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Triple Offset Valve

Remote Operated Shut-Off Valves (ROSOV)


INSTALLATION, OPERATION & MAINTENANCE
MANUAL

Website :
www.tritork.com
www.virgoengineers.com

Installation, Operation & Maintenance Manual

Content
General Instructions

Page No.

Introduction

Transportation, Reception and Storage

Dos and Donts

Installation

Operation of the valve

Trouble Shooting

Preventive Maintenance

Ordering the Spares

10

Disassembly and Assembly Instructions

10

10

Exploded View

13

11

Possible Misuse of Triple Offset Valve

14

12

Valve Ordering Information & Warranty

14

13

Address for Correspondence, Works & Sales Offices

16

Installation, Operation & Maintenance Manual

1. Introduction
Scope
The manual is provided to ensure proper installation, operation & maintenance for the TriTork Triple
Offset Valve (TOV) manufactured and supplied by Virgo Group of Companies. This manual covers
Virgos Triple Offset valve range from 3 to 30.

Fig 1.1 Identification of Valve

Installation, Operation & Maintenance Manual

2. Transportation, Reception and Storage


Valves are being packed in cartons, boxes or pallets while shipping to the customer.
While loading & unloading check for any arrow mark on cartons, boxes or pallets as indicating
upward position.
When handling the valve or the valve package, bear in mind its weight. Use crane to lift and mount
the valve on pipeline.
Place the rope securely around the valve body while handling the valve (Fig. 2.2). Lift the valve only
as shown in Fig 2.3. Lifting the valve from any other location may damage the valve / automation
components.
We recommend storing of the valves should be indoor in a dry and dust free atmosphere, protected
from rain & storm.
All wrapping and protection on the valves should not be removed until the valve is ready for
installation. All valves shall be duly packed and delivered with disc in partially open position.
While unpacking the valve, ensure that the valve and other accessories have not been damaged
during transportation.
Placing the valve directly on the ground or on a concrete floor should be avoided.
Always place the valve preferably on rubber sheets laid on ground.

Fig. 2.1 Storing the Valve

Fig. 2.2 Fixing the Rope

Fig. 2.3 Lifting of Valve

Fig. 2.4 Lifting of Valve

Installation, Operation & Maintenance Manual

3. Dos and Donts


Dos
It is recommended always, to use the Installation, Operation & Maintenance Manual before
installing, operating or repairing of any TOV.
Use the valve for specified application only. User to ensure that the valve is used only for the
specified application as agreed between the manufacturer and the purchaser.
Follow the safety rules and regulations. User of the valve must be aware of all the safety rules and
regulations related to a particular environment in which the valve is to be used.
Be aware of the type of media involved. Protect people and the environment from any harmful or
poisonous substances. Make sure that no dust; dirt can enter the pipeline during the valve
maintenance.
Periodically ensure the tightness of Gland plate & Bottom flange joint bolting.
Always use dry, dust & moisture free air while opening the valve with pneumatic actuator or for
cleaning purposes.
Ensure that thorough ventilation is provided while working on the close equipment.
Dont
Do not drag the valve on bare floor.
Do not exceed the valve pressure/temperature rating limitations.
(Exceeding the pressure/temperature rating limitations marked on the valve may result in major
damage or personal injury. Users of these valves should ensure that the valve
pressure/temperature is less than or equal to the rated pressure/temperatures. If required, end user
should incorporate appropriate limiting/monitoring devices in the system for the safe operation of
the valve.)
Do not disassemble the valve or remove it from the pipeline while the valve is in pressurized
condition.
(Disassembling or removing a valve in pressurized condition will result in uncontrolled pressure
release. Always isolate the relevant part of the pipeline, release the pressure from the valve and
remove the media before dismantling the valve.)
Do not pressurize the line without a Gear operator / actuation device properly installed & working on
the valve.
Do not try to rectify the valve leakage by reworking of seal ring. Leaking seal ring has to be replaced
with the new TriTork genuine seal ring.
Do not allow any such process that may generate spark, particularly working in Hydrogen or
Oxygen service line or any such inflammable fluids.

Installation, Operation & Maintenance Manual

4. Installation
Before installation, clean valve ends & bore using Acetone / suitable commercial solvent or as per
the Customers requirement.
Valves are bi-directional and can be installed in either direction. But TriTork recommends putting
shaft side towards upstream side.
Clean the pipeline to avoid damage of the super finish seal ring due to impurity, welding residuals,
debris, scaling, etc.
Keep the valve in closed position while installing in the pipeline.
Never install the Valve with the Actuator on the underneath side in the pipeline. (Fig. 4.1)

Fig 4.1 Avoid this mounting position.

Fig 4.2 Supporting the valve

Fig 4.3 Valve Installation

Installation, Operation & Maintenance Manual

FLANGE AND PIPING COMPATIBILITY


Valve should be checked for identification purpose and ensure that characteristics of valve matches
to those specified for piping specifications, for the line where the valve is to be mounted. Nameplate
instructions will give the necessary information.
The Triple Offset valves have been designed for installation between flanges made in accordance
with ASME B16.5 (for 3 to 24) & ASME B16.47 Series B (for 26 & above) as a standard.
Make sure that during opening of disc, there is no interference between the seal ring and piping.
If the pipeline is lined, confirm that the disc does not come in contact with the lining during opening
stroke. Failure to confirm that the disc rotation does not contact the lining may result in damage to
the valve.
During installation, valve should be in closed position so that the seal ring does not get damaged.
The mating flanges shall be aligned before final tightening of the flange bolts to ensure proper valve
operation and the seating of any seals and gaskets.
Particular care should be taken with those valves equipped with fail-open actuators while
installation.
INSTALLATION OF VALVES IN AN EXISITING PIPING - PRACTICE
Confirm that the distance between the flanges is as per valve face-to-face dimension. Stretch the
pipe flanges using a proper tool, to make the fitting easier.
Close the valve properly to keep the disc inside the valve face-to-face dimension.
Insert the valve between the flanges, centering the body and insert all the bolts.
Keep the valve aligned between the flanges and close the bolts.
Rotate the disc in counter-clockwise direction and check the disc/seal ring clearance in the pipe.
Now bring the disc in full open position and close the bolts in a cross sequence.
INSTALLATION OF VALVES IN A NEW PIPING - PRACTICE
Close the disc fully and center the valve between the flanges.
Close the valve body between some bolts and closes them partially.
Use the assembly valve/flanges for centering the valve in the piping.
Tack welds the flanges to the piping.
Remove the valve and bolts from the piping before full welding.
Dont weld the pipe on line with valve fitted as the heat may damage the valve seal ring.
Complete the welding and allow cooling.
Install the valve by same sequence as per installation in an existing piping / practice
VALVE REMOVAL FROM THE PIPING
Release the pressure from the pipeline and remove the media before valve removal from piping.
Turn the valve disc in fully closed position.
Release and remove the bolts.
Stretch pipe flanges using a proper tool.
Remove the valve.

Installation, Operation & Maintenance Manual

5. Operation of the Valve


Clockwise rotation of shaft closes the valve & counter-clockwise rotation opens the valves.
Do not disturb the Valve automation adjustment setting; unless & until it is required.
For constructional details of Valve automation, refer General Arrangement Drawing.
The valve closes in clockwise direction and can be rotated through 90 to the fully open or fully
close position. The valve disc open and close status can be visually identified by dimple position
provided on shaft. Refer figure 5.2
Valve should be opened and closed slowly to avoid hammering effect on the valve and pipeline.
Once the flushing is complete, valve should be operated 3-4 times and then kept in the fully open
position.
If the valve is not operating to fully open or fully closed position, and/or leaking, do not apply
excessive force to operate the valve. This can damage the seal ring or shaft.

Fig No. 5.2: VALVE OPEN/CLOSE ORIENTATION

Installation, Operation & Maintenance Manual

6. Trouble Shooting
The following table lists the possible malfunctions that might occur after prolonged use.
Symptom
Valve wont rotate

Possible Fault
Shaft packing is too tight
Operator has failed
Valve packed with impurities
Shaft key has sheared

Bottom flange gasket


leaking

Fluid solidification between


bearings & shaft.
Gland flange nuts too loose
Shaft Packing Damaged
Bottom flange bolting loose
Spiral wound gasket damaged.

Valve seat leaking

Valve not fully closed

Water hammer or noisy


operation
Jerky operation

Debris trapped in valve


Actuator mechanical stops
improperly set
Seal ring damage
Error in valve sizing or flow of
fluid with high velocity.
Shaft Packing is too tight

Shaft Packing leaking

Air supply to actuator is


inadequate.
Actuator and shaft coupling
misaligned

Recommended Actions
Loosen gland nuts.
Replace or repair operator.
Flush or clean the valve
Find out cause of shearing &
replace the key.
Flush the bearing

Tighten Gland flange nuts


Replace shaft packing
Tighten bottom flange bolts.
Replace gasket
Close the valve fully. When the
valve is fully closed, dimple on
the shaft will be perpendicular
to flow line axis. Refer figure 5.2
Cycle & flush the valve
Remove the stop for closure
and reset properly.
Replace the seal ring
Confirm valve sizing.
Loosen gland nuts, cycle valve
& then re-tight.
Increase pressure or volume of
supplied air.
Properly align the coupling

7. Preventive Maintenance
Note: Observe the safety precautions as outlined in Dos & Donts before performing maintenance.
In order to avoid valve failure during operation, all valves should be periodically inspected
thoroughly to detect the damage of seal ring, shaft, seals and even body.
While doing periodical checks, it is recommended that the seal ring, bottom gaskets, seals and shaft
packing should be replaced by genuine spares.
The type of process fluids involved, working conditions and location of the valves in the plants, will
determine the frequency of periodic inspection / maintenance which in fact will be made at the time
of partial or total shutdown of the plant.
Preventive maintenance is absolutely essential as the failure due to lack of the same may cause an
emergency shutdown of the plant.
Section 9 describes the procedure for complete dis-assembly & re-assembly of the valve. The
procedure for a valve failing during operation due to lack of preventive maintenance is mentioned
under maintenance of shaft packing, seal ring & bottom flange gasket.
Once a valve is repaired, it should undergo a complete set of tests to make sure that the valve is
adequate for the original working conditions. Hydro/Pneumatic tests should be carried out as per
the specifications relevant to the valve. (Refer General Arrangement Drawing).

Installation, Operation & Maintenance Manual

8. Ordering the spares


When ordering for spare parts, always convey the following information.
Size of the valve
Valve rating
Sr. No. / Batch No.
Mfg. Date
Part No.
Name of the part
Number of valves required.
P. O. Number

Available on name plate or body of the valve

Available on general arrangement drawing

Note: Selection and use of the valve for a specific application requires close consideration of
detailed aspects. Due to the nature of the product, this manual cannot cover all the individual
situations that may occur while installing, using or servicing the valve.

9. Dis-assembly & Assembly Instructions


1) Complete Dis-assembly
1. Ensure the valve is in closed condition.
2. Place the valve body face horizontally on table such that retainer ring side of body faces
upwards.
3. Remove retainer screws (07) from disc (02).
4. Lift the valve assembly and then fully open the valve.
5. Separate the gearbox (31) from bracket (18) by removing bolt (20), then remove shaft key
(27) by removing socket headed screw.
6. Rotate disc by hand such that total rotation of disc will be 180 with respect to initial closed
position.
7. Place the valve body face horizontally on table such that retainer side faces towards roof.
8. Remove bracket & its dowel pins (19) from body (01).
9. Remove gland nuts (17), gland plate (15), split ring, gland (14) & gland stud (16).
10. Remove retainer ring (05), seal ring (03), disc dowel pin (04) & disc gasket (06).
11. Remove bottom flange bolts (26) from the body.
12. Remove bottom flange (24), gasket (25) and lower-thrust washer (21) from body.
13. Unscrew adjustable screw (23) from shaft and then remove stop washer (22) from body.
14. Rotate the body by 180 so that ribs on disc face upwards.
15. Remove taper pin nuts and taper pins (09).
16. Push the shaft (08) from top till it is removed from bottom side.
17. Remove disc from body.
18. Now remove gland packing rings (13) & spacer (12).
19. Remove bearing protector (28) from bearings.
20. If required, remove bearings (11) with the help of bearing removal tool.

10

Installation, Operation & Maintenance Manual

2) Complete Re-Assembly
Before re-assembly, inspect the valve for any damage on Body, Seal ring & all internals.
Damaged internals to be replaced by genuine & with recommended parts only.
1
2

3
4
5
6

7
8
9
10
11
12
13
14

15

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Assembly should be done on perfectly horizontal table. Table must be covered with rubber
sheet. Assembly table should be clean. Ensure that tooling & other supplementary things (cotton,
lubricants etc.) easily available at assembly table.
Place the body (01) horizontally on table ensuring that body sealing area close to table platform.
Clean the body bore area with the help of dry air. Remove burr, foreign particles from body bore
area.
Apply lubricant on the outer surface of bearing (11) & place packing rope (28) in bearing groove.
Insert bearing in body shaft bore from upper side & press it with the help of nylon bar until it take
its position as shown in general assembly drawing.
Repeat the procedure 4 for inserting another bearing through bottom side body shaft bore.
Place the disc (02) in body inner pocket keeping disc ribs upward. Match the disc-offset arrow in
same direction with respect to body offset bore. Ensure that body shaft bore & disc shaft bore
are inline.
Slowly insert the shaft (08) in body bore from upper side.
Take care while shaft passing through bearing & just before entering the disc bore.
Ensure alignment of shaft pin hole and disc pin hole and insert shaft pin.
Place second pin same as described in 9.
Attach washer and heavy hex nut to shaft pin for fitment.
Insert lower thrust washer (21) from bottom side & secure it with the help of adjustable screw.
Place stop washer (22) on thrust washer with proper alignment of its slot & across flat of
adjustable screw (23).
Put the bottom flange gasket (25) on bottom flange (24). Place bottom flange on bottom face of
body, concentric with shaft axis. Rotate the bottom flange to accommodate the correct position &
center the holes with the threaded holes on body. Fix the bottom flange with body by tightening
the bolts (26).
Insert spacer (12) passing over shaft from upper side. Same way first insert anti-extrusion
packing rings (13) on spacer then graphite molded rings at center followed by top anti-extrusion
ring.
Insert gland (14) over gland packing set.
Insert studs (16) on body tapping provided for gland plate (15) assembly.
Arrange gland plate over gland. Gland plate edge should be parallel with face of body mounting
flange.
Properly tighten of gland plate with nut (17) & stud (16).
Put dowel pins (19) at body upper plate as a locator for bracket (18).
Ensure proper position of bracket with reference to dowel pin location. Fix the bracket with body
with heavy hex bolts (20).
0
Keep entire assembly perpendicular to table surface. Rotate the disc in 180 .
Place the body horizontal on table such a way that retainer side of disc will upward.
Put disc gasket (06) into the disc groove.
Insert dowel pin (04) in its position.
Place the seal ring (03) on disc with reference to dowel pin.
Put retainer ring (05) on seal ring with reference to dowel pin position.
Clamp the retainer ring with disc by hand tightening the retainer screws (07).
Place the shaft key (27) at keyway & fix it with help of disc screw.
Mount Gearbox (31) / Actuator on the bracket & fix it with the help of heavy hex bolt (20).
Operate the disc as full close-full open-full close for at least 5 cycles.
Hold the disc at perfectly close position & then tighten the retainer screws.
Confirm the exact position of disc with shaft.
Repeat the procedure 32 & 33 if valve leaks, to ensure correct positioning of seal ring.

11

Installation, Operation & Maintenance Manual

3) Maintenance of Shaft Packing, Seal Ring & Bottom Flange Gasket


If leakage is observed through the packing, tighten the gland nuts slowly and evenly until the leakage
stops.
When tightening the gland nut, use half-turn increments until leakage has stopped.
Shaft packing replacement procedure:
Ensure valve is not in pressurized condition.
Remove the gear operator/actuator & the connecting keys. Note the position of the gear
operator/actuator relative to the valve for proper reassembly.
Remove gland nuts (17), gland plate (15), split ring & gland (14) from the valve.
Remove packing (13) without damaging the shaft & the shaft bore.
Carefully clean the packing cavity & the shaft.
Insert new packing rings keeping anti-extrusions packing rings at top & bottom.
Reassemble the gland, split rings, gland plate & hand tighten the nuts.
Reassemble connecting keys & gear operator/actuator & close the valve.
Tighten the gland nuts & cycle the valve.
Pressurize the pipeline. If leakage is observed, tighten the nuts slowly & evenly until the
leakage has stopped.
Seal Ring replacement procedure:
Ensure valve is not in pressurized condition.
Remove the valve from pipeline with disc in closed position.
Clean the valve & ensure dirt/dust free atmosphere.
Open the valve & loosen the retainer screws (07).
Now fully open the valve.
Carefully remove retainer screws & the retainer ring (05) from the valve.
Remove seal ring (03) & disc gasket (06).
Clean the disc (02) & gasket seating area for any foreign particles or dust.
Assemble new gasket in the disc groove without damaging it.
Assemble the new seal ring on the disc. Ensure proper alignment of seal ring with dowel.
Assemble retainer ring & ensure alignment of punch mark on retainer ring for proper cone
matching.
Clamp the retainer ring by hand tightening the retainer screws.
Cycle the valve as full close-full open-full close for minimum 5 times.
Now tighten the retainer screws keeping the valve in closed position.
Bottom Flange Gasket replacement procedure:
Ensure valve is not in pressurized condition.
Remove the bottom flange (24).
Remove the bottom flange gasket (25).
Clean the gasket seating area & the bottom flange.
Now place the new bottom flange gasket on the bottom flange.
Insert the bottom flange in the body centering the gasket position. Rotate the bottom flange to
accommodate the correct position & center the holes with the threaded holes on body.
Fix the bottom flange with body by tightening the bolts.

12

Installation, Operation & Maintenance Manual

10. Exploded View

13

Installation, Operation & Maintenance Manual

11. Possible Misuse of TriTork Triple Offset Valve


Sr.
Possible Misuse
Recommended / Proposed actions
No.
1

Exceeding the limits of the Customer shall take care not to use valve beyond limits
Pressure/Temperature as specified on Nameplate / Body marking.
agreed between Virgo and
Customer (Ref. P.O)
Valve for dead end service Ensure marking on valve for dead end service.
Triple offset butterfly valve with blind flange is
recommended for dead end service.
Use of different application Valve data sheet / fluid details are supplied with IOM.
fluid. (Not as specified in Customer is advised to check suitability if intended service
Valve Data Sheet/P.O.)
is different from valve data sheet.
Upside down mounting of
Upside down mounting of Valve to be avoided.
Triple offset butterfly
valves.

12. Valve Ordering Information


Customer
Project
Consultant
P. O. No. and Date
Valve Data Sheet No. OR
Fluid details (if available)
Work Order No.
Date of Last Dispatch
Date of Commissioning

Warranty:
Our liability in respect of any defect in or failure of the goods supplied or for any loss, injury
or damage attributable thereto is limited to making goods by replacement or repair defects
which under proper use appear therein and arise solely from faulty materials and
workmanship within a period of 18 calendar months after the original goods shall have been
first dispatched or 12 calendar months from the date of commissioning, whichever is earlier
provided that such defective parts are returned free to our works for examination. The
undertaking shall exclude any and every other obligation.

14

Installation, Operation & Maintenance Manual

Virgo does not assume responsibilities for any liabilities/damages arriving out of
wrong application of its valves, or imprudent operations carried out by inexperienced
operators, or which does not comply with this manual, or instructions provided by
Virgo.
The valves shall be appropriately used for the purpose they are built, or applications
they are supplied. Use of standard valves for special applications is not
recommended unless it has been communicated and agreed to by Virgo.
Valves shall be operated and maintained strictly in accordance with the procedures.
Operation or maintenance outside these procedures constitutes abuse of the product
and voids all warranty and claims.
.

15

Installation, Operation & Maintenance Manual

13. Addresses for Correspondence


In case of service / repair, please contact our nearest Factory / Sales Office.

VIRGO VALVES & CONTROLS


LIMITED

VIRGO VALVES & CONTROLS


LIMITED

Regd. Office:

Sulakkal Road , Kovilpalam Via,


Mettupalayam Village, Pollachi Taluk
Coimbatore -642 110, INDIA
Phone: +91-04259-259847
Fax: +91-04259-259846
Kolkata
Gopal Sett Road, Near Sukchar
Harisabha, River side P.O.Sukchar
Kolkata-700 115
Tel
: (033) 65011417
Mobile : +91 9433070154
E-mail : Virgo.Kolkata@virgovalves.com

277,Hinjewadi Phase II, Maan (Mulshi),


Pune 411 057, INDIA.
Phone: +91-20-66744000
Fax: +91-20-66744021
Mumbai
Unit No. 103, First Floor,
A - Wing, Building No. 1,
Kailash Industrial Complex, Behind Godrej
Colony, Off. L.B.S.Marg, Parksite,
Vikhroli (E ) Mumbai - 400 079
Phone : 022 40100700
Fax : 022 40110701
E-mail : Virgo.Mumbai@virgovalves.com
Baroda
14, Guruprasad Society, Behind Akota
Stadium,
Baroda-390 015. INDIA
Phone :+91-265-2342837, 2355133, 2341053
Fax : +91-265- 2314449
E-mail : Virgo.Vadodara@virgovalves.com
Delhi
7/39, 2nd Floor, 1 B,
Vikram Vihar, Lajapat Nagar,
New Delhi 110 024. INDIA
Phone : +91-11- 51729161/2/3/4
Fax : +91-11- 51729164
E-mail : Virgo.Delhi@virgovalves.com
VIRGO ENGINEERS INC.
(Sales & distribution Office) USA
10225 MULA ROAD, SUITE 130,
STAFFORD, TEXAS 77477,
U.S.A.
TEL : +1 281 933 3100
FAX : +1 281 933 3110

Chennai
No. 59, Ground Floor, Teachers Colony,
Kamaraj Avenue, Adyar,
Chennai-600 020. INDIA
Phone : +91-44- 24404119
Fax : +91-44-24410664
E-mail : Virgo.Chennai@virgovalves.com
MALAYSIA
Virgo Valves and Controls Ltd.
Suite 1904, 19th Floor, Kenanga
International
Jalan Sultan Ismail,50250 Kuala Lumpur,
Malaysia
Ph
: +60 3 21618260
Fax : +60 3 21612220
Virgo Valves & Controls Limited
(Warehouse and Valve Automation
Center)
Unit - Fzs1 AH07,Jebel Ali Free Zone
(South),
P.O. Box 18478, Dubai-UAE
Phone : +971-4-8860980
Fax : +971-4-8860981

VIRGO EUROPE S.P.A., ITALY


VIA Sicilia, 96
20020, Magnago
Milan, Italy
Phone: +39 0331 308211
Fax: +39 0331 306299
TOV : IOM ROSOV 2013/R0

16

Instrument Air Quality Standard (ANSI/ISA-S7.0.01-1996)


Instrument air quality standard establishes four elements of instrument air
quality for use in pneumatic instruments
1. Pressure Dew point
The pressure dew point as measured at the dew point outlet shall be at least
10 deg C (18 deg F) below the minimum temperature to which any apart of
the instrument air system is exposed. The pressure dew point shall not
exceed 4 deg C (39 deg F) at line pressure. A monitored alarm is preferred .
However if a monitored alarm is not available , then per shift monitoring is
recommended. ( for explanation of "Dew point" see Appendix A below)
2. Particle size
A maximum 40 micrometer particle size in the instrument air system is
acceptable for the majority of pneumatic devices. Pneumatic devices that
require instrument air with less than 40 micrometer particle size shall have
additional filtration to meet the particulate size limit for the device.
Subsequent to any maintenance or modification of the air system ,
maximum particle size in the instrument air system should be verified to be
less than 40 micrometers.
3. Lubricant Content
The lubricant content should be as close to zero as possible, and under no
circumstances shall it exceed 1 ppm w/w or v/v. Any lubricant in the
compressed air system shall be evaluated for compatibility with end-use
pneumatic devices. For example , the use of automatic oilers is strongly
discouraged.
4. Contaminants
Instrument air should be free of corrosive contaminants and hazardous
gases , which could be drawn in the instrument air supply .The air supply
intake should be monitored for contaminants. If contaminants exists in the
compressor intake area , the intake should be moved to a different elevation
or location free from contamination. Some sources of contamination are:
a. painting
b. chemical cleaning
c. engine exhaust
Appendix A
ISA-S7.0.01 establishes a maximum pressure dew point to protect the
instrument air systems from the presence of moisture.
Compression and cooling stages in an instrument air system causes
condensation. Compression increases the partial pressure of the water
vapour present. If the water vapour partial pressure is increased to the
saturation water vapour pressure , condensation occurs. Cooling reduces the
saturation water vapour pressure , a temperature dependent variable .If the
saturation water vapour pressure is reduced to the partial pressure of the

water vapour present , water or ice will result. Therefore, moisture removal
is a major consideration of instrument air treatment systems.
The most common methods of moisture removal are compression cooling ,
absorption, chemical methods, mechanical separation, and combination of
these methods.
Note : This is only a small extract of ISA standard ANSI/ISA-S7.0.011996.For complete information please refer the ISA document mentioned.

Installation, Operation & Maintenance Manual


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Installation, Operation & Maintenance Manual


LIMIT SWITCH BOX.

Established Leaders in Valve Actuation

GP RANGE
PNEUMATIC SCOTCH YOKE ACTUATORS

INSTALLATION
AND
MAINTENANCE
MANUAL

Publication F130E
Date of issue 04/08

CONTENTS

GP RANGE
INSTALLATION AND MAINTENANCE

SECTION

CONTENT

PAGE

Introduction

Installation

Maintenance

Grease and Hydraulic Oil Specifications

Cylinder Seal Replacement

Fault Detection

Actuator Drawing / Parts List

Stop Bolt Adjustment

10

MB1 Switchbox Setting Procedure

11

Appendix

Page 2 of 12

Publication F130E
Date of issue 04/08

INTRODUCTION

GP RANGE
INSTALLATION AND MAINTENANCE

1.0

Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems GP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of GP range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.

INSTALLATION

2.0

Installation

2.1

Electrical Considerations

2.1.1

Any electrical connections required are the responsibility of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.

2.1.2

Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.

2.1.3

Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.

2.1.4

The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.

2.2

Motive Power Supply (pneumatic, hydraulic)

2.2.1

Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.

2.2.2

Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium.

2.2.3

Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.

Page 3 of 12

Publication F130E
Date of issue 04/08

INSTALLATION

GP RANGE
INSTALLATION AND MAINTENANCE

2.3

Maximum Allowable Temperature

2.3.1

The maximum temperature allowable for standard build actuators is 100C (212F).Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.

2.3.2

Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.

2.4

Operating Environment

2.4.1

The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.

2.4.2

If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.

2.5

Mechanical Considerations

2.5.1

It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.

2.5.2

Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.

2.5.3

Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.

2.54

All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.

2.5.5

When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.

2.5.6

Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.

2.5.7

Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.

2.5.8

Once in position, the actuator should operate the valve with a smooth continuous action. If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
Page 4 of 12

Publication F130E
Date of issue 04/08

MAINTENANCE

GP RANGE
INSTALLATION AND MAINTENANCE

3.0

Maintenance

3.1

Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customers individual requirements.

3.2

Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.

3.3

No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.

3.4

Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.

3.5

Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.

3.6

After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.

3.7

Periodic Inspection

3.7.1

Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.

3.7.2

Verify that the power gas supply pressure value is within the required range.

3.7.3

Visually inspect external components of the actuator for physical damage.

3.7.4

Check pneumatic/hydraulic connections for leakage. Tighten pipe fittings as required.

3.7.5

Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.

3.7.6

Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.

Page 5 of 12

Publication F130E
Date of issue 04/08

GREASE AND HYDRAULIC OIL

GP RANGE

INSTALLATION AND MAINTENANCE


4.0

Grease and Hydraulic Oil Specifications

4.1

Grease Specification
Manufacturer:

Mobil

Trade name:

Mobiltemp 78

Colour:

Gray/black

Soap type:

Inorganic

QUANTITY OF GREASE IN HOUSING


CENTRE BODY SIZE

Oil type:

Mineral

Consistency (NLGI GRADE)-ASTM D217:

Worked penetration at 25C-ASTM D217:

295/325 dmm

Dropping point - ASTM D2265

260C

Viscosity of base oil at 40C-ASTM D445:

485 cSt

Viscosity of base oil at 100C-ASTM D445:

32 cSt

QTY (kg/lb)

065, 085, 100

0.3/0.66

130

0.4/0.88

160, 161, 200, 201

0.5/1.10

270, 271

0.8/1.76

350

1.2/2.64

Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.

4.2

Hydraulic Oil Specification


Manufacturer:

Mobil

Trade name:

DTE 11

Viscosity at 40C:

16.5 cSt

Viscosity at 100C:

4.2 cSt

Viscosity index ASTM:

168

ISO Grade:

16

Pour point:

-42C

Specific weight at 15C:

0.85 kg/dm3

Equivalent to:

Statoil - Hydraway HVX-A15

Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.

Page 6 of 12

Publication F130E
Date of issue 04/08

CYLINDER SEAL REPLACEMENT

GP RANGE

INSTALLATION AND MAINTENANCE


5.0

Cylinder Seal Replacement

5.1

Disassembly

5.1.1

Disconnect pneumatic and electrical supply connections. For spring return actuators, ensure that the actuator is in the failed
position (i.e., at end of the spring stroke).

5.1.2

Remove stop bolt nut (33).

5.1.3

Loosen stop nut (31) and remove stop bolt (32).

5.1.4

Remove tie rod nuts (34) from the tie rods (22).

5.1.5

Remove bottom flange (21).

5.1.6

Remove cylinder tube (19).

5.1.7

Remove housing cover bolts (16), center body cover (15) and cover gasket (14).

5.1.8

Remove piston retaining nut (35) and separate piston (23), shoulder washer (30), and o-ring (36) from piston rod (20).

5.1.9

Remove o-ring (25) and sliding ring (24) from piston (23).

5.1.10

Remove piston rod (20) by unscrewing it from the guide block (4).

5.1.11

Remove flange retaining bolts (13) and remove head flange (18).

5.1.12

Remove head flange and bottom flange o-rings (26).

5.1.13

Remove bolts (38) and shaft seal retaining flange (37) from the head flange (18).

5.1.14

Remove o-ring (28) and shaft seal (29).

5.1.15

Clean all sealing surfaces.

5.1.16

Coat new o-rings, seals and gaskets with grease.

5.2

Assembly

5.2.1

To reassemble the actuator, follow the disassembly procedure in reverse order.

5.2.2

Reconnect power gas supply lines to the actuator.

5.2.3

Cycle the actuator several times. Movement should be smooth and continuous. If not, refer to Section 6, Fault Detection.

RECOMMENDED TIGHTENING TORQUE


BOLT SIZE

NM

M6

8.5

M8

20

15

M10

40

30

M12

55

40

M14

110

81

M16

220

162

M20

430

317

M22

425

313

M24

585

431

M27

785

579

M30

1,250

921

M33

1,400

1,030

M36

1,750

1,290

Page 7 of 12

FT. LBS

Publication F130E
Date of issue 04/08

FAULT DETECTION

GP RANGE
INSTALLATION AND MAINTENANCE

6.0

Fault Detection
In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.

SYMPTOM

CAUSE

REMEDY

6.1 Erratic movement

6.1.1 Irregular supply of operating


medium.

6.1.1.1 Check operating medium for consistent


supply pressure and correct as necessary.

6.1.2 Inadequate lubrication.

6.1.2.1 Dismantle, re-lubricate and reassemble.

6.1.3 Worn parts.

6.1.3.1 Dismantle. Visually inspect for significant


wear. Actuator replacement may be required.

6.1.4 Defective valve.

6.1.4.1 Consult the valve manufacturer's


documentation.

6.2.1 Incorrectly set stops


(valve and /or actuator).

6.2.1.1 Check the position of the travel stops and


readjust as necessary.

6.2.2 Hardened grease.

6.2.2.1 Dismantle, remove any hard grease,


re-lubricate and reassemble.

6.2.3 Debris left in the cylinder or


housing during maintenance.

6.2.3.1 Disassemble cylinder assembly to remove


debris. Reassemble cylinder assemble as
necessary.

6.2.4 Defective valve.

6.2.4.1 Consult the valve manufacturer's


documentation.

6.3.1 Inadequate supply pressure.

6.3.1.1 Ensure supply pressure is above the minimum


operating pressure of the actuator and that
output torque produced at supply pressure
exceeds valve torque demand.

6.3.2 Incorrect speed control settings.

6.3.2.1 Adjust speed controls to increase flow.

6.3.3 Exhaust port blocked.

6.3.3.1 Remove and clean the exhaust port


silencers and replace.

6.3.4 Pipe work blocked, crushed


or leaking.

6.3.4.1 Examine the pipe work for blockages,


crushed pipe or leakage. Clear or replace
as necessary.

6.3.5 Defective controls.

6.3.5.1 Examine the controls, refurbish or renew


as necessary. Refer to component
manufacturer's documentation.

6.3.6 Defective piston seal.

6.3.6.1 Dismantle the cylinder assembly, remove


the defective piston seal. Fit new seal and
reassemble.

6.3.7 Defective rod seal.

6.3.7.1 Dismantle the cylinder assembly, remove


the defective rod seal. Fit new seal and
reassemble.

6.3.8 High valve torque or valve seized.

6.3.8.1 Consult the valve manufacturers


documentation.

6.2 Short stroke

6.3 Apparent lack of power

Page 8 of 12

Publication F130E
Date of issue 04/08

DRAWING / PARTS LIST

GP RANGE
INSTALLATION AND MAINTENANCE

48
49

46

44

47

45

42
43

2
41

18

19

51

50

22
20

26

13

39
23

30
36

31
21

24
25

33
32

34
26

40
35

28

CENTRE BODY ASSEMBLY


ITEM

DESCRIPTION

MATERIAL

17

QTY

Centre body

Carbon Steel or Ductile Iron

Guide Bar

Alloy Steel - Chrome Plated

Safety Valve

Brass/Stainless Steel

Guide Block

Carbon Steel

Yoke

Carbon Steel or Ductile Iron

Guide Block Shaft Bushing Steel/Bronze/PTFE

O-ring

NBR

Upper Bushing

Bronze

Lower Bushing

Bronze

10

Sliding Block

Bronze

11

Bar Pin

Alloy Steel

12

Retaining Ring

Spring Steel

13

Flange Retaining Bolt

Carbon Steel

14

Cover Gasket

Vaporflex/SA

15

Cover

Carbon Steel

16

Cover Mounting Bolt

Carbon Steel

17

Flange Gasket

Vaporflex/SA

ITEM

DESCRIPTION

MATERIAL

18

Head Flange

19

16

14

51

4
7

15

27

38
29
Centre body cross-section

10
7

13

37

12
11

17

53

55

52

54

57
56
Typical fabricated carbon steel centre body and yoke illustrated.
Some models have a cast, ductile iron centre body and yoke.

PNEUMATIC CYLINDER ASSEMBLY

SPRING CARTRIDGE ASSEMBLY


DESCRIPTION

MATERIAL

41

Head Flange

Carbon Steel

42

Driving Flange

Carbon Steel

Carbon Steel - Chrome Plated

43

Connecting Rod

Carbon Steel - Chrome Plated

Bottom Flange

Carbon Steel

44

Bushing

Steel/Bronze/PTFE

22

Tie Rod

Alloy Steel

45

Spring Canister

Carbon Steel

23

Piston

Carbon Steel

46

Spring

Spring Steel

24

Sliding Ring

PTFE/Graphite

47

Stop Bolt

Carbon Steel

25

O-ring

NBR

48

Bottom Flange

Carbon Steel

26

O-ring

NBR

49

Protection Plug

Carbon Steel

27

Shaft Bushing

Steel/Bronze/PTFE

50

O-ring

NBR

28

Seal Washer

Carbon Steel/NBR

51

Shaft Bushing

Steel/Bronze/PTFE

29

Seal Washer

NBR/PTFE/Graphite

ITEM

DESCRIPTION

MATERIAL

52

Flange

Carbon Steel

53

Flange Nut

Carbon Steel

54

Seal Washer

Carbon Steel/NBR

55

Stop Bolt

Alloy Steel

56

Stop Bolt Cap Nut

Carbon Steel

57

Stop Bolt Fixing Nut

Carbon Steel

QTY

ITEM

Carbon Steel

Cylinder Tube

Carbon Steel - Nickel Plated

20

Piston Rod

21

30

Shoulder Washer

Alloy Steel

31

Stop Bolt Fixing Nut

Carbon Steel

32

Stop Bolt

Alloy Steel

33

Stop Bolt Cap Nut

Carbon Steel

34

Tie Rod Nut

Carbon Steel

35

Piston Retaining Nut

Carbon Steel

36

O-ring

NBR

37

Seal Retaining Flange

Stainless Steel

38

Seal Retaining Flange Bolt Stainless Steel

39

Bushing

Carbon Steel

Quantity varies with size of the actuator.

40

O-ring

NBR

Included in centre body seal kit.

QTY

CLOSURE ASSEMBLY
QTY

Included in pneumatic cylinder seal kit.

Page 9 of 12

Publication F130E
Date of issue 04/08

APPENDIX A - Stop Bolt Adjustment

GP RANGE

INSTALLATION AND MAINTENANCE


1.0

Overview

1.3

All RFS G Range actuators (ie., GP, GH, GO and HPG) incorporate adjustable stops
to limit the degree of travel in both directions. Steps are outlined below for
adjustment of the three stop configurations: pneumatic/hydraulic cylinder, spring
cartridge and, jackscrew.

Note: The jackscrew is not designed


to function as a travel stop.
Stroking the actuator against
the jackscrew may damage it.

Actuators may be damaged by improper adjustment procedure. Strictly follow


the instructions as outlined below with particular attention to the warnings is
steps 1.1.3, 1.2.2, 1.3 and 1.3.3.
1.1

1.2

Pneumatic/Hydraulic
Cylinder (See figure 1)

Spring Canister
(See figure 2)

1.1.1 Remove stop bolt cover.

1.2.1 Remove the spring stop cap.

1.1.2 Loosen stop nut.

1.2.2 Depressurize the cylinder to


allow the spring to relax.
Failure to do so may result in
damage to the actuator!

1.1.3 Apply pressure to outboard


side of cylinder to remove load
from stop bolt. Failure to do so
may result in damage to the
actuator!

1.2.3 Adjust the spring stop in/out as


desired.

1.1.5 Remove pressure from cylinder


to verify stop position.

1.2.4 Pressurize to outboard side of


power cylinder sufficiently to
induce a complete stroke of
the actuator and then check
the stop position.

1.1.6 Repeat steps 1.1.3 - 1.1.5 as


necessary to achieve desired
degree of travel.

1.2.5 Repeat steps 1.2.2 - 1.2.4 as


necessary to achieve desired
degree of travel.

1.1.7 Once desired position is


achieved, tighten stop nut,
ensuring sealing washer is
properly centered on the shaft
and fitted in the machined
recess in the flange.

1.2.6 Once the desired position is


achieved, replace spring stop
cap.

1.1.4 Adjust stop bolt in/out as


desired.

1.1.8 Re-install stop cover, ensuring


sealing washer is properly
centered on the shaft and
fitted in the machined recess in
the stop cover.

SPRING STOP
SPRING STOP CAP

Jackscrew
(See figure 3)

1.3.1 Remove stop bolt cover.


1.3.2 Loosen stop nut.
1.3.3 Turn jackscrew fully in to
compress spring and remove
any load from the stop. Failure
to do so may result in damage
to the actuator!
On fail close actuators, this is
done by turning the
handwheel anti-clockwise.
On fail open actuators, this is
done by turning the
handwheel clockwise.
1.3.4 Adjust stop bolt in/out as
desired.
1.3.5 Back jackscrew out (opposite
direction of as determined in
1.3.3) until seated against stop
screw to verify stop position.
1.3.6 Repeat steps 1.3.3 - 1.3.5 as
necessary to achieve desired
degree of travel.
1.3.7 Once desired position is
achieved, tighten stop nut,
ensuring sealing washer is
properly centered on the shaft
and fitted in the machined
recess.
1.3.8 Re-install stop cover, ensuring
sealing washer is properly
centered on the shaft and
fitted in the machined recess in
the stop cover.

figure 2
STOP SCREW
SEALING WASHER
STOP SCREW

STOP NUT

SEALING WASHER

SEALING WASHER

STOP NUT

STOP BOLT COVER

SEALING WASHER
STOP BOLT COVER

figure 1
figure 3

Page 10 of 12

Publication F130E
Date of issue 04/08

APPENDIX B - MB1 Switch Adjustment

GP RANGE

INSTALLATION AND MAINTENANCE


1.0

MB1 Limit Switch Adjustment


The MB1 is a Rotork Fluid Systems designed and manufactured switch enclosure suitable for use in harsh and/or hazardous
environments. It is available with either dry contact or proximity type switches. Consult the applicable job specific wiring
diagram for termination details. Contact Rotork Fluid Systems switch options and certification details.

1.1

Setting Dry Contact Switches

1.2

Setting Proximity Type Contact Switches

1.1.1
1.1.2

Loosen the four screws (1) and remove the cover (2).
Setting the CLOSE limit switch.

1.2.1

Loosen the four screws (1) and remove the cover (2).

1.2.2

Setting the CLOSE limit switch.

1.1.2.1 Place the actuator/valve in the fully CLOSED position.


1.2.2.1 Place the actuator/valve in the fully CLOSED position.
1.1.2.2 Locate the proper switch cam.
1.2.2.2 Locate the proper switch cam.
1.1.2.3 Loosen the setscrew (5) and rotate the cam (4) until
the switch operates. Tighten the setscrew. The
switch is now set.
1.1.3

1.2.2.3 Loosen the setscrew (5) and rotate the cam (4) until
it is on the same axis as the switch and re-tighten the
setscrews.

Setting the OPEN limit switch.


1.2.2.4 Loosen the fixing nuts on the switch. Position the
switch the proper distance from the cam to activate
the switch. Re-tighten the fixing and lock nuts. The
switch is now set.

1.1.3.1 Place the actuator/valve in the fully OPEN position.


1.1.3.2 Locate the proper switch cam.
Loosen the setscrew (5) and rotate the cam (4) until
the switch operates. Tighten the setscrew. The
switch is now set.
1.1.4

1.2.3

Setting the OPEN limit switch.

1.2.3.1 Place the actuator/valve in the fully OPEN position.

Replace the cover (2) and tighten the four screws (1).

1.2.3.2 Locate the proper switch cam.


1.2.3.3 Loosen the setscrew (5) and rotate the cam (4) until
it is on the same axis as the switch and re-tighten the
setscrew.
1.2.3.4 Loosen fixing nuts on the switch. Position the switch
the proper distance from the cam to activate the
switch. Re-tighten the fixing and lock nuts.The
switch is now set.
1.2.4

ITEM
1

Replace the cover (2) and tighten the four screws (1).

DESCRIPTION
Screw

Cover

Microswitch

Cam

Dowel

Page 11 of 12

Publication F130E
Date of issue 04/08

Manufacturing Centres
Germany
Melle
Tel: +49 (0)5422 9414-0
Fax: +49 (0)5422 9414-10
sales@rfs-pci.de

Italy
Tassignano - Lucca
Tel: +39 0583 93061
Fax: +39 0583 934612
fluid@fluidsystem.com

Sweden
Falun
Tel: +46 (0)23-587 00
Fax: +46 (0)23-587 45
Email:
info@remotecontrol.se

United States
Rochester, New York
Tel: +1 585 247 2304
Fax: +1 585 247 2308
rfsinfo@rotork.com

Centres of Excellence
Australia
Bayswater, Victoria
Tel: +61 (0) 3 9729 8882
Fax: +61 (0) 3 9729 8884
sales@rfsaustralia.com

Canada
Calgary, Alberta
Tel: +1 403 569 9455
Fax: +1 403 569 9414
info@rotork.ca

Singapore
Tel: + 65 6457 1233
Fax: + 65 6457 6011
mail@rotork.com.sg

Spain
Bilbao
Tel: + 34 94 676 6011
Fax: + 34 94 676 6018
rotork@rotork.es

United Kingdom
Bramley, Leeds
Tel: +44 (0)113 236 3312
Fax: +44 (0)113 205 7266
sales@rotorkfluidsystem.co.uk

United States
Houston, Texas
Tel: +1 713 856 5640
Fax: +1 713 856 8127
rfsinfo@rotork.com

United States
Petaluma, California
Tel: +1 707 769 4880
Fax: +1 707 769 4888
rfsinfo@rotork.com

United States
North Kingstown, Rhode Island
Tel: +1 401 294 1400
Fax: +1 401 294 3388
Email: sales@remotecontrol.us

All Rotork Fluid Systems actuators


are manufactured under a third
party accredited ISO 9001:2000
quality assurance programme.
Published and produced by Rotork
Fluid Systems. Rotork recognises
all registered trademarks.
As we are continually developing our
products, their design is subject to
change without notice. RFSMH0408

Latest information is available on

www.rotork.com

Established Leaders in Valve Actuation

CP RANGE
COMPACT PNEUMATIC ACTUATORS

INSTALLATION
AND
MAINTENANCE
MANUAL

Publication F230E
Date of issue 03/08

TABLE OF CONTENTS

CP RANGE
INSTALLATION AND MAINTENANCE

SECTION

CONTENT

PAGE

Introduction

Installation

Maintenance

Grease Specification

Cylinder Seal Replacement

Fault Detection

Drawing / Parts List

Contact Rotork Fluid Systems

10

Page 2 of 10

Publication F230E
Date of issue 03/08

INTRODUCTION

CP RANGE
INSTALLATION AND MAINTENANCE

1.0

Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems CP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of CP Range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.

INSTALLATION
2.0

Installation

2.1

Electrical Considerations

2.1.1

Any electrical connections required are the responsibilty of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.

2.1.2

Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.

2.1.3

Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.

2.1.4

The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.

2.2

Motive Power Supply (pneumatic, hydraulic)

2.2.1

Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.

2.2.2

Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid Systems must be contacted to verify compatibility of any proposed changes to supply medium.

2.2.3

Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.

Page 3 of 10

Publication F230E
Date of issue 03/08

INSTALLATION

CP RANGE
INSTALLATION AND MAINTENANCE

2.3

Maximum Allowable Temperature

2.3.1

The maximum temperature allowable for standard build actuators is 100C (212F). Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.

2.3.2

Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.

2.4

Operating Environment

2.4.1

The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.

2.4.2

If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.

2.5

Mechanical Considerations

2.5.1

It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.

2.5.2

Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.

2.5.3

Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.

2.54

All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.

2.5.5

When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.

2.5.6

Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.

2.5.7

Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.

2.5.8

Once in position, the actuator should operate the valve with a smooth continuous action.If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
Page 4 of 10

Publication F230E
Date of issue 03/08

MAINTENANCE

CP RANGE
INSTALLATION AND MAINTENANCE

3.0

Maintenance

3.1

Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customers individual requirements.

3.2

Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.

3.3

No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.

3.4

Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.

3.5

Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.

3.6

After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.

3.7

Periodic Inspection

3.7.1

Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.

3.6.2

Verify that the power gas supply pressure value is within the required range.

3.7.3

Visually inspect external components of the actuator for physical damage.

3.7.4

Check pneumatic/hydraulic connections for leakage. Tighten pipe fittings as required.

3.7.5

Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.

3.7.6

Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.

Page 5 of 10

Publication F230E
Date of issue 03/08

GREASE AND HYDRAULIC OIL

CP RANGE

INSTALLATION AND MAINTENANCE


4.0

Grease and Hydraulic Oil Specifications

4.1

Grease Specification
Manufacturer:

Mobil

Trade name:

Mobiltemp 78

Colour:

Gray/black

Soap type:

Inorganic

Oil type:

Mineral

Consistency (NLGI GRADE)-ASTM D217:

Worked penetration at 25C-ASTM D217:

295/325 dmm

Dropping point - ASTM D2265

260C

Viscosity of base oil at 40C-ASTM D445:

485 cSt

Viscosity of base oil at 100C-ASTM D445:

32 cSt

Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.

4.2

Hydraulic Oil Specification


Manufacturer:

Mobil

Trade name:

DTE 11

Viscosity at 40C:

16.5 cSt

Viscosity at 100C:

4.2 cSt

Viscosity index ASTM:

168

ISO Grade:

16

Pour point:

-42C

Specific weight at 15C:

0.85 kg/dm3

Equivalent to:

Statoil - Hydraway HVX-A15

Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.

Page 6 of 10

Publication F230E
Date of issue 03/08

CYLINDER SEAL REPLACEMENT

CP RANGE

INSTALLATION AND MAINTENANCE


5.0

Cylinder Seal Replacement


When the cylinder seals must be replaced, either due to a leak or as part of a preventative maintenance programme,
follow the procedure outlined below (reference drawing on page 9).

5.1

Disassembly

5.1.1

Ensure that the power gas supply to the actuator is shut off. For spring-return actuators, the actuator must be positioned
so that the spring is fully extended.

5.1.2

Disconnect power gas supply line from the end flange (item 4).

5.1.3

Unscrew the tie rods (item 24).

5.1.4

Remove the end flange (item 4) and the o-ring (item 14*) from the end flange.

5.1.5

Remove the cylinder tube (item 7) and o-ring (item 14*) that is between the cylinder tube and spring container (item 30)
on spring-return actuators or, on double-acting actuators is between the cylinder tube and housing (item 21).

5.1.6

For spring-return actuators, verify that the actuator is positioned so that the spring is fully extended as instructed in
step 5.1.1.
Note: When the spring is fully extended some spring force remains against the piston.

5.1.7A Double-acting actuators only: Unscrew the piston fixing bolt (item 10) and remove it and washer (item 8).
5.1.7B

Spring-return actuators only: Begin to unscrew the piston fixing bolt (item 10). Ensure that the piston is free and sliding
on the shaft as the fixing bolt is unscrewed so that all spring force is released before the fixing bolt is disengaged. Also
ensure that threaded bushing (item 18C) remains fixed inside the axial bar (item 18B). Remove piston fixing bolt (item 10)
and washer (item 8).

5.1.8

Remove the piston (item 5).

5.1.9

Remove the o-rings outside (item 6) and inside (item 9) the piston.

5.2

Reassembly

5.2.1
5.2.2

RECOMMENDED TIGHTENING TORQUE

Carefully clean the o-ring grooves and all sealing surfaces.


Lubricate all the new o-rings with clean grease and place them in the
proper locations.

5.2.3

The assembly procedure is the direct reverse of the disassembly procedure.

5.2.4

Reconnect power gas supply lines to the actuator.

BOLT SIZE

NM

M8

20

FT. LBS
15

M10

40

30

M12

55

40

M14

110

81

M16

220

162

M20

430

317

RECOMMENDED TIGHTENING TORQUE EXCEPTIONS


ACTUATOR TIE RODS (AND CYL FLG TO HOUSING CP065 ONLY)

5.2.5

Cycle the actuator several times. Its movement should be smooth and
continuous. If not, refer to Section 6, Fault Detection.
* On double-acting actuators item 14 is used in two locations: on both end
of the cylinder tube sealing against the end flange and the housing. On
spring-return actuators item 14 is used in three locations: between the end
flange and cylinder tube, between the cylinder tube and spring can, and
between the spring can and the housing.

Page 7 of 10

M16 (CP055)

130

96

M16 (CP065)

180

133

ACTUATOR HOUSING TO VALVE OR ADAPTER FLANGE


M10 (CP045)

45

M12 (CP055)

85

33
63

M20 (CP065)

300

221

Publication F230E
Date of issue 03/08

FAULT DETECTION

CP RANGE
INSTALLATION AND MAINTENANCE

6.0

Fault Detection
In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.

SYMPTOM

CAUSE

REMEDY

6.1 Erratic movement

6.1.1 Irregular supply of operating


medium.

6.1.1.1 Check operating medium for consistent


supply pressure and correct as necessary.

6.1.2 Inadequate lubrication.

6.1.2.1 Dismantle, re-lubricate and reassemble.

6.1.3 Worn parts.

6.1.3.1 Dismantle. Visually inspect for significant


wear. Actuator replacement may be required.

6.1.4 Defective valve.

6.1.4.1 Consult the valve manufacturer's


documentation.

6.2.1 Incorrectly set stops


(valve and /or actuator).

6.2.1.1 Check the position of the travel stops and


readjust as necessary.

6.2.2 Hardened grease.

6.2.2.1 Dismantle, remove any hard grease,


re-lubricate and reassemble.

6.2.3 Debris left in the cylinder or


housing during maintenance.

6.2.3.1 Disassemble cylinder assembly to remove


debris. Reassemble cylinder assemble as
necessary.

6.2.4 Defective valve.

6.2.4.1 Consult the valve manufacturer's


documentation.

6.3.1 Inadequate supply pressure.

6.3.1.1 Ensure supply pressure is above the minimum


operating pressure of the actuator and that
output torque produced at supply pressure
exceeds valve torque demand.

6.3.2 Incorrect speed control settings.

6.3.2.1 Adjust speed controls to increase flow.

6.3.3 Exhaust port blocked.

6.3.3.1 Remove and clean the exhaust port


silencers and replace.

6.3.4 Pipe work blocked, crushed


or leaking.

6.3.4.1 Examine the pipe work for blockages,


crushed pipe or leakage. Clear or replace
as necessary.

6.3.5 Defective controls.

6.3.5.1 Examine the controls, refurbish or renew


as necessary. Refer to component
manufacturer's documentation.

6.3.6 Defective piston seal.

6.3.6.1 Dismantle the cylinder assembly, remove


the defective piston seal. Fit new seal and
reassemble.

6.3.7 Defective rod seal.

6.3.7.1 Dismantle the cylinder assembly, remove


the defective rod seal. Fit new seal and
reassemble.

6.3.8 High valve torque or valve seized.

6.3.8.1 Consult the valve manufacturers


documentation.

6.2 Short stroke

6.3 Apparent lack of power

Page 8 of 10

Publication F230E
Date of issue 03/08

DRAWING / PARTS LIST

CP RANGE
INSTALLATION AND MAINTENANCE

15
11

DOUBLE-ACTING

29
13
12

21
1

25
14
SPRING-RETURN

7
19

14

26
27

16

23

22
3

17

18A

9
4

14

28
5

24
10

30

18B

18C
31

ITEM

DESCRIPTION

MATERIAL

QTY

ITEM

Stop Screw Housing

Carbon Steel

17

Stop Nut

Carbon Steel

O-ring

Buna-N

End Flange

PARTS FOR SPRING-RETURN ONLY

DESCRIPTION

MATERIAL

QTY

Spring Pin

Spring Steel

18A

Axial Bar Double-Acting

Alloy Steel (Nit-ox treated)

18B

Axial Bar Spring-Return

Alloy Steel (Nit-ox treated)

Ductile Iron

18C

Bushing threaded

Alloy Steel

Piston

Carbon Steel

19

Bushing

Steel/Bronze/Teflon

O-ring

Buna-N

20

Housing Plug (not shown)

Carbon Steel

Cylinder Tube

Carbon Steel (Nit-ox treated)

21

Housing

Carbon Steel

Washer

Carbon Steel

22

Stop Screw End Flange

Carbon Steel

O-ring

Buna-N

23

Yoke

Ductile Iron

10

Piston Retaining Bolt

Alloy Steel

24

Tie Rod

Alloy Steel

11

Retaining Ring

Spring Steel

25

Adapter Plate

Ductile Iron

12

Key

Carbon Steel

26

Washer

Carbon Steel

13

Spring

Spring Steel

27

Bushing

Steel/Bronze/Teflon

14

O-Ring

Buna-N

28

Yoke Pin

Alloy Steel (Nit-ox treated)

15

O-ring

Buna-N

29

Output Shaft

Alloy Steel (Nit-ox treated)

16

Bushing

Steel/Bronze/Teflon

30

Spring Container

Carbon Steel

31

Spring

Spring Steel

Quantity (2) for double-acting, (3) for spring-return.


Spring-return actuators only.

Page 9 of 10

Publication F230E
Date of issue 03/08

www.rotork.com
Fluid Power Actuators and Control Systems
Electric Actuators and Control Systems

Latest product information and a full listing of our worldwide


sales and service network is available on our website.
The name Rotork is a registered trademark. Rotork recognises all registered trademarks.

Gearboxes and Gear Operators

All Rotork Fluid Systems actuators are manufactured under a third-party accredited ISO 9001:2000 quality
assurance programme. As we are continually developing our products, their design is subject to change
without notice. Published data may be subject to change.

Projects, Services and Retrofit

Published and produced by Rotork Fluid Systems. RFSMH0908

DIESES MERKBLATT SOLLTE AN EINER SICHEREN STELLE AUFBEWAHRT WERDEN


THIS LEAFLET SHOULD BE KEPT IN A SAFE PLACE FOR REFERENCE

Betriebsanleitung fr Ventilmagnete Typ 46XX


Explosionsschutz
Die Ventilmagnete sind einsetzbar
- in gasexplosionsgefhrdeten Bereichen der Zonen 1
und 2. Sie entsprechen der Kategorie II2G und haben die
Zndschutzarten EEx md IIC T4/T5/T6 oder EEx me II
T4/T5/T6.
- in Bereichen mit brennbarem Staub der Zonen 21 und
22. Sie entsprechen der Kategorie II2D und haben die
Schutzart IP66. Maximale Oberflchentemperatur ist
T = 130 C.
Die elektrischen und thermischen Kenngren der einzelnen Varianten sind aus der Tabelle 2 zu entnehmen.
Der Explosionsschutz bezieht sich auf den Betrieb.

Elektrischer Anschluss
DC

1 Sicherung

Installation
Bei Installation, Wartung oder Reparatur sind unbedingt
die entsprechenden Ex-Vorschriften insbesondere EN
60079-14 und EN 50281-1-2 zu beachten.
Die elektrische Installation ist unter zustzlicher Beachtung einschlgiger nationaler Vorschriften (in Deutschland VDE 0100) von einer Elektrofachkraft bzw. unter
deren Aufsicht vorzunehmen.
Vor der Installation sind die Angaben der Gertekennzeichnung mit den vorgesehenen Betriebsbedingungen
zu vergleichen, um einen bestimmungsgemen Betrieb
sicherzustellen.

2 Varistor

3 Brckengleichrichter
4 Spule

AC / UC
1

Verwendung, Montage, Inbetriebnahme,


Instandhaltung
Ventilbettigungsmagnete sind elektrotechnische Komponenten. Sie sind ohne zugehriges Ventil nicht betriebsfhig.
Ventil-Magnet-Kombinationen werden in der Regel
komplett montiert und geprft geliefert. Beim Austausch/
Wechsel von Magneten ist darauf zu achten, dass die
Kombination mit einem Norgren-Herion-Ventil freigegeben
ist und der Magnet sachgerecht (z.B. zul. Anzugsdrehmoment) auf dem Ventil befestigt wird.
Die Magnete sind wartungsfrei. Wenn beim Betrieb
Strungen oder Ausflle mit unbekannter Ursache auftreten, sind die Magnete auszutauschen. Defekte Spulen
oder andere elektrische bzw. elektronische Bauteile knnen nicht repariert oder ersetzt werden.
Offensichtlich beschdigte Magnete drfen nicht eingebaut werden bzw. sind auszutauschen; dies gilt insbesondere fr beschdigte Oberflchen an den Stellen von
Gehusen und Deckeln, die die znddurchschlagsicheren
Spalte bilden.
Die Magnete drfen nicht als Hebelarm benutzt werden.
Werden die Magnete ueren Belastungen besonderer Art
ausgesetzt, sind erforderlichenfalls zustzliche Schutzmanahmen ntig.
Baujahr: die 2. Stelle des 5-stelligen Date-Codes entspricht der 4. Stelle des Baujahres (Zhlung ab Jahr 2000).
1

3
4

Der Magnet wird ber die Klemmen im Anschlussraum


mit der Spannungsversorgung verbunden.
Beim Anschluss braucht die Polaritt nicht beachtet zu
werden.
Die Anschlussklemmen sind fr Querschnitte bis 2,5
mm2 ausgelegt; die Klemme fr den Potentialausgleich
an der Auenseite des Gehuses erlaubt bis zu 4 mm2.
Der Schutzleiter ist immer anzuschlieen.
Anschlussklemmen
Bei den Klemmen handelt es sich um schraubenlose
Klemmen; die Klemmkraft wird allein durch ein Federelement aufgebracht. Zur Bettigung wird ein schmaler
Schraubendreher in eine der kleinen Schlitzffnungen
der Klemme eingeschoben (siehe Abb.). Damit ffnet
sich die Federklemme. Nach dem Einstecken der Kabellitze wird der Schraubendreher wieder herausgezogen
und der Anschluss ist hergestellt.

7503455.50.08.02

Kabel
Bei der Auswahl der Anschlussleitung sind sowohl die
erforderliche Kabelqualitt (EN 60079-14) als auch der
Durchmesserbereich der Kabelverschraubung zu beachten. Bei Verwendung einer Silikon- (bzw. silikonhaltigen)
Anschlussleitung bzw. einer nicht ritzbestndigen Leitung
ist diese gegen mechanische Beschdigung zu schtzen
(z.B. unterbrochenes Rohrsystem mit Kantenschutz).
Bei hheren Umgebungstemperaturen ist zu beachten:

Betrieb
100% ED sind auch bei den ungnstigsten zulssigen
Umgebungsbedingungen erlaubt.
Im Betrieb ist sicherzustellen, dass weder die max. zul.
Umgebungs- und Fluidtemperaturen noch die Grenzleistung (max. 10% berspannung) berschritten werden. Gegebenenfalls ist der Magnet gegen berlast zu
schtzen.
Alle Magnete sind mit einem Varistor beschaltet. Zur
Vermeidung von Abschaltspannungsspitzen, die in der
Anlage zu Schden fhren knnen, muss der Anwender
ggf. ber den eingebauten Varistor hinausgehende geeignete Schutzmanahmen vorsehen.
Die Oberflche des Magneten kann bei Dauerbetrieb sehr
hei werden. Achtung: Verletzungsgefahr beim Berhren!

Wenn bei

t amb
PN
Tabelle 1
0.7 W / 1 VA
>66 C
4 W / 5 VA
>58 C
8 W / 9 VA
>61 C
11 W / 13 VA
>44 C
dann muss das Kabel >95 C temperaturbestndig sein.
Werden die in Tabelle 1 genannten Umgebungstemperaturen nicht erreicht, ist die Verwendung normal temperaturbestndiger Kabel zulssig.
Kabelverschraubung
Die Magnete sind in der EEx md- und EEx me-Ausfhrung absolut baugleich. Die jeweilige Zndschutzart wird
also erst mit der verwendeten Kabelverschraubung festgelegt!
Es drfen ausschlielich EEx d IIC- bzw. EEx e II-Kabelverschraubungen mit entsprechender Baumusterprfbescheinigung verwendet werden. Mit einer EEx dVerschraubung entsteht so ein EEx md-Magnet und mit
einer EEx e-Verschraubung dementsprechend ein EEx
me-Magnet.
Reduzierungen, Erweiterungen und bergangsstcke
mssen ebenfalls entsprechend bescheinigt sein. Die
Kabelverschraubung muss sachgerecht montiert werden,
damit die Schutzart IP66 (EN 60529) gewhrleistet ist.
Sicherung
Die in der Typenbersicht aufgefhrten Magnete haben
eine eingebaute Sicherung, deren Ausschaltvermgen 35
A ist. Sollte der maximal anzunehmende Kurzschlussstrom am Einbauort grer als 35A sein, so ist ein Kurzschlussschutz mit folgenden Bedingungen vorzuschalten:
Sicherungsauslegung max. 3 x IB (nach IEC 60127-2-1)
bzw. ein Motorschutzschalter mit Kurzschluss- und thermischer Schnellauslsung (Einstellung auf Bemessungsstrom); Sicherungs-Bemessungsspannung gleich oder
grer als die angegebene Nennspannung des Magneten;
Ausschaltvermgen gleich oder grer als der maximal
anzunehmende Kurzschlussstrom am Einbauort (blicherweise 1500 A). Die Sicherung darf im zugehrigen
Versorgungsgert untergebracht sein oder muss separat
vorgeschaltet werden.
Deckelmontage
Nach dem Anschluss ist der Deckel wieder sorgfltig zu
montieren. Um mindestens die Schutzart IP66 zu
gewhrleisten, ist dazu (ebenso wie bei der Kabelverschraubung) die Originaldichtung zu verwenden.
Ausfhrungen, die ab Werk mit Anschlusskabel geliefert
werden, sind verwendungsfertig, d.h. der Anschlussraum
braucht nicht mehr geffnet zu werden.

CE-Kennzeichnung
Die CE-Kennzeichnung ist kein Qualittsmerkmal, sondern richtet sich an die zustndigen Behrden. Um speziell den freien Warenverkehr in der EU zu ermglichen,
hat der Europische Rat gemeinsame Richtlinien fr den
europischen Markt erlassen, die Mindestanforderungen
fr Sicherheit und Gesundheitsschutz vorgeben.
Mit der CE-Kennzeichnung wird besttigt, dass Produkte
den Richtlinien entsprechen, d.h. konform mit den einschlgigen, insbesondere harmonisierten Normen sind.
Hinweise zur Richtline 94/9/EG
(Explosionsschutzrichtlinie [ATEX 100a]):
Die Magnete entsprechen der in der EG-Baumusterprfbescheinigung PTB 02 ATEX 2085X beschriebenen
Bauart und erfllen die einschlgigen Anforderungen der
Richtlinie.
Hinweise zur Richtlinie 73/23/EWG
(Niederspannungsrichtlinie):
Die Magnete wurden unter Beachtung der Norm
Elektromagnetische Gerte DIN VDE 0580 entwickelt,
konstruiert und gefertigt. Damit werden auch die
Anforderungen der Niederspannungsrichtlinie, die fr
Nennspannungen von 50 bis 1000 V AC und von 75 bis
1500 V DC Gltigkeit hat, erfllt.
Hinweise zur Richtlinie 89/336/EWG (EMV-Richtlinie):
Die Magnete erfllen die Anforderungen der Fachgrundnormen fr Straussendung (EN 50081-1) und fr Strfestigkeit (EN 50082-2) sowohl im Industriebereich als
auch im Wohn-, Geschfts- und Gewerbebereich sowie
in Kleinbetrieben.
Elektromagnete als Antriebselement fr Ventile stellen im
Sinne der EMV-Richtlinie keine selbststndig betreibbaren Gerte dar und werden nur durch fachkundige Betriebe weiterverarbeitet bzw. in eine Maschine eingebaut.
Die Inbetriebnahme ist solange untersagt, bis festgestellt
wurde, dass die Gesamtmaschine bzw. Anlage den Bestimmungen der EMV-Richtlinie entspricht.
Jedem Magnet ist eingangsseitig ein Varisator vorgeschaltet.
Beim Einsatz von AC- und UC-Ausfhrungen wird dem
Anwender empfohlen, am Versorgungsnetzeingang ggf.
zustzlich einen geeigneten Netzfilter (z.B.: X-Kondensator 47 nF) vorzusehen, um die physikalisch bedingte
leitungsgebundene Abschaltstrung der Magnetspule zu
dmpfen.
2

7503455.50.08.02

Typenbersicht Magnete
Magnet
Bestell-Nr.
Magnetschlusshlsendurchmesser

Anschlussgewinde
fr Kabelverschraubung

13 mm 16 mm
4600
4650 1/2-14 NPT

4601

4651

1/2-14 NPT

4602

4652

M20 X 1,5

4603

4653

M20 X 1,5

4610

4660

1/2-14 NPT

4611

4661

1/2-14 NPT

4612

4662

M20 X 1,5

4613

4663

M20 X 1,5

4620

4670

1/2-14 NPT

4621

4671

1/2-14 NPT

4622

4672

M20 X 1,5

4623

4673

M20 X 1,5

4630

4680

1/2-14 NPT

4631

4681

1/2-14 NPT

4632

4682

M20 X 1,5

4633

4683

M20 X 1,5

Tabelle 2
Nennleistung
(Grenzleistung)

Spannung Nennstrom GerteLeistungs- Zndschutzart


sicherung aufnahme
Bemessungsstrom

0,7 W
bzw.
1,0 VA
(1,4W)

24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V DC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC

4W
bzw.
5 VA
(4,5 W)

8W
bzw.
9 VA
(8 W)

11 W
bzw.
13 VA
(13,1 W)

33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA

63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
3

0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 W
5,3 W
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 VA
5,3 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA

EEx md IIC T5/T6


bzw.
EEx me II T5/T6

Zulssige
Umgebungs- und
Fluidtemperatur fr
Temperaturklassen
sowie
Oberflchentemperatur
Kategorie II2G
(Gase)
bei T5:
-40 +80 C
bei T6:
-40 +70 C
Kategorie II2D
(Stube)
T 130 C

EEx md IIC T4/T6


bzw.
EEx me II T4/T6

Kategorie II2G
(Gase)
bei T4:
-40 +80 C
bei T6:
-40 +55 C
Kategorie II2D
(Stube)
T 130 C

EEx md IIC T4/T6


bzw.
EEx me II T4/T6

Kategorie II2G
(Gase)
bei T4:
-40 +70 C
bei T6:
-40 +40 C
Kategorie II2D
(Stube)
T 130 C

EEx md IIC T4/T5


bzw.
EEx me II T4/T5

Kategorie II2G
(Gase)
bei T4:
-40 +50 C
bei T5:
-40 +40 C
Kategorie II2D
(Stube)
T 130 C

7503455.50.08.02

Norgren GmbH, Werk Fellbach, D-70731 Fellbach


Stuttgarter Strae 120, D-70736 Fellbach
Tel.: +49 (0)7 11 / 52 09-0 Fax: +49 (0)7 11 / 52 09-614
www.norgren.de

EG - Konformittserklrung
nach Richtlinie 94/9/EG
____________________________________________________________________________
Hiermit erklren wir, dass die
Gerte:

Ventilbettigungsmagnete

Bestell-Nr.:

46xx

die Anforderungen der Richtlinie 94/9/EG zur bestimmungsgemen Verwendung in


explosionsgefhrdeten Bereichen erfllen.
Verwendete harmonisierte Normen:
EN 50 014:1997
EN 50 018:2000
EN 50 019:2000
EN 50 028:1987
EN 50 281-1-1:1998

Allgemeine Bestimmungen
Druckfeste Kapselung d
Erhhte Sicherheit e
Vergusskapselung m
Schutz durch Gehuse

Gertegruppe, Kategorien, Zndschutzarten:


II 2 G
bzw
II 2 D

EEx md IIC
EEx me II
IP 66

T4/T5/T6
T4/T5/T6
T 130 C

EG-Baumusterprfbescheinigung:
PTB 02 ATEX 2085 X
erstellt von der Physikalisch-Technischen Bundesanstalt,
D-38116 Braunschweig (Benannte Stelle Nr. 0102)
EG-Zertifikat fr das Qualittssicherungssystem :
EX3 03 07 11122 009
ausgestellt vom TV Product Service GmbH,
D-80339 Mnchen (Benannte Stelle Nr. 0123)

Fellbach, im November 2003

ppa.
(Theo Paulus)
Techn. Leiter Deutschland

i.V.
(Dieter Maisch)
Explosionsschutzbeauftragter

Ein Unternehmen der IMI- Gruppe

DIESES MERKBLATT SOLLTE AN EINER SICHEREN STELLE AUFBEWAHRT WERDEN


THIS LEAFLET SHOULD BE KEPT IN A SAFE PLACE FOR REFERENCE

Operating Instructions for Solenoids Type 46XX


Explosion Protection
Valve solenoids can be used
- in areas where gas-, vapour- and mist-air-mixtures are
present, i.e. in Zones 1 and 2. They correspond to Category II2G with protection class EEx md IIC T4/T5/T6 or
EEx me II T4/T5/T6.
- in areas with combustible dust in Zones 21 and 22.
They correspond to Category II2D with protection class
IP 66. Maximum surface temperature T = 130 C.
The electrical and thermal characteristics of the different
versions can be found in Table 2.
Explosions protection refers to the usage.

Electrical Connection
DC

Installation
It is essential that the appropriate explosion regulations
in particular, EN 60079-14 and EN 50281-1-2 are
observed during installation, maintenance and repair.
Electrical installation is also to be carried out by or under
the supervision of a skilled electrician taking into account
the relevant national regulations (in Germany, VDE 0100).
Before installation, the device identification information
must be compared with the planned operating conditions
to ensure compliant usage.

1 Fuse

2 Varistor

3 Bridge rectifier
4 Coil

AC / UC
1
2

3
4

The solenoid is connected to the voltage supply via the


terminal. When connecting the solenoid there is no need
to take notice of the polarity.
The terminals are suitable for cross sections up to 2,5
mm 2. The terminal for the potential compensate on the
outside of the housing allows up to 4 mm 2.
The protective conductor must always be connected.

Usage, Mounting, Implementing, Service


Valve actuating solenoids are electrical components.
They are not suitable for use without the associated
valve. Valve-solenoid combinations are usually supplied
fully assembled and tested. When replacing or changing
solenoids care should be taken to ensure that the combination is approved for a Norgren-Herion valve and that
the solenoid is properly fixed to the valve (e.g. permissible tightening torque).
The solenoids are maintenance-free. Should there be
some interruptions or failures with unknown origin the
solenoids have to be changed. Damaged coils or other
electric components can not be repaired or replaced.
Solenoids that appear to be damaged must not be fitted
or must be replaced.
This especially the case for damaged surfaces on housings
and covers which build the flameproof joint. Solenoids
must not be used as lever arms. Additional protective
measures are necessary if solenoids are exposed to certain kinds of external loading.
Year of manufacture: The second figure of the 5-digit
date code corresponds to the fourth figure of the year of
manufacture (from 2000 onwards).

Terminals
The terminals are made without screws. The attachment
is only secured by a spring. To make the attachment, a
small screw driver, is pushed into one of the small slots
(see at illustration).
This then opens the spring.
After putting in the cable flex pull out the screw driver
again and the connection is established.

7503455.50.08.02

Cable
When selecting the connection cable, both the required
cable quality (EN 60079-14) and the cable gland diameter range should be taken into account. Silicone connecting leads, silicone containing connecting leads or cables
which are not scratch resistant have to be protected
against mechanical deterioration (e.g. intermittent piping
system with edge protection). In addition, the following
is applicable for versions that are supplied exworks without connecting cables:

All solenoids are fitted with a varistor. To avoid switchoff voltage spikes, which could lead to damage in the
equipment, the user must provide suitable protection
over and above the integral varistor if necessary.
Solenoid surfaces can become very hot during continuous operating. Warning: Risk of injury when touching!
CE Marking
The CE mark is not sign of quality but is directed
towards the responsible authorities.
The Council has published common directives for the
European Market especially to enable the free transfer of
goods within the EU, which prescribe minimum requirements for safety and the protection of health.
The CE mark confirms that products comply with the
Directives, i.e. conform to the relevant and in particular,
to the harmonised standards.
Comments on Directive 94/9/EC (Equipment in Explosive
Atmospheres [ATEX 100a]):
The solenoids comply with the type of construction
described in the EC Type Examination Certificate PTB 02
ATEX 2085 X and the relevant requirements of the Directive.
Comments on Directive 73/23/EEC (Low Voltage Directive):
The solenoids have been developed, designed and manufactured taking into account the standard on
Electromechanical Devices DIN VDE 0580. The requirements of the Low Voltage Directive, which is applicable
to rated voltages from 50 to 1000 V AC and from 75 to
1500 V DC, are thereby fulfilled.
Comments on Directive 89/336/EEC (EMC Directive):
The solenoids meet the requirements of the generic standards for emissions (EN 50081-1) and for immunity (EN
50082-2) both in the industrial area and in the domestic,
commercial and trading areas as well as in small businesses.
Electromagnets as actuators for valves do not represent
independently operated devices in the sense of the EMC
Directive and are only applied or fitted to a machine by
specialist operatives. It is not permissible to put the
machine into operation until it has been established that
the entire machine or system accords with the requirements of the EMC Directive.
All solenoids are fitted with a varistor. When using AC
and UC versions, the user must provide a suitable mains
filter (e.g. X-capacitor 47 nF) on the mains supply input
to suppress the physically inherent switch-off interference from the solenoid coil associated with the cables.

If used by

PN
t amb
Table 1
0.7 W / 1 VA
>66 C
4 W / 5 VA
>58 C
8 W / 9 VA
>61 C
11 W / 13 VA
>44 C
then the cable must be able to withstand temperatures of
>95 C. If the ambient temperatures given in Table 1 are
not reached, the use of normally temperature resistant
cable is permissible.
Cable gland
The EEx md- and EEx me-versions of the solenoids are
built absolutely identically. Each type of protection will be
defined by the applied cable connectors.
Only EEx d IIC- or EEx de II-cable glands with test certificates are allowed to be used. With EEx d-connection is a
EEx md-solenoid and with a EEx e-connection is a EEx
me-solenoid.
Reductions, extentions and spare parts have to be certificated also. The cable connection has to be fitted suitably
for IP66 (EN 60529) is guaranteed.
Fuse
The solenoids of the chart are fitted with a fuse whose
breaking capacity is 35 A. Should the short circuit current at the place of fitting higher than 35A, a protection
will work and switch on a rated voltage that has at least
the nominal voltage.
Fuse assembly max. 3 x IB (according IEC 60127-2-1) or
motor protection switch with short circuit- and thermal
action (set to current rating); fuse voltage rating equal or
more than voltage rating of the solenoid; breaking capacity equal or more than max. possible fault current in the
place of installation (normally 1500 A). The fuse may be
located in power source or must be separately ballasted.
Mounting of cover
After connecting, the cover must be carefully refitted.
The original gasket must be used to guarantee a protection category of at least IP 66 (as with the cable gland).
Versions that are supplied ex-works with a connection
cable are ready for use, i.e. it is not necessary for the
terminal box to be re-opened.
Operation
100% ED is allowed even under the most unfavourable
permissible ambient conditions.
It must be ensured that neither the maximum permissible ambient and fluid temperatures nor the limiting
power (max. 10% overvoltage) are exceeded during
operation. The solenoid must be protected against overload if necessary.
2

7503455.50.08.02

Overview solenoid types


Solenoid
Type-No.
Core tube
diameter

Table 2

Connection
thread for
cable gland

Nominal
power
(max.
power)

Nominal
voltage

Nominal
current

Rated
Power
Protection class
current of consumpintegrated tion
fuse

Max. permissible
ambient and fluid
temperature for
temperature classes
and surface temperature

0,7 W
or
1,0 VA
(1,4W)

24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V DC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC
24 V DC
48 V DC
110 V DC
24 V UC
48 V AC
110 V AC
230 V AC

33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
33 mA
15 mA
12 mA
43 mA
17 mA
11 mA
6 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
162 mA
101 mA
41 mA
217 mA
107 mA
49 mA
23 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
369 mA
156 mA
69 mA
346 mA
210 mA
80 mA
43 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA
475 mA
240 mA
116 mA
557 mA
328 mA
133 mA
66 mA

63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
63 mA
40 mA
40 mA
80 mA
40 mA
40 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
400 mA
200 mA
80 mA
400 mA
250 mA
100 mA
40 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
800 mA
315 mA
160 mA
630 mA
400 mA
160 mA
80 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA
1000 mA
500 mA
250 mA
1000 mA
630 mA
250 mA
125 mA

Category II2G
(gases)
for T5:
-40 +80 C
for T6:
-40 +70 C

13 mm 16 mm
4600

4650

1/2-14 NPT

4601

4651

1/2-14 NPT

4602

4652

M20 X 1,5

4603

4653

M20 X 1,5

4610

4660

1/2-14 NPT

4611

4661

1/2-14 NPT

4612

4662

M20 X 1,5

4613

4663

M20 X 1,5

4620

4670

1/2-14 NPT

4621

4671

1/2-14 NPT

4622

4672

M20 X 1,5

4623

4673

M20 X 1,5

4630

4680

1/2-14 NPT

4631

4681

1/2-14 NPT

4632

4682

M20 X 1,5

4633

4683

M20 X 1,5

4W
or
5 VA
(4,5 W)

8W
or
9 VA
(8 W)

11 W
or
13 VA
(13,1 W)

0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
0,8 W
0,7 W
1,3 W
1,0 VA
0,8 VA
1,2 VA
1,3 VA
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 W
5,3 W
3,9 W
4,8 W
4,5 W
4,9 W
5,1 W
5,4 VA
5,3 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
8,9 W
7,5 W
7,6 W
7,7 VA
10,1 VA
8,8 VA
10,0 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA
11,4 W
11,5 W
12,8 W
14,3 VA
15,8 VA
14,6 VA
15,2 VA

EEx md IIC T5/T6


or
EEx me II T5/T6

Category II2D
(dusts)
T 130 C

EEx md IIC T4/T6


or
EEx me II T4/T6

Category II2G
(gases)
for T4:
-40 +80 C
for T6:
-40 +55 C
Category II2D
(dusts)
T 130 C

EEx md IIC T4/T6


or
EEx me II T4/T6

Category II2G
(gases)
for T4:
-40 +70 C
for T6:
-40 +40 C
Category II2D
(dusts)
T 130 C

EEx md IIC T4/T5


or
EEx me II T4/T5

Category II2G
(gases)
for T4:
-40 +50 C
for T5:
-40 +40 C
Category II2D
(dusts)
T 130 C

7503455.50.08.02

Norgren GmbH, Werk Fellbach, D-70731 Fellbach


Stuttgarter Strae 120, D-70736 Fellbach
Tel.: +49 (0)7 11 / 52 09-0 Fax: +49 (0)7 11 / 52 09-614
www.norgren.de

EC - Declaration of Conformity
In accordance with Directive 94/9/EC

____________________________________________________________________________
This is to declare that the
Equipment:

Valve Solenoids

Model Series:

46xx

is in conformity with the provisions of the Directive 94/9/EC for use in potentially explosive atmospheres.
Referenced normative documents:
EN 50 014:1997
EN 50 018:2000
EN 50 019:2000
EN 50 028:1987
EN 50281-1-1:1998

General requirements
Flameproof enclosures d
Increased safety e"
Encapsulation "m"
Protection by enclosure

Equipment group, Categories, Types of protection:


II 2 G
resp.
II 2 D

EEx md IIC
EEx me II
IP 66

T4/T5/T6
T4/T5/T6
T 130 C

EC-Type Examination Certificate:


PTB 02 ATEX 2085 X
issued by Physikalisch-Technischen Bundesanstalt,
D-38116 Braunschweig (Notified Body No. 0102)
EC Certificate for quality system:
EX3 03 07 11122 009
issued by TV Product Service GmbH,
D- 80339 Mnchen (Notified Body No. 0123)

Fellbach, November 2003

ppa.
(Theo Paulus)
Technical Director Germany

i.V.
(Dieter Maisch)
Authorized Representative

Ein Unternehmen der IMI- Gruppe

B73G
Installation & Maintenance
Instructions

Filter/Regulator
B73G - - -
Port
2 ....1/4"
3 ....3/8"
4 ....1/2"

Adjustment
Thread Form
K....Knob
A....PTF
B....ISO Rc taper T ....T-bar
G....ISO G parallel

Drain
Bowl
A....Automatic
D....Metal with liquid level indicator
Q....Manual, 1/4 turn P....Transparent with guard
T ....Transparent

Diaphragm
Element
1 ....5 m N....Non-relieving
2 ....25 m R....Relieving
3 ....40 m

Spring (Outlet Pressure Range) *


F ....0,3 to 4 bar (5 to 60 psig)
M...0,3 to 10 bar (5 to 150 psig)
S....0,7 to 17 bar (10 to 250 psig)

Gauge
G....With
N....Without

* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges.
TECHNICAL DATA
Fluid: Compressed air
Maximum pressure:
Transparent bowl: 10 bar (150 psig)
Metal bowl: 17 bar (250 psig)
Operating temperature*:
Transparent bowl: -20 to +50C (0 to +125F)
Metal bowl: -20 to +80C (0 to +175F)
* Air supply must be dry enough to avoid ice formation at
temperatures below +2C (+35F).
Particle removal: 5 m, 25 m, or 40 m filter element
Air quality: Within ISO 8573-1, Class 3 and Class 5
(particulates)
Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar
(90 psig) set pressure and 1 bar (15 psig) droop from
set: 50 dm3/s (106 scfm)
Nominal bowl size: 0,1 litre (3.5 fluid ounce)
Manual drain connection: 1/8"
Automatic drain connection: 1/8"
Automatic drain operating conditions (float operated):
Bowl pressure required to close drain: Greater than 0,3
bar (5 psig)
Bowl pressure required to open drain: Less than 0,2 bar
(3 psig)
Minimum air flow required to close drain: 0,1 dm3/s (0.2
scfm)
Manual operation: Depress pin inside drain outlet to
drain bowl
Gauge ports:
14 PTF with PTF main ports
Rc1/4 with ISO Rc main ports
Rc1/8 with ISO G main ports
Materials:
Body: Aluminum
Bonnet: Aluminum
Valve: Brass
Bowl:
Transparent: Polycarbonate
Transparent with guard: Polycarbonate, steel guard
Metal: Aluminum
Metal bowl liquid level indicator lens: Transparent nylon
Element: Sintered polypropylene
Elastomers: Neoprene and nitrile
REPLACEMENT ITEMS
Service Kit (includes items circled on exploded view):
Relieving.............................................................4383-600
Nonrelieving .......................................................4383-601
Liquid level lens kit (43, 45, 46, 47) ......................4380-020
Filter element, 5m (50) ..........................................4438-01
Filter element, 25m (50) ........................................4438-02
Filter element, 40m (50) ........................................4438-03
Manual drain (18, 19, 20) ..........................................619-50
Automatic drain (21, 22, 23) .................................4000-51R
Tamper resistant cover (knob adjustment only).......4455-51
PANEL MOUNTING DIMENSIONS
Panel mounting hole diameter: 48 mm (1.89")
Panel thickness: 2 to 6 mm (0.06" to 0.24")
INSTALLATION
1. Shut off air pressure. Install filter/regulator in air line vertically (bowl down),
with air flow in direction of arrow on body,
upstream of lubricators and cycling valves,
as close as possible to the device being serviced.
2. Connect piping to proper ports using pipe thread sealant
on male threads only. Do not allow sealant to enter
interior of unit.
3. Push bowl, or bowl with guard, into body and turn fully
clockwise before pressurizing.
4. Install a pressure gauge or plug the gauge ports. Gauge
ports can also be used as additional outlets for regulated air.

ADJUSTMENT
1. Before applying inlet pressure to filter/regulator, turn
adjustment (1 or 7) counterclockwise to remove all force
on regulating spring (12).
2. Apply inlet pressure, then turn adjustment (1 or 7)
clockwise to increase and counterclockwise to decrease
pressure setting.
3. Always approach the desired pressure from a lower
pressure. When reducing from a higher to a lower
setting, first reduce to some pressure less than that
desired, then bring up to the desired pressure.
NOTE
With non-relieving filter/regulators, make pressure
reductions with some air flow in the system. If
made under no flow (dead-end) conditions, the
filter/regulator will trap the over-pressure in the
downstream line.
4. KNOB ADJUSTMENT. Push knob down to lock pressure
setting. Pull knob up to release. Install tamper resistant
cover (see Replacement Items) to make setting tamper
resistant.
5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock
pressure setting.
SERVICING
1. Open manual drain to expel accumulated liquids. Keep
liquids below baffle (49).
2. Clean or replace filter element when dirty.
DISASSEMBLY
1. Filter/regulator can be disassembled without removal
from air line.
2. Shut off inlet pressure. Reduce pressure in inlet and
outlet lines to zero.
3. Turn adjustment (1 or 7) fully counterclockwise.
4. Remove bowl - push into body and turn
counterclockwise.
5. Disassemble in general accordance with the item
numbers on exploded view. Do not remove the drains
unless replacement is necessary. Remove and replace
drains only if they malfunction.
CLEANING
1. Clean plastic bowl (25, 35) with warm water only. Clean
other parts with warm water and soap.
2. Rinse and dry parts. Blow out internal passages in body
(16) with clean, dry compressed air. Blow air through
filter element (50) from inside to outside to remove
surface contaminants.
3. Inspect parts. Replace those found to be damaged.
Replace plastic bowl with a metal bowl if plastic bowl
shows signs of cracking or cloudiness.
ASSEMBLY
1. Lubricate the following items with o-ring grease.
4 (Thrust washer) - outer circumference and both sides.
5, 7 (Adjusting screw) - threads and tip.
18, 28, 37 (Manual drain body) - the portion of the
body that contacts the bowl, and the hole that
accommodates the stem of drain valve (19, 29, 38).
53 (Valve) - stem.
26, 34, 47, 54 (O-rings)
2. Assemble the unit as shown on the exploded view. Push
bowl, or bowl with guard, into body and turn fully
clockwise.
3. Torque Table
Item
Torque in Nm (Inch-Pounds)
2, 9 (Screw)
2,3 to 3,4 (20 to 30)
22, 32, 41 (Nut)
2,3 to 2,8 (20 to 25)
43 (Screw)
1,7 to 3,4 (15 to 30)
49 (Baffle), 51 (Louver)
1,1 to 2,2 (10 to 20)

12

13

2
16

15

5
14
53
54

52

7
8

51

10
9

50
11
49

26
18

21

23

17

25

24

20
19
22

34

28

31

27

35
33
30
29
32
47
37

40

48
46

36

45
43

42
39
38
41

44

Norgren 1998

IM-180.300.01 (4/98)
a subsidiary of IMI plc

Supersedes 12/97

B73G
Installation & Maintenance
Instructions
CAUTION
Water vapor will pass through these units and could
condense into liquid form downstream as air temperature
drops. Install an air dryer if water condensation could have
a detrimental effect on the application.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
Polycarbonate plastic bowls can be damaged and
possibly burst if exposed to such substances as certain
solvents, strong alkalies, compressor oils containing esterbased additives or synthetic oils. Fumes of these
substances in contact with the polycarbonate bowl,
externally or internally, can also result in damage. Clean
with warm water only.
Use metal bowl in applications where a plastic bowl
might be exposed to substances that are incompatible with
polycarbonate.
If outlet pressure in excess of the filter/regulator
pressure setting could cause downstream equipment to
rupture or malfunction, install a pressure relief device
downstream of the filter/regulator. The relief pressure and
flow capacity of the relief device must satisfy system
requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.

Norgren 1998

IM-180.300.02 (4/98)
a subsidiary of IMI plc

Supersedes 12/97