INSTALLATION, COMMISSIONING

AND
MAINTENANCE MANUAL

MM-018-1-E

DOUBLE ACTING

GAS OVER OIL ACTUATORS

GO SERIES

Rev. Description Pages Date Issued by Approved by

00 Issue 45 24.03.05 Cocliti Pisaroni
01 Section B - Par. 1 revised 45 20.07.05 Cocliti Pisaroni
02 Sections (B – E –F) revised 47 15.02.06 Cocliti Pisaroni

Rotork Fluid System S.r.l tel. (+39) 0583.93061

Via del Casalino, 6 fax (+39) 0583.934612
55012 Tassignano, Lucca - Italy http://www.Rotork .com
E-mail: fluid@fluidsystem.it

1
 INDEX
File GO_INDEX

• INTRODUCTION page 3

• SECTION (A) page 4

1. GO series actuator description page 5

• SECTION (B) page 6

1. Checks to be carried out upon delivery page 7
2. Storage page 8
3. Safety Considerations page 9
4. Instructions for assembling the actuator onto the valve page 10

• SECTION (C) page 11

1. Setting of angular stroke page 12 to 13

• SECTION (D) page 14

1. Setting of electric limit switches page 15 to 16

• SECTION (E) page 17

1. Arrangement for start-up and actuator/line connections page 18 to 20
2. Start-up page 21
3. Line break page 22 to 24

• SECTION (F) page 25

1. Maintenance and instructions for changing oil in the tanks page 26
2. Gas / oil tanks oil filling instructions and hydraulic circuit purge page 27

• SECTION (G) page 28

1. Replacement of cylinder seals page 29 to 31

• SECTION (H) page 32

1. Lubrication page 33
2. Hydraulic oil features page 34

• SECTION (I) page 35

1. Typical sectional drawings and parts-list page 36 to 41

• SECTION (L) page 42

1. Instructions for actuator lifting page 43

• SECTION (M) page 44

1. Operating instructions for electric control systems page 45 to 46
2. Features of the Rotork limit switch box type MB1 page 47

2
 INTRODUCTION
File GO_INTR.

This manual is produced to enable a competent user to install, operate, adjust, inspect, and
maintain Rotork Fluid System GO Range actuators. It is users responsibility to follow the
instructions in this manual as well as any additional documentation that has been supplied
regarding the actuator or the accessories supplied by Rotork Fluid System. Should further
information or guidance concerning to the safe use of GO Range actuators be required, it
will be provided up on request.
Users are also 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 related to health and safety in the
workplace.
It is extremely important that precautions be taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid System 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.

3
 S

T
Par. 1. – GO series actuator description

(A)

4
 GO SERIES ACTUATOR DESCRIPTION SECTION (A) - Par. 1
File GO_DESC

GENERAL DESCRIPTION

The GO series actuator is gas over oil double acting actuator, fed by pressurized gas.
After being filtered, gas flows into the tank through the control valves with respect to the operation (opening or
closing) to be performed.
Hydraulic oil contained in the tank is pressurized by gas and flows into the respective cylinder chamber, while
the oil contained in the other chamber flows into the second tank. The cylinder piston stroke triggers the
operation of the actuator.
The design characteristics are shown on the data plate attached to the actuator.
These actuators are fitted with a hydraulic emergency manual override and operated by means of two
hydraulic hand pumps.
There are two types of Rotork Fluid System actuators of GO series: the scotch yoke and the rack and pinion
series.
The main components of these units are the following:
GO scotch yoke series: GO rack and pinion series:
GO-65; GO-85: GO-100; GO-130; GO-160 GO-15; GO-30; GO-60; GO-120; GO-240
GO-161; GO-200; GO-201 GO-270; GO-271
A scotch-yoke mechanism (see table DSGA006) A rack and pinion mechanism (see table DSRA001)
which transforms the linear movement of the which transforms the linear movement of the
hydraulic cylinder into a rotary movement suitable hydraulic cylinders into a rotary movement suitable
to operate quarter turn valves such as ball valves, to operate quarter turn valves such as ball valves,
butterfly valves or plug valves. butterfly valves or plug valves.
The scotch-yoke mechanism is included into a The rack and pinion mechanism is made of alloy
perfectly sealed housing, made of welded carbon steel and is included into a perfectly sealed
steel, that protects it against corrosion and that housing, made of nodular cast iron, which protects
guarantees safety the personnel during the it against corrosion and guarantees safety to the
operations. It is also fitted with a guide bar personnel during the operations.
suitable for supporting the transverse forces, to Two opposed hydraulic cylinders (see table
ensure the proper alignment of the piston rod and DSRE004), made of nodular cast iron.
with bronze sliding blocks and yoke bushing The cylinder tube is nickel plated internally, in order
suitable for reducing the friction, to guarantee a to reduce roughness of the surface to a minimum
long working life. In particular, the guide bar is value and to provide highest protection against
chromium plated in order to guarantee its corrosion.
protection against corrosion. The relevant piston is made of carbon steel with
Hydraulic cylinder (see table DSGE119), made of dynamic seals realized in Buna-N and PTFE.
carbon steel.
The cylinder tube is nickel plated internally, in
order to reduce roughness of the surface to a
minimum value and to provide highest protection
against corrosion.
The piston is made of carbon steel with dynamic
seals realized in Buna-N and Teflon.
In both series, there are two mechanical stops to enable the adjustment of the valve angular stroke by
means of stop bolts. In case of a scotch yoke type, the stop bolt for the adjustment of the open position of
the valve is screwed into the center body closing flange, while the stop bolt for the adjustment of the closed
position of the valve is screwed into the bottom flange of the hydraulic cylinder. In case of a rack and pinion
type, the stop bolt for the adjustment of the open position of the valve is screwed into the cylinder used to
close the valve, while the stop bolt for the adjustment of the closed position of the valve is screwed into the
cylinder used to open the valve.
In both series, the mechanical visual indicator showing the valve position during the stroke of the actuator
is directly connected to the valve stem.
If required, the GO series actuators may also be supplied complete with accessories, such as signalling
limit switches, position transmitter etc.

5
 S

C
Par. 1. - Checks to be carried out upon delivery

T
Par. 2. - Storage

I
Par. 3. - Safety Considerations

O
Par. 4. - Instructions for assembling the actuator onto the valve

(B)

6
 CHECKS TO BE CARRIED OUT UPON
SECTION (B) - Par.1
File CHECK_04
DELIVERY

DAMAGE DURING TRANSPORT

Upon delivery, check if the actuator has been damaged during transport and, if necessary, repair the
possible damages to the paint-work.

DATA PLATE

The following information are contained on the actuator data plate:

- Serial number.
- Tag number.
- Model.
- Min/max operating pressure.
- Order number
- Month / year of manufacture.

CE MARK:
Where applicable, the following plates will be placed, in line with the directives:
ATEX 94/9/CE
PED 97/23/CE

Please make sure that information printed on the data plate are in conformity with those specified in
the order, in the test certificate and in the delivery note.

ACCESSORIES

When the supply includes accessories, please check if they are in conformity with those listed in the
order and in the shipping documents.

SETTING OF MECHANICAL STOPS AND LIMIT SWITCHES

In the event that the actuator has been delivered already assembled onto the valve, the mechanical
stops and electric limit switches (if foreseen) have already been set during assembling.
In the event that the actuator has been delivered separately from the valve, the setting of the
mechanical stops and electric limit switches (if foreseen), must be carried out after the assembling of
the actuator onto the valve according to the instructions stated herein under the applicable
paragraph of sections (C) and (D).

7
 STORAGE SECTION (B)-Par.2
File STORAGE _01

GENERAL INSTRUCTIONS

The actuators leave the Rotork Fluid System factory in excellent finishing and working conditions, as
guaranteed by the inspection certificate issued for each single actuator.

In order to keep the actuators in a good condition until they are assembled on the plant, we
recommend that the following measures be taken, during the period of storage:

Check if the plugs have been properly assembled on the fluid and electric connections, in
order to prevent dust/sand/water from entering during transport and storage.

Actuators awaiting to be assembled onto the valves, must be placed onto wooden pallets, so
as to prevent any damage on the valve coupling flange.

Protect the coupling parts (adapter and coupling joint, flange, etc.) with grease or protective
oil.

Keep the actuators in a dry place or provide protection against the direct effect of weather
agents.

LONG-TERM STORAGE

In case of storage for over 12 months, further operations must be carried out to maintain the
actuator in a good working condition, namely:
The actuator must be stroked on a 6-month basis, using filtered, dehydrated and lubricated
air in case of pneumatic actuators, or nominated hydraulic mineral oil with NAS 1638 class 6
as minimum cleanliness level in case of hydraulic actuators. Control panel functionality must
also be verified. Subsequently, all the threaded connections of the actuator and the control
panel are to be carefully closed.

While checking the functionality of the panel and the actuator, examine the electric
connections and terminals to make sure that they are clean and free from oxidation and
humidity. Also check the tightness of terminal screws.

The tightness and the functionality of the seals must be checked every 6 months.

All seals must be changed after 3 years of storage.

8
 SAFETY CONSIDERATIONS SECTION (E)-Par.3
File SAFETY_01

3.1 MAXIMUM ALLOWABLE TEMPERATURE

The maximum temperature allowable for standard build actuators is 100°C (212°F). 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.
Be aware that the temperature of the contents of the valve/pipeline as well as that of the power
supply fluid 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.

3.2 OPERATING ENVIRONMENT

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.
If the unit has a nameplate indicating that it is suitable for installation in a 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.

3.3 MECHANICAL CONSIDERATIONS

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.
Rotork actuators can be mounted on valves in almost any desired position. It is usual however
to align the centreline of the cylinder to the centreline 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 System if in
doubt.
Ensure all fasteners are adequately tightened to avoid loosening during the course of operation,
taking into account vibration induced by the dynamics of the pipeline.
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.
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 stop nuts 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 stop nuts.
Certain valves incorporate their own stops. In these cases it is recommended that the actuator
stop bolt positions coincide with the valve stop positions.
Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
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.

9
 INSTRUCTIONS FOR ASSEMBLING THE
SECTION (B) - Par.4
File GO_ASSY ACTUATOR ONTO THE VALVE

The assembling of the actuator onto the valve can be performed by:
- using the actuator housing flange with threaded holes.
- interposing an adapter and a coupling joint.
The assembly position of the actuator must be in accordance with plant requirements and with the
valve model.
In order to assemble the actuator onto the valve, proceed as follows:
Make sure that the coupling dimensions of the valve flange and stem meet the actuator coupling
dimensions.
Set the valve in the open or closed position, according to the actual position of the actuator.
Clean the coupling flange of the valve and remove anything that might prevent a perfect
adherence to the actuator flange. Make sure grease has been perfectly removed.
Lubricate the valve stem with oil or grease, to facilitate assembling.
Lift the actuator by connecting the sling to the support points of the actuator.
Make sure the sling is suitable for the weight of the actuator.
If possible, place the valve stem in a vertical position to facilitate assembling.
In this case the actuator must be lifted while the coupling flange is kept in the horizontal position.
Clean the coupling flange of the actuator and remove anything that might prevent a perfect
adherence to the valve flange. Make sure grease has been perfectly removed.
If the assembling is carried out by means of a spool piece together with a coupling joint,
assemble the latter onto the valve stem before proceeding with the assembling of the actuator.
Lower the actuator onto the valve so that the valve stem slips in the actuator yoke (or in the
actuator pinion, on rack and pinion models) or into the groove of the coupling joint, without
exercising any force and only with the weight of the actuator.
Fasten the actuator to the valve by tightening the nuts of the connecting stud bolts.

If possible, operate the actuator in order to check whether the valve is actuated smoothly.

10
 S

T
Par. 1. - Setting of angular stroke

(C)

11
 SETTING OF ANGULAR STROKE SECTION (C)-PAR.1
File GO_AST (Scotch yoke actuator series)

The angular stroke is set by adjusting the stop bolts which are screwed into the end flange of the
hydraulic cylinder and in the housing closing flange.

1 - SETTING OF THE ‘CLOSED VALVE’ POSITION

Adjust the stop bolt which is screwed into the end flange of the hydraulic cylinder as follows:
1.1 - Remove the cap nut (item 1).
1.2 - Loosen the lock nut (item 4).
1.3 - Pressurize the hydraulic cylinder (moving the valve towards the opening position) in order to
obtain the detachment of the piston (item 6) from the stop bolt (item 2).
Screw or unscrew the stop bolt (item 2) and verify, with one closing stroke, the newly obtained
angular position.
Repeat this operation until the desired angle is obtained.
During this operation there will be a small loss of oil through the thread of the stop bolt (item
2).
Note:
Attention must be paid so as to avoid direct contact between the stop bolt (item 2) and the piston
(item 6), as this may cause fluid pollution.
1.4 - Tighten the fixing nut (item 4).
1.5 - Reassemble the cap nut (item 1).

2 - SETTING OF THE ‘OPEN VALVE’ POSITION

Adjust the stop bolt which is screwed into the closing flange of the center body, as follows:
2.1 - Remove the cap nut (item 1).
2.2 - Loosen the lock nut (item 4).
2.3 - Pressurize the hydraulic cylinder (moving the valve towards closing position) in order to obtain
the detachment of the plug for the guide block (item 5) from the stop bolt (item 2).
Screw or unscrew the stop bolt (item 2) and verify, with one opening stroke the newly
obtained angular position.
Repeat this operation until the desired angle is obtained.
2.4 - Tighten the lock nut (item 4).
2.5 - Reassemble the cap nut (item 1).
Certain valves incorporate their own stops. For such valves it is recommended that the actuator stop
bolt positions coincide with the valve stop position.

12
 SETTING OF ANGULAR STROKE SECTION (C)-PAR.1
File GO_AST (Rack and pinion actuator series)

The angular stroke is set by adjusting the stop bolts which are screwed into the hydraulic cylinders.

1 - SETTING OF THE ‘CLOSED VALVE’ POSITION

Adjust the stop bolt which is screwed into hydraulic cylinder for open operation as follows:
1.1 - Remove the cap nut (item 1).
1.2 - Loosen the lock nut (item 4).
1.3 - Pressurize the hydraulic cylinder (moving the valve towards the opening position) in order to
obtain the detachment of the piston (item 5) from the stop bolt (item 2).
Screw or unscrew the stop bolt (item 2) and verify, with out one closing stroke, the newly
obtained angular position.
Repeat this operation until the desired angle is obtained.
During this operation there will be a small loss of oil through the thread of the stop bolt (item
2).
Note:
Attention must be paid so as to avoid direct contact between the stop bolt (item 2) and the piston
(item 5), as this may cause fluid pollution.
1.4 - Tighten the fixing nut (item 4).
1.5 - Reassemble the cap nut (item 1).

2 - SETTING OF THE ‘OPEN VALVE’ POSITION

Adjust the stop bolt which is screwed into the hydraulic cylinder for close operation, as follows:
2.1 - Remove the cap nut (item 1).
2.2 - Loosen the lock nut (item 4).
2.3 - Pressurize the hydraulic cylinder (moving the valve towards the closing position) in order to
obtain the detachment of the piston (item 5) from the stop bolt (item 2).
Screw or unscrew the stop bolt (item 2) and verify, with one opening stroke, the newly
obtained angular position.
Repeat this operation until the desired angle is obtained.
During this operation there will be a small loss of oil through the thread of the stop screw (item
2).
2.4 - Tighten the lock nut (item 4).
2.5 - Reassemble the cap nut (item 1).
Certain valves incorporate their own stops. For such valves it is recommended that the actuator stop
bolt positions coincide with the valve stop position.

13
 S

T
Par. 1. - Setting of electric limit switches

(D)

14
 SETTING OF ELECTRIC LIMIT SWITCHES SECTION (D) - Par. 1
File LSW_01

In case the actuator is provided with limit switches their setting should be performed by the user
during the actuator testing operations on the valve.

1 - SETTING OF MECHANICALLY OPERATED ELECTRIC LIMIT SWITCHES

ASSEMBLED INTO THE LIMIT SWITCHES BOX.
1.1 - SETTING OF THE CLOSING LIMIT SWITCH
Place the actuator in the fully closed position of the valve.
a.1 Unscrew the four screws (item 1).
a.2 Remove the cover (item 2).
a.3 Loosen the dowel (item 5) of the cam (item 4), which operates the closing limit switch.
a.4 Rotate the cam in order to operate the limit switch.
a.5 Tighten the dowel (item 5).

1.2 - SETTING OF THE OPENING LIMIT SWITCH

Place the actuator in the fully open position of the valve.
b.1 Loosen the dowel (item 5) of the cam (item 4) which operates the opening limit
switch.
b.2 Rotate the cam in order to operate the limit switch.
b.3 Tighten the dowel (item 5).
b.4 Reassemble the cover (item 2) and screw the four screws (item 1).

NOTE
Should the electric switches box be fitted with a single limit switch, arrange the actuator in the
required position of the valve (fully closed or fully open), remove the cover and proceed in line with
the above mentioned items a.3 up to a.5 (or b.1 up to b.4).
Should the electric switches box be fitted with more than 2 switches, repeat the above operations for
all the remaining limit switches.

15
 SETTING OF ELECTRIC LIMIT SWITCHES SECTION (D) - Par. 1
File LSW_01

2 - SETTING OF PROXIMITY LIMIT SWITCHES ASSEMBLED INTO THE LIMIT

SWITCHES BOX
2.1 - SETTING OF THE CLOSING LIMIT SWITCH
Place the actuator in the fully closed position of the valve.
a.1 Unscrew the four screws (item 1) and remove the cover (item 2).
a.2 Loosen the dowel (item 5) of the cam (item 4) which operates the closing electric limit
switch, rotate the cam by placing it on the same axis of the electric limit switch.
a.3 In order to adjust the switching point of the electric limit switch, loosen its fixing nuts.
Slide it axially and vary the positioning distance between the electric limit switch and
the operating cam.
Tighten the fixing nuts.

2.2 - SETTING OF THE OPENING LIMIT SWITCH

Place the actuator in the fully open valve position.
b.1 Proceed according to the above mentioned points a.1 and a.3 operating on the cam
and on the opening electric limit switch.
b.2 Reassemble the cover (item 2) and screw the four screws (item 1).

16
 S

E
Par. 1. - Arrangement for start-up

T
Par. 2. - Start-up

O
Par. 3. – Line break technical information

(E)

17
 ARRANGEMENT FOR START-UP SECTION (E)-Par.1
File ARRANGE_GO

1.1 MOTIVE POWER SUPPLY

Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as
indicated on the nameplate.
Verify that medium composition (e.g., filtration, hydration) corresponds to that for which the
actuator was manufactured. Rotork Fluid System must be contacted to verify compatibility of
any proposed changes to supply medium.
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 System if in doubt as to the
suitability of the equipment supplied for your application.

1.2 ACTUATOR / LINE CONNECTIONS

Before connecting the actuator to the gas supply line, make sure that pipes and fittings are
according to the applicable plant specifications, in order to guarantee the gas flow required for
the operation of the actuator and to avoid that supply pressure drops below the minimum
allowable value.
Take every precaution to remove any solid or liquid foreign matter from the pipe work into the
actuator, in order to avoid possible damages to the actuator itself or loss of performance.
Clean the inside of the pipes used for connection by washing them with suitable detergent and
by blowing air into them.
Fasten the piping properly, so as to prevent the loosening of threaded connections, in case the
system undergoes strong vibrations.
Once the gas connections have been completed, operate the actuator and check if it works
correctly.
Also make sure that its operating times are in accordance with those specified in the test
certificate and that there aren’t any leakages in the gas/hydraulic connections.

In accordance with the operating diagram, the gas line can be connected to the control panel in the
following two ways:

1 Directly to the shuttle valve (item 17).

17

X1 X2 17: Gas shuttle valve (supply)

X1-X2: 1/4 NPT (Female) Gas connections

18
 ARRANGEMENT FOR START-UP SECTION (E)-Par.1
File ARRANGE_GO

2 Indirectly to the shuttle valve (item17), via 2 isolation filters (items 19) and isolation valves (items16)

16 16

17

19 19

16: Isolation valve

17: Gas shuttle valve
19: Filter (supply)
X1-X2: 1/4 NPT (Female) Gas connections
X1 TO PANEL X2
The suggested tubing between actuator and main pipe (at user is care) is: O.D. 12 mm rigid tube 1mm
thickness, carbon steel/stainless steel, suitable for pressure as per applicable plant specification.

In case the control panel is provided with a low pressure sensor (item 23), follow the instructions below:
23

K: 1/2” NPT (Male) or 1/4" NPT (Female) - Pilot

connection

In case the control panel is provided with an adjustable pilot differential (item 27), follow the instructions below:

27

K1 K2 K1: 1/4" NPT (female) - Pilot gas connection - low

pressure - downstream
K2: 1/4" NPT (female) - Pilot gas connection - high
pressure - upstream

19
 ARRANGEMENT FOR START-UP SECTION (E)-Par.1
File ARRANGE_GO

1.3 ELECTRIC CONNECTIONS

The following instructions are applicable to actuators provided with electric accessories (such as
limit switches, solenoid valves, etc.).

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.
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. Make sure that the components used for electrical
connections (such as cable hose conduits, cable glands) are in accordance with the
requirements and codes applicable to the plant, with reference to mechanical and/or explosion-
proof protection.

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

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

Electric connections are to be made by using rigid conduits and trailing cables so as to prevent
anomalous mechanical stresses in the cable entries.

Remove the plugs from the cable entries.

Connect the electric feed, control and signal lines to the actuator, by linking them up with the
terminal blocks of electric components in accordance with the applicable wiring diagram.

On the unused entries of the pull box, replace the plastic plugs with the metal ones, in order to
guarantee perfect seal and to comply with explosion safety protection codes (where applicable).

Once connections have been completed, check if controls and signals work properly.

20
 START-UP SECTION (E) - Par.2
File STARTUP GO

During the start-up of the actuator, it is necessary to check if:

The oil level in the gas/oil tanks is in accordance with the instructions brought in the “section F”
paragraph 2.
Gas supply pressure, is as prescribed.

Feed voltage values of electric components (solenoid valves coils, limit switches, pressure
switches etc., if applicable) are as prescribed.
Actuator controls, such as remote control, local control, emergency control (if applicable), etc.
work properly.
The required remote signals (such as valve position, gas supply pressure, etc.) are correct.
The setting of the actuator control unit components is according to the requirements of the
plant.
Gas/hydraulic connections show any leakage. If necessary, tighten the nuts of the pipe fittings.
The painted parts have been damaged during transport, assembling or storage operations.
Having removed rust, repair the damaged parts following the painting specification.

In case the control panel is provided with a

local/remote selector valve (18) may be
positioned by means of manual levers located on
the poppet valves (4a and 4b) for LOCAL control
or by means of the solenoids (5a and 5b) for
REMOTE control.

21
 LINE-BREAK SECTION (E) - Par.3
File linebreak GO TECHNICAL INFORMATION

INTRODUCTIONS:
40
The Rotork Line-Break system detector (RLD) is
designed to close the valves automatically in case
pre-determined pressure drop rate is exceeded, in
order to prevent gas leakage due to pipeline
breaking.
Under normal working conditions, gas pressure
will be steady or it will slowly change due to many
factors (e.g. increase/decrease of gas users).
In case of pipeline break down, the variation of
pressure drop will depend on the absolute 35
pressure, the gas density, the dimensions and the 36
type of failure, the pipe line dimensions, the
location of the failure (upstream or downstream)
and the distance from the break (i.e. the greater
41
the distance the lower the speed).
Therefore, Line-break devices ought to be easily
regulated to meet different working conditions and
all the characteristics of the line. 32
A compromise must also be made in adjusting the 37
pressure drop speed setpoint.
In fact, it must be as low as possible to detect 10
remote failures, but not too close to the normal
variation of the pipeline pressure, as the line 34
would have to be closed.

FUNCTIONALITY DESCRIPTION:
Due to the fact that many Line-break detectors
(RLD) have been mounted as a protection on the
gasline , they are placed in countryside areas, far
away from stations and cities. They need to have
their own source of energy, directly from the line
pressure.
The RLD system (see the control schematic)
includes the followings components: reference
tank (33), adjustable differential pressure switch
(40), 3/2 pilot manual reset valve (41), check
valve (35), calibrated orifice (36), gauges (10)
filters (32-37) and stop valves (31-34).
The RLD has to be connected to the pipeline
downstream from the main valve so as to avoid
undesirable closing operations during the opening
of the valve because pressure drops quickly in the
upstream line during this operation.

22
 LINE-BREAK SECTION (E) - Par.3
File linebreak GO TECHNICAL INFORMATION

The connection coming from the gasline can be intercepted using a stop valve (34) and the gas is
filtered (37). When pipeline pressure rises, gas flows through the check valve (35) and orifice (36),
into the reference tank (33).
When pressure falls, it remains higher in the tank than in the line because the check valve closes
and the gas flows back into the pipeline through the orifice only. This orifice restrictor creates a
differential pressure (∆P) that acts upon the adj. pressure switch (40) if it exceeds the adjusted
value. The pressure switch acts upon the valve (Item 41) which permits the closing of the main
valve.
In order to open the main valve again, once normal conditions have been re-established, it is
necessary to reset the valve (41) with the relevant manual reset.
The faster the drop rate in the pipeline, the smaller the orifice, the bigger the volume of the rate tank
and the lower the absolute pressure the greater the differential pressure (∆P) across the diaphragm
valve.
When pressure starts to drop due to a pipeline break down, the ∆P takes time to reach its maximum
value.
The time elapsed depends on the diameter of the calibrated orifice, the absolute pressure in the line
and the pressure drop speed: the smaller the orifice, the lower the line pressure and the greater the
drop rate, the longer the time required to reach the maximum value of differential pressure.
The value of the ∆P for the operation of the adj. pressure switch valve can be adjusted within the
range from 0.2 up to 4 Barg by rotating the relevant pommel nut referring to the indicator scale.
As differential pressure needs to be limited within the selected range, it is necessary to use the 0.4
mm diameter calibrated orifice hole for the lower values of pressure drop speed at a high value of
working pressure, or the 0.8 mm diameter calibrate orifice hole, for the higher value of pressure drop
speed at low working pressure.

FIGURE 1 Curves related to maximum ∆P acting upon the pressure switch at differential initial
pressure and at differential pressure drop rate, with the 0.4mm orifice.

ORIFICE 0.4 mm (Time from 2 up to 8 minutes)

4,25
Pres. 25 Bar
4
3,75
∆P ( Bar ) for NATURAL GAS at 20 °C

3,5
Pres. 35 Bar
3,25
3
2,75
Pres. 45 Bar
2,5
2,25
2
Pres. 55 Bar
1,75
1,5
1,25
Pres. 65 Bar
1
0,75
0,5
Pres. 75 Bar
0,25
0
Pres. 85 Bar
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9
Pressure Drop Speed ( Bar / min )

FIGURE 1
The ∆P is obtained within the maximum time of 480 seconds for Natural Gas at 20 °C.

23
 LINE-BREAK SECTION (E) - Par.3
File linebreak GO TECHNICAL INFORMATION

FIGURE 2 Curves related to maximum ∆P acting upon the diaphragm valve at differential initial
pressure and at differential pressure drop rate, with the 0.8mm orifice.

ORIFICE 0.8 mm (Time from 1 up to 4 minutes )

4,25 Pres. 25 Bar

4
3,75
∆P ( Bar ) for NATURAL GAS at 20 °C

3,5 Pres. 35 Bar

3,25
3
2,75 Pres. 45 Bar
2,5
2,25
2
Pres. 55 Bar
1,75
1,5
1,25
Pres. 65 Bar
1
0,75
Pres. 75 Bar
0,5
0,25
0
0 0,25 0,5 0,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5 3,75 4 4,25
Pres. 85 Bar
Pressure Drop Speed ( Bar / min )
FIGURE 2
The ∆P is obtained within the maximum time of 240 seconds for Natural Gas at 20 °C.

CALIBRATION AND SETTING OF LINE-BREAK DEVICE:

To carry out the setting and calibration of the Line-break device, it necessary to know:
- the variation range of working pressure.
- the pressure drop speed at minimum working pressure. The minimum working pressure has been
chosen to prevent undesired line break interventions (in fact at this time the ∆P is higher than at
maximum working pressure).
Use of Calibration charts (Figures 1 & 2) to find the correct orifice and the ∆P: find the specified
drop rate along the horizontal axis and trace a line upward to where it intersects the specified
minimum working pressure. From this intersection trace a horizontal line to the vertical axis and
read the ∆P value.
To carry out the setting on the diaphragm valve, remove the cover, unscrew the “5.5 mm”
hexagonal screw and rotate the pommel nut on the top, referring to the graded scale indicator. up
to the desirable value,
To change the calibrated orifice (36), first make sure that the system is depressurised. Then
remove the cap by means of “17 mm” Allen key and then the second screw inside the block by
means of a “8 mm” Allen key. Now, screw the replacing orifice tightly by means of a “8 mm” Allen
key and screw back the cap screw tightly using the “17 mm” Allen key. Ensure that all connections
are leak tight and check with soapy water when the system is pressurized

24
 S

T
Par. 1. - Maintenance

(F)

25
 MAINTENANCE SECTION (F) - Par.1
File MAINT_GO

Rotork actuators are designed to work for long periods of time under severe conditions. However, a
preventive approach to maintenance helps prevent costly down time and can actually reduce the
cost of ownership.
Rotork can provide actuator maintenance contracts tailored to meet each individual customer’s
requirements.
Any personnel working with or on the equipment must be properly trained for the work they are
performing and aware of their responsibilities relating to health and safety in the workplace.
No inspection or repair should be undertaken unless it conforms with 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.
Before performing maintenance, the actuator should be isolated from remote control signals and
pneumatic/hydraulic power supply. The system should then be relieved of any internal pressure prior
to disassembly.
Improper operation, adjustment or maintenance of the actuator and controls may, depending on the
application, release potentially explosive gases and / or dangerous liquids.
After maintenance has been performed and re-assembly completed, follow the inspection guidelines
as outlined below:

PERIODIC INSPECTION
Ensure that the actuator operates the valve correctly 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 operated frequently enough.
Verify that the power fluid supply pressure value is within the required range.
Visually inspect the external components of the actuator for physical damage.
Check pneumatic/hydraulic connections for leaks. Tighten pipe fittings as required.
Remove build-up dust and dirt from all actuator surfaces. They can inhibit cooling and thus raise the
temperature above the maximum allowable limit.
Inspect actuator paint work for damages to ensure continued corrosion protection. Touch-up
as required in accordance to applicable paint specification

INSTRUCTIONS FOR CHANGING OIL IN THE TANKS AND IN THE HYDRAULIC

CIRCUIT.

Rotork Fluid System recommends to change

hydraulic oil at 6-year or 20000-operations
intervals.
Proceed as follows:
Place the actuator in the close position.
Close the isolation valves (16).
Operate with the valves (4A and 4B) so as to
drain the gas from the circuit.
P7 If there is a storage tank in the circuit, use the
drain valve to drain the gas.
Unscrew the plugs (P7 & P8) and discharge the
oil from the tanks.
P8 Unscrew the plugs (P5 & P6) and discharge the
oil from the cylinder.
Reassemble the plugs and fill the tanks in
accordance with the instructions brought in this
section, paragraph 2.
P6 P5
4B
4A 16

26
 GAS / OIL TANKS OIL FILLING INSTRUCTIONS SECTION (F) - Par.2
File FILL_GO AND HYDRAULIC CIRCUIT PURGE

The following instructions prescribe the procedure for filling the gas/oil tanks of the GO series
actuator.

P4 P3 This operation should precede the assembling of

the actuator on to the valve and the connecting of
the gas supply line, as described below:
Actuators have been sent by Rotork Fluid
System set in the close position; this setting
26.1 can be checked through the position indicator
displayed on the carter cover or on the
26.2 microswitches box, (if applicable).
Unscrew and remove the plug (P3), with the
respective dipstick.
Fill the tank (26.1) with oil to the max level of
the dipstick.
Place the 3-way hand operated valve (28A1) in
28B2 28B1 the “manual” position.
Unscrew the drain plug (P1).
Start pumping (28B1) until oil spills out from the
P2 P1 hole of the drain plug (P1); close the drain plug.
Always acting with the pump (28B1), take the
actuator in the completely open position.
Place the 3-way hand operated valve (28A1) in
the “remote” position.
Unscrew and remove the plug (P4), with the
respective dipstick.
28A1 Fill the tank (26.2) with oil to the max level of
28A2 the dipstick.
Place the 3-way hand operated valve (28A2) in
the “manual” position.
Unscrew the drain plug (P2).
Start pumping (28B2) until oil spills out from the
hole of the drain plug (P2); close the drain plug.
Always acting with the pump (28B2) take the
actuator in the complete close position.
Check the oil level in the tank (26.1) using a
dipstick, if necessary refill to max level.
Screw the plugs (P3).
Place the 3-way hand-operated valve (28A2) in
the “remote” position and the valve (28A1) in
the “manual” position.
Using the pump (28B1) set the actuator in the
completely open position.
Check the oil level in the tank (26.2) using
dipstick, if necessary refill to max level.
Screw the plugs (item P4).
Place the 3-way hand operated valves (28A1)
in the “remote” position.
The actuator is now ready to be assembled to the
valve and connected to the gas supply line.

27
 S

C
Par. 1. - Replacement of cylinder seals

(G)

28
 REPLACEMENT OF CYLINDER SEALS SECTION (G) - Par.1
File GO_SEAL (scotch yoke series)

When cylinder seals need to be replaced, due to a leakage or for scheduled preventive
maintenance, proceed as described here below (See tables DSGA006 and DSGE119):

This procedure is applicable after making sure that pneumatic/hydraulic pressure and
electrical power have been removed from the actuator.

- Disconnect the hydraulic supply tubes from

the cylinder head and bottom flanges.
HYDRAULIC CYLINDER (Table DSGE119)
PHASE 1-DISASSEMBLY
1.1 - CENTER BODY (See table DSGA006)
- Unscrew the bolts (17).
- Remove the cover (22), screwing 2 screws
in the appropriate thread holes on the
cover to facilitate the removing operation.
- Loosen the dowel (item 4).

1.2 - HYDRAULIC CYLINDER (See table

DSGE119)
- Unscrew the nuts (17).
- Remove the end flange (13).
- Remove the cylinder tube (7).
- Unscrew the piston rod (6) from the guide CENTER BODY (Table DSGA006)
block (table A item 7) and slide it off.
- Unscrew the screws (2).
- Remove the head flange (4).

PHASE 2-SEALS REPLACEMNT

- Remove the o-rings (12 ; 21) the back-up
rings (23 ;24), the piston gasket (10), the
sliding rings (9) and the gaskets (1 & 5).
Carefully clean the respective grooves.
Make sure that the cylinder components
are in a good condition and clean.
Replace all the above mentioned seals
and lubricate them with a grease film.

29
 REPLACEMENT OF CYLINDER SEALS SECTION (G) - Par.1
File GO_SEAL (scotch yoke series)

PHASE 3 REASSEMBLY HYDRAULIC CYLINDER (Table DSGE119)

3.1 - HYDRAULIC CYLINDER (See table
DSGE119)
Taking care not to damage the seals
proceed with the reassembling as follows:
- Reassemble the head flange (4) and
screw the bolts (2) to the recommended
torque (see table), alternating between
opposite corners.
- Reassemble the piston rod (6) by screwing
it in onto the guide block (See table A item
7).
- Tighten the dowel (table A item 4).
- Reassemble the cylinder tube (7). CENTER BODY (Table DSGA006)
- Reassemble the end flange (13).
- Tighten the nuts (17) to the recommended
torque (see table), alternating between
opposite corners.

3.2 - CENTER BODY (See table A)

- Check if the cover gasket (13) is in a good
condition, otherwise replace it.
- Reassemble the cover (22) using the
parallel pin reference.
- Screw the bolts ( 17) to the recommended
torque (see table), alternating between
opposite corners.

- Connect the oil supply tubes to the cylinder RECOMMENDED

end and head flanges. TIGHTENING TORQUE
- Carry out a few operations with the actuator in Bolt size NM FT. LBS
order to check if the movement is regular and M6 8.5 6
if there are leakages through the seals. M8 20 15
- If necessary, reset the angular stroke in M10 40 30
accordance with the instructions in section “C”. M12 55 40
Check if the painted parts have been damaged M14 110 81
during the disassembly and reassembly. If M16 220 162
necessary repaint them in accordance with the M20 430 317
applicable painting specifications. M22 425 313
M24 585 431
M27 785 579
M30 1250 921
M33 1400 1030
M36 1750 1290

30
 REPLACEMENT OF CYLINDER SEALS SECTION (G) - Par.2
File GO_SEAL (rack and pinion series)

PHASE 1-DISASSEMBLY HYDRAULIC CYLINDER (Table DSRE004)

- Disconnect the hydraulic supply tube from the
cylinder.
- Unscrew the screw (2).
- Remove the cylinder (10).

PHASE 2-SEALS REPLACEMENT

- Remove the piston gasket (8),
the sliding rings (9) and the o-ring (11).
- Carefully clean the relative grooves.
- Make sure that the cylinder components are in
a good condition and clean.
Replace all the above mentioned seals and
lubricate them with a grease film.

PHASE 3-REASSEMBLY
Taking care not to damage the seals, proceed
with the reassembling in the following way.
- Reassemble the cylinder tube (10).
- Tighten the screw (2) to the recommended
torque (see table) alternating between opposite
corners.
- Connect the hydraulic supply tube to the
cylinder.
- Carry out a few operations with the actuator in
order to check if the movement is regular and if RECOMMENDED
there are any leakages through the seals. TIGHTENING TORQUE
Check if the painted parts have been damaged
during disassembly and/or reassembly. Bolt size NM FT. LBS
If necessary repaint them in accordance with M6 8.5 6
the applicable painting specifications. 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 1250 921
M33 1400 1030
M36 1750 1290

31
 S

C
Par. 1 - Lubrication

T
Par. 2 - Hydraulic oil features

(H)

32
 LUBRICATION SECTION (H) - Par.1
File GREASE

In general, there is no need to lubricate the actuator because its mechanism is lubricated-for life.
The following greases are used by Rotork Fluid System to lubricate the mechanical components
and they are recommended for a possible lubrication:

GREASE FOR GO SCOTCH YOKE SERIES

MANUFACTURER: MOBIL
TRADE NAME: MOBILTEMP 78
COLOR: GRAY/BLACK
SOAP TYPE: INORGANIC
OIL TYPE: MINERAL
CONSISTENCY (NLGI GRADE)-ASTM D217: 1
WORKED PENETRATION AT 25°C-ASTM D217: 295/325 dmm
DROPPING POINT-ASTM D2265 260°C
VISCOSITY OF BASE OIL AT 40°C-ASTM D445: 485 cSt
VISCOSITY OF BASE OIL AT 100°C-ASTM D445: 32 cSt

GREASE FOR GO RACK AND PINION SERIES

MANUFACTURER: TEXACO
TRADE NAME: GREASE L00
COLOR: DARK BROWN
CONSISTENCY NLGI-ASTM D217: 00
LITHIUM SOAP: 6%
DROPPING POINT-ASTM D566: 180°C
BASE OIL FLASH POINT-ASTM D92: 220°C
OIL SEPARATION-DIN 51817: 2% MAX
OPERATING TEMPERATURE: -30°/+110°C

Note:
The above described grease types is the Rotork Fluid System standard for lubrication of scotch
yoke and rack and pinion actuators. In case a different grease type is requested, refer to the type
described in the Instructions Manual.

33
 HYDRAULIC OIL FEATURES SECTION (H) - Par.2
File HYDROIL_03

MANUFACTURER: MOBIL
TRADE NAME: DTE 11
VISCOSITY AT 40°C: 16,5 cSt
VISCOSITY AT 100°C: 4,2 cSt
VISCOSITY INDEX ASTM: 168
ISO GRADE: 16
POUR POINT: -42 °C
SPECIFIC WEIGHT AT 15°C: 0,85 kg/dm3

Note:
The above described oil type is the Rotork Fluid System standard. In case a different oil type is
requested, refer to the type described in the Instruction Manual.

34
 S

T
Par. 1 - Typical sectional drawings with parts-list

(I)

35
36
37
38
39
40
41
 S

T
Par. 1 - Instructions for actuator lifting

(L)

42
43
 S

T
Par. 1 – Operating instructions for electric control systems

I
Par. 2 – Features of the Rotork limit switch box type MB1

(M)

44
 OPERATING INSTRUCTIONS FOR ELECTRIC SECTION (M) - Par.1
CONTROL SYSTEMS

In case the actuator is provided with an electric control system, the setting is performed by Rotork Fluid
System during actuator testing operations.
For the start-up and should it be necessary to re-set the electric components, please proceed as
described here below:

WARNING

• DO NOT OPEN ELECTRIC COMPONENTS UNDER VOLTAGE!

• CHECK THE ELECTRIC EARTH BEFORE OPERATING ELECTRIC COMPONENTS!

• REFER TO THE MANUFACTURER USER GUIDE FOR THE CORRECT USE OF

ELECTRIC COMPONENTS.

45
 OPERATING INSTRUCTIONS FOR ELECTRIC SECTION (M) - Par.1
CONTROL SYSTEMS

Purpose of these instructions

During work in explosive environments, the safety of the people and the plant depends on the adherence
to all safety regulations.
Assembling and maintenance staff therefore bear particular responsibility. The prerequisite is a thorough
knowledge and understanding of the rules and regulations in place.
These introductions give a brief summary of the most important safety measures and regulations to be
observed by the staff.

Safety instructions
Observe the following during setting-up and operation:
• National safety regulations.
• National accident prevention regulations.
• Safety guidelines contained herein.
• Characteristic values on the rating and data plates.
• Test certificates and special conditions outlined in them.
Conversions and modifications to equipment which might impair explosion protection are not
allowed.
The equipment may be operated only if undamaged and clean.

Installation and operation

The following must be observed with regards to setting up and operating the explosion-proof equipment:
• National safety regulations
• National equipment safety legislation
• National installation regulations
• Generally recognized technical regulations
This equipment may be transported and stored only in its original packaging.
Damages neutralize explosion safety.

Technical data
Refer to the technical data on the rating plate on each control component or to the manufacture user
guide.

Conformity to standards
Controls are state of the art. They have been developed, manufactured and inspected in accordance with
ISO 9001.

46
 ROTORK LIMIT SWITCH BOX TYPE MB1 SECTION (M) - Par.2

FEATURES

• Electric protection EEx d IIC T6

• Mechanical protection IP67
• MAX voltage 250 V
• MAX current 25 A
• Nominal frequency 50/60 Hz
• Tested according to EN 50.014 and EN 50.018

The ROTORK limit switch enclosure can contain electric limit switches and terminal boards where
switches wires are connected according as required by the customer.

The external cable connection to terminals is at user’s care.

MICROSWITCHES
TYPE VOLTAGE RESISTIVE LOAD INDUCTIVE LOAD MANUFACTURER
250 V.c.c. 0.5 A 0.25 A
M2 BURGESS
250 V.a.c. 15 A 15 A
250 V.c.c. 0.5 A 0.25 A
K5 BURGESS
250 V.a.c. 25 A 15 A
250 V.c.c. 0.25 A 0.03 A
VCF BURGESS
250 V.a.c. 10 A 10 A
250 V.c.c. 0.25 A 0.03 A
V37YR BURGESS
250 V.a.c. 5A 10 A
28 V.c.c. 25 A 10 A
1HS3 HONEYWELL
115 V.a.c. 1A 1A
BZ-2RW8227
125 V.a.c. 1A 1A HONEYWELL
2551-A2
250 V.c.c. 0.25 A 0.25 A
Z 15GW22 OMRON
250 V.a.c. 15 A 15 A

TERMINALS
TYPE VOLTAGE NOMINAL SECTION mm2 MANUFACTURER
CURRENT
MK3 380 V 25A 2.5 WEIDMULLER
AKZ 1.5 250 V 18A 1.5 WEIDMULLER
SAK 2.5 750 V 26A 2.5 WEIDMULLER
MK3 380 V 25A 2.5 WEIDMULLER
AKZ 1.5 250 V 18A 1.5 WEIDMULLER
SAK 2.5 750 V 26A 2.5 WEIDMULLER

IMPORTANT NOTICE:
Before operating any of the above electric components, see section (M) - Par.1

47