Spirax Sarco AEL7 Series Installation And Maintenance Instructions Manual
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Spirax Sarco AEL7 Series Installation And Maintenance Instructions Manual

Spirax Sarco AEL7 Series Installation And Maintenance Instructions Manual

Electric linear actuators
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3582750/1
IM-P713-01
CTLS Issue 1
AEL7 Series
Electric Linear Actuators
Installation and Maintenance Instructions
1. Safety information
2. General product information
3. Installation
4. Electrical connection
5. Actuator Accessories
6. Commissioning
7. Maintenance
8. Declaration of conformity
AEL7 Series Electric actuator
© Copyright 2022
1
IM-P713-01 CTLS Issue 1
Printed in GB

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Summary of Contents for Spirax Sarco AEL7 Series

  • Page 1 Installation and Maintenance Instructions 1. Safety information 2. General product information 3. Installation 4. Electrical connection 5. Actuator Accessories 6. Commissioning 7. Maintenance 8. Declaration of conformity AEL7 Series Electric actuator © Copyright 2022 IM-P713-01 CTLS Issue 1 Printed in GB...

  • Page 2: Table Of Contents

    3.1 Location 3.2 Operational Considerations – End Position and Stroke Settings 3.3 Operational Considerations – Motor Brake 3.4 Hand wheel Assembly (6 – 20 kN) 3.5 Coupling the Actuator to a Valve AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 3 Work(s) may not be used, sold, licensed, transferred, copied or reproduced in whole or in part or in any manner or form other than as expressly granted here without the prior written consent of Spirax-Sarco Limited. AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...

  • Page 4: Safety Information

    The requirement s for the disconnec ting device are specif ied in IEC 60947-1 and IEC 60947- 3 or equivalent . viii) The actuator must not be located in such a way that the disconnecting device is made difficult to operate. AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...

  • Page 5: Safety Requirements And Electromagnetic Compatibility

    For a copy of the declaration of conformity please refer to page 58. 1.3 Intended use The AEL7 Series actuator must only be used to modulate Spirax Sarco and Gestra valves (including Hiter). The actuator must not be used for any other purpose.

  • Page 6: Hazardous Liquids Or Gases In The Pipeline

    1.12 Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts. AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...

  • Page 7: Protective Clothing

    Should any substances of very high concern be found within a product, details of the location will be identified within installation and maintenance instructions Section 2.4 : Materials. Further information about product compliance is be available at www.spiraxsarco.com/product- compliance AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...

  • Page 8: Returning Products

    Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to Spirax Sarco they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk.

  • Page 9: General Product Information

    2. General product information 2.1 Introduction AEL7 series electric linear actuators are only suitable for the use on Spirax Sarco, Gestra and Hiter Valves. Refer to TI-P713-02 for product compatibility and linkage requirements. The AEL7 Series actuators must not be used for any other purpose. Actuators will normally be supplied fitted to the control valve. When supplied separately, ensure the actuator selected is capable of providing the force necessary to close the two-port or three-port control valve against the expected differential pressure.

  • Page 10: Series In The Ael7 Range

    2.2 Series in the AEL7 range Table 1 AEL7 Series Nomenclature Actuator Type Electric Action Linear Series 1.2 kN 0.9 kN for AEL71T 2.0 kN 4.0 kN 6.0 kN Thrust 8.0 kN 2.1 kN for AEL72T 12.0 kN 15.0 kN 20.0 kN...

  • Page 11: Operating Principle

    2.3 Operating principle The AEL7 Series is a range of linear electric actuators of various voltages and thrusts suitable for the modulation of Spirax Sarco Group valves either by means of VMD or modulating signal. Independent of the control method, the actuators typically uses two physical force dependent (torque) switches to determine the end position of the actuator stroke in both directions and stop the actuator motor i.e.

  • Page 12: Installation

    3. Installation Before considering installation of an AEL7 Series actuator please read to Section 1 "Safety Information" on page 4. Installation awareness Lifting and fitting of actuators increases the risk of personal injury Mains connection and commissioning of the AEL7 Series actuator requires specialist knowledge of electrical circuits and systems, and the inherent dangers.

  • Page 13: Operational Considerations - End Position And Stroke Settings

    3.3 Operational Considerations – Motor Brake The motor of the AEL7 Series actuator typically slows and stops under its own momentum when the control power is removed. For the 20 kN version only (AEL78), an electronic brake is used on the motor in order to reduce inertial overrun and positioning inaccuracy, therefore reducing the wear on the actuator components.

  • Page 14: Hand Wheel Assembly (6 - 20 Kn)

    The operator is responsible for ensuring that safe systems of operation and practice are implemented and maintained. Only competent persons must be allowed to be couple the AEL7 Series actuator to a valve, and these persons must be familiar with, and comply with the applicable health and safety standards or guidelines.
  • Page 15 Couple the adapter locking plate Tighten the pillar nuts to 30 Nm Tighten the 4 valve adaptor screws to 8 Nm Tighten the thread lock nut to 15 Nm Fig. 4 Thread Engagement AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 16 1.2 kN 2.0 kN 4.0 kN 6.0 kN 12 mm 14 mm 8.0 kN 12.0 kN 15.0 kN 18 mm 20.0 kN 18 mm 27 mm Requires AEL7XM12 adapter Requires AEL7XQ18 adapter AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 17 01-11-51-61-21-71 Full Bore 01-11-51-61-21-71 Red. 08-18-58-68-02-12-52-62 01-11-51-61-21-71 Full Bore 01-11-51-61-21-71 Red. Bore 51-61-71 - Stroke 2" 51-61-71 - Stroke 3" 51-61-71 - Stroke 4" 51-61-71 - Stroke 2" 51-61-71 - Stroke 4" AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 18 1.2 kN actuators - larger cable cores can prevent the cover from seating correctly) Ensure that the power supply is correctly fused for the maximum expected load. Details of the requirements for each AEL7 Series actuator can be found in Tables 6 to 9 AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 19 8 kN AEL75322--- 1.2 mm/s 110.0 1.10 2.20 AEL76312--- 12 kN 0.4 mm/s 51.5 0.47 0.47 AEL77312--- 15 kN 0.4 mm/s 51.5 0.47 0.47 AEL78422--- 20 kN 0.8 mm/s 200.0 2.00 4.50 AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 20 1.10 9.50 AEL75324--- 1.2 mm/s 26.5 1.10 9.50 AEL76314--- 12 kN 0.4 mm/s 26.5 1.10 9.50 AEL77314--- 15 kN 0.4 mm/s 48.0 2.00 13.00 AEL78424--- 20 kN 1.0 mm/s 118.0 4.90 33.00 AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 21 Fit the correct cable gland for the location and remove the blanking plate (the AEL7 Series actuator is supplied with metallic cable glands that conform to IP65 enclosure ingress protection assuming that the correct diameter of cable is installed.
  • Page 22 Please refer to Fig. 5 and Fig. 6 for all 1-20 kN actuator electical connections unless otherwise stated Power Supply ( Vac) Modulating Signal Positioner Setpoint Position Feedback ▼ ▲ ▲ ▲ ▼ ▼ Fig.5 AEL71-78 Vac Terminal Diagram AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 23 Options Heater Potentiometer Position Switches ▲ ▼ (NC) (NO) (NC) (NO) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 24 Power Supply (Vdc) Modulating Signal Positioner Setpoint Position Feedback ▲/ ▼ ▼/▲ ▲ ▼ ▲ ▲ ▼ ▼ + / - - / + Fig.6 AEL71-78 Vdc Terminal Diagram AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 25 Options Heater Potentiometer Position Switches ▲ ▼ (NC) (NO) (NC) (NO) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 26 Section 4.1 "Electrical Connection Safety Considerations". In order to select the correct accessories for each actuator, refer to Table 10. and Table 11. The AEL7 Series actuators are modular (based on frame size). However for actuators that require a positioner card, it is recommend that the actuators are supplied fitted with the positioner card direct from the factory.
  • Page 27 6 kN AEL7X015 AEL7X003 24 Vac AEL7X233 AEL7X203 24Vdc AEL7X224 230 Vac AEL7X241 AEL7X211 110 Vac 8-20 kN AEL7X012 AEL7X004 24 Vac AEL7X233 AEL7X213 24Vdc AEL7X224 Requires Auxiliary switch assembly Requires potentiometer AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 28 5.2 Auxiliary Travel Switches The AEL7 Series actuator can be equipped with auxiliary travel switches. The auxiliary travel switch is only a means of providing a Volt Free Contact enabling the user to identify when the actuator is in a user defined position.
  • Page 29 The correct setting can be achieved when the potentiometer cam is 2-3 mm from the actuator base plate with the actuator spindle fully extended. AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 30 Aux. Travel Switch (S4) Aux. Travel Switch (S5) Switch Retaining Plate Travel Dependent Switch Retaining Nut Switch (S3) Knurled Nut Switch Cams Locknut Transmitter Plate Fig. 9 Auxiliary Travel Switch (WE) Arrangement (8 kN+) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 31 Configure the switches to the control system is also shown shown in Fig. 10 Auxiliary Travel Switch Terminal Diagram Position Switches (NC) (NO) (NC) (NO) Potential Free Position Switch S4 Potential Free Position Switch S5 Fig. 10 Auxiliary Travel Switch Terminal Diagram AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 32 Connect the wiring harness to the potentiometer socket as detailed in Fig. 11 Potentiometer Installation and Adjustment (1-6 kN) Using an insulated terminal screwdriver, carefully turn the potentiometer fully clockwise in order to zero the device (confirm with a measurement instrument if necessary) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 33 Potentiometer Wiring Harness Potentiometer Spindle Potentiometer Socket Auxiliary Switch PCB Aux Switch Cams Transmitter Plate Fig. 11 Potentiometer Installation and Adjustment (1-6 kN) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 34 Connect the wiring harness to the terminals as detailed in Fig. 13 Potentiometer Terminal Diagram Using an insulated terminal screwdriver, carefully turn the potentiometer fully spindle clockwise in order to zero the device (confirm with a measurement instrument if necessary) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 35 Potentiometer Wiring Harness Knurled Nut Lock Nut Potentiometer Spindle Transmitter Plate Fig. 12 Potentiometer Installation and Adjustment (8kN+) Potentiometer ▼ ▼ ▲ Feedback signal (passive) Fig. 13 Potentiometer Terminal Diagram AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 36 Fix the heater to the main terminal plate as indicated with the M3 screws provided Connect the wires as indicated in Fig. 22 Anti-Condensation Heater Terminal Diagram and cable tie the wiring harness carefully as indicated AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 37 Anti-Condensation Heater Wiring Harness Anti-Condensation Heater Terminal Board Main Board Fig. 14 Anti-Condensation Heater Installation (1kN) Main Board Anti-Condensation Heater Wiring Harness Anti-Condensation Heater Fig. 15 Anti-Condensation Heater Installation (1 kN) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 38 Anti-Condensation Heater Terminal Board Anti-Condensation Heater Wiring Harness Fig. 16 Anti-Condensation Heater Installation (2 - 4 kN) Anti-Condensation Heater Anti-Condensation Heater Wiring Harness Fig. 17 Anti-Condensation Heater Installation (2 - 4 kN) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 39 Main Board Anti-Condensation Heater Wiring Harness Anti-Condensation Heater Terminal Board Fig. 18 Anti-Condensation Heater Installation (6 kN) Anti-Condensation Heater Wiring Harness Anti-Condensation Heater Fig. 19 Anti-Condensation Heater Installation (6 kN) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 40 Fix the heater to the main terminal plate as indicated with the M3 screws provided Connect the wires as indicated in Fig. 22 Anti-Condensation Heater Wiring Diagram Anti-Condensation Heater Terminal Board Fig. 20 Anti-Condensation Heater Installation (8-20 KN) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 41 Anti-Condensation Heater Fig. 21 Anti-Condensation Heater Installation (8-20 KN) Potentiometer ▼ ▼ ▲ Feedback signal (passive) Fig. 22 Anti-Condensation Heater Terminal Diagram AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 42 5.5 Positioner Card The AEL7 Series actuator can be used for modulating control by use of a positioner card (requires potentiometer). The positioner card can be configured to mA or Vdc input signals. The positioner card will also provide a position feedback (mA or Vdc). Please refer to section 6.4 Positioner Card Commissioning for details.
  • Page 43 Positioner Support Spacer Fig. 23 Positioner Installation Potentiometer Plug Potentiometer Wiring Harness Positioner Support Pin Positioner Location Piece DE Wiring Harness (1-6kN) S3 Wiring Harness (8kN+) Fig. 24 Installation of Positioner Card AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 44 Main board Positioner Fig. 25 Positioner Installation Terminal Diagram (1 – 6 kN) Main Terminal (S3) Positioner Fig. 26 Positioner Installation Terminal Diagram (8 kN+) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 45 "Electrical Connection Safety Considerations". The 8-20 kN AEL7 Series actuators are supplied with three switch cams. One is for the travel dependent switch (S3 – used to limit the actuator stroke for larger thrust actuators when used on shorter stroke valves).
  • Page 46 Connection Safety Considerations" and Section 6.1 "Commissioning Safety Information". The 1- 6 kN AEL7 Series actuators are supplied with two auxiliary switch cams (S4 and S5). The 8-20 kN AEL7 Series actuators are supplied with three switch cams as standard. The S4 and S5 auxiliary travel switches can be used to notify the user of a user defined valve and actuator position by means of a volt free contact (VFC).
  • Page 47 DIP switches that can be used to configure: Input signal Feedback signal Direction of action Hysteresis Failure mode (loss of control signal only) Seating (commissioning) function For split range applications refer to addendum IM. AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 48 PROG Positioner (Orange LED) Support (Green LED) DOWN (Red LED) HAND (Blue LED) Fig.27 The setting of DIP switches will be updated after power on or reset by simultaneous pressing HAND+UP+DOWN+PROG buttons. AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 49 Off* 1.5% Off* Off* WE/WE 1.0% DE/WE 0.5% WE/DE 0.3% DE/DE Table 14 Failure Mode Configuration S2.5 S2.6 Failure mode Off* Off* Extend Fail in place X=100% X=0% * Indicates default setting AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 50 When commissioning is complete, the red and green LEDs will switch off; "PROG" LED which will flash. Set S1.2 to OFF and apply a modulating signal. The actuator movement will now correspond to the input signal AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 51 Press "PROG" and "DOWN" simultaneously for 5s to set 100% (orange LED flashing and green LED illuminates) Stroke is now set Set S1.1 to "OFF" Apply a modulating signal. The actuator movement will now correspond to the input signal AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 52 6.7 Adjustment of Actuator Stroke (8 kN+) The physical stroke of the 8 kN+ AEL7 Series actuator can be adjusted precisely to meet the valve stroke requirements, for example when the actuator thrust could damage the valve. This is controlled by Stroke Dependent Switch S3.
  • Page 53 S3. S3 must be adjusted to match or exceed the required stroke in order not to restrict valve travel. Torque Switch Potentiometer Lever Stroke Slider Stroke Arm Fig. 28 8 kN+ AEL7 Stroke Arm Arrangement Fig. 29 AEL7 Stroke Arm (8 kN+) AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 54 Mains connection and maintenance of the AEL7 Series actuator or control valve requires specialist knowledge of electrical circuits and systems, and the inherent dangers. A working knowledge of linear actuators and control valves is also required.
  • Page 55 Company for product return instructions. The AEL7 Series actuator should not be repaired in the field. In the rare event that The AEL7 Series actuator should need to be repaired, the actuator must be returned to the factory with a full field failure report.
  • Page 56 Loosen the pillar nuts and remove the actuator from the valve To return or replace the actuator to the valve, refer to Section 3.5 "Coupling the Actuator to a Valve". To commission the actuator, refer to Section 6. "Commissioning". AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 57 Stroke arm incorrectly commissioned Control signal out of range (check voltage/ current) Actuator does not respond to signal Positioner incorrectly commissioned (positioner) Potentiometer failure Poor PID set-up Actuator moving continuously Motor capacitor failure AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 58 8. Declaration of Conformity AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 59 AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...
  • Page 60 AEL7 Series Electric actuator IM-P713-01 CTLS Issue 1...

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