecontrol and supervision of such an electrician and in accordance with theapplicable electrical engineering rules.

1.3. Maintenance The maintenance instructions (refer to page 23) must be observed, other-wise a safe operation of the valve position indicator is no longer guaranteed.

1.4. Warnings and notes Failure to observe of the warnings and notes may lead to serious injuries ordamage. Qualified personnel must be thoroughly familiar with all warningsand notes in these operation instructions.Correct transport, proper storage, mounting, and installation, as well ascareful commissioning are essential to ensure a trouble-free and safeoperation.The following references draw special attention to safety-relevant proce-dures in these operation instructions. Each is marked by the appropriatepictograph.This pictograph means: Note!“Note” marks activities or procedures which have major influence on thecorrect operation. Non-observance of these notes may lead to consequen-tial damage.This pictograph means: Electrostatically endangered parts!If this pictograph is attached to a printed circuit board, it contains partswhich may be damaged or destroyed by electrostatic discharges. If theboards need to be touched during setting, measurement, or for exchange, itmust be assured that immediately before a discharge through contact withan earthed metallic surface (e.g. the housing) has taken place.This pictograph means: Warning!“Warning” marks activities or procedures which, if not carried out correctly,can affect the safety of persons or material.

2. Short descriptionAUMA valve position indicators type WSG 90.1 are designed for continuous,mechanical position indication and electric position feedback.To generate swing movements of 90°, it is often required to implementmulti-turn actuator - part-turn gearbox combinations. When using thesecombinations, the valve position is transmitted to the limit switching withinthe multi-turn actuator via several steps.In applications where intermediate positions are required, e.g. for controlvalves, a hysteresis is obtained when cumulating the sum of all backlashes.This means that for an identical nominal value, the switching point in direc-tion OPEN deviates from the switching point in direction CLOSE. If the appli-cations requires high position accuracy, this effect has a negative impact.This drawback can be avoided when using valve position indicatorWSG 90.1. Direct coupling to the worm wheel of the gearbox enablesprecise, low-backlash position feedback.

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Operation instructions Valve position indicator WSG 90.1

3. Technical data

Features and functionsVersion Clockwise closing, counterclockwise closingSwing angle Standard: 90° adjustable within a range of ± 8 °;

Set in the factory to 90°, unless ordered otherwise.Options: 34° – 50°1), 50° – 66°, 66° – 82°, 98° – 130°, 130° – 180°; infinitely adjustable

Power supply 24 V DC +/– 15 % smoothed, max. 80 mAOutput signals Contactless end position switches (Hall sensors) for end positions OPEN and CLOSED

Standard: 2 potential-free signal relays with one common, for signallingthe end position OPEN, the end position CLOSEDmax. 250 V AC, 3 A (resistive load), min. 12 V, 10 mA

Option: RWG with max. 250 V AC, 3 A (resistive load), min. 5 V, 10 mAPosition feedback, analogue(option)

Potentiometer: Film potentiometer, 5 kΩ/ 0,5 W/linearity ± 0.5 %Wire wound potentiometer 5 kΩ/ 1.5 W/linearity ± 0.5 %

Position transmitter: Electronic position transmitter RWG0/4 – 20 mA in 3- or 4-wire version4 – 20 mA in 2-wire versionFor further information regarding the RWG, refer to page 19

Mechanical position indicator Standard: Continuous indicationOption: Adjustable indicator disc with symbols OPEN and CLOSED

Heater in switch compartment Self-regulating PTC heater, 5 – 20 W110 – 250 V DC/ DC or24 – 48 V DC/AC

Electrical connection Standard: AUMA plug/socket connector with crimp type connectionThreads for cable glands Standard: 1 x M 20 x 1.5, 1 x M 25 x 1.5

Options: Pg-threads, NPT-threads, G-threadsTerminal plan APG AP301 (basic version)Service conditionsEnclosure protection accordingto EN 60 5291)

Standard: IP 68-3, dust and water tight up to max. 3 m head of waterOptions: IP 68-6, dust and water tight up to max. 6 m head of water

Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plantswith a low pollutant concentration

Options: KS Suitable for installation in occasionally or permanently aggressiveatmosphere with a moderate pollutant concentration(e.g. in wastewater treatment plants, chemical industry)

KX Suitable for installation in extremely aggressive atmosphere with highhumidity and high pollutant concentration

Finish coating Standard: Two-component iron-mica combinationColour Standard: Grey (DB 702, similar to RAL 9007)

Option: Other colours are possible on requestAmbient temperature Standard: – 25 °C to + 80 °C

Options: – 25 °C to + 70 °C (in combination with position transmitter RWG)Mounting to gearbox Standard: AUMA part-turn gearboxes GS/ lever gearboxes GF with AUMA adapter

Delivery for mounting to foreign gearbox without adapter or retrofit-kitOption: Subsequent mounting to AUMA part-turn gearboxes GS/ lever gearboxes GF

including AUMA retrofit-kitOther informationEU Directives Electromagnetic Compatibility (EMC): (89/336/EEC)

Low Voltage Directive: (73/23/EEC)Machinery Directive: (98/37/EC)

Reference documents Product description Worm gearboxes GS 50.3 – GS 250.3 / GS 315 – GS 500Product description Lever gearboxes GF 50.3 – GF 250.3

1) Swing angle resolution limited at potentiometer2) Refer to enclosure protection IP 68 clause

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4. Transport and storage4.1. Transport .Transport to place of installation in sturdy packing..For products equipped with handwheel, do not attach ropes or hooks to

the handwheel for the purpose of lifting by hoist.. If the valve position indicator and gearbox are mounted on the valve,attach ropes or hooks for the purpose of lifting by hoist to the valve andnot to the position indicator/gearbox.

4.2. Storage .Store in well-ventilated, dry room..Protect against floor dampness by storage on a shelf or on a woodenpallet..Cover to protect against dust and dirt..Apply suitable corrosion protection agent to bright surfaces.

In case valve position indicator is to be stored for a long period(more than 6 months), the following points must imperatively andadditionally be observed:.Prior to storage: Protect bright surfaces, in particular the output drive parts

and mounting surface, with long-term corrosion protection agent..Check for corrosion approximately every 6 months. If first signs of corro-sion show, apply new corrosion protection.

After mounting the valve position indicator, connect the unit immediately toelectrical mains, so that condensation is prevented by the heater.

4.3. Packaging Our products are protected by special packaging for the transport ex works.The packaging consists of environmentally friendly materials which caneasily be separated and recycled.For the disposal of the packaging material, we recommend recycling andcollection centres.We use the following packaging materials:wood, cardboard, paper, and PE foil.

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5. Mounting to gearbox If the valve position indicator has already been mounted to the gearbox atthe time of delivery, the mounting description below may be ignored.For later mounting to AUMA gearboxes, an appropriate retrofit-kit is includedwithin the scope of delivery.

5.1. Removing the protection cover or pointer cover

Part-turn gearboxes and lever gearboxes may be equipped with protectioncover or pointer cover.

For the version with protection cover (figures 1 and 2):.Loosen 4 bolts (17.1) and remove protection cover (17.0).(there are 6 bolts for type range GS 315 to GS 500 – not illustrated).. Insert clamping washer (12) with snap ring (32)..Place actuator plate (3) and fasten with 2 bolts (11.1).

For the version with pointer cover (figures 3 and 4):.Loosen 2 bolts (11.1) and remove pointer cover (11.0).(there are 3 bolts for type range GS 315 to GS 500 – not illustrated).Remove upper O-ring (011) from worm wheel..Unscrew grub screws (C)..Place actuator plate (3) and fasten with 2 bolts (11.1).

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Figure1:Removing theprotection cover

Figure 2: Fitting the actuator plateprotection cover version

Figure 3: Removing thepointer cover

Figure 4: Fitting the actuator platepointer cover version

5.2. Part-turn gearboxes GS 50.3 – GS 125.3 and lever gearboxes GF 50.3 – GF 125.3Remove protection cover or pointer cover (refer to subclause 5.1.)Mount adapter to valve position indicator (figure 5):.Place O-ring (012) onto adapter (2)..Fit adapter (2) to valve position indicator using four bolts M4 (2.1), at a

torque according to table 1. The position of the adapter with reference tothe valve position indicator may be determined as appropriate..Mount coupling from retrofit-kit.

Mount valve position indicator to gearbox (figure 6):.Position valve position indicator into the same position as gearbox (OPEN orCLOSED) by turning the coupling.. Insert O-ring (013) into the groove at the adapter..Apply sealing compound (e.g. Loctite type 573) to the mounting surface atgearbox housing cover..Fit complete valve position indicator using bolts (11.1) and lock washers (04)without major coupling torsion onto gearbox.The position of the valve positionindicator with reference to the gearbox may be determined as appropriate..Fasten bolts crosswise with a torque according to table 1.

.After mounting to gearbox, touch up any possible damageto paint finish.

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Figure 5: Mounting the adapter

012

2.1

Valve position indicator

2

Coupling

Figure 6: Mounting the valve position indicator

013

11.1/04

Valve position indicatorwith adapter

Gearbox

Fastening torque TA [Nm]

Type ScrewsStrength class A2-70/A4-70

A2-70/A4-70 A2-80/A4-80

Adapter M 4 2GS/GF 50.3 M 5 5GS/GF 63.3 – 125.3 M 6 8 10GS/GF 160.3 M 8 18 24GS/GF 200.3 M 10 36 48GS/GF 250.3 M 12 61 82GS 315 – 500 M12 61 82

Table 1: Fastening torques for bolts

5.3. Part-turn gearboxes GS 160.3 – GS 250.3 and GS 315 – GS 500 andlever gearboxes GF 160.3 – GF 250.3

Remove protection cover or pointer cover (refer to subclause 5.1.)

Mount small adapter to valve position indicator (figure 7).Place O-ring (012) onto small adapter (2)..Fit small adapter (2) to valve position indicator using four bolts M4 (2.1), ata torque according to table 1. The position of the adapter with reference tothe valve position indicator may be determined as appropriate.

Mount large adapter to gearbox:. Insert O-ring (4.09) into the groove at the large adapter..Apply sealing compound (e.g. Loctite type 573) to the mounting surface atgearbox housing cover..Secure large adapter with bolts (11.1) and lock washers (04) ontogearbox. The position of the adapter with reference to the gearbox may bedetermined as appropriate..Fasten bolts crosswise with a torque according to table 1.

Fasten Oldham coupling from retrofit-kit:.Mount hub 1 of Oldham coupling (1.4) onto the shaft of the valve positionindicator and fasten with screws..Mount hub 2 onto the shaft of the indicator disc and fasten with bolts.

Mount valve position indicator to gearbox:.Position valve position indicator into the same position as gearbox (OPEN orCLOSED) by turning the coupling.. Insert clutch disc in one of the hubs of the Oldham coupling.. Insert O-ring (013) into the groove on the small adapter (2)..Apply sealing compound (e.g. Loctite type 573) onto the mounting surface..Fasten small adapter (2) using bolts M6 (4.21) and lock washers (04) withoutmajor coupling torsion to large adapter (4.2) (for torques, refer to table 1).

5.4. Foreign gearboxes The valve position indicator WSG 90.1 may also mounted to other gear-boxes. For further information (e.g. dimensions for adapter’s production bycustomer), please contact AUMA.

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Figure 7: Oldham coupling and adapter

2012

013

4.2

2.1

4.21/04

11.1/04

4.09Oldham coupling (1.4):

Hub 1

Clutch disc

Hub 2

6. Electrical connection .Work on the electrical system or equipment must only becarried out by a skilled electrician himself or by speciallyinstructed personnel under the control and supervision ofsuch an electrician and in accordance with the applicableelectrical engineering rules..Before connection check whether type of current and vol-tage fulfil the indications on the wiring diagram

6.1. Connection with AUMA plug/socket connector in crimp version

.Loosen bolts (50.01) (figure 8) and remove plug cover..Loosen screws (51.01) and remove socket carrier (51.0) from plug cover (50.0).. Insert cable glands suitable for connecting cables(The enclosure protection stated on the name plate is only ensured ifsuitable cable glands are used)..Seal cable entries which are not used with suitable plugs..Connect cables according to order-related wiring diagram..The pertaining wiring diagram is attached to the product in aweather-proof bag, together with these operation instructions. In case theterminal plan is not available, it can be obtained from AUMA (statecommission no., refer to name plate) or downloaded directly from theInternet (www.auma.com).

Crimp sockets are supplied separately and in sufficient number inside theplug cover.For crimping, a suitable tool, e.g. the BUCHANAN four indent crimp tool,must be used.

Cross sections:0.75 – 1 mm2, on request 0.5 mm2 or 1.5 mm2

6.2. Heater To prevent condensation within the housing, the heater must be connected.

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Figure 8: Connection

50.0

50.01

51.0

51.01

Technical data Protective earth Control pinsNumber of contacts max. 1 (leading contact) 50 pins/sockets (40 are used)Designation according to VDE A1 to I4Connecting voltage max. – 250 VNominal current max. – 16 AType of customer connection Crimp connection Crimp connectionCross section max. 1.5 mm2 1.5 mm2

Material: Pin/socket carrier Polyamide PolyamideContacts Brass Brass tin-plated or gold-plated (option)

Table 2: Technical data AUMA plug/ socket connecter in crimp version

7. Switch compartment The following subassemblies are located within the switch compartment:

.Relay board with output contacts (page 11).End position detection (page 13).Mechanical position indicator (page 17 ).Potentiometer (option) (page 18).Electronic position transmitter (option) (page 19)

The switch compartment must be opened to perform the setting of thesesubassemblies.

7.1. Opening theswitch compartment

Work on the electrical system or equipment must only becarried out by a skilled electrician himself or by speciallyinstructed personnel under the control and supervision ofsuch an electrician and in accordance with the applicableelectrical engineering rules.

.Remove 4 bolts (A) and take off the cover at the switch compartment(figure 10 or figure 9).

7.2. Closing theswitch compartment

After having worked at the switch compartment:

.Clean sealing faces of housing and cover..Check whether O-ring is in good condition..Apply a thin film of non-acidic grease to the sealing faces..Place cover on switch compartment and fasten bolts evenly crosswise.

Touch up possible defects to paint finish after commissioning.

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Figure 9: Position indicator(standard)

A

Figure 10: Position indicator(special swing angle)

A

8. Changing the settings8.1. Power supply of output contacts

The output contacts K1 and K2 (refer to terminal plan) indicate the end posi-tions OPEN and CLOSED.

The power supply for the output contacts is set in the factory according tothe order data and shown on the terminal plan as follows:

Standard: Voltage supply must be supplied via external circuit:(max. 250 V AC, 3 A resistive load, min. 12 V, 10 mA)Jumper J1 via X5.2 - X5.3Jumper J2 via X6.2 - X6.3

Option: Output contacts are connected to internal voltage (24 V DC):Jumper J1 via X5.1 - X5.2Jumper J2 via X6.1 - X6.2

Change power supply for relay contacts:Attention: In case of change, the supplied terminal plan is no longer valid!.Open the switch compartment.Remove mechanical position indicator..Remove position transmitter board..The power supply may be modified via the jumpers J1 and J2 on the relay

board (figure 11)

Voltage supply must be provided via external circuit(standard)

Output contacts are connected to 24 V DC powersupply (option)

.Fit position transmitter board and set final position detection anew (refer topage 13)..Fit mechanical position indicator and set anew (refer to page 17)..Close switch compartment (refer to page 10).

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3

J1 J2

3

3 3

J1 J2

Figure 11: Relay board

J6/J5

J1/J2

J3/J4

8.2. Clockwise and counterclockwise closing

The direction of rotation (clockwise or counterclockwise closing) is preset inthe factory according to the purchase order and can be identified by meansof the terminal plan number (1st digit before “AP”):

Identification within the wiring diagram:APG- AP... for “clockwise closing”APG-1AP... for “counterclockwise closing”

Change direction of rotation:Attention: In case of subsequent change, the supplied terminal plan is nolonger valid!.Opening the switch compartment.Remove mechanical position indicator..Remove position transmitter board..The direction of rotation may be changed via the jumpers J3 and J6 on the

relay board (figure 11).

clockwise closing

counterclockwise closing

.Fit position transmitter board and set final position detection anew(refer to page 13)..Fit mechanical position indicator and set anew (refer to page 17)..Close switch compartment (refer to page 10).

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1 2 3

4 5 6

1 2 3

4 5 6

12

3

45

6

12

3

45

6

9. Checking and setting the end position detectionThe end position detection is set in the factory according to the swing anglestated in the purchase order. If no swing angle has been stated in thepurchase order, the swing angle is set to 90 ° (standard) in the factory. Alater modification is only required if this value needs to be changed.Prior to setting the end position detection, the end stops in the gearbox mustbe set (refer to operation instructions of the gearbox).If the gearbox is mounted to a multi-turn actuator, the limit swiching of themulti-turn actuator must be set first (refer to operation instructions of themulti-turn actuator).End recognition detection is made in manual operation.

9.1. Standard swing angle (82° to 98°)

9.1.1 Clockwise closing: The following description is only valid for “clockwise closing”, i.e. driven shaftturns clockwise to close the valve.Identification within the wiring diagram:APG- AP... for “clockwise closing”.Switch on the power supply.

End position CLOSED .Move valve to end position CLOSED.The final position detection is correctly set if the yellow LED is illuminatedand the relays (refer to terminal plan) indicate “end position CLOSED”.If this is not the case, correct the end position detection as follows:.Figure 12 : Loosen both screws (01).Now the control disc (02) can be turned for setting.If the yellow LED is fully illuminated, the switching point has been correctlyset.If the LED is only slightly illuminated, the switching point has not yet beenreached.When having turned too far, the yellow LED goes out again.The control disc should be positioned in such a way that it is situatedmidway between the yellow LED lighting up and going out..After the setting procedure, hold the control disc in position and tightenboth screws (01)..Move valve away from the end position..Check setting by approaching the switching point CLOSED anew.. If the switching point is not reached: re-adjust control disc(refer to page 16) and repeat the setting as described above.

End position OPEN .Move valve to end position OPEN.The final position detection is correctly set if the green LED is illuminatedand the relays (refer to terminal plan) indicate “end position OPEN”. If thisis not the case, correct the end position detection as follows:.Loosen screw (04) (figure 3) and pull off control disc (02) (heed parallel key!)..Figure 13: Loosen screw (05) at lower side of control disc.

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MP1

MP2

Figure12: Switch compartmentstandard

01

04

LED green LED yellow

02

03

02

Figure 13: Control disc

Lower side

Lateral view

05

02

.Set indicator dial (03) to required swing angle by turning.(set approx. 3 ° – 4 ° less than the actual swing angle).Fasten screw (05)..Fit control disc (02) while taking care of parallel key and secure with screw (04)..Check setting by approaching the switching point OPEN anew.

9.1.2 Counterclockwise closing: The following description is only valid for “counterclockwise closing”, i.e.driven shaft turns counterclockwise to close the valve.Identification within the wiring diagram:APG-1AP... for “counterclockwise closing”.Switch on the power supply.

End position CLOSED .Move valve to end position CLOSED.The final position detection is correctly set if the green LED is illuminatedand the relays (refer to terminal plan) indicate “end position CLOSED”. Ifthis is not the case, correct the end position detection as follows:.Figure 12: Loosen both screws (01).Now the control disc (02) can be turned for setting.If the green LED is fully illuminated, the switching point has been correctly set.If the LED is only slightly illuminated, the switching point has not yet beenreached.When having turned too far, the green LED goes out again.The control disc should be positioned in such a way that it is (situated)midway between the green LED lighting up and going out..After the setting procedure, hold the control disc in position and tightenboth screws (01)..Move valve away from the end position..Check setting by approaching the switching point CLOSED anew.. If the switching point is not reached: re-adjust control disc(refer to page 16) and repeat the setting as described above.

End position OPEN .Move valve to end position OPEN.The final position detection is correctly set if the yellow LED is illuminatedand the relays (refer to terminal plan) indicate “end position OPEN”. If thisis not the case, correct the end position detection as follows:.Loosen screw (04) (figure 3) and pull off control disc (02) (heed parallel key!)..Figure 13: Loosen screw (05) at lower side of control disc..Set indicator dial (03) to required swing angle by turning.(set approx. 3 ° – 4 ° less than the actual swing angle)..Fasten screw (05)..Fit control disc (02) while taking care of parallel key and secure with screw (04)..Check setting by approaching the switching point OPEN anew.

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9.2. Special swing angle (option)

9.2.1 Clockwise closing: The following description is only valid for “clockwise closing”, i.e. driven shaftturns clockwise to close the valve.Identification within the wiring diagram:APG- AP... for “clockwise closing”.Switch on the power supply.

Setting end position CLOSED.Move valve to end position CLOSED.The final position detection is correctly set if the yellow LED is illuminatedand the relays (refer to terminal plan) indicate “end position CLOSED”. Ifthis is not the case, correct the end position detection as follows:.Figure 14: Loosen both screws (01) in the black section.The upper (transparent) control disc (02) (with symbol ) can beturned for setting:If the yellow LED is fully illuminated, the switching point has been correctlyset.If the LED is only slightly illuminated, the switching point has not yet beenreached.When having turned too far, the yellow LED goes out again.The control disc should be positioned in such a way that it is situatedmidway between the yellow LED lighting up and going out..After the setting: Hold control disc in position and tighten both screws (01)..Move valve away from the end position..Check setting by approaching the switching point CLOSED anew.. If the switching point is not reached: re-adjust control disc(refer to page 16) and repeat the setting as described above.

Setting end position OPEN .Move valve to end position OPEN.The final position detection is correctly set if the green LED is illuminatedand the relays (refer to terminal plan) indicate “end position OPEN”. If thisis not the case, correct the end position detection as follows:.Loosen both screws (03) (in the white section)..Turn lower (black) control disc (04) (with symbol ), until green LEDlights up to indicate switching point OPEN. When having turned too far,the green LED goes out again. The control disc should be positioned insuch a way that it is situated midway between the green LED lighting upand going out..Hold control disc in position and tighten both screws (03)..Check setting by approaching the switching point OPEN anew.

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MP1

MP2

Figure 14: Switch compartment – special swing angle

02

LED yellow01

LED green

03

04

9.2.2 Counterclockwise closing: The following description is only valid for “counterclockwise closing”, i.e.driven shaft turns counterclockwise to close the valve.Identification within the wiring diagram:APG-1AP... for “counterclockwise closing”.Switch on the power supply.

Setting end position CLOSED.Move valve to end position CLOSED.The final position detection is correctly set if the green LED is illuminatedand the relays (refer to terminal plan) indicate “end position CLOSED”. Ifthis is not the case, correct the end position detection as follows:.Figure 14: Loosen both screws (03) in the white section.The lower (black) control disc (04) (with symbol ) can be turned forsetting:If the green LED is fully illuminated, the switching point has been correctly set.If the LED is only slightly illuminated, the switching point has not yet beenreached.When having turned too far, the green LED goes out again.The control disc should be positioned in such a way that it is situatedmidway between the green LED lighting up and going out..After the setting: Hold control disc in position and tighten both screws (03)..Move valve away from the end position..Check setting by approaching the switching point CLOSED anew.. If the switching point is not reached: re-adjust control disc(refer to clause 9.3.) and repeat the setting as described above.

Setting end position OPEN .Move valve to end position OPEN.The final position detection is correctly set if the yellow LED is illuminatedand the relays (refer to terminal plan) indicate “end position OPEN”. If thisis not the case, correct the end position detection as follows:.Loosen both screws (01) (in black section)..Turn upper (transparent) control disc (2.0) (with symbol ), until yellowLED lights up to indicate switching point OPEN. When having turned toofar, the yellow LED goes out again. The control disc should be positionedin such a way that it is situated midway between the yellow LED lighting upand going out..Hold control disc in position and tighten both screws (01)..Check setting by approaching the switching point OPEN anew.

9.3. Re-adjust control disc If the switching point is not reached for end position detection, the controldisc might have to be adjusted again.For correct mounting, both end positions for valve, gearbox, and WSG 90.1must match. Special care must be taken with the WSG 90.1, that the posi-tions of the magnets on the bottom of the control disc (figure 13) match therespective hall sensor of the board for every respective end position,If this is not the case, remove the WSG 90.1 from the gearbox again andadjust the control disc position to the hall sensors. After this, remount theWSG 90.1 with the coupling avoiding to turn the control disc. A slight turningof the control disc might be necessary to match the multitoothing of thecoupling.

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10. Setting of mechanical position indicator

Version with standard swing angle (figure 15):The mechanical position indication is realised using the white pointer belowthe indicator glass of the cover. The pointer setting shows the positionCLOSED or OPEN with respect to the pipeline. Once the cover removed,the symbols OPEN ( ) and CLOSED ( ) on the board show theelectrically set end positions..Move valve to end position CLOSED..Slighlty lift and turn pointer so that it points crosswise to the pipeline.

When changing the mounting position of the gearbox or ofthe valve position indicator, set the mechanical position indi-cation anew, if required.

Version with special swing angle (figure 16):The mechanical position indicator is set anew when setting the end positiondetection (page 15). Consequently, separate settings are not required.

The indication is realised by means of the symbols OPEN ( ) andCLOSED ( ) on both controls discs below the indicator glass. The corre-sponding end position has been reached when the symbol is in alignmentwith the indicator mark on the cover.

The mechanical position indicator can be removed by loosening the screw inthe middle.

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Figure15: Standard

Pipeline

Figure 16: Special swing angle

Pointer

Pipeline

11. Setting the potentiometer (option)

The potentiometer records the valve position.

If an electronic position transmitter (RWG) is installed, the potentiometersetting is performed with the RWG setting (please refer to pages 19 etseqq.)..Move valve to end position CLOSED..Turn potentiometer (R11) counterclockwise until stop is felt.

End position CLOSED corresponds to 0 %, end position OPEN to 100 %..Turn potentiometer (R11) slightly back from the stop..Perform fine-tuning of the zero point at external setting potentiometer(for remote indication).

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MP1

MP2

Figure 17: Standard

MP1

MP2

Figure 18: Special swing angle

R11(Potentiometer)

12. Setting the electronic position transmitter RWG (option)

The electronic position transmitter records the valve position and generatesa current signal between 0/4 and 20 mA, using the actual position valuemeasured by the potentiometer.

After mounting the valve position indicator to the gearbox, the setting mustbe checked (refer to clause 12.1. or 12.2.).

2-, 3-, or 4-wire-system

The 2-wire version (subclause 12.1.) or the 3- or 4-wire version (subclause12.2.) is set in the factory according to the order data.

Dot visible:3- or 4-wire system 0/ 4- 20 mASolder bridges J7 and J8 must be linked.

Dot not visible:2-wire system 4 - 20 mASolder bridges J7 and J8 must be open.

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MP1

MP2

Figure19: Position transmitter board(standard)

Figure 20: Relay board(below position transmitterboard)

S1J7/J8

Wiring diagrams APG AP_ 2 / _ _ _APG1AP_ 2 / _ _ _3- or 4- wire system

APG AP _3 _ / _ _ _APG1AP _3 _ / _ _ _

for 2-wire systemOutput current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mAPowersupply

Uv 24 V DC 14 V DC + (I x RB),max. 30 V

max.current input

I 24 mA at 20 mAoutput current

20 mA

Max. load RB 600 Ω (Uv - 14 V)/20 mA

Table 3: Technical data RWG

12.1. Setting 2-wire system 4 – 20 mA and 3- or 4-wire system 0 – 20 mA.Connect voltage to electronic position transmitter..Move valve to end position CLOSED..Connect ammeter for 0 – 20 mA to measuring points 1 and 2 (figure 21).

The circuit (external load) must be connected(max. load RB), or the appropriate poles at the terminals(refer to wiring diagram) must be linked, otherwise novalue can be measured.

.Turn potentiometer (R11) counterclockwise until stop is felt..Turn potentiometer (R11) slightly back from the stop.

.Turn potentiometer “0” clockwise until output current starts to increase..Turn potentiometer “0” back until the following value is reached:for 3- or 4-wire system: approx. 0.1 mAfor 2-wire system: approx. 4.1 mAThis ensures that the signal remains above the dead and live zero point..Move valve to end position OPEN..Set potentiometer “Rmax.” to end value 20 mA..Approach end position CLOSED anew and check minimum value(0.1 mA or 4.1 mA). If necessary, correct the setting.

20


MP1

MP2

Figure 21

“0” (0/4 mA)

“Rmax.” (20 mA)

Meas.Point 1 (+)0/4 – 20 mA

Meas.Point 2 (–)0/4 – 20 mA

R11(Potentiometer)

12.2. Setting 3- or 4- wire system 4 – 20 mA.Connect voltage to electronic position transmitter..Move valve to end position CLOSED..Connect ammeter for 0 – 20 mA to measuring points 1 and 2 (figure 22).

The circuit (external load) must be connected (max. loadRB), or the appropriate poles at the terminals (refer towiring diagram) must be linked, otherwise no value can bemeasured.

.Turn potentiometer (R11) counterclockwise until stop is felt..Turn potentiometer (R11) slightly back from the stop.

.Turn potentiometer “0” clockwise until output current starts to increase..Turn back potentiometer “0” until a residual current of approx. 0.1 mAis reached..Move valve to end position OPEN..Set potentiometer “Rmax.” to end value 16 mA..Move valve to end position CLOSED..Set potentiometer “0” from 0.1 mA to initial value 4 mA.This results in a simultaneous shift of the end value by 4 mA, so that thetravel range is now 4 – 20 mA..Approach both end positions anew and check setting. If necessary, correctthe setting.

21


MP1

MP2

Figure 22

“0” (0/4 mA)

“Rmax.” (20 mA)

Meas.Point 1 (+)0/4 – 20 mA

Meas.Point 2 (–)0/4 – 20 mA

R11(Potentiometer)

13. Enclosure protection IP 68

Definition According to EN 60 529, the conditions for meeting the requirements ofenclosure protection IP 68 are to be agreed between manufacturer anduser.AUMA devices in enclosure protection IP 68 fulfil the following requirementsin compliance with AUMA definitions:.Duration of submersion in water max. 72 hours. IP 68-3, submersible in water up to 3 m head of water. IP 68-6, submersible in water up to 6 m head of water.Up to 10 operations during submersion

If submersed in other media, additional measures for corrosion protectionmay be necessary; please consult AUMA. Submersion in aggressive media,e.g. acids or alkaline solutions, is not permitted.

Cable glands .For devices with electrical components, appropriate cable glands in enclo-sure protection IP 68 must be used for the entries of electrical cables. Thesize of the cable glands must be suitable for the outside diameter of thecables, refer to recommendations of the cable gland manufacturers.. Instruments are usually supplied without cable glands. For delivery, thethreads are sealed with plugs in the factory..When ordered, cable glands can also be supplied by AUMA at an addi-tional charge. For this, it is necessary to state the outside diameter of thecables..The cable glands must be sealed against the housing at the thread with anO-ring.. It is recommended to additionally apply a liquid sealing material (Loctite orsimilar).

Notes .The enclosure protection IP 68 refers to the interior compartment.. If the valve position indicator is likely to be repeatedly submersed, a highercorrosion protection KS or KX is required.

Commissioning When commissioning, the following should be observed:.Sealing faces of housing and covers must be clean.O-rings of the covers must not be damaged.A thin film of non-acidic grease should be applied to sealing faces.Covers should be tightened evenly and firmly

After ingress of water .Check: In case of ingress of water, dry instrument correctly andcheck for proper function.

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14. Maintenance After commissioning, check valve position indicator for damage to paintfinish. Do a thorough touch-up to prevent corrosion. Original paint in smallquantities can be supplied by AUMA.

AUMA valve position indicators require only very little maintenance.Precondition for reliable service is correct commissioning.

Seals made of elastomers are subject to ageing and must therefore beregularly checked and, if necessary, exchanged.

It is also very important that the O-rings at the covers are placed correctlyand cable glands fastened firmly to prevent ingress of dirt or humidity.

We recommend additionally:. If rarely operated, perform a test run about every 6 months. This ensuresthat the device is always ready to operate..Approximately six months after commissioning and then every year checkbolts between valve position indicator and gearbox for tightness. Ifrequired, tighten applying the torques given in table 1, page 7.

15. Lubrication The valve position indicator is lubricated for life. Therefore, subsequent lubri-cation is not required.

16. Disposal and recyclingAUMA devices have an extremely long lifetime. However, they have to bereplaced at one point in time.The devices have a modular design and may, therefore, easily be separatedand sorted according to materials used, i.e.:.electronic scrap.various metals.plastics.greases and oils

The following generally applies:.Collect greases and oils during disassembly. As a rule, these substancesare hazardous to water and must not be released into the environment..Arrange for controlled waste disposal of the disassembled material or forseparate recycling according to materials..Observe the national regulations for waste disposal.

17. Service AUMA offers extensive services such as maintenance and inspection foractuators. Addresses of AUMA offices and representatives can be found onpage 28 and on the Internet (www.auma.com).

23


18. Declaration of Conformity and Declaration of Incorporation

24


BiererI

ze_ei_ko_wsg_wgd_wsh_en

25


IndexCCorrosion protection 5,23Cross sections 9

DDeclaration of Conformity 24Declaration of Incorporation 24Direction of rotation (clockwise orcounterclockwise closing) 12Disposal and recycling 23

EElectrical connection 9Electronic position transmitter RWG19

2-wire system 203-/ 4-wire system 21

Enclosure protection IP 68 22End position detection 13

HHeater 9

LLubrication 23

MMaintenance 3Mechanical positon indicator 17Mounting to gearbox 6

OOutput contacts 11

PPackaging 5Position indicator 17Position transmitter RWG 19Potentiometer 18

RRWG 19

SSafety instructions 3Service 23Storage 5Switch compartment 10

TTechnical data 4Transport 5

EuropeAUMA Riester GmbH & Co. KGFactory MüllheimDE-79373 MüllheimTel +49 7631 809 - 0Tax +49 7631 809 - [email protected]

Factory Ostfildern-NellingenDE-73747 OstfildernTel +49 711 34803 - 0Tax +49 711 34803 - [email protected]

Service Centre CologneDE-50858 KölnTel +49 2234 2037 - 9000Tax +49 2234 2037 - [email protected]

Service Centre MagdeburgDE-39167 NiederndodelebenTel +49 39204 759 - 0Tax +49 39204 759 - [email protected]

Service Centre BavariaDE-85386 EchingTel +49 81 65 9017- 0Tax +49 81 65 9017- [email protected]

AUMA Armaturenantriebe GmbHAT-2512 TribuswinkelTel +43 2252 82540Tax +43 2252 [email protected]

AUMA (Schweiz) AGCH-8965 BerikonTel +41 566 400945Tax +41 566 [email protected]

AUMA Servopohony spol. s.r.o.CZ-10200 Praha 10Tel +420 272 700056Tax +420 272 [email protected]

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AUMA ACTUATORS Ltd.GB- Clevedon North Somerset BS21 6QHTel +44 1275 871141Tax +44 1275 [email protected]

AUMA ITALIANA S.r.l. a socio unicoIT-20023 Cerro Maggiore (MI)Tel +39 0331 51351Tax +39 0331 [email protected]

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IBEROPLAN S.A.ES-28027 MadridTel +34 91 3717130Tax +34 91 [email protected]

D. G. Bellos & Co. O.E.GR-13671 Acharnai AthensTel +30 210 2409485Tax +30 210 [email protected]

SIGURD SØRUM A. S.NO-1301 SandvikaTel +47 67572600Tax +47 [email protected]

INDUSTRAPT-2710-297 SintraTel +351 2 1910 95 00Tax +351 2 1910 95 [email protected]

MEGA Endüstri Kontrol Sistemieri Tic. Ltd.Sti.TR-06810 AnkaraTel +90 312 242 18 88 pbxTax +90 312 242 18 [email protected]

CTS Control Limited Liability CompanyUA-02099 KiyivTel +38 044 566-9971, -8427Tax +38 044 [email protected]

AfricaAUMA South Africa (Pty) Ltd.ZA-1560 SpringsTel +27 11 3632880Tax +27 11 [email protected]

A.T.E.C.EG- CairoTel +20 2 3599680 - 3590861Tax +20 2 [email protected]

AmericaAUMA ACTUATORS INC.US-PA 15317 CanonsburgTel +1 724-743-AUMA (2862)Tax +1 [email protected]

AUMA Chile Respresentative OfficeCL- BuinTel +56 2 821 4108Tax +56 2 281 [email protected]

LOOP S. A.AR-C1140ABP Buenos AiresTel +54 11 4307 2141Tax +54 11 4307 [email protected]

Asvotec Termoindustrial Ltda.BR-13190-000 Monte Mor/ SP.Tel +55 19 3879 8735Tax +55 19 3879 [email protected]

TROY-ONTOR Inc.CA-L4N 5E9 Barrie OntarioTel +1 705 721-8246Tax +1 705 [email protected]

MAN Ferrostaal de Colombia Ltda.CO- Bogotá D.C.Tel +57 1 401 1300Tax +57 1 416 [email protected]

PROCONTIC Procesos y Control AutomáticoEC- QuitoTel +593 2 292 0431Tax +593 2 292 [email protected]

IESS DE MEXICO S. A. de C. V.MX-C.P. 02900 Mexico D.F.Tel +52 55 55 561 701Tax +52 55 53 563 [email protected]

Corsusa S.A.C.PE- Miralflores - LimaTel +511444-1200 / 0044 / 2321Tax [email protected]

PASSCO Inc.PR-00936-4153 San JuanTel +18 09 78 77 20 87 85Tax +18 09 78 77 31 72 [email protected]

SuplibarcaVE- Maracaibo Estado, ZuliaTel +58 261 7 555 667Tax +58 261 7 532 [email protected]

AsiaAUMA Actuators (Tianjin) Co., Ltd.CN-300457 TianjinTel +86 22 6625 1310Tax +86 22 6625 [email protected]

AUMA (INDIA) PRIVATE LIMITEDIN-560 058 BangaloreTel +91 80 2839 4655Tax +91 80 2839 [email protected]

AUMA JAPAN Co., Ltd.JP-210-0848 Kawasaki-ku, Kawasaki-shiKanagawaTel +81 44 329 1061Tax +81 44 366 [email protected]

26

AUMA wordwide

AUMA ACTUATORS (Singapore) Pte Ltd.SG-569551 SingaporeTel +65 6 4818750Tax +65 6 [email protected]

Al Ayman Industrial. EqptsAE- DubaiTel +971 4 3682720Tax +971 4 [email protected]

PERFECT CONTROLS Ltd.HK- Tsuen Wan, KowloonTel +852 2493 7726Tax +852 2416 [email protected]

DW Controls Co., Ltd.KR-153-803 Seoul KoreaTel +82 2 2113 1100Tax +82 2 2113 1088/[email protected]

AL-ARFAJ Eng. Company W. L. L.KW-22004 SalmiyahTel +965 4817448Tax +965 [email protected]

Petrogulf W.L.LQA- DohaTel +974 4350 151Tax +974 4350 [email protected]

Sunny Valves and Intertrade Corp. Ltd.TH-10120 Yannawa BangkokTel +66 2 2400656Tax +66 2 [email protected]/

Top Advance Enterprises Ltd.TW- Jhonghe City Taipei Hsien (235)Tel +886 2 2225 1718Tax +886 2 8228 [email protected]

AustraliaBARRON GJM Pty. Ltd.AU-NSW 1570 ArtarmonTel +61 294361088Tax +61 [email protected]

2006-12-08

27

Zertifikat-Registrier-Nr.12 100/104 4269

AUMA Riester GmbH & Co. KGP.O.Box 1362D-79373 MüllheimTel +49 7631 809 - 0Fax+49 7631 809 - [email protected]

For detailed information on AUMA products refer to the Internet: www.auma.comY001.149/003/en/1.10

valve position indicator - auma

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