Valbia Electric Actuators Series 85 Installation and Maintenance Instructions Manual

1.0 Warning

• Please read the following instructions before making any installation of the actuator. Damages caused by non-observance are not covered by warranty.
• This documentation must be kept in a dry place and available for use.
• The actuator is an electronic device with live components during operation. Installation and maintenance must be performed only by qualified personnel, in accordance with current electrical engineering and safety standards and all applicable directives.
• Valbia s.r.l. reserves the right to change data and characteristics without notice for continuous updating and technological improvement.
• Mechanical and electronic parts are not eligible for modifications.

2.0 Transportation and Storage

Valbia electric actuators are supplied in sturdy cardboard boxes. Handle with care and keep the cover until installation. Store actuators in a covered, dry, and ventilated environment, protected from temperature changes, with the cover mounted. Visual inspection before installation is recommended to detect any transport or storage anomalies.

Warning: Do not lift or move the actuator by the manual hand-wheel.

3.0 Field Application

Valbia electric actuators are designed and tested for ball and butterfly valves and dampers in the industrial sector. Standard rotation is 0°-90°. 0°-180° or 0°-270° rotation is available on request. For other applications, contact Valbia sales department.

4.0 Valve Automation

Mechanical assembly with valves can be done by direct mounting or a mounting kit. Ensure correct alignment and dimensions of power transmission parts to avoid axial stress. All Valbia electric actuators conform to EN ISO 5211 (DIN 3337).

For proper valve automation, the actuator's torque range should be at least 25% over the valve's maximum torque. Verify actuator duty rating suitability.

Warning: Do not use the motorized valve or electric actuator as a grip or hold point.

5.0 Specifications and Technical Information

5.1 Technical Features

• Heater: Standard equipment to prevent condensation (see paragraph 6.4).
• Torque Limiter: Safety system detects excessive torque, making three attempts before a short reverse rotation. Indicated by a red LED and opening of the remote signal auxiliary contact.
• Time-Out Operation: Safety system shuts off the actuator if it exceeds allowable operation time. Indicated by a red LED and opening of the auxiliary contact.
• Duty Rating: Designed for 75% duty rating (50% for 12V ac/dc models), referring to working time, temperature, and nominal load. This parameter defines rest time. Exceeding duty rating or operating above 55°C (131°F) can cause improper torque limiter intervention or electronic component failure.

5.2 Power Requirements and Current Draw Information

General Technical Data:

• Object of device: Electric actuator
• Enclosure material: Self-estinguish technopolymer (V0)
• Enclosure rating: IP67
• Duty Cycle: 75% (12V version 50%)
• Ambient temperature range: -20 °C ÷ +55 °C (-4 °F ÷ +131 °F)
• Auxiliary limit switches: 1A @ 250Vac - 1A @ 30 Vdc (resistive load)
• Fault auxiliary contact: 1A @ 120Vac - 1A @ 24Vdc (resistive load)
• Terminal block type: Plug in connector
• Section of terminal block: 14 ÷ 22 AWG (0.32 ÷ 0.08 mm²)
• Minimum conductors temperature: 85 °C (185 °F)
• Protection class against electric shock: Class I
• Restriction of continue operation time (time out): Standard
• Power supply voltage tolerance: ±10%
• Multiple parallel actuators wiring: Standard (*)
• Cable entries: PG11 electric connections (cable diam. 5÷10mm/0.20”÷0.39”)
• Standard stroke: 90°
• Position indicator: Standard
• Manual override: Standard
• (*) It is important to verify that the application and its components are properly sized with the actuator characteristics and requirements.

Requested Features for UL508 Standard:

• UL listed file number: NMTR.E303174
• Enclosure Type: Type 4x Indoor Use Only
• Connection conductor/wires: Listed flexible cord (ZJCZ) minimum S or SJ
• Green terminal block screws maximum tightening capacity of model 100-240 Vac: 0.56 Nm (5 LbIn)
• Black terminal block screws maximum tightening capacity of model 100-240 Vac: 0.50 Nm (4.50 LbIn)
• Terminal block screws maximum tightening capacity of model 12-24 Vac/dc: 0.50 Nm (4.50 LbIn)
• Enclosure screws maximum tightening capacity: 2.5 Nm (22.15 LbIn)
• External pollution degree: 3
• Internal pollution degree: 2
• Overvoltage category: 2

Product in conformity with European Community norms:

• LOW VOLTAGE 2014/35/UE (LVD)
• ELECTROMAGNETIC COMPATIBILITY 2014/30/UE (EMC)
• MACHINERY 2006/42/CE
• ROHS 2011/65/UE
• REGULATION No 1907/2006 (REACH)

Use copper (CU) conductor.

6.0 Installation Instruction

Warning: Actuators should be properly grounded and wired according to local electrical code.

Warning: Always shut off power supply before performing maintenance.

Warning: Ensure power supply is within the indicated values on the actuator label.

Valbia electric actuators can be mounted in various positions. Avoid mounting with cable glands positioned upright to ensure wiring tightness. Avoid using with the indicator facing down. If assembly and electrical connection are done at different times, ensure cable entries are hermetically sealed.

Warning: Use suitably rated cable glands and protection plugs according to IP protection rating. Properly seal electrical connectors to prevent liquid and dust infiltration; warranty is voided otherwise.

Use appropriate size cables for the selected electrical connector. Verify correct tightening of electrical connectors.

Warning: Manufacturer specifications must be respected to maintain provided protection.

To wire, open the upper cover “A” to access the terminal block on the power supply board.

Warning: Shut down power supply before opening the upper cover.

To remove cover “A”, untighten screws “D”, avoiding contact with internal electrical parts. Insert power supply cables through lower enclosure entries “E” and tighten. Terminal block “F” has a removable part for easier wiring. Connect cables to terminal block “F” following the wiring diagram (paragraph 6.1).

Warning: Be careful during wiring and limit switch setting to prevent fluids or substances from contacting electronic components. Ensure the o-ring is properly seated and there are no impediments before closing the cover to maintain enclosure sealing.

Anomalies are indicated by a specific number of RED LED flashes on the logic board.

Warning: To reset anomalies, shut off power supply for over 10 seconds to ensure full capacitor discharge.

6.1 Electrical Connection

The wiring diagram is shown in Paragraph 10.0 and on the label inside the upper cover. Follow maximum allowed electrical rating values. Terminal block “F” is shown in Fig. 3 for 100-240Vac and Fig. 2 for 12Vac/dc and 24Vac/dc. Use proper size cables.

• Signal cable for “closing (clockwise rotation)” (positive supply +12Vdc / +24Vdc or phase 12Vac / 24Vac / 100-240Vac) connects to terminal “1” of terminal block “F”.
• Signal cable for “opening (counter-clockwise rotation)” (positive supply +12Vdc / +24Vdc or phase 12Vac / 24Vac / 100-240Vac) connects to terminal “3” of terminal block “F”.
• Signal cable “common” (0V / neutral) connects to terminal “2” of terminal block “F”.
• Grounding cable connects to the properly signaled terminal.

A 2-point control mode is also available besides the 3-point control mode.

Warning: Ground wiring system is mandatory.

6.2 Auxiliary Switches Wiring (Fig.4)

Terminal block “G” connects to two auxiliary, independent limit switches (SPDT free contacts), FCU1 and FCU2, indicating actuator position. Terminal block “G” has a removable part for easier wiring.

• Connect between terminals “B” and “C” for closing position signal.
• Connect between terminals “E” and “H” for opening position signal.

The opening or closing signal is generated when blue cams push the auxiliary electromechanical limit switches on the logic board. Cam adjustment is described in paragraph 6.6.

Warning: During installation, verify auxiliary limit switch alignment using a multimeter/tester.

Terminal block “R” connects to a free NO contact that closes when the actuator is powered and no anomaly is detected. The contact opens if anomalies occur or if the actuator is not powered. Terminal block “R” also has a removable part.

6.3 Potentiometer Wiring (Optional) (Fig.5)

Actuators with potentiometers include an extra terminal block “POT” (Fig.5) for resistive position information. Wiring instructions are in Paragraph 10.0. At 45° actuator position, the potentiometer resistance is 2.5KΩ.

6.4 Heater (Fig.6)

All actuators have a “RIS” heating resistor that activates when the actuator is powered, the motor is not rotating, and internal temperature drops below 25°C / 77°F. It prevents condensation. The resistor is integrated into the electronics, requires no additional wiring, and is disabled when internal temperature exceeds 25°C / 77°F.

Warning: To ensure proper resistor operation, keep the actuator connected to the power supply even in open/close positions.

6.5 Signal Lamp Unit

A green LED on the power supply board indicates power is on.

A multicolor LED on the logic board indicates actuator modes:

Anomalies are indicated by RED LED flashes:

6.6 Setting Actuator Stop Positions (Fig.7)

Actuator opening/closing occurs when black cams push electromechanical limit switches (POS1 for closing, POS2 for opening). Blue cams signal opening/closing. Follow these steps for adjustment:

1. Ensure power supply is OFF.
2. Remove the upper cover (paragraph 6.0).
3. For easier operation, remove removable parts of terminal blocks “G” and “R”.
4. Ensure the automated device (e.g., valve) is in the “OPEN” position. Use manual override “H” (paragraph 7.0) for precision.
5. Loosen the set screw on cam 1 (black), rotate until it pushes limit switch POS2 and clicks. Tighten the screw.
6. Loosen the set screw on cam 3 (blue), rotate until it pushes limit switch FCU2 and clicks. Tighten the screw.
7. Power ON the actuator and perform the closing operation.
8. Wait for completion, then shut off power supply.
9. Ensure the automated device is in the “CLOSED” position. Use manual override “H” for precision.
10. Loosen the set screw on cam 2 (black), rotate until it pushes limit switch POS1 and clicks. Tighten the screw.
11. Loosen the set screw on cam 4 (blue), rotate until it pushes limit switch FCU1 and clicks. Tighten the screw.

6.7 Closure of Electric Actuator Enclosure (Fig.1)

• After making connections, carefully reassemble cover “A”, avoiding contact with electronic parts.
• Re-assemble position indicator “B” on “OPEN” position, securing with screw “C”.
• Ensure cable tightening is secure by screwing gland “E”.
• Secure cover “A” by tightening fasteners “D”.

7.0 Emergency Operation

All Valbia electric actuators have an external handwheel “H” (Fig.1) for manual opening and closing. Engage the handwheel by pressing down and rotating slightly. Maintain pressure while turning the handwheel to achieve the desired position.

Warning: Use the manual override only when the actuator is NOT powered. Do not use tools on the handwheel.

Warning: Do not operate the manual override while the actuator is turning.

8.0 Fail-Safe Operation with Battery Backup (Optional)

Battery versions use NiMh cell packs with a nominal voltage of 24Vdc. In case of power outage, Valbia can configure the actuator to perform one of the following actions:

• Opening: Interrupts the current operation.
• Closing: Interrupts the current operation.
• Completes the in-progress operation: Continues the current action until travel stops/limit switches are reached.

Battery operation is enabled after a ~1-second delay, or instantaneously if the emergency action is consistent with the ongoing operation (e.g., closing operation interrupted by power loss, and battery set to normally closed). The operation in progress with battery power is interrupted by mains voltage recovery.

A yellow LED on the power supply board indicates trickle charging. The LED turns off when the battery is fully charged. The LED signal is reliable if the battery backup is not damaged.

Batteries have a limited number of charge/discharge cycles (over 500); life is inversely proportional to intervention frequency.

Warning: For emergency battery intervention, the actuator must remain powered for over 3 hours.

Warning: For battery versions, power the actuator within 3 months of purchase.

The actuator can also be used in “solenoid” mode (two-wire wiring). Follow the above warnings for this mode.

9.0 Maintenance

The electric actuator requires no maintenance. Internal gear lubrication is sufficient for the device's lifespan. For enclosure cleaning, use a mild, non-aggressive detergent. For damages or operational issues, return actuators to Valbia for inspection.

Valbia s.r.l. disclaims responsibility and warranty for actuators repaired by third parties.

10.0 Wiring Diagrams

The wiring diagram for proper actuator cabling is shown in Fig.8 and on the tag inside the cover. Both 3-point and 2-point control modes are supported.

11.0 Disposal of Electrical Actuators at End of Life Cycle

In accordance with European directives 2011/65/UE and 2012/19/UE (RoHS and WEEE), Valbia electric actuators are designed for complete disassembly. Separate materials for proper disposal and/or recovery.

The crossed-out rubbish bin symbol indicates the product is Waste Electrical and Electronic Equipment (WEEE) and must be collected separately.

Do not dispose of as mixed urban waste. Recycle through designated collection systems.

Collection systems are guaranteed by national consortia for eco-sustainable WEEE management. Contact Valbia s.r.l. for information.

At end of life, follow these precautions:

• Demolish and separate components by type if unusable to aid collection, disposal, and recycling, minimizing environmental impact.
• Separate waste collection for recycling, treatment, and compatible environmental disposal prevents negative environmental effects and favors material recycling.
• Illegal disposal incurs penalties according to current regulations.

Properly disposed products are not dangerous. Improper disposal can negatively impact the ecosystem.