Maintenance 8506.84/2-EN ACTO 400 to 1600 - MAINTENANCE INSTALLATION MAINTENANCE 1- General overview 2- Tooling 3- Installation 4- Draining Procedure and Hydraulic remote control 5- Adjustment of end stops 6- Actuator disassembly 7- Actuator re assembly 8- Actuator/Valve coupling and protection 9- Trouble shooting KSB is approved by ISO 9001
The purpose of this manual is to describe the installation/maintenance procedures and actions to be carried out in case of breakdowns or faulty operation of the ACTO 400 to 1600 hydraulic actuators. 1- General over view Draining and connection of hand pump 412.8 Section A - 412.8 A Constitutive parts of the spare kits Item Designation Item Designation 59-40 Chuck + pointer shaft 553 Adjustable end stop 81.68 Pressure pad 554.1 Washer 103 Housing 595 Piston 141 Cylinder 629 Pointer 142 Cover 731.1 Quick coupling 310.1 Self - lubricating strip 813 Supporting plate 310.2 Bearing 900 Cheese head screw 310.3 Self - lubricating strip 901.1 Hexagon head screw 310.4 Self - lubricating strip 901.2 Hexagon head screw 412.1 O--ring 903 Threaded plug 412.2 O--ring 916.1 Check valve plug 412.4 O--ring 916.2 Protection plug 412.5 O--ring 920.1 Operating nut 412.6 O--ring 920.2 Hexagon nut 412.8 O--ring 932 Ring 415 Lip seal ring 950 Check valve spring 486.2 Ball 970 Identity plate 486.2 Ball Grease NOTE : The identity plate 970 shows the reference data of the unit. These data are to be specified for each inquiry. 2
2- RECOMMENDED TOOLING (not supplied) Pneumatic screwdriver Mallet Open ended spanner Allen key Mounting spanner for end stops (see definition on page 7) TEST EQUIPMENT (not supplied) Hydraulic power pack 0... 350 bar CONSUMABLES Oil: Superflux HV46 Grease Multi MS2 (Total), EPEXELF MO2 (Elf) or RETINAX AM (Shell) or equivalent. You need a quantity of 250 to 450 ml. If you have a surplus in grease, it is not a problem for the correct operation of thesemanual actuators. Glue Loctite 242 or equivalent. Flange sealant Loctite 58-14 or 58-31, Omnifit FD30 or equivalent KSB spare parts kits, according to the actuator size (see kit sheets at the end of the document). 3- Installation BEFORE ANY ACTION Index the mounting position of the actuator onto the valve before dismantling Index the pointer position 629 ADAPTATION ONTO THE VALVE In case of thick paint on the valve, put washers to avoid the nut to damage the paint The adaptation onto the valves is achieved either directly or through adaptors parts: ACTUATOR POSITION ONTO THE VALVE The actuator can be positioned in 4 positions, at 90 intervals. Standard arrangement is N position 1 When a manual override is fitted on the actuator, the actuator should be mounted in accordance with M position 2. If the actuator is disconnected, fit it onto the valve following the steps as defined before the uncoupling, then drain the actuator. 3
Arrangement N Arrangement M Position 1 Position 2 Position 1 Position 2 F 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. TRANSFORMATION Arrangement N Arrangement M Uncouple the actuator from the valve, Remove the screw 900 and pointer 629, Remove the ball 486 from its groove using a screwdriver, pin punch,... Insert the ball 486 into the perpendicular groove, Refit the pointer at 90 from its original position and retighten the screw 900, Refit the actuator onto the valve at 90 from its initial position. 4- DRAINING PROCEDURE AND HYDRAULIC REMOTE CONTROL: 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,...) are to be isolated and bypassed. All traces of pickling, neutralising and cleansing solutions must be removed from the system before connection and oil filling. 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 30-40 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. 4
It is recommended to use the KSB AMRI flexible connector R471 10200. This equipment can be connected to the hydraulic block fitted on the actuator. All opened lines and parts must be efficiently sealed. R471-10200 N 42074021 P T Flushing unit 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. The required cleanliness class must be minimum ISO 18/15 according to ISO 4406 standards (equivalent to NAS 1638 class 9). SYSTEM FILLING During the filling operations, the flowmeter must be protected, therefore : after flushing connect the hydraulic pipes to the components open the flow restrictors F, O C V O connect the flexible connector R471 10200 to the hydraulic block fitted on the actuator, valve V closed. C disconnect flexible connector from the closed connection, open the valve V, operate the solenoïd valve (4 way 3 position see note) to open direction, F when the oil flows out of the flexible connector Close the valve V, connect the flexible connector to the open connection and disconnect it from closed connection, Open the valve V, operate the solenoïd valve (4way 3 position see note) to closing direction, when the oil flows out of flexible connector close the valve V, disconnect the flexible connector from the hydraulic block. C V O F C 5
NOTE: Before operating the 4 way 2 position solenoïd valve before operating in the required position, close the valve rack pressure isolating valve To supply oil to the hydraulic pipe open the pressure isolating valve. DRAINING connect the flexible R471-10200 to the actuator, valve V closed, open the valve V, open the flow restrictors F, operate the solenoïd valve to opening direction, let the oil circulate for a 15 minute minimum period, operate the solenoïd valve to closing direction, let the oil circulate for a 15 minute minimum period, close the valve V, disconnect the flexible from the actuator. O C V O C F 6
5- ADJUSTMENT OF STANDARD CLOSING END STOPS (±2 ) ACTO 400 to 1600 - MAINTENANCE Adjustable end stops are 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 stops must be verified. If need be, this adjustment will be modified as per the following procedure: Adjustment procedure for the unit valve + actuator Operate the actuator to the closing position and disconnect the oil supply, Loosed the nut 920.2 on the closing end stop, Adjust the closing end stop 553 and ensure that the desired position is obtained by pressurizing the closing chamber, then lock the nut 920.2, Opening end stop Closing chamber Opening chamber Closing end stop Operate the actuator to the opening position and disconnect the oil supply, Loosed the nut 920.2 on the opening end stop, Adjust the opening end stop 553 and ensure that the desired position is obtained by pressurizing the opening chamber, then lock the nut 920.2, SPECIAL CASE: ACTUATOR FITTED WITH AN OVERRIDE CONTROL Adjustment to be performed on the unit valve + hydraulical actuator + manual override In automatic operation under oil pressure, the assembly must be stopped in position against the hydraulic actuator end stops. The following adjustment sequence must be strictly followed: Operate the actuator to the closing position and disconnect the oil supply, Unscrew the 2 adjustable end stops of the override reducer (at least 4-5 ), Loosed the nut 920.2 on the closing end stop, Adjust the closing end stop 553 and ensure that the desired position is obtained by pressurizing the closing chamber, then lock the nut 920.2, Maintain the hydraulic pressure inside the actuator, Screw the closing stop of the override control until it contacts the wheel then unscrew it by one quarter (1/4) turn and tighten the corresponding lock nut, Operate the actuator to the opening position and disconnect the oil supply, Loosed the nut 920.2 on the opening end stop, Adjust the opening end stop 553 and ensure that the desired position is obtained by pressurizing the opening chamber, then lock the nut 920.2, Screw the opening stop of the override control until it contacts the wheel then unscrew it by one quarter (1/4) turn and tighten the corresponding lock nut, Check the good operation of the unit. 7
6- ACTUATOR DISASSEMBLY First record 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 901.1 Remove the cover 142, the O - ring 412.5, the self - lubricating ring 310.2 and the O - ring 412.7 CYLINDERS DISASSEMBLY Removal of one cylinder: Unscrew the screws 901.2 and remove the supporting plates 813 Cautiously remove the cylinder 141 taking care not to damage the piston 595. Cover the piston with a film or a plastic tube plastique in order to protect it against impacts Remove the lip seal 412 and the O - ring 412.1 Removal of the other cylinder: Follow the same procedure as above Removal of adjustable end stops Procedure to be followed for each cylinder: Measure and notify the overlength of the adjustable end stops with respect to the cylinder bottom, Remove the adjustable end stops through the inside of the cylinder using the mounting key of the adjustable end stop (see definition drawing below) Remove the O - ring 412.2 2 dia. 8 2 75 dia. 20 dia. 18 6 8 520 20
7- ACTUATOR RE-ASSEMBLY 7.1 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. 7.2 KINEMATICS GREASING Grease the nut 920.1 (where the pressure pads 81-68 slide), on the upper and lower sides with 100ml of grease. For specific applications with considerable and frequent temperature changes, it is strongly recommended to brush all the internal areas (gear casing, cap, cover, bottom, chuck, thrust washer ) with 200ml grease at least. Specific grease may also be used. 7.3 REFITTING OF CYLINDERS Ensure that the cylinders 141 are internally clean and remove any impurity. Preparation of each cylin Place the O - ring 412.2 on the adjustable end stop 553 and lubricate it. 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 1- Insert the O-ring seal and apply the - Insert the O - ring 412.1 and lubricate it lubricate (grease) on and around O- ring 2- Apply a little of sealant on the flat surface, outside area of O-ring. Do not put sealant on the O-ring seal. 9
Remove the protection film from the pistons and lubricate them Reinstall the cylinders by sliding them with care in order not to damage the O - rings Put in place the supporting plate 813 and screws 901.2 and tighten diagonally 7.4 TIGHTNESS TEST FOR THE CYLINDERS 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 in so far as the actuator is not subjected to any load (resistant torque). This kind of operation must never be done when the actuator is coupled to the valve. Test to be perfomed on each cylinder: 1st 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 in good repair. Replace any defective O - rings and repeat the assembly steps until correct tightness is ensured. 2nd cylinder: Disconnect the oil supply and disconnect the first cylinder. Disconnect the second cylinder, pressurize and operate the actuator Caution for the draining of the first cylinder Realize the tightness test as defined above. If the actuator is equipped with a distributor strip, refit it in its initial position. 10
7.5 COVER REASSEMBLY Ensure that the cover is clean Lubricate the housing of the guide strip 310.2 and install the strip. Insert the O - ring 412.5 and lubricate it onto the cover142 1- Insert the O-ring seal and apply the lubricate (grease) on and around O-ring 2- Apply a little of sealant on the flat surface, outside area of O-ring. Do not put sealant on the O-ring seal. Refit the O - ring 412.7 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 901.1 11
Connect the actuator to the hydraulic power pack and check the actuator for correct operation (stroke, tightness) under motor oil pressure 120 bar. 8- ACTUATOR/VALVE COUPLING Take off the grease clean and paint the shocks and metallical areas non protected to avoid any corrosion : This is the custom responsibility to protect against the corrosion. Some silicone seals can also be used and added in severe environments. 8.1 PROTECTION Clean, degrease and paint all the surfaces, all the contact junctions in order to prevent rust. The paint must be chosen according to the environment. 8.2 COUPLING Fit the pointer 629 and/or the accessories on the actuator in their initial position. DIRECT FITTING following figure 1 3 Put some drops of glue on the threads of tie-bolts and screw Cover all the area of the base plate Actuator/Valve with flange sealant or ADAPTOR FLANGE FITTING following figure 2 3 Actuator side, cover all the area of the base plate Actuator/ Valve with flange sealant Fit the flange onto the actuator Put some drops of glue on the threads of screws and screw them Put some drops of glue on the threads of tie-bolts and screw them Valve side, cover all the area of the base plate Actuator / Valve with flange sealant For a better protection of the actuator, it is recommended to clean, dry and paint all the interfaces after fitting (interfaces gear casing / bottom, gear casing/ cover and gear casing / cap) - Couple the actuator onto the valve in its initial position - Check the correct operation of the unit Valve / Actuator / Accessories - If necessary, re-adjust the adjustable end stop : see 5 Adjustement of closing adjustable end stop. 12
Notes 13
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8506.84/2-EN 04.04.14 This leaflet is not contractual and may be amended without notice. ACTO 400 to 1600 9- TROUBLE SHOOTING At end adjustable stops 553 At plugs 916.1 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 External leaks O-- -ring 412.2 damaged Change O-- -ring 412.2 Check valve 486.2 defective Change sub-- -unit adjustable end stop 553 + cylinder cover 916.1 +O-- -ring 412.2 Lip seal 415 damaged Change lip seal 415 + check the cleanliness of the oil in the actuator O-- -ring damaged at the strip Change the O-- -rings of the strip Manual override engaged or bypass open Missing or insufficient pressure Valve blocked Disconnect the hydraulical pressure Disengage the manual override and/or close by-- -pass Check hydraulic power pack and its associated components Check valve and/or interfacing with piping Internal leaks Change O-- -rings 415 Check the cleanliness of the oil Corrosion :chuck 59-- -40 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 stops System improperly drained Actuator closed / valve opened or closed valve / actuator opened Inversed hydraulic connections Hydrodynamiqc torque Loss of air pressure Wrong assembly of the actuator onto the valve Check drive and/or adapter flange Consult the leaflet 8506 or contact the manufacturer Refer to chapter Adjusting of adjustable end stops of the maintenance leaflet Drain the actuator according to the procedure of the maintenance manual Put valve and actuator in the same position Vérifier le branchement hydraulique Check the safe box and its components Pressurize the equipment and keep it under pressure Refer to transformation arrangement N < -- --- -> M in manual maintenance concerned KSB S.A.S 4, allée des Barbanniers 92635 Gennevilliers Cedex (France) Tel. : +33 1 41 47 75 00 Fax : +33 1 41 47 75 10 www.ksb.com