VALV-POWR VALUE-LINE DOUBLE-OPPOSED PISTON ACTUATORS MODEL A. Installation, Maintenance and Operating Instructions

Transcription

1 VALV-POWR VALUE-LINE DOUBLE-OPPOSED PISTON ACTUATORS MODEL A Installation, Maintenance and Operating Instructions IMO-529 EN /208

2 2 IMO-529 EN TABLE OF CONTENTS. GENERAL TECHNICAL DATA INSTALLATION General Operating.... MAINTENANCE.... General....2 Disassembly....3 Assembly SERVICE / SPARE PARTS... 2 READ THESE INSTRUCTIONS FIRST! These instructions provide information about safe handling and operation of the actuator. If you require additional assistance, please contact the manufacturer or manufacturer s representative. Addresses and phone numbers are printed on the back cover. See also for the latest documentation. SAVE THESE INSTRUCTIONS! IMO /8

3 IMO-529 EN 3. GENERAL This instruction manual contains important information regarding the installation, operation and troubleshooting of the Jamesbury Valv-Powr Value-Line Double- Opposed Piston Actuators Model A. Please read these instructions carefully and save them for further reference. WARNING. KEEP HANDS AND CLOTHING AWAY FROM THE VALVE PORTS AND ACTUATOR PINION AT ALL TIMES. 2. DO NOT ATTEMPT TO DISASSEMBLE INDIVIDUAL SPRING CARTRIDGES. DISASSEMBLY OF THE CARTRIDGE MAY RESULT IN SERIOUS PERSONAL INJURY. IF MAINTENANCE OF THE CARTRIDGE IS NECESSARY, IT MUST BE RETURNED TO METSO. 3. SHUT OFF AND BLEED ALL SUPPLY LINES BEFORE INSTALLATION OR SERVICING. DO NOT REMOVE END CAPS WHILE THE ACTUATOR IS PRESSURIZED.. BEFORE INSTALLING THE VALVE AND ACTUATOR, BE SURE THAT THE INDICATOR ON TOP OF THE ACTUATOR IS CORRECTLY SHOWING THE VALVE POSITION. FAILURE TO ASSEMBLE THESE PRODUCTS TO INDICATE THE CORRECT VALVE POSITION COULD RESULT IN PERSONAL INJURY. 5. AN ACTUATOR MUST BE SIZED ACCURATELY FOR PROPER OPERATION. REFER TO INFORMATION ON ACTUATOR OUTPUT TORQUES IN THIS BULLETIN AND VALVE TORQUE REQUIREMENTS IN THE APPROPRIATE VALVE BULLETIN. 6. OPERATING THE ACTUATOR OVER TEMPERATURE LIMITS MAY DAMAGE INTERNAL AND EXTERNAL COMPONENTS (DISASSEMBLY OF SPRING RETURN ACTUATORS MAY BE DANGEROUS). 7. OPERATING OVER PRESSURE LIMITS MAY RESULT IN PREMATURE FAILURE AS WELL AS DAMAGE TO THE HOUSING. 2. TECHNICAL DATA. Operating Media: Dry or lubricated air, non-corrosive and inert gas, or light hydraulic oil. 2. Air Supply: 0 bar (50 psi) Maximum. 3. Temperature: Standard; - to 75 F (-20 to 80 C) Viton O-rings: - to 300 F (-20 to 50 C) Silicon O-rings: -0 to 75 F (-0 to 80 C). Lubrication: Factory lubricated for the life of the actuator under normal operating conditions. 5. Construction: Suitable for indoor and outdoor use. 6. External/Internal Travel Stops: ± degree adjustment on 90 degree stroke. 3. INSTALLATION 3. General. Check to see that the desired failure mode is correct (Figures & 2). In the spring-to-close mode, the actuator will cycle clockwise to close upon loss of pressure. If the spring return actuator is not set up in the configuration desired, follow the disassembly procedure Section.2. Reverse the orientation of the pistons, then reassemble following the assembly procedure, Section Mount the actuator to the valve, following the direction in the linkage AMI or valve IMO. Double-Acting (Top View) PORT B PORT A PORT "B" PORT "A" Air supplied to Port A forces pistons apart and toward end positions with exhaust air exiting at Port B (a counterclockwise rotation is obtained). Figure Air supplied to PortBforces pistons toward center with exhaust air exiting at Port A (a clockwise rotation is obtained). Double-Acting (Top View) PORT B PORT A PORT "B" PORT "A" Air supplied to Port A forces pistons apart and toward end position, compressing springs. Exhaust air exits at Port B (a counterclockwise rotation is. Figure 2 Loss of air pressure allows springs to force pistons toward center position with exhaust air exiting at Port A (a clockwise rotation is obtained). IMO /8

4 IMO-529 EN 3. Connect a regulated air supply to the NPT fitting in the actuator housing. CAUTION: The maximum operating pressure is 50 psi (0 bar).. Adjust the stop screw screws following assembly Sections.3.3 and.3.5. Stops can be adjusted by up to ± degrees. spring return actuators. CAUTION: Do not use the M5 VDE/VDI mounting holes or the M6 hole in the pinion for lifting the actuator. When disassembling VPVL actuators, use caution and be certain that the actuator is free from accessories and the air supply is disconnected. When the actuator is a spring-return unit, make sure that the actuator is in the failed position before disassembling. 3.2 Operating. The actuator series, size, operating pressure, output torque, spring directions, and drive type is determined by the actuator designation The label lists the actuator series, size, operating pressure, maximum pressure, and series number. Actuator designation example, VPVL30 SR6 A F07/ [9], is a spring-return series, VPVL30 double-opposed piston actuator that has 80-psi (5.5-bar) springs, an anodized housing (protection A), an end-of-stroke output torque of 08 lb-ft (6 Nm), mounts via an F07 pattern, and uses a 9-mm female parallel square to drive the valve.. MAINTENANCE. General Although Metso s Jamesbury actuators are designed to work under severe conditions, proper preventative maintenance can significantly help to prevent unplanned downtime and in real terms reduce the total cost of ownership. Metso recommends inspecting actuators at least every five (5) years. The inspection and maintenance frequency depends on the actual application and process condition. NOTE: All VPVL actuator fasteners are metric. Under normal operating conditions the actuator requires only periodic observation to ensure proper adjustment. Repair kits are available to replace seals and bearings (soft parts). These are identified in Figure 20 and listed in the table on page 8. Table below lists kit part numbers. Table Actuator Repair Kit Actuator Repair Kit VPVL0 RKP-95 VPVL0 RKP-02 VPVL05 RKP-96 VPVL5 RKP-03 VPVL0 RKP-97 VPVL50 RKP-0 VPVL20 RKP-98 VPVL55 RKP-05 VPVL25 RKP-99 VPVL60 RKP-06 VPVL30 RKP-00 VPVL70 RKP-08 VPVL35 RKP-0. Removal of optional position indicator assembly (9, 20), Figure 3: a) Remove cap screw and washer (20). b) Lift position indicator (9) off shaft; it may be necessary to pry gently with a screwdriver. * a Figure 3 2 0a Figure 2. O-ring seal () replacement on external stroke adjustment screw (0), Figure : a) Remove stop adjustment nut (2). b) Remove stop adjustment screw (0), washer (a), and o-ring seal (). Discard o-ring seal..2 Disassembly When disassembly of the actuator is required for maintenance, remove the actuator from the valve. Ensure proper lifting procedures are followed when moving or carrying actuators. The Dimensions table on page 0 lists the approximate weights of the VPVL actuators and provides outline dimensions for the double acting and 2 3 Figure IMO /8

5 IMO-529 EN 5 c) Fit washer (a), stop adjustment nut (2), and new o-ring seal () onto stop adjustment screw (0). Proceed by gently screwing down the group of parts until they are hand tight. Final adjustment of the stroke will be done during final assembly of the actuator. This operation must be done on both sides of the actuator. 3. End Cap (3) Disassembly, Figure 5: a) Remove the end cap bolts (3) in the sequence shown in the Figure. CAUTION: When disassembling a spring return actuator, the end cap (3) should be loose after unscrewing end cap bolts (3) -5 turns. If there is still force on the end cap (3) after -5 turns of the end cap bolt (3), this may indicate a damaged spring cartridge and any further disassembly should be discontinued. Further disassembly of the end-caps may result in serious personal injury. Return actuator to Metso for further maintenance. b) For spring return actuators, remove spring cartridge. c) Remove end cap o-rings () and discard if replacing all soft parts. parts until they are hand tight. Final adjustment of the stroke will be done during final assembly of the actuator. This operation must be done on both sides of the actuator. 5. Piston (2) Disassembly, Figure 7: a) Holding the body () in a vice (or similar device), rotate the drive shaft () until the pistons (2) are released. CAUTION: Air Pressure should not be used to remove the pistons from the body. Clean and inspect the piston teeth for signs of wear. Replace piston if wear seems excessive. b) Remove piston o-ring seal (6)* using a screw driver. Remove the piston head (5)* and piston back (5)* bearings. Discard bearings if replacing all soft parts, * as shown in Figure 20 *2 **6. O-ring seal () replacement on internal stroke adjustment screw (0a), Figure 6: **7 *22 * a 2 0a Figure 6 a) Remove stop adjustment nut (2). b) Remove stop adjustment screw (0a), washer (a), and o-ring seal (). Discard o-ring seal. c) Fit washer (a), stop adjustment nut (2), and new o-ring () onto adjustment screw (0a). Proceed by gently screwing down the group of Figure 6 6. Drive Shaft () and Bearing (6, 7) Disassembly, Figures 8 and 9. a) Remove spring clip (8) carefully, using snap-ring pliers. b) Remove thrust bearing (8) and thrust washer (8a) Discard thrust bearing (8) if replacing all soft parts. c) Apply force to top of drive shaft () until it is out of the bottom of the body (). (If drive shaft does not move freely, tap the top of shaft () with a plastic mallet.) Clean and inspect drive shaft teeth for signs of wear. Replace drive shaft if wear appears excessive. *6 8a **8 Figure 7 Figure 9 IMO /8

6 6 IMO-529 EN d) Remove the top and bottom shaft bearings (6, 7) and o-rings (2, 22) from the drive shaft as shown in Figure 0. Discard bearings and o-rings if replacing all soft parts..3 Assembly Prior to assembly, ensure all components are clean and in proper working order. NOTE: Table 2 lists the recommended Valv-Powr lubricants.. Drive Shaft (0) Assembly, Figure 0-2: a) Install the top and bottom shaft bearings (6, 7) and o-rings (2,22) onto the shaft (). Figure b) Grease the outside surface of the drive shaft () on top and bottom as shown in Figure 0. c) Insert the drive shaft () in the body (), as shown in Figure. Fit the thrust bearing (8), the thrust washer (8a), and the spring clip (8) using snap ring pliers as shown in Figure Piston (2) Assembly, Figures 3-5: a) Install the piston o-ring seal (6) and the piston head (5) and piston back (5) bearings. 8 8a **8 b) Install internal stroke adjustment screw components (0a, a,) per Section.2.. Figure 2 c) Grease the internal surface of the body () and the piston (2) rack teeth. d) Place the body () upside down (top of shaft pointing downwards). Hold the body () in a horizontal position by inserting the shaft () flats into a vice and secure. Table 2 Recommended VPVL Lubricants For General Use Kluber UniGear LA 02 Grease Esso(Exxon) Beacon EP2 Fina Marson EP L2 Shell Alvania EP2 Mobilux EP2 Drydene Pyroplex EP2 Oilzum Multiplex 2 Figure Figure 0 Figure IMO /8

7 IMO-529 EN Figure 5 Figure 7 e) Rotate the body () about 5-20 degrees counter clockwise as shown in Figure. While pressing on the two pistons (2) simultaneously, rotate the body () clockwise until the pistons are engaged and the stroke is complete. It may be necessary to make more than one attempt to obtain the proper shaftpiston alignment. Make sure the internal stroke adjustment screw (0a) does not influence the stroke of the pistons (2). In fact, with the pistons fully retracted, the shaft () slot rotation referred to the centerline will be 3-5 degrees greater than 0 degrees, as shown in Figure Internal Travel Stroke Adjustment a) For internal travel stroke adjustment, screw or unscrew the internal stroke adjustment screw (0a) until the desired stop location is obtained, then tighten the stop adjustment nut (2) to lock it in place. This operation must be done on both sides External travel stroke adjustment, Figure 9: a) External adjustment can only be made with the actuator totally assembled with pistons (2) extended outward toward the body () as shown in Figure 9. On double-acting units this can be done by rotating the shaft (); for spring return units it is necessary to use supply air. 3 Figure 8 3. End Cap (3) and Spring Cartridge (7) Assembly, Figures 6-8 Figure 9 Figure 6 a) For spring-return actuators, insert the proper quantity of spring cartridges (7) according to the pattern shown in Figure 7 (referring to the total number of springs). Insert spring cartridges (7) as shown in Figure 7. b) Fit the end cap o-ring seal () into the groove in the end cap (3). This must be done for both sides. c) Fit the end caps (3) onto the body (), verifying that the o-ring seal () remains in the groove. d) Insert all body bolts (3) and tighten only partially. Complete tightening by following the sequence indicated in Figure 8. b) Screw or unscrew the external stroke adjustment screw (0) until the desired stop location is achieved and then tighten the stop adjustment nut (2) to lock it in place. This operation must be done on both sides. 6. Actuator Storage If the actuators are not for immediate use, the following precautions must be taken for storage: a) Store in a dry environment. b) It is recommended that the actuator be stored in its original box. c) Do not remove the plastic plugs on the air supply ports. IMO /8

8 8 IMO-529 EN EXPLODED VIEW Double-Acting and Spring-Return Actuator Part Identification a = Optional at added cost 3a 3 2 2* 6* 7* 5* High-Visibility Position Monitor 2 a * 0 * 2 a 0a 5** 6* 22* Figure 20 IMO /8

9 IMO-529 EN 9 Parts List For Figure 20 No. Unit Qty Part Description Material Specifications Protection Body Extruded aluminum alloy ASTM 6063 T6 A-B 2 2 Piston Aluminum alloy ASTM B79-DIN 725/5 3 2 End caps Aluminum alloy ASTM B79-DIN 725/5 A-B Drive shaft Forged steel ASTM A05 Nickel-plated **5 2 Bearing (piston back) Nylon 6 **6 Bearing (pinion top) Nylon 6 **7 Bearing(pinion bottom) Nylon 6 **8 Thrust bearing (pinion) Nylon 6 8a Thrust washer (pinion) Stainless steel AISI 30 **9 2 Plug (transfer port) Nitrile (NBR) 0 2 Screw (ext. stoke adj.) Stainless steel 8-8 0a 2 Screw ( int. stroke adj.) Stainless steel 8-8 * O ring (screw seal) Nitrile (NBR) a Washer (seal) Stainless steel AISI 30 2 Nut (stop adjustment) Stainless steel Cap screw (end cap) Stainless steel 8-8 3a 8 Washer (cap screw Stainless steel 8-8 * 2 O ring (end cap) Nitrile (NBR) **5 2 Bearing (piston head) Nylon 6 *6 2 O ring (piston) Nitrile (NBR) 7 2 max Spring (cartridge) High-alloy spring steel Epoxy-coated 8 Spring clip (pinion) High-alloy spring steel Nickel-plated 9 Position indicator Polyamide 20 Cap screw & washer Stainless steel 8-8 *2 O ring (pinion top) Nitrile (NBR) *22 O ring (pinion bottom) Nitrile (NBR) 2 2 Guide piston Polyphthalamide 5% FG NOTES: ) * These components should be replaced every 500,000 cycles. ** These components should be replaced every 800,000 cycles. 2) On Model VPVLB0 Part nos. 3a-7-0a are not applicable. (Part no Material Polyphthalamide +5%FG) On Model VPVL05 Part no. 0a is available only on request. On Model VPVL70 Part nos. 3 and 3a Unit Quantity 2 purchase. 3) Position Indicator (Parts 9 and 20) is an Optional Item. IMO /8

10 0 IMO-529 EN EXPLODED VIEW VPVL Outline and Dimensions Figure 2 IMO /8

11 IMO-529 EN Actuator Model* Approximate Dimensions inches A B C D E F G H I L M N O P Q Q W W T NPT Flange Wt. lb CH DA SR VPVL M5-7 /8 F M5-8 /8 F M6-9 / F M6-9 / F M8-2 / F M8-2 / F M0-5 / F M0-5 / F M2-8 / F M2-8 / F M6-2 / F M20-30 /2 F Actuator Model* Approximate Dimensions mm A B C D E F G H I L M N O P Q Q W W T NPT Flange Wt. kg CH DA SR VPVL M5-7 /8 F M5-8 /8 F M6-9 / F M6-9 / F M8-2 / F M8-2 / F M0-5 / F M0-5 / F M2-8 / F M2-8 / F , M6-2 / F M20-30 /2 F IMO /8

12 2 IMO-529 EN 5. SERVICE / SPARE PARTS We recommend that actuators be directed to our service centers for maintenance. The service centers are equipped to provide rapid turn-around at a reasonable cost and offer new actuator warranty with all reconditioned actuators. NOTE: When sending goods to the service center for repair, do not disassemble them. Clean the actuator prior to shipping. For further information on spare parts and service or assistance visit our web-site at NOTE: When ordering spare parts, always include the following information: a. Actuator catalog code from label, b. If the actuator is serialized the serial number (from identification plate) c. From Figure 20, the ballooned part number, part name and quantity required. Subject to change without prior notice. Metso Flow Control Inc. Europe, Vanha Porvoontie 229, P.O. Box 30, FI-030 Vantaa, Finland. Tel Fax North America, Bowditch Drive, P.O. Box 80, Shrewsbury, M A 055, USA. Tel Fax South America, Av. Independéncia, 2500-Iporanga, , Sorocaba-São Paulo, Brazil. Tel Fax Asia Pacific, 238B Thomson Road, #7-0 Novena Square Tower B, Singapore Tel Fax China, /F, China Youth Plaza, No.9 North Rd of East 3rd Ring Rd, Chaoyang District, Beijing 00020, China. Tel Fax Middle East, Roundabout 8, Unit AB-07, P.O. Box 775, Jebel Ali Freezone, Dubai, United Arab Emirates. Tel Fax