CPA SRL Actuator User Manual
Models: 1080292-1080293
Introduction and Copyrights
Copyrights: This manual is copyrighted by Praher Plastics Austria GmbH and is intended for operating personnel only. Unauthorized reproduction or translation requires written permission.
Introduction to Operation Manual: This manual facilitates familiarization with and utilization of the actuator for its intended purpose, providing information for safe, proper, and economical operation. It supplements existing safety and environmental regulations and must be read by all personnel involved in operation, including maintenance and fault correction.
Warranty and Liability
Warranty and liability claims are excluded for damages resulting from:
- Improper use, installation, operation, or maintenance.
- Operation with defective safety devices.
- Non-compliance with manual instructions.
- Unauthorized modifications.
- Insufficient monitoring of wear components.
- Inadequately performed repairs.
- Damage from foreign matter or Force Majeure.
Leak and function tests are required before commissioning. Retighten all nuts and screws after pressure testing. Regular maintenance and visual inspection are recommended, with shortened intervals for aggressive media or extreme conditions. Seals are wear parts and require regular lubrication/replacement. Line strainers are recommended for unfiltered media.
Neglecting the manual or damaging sealed parts voids the warranty.
Safety Instructions
Instructions for Safety at Work: All personnel involved must read and understand this manual, especially the safety instructions. Warning signs must be heeded.
General Safety:
- Equipment is built to safety standards for electronic devices.
- Observe safety instructions for safe operation.
- Installation must be done by authorized personnel.
- Not intended for use by persons with reduced physical/mental abilities or lack of experience without supervision. Children should be supervised.
- Electrical installations must comply with local and regional regulations (e.g., ÖVE, VDE).
- Electrical connections require a separating device with a minimum 3mm contact gap. Ensure correct supply voltage protection and an earth-leakage circuit breaker (≤ 30 mA).
- Use only in dry rooms without combustible gases/vapors.
- Avoid immediate operation if moved from cold to warm environments due to condensation risk.
- If damaged, not working, or stored improperly, secure against unintentional start-up and decommission if necessary.
- Live parts may be exposed when opening covers. Disconnect all voltage supplies before maintenance or repair. Work on live equipment must be done by skilled personnel.
- Capacitors can remain charged even after power disconnection.
- Assembly/disassembly must be done in a pressure-free state (empty piping).
- Follow specified installation positions and consider valve flow direction.
Residual Risk:
- Hazard by Current: Manipulation by operating staff is prohibited; only authorized, qualified personnel may perform electrical work.
- Hazard by Human Error: Operating staff must be instructed on residual dangers from electricity and correct operation. Safety training effectiveness must be verified.
- Hazard by Current During Cleaning: Cleaning must only be performed after power disconnection (lever switch).
General Information
Actuator controls are high-precision technical products. Complaints will be rectified promptly. The equipment is covered by a warranty according to European law, starting from the purchase date.
Attention: Rotate the valve with manual override upon first installation or if unused for over 2 months. Hand-tighten union nuts and ensure O-rings are correctly positioned.
Directions for Use
The ball valve with electric actuator complies with European standards:
- CE: Electromagnetic compatibility (2014/30/EU), Low Voltage Directive (2014/35/EU), Machinery Directive (2006/42/EG).
- UKCA: Electromagnetic Compatibility Regulations 2016, Electrical Equipment (Safety) Regulations 2016, Supply of Machinery (Safety) Regulations 2008.
Refer to specific EN/BS EN standards listed for EMC and safety compliance.
Technical Data
Actuator
Operation Voltage: 24V AC 50/60 Hz or 12-24V DC
Type of Protection: IP65
Duration: 60% / max. 20 min.
Power Consumption: P = 4 Watt / Pmax = 8 Watt
Ambient Temperature: -10°C to +60°C
Screw Torque: 0.4 Nm
Installation Position: Not upside-down (handle pointing vertical downward)
Actuator Assembly Notes:
- Ensure the sealing cord is correctly inserted in the housing base and sealing rings are between the screw head and housing cover when closing the housing.
- Comply with the specified screw torque (0.4 Nm) for housing screws.
- Manual operation is for emergencies only; turn clockwise following the arrow on the handle.
Actuator Diagram Description: An exploded view of the actuator housing components: 1. Screws (0.4 Nm), 2. Sealing rings, 3. Housing cover, 4. Sealing cord, 5. Housing base.
Dimensions 2-way Ball Valve (PVC-U)
Dimensional drawings are provided for DN32-50/S6 and DN10-25/M1 configurations, showing various views and key dimensions. Tables list dimensions (d, A, D, t SSO, Z, PN, E, H, M, J, K) for different sizes.
| DN | 32 | 40 | 50 |
|---|---|---|---|
| d | 40 | 50 | 63 |
| A | 77 | 77 | 87 |
| D | 101.5 | 101.5 | 115.3 |
| t SSO¹ | 26.5 | 31.5 | 38.5 |
| Z | 87 | 87 | 99 |
| PN | 3 | 3 | 3 |
| E | 138.5 | 138.5 | 143.5 |
| H | 172 | 172 | 177 |
| M | 77 | 77 | 77 |
| J | 49.5 | 49.5 | 49.5 |
| K | 102.5 | 102.5 | 102.5 |
¹ SSO = solvent socket
| DN | 10 | 15 | 20 | 25 |
|---|---|---|---|---|
| d | 16 | 20 | 25 | 32 |
| ISO F flange | F04 | F04 | F04 | F04 |
| A | 45 | 45 | 53.5 | 54 |
| B | 239 | 239 | 251.5 | 257 |
| C | 33 | 33 | 40 | 43 |
| D | 55.5 | 55.5 | 62 | 70 |
| E | 5.5 | 5.5 | 5.5 | 6.5 |
| F | 34 | 34 | 36 | 38 |
| H | 80 | 80 | 85.5 | 88 |
| J | 49.5 | 49.5 | 49.5 | 49.5 |
| K | 102.5 | 102.5 | 102.5 | 102.5 |
| t SSO¹ | 16 | 16.5 | 19.5 | 23 |
| Z SSO¹ | 51 | 50 | 59.5 | 60 |
| M | 77 | 77 | 77 | 77 |
| N | 93 | 93 | 93 | 93 |
¹ SSO = solvent socket
Dimensions 3-way Ball Valve (PVC-U)
Dimensional drawings and tables are provided for various DN sizes (10-50) for 3-way ball valves, with and without console. Tables list dimensions (d, A, C, D, t SSO, Y, Z SSO, bar, E, H, M, J, K, L, B) for different sizes.
| DN | 10 | 15 | 20 | 25 | 32 | 40 |
|---|---|---|---|---|---|---|
| d | 16 | 20 | 25 | 32 | 40 | 50 |
| A | 100 | 100 | 120 | 120 | 162 | 162 |
| C | 50 | 50 | 60 | 60 | 81 | 81 |
| D | 53 | 53 | 70 | 70 | 101 | 101 |
| t SSO¹ | 16.5 | 16.5 | 20 | 22.5 | 27.5 | 31.5 |
| Y | 53 | 53 | 63 | 63 | 84.5 | 85.5 |
| Z SSO¹ | 106 | 106 | 126 | 126 | 169 | 171 |
| bar | 10 | 10 | 10 | 10 | 3 | 3 |
| E | 196.5 | 196.5 | 216.5 | 216.5 | 205 | 205 |
| H | 229.5 | 229.5 | 249.5 | 249.5 | 238 | 238 |
| M | 77 | 77 | 77 | 77 | 77 | 77 |
| J | 49.5 | 49.5 | 49.5 | 49.5 | 49.5 | 49.5 |
| K | 102.5 | 102.5 | 102.5 | 102.5 | 102.5 | 102.5 |
| L | 33 | 33 | 43 | 43 | 56 | 56 |
| B | 38 | 38 | 38 | 38 | 38 | 38 |
¹ SSO = solvent socket
Dimensions 3-way Solar Ball Valve (PVC-U)
Dimensional drawings and tables are provided for DN sizes 32, 40, 50 for 3-way Solar ball valves. Tables list dimensions (d, A, C, D, t SSO, Y SSO, Z SSO, bar, E, H, L, M, J, K) for different sizes.
| DN | 32 | 40 | 50 |
|---|---|---|---|
| d | 40 | 50 | 63 |
| A | 162 | 162 | 181 |
| C | 81 | 81 | 90.5 |
| D | 101 | 101 | 124.5 |
| t SSO¹ | 27.5 | 31.5 | 38.5 |
| Y SSO¹ | 85 | 85 | 96 |
| Z SSO¹ | 170 | 171 | 192 |
| bar | 3 | 3 | 3 |
| E | 205 | 205 | 221 |
| H | 238 | 238 | 254 |
| L | 56 | 56 | 65 |
| M | 77 | 77 | 77 |
| J | 49.5 | 49.5 | 49.5 |
| K | 102.5 | 102.5 | 102.5 |
¹ SSO = solvent socket
Comments to the 3-way Solar Ball Valve:
The ball seating joint with the pressure compensation system must be installed on the side with higher pressure (pump side) to ensure functionality and prevent valve destruction. This seating joint can be adjusted using the provided spanner; it is in the middle position as delivered. The solar ball valve has a pressure-compensation system to manage pressure changes. If a process is interrupted (e.g., power failure), a position can be reset manually.
Pressure - Temperature Diagrams
Diagrams illustrate the operating limits for 2- and 3-way ball valves based on material and pressure rating:
- PVC-U: Shows pressure vs. temperature for PN3, PN10, and PN16 ratings.
- PP-H: Shows pressure vs. temperature for PN10 rating.
- PVDF: Shows pressure vs. temperature for PN10 and PN16 ratings.
Wiring and Connection Diagrams
Detailed wiring and connection information is provided for different valve types.
2-ways Ball Valve
Position of Ball Valve: Position 1, Position 2.
Terminal Assignments:
| No. of terminal | Common Point | Supply | Connection for position indication | Changing over time |
|---|---|---|---|---|
| Position 1 | 11 | 4 | 13 | 12 sec |
| Position 2 | 11 | 3 | 12 | 12 sec |
Wiring Diagram Description: The diagram shows connections for motor (M), contact switches (S1, S2), and disc cam (ST). It illustrates power supply (L1(+), N(-), PE) and terminal connections (3, 4, 11, 12, 13) for the 2-way valve, including position indication outputs (POS1, POS2).
U ... electricity supply: 12-24V DC, 24V AC 50/60 Hz.
Solar 3-ways T-ball 2-position
Position of Ball Valve: Position 2, Position 4.
Terminal Assignments:
| No. of terminal | Common point | Supply | Connection for position indication | Changing over time |
|---|---|---|---|---|
| Position 2 | 11 | 4 | 13 | 24 sec |
| Position 4 | 11 | 6 | 15 | 24 sec |
Wiring Diagram Description: Similar to the 2-way valve, this diagram shows connections for motor (M), contact switches (S1, S2), and disc cam (ST), with terminal connections (4, 6, 11, 13, 15) for the 3-way T-ball valve, including position indication outputs (POS2, POS4).
U ... electricity supply: 12-24V DC, 24V AC 50/60 Hz.
3-ways T-ball
Position of Ball Valve: Position 1, Position 2, Position 3, Position 4.
Terminal Assignments:
| No. of terminal | Common Point | Supply | Connection for position indication | Changing over time |
|---|---|---|---|---|
| Position 1 | 11 | 3 | 12 | 12 sec |
| Position 2 | 11 | 4 | 13 | 12 sec |
| Position 3 | 11 | 5 | 14 | 12 sec |
| Position 4 | 11 | 6 | 15 | 12 sec |
Wiring Diagram Description: The diagram shows connections for motor (M), contact switches (S1, S2, S3, S4), and disc cam (ST). It details power supply and terminal connections (3-6, 11-15) for the 3-way T-ball valve, including position indication outputs (POS1, POS2, POS3, POS4).
U ... electricity supply: 12-24V DC, 24V AC 50/60 Hz.
3-ways L-ball
Position of Ball Valve: Position 1, Position 2, Position 3, Position 4.
Terminal Assignments:
| No. of terminal | Common Point | Supply | Connection for position indication | Changing over time |
|---|---|---|---|---|
| Position 1 | 11 | 3 | 12 | 12 sec |
| Position 2 | 11 | 4 | 13 | 12 sec |
| Position 3 | 11 | 5 | 14 | 12 sec |
| Position 4 | 11 | 6 | 15 | 12 sec |
Wiring Diagram Description: Similar to the 3-way T-ball, this diagram shows connections for motor (M), contact switches (S1, S2, S3, S4), and disc cam (ST), with terminal connections (3-6, 11-15) for the 3-way L-ball valve, including position indication outputs (POS1, POS2, POS3, POS4).
U ... electricity supply: 12-24V DC, 24V AC 50/60 Hz.
Troubleshooting
Ball valve does not move freely:
- Thrust collar over-tightened: Reset to original position. Do not modify preset collars.
- Union nut over-tightened: Loosen and tighten manually.
- Compensating thrust collar on solar ball valve in wrong position: Refer to section 12.1.
Temperatures in the system too high: Use appropriate ball valve material for the temperatures. Consult service engineers.
Medium does not match material: Use appropriate ball valve material for the medium. Consult service engineers.
Drive is no longer rotating:
- No voltage: Check voltage at terminals and electrical installation.
- Incorrect voltage: Check voltage at terminals and ensure correct voltage is supplied per type plate.
- Extended period of disuse: Rotate ball valve manually.
- Compensating thrust collar on solar ball valve in wrong position: Refer to section 12.1.
Foreign matter in the system: Remove foreign matter, integrate a filter.
Damage to the ball and seal: Replace ball and seals, integrate a filter.
Ball valve is leaking:
- If using a Solar ball valve, note it does not provide a hermetic seal.
- Foreign matter in the system: Remove foreign matter, integrate a filter.
- Damage to the ball and seal: Replace ball and seals, integrate a filter.
