RACK AND PINION PNEUMATIC ACTUATORS, SERIES DC DOUBLE ACTING AND SERIES DJ SPRING RETURN

Transcription

1 RACK AND PINION PNEUMATIC ACTUATORS, SERIES DC DOUBLE ACTING AND SERIES DJ SPRING RETURN 6 DC/DJ 20 Issue 10/98 FEATURES Dual-piston rack and pinion design for compact construction, symmetric mounting positions, high-cycle life and fast operation. Series DC and DJ double-opposed piston actuators provide the benefits of high cycle life, good corrosion resistance and a flexible compact design with an outstanding range of features. They are designed for fast, efficient and reliable operation of ball, butterfly and other rotary valve designs. These actuators can be operated with air or gas up to 10 bar/150 psi and provide a torque output range up to 5000 Nm/3700 lb ft in double acting and 1800 Nm/1300 lb ft in spring return version. Spring return versions are available in a number of different spring ratings to suit various operating pressure supplies. Code DJ designates a failure mode corresponding to the valve closed position and DJA designates reverse operation providing a failure mode corresponding to the valve open position. Extruded aluminium body with both external and internal corrosion protection. Honed cylinder surface for longer life and lower coefficient of friction. Travel stop adjustment in both directions as standard provides + or - 4 degree adjustment on 0 and 90 positions for accurate alignment of valve ball, disc or segment. Identical body and end-caps for double acting and spring return models to reduce inventory and allow field conversion, by adding or removing spring cartridges. Multiple bearings and guides around pistons and racks for precise operation, low friction and high-cycle life. Fully machined teeth on piston racks and pinions for accurate, low backlash rack and pinion engagement and maximum efficiency. Electroless nickel-plated anti-blow-out one-piece pinion for improved safety and corrosion resistance. Top and bottom pinion bearings for maximum wear resistance and tolerance of incorrect valve shaft alignment. Machined flats on top of shaft allows for manual operation. Reverse rotation, to change the failure mode of spring return actuators, can be accomplished in the field by simply inverting the pistons. Multi-spring design with preloaded and self contained spring cartridges for improved safety and easy adaptation to changing air supply pressures. Epoxy coated springs for corrosion resistance and extended life. High-quality bearings and seals for low friction and wide operating temperature range (-20 C to 80 C / -4 F to 176 F) with extended temperature options. Internal and external stainless steel fasteners for long term corrosion resistance. Full conformance to ISO 5211, VDI/VDE 3845 NAMUR, DIN 3337 specifications for product interchangeability and easy mounting of solenoids, limit switches and other accessories. Manufactured under a quality system independently assessed and approved to EN ISO Every actuator factory tested and provided with a unique serial number for traceablity.

2 N E L E S C O N T R O L S EXPLODED VIEW A * ** 09 ** 06 * 16 10A 11A * A * **15 17 ** 05 ** 09 **05 02 * A 13 * 14 10A 11A 02 24* * 06 * 21 11A 10 * **15 04 * ** 07 * 22 PART. N. UNIT. Q.ty Note: *SPARE PARTS CONTAINED IN STANDARD SERVICE KIT - MODEL DC/DJ 70 PART. N. 13 AND 13a UNIT QUANTITY 12 PCS. PARTS LIST (standard construction) PART MATERIAL SPECIFICATIONS PROTECTION 01 1 Body Extruded aluminum alloy ASTM 6063 T6 Anodized + PTFE or ENP 02 2 Piston Aluminum alloy ASTM B179 - DIN 1725/ End-caps Aluminum alloy ASTM B179 - DIN 1725/5 Polyester coated 04 1 Drive shaft Forged steel - ENP ASTM A105 Nickel plated (ENP) *05 2 Bearing (piston back) Nylon 46 *06 1 Bearing (pinion top) Nylon 46 *07 1 Bearing (pinion bottom) Nylon 46 *08 1 Thrust bearing (pinion) Nylon 46 08a 1 Thrust washer (pinion) Stainless steel AISI 304 *09 2 Plug (transfer port) Nitrile (NBR) 10 2 Screw (ext. stroke adj.) Stainless steel a 2 Screw (int. stroke adj.) Stainless steel 18-8 *11 4 O ring (screw seal) Nitrile (NBR) 11a 4 Washer (seal) Stainless steel AISI Nut (stop adjustment) Stainless steel Cap screw (end-cap) Stainless steel a 8 Washer (cap screw) Stainless steel 18-8 *14 2 O ring (end-cap) Nitrile (NBR) *15 2 Bearing (piston head) Nylon 46 *16 2 O ring (piston) Nitrile (NBR) max Spring (cartridge)dj/dja only High alloy spring steel Epoxy coated 18 1 Spring clip (pinion) High alloy spring steel Nickel plated 19 1 Position indicator Polyamide 20 1 Cap screw/washer Stainless steel 18-8 *21 1 O ring (pinion top) Nitrile (NBR) *22 1 O ring (pinion bottom) Nitrile (NBR) 24 2 Guide piston Polyphthalamide + 45% FG Please refer to the separate Neles Controls IMO instructions before installing, maintaining or operatings these products

3 R A C K A N D P I N I O N P N E U M A T I C A C T U A T O R S, S E R I E S D C D O U B L E A C T I N G A N D S E R I E S D J S P R I N G R E T U R N Operating Media: Dry or clean air, non corrosive and inert gas or light hydraulic oil. Supply pressure range: Double acting from 2 bar to 10 bar max /30 to 150 psi max. Spring return from 3 bar to 10 bar max/45 to 150 psi max. Operating Temperature: Standard product -20 C to 80 C /-4 F to 176 F. High temperature option (H): With Viton o-rings -20 to 150 C /-4 F to 300 F. SPECIFICATIONS Environment: Suitable for indoor or outdoor installation. External Travel Stop Adjustment: ±4 degree adjustment on 90 degree stroke. Internal Travel Stop Adjustment: ±4 degree adjustment on 0 degree stroke. STANDARDS Actuator to valve mounting: ISO 5211/1 Actuator to solenoid mounting: Namur, VDI/VDE 3845* Actuator to accessory mounting: VDI/VDE 3845 Lubrication: Factory lubricated for the life of the actuator under normal working conditions. *Except DC/DJ 70 TECHNICAL DATA ACTUATOR SIZE MODEL DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA DC DJ/DJA Volume-Lt Opening time-sec* Closing time-sec* Weight-kg Weight-lbs * Actual times depend on various factors including: Supply pressure, valve torque, instrumentation piping size and solenoid selected. Hard anodized and PTFE standard (class B) Hard Anodic oxidation is an electrolytic conversion process which results in the formation of an oxide film approximately one half of the total depth of the entire hard anodizing process. Continuation of the process produces the hard anodic coating to approximately 50 microns. The resulting part resists corrosion in sodium chloride spray and immersion tests and also resists stress corrosion cracking. The oxide coating is integral with the base substrate and will not spall off by impacting thermal shock nor to temperatures to aluminum s melting point. Aluminum oxide is one of the hardest materials known with a hardness of corundum (45 to 65 Rockwell C). Aluminum oxide is relatively stable and chemically inert. The oxide is usually stable over a ph range of 4.5 to 8.5, but can be dissolved by strong acids and alkalis, whereas it normally resists concentrated nitric acid at ph 1 and ammonium hydroxide at ph 13. For additional protection after anodizing, the external body surface is coated with a film of PTFE, which fills the micropores of the surface. PTFE coating is also a dirt repelling and chemically inert surface protection. End-caps are externally protected with a blue polyester resin finish. The pinion is ENP plated and external bolting is in stainless steel. EXTERNAL CORROSION PROTECTION TO BODY Electroless Nickel Coating - ENP (Option class C) Electroless nickel plating is a chemical plating process that autocatalytically deposits nickel alloyed with up to 12% by weight phosphorus. Electroless nickel deposits are produced by chemical reduction of nickel onto catalytic metallic or catalyzed nonmetallic substrates without the use of electricity. Blind holes, threads, channels, recesses or internal areas receive the same amount of plate as sharp corners, edges or flat surfaces. Therefore, total as plated thickness can often be reduced and close tolerances (within 20 to 30 microns) maintained. Normal hardness averages about 49 Rockwell C; however, heat treatment could increase hardness. It offers a good corrosion resistance (in salt fog) and is more resistant in alkaline environments than in acid environments. Care should be taken not to damage the ENP surface by scratching or gouging because this exposes the base metal to corrosion. A polyester coating is applied to the external surfaces of the body for additional protection. End-caps are externally protected with a blue polyester resin finish. The pinion is ENP plated and external bolting is in stainless steel

4 N E L E S C O N T R O L S DESIGN AND OPERATION Series DC double acting (top view) Air supplied via Port A forces pistons apart and toward end caps, exhaust air exits via Port B (pinion rotates counterclockwise). Air supplied via Port B forces pistons toward centre, exhaust air exits via Port A (pinion rotates clockwise). Series DJ spring return, spring to close (top view) Air supplied via Port A forces pistons apart and toward end caps, compressing springs. Exhaust air exits via Port B (pinion rotates counter-clockwise). Air failure/exhaust allows springs to force pistons toward centre position, exhaust air exits via Port A (pinion rotates clockwise). Reverse rotation series DJA spring return, spring to open (top view) Pistons are inverted in order to provide clockwise pinion rotation when air pressure is applied via Port A. Counter-clockwise pinion rotation is achieved in the failure mode

5 R A C K A N D P I N I O N P N E U M A T I C A C T U A T O R S, S E R I E S D C D O U B L E A C T I N G A N D S E R I E S D J S P R I N G R E T U R N In rack and pinion construction the output torque of a double acting actuator is the result of the piston force (given by air supply pressure) multiplied by the pitch shaft radius (lever or ACTUATOR OUTPUT CHARACTERISTICS arm) as shown below less the force lost for friction (efficiency). The resulting output torque is linear as shown in the diagram A in both clockwise and counterclockwise rotation. Diag. A In spring return actuator applications output torque comes from in two different operations as shown below. Each operation produces a constanly decreasing torque output, which for sizing purposes is normally expressed as two different values in relation to the end stroke positions (0 and 90 ). For spring return actuators the output torque is produced by multiplying the force (air or springs acting on the pistons) by the lever or arm. AIR STROKE: output torque is generated by air supply pressure via Port A after compressing the springs. In this case air forces the pistons from the 0 to the 90 position and consequently the torque starts from a high value and during the stroke it constantly decreases until 90 due to the natural force that springs oppose when they compress (see diag. B). SPRING STROKE: output torque is generated by the power that springs release on the pistons when air fails and is exhausted. In this case the torque, starting from the 90 position, constantly decreases until 0 as a result of spring extension. (see diag. C) Diag. B The standard DJ spring return actuator has been designed to produce a balanced torque in the two conditions explained above when the spring number per side is equal to the air pressure supply (5 bar - 5 springs each side). For some applications it is also possible to obtain, if desired, an unbalanced torque, by changing the relationship Diag. C between the number of springs per side and air pressure supply in bar (for example 6 springs and 5.5 bar or viceversa). In spring return applications two operating conditions can be required: air failure to close (DJ) or air failure to open (DJA)

6 N E L E S C O N T R O L S ACTUATOR OUTPUT TABLES, Nm DOUBLE ACTING TORQUE RATINGS IN Nm ACTUATOR MODEL AIR SUPPLY IN bar AND SIZE (cylinder ø) DC O5 (50) DC 10 (63) DC 20 (75) DC 25 (85) DC 30 (100) DC 35 (115) DC 40 (125) DC 45 (145) DC 50 (160) DC 60 (200) DC 70 (270) ACTUATOR MODEL AND SIZE (cylinder ø) DJ/DJA 05 SR (50) DJ/DJA 10 SR (63) DJ/DJA 20 SR (75) DJ/DJA 25 SR (85) DJ/DJA 30 SR (100) DJ/DJA 35 SR (115) DJ/DJA 40 SR (125) DJ/DJA 45 SR (145) DJ/DJA 50 SR (160) DJ/DJA 60 SR (200) DJ/DJA 70 SR (270) Standard SPRING RETURN TORQUE DJ/DJA RATINGS IN Nm SPRING AIR STROKE (supply pressure in bar) SPRING SET STROKE NUMBER START END START END START END START END START END START END START END

7 R A C K A N D P I N I O N P N E U M A T I C A C T U A T O R S, S E R I E S D C D O U B L E A C T I N G A N D S E R I E S D J S P R I N G R E T U R N ACTUATOR OUTPUT TABLES, lb ft DOUBLE ACTING TORQUE RATINGS IN lb ft ACTUATOR MODEL AIR SUPPLY IN psi AND SIZE (cylinder ø) DC O5 (50) DC 10 (63) DC 20 (75) DC 25 (85) DC 30 (100) DC 35 (115) DC 40 (125) DC 45 (145) DC 50 (160) DC 60 (200) DC 70 (270) ACTUATOR MODEL AND SIZE (cylinder ø) DJ/DJA 05 SR (50) DJ/DJA 10 SR (63) DJ/DJA 20 SR (75) DJ/DJA 25 SR (85) DJ/DJA 30 SR (100) DJ/DJA 35 SR (115) DJ/DJA 40 SR (125) DJ/DJA 45 SR (145) DJ/DJA 50 SR (160) DJ/DJA 60 SR (200) DJ/DJA 70 SR (270) Standard SPRING RETURN TORQUE DJ/DJA RATINGS IN lb ft SPRING AIR STROKE (supply pressure in psi) SPRING SET STROKE NUMBER START END START END START END START END START END START END START END

8 N E L E S C O N T R O L S DIMENSIONAL DRAWINGS Q M5xD X N T SPIGOT WHEN SPECIFIED h R PORT 'B' PORT 'A' B MAX. PRESSURE 10BAR-142P.S.I. ød J C L H A I X M6 4 M5xE VDI/VDE 3845 (except DC/DJ 70 solenoid mounting) 4 12 G F MOUNTING DIMENSIONS DC/DJ 20, BOTTOM VIEW-ISO 5211 DC/DJ AND 25-70, BOTTOM VIEW-ISO CH 45 ø 5O 45 P M6x9 M8x M6x9 M8x U S U M S APPROXIMATE DIMENSIONS in mm ACTUATOR SIZE ALL MODELS A B C F G L J N Q R T - ISO 228 1/8 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/2" DOUBLE ACTING (INCLUDING SQUARE DRIVE) MODEL AND SIZE DCO5 DC10 DC20 DC25 DC30 DC35 DC40 DC45 DC50 DC60 DC70 ISO FLANGE F04 F05 F05/F07 F07 F07 F10 F10 F12 F12 F14 F16 S / U M5 M6 M6/M8 M8 M8 M10 M10 M12 M12 M16 M20 ø d* h max,* øo M P CH ** 17** I min, key I min, square ** 19** - 8 -

9 R A C K A N D P I N I O N P N E U M A T I C A C T U A T O R S, S E R I E S D C D O U B L E A C T I N G A N D S E R I E S D J S P R I N G R E T U R N SPRING RETURN (INCLUDING SQUARE DRIVE) MODEL AND SIZE DJ/DJAO5 DJ/DJA10 DJ/DJA20 DJ/DJA25 DJ/DJA30 DJ/DJA35 DJ/DJA40 DJ/DJA45 DJ/DJA50 DJ/DJA60 DJ/DJA70 ISO FLANGE F04 F05 F05/F07 F07 F07 F07 F07 F10 F12 F12 F14 S / U M5 M6 M6/M8 M8 M8 M8 M8 M10 M12 M12 M16 ø d* h max,* øo M P CH ** 17** Imin, key Imin, square ** 19** * Optional ** Standard in protection C APPROXIMATE DIMENSIONS in inch ACTUATOR SIZE ALL MODELS A B C F G L J N Q R T - ISO 228 1/8 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/4 "1/2" DOUBLE ACTING (INCLUDING SQUARE DRIVE) MODEL AND SIZE DCO5 DC10 DC20 DC25 DC30 DC35 DC40 DC45 DC50 DC60 DC70 ISO FLANGE F04 F05 F05/F07 F07 F07 F10 F10 F12 F12 F14 F16 S / U M5 M6 M6/M8 M8 M8 M10 M10 M12 M12 M16 M20 ø d* h max,* øo M P CH ** 0.67** Imin, key Imin, square ** 0.75** SPRING RETURN (INCLUDING SQUARE DRIVE) MODEL AND SIZE DJ/DJAO5 DJ/DJA10 DJ/DJA20 DJ/DJA25 DJ/DJA30 DJ/DJA35 DJ/DJA40 DJ/DJA45 DJ/DJA50 DJ/DJA60 DJ/DJA70 ISO FLANGE F04 F05 F05/F07 F07 F07 F07 F07 F10 F12 F12 F14 S / U M5 M6 M6/M8 M8 M8 M8 M8 M10 M12 M12 M16 ø d* h max,* øo M P CH ** 0.67** Imin, key Imin, square ** 0.75** * Optional ** Standard in protection C - 9 -

10 N E L E S C O N T R O L S HOW TO ORDER TYPE CODING Double acting actuators TYPE CODING Single acting actuators DC 20 C H P F05 / 20 K DJ A 20 SR5 C H P F05 / 20 K sign Product series DC Double acting cylinder actuator, DC-series 1. sign Product series DJ Single acting cylinder actuator, DJ-series 2. sign Size - Actuator size eg sign Surface protection - C Protection class B, standard without sign. Hard anodized + PTFE coated body Protection class C. ENP coated body 4. sign Materials of seals and bearings - H Standard without sign, for temperatures C / F * bearings: POM + PTFE * o-rings: Nitrile rubber (NBR) For temperatures C / -4 F F * bearings: PA (Nylon 46) * o-rings: FPM (Viton) 5. sign Painting - Neles Controls standard painting without sign P Non standard painting (special colour end caps), to be specified in order 6. sign Mounting pattern - Neles Controls standard ISO 5211 mounting pattern without sign F05 S Special size of ISO mounting pattern, to be specified. Mounting pattern with a guidance spigot, eg. F05S 7. sign Stem size - Stem size (diameter or square flat width), eg sign Stem type - Square stem without sign K Key stem 2. sign Spring action - Spring to close without sign A Spring to open 3. sign Size - Actuator size, eg sign Spring rate SR5 Spring rate, the number indicates the amount of springs. SR5 is standard spring rate, other alternatives are SR3, SR4 and SR6. 5. sign Surface protection - C Protection class B, standard without sign. Hard anodized + PTFE coated body Protection class C. ENP coated body 6. sign Materials of seals and bearings - H Standard wihout sign, for temperatures C / F * bearings: POM + PTFE * o-rings: Nitrile rubber (NBR) For temperatures C / -4 F F * bearings: PA (Nylon 46) * o-rings: FPM (Viton) 7. sign Painting - Neles Controls standard painting without sign P Non standard painting (special colour end caps), to be specified in order 8. sign Mounting pattern - Neles Controls standard ISO 5211 mounting pattern without sign F05 S Special size of ISO mounting pattern, to be specified. Mounting pattern with a guidance spigot, eg. F05S 9. sign Stem size - Stem size (diameter or square flat width), eg sign Stem type - Square stem without sign INTERNATIONAL MANUFACTURING AND SALES LOCATIONS Subject to change without prior notice. UNITED STATES: Shrewsbury, Massachusetts. MEXICO: Chihuahua. BRAZIL: São José dos Campos. FINLAND: Helsinki. FRANCE: Wittenheim. PEOPLE S REPUBLIC of CHINA: Shanghai. Our products are available through Neles Controls sales offices in Australia, Austria, Belgium, Canada, Chile, Denmark, England, Germany, Indonesia, Italy, Japan, The Netherlands, Norway, Portugal, Russia, Saudi Arabia, Singapore, South Africa, South Korea, Spain, Sweden, Switzerland, Thailand, United Arab Emirates, Venezuela, as well as through a world-wide network of representatives. K Key stem Neles Controls Oy P.O. Box 110, Helsinki, Finland Tel. int Fax int Neles Controls Inc. P.O. Box 8004, Shrewsbury, MA 01545, USA Tel. int Fax int Neles Controls PTE. LTD 501 Orchard Road, #05-09 Wheelock Place, Singapore Tel. int Fax int NELES CONTROLS GROUP A MEMBER OF RAUMA CORPORATION