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Website :
www.tritork.com
www.virgoengineers.com
Content
General Instructions
Page No.
Introduction
Installation
Trouble Shooting
Preventive Maintenance
10
10
10
Exploded View
13
11
14
12
14
13
16
1. Introduction
Scope
The manual is provided to ensure proper installation, operation & maintenance for the TriTork Triple
Offset Valve (TOV) manufactured and supplied by Virgo Group of Companies. This manual covers
Virgos Triple Offset valve range from 3 to 30.
4. Installation
Before installation, clean valve ends & bore using Acetone / suitable commercial solvent or as per
the Customers requirement.
Valves are bi-directional and can be installed in either direction. But TriTork recommends putting
shaft side towards upstream side.
Clean the pipeline to avoid damage of the super finish seal ring due to impurity, welding residuals,
debris, scaling, etc.
Keep the valve in closed position while installing in the pipeline.
Never install the Valve with the Actuator on the underneath side in the pipeline. (Fig. 4.1)
6. Trouble Shooting
The following table lists the possible malfunctions that might occur after prolonged use.
Symptom
Valve wont rotate
Possible Fault
Shaft packing is too tight
Operator has failed
Valve packed with impurities
Shaft key has sheared
Recommended Actions
Loosen gland nuts.
Replace or repair operator.
Flush or clean the valve
Find out cause of shearing &
replace the key.
Flush the bearing
7. Preventive Maintenance
Note: Observe the safety precautions as outlined in Dos & Donts before performing maintenance.
In order to avoid valve failure during operation, all valves should be periodically inspected
thoroughly to detect the damage of seal ring, shaft, seals and even body.
While doing periodical checks, it is recommended that the seal ring, bottom gaskets, seals and shaft
packing should be replaced by genuine spares.
The type of process fluids involved, working conditions and location of the valves in the plants, will
determine the frequency of periodic inspection / maintenance which in fact will be made at the time
of partial or total shutdown of the plant.
Preventive maintenance is absolutely essential as the failure due to lack of the same may cause an
emergency shutdown of the plant.
Section 9 describes the procedure for complete dis-assembly & re-assembly of the valve. The
procedure for a valve failing during operation due to lack of preventive maintenance is mentioned
under maintenance of shaft packing, seal ring & bottom flange gasket.
Once a valve is repaired, it should undergo a complete set of tests to make sure that the valve is
adequate for the original working conditions. Hydro/Pneumatic tests should be carried out as per
the specifications relevant to the valve. (Refer General Arrangement Drawing).
Note: Selection and use of the valve for a specific application requires close consideration of
detailed aspects. Due to the nature of the product, this manual cannot cover all the individual
situations that may occur while installing, using or servicing the valve.
10
2) Complete Re-Assembly
Before re-assembly, inspect the valve for any damage on Body, Seal ring & all internals.
Damaged internals to be replaced by genuine & with recommended parts only.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Assembly should be done on perfectly horizontal table. Table must be covered with rubber
sheet. Assembly table should be clean. Ensure that tooling & other supplementary things (cotton,
lubricants etc.) easily available at assembly table.
Place the body (01) horizontally on table ensuring that body sealing area close to table platform.
Clean the body bore area with the help of dry air. Remove burr, foreign particles from body bore
area.
Apply lubricant on the outer surface of bearing (11) & place packing rope (28) in bearing groove.
Insert bearing in body shaft bore from upper side & press it with the help of nylon bar until it take
its position as shown in general assembly drawing.
Repeat the procedure 4 for inserting another bearing through bottom side body shaft bore.
Place the disc (02) in body inner pocket keeping disc ribs upward. Match the disc-offset arrow in
same direction with respect to body offset bore. Ensure that body shaft bore & disc shaft bore
are inline.
Slowly insert the shaft (08) in body bore from upper side.
Take care while shaft passing through bearing & just before entering the disc bore.
Ensure alignment of shaft pin hole and disc pin hole and insert shaft pin.
Place second pin same as described in 9.
Attach washer and heavy hex nut to shaft pin for fitment.
Insert lower thrust washer (21) from bottom side & secure it with the help of adjustable screw.
Place stop washer (22) on thrust washer with proper alignment of its slot & across flat of
adjustable screw (23).
Put the bottom flange gasket (25) on bottom flange (24). Place bottom flange on bottom face of
body, concentric with shaft axis. Rotate the bottom flange to accommodate the correct position &
center the holes with the threaded holes on body. Fix the bottom flange with body by tightening
the bolts (26).
Insert spacer (12) passing over shaft from upper side. Same way first insert anti-extrusion
packing rings (13) on spacer then graphite molded rings at center followed by top anti-extrusion
ring.
Insert gland (14) over gland packing set.
Insert studs (16) on body tapping provided for gland plate (15) assembly.
Arrange gland plate over gland. Gland plate edge should be parallel with face of body mounting
flange.
Properly tighten of gland plate with nut (17) & stud (16).
Put dowel pins (19) at body upper plate as a locator for bracket (18).
Ensure proper position of bracket with reference to dowel pin location. Fix the bracket with body
with heavy hex bolts (20).
0
Keep entire assembly perpendicular to table surface. Rotate the disc in 180 .
Place the body horizontal on table such a way that retainer side of disc will upward.
Put disc gasket (06) into the disc groove.
Insert dowel pin (04) in its position.
Place the seal ring (03) on disc with reference to dowel pin.
Put retainer ring (05) on seal ring with reference to dowel pin position.
Clamp the retainer ring with disc by hand tightening the retainer screws (07).
Place the shaft key (27) at keyway & fix it with help of disc screw.
Mount Gearbox (31) / Actuator on the bracket & fix it with the help of heavy hex bolt (20).
Operate the disc as full close-full open-full close for at least 5 cycles.
Hold the disc at perfectly close position & then tighten the retainer screws.
Confirm the exact position of disc with shaft.
Repeat the procedure 32 & 33 if valve leaks, to ensure correct positioning of seal ring.
11
12
13
Exceeding the limits of the Customer shall take care not to use valve beyond limits
Pressure/Temperature as specified on Nameplate / Body marking.
agreed between Virgo and
Customer (Ref. P.O)
Valve for dead end service Ensure marking on valve for dead end service.
Triple offset butterfly valve with blind flange is
recommended for dead end service.
Use of different application Valve data sheet / fluid details are supplied with IOM.
fluid. (Not as specified in Customer is advised to check suitability if intended service
Valve Data Sheet/P.O.)
is different from valve data sheet.
Upside down mounting of
Upside down mounting of Valve to be avoided.
Triple offset butterfly
valves.
Warranty:
Our liability in respect of any defect in or failure of the goods supplied or for any loss, injury
or damage attributable thereto is limited to making goods by replacement or repair defects
which under proper use appear therein and arise solely from faulty materials and
workmanship within a period of 18 calendar months after the original goods shall have been
first dispatched or 12 calendar months from the date of commissioning, whichever is earlier
provided that such defective parts are returned free to our works for examination. The
undertaking shall exclude any and every other obligation.
14
Virgo does not assume responsibilities for any liabilities/damages arriving out of
wrong application of its valves, or imprudent operations carried out by inexperienced
operators, or which does not comply with this manual, or instructions provided by
Virgo.
The valves shall be appropriately used for the purpose they are built, or applications
they are supplied. Use of standard valves for special applications is not
recommended unless it has been communicated and agreed to by Virgo.
Valves shall be operated and maintained strictly in accordance with the procedures.
Operation or maintenance outside these procedures constitutes abuse of the product
and voids all warranty and claims.
.
15
Regd. Office:
Chennai
No. 59, Ground Floor, Teachers Colony,
Kamaraj Avenue, Adyar,
Chennai-600 020. INDIA
Phone : +91-44- 24404119
Fax : +91-44-24410664
E-mail : Virgo.Chennai@virgovalves.com
MALAYSIA
Virgo Valves and Controls Ltd.
Suite 1904, 19th Floor, Kenanga
International
Jalan Sultan Ismail,50250 Kuala Lumpur,
Malaysia
Ph
: +60 3 21618260
Fax : +60 3 21612220
Virgo Valves & Controls Limited
(Warehouse and Valve Automation
Center)
Unit - Fzs1 AH07,Jebel Ali Free Zone
(South),
P.O. Box 18478, Dubai-UAE
Phone : +971-4-8860980
Fax : +971-4-8860981
16
water vapour present , water or ice will result. Therefore, moisture removal
is a major consideration of instrument air treatment systems.
The most common methods of moisture removal are compression cooling ,
absorption, chemical methods, mechanical separation, and combination of
these methods.
Note : This is only a small extract of ISA standard ANSI/ISA-S7.0.011996.For complete information please refer the ISA document mentioned.
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GP RANGE
PNEUMATIC SCOTCH YOKE ACTUATORS
INSTALLATION
AND
MAINTENANCE
MANUAL
Publication F130E
Date of issue 04/08
CONTENTS
GP RANGE
INSTALLATION AND MAINTENANCE
SECTION
CONTENT
PAGE
Introduction
Installation
Maintenance
Fault Detection
10
11
Appendix
Page 2 of 12
Publication F130E
Date of issue 04/08
INTRODUCTION
GP RANGE
INSTALLATION AND MAINTENANCE
1.0
Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems GP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of GP range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.
INSTALLATION
2.0
Installation
2.1
Electrical Considerations
2.1.1
Any electrical connections required are the responsibility of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.
2.1.2
Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.
2.1.3
Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.
2.1.4
The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.
2.2
2.2.1
Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.
2.2.2
Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium.
2.2.3
Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.
Page 3 of 12
Publication F130E
Date of issue 04/08
INSTALLATION
GP RANGE
INSTALLATION AND MAINTENANCE
2.3
2.3.1
The maximum temperature allowable for standard build actuators is 100C (212F).Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.
2.3.2
Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.
2.4
Operating Environment
2.4.1
The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.
2.4.2
If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.
2.5
Mechanical Considerations
2.5.1
It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.
2.5.2
Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.
2.5.3
Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.
2.54
All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.
2.5.5
When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.
2.5.6
Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.
2.5.7
Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
2.5.8
Once in position, the actuator should operate the valve with a smooth continuous action. If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
Page 4 of 12
Publication F130E
Date of issue 04/08
MAINTENANCE
GP RANGE
INSTALLATION AND MAINTENANCE
3.0
Maintenance
3.1
Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customers individual requirements.
3.2
Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.
3.3
No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.
3.4
Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.
3.5
Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.
3.6
After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.
3.7
Periodic Inspection
3.7.1
Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.
3.7.2
Verify that the power gas supply pressure value is within the required range.
3.7.3
3.7.4
3.7.5
Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.
3.7.6
Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.
Page 5 of 12
Publication F130E
Date of issue 04/08
GP RANGE
4.1
Grease Specification
Manufacturer:
Mobil
Trade name:
Mobiltemp 78
Colour:
Gray/black
Soap type:
Inorganic
Oil type:
Mineral
295/325 dmm
260C
485 cSt
32 cSt
QTY (kg/lb)
0.3/0.66
130
0.4/0.88
0.5/1.10
270, 271
0.8/1.76
350
1.2/2.64
Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.
4.2
Mobil
Trade name:
DTE 11
Viscosity at 40C:
16.5 cSt
Viscosity at 100C:
4.2 cSt
168
ISO Grade:
16
Pour point:
-42C
0.85 kg/dm3
Equivalent to:
Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.
Page 6 of 12
Publication F130E
Date of issue 04/08
GP RANGE
5.1
Disassembly
5.1.1
Disconnect pneumatic and electrical supply connections. For spring return actuators, ensure that the actuator is in the failed
position (i.e., at end of the spring stroke).
5.1.2
5.1.3
5.1.4
Remove tie rod nuts (34) from the tie rods (22).
5.1.5
5.1.6
5.1.7
Remove housing cover bolts (16), center body cover (15) and cover gasket (14).
5.1.8
Remove piston retaining nut (35) and separate piston (23), shoulder washer (30), and o-ring (36) from piston rod (20).
5.1.9
Remove o-ring (25) and sliding ring (24) from piston (23).
5.1.10
Remove piston rod (20) by unscrewing it from the guide block (4).
5.1.11
Remove flange retaining bolts (13) and remove head flange (18).
5.1.12
5.1.13
Remove bolts (38) and shaft seal retaining flange (37) from the head flange (18).
5.1.14
5.1.15
5.1.16
5.2
Assembly
5.2.1
5.2.2
5.2.3
Cycle the actuator several times. Movement should be smooth and continuous. If not, refer to Section 6, Fault Detection.
NM
M6
8.5
M8
20
15
M10
40
30
M12
55
40
M14
110
81
M16
220
162
M20
430
317
M22
425
313
M24
585
431
M27
785
579
M30
1,250
921
M33
1,400
1,030
M36
1,750
1,290
Page 7 of 12
FT. LBS
Publication F130E
Date of issue 04/08
FAULT DETECTION
GP RANGE
INSTALLATION AND MAINTENANCE
6.0
Fault Detection
In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.
SYMPTOM
CAUSE
REMEDY
Page 8 of 12
Publication F130E
Date of issue 04/08
GP RANGE
INSTALLATION AND MAINTENANCE
48
49
46
44
47
45
42
43
2
41
18
19
51
50
22
20
26
13
39
23
30
36
31
21
24
25
33
32
34
26
40
35
28
DESCRIPTION
MATERIAL
17
QTY
Centre body
Guide Bar
Safety Valve
Brass/Stainless Steel
Guide Block
Carbon Steel
Yoke
O-ring
NBR
Upper Bushing
Bronze
Lower Bushing
Bronze
10
Sliding Block
Bronze
11
Bar Pin
Alloy Steel
12
Retaining Ring
Spring Steel
13
Carbon Steel
14
Cover Gasket
Vaporflex/SA
15
Cover
Carbon Steel
16
Carbon Steel
17
Flange Gasket
Vaporflex/SA
ITEM
DESCRIPTION
MATERIAL
18
Head Flange
19
16
14
51
4
7
15
27
38
29
Centre body cross-section
10
7
13
37
12
11
17
53
55
52
54
57
56
Typical fabricated carbon steel centre body and yoke illustrated.
Some models have a cast, ductile iron centre body and yoke.
MATERIAL
41
Head Flange
Carbon Steel
42
Driving Flange
Carbon Steel
43
Connecting Rod
Bottom Flange
Carbon Steel
44
Bushing
Steel/Bronze/PTFE
22
Tie Rod
Alloy Steel
45
Spring Canister
Carbon Steel
23
Piston
Carbon Steel
46
Spring
Spring Steel
24
Sliding Ring
PTFE/Graphite
47
Stop Bolt
Carbon Steel
25
O-ring
NBR
48
Bottom Flange
Carbon Steel
26
O-ring
NBR
49
Protection Plug
Carbon Steel
27
Shaft Bushing
Steel/Bronze/PTFE
50
O-ring
NBR
28
Seal Washer
Carbon Steel/NBR
51
Shaft Bushing
Steel/Bronze/PTFE
29
Seal Washer
NBR/PTFE/Graphite
ITEM
DESCRIPTION
MATERIAL
52
Flange
Carbon Steel
53
Flange Nut
Carbon Steel
54
Seal Washer
Carbon Steel/NBR
55
Stop Bolt
Alloy Steel
56
Carbon Steel
57
Carbon Steel
QTY
ITEM
Carbon Steel
Cylinder Tube
20
Piston Rod
21
30
Shoulder Washer
Alloy Steel
31
Carbon Steel
32
Stop Bolt
Alloy Steel
33
Carbon Steel
34
Carbon Steel
35
Carbon Steel
36
O-ring
NBR
37
Stainless Steel
38
39
Bushing
Carbon Steel
40
O-ring
NBR
QTY
CLOSURE ASSEMBLY
QTY
Page 9 of 12
Publication F130E
Date of issue 04/08
GP RANGE
Overview
1.3
All RFS G Range actuators (ie., GP, GH, GO and HPG) incorporate adjustable stops
to limit the degree of travel in both directions. Steps are outlined below for
adjustment of the three stop configurations: pneumatic/hydraulic cylinder, spring
cartridge and, jackscrew.
1.2
Pneumatic/Hydraulic
Cylinder (See figure 1)
Spring Canister
(See figure 2)
SPRING STOP
SPRING STOP CAP
Jackscrew
(See figure 3)
figure 2
STOP SCREW
SEALING WASHER
STOP SCREW
STOP NUT
SEALING WASHER
SEALING WASHER
STOP NUT
SEALING WASHER
STOP BOLT COVER
figure 1
figure 3
Page 10 of 12
Publication F130E
Date of issue 04/08
GP RANGE
1.1
1.2
1.1.1
1.1.2
Loosen the four screws (1) and remove the cover (2).
Setting the CLOSE limit switch.
1.2.1
Loosen the four screws (1) and remove the cover (2).
1.2.2
1.2.2.3 Loosen the setscrew (5) and rotate the cam (4) until
it is on the same axis as the switch and re-tighten the
setscrews.
1.2.3
Replace the cover (2) and tighten the four screws (1).
ITEM
1
Replace the cover (2) and tighten the four screws (1).
DESCRIPTION
Screw
Cover
Microswitch
Cam
Dowel
Page 11 of 12
Publication F130E
Date of issue 04/08
Manufacturing Centres
Germany
Melle
Tel: +49 (0)5422 9414-0
Fax: +49 (0)5422 9414-10
sales@rfs-pci.de
Italy
Tassignano - Lucca
Tel: +39 0583 93061
Fax: +39 0583 934612
fluid@fluidsystem.com
Sweden
Falun
Tel: +46 (0)23-587 00
Fax: +46 (0)23-587 45
Email:
info@remotecontrol.se
United States
Rochester, New York
Tel: +1 585 247 2304
Fax: +1 585 247 2308
rfsinfo@rotork.com
Centres of Excellence
Australia
Bayswater, Victoria
Tel: +61 (0) 3 9729 8882
Fax: +61 (0) 3 9729 8884
sales@rfsaustralia.com
Canada
Calgary, Alberta
Tel: +1 403 569 9455
Fax: +1 403 569 9414
info@rotork.ca
Singapore
Tel: + 65 6457 1233
Fax: + 65 6457 6011
mail@rotork.com.sg
Spain
Bilbao
Tel: + 34 94 676 6011
Fax: + 34 94 676 6018
rotork@rotork.es
United Kingdom
Bramley, Leeds
Tel: +44 (0)113 236 3312
Fax: +44 (0)113 205 7266
sales@rotorkfluidsystem.co.uk
United States
Houston, Texas
Tel: +1 713 856 5640
Fax: +1 713 856 8127
rfsinfo@rotork.com
United States
Petaluma, California
Tel: +1 707 769 4880
Fax: +1 707 769 4888
rfsinfo@rotork.com
United States
North Kingstown, Rhode Island
Tel: +1 401 294 1400
Fax: +1 401 294 3388
Email: sales@remotecontrol.us
www.rotork.com
CP RANGE
COMPACT PNEUMATIC ACTUATORS
INSTALLATION
AND
MAINTENANCE
MANUAL
Publication F230E
Date of issue 03/08
TABLE OF CONTENTS
CP RANGE
INSTALLATION AND MAINTENANCE
SECTION
CONTENT
PAGE
Introduction
Installation
Maintenance
Grease Specification
Fault Detection
10
Page 2 of 10
Publication F230E
Date of issue 03/08
INTRODUCTION
CP RANGE
INSTALLATION AND MAINTENANCE
1.0
Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems CP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of CP Range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.
INSTALLATION
2.0
Installation
2.1
Electrical Considerations
2.1.1
Any electrical connections required are the responsibilty of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.
2.1.2
Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.
2.1.3
Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.
2.1.4
The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.
2.2
2.2.1
Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.
2.2.2
Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid Systems must be contacted to verify compatibility of any proposed changes to supply medium.
2.2.3
Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.
Page 3 of 10
Publication F230E
Date of issue 03/08
INSTALLATION
CP RANGE
INSTALLATION AND MAINTENANCE
2.3
2.3.1
The maximum temperature allowable for standard build actuators is 100C (212F). Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.
2.3.2
Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.
2.4
Operating Environment
2.4.1
The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.
2.4.2
If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.
2.5
Mechanical Considerations
2.5.1
It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.
2.5.2
Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.
2.5.3
Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.
2.54
All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.
2.5.5
When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.
2.5.6
Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.
2.5.7
Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
2.5.8
Once in position, the actuator should operate the valve with a smooth continuous action.If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
Page 4 of 10
Publication F230E
Date of issue 03/08
MAINTENANCE
CP RANGE
INSTALLATION AND MAINTENANCE
3.0
Maintenance
3.1
Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customers individual requirements.
3.2
Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.
3.3
No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.
3.4
Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.
3.5
Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.
3.6
After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.
3.7
Periodic Inspection
3.7.1
Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.
3.6.2
Verify that the power gas supply pressure value is within the required range.
3.7.3
3.7.4
3.7.5
Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.
3.7.6
Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.
Page 5 of 10
Publication F230E
Date of issue 03/08
CP RANGE
4.1
Grease Specification
Manufacturer:
Mobil
Trade name:
Mobiltemp 78
Colour:
Gray/black
Soap type:
Inorganic
Oil type:
Mineral
295/325 dmm
260C
485 cSt
32 cSt
Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.
4.2
Mobil
Trade name:
DTE 11
Viscosity at 40C:
16.5 cSt
Viscosity at 100C:
4.2 cSt
168
ISO Grade:
16
Pour point:
-42C
0.85 kg/dm3
Equivalent to:
Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.
Page 6 of 10
Publication F230E
Date of issue 03/08
CP RANGE
5.1
Disassembly
5.1.1
Ensure that the power gas supply to the actuator is shut off. For spring-return actuators, the actuator must be positioned
so that the spring is fully extended.
5.1.2
Disconnect power gas supply line from the end flange (item 4).
5.1.3
5.1.4
Remove the end flange (item 4) and the o-ring (item 14*) from the end flange.
5.1.5
Remove the cylinder tube (item 7) and o-ring (item 14*) that is between the cylinder tube and spring container (item 30)
on spring-return actuators or, on double-acting actuators is between the cylinder tube and housing (item 21).
5.1.6
For spring-return actuators, verify that the actuator is positioned so that the spring is fully extended as instructed in
step 5.1.1.
Note: When the spring is fully extended some spring force remains against the piston.
5.1.7A Double-acting actuators only: Unscrew the piston fixing bolt (item 10) and remove it and washer (item 8).
5.1.7B
Spring-return actuators only: Begin to unscrew the piston fixing bolt (item 10). Ensure that the piston is free and sliding
on the shaft as the fixing bolt is unscrewed so that all spring force is released before the fixing bolt is disengaged. Also
ensure that threaded bushing (item 18C) remains fixed inside the axial bar (item 18B). Remove piston fixing bolt (item 10)
and washer (item 8).
5.1.8
5.1.9
Remove the o-rings outside (item 6) and inside (item 9) the piston.
5.2
Reassembly
5.2.1
5.2.2
5.2.3
5.2.4
BOLT SIZE
NM
M8
20
FT. LBS
15
M10
40
30
M12
55
40
M14
110
81
M16
220
162
M20
430
317
5.2.5
Cycle the actuator several times. Its movement should be smooth and
continuous. If not, refer to Section 6, Fault Detection.
* On double-acting actuators item 14 is used in two locations: on both end
of the cylinder tube sealing against the end flange and the housing. On
spring-return actuators item 14 is used in three locations: between the end
flange and cylinder tube, between the cylinder tube and spring can, and
between the spring can and the housing.
Page 7 of 10
M16 (CP055)
130
96
M16 (CP065)
180
133
45
M12 (CP055)
85
33
63
M20 (CP065)
300
221
Publication F230E
Date of issue 03/08
FAULT DETECTION
CP RANGE
INSTALLATION AND MAINTENANCE
6.0
Fault Detection
In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.
SYMPTOM
CAUSE
REMEDY
Page 8 of 10
Publication F230E
Date of issue 03/08
CP RANGE
INSTALLATION AND MAINTENANCE
15
11
DOUBLE-ACTING
29
13
12
21
1
25
14
SPRING-RETURN
7
19
14
26
27
16
23
22
3
17
18A
9
4
14
28
5
24
10
30
18B
18C
31
ITEM
DESCRIPTION
MATERIAL
QTY
ITEM
Carbon Steel
17
Stop Nut
Carbon Steel
O-ring
Buna-N
End Flange
DESCRIPTION
MATERIAL
QTY
Spring Pin
Spring Steel
18A
18B
Ductile Iron
18C
Bushing threaded
Alloy Steel
Piston
Carbon Steel
19
Bushing
Steel/Bronze/Teflon
O-ring
Buna-N
20
Carbon Steel
Cylinder Tube
21
Housing
Carbon Steel
Washer
Carbon Steel
22
Carbon Steel
O-ring
Buna-N
23
Yoke
Ductile Iron
10
Alloy Steel
24
Tie Rod
Alloy Steel
11
Retaining Ring
Spring Steel
25
Adapter Plate
Ductile Iron
12
Key
Carbon Steel
26
Washer
Carbon Steel
13
Spring
Spring Steel
27
Bushing
Steel/Bronze/Teflon
14
O-Ring
Buna-N
28
Yoke Pin
15
O-ring
Buna-N
29
Output Shaft
16
Bushing
Steel/Bronze/Teflon
30
Spring Container
Carbon Steel
31
Spring
Spring Steel
Page 9 of 10
Publication F230E
Date of issue 03/08
www.rotork.com
Fluid Power Actuators and Control Systems
Electric Actuators and Control Systems
All Rotork Fluid Systems actuators are manufactured under a third-party accredited ISO 9001:2000 quality
assurance programme. As we are continually developing our products, their design is subject to change
without notice. Published data may be subject to change.
Elektrischer Anschluss
DC
1 Sicherung
Installation
Bei Installation, Wartung oder Reparatur sind unbedingt
die entsprechenden Ex-Vorschriften insbesondere EN
60079-14 und EN 50281-1-2 zu beachten.
Die elektrische Installation ist unter zustzlicher Beachtung einschlgiger nationaler Vorschriften (in Deutschland VDE 0100) von einer Elektrofachkraft bzw. unter
deren Aufsicht vorzunehmen.
Vor der Installation sind die Angaben der Gertekennzeichnung mit den vorgesehenen Betriebsbedingungen
zu vergleichen, um einen bestimmungsgemen Betrieb
sicherzustellen.
2 Varistor
3 Brckengleichrichter
4 Spule
AC / UC
1
3
4
7503455.50.08.02
Kabel
Bei der Auswahl der Anschlussleitung sind sowohl die
erforderliche Kabelqualitt (EN 60079-14) als auch der
Durchmesserbereich der Kabelverschraubung zu beachten. Bei Verwendung einer Silikon- (bzw. silikonhaltigen)
Anschlussleitung bzw. einer nicht ritzbestndigen Leitung
ist diese gegen mechanische Beschdigung zu schtzen
(z.B. unterbrochenes Rohrsystem mit Kantenschutz).
Bei hheren Umgebungstemperaturen ist zu beachten:
Betrieb
100% ED sind auch bei den ungnstigsten zulssigen
Umgebungsbedingungen erlaubt.
Im Betrieb ist sicherzustellen, dass weder die max. zul.
Umgebungs- und Fluidtemperaturen noch die Grenzleistung (max. 10% berspannung) berschritten werden. Gegebenenfalls ist der Magnet gegen berlast zu
schtzen.
Alle Magnete sind mit einem Varistor beschaltet. Zur
Vermeidung von Abschaltspannungsspitzen, die in der
Anlage zu Schden fhren knnen, muss der Anwender
ggf. ber den eingebauten Varistor hinausgehende geeignete Schutzmanahmen vorsehen.
Die Oberflche des Magneten kann bei Dauerbetrieb sehr
hei werden. Achtung: Verletzungsgefahr beim Berhren!
Wenn bei
t amb
PN
Tabelle 1
0.7 W / 1 VA
>66 C
4 W / 5 VA
>58 C
8 W / 9 VA
>61 C
11 W / 13 VA
>44 C
dann muss das Kabel >95 C temperaturbestndig sein.
Werden die in Tabelle 1 genannten Umgebungstemperaturen nicht erreicht, ist die Verwendung normal temperaturbestndiger Kabel zulssig.
Kabelverschraubung
Die Magnete sind in der EEx md- und EEx me-Ausfhrung absolut baugleich. Die jeweilige Zndschutzart wird
also erst mit der verwendeten Kabelverschraubung festgelegt!
Es drfen ausschlielich EEx d IIC- bzw. EEx e II-Kabelverschraubungen mit entsprechender Baumusterprfbescheinigung verwendet werden. Mit einer EEx dVerschraubung entsteht so ein EEx md-Magnet und mit
einer EEx e-Verschraubung dementsprechend ein EEx
me-Magnet.
Reduzierungen, Erweiterungen und bergangsstcke
mssen ebenfalls entsprechend bescheinigt sein. Die
Kabelverschraubung muss sachgerecht montiert werden,
damit die Schutzart IP66 (EN 60529) gewhrleistet ist.
Sicherung
Die in der Typenbersicht aufgefhrten Magnete haben
eine eingebaute Sicherung, deren Ausschaltvermgen 35
A ist. Sollte der maximal anzunehmende Kurzschlussstrom am Einbauort grer als 35A sein, so ist ein Kurzschlussschutz mit folgenden Bedingungen vorzuschalten:
Sicherungsauslegung max. 3 x IB (nach IEC 60127-2-1)
bzw. ein Motorschutzschalter mit Kurzschluss- und thermischer Schnellauslsung (Einstellung auf Bemessungsstrom); Sicherungs-Bemessungsspannung gleich oder
grer als die angegebene Nennspannung des Magneten;
Ausschaltvermgen gleich oder grer als der maximal
anzunehmende Kurzschlussstrom am Einbauort (blicherweise 1500 A). Die Sicherung darf im zugehrigen
Versorgungsgert untergebracht sein oder muss separat
vorgeschaltet werden.
Deckelmontage
Nach dem Anschluss ist der Deckel wieder sorgfltig zu
montieren. Um mindestens die Schutzart IP66 zu
gewhrleisten, ist dazu (ebenso wie bei der Kabelverschraubung) die Originaldichtung zu verwenden.
Ausfhrungen, die ab Werk mit Anschlusskabel geliefert
werden, sind verwendungsfertig, d.h. der Anschlussraum
braucht nicht mehr geffnet zu werden.
CE-Kennzeichnung
Die CE-Kennzeichnung ist kein Qualittsmerkmal, sondern richtet sich an die zustndigen Behrden. Um speziell den freien Warenverkehr in der EU zu ermglichen,
hat der Europische Rat gemeinsame Richtlinien fr den
europischen Markt erlassen, die Mindestanforderungen
fr Sicherheit und Gesundheitsschutz vorgeben.
Mit der CE-Kennzeichnung wird besttigt, dass Produkte
den Richtlinien entsprechen, d.h. konform mit den einschlgigen, insbesondere harmonisierten Normen sind.
Hinweise zur Richtline 94/9/EG
(Explosionsschutzrichtlinie [ATEX 100a]):
Die Magnete entsprechen der in der EG-Baumusterprfbescheinigung PTB 02 ATEX 2085X beschriebenen
Bauart und erfllen die einschlgigen Anforderungen der
Richtlinie.
Hinweise zur Richtlinie 73/23/EWG
(Niederspannungsrichtlinie):
Die Magnete wurden unter Beachtung der Norm
Elektromagnetische Gerte DIN VDE 0580 entwickelt,
konstruiert und gefertigt. Damit werden auch die
Anforderungen der Niederspannungsrichtlinie, die fr
Nennspannungen von 50 bis 1000 V AC und von 75 bis
1500 V DC Gltigkeit hat, erfllt.
Hinweise zur Richtlinie 89/336/EWG (EMV-Richtlinie):
Die Magnete erfllen die Anforderungen der Fachgrundnormen fr Straussendung (EN 50081-1) und fr Strfestigkeit (EN 50082-2) sowohl im Industriebereich als
auch im Wohn-, Geschfts- und Gewerbebereich sowie
in Kleinbetrieben.
Elektromagnete als Antriebselement fr Ventile stellen im
Sinne der EMV-Richtlinie keine selbststndig betreibbaren Gerte dar und werden nur durch fachkundige Betriebe weiterverarbeitet bzw. in eine Maschine eingebaut.
Die Inbetriebnahme ist solange untersagt, bis festgestellt
wurde, dass die Gesamtmaschine bzw. Anlage den Bestimmungen der EMV-Richtlinie entspricht.
Jedem Magnet ist eingangsseitig ein Varisator vorgeschaltet.
Beim Einsatz von AC- und UC-Ausfhrungen wird dem
Anwender empfohlen, am Versorgungsnetzeingang ggf.
zustzlich einen geeigneten Netzfilter (z.B.: X-Kondensator 47 nF) vorzusehen, um die physikalisch bedingte
leitungsgebundene Abschaltstrung der Magnetspule zu
dmpfen.
2
7503455.50.08.02
Typenbersicht Magnete
Magnet
Bestell-Nr.
Magnetschlusshlsendurchmesser
Anschlussgewinde
fr Kabelverschraubung
13 mm 16 mm
4600
4650 1/2-14 NPT
4601
4651
1/2-14 NPT
4602
4652
M20 X 1,5
4603
4653
M20 X 1,5
4610
4660
1/2-14 NPT
4611
4661
1/2-14 NPT
4612
4662
M20 X 1,5
4613
4663
M20 X 1,5
4620
4670
1/2-14 NPT
4621
4671
1/2-14 NPT
4622
4672
M20 X 1,5
4623
4673
M20 X 1,5
4630
4680
1/2-14 NPT
4631
4681
1/2-14 NPT
4632
4682
M20 X 1,5
4633
4683
M20 X 1,5
Tabelle 2
Nennleistung
(Grenzleistung)
0,7 W
bzw.
1,0 VA
(1,4W)
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V DC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
4W
bzw.
5 VA
(4,5 W)
8W
bzw.
9 VA
(8 W)
11 W
bzw.
13 VA
(13,1 W)
33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA
63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
3
0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 W
5,3 W
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 VA
5,3 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA
Zulssige
Umgebungs- und
Fluidtemperatur fr
Temperaturklassen
sowie
Oberflchentemperatur
Kategorie II2G
(Gase)
bei T5:
-40 +80 C
bei T6:
-40 +70 C
Kategorie II2D
(Stube)
T 130 C
Kategorie II2G
(Gase)
bei T4:
-40 +80 C
bei T6:
-40 +55 C
Kategorie II2D
(Stube)
T 130 C
Kategorie II2G
(Gase)
bei T4:
-40 +70 C
bei T6:
-40 +40 C
Kategorie II2D
(Stube)
T 130 C
Kategorie II2G
(Gase)
bei T4:
-40 +50 C
bei T5:
-40 +40 C
Kategorie II2D
(Stube)
T 130 C
7503455.50.08.02
EG - Konformittserklrung
nach Richtlinie 94/9/EG
____________________________________________________________________________
Hiermit erklren wir, dass die
Gerte:
Ventilbettigungsmagnete
Bestell-Nr.:
46xx
Allgemeine Bestimmungen
Druckfeste Kapselung d
Erhhte Sicherheit e
Vergusskapselung m
Schutz durch Gehuse
EEx md IIC
EEx me II
IP 66
T4/T5/T6
T4/T5/T6
T 130 C
EG-Baumusterprfbescheinigung:
PTB 02 ATEX 2085 X
erstellt von der Physikalisch-Technischen Bundesanstalt,
D-38116 Braunschweig (Benannte Stelle Nr. 0102)
EG-Zertifikat fr das Qualittssicherungssystem :
EX3 03 07 11122 009
ausgestellt vom TV Product Service GmbH,
D-80339 Mnchen (Benannte Stelle Nr. 0123)
ppa.
(Theo Paulus)
Techn. Leiter Deutschland
i.V.
(Dieter Maisch)
Explosionsschutzbeauftragter
Electrical Connection
DC
Installation
It is essential that the appropriate explosion regulations
in particular, EN 60079-14 and EN 50281-1-2 are
observed during installation, maintenance and repair.
Electrical installation is also to be carried out by or under
the supervision of a skilled electrician taking into account
the relevant national regulations (in Germany, VDE 0100).
Before installation, the device identification information
must be compared with the planned operating conditions
to ensure compliant usage.
1 Fuse
2 Varistor
3 Bridge rectifier
4 Coil
AC / UC
1
2
3
4
Terminals
The terminals are made without screws. The attachment
is only secured by a spring. To make the attachment, a
small screw driver, is pushed into one of the small slots
(see at illustration).
This then opens the spring.
After putting in the cable flex pull out the screw driver
again and the connection is established.
7503455.50.08.02
Cable
When selecting the connection cable, both the required
cable quality (EN 60079-14) and the cable gland diameter range should be taken into account. Silicone connecting leads, silicone containing connecting leads or cables
which are not scratch resistant have to be protected
against mechanical deterioration (e.g. intermittent piping
system with edge protection). In addition, the following
is applicable for versions that are supplied exworks without connecting cables:
All solenoids are fitted with a varistor. To avoid switchoff voltage spikes, which could lead to damage in the
equipment, the user must provide suitable protection
over and above the integral varistor if necessary.
Solenoid surfaces can become very hot during continuous operating. Warning: Risk of injury when touching!
CE Marking
The CE mark is not sign of quality but is directed
towards the responsible authorities.
The Council has published common directives for the
European Market especially to enable the free transfer of
goods within the EU, which prescribe minimum requirements for safety and the protection of health.
The CE mark confirms that products comply with the
Directives, i.e. conform to the relevant and in particular,
to the harmonised standards.
Comments on Directive 94/9/EC (Equipment in Explosive
Atmospheres [ATEX 100a]):
The solenoids comply with the type of construction
described in the EC Type Examination Certificate PTB 02
ATEX 2085 X and the relevant requirements of the Directive.
Comments on Directive 73/23/EEC (Low Voltage Directive):
The solenoids have been developed, designed and manufactured taking into account the standard on
Electromechanical Devices DIN VDE 0580. The requirements of the Low Voltage Directive, which is applicable
to rated voltages from 50 to 1000 V AC and from 75 to
1500 V DC, are thereby fulfilled.
Comments on Directive 89/336/EEC (EMC Directive):
The solenoids meet the requirements of the generic standards for emissions (EN 50081-1) and for immunity (EN
50082-2) both in the industrial area and in the domestic,
commercial and trading areas as well as in small businesses.
Electromagnets as actuators for valves do not represent
independently operated devices in the sense of the EMC
Directive and are only applied or fitted to a machine by
specialist operatives. It is not permissible to put the
machine into operation until it has been established that
the entire machine or system accords with the requirements of the EMC Directive.
All solenoids are fitted with a varistor. When using AC
and UC versions, the user must provide a suitable mains
filter (e.g. X-capacitor 47 nF) on the mains supply input
to suppress the physically inherent switch-off interference from the solenoid coil associated with the cables.
If used by
PN
t amb
Table 1
0.7 W / 1 VA
>66 C
4 W / 5 VA
>58 C
8 W / 9 VA
>61 C
11 W / 13 VA
>44 C
then the cable must be able to withstand temperatures of
>95 C. If the ambient temperatures given in Table 1 are
not reached, the use of normally temperature resistant
cable is permissible.
Cable gland
The EEx md- and EEx me-versions of the solenoids are
built absolutely identically. Each type of protection will be
defined by the applied cable connectors.
Only EEx d IIC- or EEx de II-cable glands with test certificates are allowed to be used. With EEx d-connection is a
EEx md-solenoid and with a EEx e-connection is a EEx
me-solenoid.
Reductions, extentions and spare parts have to be certificated also. The cable connection has to be fitted suitably
for IP66 (EN 60529) is guaranteed.
Fuse
The solenoids of the chart are fitted with a fuse whose
breaking capacity is 35 A. Should the short circuit current at the place of fitting higher than 35A, a protection
will work and switch on a rated voltage that has at least
the nominal voltage.
Fuse assembly max. 3 x IB (according IEC 60127-2-1) or
motor protection switch with short circuit- and thermal
action (set to current rating); fuse voltage rating equal or
more than voltage rating of the solenoid; breaking capacity equal or more than max. possible fault current in the
place of installation (normally 1500 A). The fuse may be
located in power source or must be separately ballasted.
Mounting of cover
After connecting, the cover must be carefully refitted.
The original gasket must be used to guarantee a protection category of at least IP 66 (as with the cable gland).
Versions that are supplied ex-works with a connection
cable are ready for use, i.e. it is not necessary for the
terminal box to be re-opened.
Operation
100% ED is allowed even under the most unfavourable
permissible ambient conditions.
It must be ensured that neither the maximum permissible ambient and fluid temperatures nor the limiting
power (max. 10% overvoltage) are exceeded during
operation. The solenoid must be protected against overload if necessary.
2
7503455.50.08.02
Table 2
Connection
thread for
cable gland
Nominal
power
(max.
power)
Nominal
voltage
Nominal
current
Rated
Power
Protection class
current of consumpintegrated tion
fuse
Max. permissible
ambient and fluid
temperature for
temperature classes
and surface temperature
0,7 W
or
1,0 VA
(1,4W)
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V DC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA
63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
Category II2G
(gases)
for T5:
-40 +80 C
for T6:
-40 +70 C
13 mm 16 mm
4600
4650
1/2-14 NPT
4601
4651
1/2-14 NPT
4602
4652
M20 X 1,5
4603
4653
M20 X 1,5
4610
4660
1/2-14 NPT
4611
4661
1/2-14 NPT
4612
4662
M20 X 1,5
4613
4663
M20 X 1,5
4620
4670
1/2-14 NPT
4621
4671
1/2-14 NPT
4622
4672
M20 X 1,5
4623
4673
M20 X 1,5
4630
4680
1/2-14 NPT
4631
4681
1/2-14 NPT
4632
4682
M20 X 1,5
4633
4683
M20 X 1,5
4W
or
5 VA
(4,5 W)
8W
or
9 VA
(8 W)
11 W
or
13 VA
(13,1 W)
0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 W
5,3 W
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 VA
5,3 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA
Category II2D
(dusts)
T 130 C
Category II2G
(gases)
for T4:
-40 +80 C
for T6:
-40 +55 C
Category II2D
(dusts)
T 130 C
Category II2G
(gases)
for T4:
-40 +70 C
for T6:
-40 +40 C
Category II2D
(dusts)
T 130 C
Category II2G
(gases)
for T4:
-40 +50 C
for T5:
-40 +40 C
Category II2D
(dusts)
T 130 C
7503455.50.08.02
EC - Declaration of Conformity
In accordance with Directive 94/9/EC
____________________________________________________________________________
This is to declare that the
Equipment:
Valve Solenoids
Model Series:
46xx
is in conformity with the provisions of the Directive 94/9/EC for use in potentially explosive atmospheres.
Referenced normative documents:
EN 50 014:1997
EN 50 018:2000
EN 50 019:2000
EN 50 028:1987
EN 50281-1-1:1998
General requirements
Flameproof enclosures d
Increased safety e"
Encapsulation "m"
Protection by enclosure
EEx md IIC
EEx me II
IP 66
T4/T5/T6
T4/T5/T6
T 130 C
ppa.
(Theo Paulus)
Technical Director Germany
i.V.
(Dieter Maisch)
Authorized Representative
B73G
Installation & Maintenance
Instructions
Filter/Regulator
B73G - - -
Port
2 ....1/4"
3 ....3/8"
4 ....1/2"
Adjustment
Thread Form
K....Knob
A....PTF
B....ISO Rc taper T ....T-bar
G....ISO G parallel
Drain
Bowl
A....Automatic
D....Metal with liquid level indicator
Q....Manual, 1/4 turn P....Transparent with guard
T ....Transparent
Diaphragm
Element
1 ....5 m N....Non-relieving
2 ....25 m R....Relieving
3 ....40 m
Gauge
G....With
N....Without
* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges.
TECHNICAL DATA
Fluid: Compressed air
Maximum pressure:
Transparent bowl: 10 bar (150 psig)
Metal bowl: 17 bar (250 psig)
Operating temperature*:
Transparent bowl: -20 to +50C (0 to +125F)
Metal bowl: -20 to +80C (0 to +175F)
* Air supply must be dry enough to avoid ice formation at
temperatures below +2C (+35F).
Particle removal: 5 m, 25 m, or 40 m filter element
Air quality: Within ISO 8573-1, Class 3 and Class 5
(particulates)
Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar
(90 psig) set pressure and 1 bar (15 psig) droop from
set: 50 dm3/s (106 scfm)
Nominal bowl size: 0,1 litre (3.5 fluid ounce)
Manual drain connection: 1/8"
Automatic drain connection: 1/8"
Automatic drain operating conditions (float operated):
Bowl pressure required to close drain: Greater than 0,3
bar (5 psig)
Bowl pressure required to open drain: Less than 0,2 bar
(3 psig)
Minimum air flow required to close drain: 0,1 dm3/s (0.2
scfm)
Manual operation: Depress pin inside drain outlet to
drain bowl
Gauge ports:
14 PTF with PTF main ports
Rc1/4 with ISO Rc main ports
Rc1/8 with ISO G main ports
Materials:
Body: Aluminum
Bonnet: Aluminum
Valve: Brass
Bowl:
Transparent: Polycarbonate
Transparent with guard: Polycarbonate, steel guard
Metal: Aluminum
Metal bowl liquid level indicator lens: Transparent nylon
Element: Sintered polypropylene
Elastomers: Neoprene and nitrile
REPLACEMENT ITEMS
Service Kit (includes items circled on exploded view):
Relieving.............................................................4383-600
Nonrelieving .......................................................4383-601
Liquid level lens kit (43, 45, 46, 47) ......................4380-020
Filter element, 5m (50) ..........................................4438-01
Filter element, 25m (50) ........................................4438-02
Filter element, 40m (50) ........................................4438-03
Manual drain (18, 19, 20) ..........................................619-50
Automatic drain (21, 22, 23) .................................4000-51R
Tamper resistant cover (knob adjustment only).......4455-51
PANEL MOUNTING DIMENSIONS
Panel mounting hole diameter: 48 mm (1.89")
Panel thickness: 2 to 6 mm (0.06" to 0.24")
INSTALLATION
1. Shut off air pressure. Install filter/regulator in air line vertically (bowl down),
with air flow in direction of arrow on body,
upstream of lubricators and cycling valves,
as close as possible to the device being serviced.
2. Connect piping to proper ports using pipe thread sealant
on male threads only. Do not allow sealant to enter
interior of unit.
3. Push bowl, or bowl with guard, into body and turn fully
clockwise before pressurizing.
4. Install a pressure gauge or plug the gauge ports. Gauge
ports can also be used as additional outlets for regulated air.
ADJUSTMENT
1. Before applying inlet pressure to filter/regulator, turn
adjustment (1 or 7) counterclockwise to remove all force
on regulating spring (12).
2. Apply inlet pressure, then turn adjustment (1 or 7)
clockwise to increase and counterclockwise to decrease
pressure setting.
3. Always approach the desired pressure from a lower
pressure. When reducing from a higher to a lower
setting, first reduce to some pressure less than that
desired, then bring up to the desired pressure.
NOTE
With non-relieving filter/regulators, make pressure
reductions with some air flow in the system. If
made under no flow (dead-end) conditions, the
filter/regulator will trap the over-pressure in the
downstream line.
4. KNOB ADJUSTMENT. Push knob down to lock pressure
setting. Pull knob up to release. Install tamper resistant
cover (see Replacement Items) to make setting tamper
resistant.
5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock
pressure setting.
SERVICING
1. Open manual drain to expel accumulated liquids. Keep
liquids below baffle (49).
2. Clean or replace filter element when dirty.
DISASSEMBLY
1. Filter/regulator can be disassembled without removal
from air line.
2. Shut off inlet pressure. Reduce pressure in inlet and
outlet lines to zero.
3. Turn adjustment (1 or 7) fully counterclockwise.
4. Remove bowl - push into body and turn
counterclockwise.
5. Disassemble in general accordance with the item
numbers on exploded view. Do not remove the drains
unless replacement is necessary. Remove and replace
drains only if they malfunction.
CLEANING
1. Clean plastic bowl (25, 35) with warm water only. Clean
other parts with warm water and soap.
2. Rinse and dry parts. Blow out internal passages in body
(16) with clean, dry compressed air. Blow air through
filter element (50) from inside to outside to remove
surface contaminants.
3. Inspect parts. Replace those found to be damaged.
Replace plastic bowl with a metal bowl if plastic bowl
shows signs of cracking or cloudiness.
ASSEMBLY
1. Lubricate the following items with o-ring grease.
4 (Thrust washer) - outer circumference and both sides.
5, 7 (Adjusting screw) - threads and tip.
18, 28, 37 (Manual drain body) - the portion of the
body that contacts the bowl, and the hole that
accommodates the stem of drain valve (19, 29, 38).
53 (Valve) - stem.
26, 34, 47, 54 (O-rings)
2. Assemble the unit as shown on the exploded view. Push
bowl, or bowl with guard, into body and turn fully
clockwise.
3. Torque Table
Item
Torque in Nm (Inch-Pounds)
2, 9 (Screw)
2,3 to 3,4 (20 to 30)
22, 32, 41 (Nut)
2,3 to 2,8 (20 to 25)
43 (Screw)
1,7 to 3,4 (15 to 30)
49 (Baffle), 51 (Louver)
1,1 to 2,2 (10 to 20)
12
13
2
16
15
5
14
53
54
52
7
8
51
10
9
50
11
49
26
18
21
23
17
25
24
20
19
22
34
28
31
27
35
33
30
29
32
47
37
40
48
46
36
45
43
42
39
38
41
44
Norgren 1998
IM-180.300.01 (4/98)
a subsidiary of IMI plc
Supersedes 12/97
B73G
Installation & Maintenance
Instructions
CAUTION
Water vapor will pass through these units and could
condense into liquid form downstream as air temperature
drops. Install an air dryer if water condensation could have
a detrimental effect on the application.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
Polycarbonate plastic bowls can be damaged and
possibly burst if exposed to such substances as certain
solvents, strong alkalies, compressor oils containing esterbased additives or synthetic oils. Fumes of these
substances in contact with the polycarbonate bowl,
externally or internally, can also result in damage. Clean
with warm water only.
Use metal bowl in applications where a plastic bowl
might be exposed to substances that are incompatible with
polycarbonate.
If outlet pressure in excess of the filter/regulator
pressure setting could cause downstream equipment to
rupture or malfunction, install a pressure relief device
downstream of the filter/regulator. The relief pressure and
flow capacity of the relief device must satisfy system
requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.
Norgren 1998
IM-180.300.02 (4/98)
a subsidiary of IMI plc
Supersedes 12/97