Single acting hydraulic actuators with gas cartridge (Nitrogen) ENNACTO 200 to 1600: scotch -yoke kinematic

Transcription

1 Operating instructions /4--10 Single acting hydraulic actuators with gas cartridge (Nitrogen) ENNACTO 200 to 1600: scotch -yoke kinematic ENNACTO 3200 to 12500: Rod and crank kinematic Output torques up to Nm 1. Declaration of conformity 2 2. General 3 3. Safety 3 4. Transport and interim storage 4 5. Description of actuators 5 6 Installation Commissioning / Decommissioning Monthly checking Maintenance Gas spring cartridge Dismantling actuator Re -assembly actuator Tests Actuator / valve coupling Residual risks Trouble shooting 22

2 1. Declaration of conformity Hereby we, KSB S.A.S Zone industrielle Gagnaire Fonsèche LA ROCHE CHALAIS Registered Office: Gennevilliers France declare that the actuators listed below comply with the requirements of the Pressure Equipment Directive 97/23/EC. Description of the actuator types: Single acting hydraulic actuator with gas cartridge (Nitrogen) As per harmonized European standards: EN and other standards / directives: EN ; EN Suitable for: Fluid group 2 Conformity Assessment Procedure: Name and address of the notified body for orders made until 30/09/2011: Module H Lloyd s Register Verification Limited 71 Fenchurch Street, London EC3M 4BS England Number of notified body: 0038 Number of certificate: RPS /01 Name and address of the notified body for orders made from the 01/10/2011: Bureau Veritas 67/71 boulevard du Château Neuilly -sur -Seine FRANCE Number of notified body: 0062 Number of certificate: CE -PED -H -KSB FRA Michel Delobel Quality Assurance (This document was prepared electronically and is valid without signature) rev /11 2

3 2. General These operating instructions apply to KSB single acting hydraulical actuators ENNACTO type, with pressurized gas cartridge used as energy acccumulator (see section 5). ENNACTO actuators are safety actuators. Theirs operations must be spaced out in the time. It is not autorized to make more than 4 operations by hour. A greater important number of operations lead to an overheating of the spring gas: see section Residual risks. Design, manufacturing and testing of the KSB actuators are subject to a Quality Assurance System according to EN ISO 9001 and to the European Pressure Equipment Directive 97/23/EC (PED). Correct installation and maintenance or repair are mandatory to ensure trouble free operation of these actuators. The manufacturer cannot be made liable for these actuators if operating instructions are not observed. ATTENTION The actuators must not be operated outside the permissible operating range. The limits are indicated on the name plate or currently applicable type leaflet. The pressure and temperature, in particular, must not be exceeded. An use outside the above-mentioned conditions may result in overpressure of the energy accumulator, which may not be bearable. The type series booklets can be found at product catalogue. Nonobservance of this warning may lead to personal injury or property damage, e.g.: - Destruction of the gas cartridge or the actuator - Injury caused by escaping fluids (cold/hot, flammable, corrosive or under pressure) - Incorrect operation or destruction of the actuator. - Fierce expulsion of the gas spring cartridge. The descriptions and instructions in this manual refer to the standard versions but also apply to the related variants. These operating instructions do not take into consideration: - incidents which may occur during installation, operation and maintenance. - the local safety regulations. lt is the user s responsibility to ensure that these are also observed by the installation staff involved. ATTENTION Handling an actuator requires skilled and experienced personnel. The personnel in charge of operation, maintenance and installation of this actuator must be aware of the interaction between the actuator and the plant. Operator s errors concerning the actuator may have serious consequences for the entire plant, e.g.: - fluid may escape - downtime of the plant/machine - adverse effect/reduction/increase of the efficiency/function of a plant/machine. For further questions or in case of damage to the actuator, please contact your KSB Sales Office. For further questions and supplementary orders, especially when ordering spare parts, please always state the indications of the marking plate. The specifications (operating data) of the actuator are listed in the technical documentation & type series booklet of the related actuator (see also section 5). When returning actuators to the manufacturer, please refer to section Safety This manual contains basic instructions to be complied with during operation and maintenance. lt is therefore vital for the fitter and the operator/user to read this manual before installing/commissioning the actuator. Also, this manual must always be available at the site where the actuator is installed. lt is not enough to observe the general instructions listed in the section safety, the specific safety instructions listed in the other sections should also be observed Safety Symbols in these Operating Instructions Safety instructions put forth in this instruction manual, which the nonobservance would involve the risk of personal injury, are specially marked with the general hazard symbol: in accordance with ISO B.3.1. or with the electric voltage warning sign: In accordance with ISO B.3.6. Safety instructions which nonobservance would involve hazard to the actuator and jeopardize its operation have been marked with the word ATTENTION lnstructions directly attached to the valve, (e.g. nominal pressure) must be complied with and maintained in a legible condition Qualification of personnel and training The personnel for operation, maintenance, Inspection and installation must be adequately qualified for the work involved. The personnel responsibility, competence and supervision must be clearly defined by the user. lf the personnel in question is not already in possession of the required know-how, appropriate training and instructions must be provided. lf deemed necessary, the manufacturer/supplier will provide such training and instructions at the user s request. In addition, the user is responsible for ensuring that the contents of these operating instructions are fully understood by the personnel involved Danger or nonobservance of the safety instructions Nonobservance of the safety instructions may lead to personal injury and danger for both the environment and the actuator itself. Nonobservance of these safety instructions will also forfeit the user s warranty. Such noncompliance could result in for example : - failure of essential functions of the valve/plant - failure of prescribed maintenance and repair practices - hazard to people by electrical, mechanical effects (parts expulsion, cartridge breakdown,...) or chemical. - hazard to the environment due to leakage of hazardous substances 3.4. Safety Consciousness The safety instructions contained in this manual, the applicable national accident prevention regulations and any of the user s own applicable internal work, operation or safety instructions must be fully complied with Safety Instructions for the User/Operator Any hot or cold parts of the actuator that could cause a hazard must be protected by the user against accidental contact. Leakage of hazardous substance (e.g. flammable, corrosive, toxic, hot which can come qui peut provenir du robinet) must be drained so as to avoid all danger to people or the environment. Electrical hazards must be effectively prevented. (For details, please refer to the IEC 364 or equivalent national standard and/or local utility energy supply regulations). 3

4 3.6. Safety lnstructions for Maintenance, Inspection and Installation work The user is responsible for ensuring that all maintenance, inspection and installation work is carried out by authorized, adequately qualified staff who are thoroughly familiar with this instruction manual. Any work on a actuator may only be performed after the deconnecting hydraulical energy supply. The procedure described in the operating instructions to shut down the actuator must be observed. Immediately following completion of the work, all safety relevant must be reinstalled and/or re-enabled. Prior to recommissioning, refer to the points listed under section 7. - Inflating and deflating operations have to be undertaken in open air area. -- Inflation pressure of the spring gas must not be exceeded limits stated in this operating instruction. -- Do not use corrosive products on gas spring and do not expose in a corrosive ambiance. -- Spring gas temperature must always be maintened within the following range: ENNACTO 200 to 1600: Standard: min C / max. +65 C ENNACTO 3200 to 12500: Option: min C / max. +65 C Standard: min C / max. +45 C Option: min C / max. +65 C according to the identity plate. -- Protect the actuator against the sun or other radiance (infrared,...) -- Do not fill the gas spring with a fluid other than nitrogen gas. -- Do not replace parts with parts which are not supplied by KSB Unauthorized Modification and Manufacturing of Spare Parts The equipment shall not be altered or modified in any way prior to consultation with the manufacturer. Genuine spare parts and accessories authorized by the manufacturer will ensure operational safety. The manufacturer cannot be held responsible for damage resulting from the use of non-genuine parts or accessories Inadmissible Modes of Operation Operational safety and reliability of the actuator supplied is only warranted for its designated use as defined in section 2 General of the operating instructions. The limits stated in this technical documentation must not be exceeded under any circumstances Periodical checking -- With regard to an installation in France, as forecasted in the current regulations, according to the third Title of the decree dated 15 th March 2000,amended by the decree dated 13 th October 2000, every gas spring submitted to the regulations (*), has to be periodically inspected. This inspection happens 40 months after its first putting into operation or its lastest inspection or its lastest periodical control in accordance with regulations in the country. This inspection must be executed by a qualification organism. -- Gas spring which are submitted to the regulations, have to undergo a periodical control in accordance with regulations of the country. In France, it is required every ten years. During these hydraulical tests: -- the gas cartridge must be assembled on the actuator, -- the used oil must be compatible with the seals; others oils or water are strictly forbidden, -- then, the oil must be completely extract, with the opening down. For more informations, please consult KSB. (*) Actually, this decree specifies that only the gas springs (group II), -- which working pressure is higher than 4 bar (Ps>4 bar), -- which working pressure multiplied by the gas spring s capacity (inside volume) is higher than 200 bars L (Ps.V > 200barL) -- which spring internal capacity is higher than 1 L ( V>1L) With regard to an installation of these gas springs in a country different than France, please comply with the current regulations. 4

5 4. Transport and Interim Storage 4.1. Transport ATTENTION For transport and storage, the actuators must always be maintained in the closed position and be packed in wood crate with suitable protection (dessicant, thermowelded barrier). Please check if loaded gas cartridges are allowed by the transportation regulations. ATTENTION In order to prevent damage, only raise the actuator by the dedicated slings (adequate support plate). After delivery or prior to installation, the actuator should be checked for damage during transit (in particular the manometer of the gas cartridge,...) Interim Storage The actuators must be stored in such a way that correct operation is ensured even after prolonged storage. This comprises: -- Storing in closed position (version with closing upon lack of oil pressure) -- Suitable measures against contamination, frost and corrosion (e.g. by using thermowelded plastic bags with dessicant, protection caps and plugs onto threaded holes). 5. Description of actuators The sectional drawings shown hereafter are examples for the general design of our actuators Marking In Europe, the actuators are marked according to PED 97/23/EC.. Identity plate marking 1 - Actuator type 2 - Test pressure of the gas cartridge 3 - Volume under pressure (liters) 4 - Nature of the compressed gas 5 - Maximum service pressure of the gas cartridge 6 - Maximum and minimum allowable temperature 7 - Month and year of production 8 - Equipment serial number 9 - CE marking with notified body identification number (if used in Europe) Example 5

6 5.3. Drawings and documents ENNACTO 200 to 1600 Construction Draining and connection of hand pump Version with quick coupling 622 Sub -unit : Grease Depressurizing tooling 1969 (1/8 Gas threaded) Parts included in the spare parts Nr.1 + Parts included in the spare parts Nr.2 The nitrogen gas cartridge is supplied fully assembled (parts marked ) Do not dismantle this assembly NOTA: The specific references of each actuator are written on the identity plate These indications must be specified to each order

7 ENNACTO 200 to 1600 Construction Item Designation Materials (the materials can be equivalent to the ones below ) 103 Housing JS 1030 ductile iron Cylinder ASTM A536 gr ductile iron Cylinder Treated Steel 142 Cover JS 1030 ductile iron Self--lubricating bearing Stainless steel + PTFE Self--lubricating bearing Stainless steel + PTFE Self--lubricating bearing Stainless steel + PTFE Self--lubricating bearing Stainless steel + PTFE O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile Leap seal ring Nitrile Leap seal ring Nitrile Leap seal ring Nitrile 486 Ball Stainless steel Ball Stainless steel 500 Ring Nitrile 547 Guide bush Steel 553 Thrust insert Stainless steel type 316L Washer Stainless steel A Washer Stainless steel A Washer Stainless steel A4 574 Rod Steel Chuck + pointer shaft JS 1030 ductile iron + Stainless steel Hydraulic piston Steel Gas piston Steel 622 Manometer Stainless steel type Pointer Polyamide treatment against U.V. rays Quick coupling Stainless steel 741 Manometer and plugs assembled Stainless steel Body for manometer Stainless steel 747 No--return valve Wire Stainless steel Protection sheet Stainless steel type 316L Pressure pad Nitrured steel 890 Base plate Bronze -- UA10N 893 Support plate Stainless steel type 316L Warning plate Stainless steel Cheese head screw Stainless steel A Hollow screw 1/8 Gas Stainless steel type 316L Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A Stud bolt Stainless steel A Stud bolt Stainless steel A Plug Polyethylene Safety plug Elastomer Plug 1/8 Gas Stainless steel type 316L 914 Cylindrical head screw Stainless steel A Protection plug Stainless steel A Operating nut JS 1060 ductile iron Hexagon nut Stainless steel A Hexagon nut Stainless steel A Ring Steel Ring Steel 950 Check valve spring Treated steel Identity plate Stainless steel Position plate Stainless steel Safety plate Polyester Grease 1969 Depressurizing tooling 1/8 Gas 7

8 ENNACTO 3200 Construction Silicone Mastic Pressoswitch option Sub -unit 741: Manometer and Quick Coupling see pages 6 and Parts included in the spare parts N 1 + Parts included in the spare parts N 2 The nitrogen gas cartridge subunit is supplied fully assembled (parts marked with ). Do not dismantle this assembly. NOTA: The specific references of each actuator are written on the identity plate These indications must be specified to each order. Depressurizing tooling 1969 (1/8 Gas threaded) 8

9 ENNACTO 3200 Construction Item Designation Materials 103 Housing JS 1030 ductile iron Cylinder Steel 160 Cover Steel 188 Plate Stainless steel Shaft Bronze 300 Bearing Steel 310.1/310.2/310.3 Self--lubricating bearing Stainless steel + PTFE Self--lubricating bearing PTFE 314 Washer Stainless steel Needle Treated steel to O--Ring Nitrile 486 Ball Stainless steel 540 Guiding Steel Arm thrust insert Phosphated steel to Washer Treated steel 561 Grooved pin Steel 574 Rod Treated steel Piston Steel 598 Gas cartridge Steel Fork Steel Connection rod Steel Roller Steel Arm Steel Chuck JS 1030 ductile iron 629 Pointer Polyamide 719 Tube Stainless steel type Guide flange Steel Centering flange Steel 741 Manometer sub--unit Steel type Wire Stainless steel type Protection sheet Stainless steel type Clamp Steel type Pressoswitch Stainless steel type Base plate Bronze Hexagon head screw Stainless steel 901.1/901.2/901.4 Hexagon head screw Stainless steel 904.1/904.2 Socket screw Steel Safety plug Elastomer Hexagon socket head cap screw Steel 914.2/914.3 Hexagon socket head cap screw Stainless steel 916/916.2/916.4 Protection plug Polyethylene 920.1/920.2 Nut with notches Steel 930 Retainer Steel to Ring Steel Identity plate Stainless steel Safety instructions plate Stainless steel Position plate Stainless steel Warning plate Stainless steel type Depressurizing tool Parts included in the spare parts N 1 Spare parts N 2 is composed of the parts included in spare parts N 1 (parts marked with ) and of the nitrogen gas cartridge subunit supplied fully assembled (parts marked with ). 9

10 ENNACTO 6400 and Construction Parts included in the spare parts N 1 + Parts included in the spare parts N The nitrogen gas cartridge subunit is supplied fully assembled (parts marked with ). Do not dismantle this assembly. NOTA: The specific references of each actuator are written on the identity plate These indications must be specified to each order. 10

11 ENNACTO 6400 and Construction Item Designation Materials 103 Housing JS 1030 ductile iron 141 Cylinder ASTM A536 gr ductile iron 160 Cover ASTM A536 gr ductile iron 210 Shaft Bronze 300 Bearing Bronze 310 Self--lubricating bearing Stainless steel + PTFE 314 Thrust bearing Stainless steel type Ball bearing Treated steel O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile O--Ring Nitrile 415 Leap seal ring Nitrile 486 Ball Stainless steel Bush Phosphated steel Bush Phosphated steel 553 Thrust insert Stainless steel type Washer Steel Washer Steel 560 Grooved pin Stainless steel 561 Grooved nail Stainless steel 574 Rod Treated steel 595 Piston JS 1030 ductile iron 598 Gas cartridge Steel Fork Steel Connection rod Phosphated steel Roller Steel Arm Steel Chuck JS 1030 ductile iron + Stainless steel 629 Pointer Polyamide treatment against U.V. rays 726 Guide flange Steel 729 Flange Steel Protection sheet Stainless steel type Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A Hexagon head screw Stainless steel A4 902 Stud Stainless steel 903 Threaded plug Stainless steel Protection plug Polyethylene Protection plug Polyethylene Nut with notches Steel Hexagon nut Stainless steel A Nut with notches Steel Ring Stainless steel Ring Stainless steel Ring (cartridge) Stainless steel Spring retaining ring Steel 933 Pin Steel Identity plate Stainless steel Position plate Stainless steel Safety plate Stainless steel 1969 Depressurizing tooling Parts included in the spare parts N 1 Spare parts N 2 is composed of the parts included in spare parts N 1 (parts marked with ) and of the nitrogen gas cartridge subunit supplied fully assembled (parts marked with ). 11

12 5.4. Operating principle ENNACTO single acting actuator is designed for the operation of 1/4 turn valve with a motor oil pressure and to maintain it in position. In case of an oil pressure drop, the energy accumulator or gas spring under nitrogen pressure operates the valve in the opposite direction Version with closing on lack oil pressure Opening by control oil pressure Actuator/Valve closed P Actuator/Valve open P Nitrogen cartridge Hydraulic actuator Closing operation with nitrogen cartridge Actuator/Valve open Actuator/Valve closed E E Version with opening on lack oil pressure Closing by control oil pressure Actuator/Valve open Actuator/Valve closed P P Hydraulic actuator Nitrogen cartridge Opening operation with nitrogen cartridge E Actuator/Valve closed E Actuator/Valve open 12

13 6. Installation 6.1. General 6.4. Electrical connection These connections do not concern the ENNACTO actuator, but for example the indication. ATTENTION actuator weight. The piping must be strong enough to bear the Electrical cables may only be connected by qualified personnel. lf construction work is still in progress, non -mounted valves must be protected against dust, sand and building material etc.(cover with suitable means). Do not use actuators as footholds and do not put weight on any parts of the actuator! 6.2. Handling It is forbitten to hold up the whole set actuator + valve using the dedicated actuator slings. You might have to use special handling means. Handling means may be necessary to install large actuators. They must be used as shown. CORRECT 200 to to FORBIDDEN 6.3. Recommendations for installation Before assembling - Verify that the shaft and the base of the valve and the actuator are free from metallic chips and welds platter. - Verify that the valve is in closed position ( the actuator is delivered in closed position). - Verify that nothing hinders the installation of the actuator. Installation procedure (draining, gas pressurization,...) are described in the chapter 9. The applicable electrical regulations (e.g. IEC and national standards), also for equipment in hazardous locations, must be observed.all electrical equipment such as actuator, switchboard, magnetic drive, limit switch etc. must be installed in floodproof dry locations.voltage and frequency must match the actuators stated on the identity plate. 7. Commissioning/decommissioning 7.1. Commissioning General Prior to commissioning the actuator, the pressure, temperature and material data stated on the actuator should be compared to the actual operating conditions in the piping system to check whether the actuator can withstand the loads occurring in the system. When you receive the actuator, the gas cartridge pressure is less than 10 bars. To pressurize the cartridge, please refer to Operation The position of the disc is indicated by the pointer of the actuator. The valves are closed by turning in the clockwise direction (top view) and opened in the counterclockwise direction Functional Check The following functions should be checked: Before commissioning, the shut-off-function of the valves should be checked by repeated opening and closing Adjustment Adjustable end stops and torque limiter of actuators have been adjusted in factory. There is only one adjustable end stop (adjusted in factory) in closing for the closing version by lack of oil Decommissioning The actuator decommissioning must never be done with the actuator opened,the hydraulical cylinder full of oil. The oil dilatation may destroys the actuator. Also, the temperature must not exceed 65 C. 8. Monthly checking Nitrogen gas under pressure ensures the spring function. It is mandatory to check regularly this gas pressure on the manometer and/or the pressure sensor to detect an eventual gas leakage. It is also necessary to check the good operating of the manometer and/or the pressure sensor: During a cycle opening and closing, check that the pressure information is: - opening version : increasing during the opening and decreasing during the closing - closing version: increasing during the closing and decreasing during the opening The information of the manometer and/or pressure sensor must be almost the same before and after the opening and closing cycle (as the temperature increase a bit). It is also necessary to check the safety plug In the case of it is opened or destroyed, it can be a gas or oil leakage. - Check if a little of oil escaped outside by the orifice. If yes, depressurize the gas cartridge and dissassembly the cover, then the hydraulical cylinder, to change the hydraulic seals. - Check the gas pressure and pressurize the gas cartridge if the pressure is lower than la specification. Check each month. - And replace the new safety plug and check each month or more. Check the correct state of paint. Do not paint the safety plug and

14 9. Maintenance BEFORE ANY ACTION - Index the mounting position of the actuator onto the valve before dismantling - Index the pointer position 629 or the flag (option) 9.1. Recommended tooling (not supplied) - Pneumatic screwdriver - Mallet - Open_ended spanner - Allen key - Mounting spanner for end stops (see definition chapter 11) - Adaptator to inflate the gas cartridge, with 1/8 Gas threaded - Bottle of gaseous nitrogen (200 bar maximum) and its connecting device Test equipment (not supplied) - hydraulic power pack bar CONSUMABLES - Oil: Superflux HV46 - Grease EPEXELF MO2 (Elf) or MULTIS MS2(Total) or RETINAX HDM (Shell) or RENOLIT MO2 (Fuchs) 9.2. Standard maintenance ENNACTO actuator is designed and greased to realize 4000 cycles. This life time is not guaranteed. the life time can be lower or upper depending of the real use: torque, opening or closing speed of the valve, oil pressure, ambient temperature,... The only operations which must be regularly realized are defined in the chapter Actuator removal Identify the actuator refering to the identity plate. ATTENTION : Verify you have the correct spare kit checking the actuator reference mentionned on the identity plate. In case you plan to dissassemble the valve, you must disconnect the energy supply. Dismantle the actuator and take care of the connection bolting Actuator position ADAPTATION The adaptation onto the valves is achieved either directly or through adaptor parts : - interchangeable inserts manufactured to the size and the shape of the different valve shafts - adaptor flanges for coupling. ACTUATOR POSITION ONTO THE VALVE The actuator can be positioned in 4 positions, at 90 intervals. Standard arrangement is N position 1 If the actuator is disconnected, fit it onto the valve following the steps as defined before the uncoupling, then drain the actuator. Arrangement N Arrangement M Position 1 Position 2 Position1 Position to to Flow pressure direction the valve The arrangement position can be modified at site. The procedure below should be followed as well as the specific assembly operations as described in the maintenance procedure. 14

15 TRANSFORMATION Arrangement N Arrangement M - Drop the oil pressure to put the valve in safety position (opened or closed according to the opening or closing version). - Uncouple the actuator from the valve, - Remove the screw and the pointer 629, - Remove the ball 486 out of the groove using a screwdriver, pin punch,... - Refit the pointer at 90 from its original position and retighten the screw 900, - Insert the ball 486 into the perpendicular groove, - Refit the actuator onto the valve at 90 from its initial position PIPING CONNECTION All components and pipework must remain sealed until connected. All openings must be fitted with recommended plugs. Pickling of internal surfaces of pipework is always necessary when pipes and fittings contain scale, corrosive products, magnetic particles or when pipeworks have to be welded or heated. Pickling must be confined only to the pipework. All sensitive components (actuators, solenoïd valves, deck boxes,...) have to be isolated and bypassed. CLEANING - FLUSHING All newly installed hydraulic systems require cleaning to remove foreign matters and any contamination. In order to reduce the circulation time, it is advised to perform a first injection with nitrogen under a bar pressure for a 30 second to 1 minute period. All elements, part of the system (hydraulic power pack, distribution panel or stand, actuators) are delivered perfectly clean, with obturated ends. Therefore, it is most important to flush all the pipe connections to the various equipment : - hydraulic power pack towards solenoïd valves rack or deck boxes - solenoïd valves rack or deck boxes towards the actuators. Flushing through KSB AMRI components is not allowed. All components must be disconnected or by -passed. Under no circumstances, process pumps should be used for flushing. The pump used for flushing must be a dedicated unit and be external to the system. The pump capacity should be such that the flow speed be maintained at a minimum of 5m/s to 8m/s (turbulent flow) throughout the system. Oil must be introduced through the filling orifice ; it should be properly filtered in accordance with cleanliness standards in force. The filter must have the ability to accomodate the high flow rates required for turbulent flow flushing. Le filtre doit pouvoir supporter la vitesse d écoulement élevée requise pour le rinçage. The required cleanliness class must be minimum ISO 18/15 according to ISO 4406 standards (equivalent to NAS 1638 class 9). SYSTEM FILLING AND DRAINING - Connect the flexible R to the actuator, valve V closed This flexible is design to push the no return valve ball. The end of the flexible can be filling a bucket or be connecting back to the oil pump. - Open the valve V, - Open the flow restrictors F, - Operate the solenoïd valve to opening direction, - Let the oil circulate for a 15 minutes minimum period, - Close the valve V, - Disconnect the flexible from the actuator. V GAS O C F pump 9.6. Adjustment of standard closing end stop (±2 ): ENNACTO 200 to 1600 The adjustable end stop is adjusted in the factory and do not need further adjustment at site. This is of utmost importance for the perfect tightness of the valve. After any intervention on the actuator, the correct adjustment of the adjustable end stop must be verified (closing for a closing actuator by missing oil, opening for an opening actuator). If need be, this adjustment will be modified as per the following procedure: Adjustment procedure for the unit valve + actuator - Identify if the valve is not enough or too much closed - Put the valve in semi -opening position with the necessary hydraulical pressure, and the nitrogen nominal pressure, - Loosed the nut on the end stop, - Screw or unscrew the end stop 553 according that the valve is respectively not enough or too much closed - Close the valve decreasing the hydraulic pressure to check the correct adjustment. In case of bad adjustment, remake all the previous operations - When the correct adjustment is obtained, lock the nut ENNACTO 3200 to do not have adjustable stop end in standard 15

16 10. GAS SPRING CARTRIDGE 10.1 Pressurization If the gas pressure is lower than the low specification limit in the requested temperature conditions (usually ±5 C) in released cartridge position, the cartridge must be repressurized. The pressurization of the gas cartridge may be achieved as follow. It is not allowed to unscrew nor to remove the manometer 622 and/or the connecting block from the cartridge Remove the plug while holding the hollow screw Install your adaptator 1/8 Gas on the connecting block after removing the plug, and connect it to the nitrogen (N2) bottle. - Pressurize the gas cartridge slowly, up to the requested nominal pressure without exceeding this value. - Check the pressure with the manometer in place on the block. Check that the indicated pressures by the manometer of the gas cartridge and the infaltion kit are approximately indentical : allowance ±15 bar. If the values exceed this allowance, measure the manometer of the inflation kit and do again the inflation. The manometer of the inflation kit is the reference. WARNING: wait some minutes (10 minimum) for stabilisation and adjust the pressure. Disconnect the nitrogen (N2) bottle, remove the adaptator and put in place the plug to secure the system. If a gas leakage involves a fall of pressure too fast, the gas cartridge must be entirely changed. It is not possible nor allowed to repair it. For information, the maxima inflation pressures are defined in the table below: ENNACTO Nominal oil pressure (1) bar Inflation pressure at 15 C of the spring cartridge (2) bar * * (break to close torque: 12000Nm) (break to close torque: 18000Nm) * : Filling maximum pressure of the spring cartridge (1) This pressure is also the oil pressure full opened, compressed spring (2) This pressure is also the gas pressure released spring, = piston out (Closing by lack of oil version) = valve closed Gas pressure (bar) in the cartridge according to the temperature ( C) Gas pressure (bar) with actuator in safety position ENNACTO 0 C 15 C 25 C 35 C 45 C 55 C 65 C

17 10.2 Depressurization If the gas pressure is higher than the high specification limit in the requested temperature conditions (usually +15 C) in released cartridge position, the cartridge must be depressurized. The depressurization of the gas cartridge may be achieved as follow. It is not allowed to unscrew nor to remove the manometer 622 and/or the connecting block from the cartridge Remove the plug 903.3, while holding the hollow screw Screw slowly the depressurizing device 1969 in the hollow screw The device push the no return valve 747 and permits the gas leakage WARNING: depressurize very slowly the gas, otherwise the no -return valve may be destroyed. - Check the pressure with the manometer in place on the block. WARNING: wait some minutes (10 minimum) for stabilisation and adjust the pressure. - Remove the device and put in place the plug to secure the system. If a gas leakage involves a fall of pressure too fast, the gas cartridge must be entirely changed. It is not allowed to repair it Change of the no -return valve The depressurization can destroy the no -return valve and realize a gas leakage. Change the no -return valve as follow: ( the gas pressure must be down to zero) - remove the plug unscrew and remove the no -return valve 747 using the tool take in the spare kit, the new no -return valve screw the new no -return valve 747 using the tool pressurize at 5 bar the nitrogen (the compressed air is not allowed) to put in storage conditions - pressurize at the working pressure to put in working conditions - screw correctly the plug The tightness is ensured by the plug and nor by the no -return valve Dismantling On no account, the valve must not be able to turn the shaft of the actuator. If needed, remove the actuator from the valve. Dismantling of the gas spring cartridge: - Decrease the oil pressure to release the spring gas - Disconnect the oil supply - Depressurize the gas cartridge slowly down to 0 bar (see chapter 10.2) - Unscrew the screw of the gas cartridge together, and not the screws of oil cartridge. If it is difficult to unscrew, it means that the pressure in the catridge is too high: depressurize the gas cartridge (see chapter 10.2) WARNING: EXPULSION DANGER the threads can be thrown away - Remove carefully the gas cartridge. It can be difficult because the sliding of the rod 574 out of the piston (ENNACTO 200 to 1600). - Cover the piston with a very thick film or a plastic tube in order to protect it against impacts WARNING: the dismantling of the gas cartridge is forbiddden. 17

18 10.5 Reassembling The gas cartridge, after its disassembly, or a KSB new delivered one, is pressurised down to 0-5 bar with nitrogen (N2). Its piston must be protected (with a plastic). The actuator is already in: - closed position if it is a closing actuator by pressure lack - opened position if it is an opening actuator by pressure lack after the disassembly, and must stay like this. - Take off the plastic protection from the gas piston Check that this piston has no bump at all. - Check that all the area between the gas piston and gas cylinder is clean and greased, and also the housing 103, - Check that the outside of the gas piston and its inner hole is perfectly clean and grease it a little; - Slide the rod 574 into the piston Put in place the manometer protection plate and screw the screws in diagonal. The screws must be the original ones or the ones delivered by KSB, because its material is high characteristic. - Then inflate the gas cartridge according to the chapter Take off the grease and paint the shocks and metallical areas not protected to avoid any corrosion; Do not paint the safety plug and (see picture page 21). 11. Actuator dismantling for ENNACTO 200 to Before dismantling, depressurize enterly the spring cartridge (See chapter 10.2). - Identify the pointer position and the actuator mounting position on the valve. - Disconnect the oil supply - Uncouple the actuator with its accessories from the valve and lay it on the workbench - Remove all accessories from the actuator - If the actuator is fitted with a pointer 629, remove the sub -unit plug 916, screw 900 and pointer 629 DISASSEMBLY COVER 142 SIDE Unscrew the 4 screws Remove the cover 142, the O -ring 412.5, the self -lubricating ring and the O -ring HYDRAULICAL CYLINDER DISASSEMBLY Removal of the cylinder: - Unscrew the screws Cautiously remove the hydraulical cylinder taking care not to damage the piston Cover the piston with a film or a plastic tube plastique in order to protect it against impacts - Remove the lip seal and the O -ring Removal of the adjustable end stop Procedure to be followed for the hydraulical cylinder: - Measure and notify the overlength of the adjustable end stop with respect to the cylinder bottom, - Remove the adjustable end stop through the inside of the cylinder using the mounting key of the adjustable end stop (see definition drawing below) - Remove the O -ring dia. 8 2 dia dia

19 12. ACTUATOR RE -ASSEMBLY for ENNACTO 200 to 1600 PREPARATION OF PARTS All the constitutive parts of the kit must be used. The O--rings and their respective housings must be lubricated or oiled prior to insertion. REFITTING OF THE HYDRAULICAL CYLINDER Ensure that the cylinder is internally clean and remove any impurity. -- Place the O--ring on the adjustable end stop 553 and lubricate it. (only for ENNACTO 200 to 1600) -- Position the adjustable end stop on the mounting key and insert it though the inside of the cylinder in its initial position as notified prior to removal. -- Insert the lip seal 415 into its groove by warping it for easier insertion. Special precaution: The sealing lips must be oriented towards the cylinder bottom -- Insert the O--ring and lubricate it Remove the protection film from the piston and lubricate it Reinstall the cylinder by sliding it with care in order not to damage the O--rings Put in place the supporting plate 813 and screws and tighten diagonally 19

20 The functional tightness test is to be performed on the actuator without its cover in order to allow the detection of possible leaks. This operation involves no risk so far as the actuator is not subjected to any load (resistant torque). If the spring gas cartridge has its nominal pressure, you can make a few cycles (opening and closing). This kind of operation must never be done when the actuator is coupled to the valve. Test to be perfomed on the hydraulical cylinder: -- Connect the cylinder to the hydraulic power pack and pressurize: -- at 40 bar during one minute -- then, at 180 bar during three minutes. Check the tightnesses at: -- lip seal 415: if leak: visible inside the housing -- O--ring 412.2: if leak: visible at the end adjustable stop 553 If a leak is detected, remove the cylinder and check that the O--rings are good. Replace any defective O--rings and repeat the assembly steps until correct tightness is ensured. -- Ensure that the cover is clean TIGHTNESS TEST FOR THE HYDRAULICAL CYLINDER COVER REASSEMBLY -- Lubricate the housing of the guide strip and install the strip. -- Insert the O--ring and lubricate it onto the cover Refit the O--ring Lubricate the O--ring and the upper part of the yoke. Cautiously refit the cover. Take care not to damage the O--rings and guide strip. If necessary, use a mallet to finish the insertion and refit the 4 screws TESTS After the checking of all the screw, check the good operating of the actuator: -- Increase the oil pressure as slowly as possible Opening operation: Check that the operation is smooth and that the Nitrogen (N2) pressure of the gas spring cartridge rises continuously up to the predicted value (refer to the table section 10.1) Closing operation: Relieve the oil pressure Check that the valve moves smoothly up to the final seating. Check the Nitrogen (N2) pressure. Repeat the above operations cycle two times. The opening and closing must be completed (89 to 90 ) -- Connect the actuator to the hydraulic power pack and check the actuator for correct operation (stroke, tightness) under motor oil pressure. WARNING: The oil pressure must be the lower which can open/close the valve, in order not to damage the valve. If needed, instal and adjust a pressure reducer. 20

21 14. ACTUATOR/VALVE COUPLING -- Refit the pointer 629 and/or the accessories onto the actuator in their initial position. -- Couple the actuator to the valve in its original position, -- Check the good operation of the unit valve/actuator/hydraulical actuator/accessories. -- If necessary, adjust the adjustable end stop as defined on chapter Take off the grease clean and paint the shocks and metallical areas non protected to avoid any corrosion : This is the customer responsability to protect against the corrosion. Some silicone seals can also be used and added in severe environments. Do not paint the safety plug and RESIDUAL RISKS For a closing actuator by oil pressure lack CAUSE DETECTION MAXIMA POSSIBLE RISK Broken manometer - Checking during the inflation - Monthly checking - Overpressurized gas spring cartridge no operable actuator - Gas leakage, actuator not able to close the valve More than 4 cycles per hour Operation supervision Spring gas warming : no operable actuator Actuator external surface warming: explosion in some specific atmospheres (ATEX) Fire Site supervision Seals melting, gas leakage, no operable actuator Quick ponctual heating Site and people supervision Valve going in safety position and overpressure Ambient temperature - higher than 65 C (sun,...) or 45 C - lower than -20 C or -10 C Site supervision Site conception - No operating valve Valve going in safety position - No operating valve Fragile break of parts Broken pressoswitch - Checking during the inflation - Gas leakage, actuator not able to close the valve Pressoswitch or manometer Connections not tighten - Checking during the installation - Gas leakage, actuator not able to close the valve Pressoswitch cable gland not tighten - Checking during the installation - Corrosion inside the pressoswitch - Security signal lost - Explosion if on ATEX area Safety plug lost - Monthly checking - Corrosion inside the kinematics - No operating valve 21

22 16. TROUBLE SHOOTING At end adjustable stop 553 At plugs In connection or indication zone At hydraulical connection interface Non -operation Incomplete operation or overstroke Operating with jerks Reversed operation Device drift Incorrect or inadequate Indication Impossible or inadequate coupling Fast drop of gas pressure (less than 1 month) Oil external leaks O -ring damaged Change O -ring No return valve defective Change sub -unit adjustable end stop cylinder cover O -ring Lip seal 415 damaged O -ring damaged at the strip Gas pressure too low Missing or insufficient pressure Change lip seal check the cleanliness of the oil in the actuator Change the O -rings of the strip Check gas pressure and repressurize Check hydraulic power pack and its associated components Valve blocked Check valve and/or interfacing with piping Internal leaks Change seal 415 Check the cleanliness of the oil Corrosion :chuck blocked Mechanical components breakage Safety box check valve blocked or defective Change actuator Check hydraulic power pack Wrong actuator selection Consult the leaflet 8506 Consult the valve leaflet Wrong interface Wrong adjusting of the adjustable end stop Check drive and/or adapter flange Consult the leaflet 8506 or contact the manufacturer Refer to chapter 9.6 System improperly drained Drain the actuator according to chapter 9.5 Actuator closed / valve opened or closed valve / actuator opened Hydrodynamic torque Loss of air pressure Wrong assembly of the actuator onto the valve Nitrogen gas leakage Put valve and actuator in the same position Check the safe box and its components Pressurize the equipment and keep it under pressure Refer to chapter 9.3 Change the no return valve 747 or the gas spring cartridge concerned 22

23 Notes 23

24 ENNACTO Legal information/copyright -- Original operating manual -- all right reserved Contents provided herein must neither be processed without KSB express written consent Subject to technical modification without prior notice / KSB S.A.S. 4, allée des Barbanniers Gennevilliers Cedex (France) Tel.: Fax: