Operation Manual For KITZ B Series Pneumatic Valve Actuators

Transcription

1 Operation Manual For KITZ B Series Pneumatic Valve Actuators Thank you for choosing KITZ products. For safe and trouble-free function and performance of the product, ensure to read and understand all items of this manual before valve mounting and operation. Keep this manual in a convenient place for your valve operators easy access.

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3 C O N T E N T S 1 Attentions for user s system design 1 2 Storage and Handling 2 3 Product Codes 3 4 Driving Mechanism 4 5 Standard Technical Specifications 6 6 Cylinder Volume and Air Supply Requirement 7 7 Air Piping and Electric Wiring 9 8 KITZ Optional Accessories 11 9 Mounting Valve-Actuator Units on Pipes Automated Operation Manual Operation Periodic Inspection and Maintenance of Valves and Actuators Trouble Shooting Disassembly and Reassembly Adjustment of Valve Operating Positions Product Warranty Standard Spare Parts Emergency Call for Technical Assistance 50

4 1 Attentions for user s system design

5 2 Storage and Handling Fig. 1

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7 4 Driving Mechanism 4.1 Type B double-action actuator The air pressure supplied into the port A pushes the piston inward and energizes its movement to rotate the scotch-yoke counterclockwise. The scotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the drive shaft by 90 to open or close the valve, following the preset mode. Reverse supply of the air pressure into the portbactivates the reverse valve operation. Air failure will cause the valve stay at the position. Fig. 2 Pin Roller Scotch yoke Driven shaft A Piston Piston rod B 4.2 Type BD double-action and double cylinder actuator The air pressure supplied into the portaanda pushes the piston inward and energizes its movement to rotate the scotch-yoke counterclockwise. The scotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the drive shaft by 90 to open or close the valve, following the preset mode. Reverse supply of the air pressure into the portbandb activates the reverse valve operation. Air failure will cause the valve stay at the position. Fig. 3 B A B A

8 4.3 Type BS or BSW spring-return actuator The air pressure supplied into the portapushes the piston outward and energizes its movement to rotate the scotch-yoke counterclockwise, compressing the spring. The scotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the drive shaft by 90, to open or close the valve, following the preset made. At the moment the air is discharged to the atmosphere through the solenoid valve, the spring force pushes the piston to the reverse direction, and the scotch-yoke activates clockwise rotation of the shaft to reversely operate the valve. Air failure will cause the valve return to the original open or closed position automatically, following the preset mode, unlike the value driven by Type B actuator. Type BSW actuator is combination of Type BS actuator and a hand wheel for manual operation, and its driving mechanism is exactly same as that of Type BS actuator Fig. 4 Pin Roller Scotch yoke Driven shaft Piston A Piston rod 4.4 Type BS-7 or BSW-7 spring-return with manual operate equipment The air pressure supplied into the portaanda pushes the piston outward and energizes its movement to rotate the scotch-yoke counterclockwise, compressing the spring. The scotchyoke converts linear movement of the piston rod to counterclockwise rotational movement of the drive shaft by 90, to open or close the valve, following the preset made. At the moment the air is discharged to the atmosphere through the solenoid valve, the spring force pushes the piston to the reverse direction, and the scotch-yoke activates clockwise rotation of the shaft to reversely operate the valve. Air failure will cause the valve return to the original open or closed position automatically, following the preset mode, unlike the value driven by Type B actuator. Type BSW actuator is combination of Type BS actuator and a hand wheel for manual operation, and its driving mechanism is exactly same as that of Type BS actuator Fig. 5 A A

9 5 Standard Technical Specifications Operating media Standard operating pressure Pressure supply range Standard durability Housing test pressure Drive shaft rotation Service temperature range Compressed instrumentation air 0.39MPa; factory preset pressure 0.29MPa to 0.69MPa Contact KITZ when other than the standard operating pressure. 100,000 cycles under moderate service conditions 0.97MPa 90(5) -20to +60( -4 F to +140 F) When the air remains unfrozen Output torque UNIT : N-m UNIT : N-m

10 6 Cylinder Volume and Air Supply Requirement 6.1 Cylinder volume Type B actuator Fig. 6 Double cylinder actuator Air Air unit: liter Cylinder Type-size V1 V2 B B B B B B B BD B BD a1 a a1+a=v1 Air Air b1+b=v2 b2 b Air Air 6.2 Type BS or BSW Cylinder volume of Type BS or BSW actuators Fig. 7 BS-7BSW-7 Air unit: liter Cylinder Type-size V BS0 / BSW BS1 / BSW BS2 / BSW BS3 / BSW BS4 / BSW BS5 / BSW BS6 / BSW BS7 / BSW b1 b b1+b=v Air Air BS and BSW have same cylinder volumes.

11 6.3 Air Supply Requirement (Flow Rate) Actuators should be supplied with air sufficient to operate the valve through one full stroke from the open to closed position or vice versa in t seconds, as converted into flow rates per minute. The required air volume Q is expressed with the following equation. Q=V ((P )/0.1013) 60 t (Nl/min.) Nl: Volume of standard air where Q=Air volume requirement per minute (Nl/min.) V=Cylinder Volume (liters) V1 or V2, whichever larger, for double-action actuators P=Supply pressure (MPa in gauge) t =Time required per stroke (seconds) Condition of standard air Air temperature: 20 Absolute pressure: 760mmHg Relative humidity: 65% 6.4 Air Consumption Air consumption means the volume of air discharged into the atmosphere from an actuator operating n times forward and backward per hour as converted into volumes per minute. The valve is calculated with the following equation, Type B actuator Q=(V1+V2)((P )/0.1013)n 1 60 (Nl/min.) Type BS or BSW actuator Q=V ((P )/0.1013)n 1 60 (Nl/min.)

12 7 Air tubing and Electric Wiring 7.1 Air tubing for actuators Type B-07 Fig. 8 Solenoid valve energized to open valve Solenoid valve energized to close valve Pressure equalizing valve Pressure equalizing valve Air supply 4-way solenoid valve Air supply 4-way solenoid valve Filter regulator Filter regulator Type B-D6,D7 Solenoid valve energized to open valve Solenoid valve energized to close valve Fig. 9 Pressure equalizing valve Pressure equalizing valve Air supply Filter regulator 4-way solenoid valve Air supply 4-way solenoid valve Type BS-06,BSW-06 Filter regulator Fig. 10 Solenoid valve energized to open valve Solenoid valve energized to close valve Air supply Type BS-7,BSW-7 Filter regulator 4-way or 3way solenoid valve Air supply Filter regulator 4-way or 3way solenoid valve Fig. 11 Solenoid valve energized to open valve Solenoid valve energized to close valve Air supply Filter regulator 4-way or 3way solenoid valve Air supply Filter regulator 4-way or 3way solenoid valve

13 7.2 Air supply port Select copper tubes for air supply and exhaust ports according to the following table: Nominal size of piping threads (Rc) 7.3 Tubing Actuator size Type B 1/8 1/4 1/4 1/4 1/4 1/2 1/2 1/2 Type BS/BSW 1/8 1/4 1/4 1/4 1/2 1/2 1/2 1/2 Actuator size Tube (Outer diameterinner diameter) Specification of solenoid valves Type B actuators need 4-way solenoid valves. 4-way solenoid valves with one OUT port plugged or 3-way solenoid valves can energize Type BS or Type BSW actuators. Electric wiring should be made as shown in Fig. 8 to Fig. 11, depending on the planned mode of operation. KITZ B Series actuators assembled with solenoid valves at the manufacturer have been complete with copper tubing for air supply and exhaust pens. Users should make air supply tubing between air compressors and solenoid valves. 7.5 Pressure equalizing valves (By-pass valves) Manual operation of Type B actuators needs a pressure equalizing valve installed between an actuator and a solenoid valve. 7.6 Speed controllers Mount a speed controller also between an actuator and a solenoid valve, if needed. 7.7Silencers Install a silencer directly in the exhaust port of a solenoid valve 1. For manual operation of Type B actuators, the air residue in the actuator housing must be discharged to the atmosphere. Ensure to install a pressure equalizing valve between an actuator and a solenoid valve. Connect copper tubes, covered or uncovered, of a suitable diameter and wall thickness between actuators and pressure sources to maintain sufficient air pressure during valve operation. Securely seal all tubing joints to avoid air leakage, which may occur through connections or accessories and tubes. Ensure that loose sealing tape ends do not extend into tubes, which may block ports and affect air supply into actuators.

14 8 KITZ Optional Accessories The following standard accessories are recommended for KITZ B Series actuators. For other accessories, contact your local KITZ agent or distributor. Limit Switch LS AC: DC: LS 10A/125V 10A/250V 10A/480V 0.8A/115V 0.4A/230V LS-F AC: 5A/125V 5A/250V DC: 0.8A/125V 0.4A/250V LS-F Contact circuit: 2-Circurt double break Solenoid Valve Connecting pipe thread: Rc 1/4 Working pressure: 00.97MPa(140psi) SOV Orifice diameter: 6mm Electric source: 100V/50Hz 100V60Hz SOV-F 110V/60Hz 200V50Hz 200V60HZ 220V/60Hz Air Filter-Regulator Connecting pipe thread: Rc 1/4,1/2 Working pressure: Max. inlet pressure; F+R 0.97MPa (140psi) Max. outlet pressure; 0.04MPa0.83MPa (8120psi) Speed Controller Connecting pipe thread: Rc 1/8,1/4,1/2 Operation pressure: 0.97MPa (140psi) max. SP Quick Exhaust Valve QE Connecting pipe thread: Rc 1/4,1/2 Working pressure: 0.97MPa (140psi) max Valve Positioner Connecting pipe thread: Rc 1/4 P Supply pressure: Signal pressure: Silencer K Air Filter F Lubricator L Pressure Equalizing Valve C Signal Current Air consumption: Connecting pipe thread: Working pressure: (pressure gauge: Rc 1/8) 0.29~0.69MPa (43~100psi) 0.02~0.1MPa (3~15psi) 4~20mA 20Nl/min. max. (at supply pressure 0.49MPa(70psi)) Rc 1/8,1/4,1/2 0.97MPa (140psi)max. Connecting pipe thread: Rc 1/4,1/2 Working pressure: 0.97MPa (140psi)max. Connecting pipe thread: Rc 1/4,1/2 Working pressure: 0.97MPa (140psi)max. Recommended oil: Turbine oil ISO VG32 equivalent Connecting pipe thread: Rc 1/4 Working pressure: 1.37MPa (200psi)max. For initiating electric signals to check open or close position of the valve; A separate limit switch is recommended for each of open and close indication. Flow switching over air flow by electric signal 4-way solenoid valves for double-action actuators, 4-way solenoid values for spring-return actuators, with one OUT port plugged, or 3-way solenoid valves used. For removing moisture, water and other foreign objects form operating air and for regulating air pressure at a desire level. For reducing actuator operating speeds. For increasing actuator operation speeds; With spring-return actuators, speed increase is possible only in spring-return direction.(usable only for actuators without positioners.) For operating actuators at any desired position, with the flow rate controlled by a valve: Valve positioner may be mounted on both double-action and spring-return actuator. With use of valve positioners, flow rate may be stably controlled. Both airto-open and air-to-close actuation modes can be obtained by simply reversing air. For reducing air exhaust noise in solenoid valve: To be installed in the exhaust port of a solenoid valve. For removing moisture, water and other foreign objects from operating air. Although KITZ B Series actuators and their standard solenoid valves are designed for no need of lubrication, when other solenoid valves are used, or when actuators are subjected to high operating frequency for long periods of time, lubrication is recommended. For equalizing internal air pressure to atmospheric pressure to manually operate actuators. Above specifications are KITZ standards. Different specifications are optionally available.

15 9 Mounting Valve-Actuator Units on Pipes

16 Fig. 12 Supporter Fig. 13 Breathing port Supporter Nipple Elbow Support stand 10 Automated Operation Apply the standard pressure at 0.39MPa (60psi) for trouble-free operation, although KITZ B Series actuators are designed for operating pressure ranging from 0.29MPa (40psi) to 0.69MPa(100psi). When you specified the operating pressure in your order, the unit must have been set to your specification at the factory. Energizing an actuator with any different pressure may cause a malfunction. Operating media must be compressed air or Nitrogen gas.

17 11 Manual Operation 11.1 Type B actuators Size 0 to 4 can be manually operated with a spanner wrench or a lever handle properly fitted to the top of the drive shaft(fig14). Size 5 to 7, however, do not accommodate such a temporary provision, and an optional manual operating device must be supplied by KITZ in advance. Turning the operating device clockwise or counter-clockwise will close or open the valve respectively. Fig. 14 Provision for fitting a wrench Before energizing Type B actuators, never forget to remove the spanner wrench or the lever handle used for manual operation. Starting actuator operation without removal of such manual operating device is extremely dangerous Before manual operation of Type B actuators, open the pressure equalizing valve to discharge the air residue in the actuator housing to the atmosphere. Any air residue will disturb manual operation of the actuator. Ensure to securely fit the operating device to the top of the drive shaft of Type B actuator for manual operation. Manual operation with a spanner wrench or a lever handle is impossible for Type B-5 to B-7 actuators. Order an actuator with manual operation unit if you need manual operation for these actuators. Actuator Manual operation unit Valve

18 Parts construction of B-5 to B-7 Manual operation unit Some parts are different depend on the manual operation unit types. (Manual operation unit for B-5 is illustrated here.)

19 Manual operation by the manual operation unit Never insert a finger into the manual operation unit pin hole. It is very dangerous because inside parts are driven with a strong force. Never operate the valve automatically when a pin is inserted into the pin hole. It may break the manual operation unit. Insert the pin into the pin hole completely in case of manual operation. It may break the manual operation unit if the pin is inserted half. When the valve is operated automatically, insert a plug into the pin hole. Rainwater and dust cause corrosion on inside parts of the manual operation in case without plug on the pin hole. (1) Manual operation Stop supplying air to the actuator. Open a pressure equalizing valve. Remove a plug from the manual operation unit pin hole. Adjust an indicator to the pin hole rotating a handle. Insert a pin into the pin hole completely. Operate the valve with the handle. (2) Automated operation Remove the pin form the pin hole. (If the pin is hard to remove, rotate the handle little and free the pin from any forces.) Insert the plug into the pin hole. Close the pressure equalizing valve. Supply air to the actuator.

20 Trouble shooting of the manual operation unit Malfunction of automated operation Detected Trouble Causes of Troubles Remedial Measures Do not operate a valve automatically. Operation speed is slow. Do not operate a valve manually. Operate the valve with the pin is inserted into the pin hole. The pressure equalizing valve is opened. No air is supplied. Malfunction of the valve. Malfunction of the actuator. Air pressure is low. Too much throttling of speed controller. Corrosion on inside parts. The pin is not inserted into the pin hole. Air is supplied to the actuator. A pressure equalizing valve is closed. Remove the pin from the pin hole and insert a plug into it. Open the pressure equalizing valve. Supply air to the actuator. Disassembly/check/cleaning the valve and replacement of valve seats. Disassembly/replacement of actuator parts or replacement of the actuator. Readjustment of the filter regulator. Readjustment of the speed controller. Replacement of the manual operation unit. Insert the pin into the pin hole completely. Stop supplying air to the actuator and open the pressure equalizing valve. Open the pressure equalizing valve. Malfunction of manual operation Impossible to insert the pin into the pin hole. Impossible to remove the pin from the pin hole. Indicator is not adjusted to the pin hole. A pin hole on a worm wheel and a pin hole on a shaft is not adjusted. Foreign objects are stuck on the pin The pin is deformed. The pin is locked with inside parts. Air pressure is supplied. Adjust the indicator to the pin hole rotating handle. Adjust the pin hole on the worm wheel and the pin hole on the shaft rotating handle little by little. Clean up the pin. Replace the pin. Free the pin form any forces rotating handle little by little. Stop supplying air.

21 11.2 Type BS actuators All sizes have no accommodation of manual operation. When you need manual operation, Type BSW actuators must be ordered instead Type BSW actuators This is BS type actuator provided permanently with a manual operation device. Turning the hand wheel clockwise or counter-clockwise will close or open the valve respectively. (Fig.15) Fig. 15 Hand wheel Valve stem rotation Clockwise Counter-clockwise Counterclockwise Clockwise Hand wheel Before energizing Type BSW actuators, manually turn the hand wheel clockwise to the maximum depth of its reach. Automated operation needs that the drive shaft has been completely hidden in the actuator housing to its full depth and the spring retainer has returned to the side of the rod guide. No manual operation is possible for Type BS actuators.

22 12 Periodic Inspection and Maintenance of Valves and Actuators

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24 13 Trouble Shooting Detected Trouble Causes of Troubles Remedial Measures Air pressure lower than specified. Compressor malfunction or insufficient capacity. Air leakage from tubing. Check of compressors; Check/repair of tubing systems. Compressor malfunction. Valve Malfunction. No supply of air pressure. Airflow disturbed by foreign objects stuck within tubes; Tube damaged or frozen. Filter regulator malfunction. Check/repair of tubes. Disassembly/check/repair/replacement of filter regulators. Foreign objects stuck with valve seats. Disassembly/check/cleaning of valves. No activation or disturbed activation of actuators under full air pressure. Excessive raise of valve operating torque caused by foreign objects stuck to the valve interior. Excessively throttled speed controllers. Disassembly/check/cleaning of valves: Readjustment of actuator operation. Readjustment of speed controllers. Defective actuators. Repair/replacement of actuators or parts. Breaks of electric circuits. Check of electric circuits and voltage. Troubles with solenoid valve. No activation of energized solenoid valve; Abnormal noise; Excessive temperature raise. Defective electromagnets. Water intrusion into electromagnets or terminals. Check of excessive voltage and currency; Replacement of coils. Water prevention; Replacement of coils. Inadequate voltage or cycles (Hz). Check/adjustment of voltage or cycles. Short circuit in solenoid valve interior. Check/replacement of solenoid valves. Air exhaust disturbed. Air exhausts while actuator is in no operation. Piston O-ring worn; Foreign objects stuck to piston O-rings. Sealing parts of solenoid valves worn. Disassembly/cleaning of actuator; Replacement of O-rings. Check/replacement of solenoid valves or parts. Equalizing valves left open. Close equalizing valves.

25 14 Disassembly and Reassembly

26 CAUTION FOR REASSEMBLY

27 Construction Details of Type B Actuators Fig. 16 Screw Indicator Snap ring Thrust washer Bolt Adjust screw Nut Packing Cylinder Bolt Housing cover O-ring O-ring Nut Bearing Snap ring Shaft Key Snap ring Roller Bearing Bearing Piston rod O-ring O-ring O-ring Rod guide Piston Bearing Housing cap Bolt Nut Housing Pin Bearing Roller Snap ring Scotch yoke Thrust bearing Bearing O-ring Adjust screw Bolt Bracket Connector Type B-3 is illustrated here.

28 Type B-0 Actuator Disassembly

29 Fig. 17

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31

32 Fig. 18 Some parts are different depend on the actuator types. B-6 actuator shaft parts detail

33 Fig. 19 Fig. 20 Fig. 21

34 Screw Fig. 22 Snap ring Indicator Adjust screw Thrust washer Bolt Nut Nut Packing Cylinder Housing cover Bolt O-ring Rod guide (A) Bolt Bearing O-ring Snap ring Piston O-ring Shaft Snap ring Bearing Roller Key Bearing Piston rod Pin Bearing Housing Bearing Roller Snap ring Rod guide (B) Scotch yoke Thrust bearing Bolt Bearing Snap retainer O-ring Nut Tie rod Spring Bracket Bolt Connecter Spring case Nut Spring cover Adjust screw Nut

35 Fig. 23 Threaded rod Spring pin

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37 Fig. 24

38 Fig. 25 Threaded rod

39

40

41 Fig. 26 BS-6 actuator shaft parts detail

42 Fig. 27 Threaded rod Spring pin

43

44 Fig. 28

45 Fig. 29 Threaded rod

46

47 Fig. 30

48 BSW-6 actuator shaft parts detail

49 15 Adjustment of Valve Opening Positions Appropriately adjust screw and opening stopper bolt to ensure the dimensional requirement ball of ball valve and disc of butterfly valve as listed below, for the desired valve opening position. Adjustment for KITZ butterfly valves (*1) (*1) Set [A less B] to zero for KITZ UB Series butterfly valves. (*2) Contact KITZ Corporation for information on Size DN250 and DN300. (*3) Contact KITZ Corporation for information on Size DN350. (*4) (*4) Applicable to KITZ JIS 10K/20K ASME Class 150/300 full bore floating ball valves. Fig. 31 Stopper bolt Type BS actuator Adjust screw

50 16 Product Warranty

51 17 Standard Spare Parts NBR O-rings for KITZ B Series Actuators Apply following tables to replace the O-ring for maintenance. O-ring dimension for drive shaft have been changed since November Apply another table on the next page.

52 Apply following tables for which produced before November Piston O-ring 45D should not be replaced, unless it directly causes air leakage. In case of replacement, degrease and apply some locking liquid (KITZ standard: LOCTITE No.262) to the threads of piston rod 103 and anchor nut 13 for tight assembly. Note 1. Specify product code (such as ) or size (such as P40) in your purchase orders. Note 2. O-ring sizes (such as P40 or P50) conform to JIS B2401 1A requirement.

53 18 Emergency Call for Technical Assistance