VAAS

INSTALLATION OPERATION AND MAINTENANCE MANUAL

ENGINEERING DATA SHEET E.D.S. NO: EDS001 ISSUE DATE : 06.08.2011

FROM ONE SOURCE

DEDICATED TO QUALITY & SERVICE

(Please read the entire instructions carfully before installation and servicing) Guarantee: Our liability, with respect of any defect or failure of the goods supplied or for any loss, Injury or damage attributable onward is limited to replacement or repair of the defects which under proper use appear therein and arise solely from faulty materials and workmanship. This guarantee is for period of 18 calender months after the original goods were first shipped or within 12 calendar months from the date of installation, whicher is earlier, provided that such defective parts are returned whithout charge to our factory for examination. No other warranty is either expressed or implied.

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

TABLE OF CONTENT

Item 1. 2. 3. 4.

Description General Technical Data Installation Operation 1- Double Acting 2- Spring Return

Page no 3 4 4 4 4 4 5 5 5 7 9 9 9 10 10

5.

Maintanence 5.1 General 5.2 Disassembly 5.3 Assembly

6. 7. 8. 9. 10.

Actuator testing Air Supply Storage Exploded View Parts list

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1.General:

INSTALLATION OPERATION AND MAINTENANCE MANUAL

This manual contains the important information regarding the installation, operation and trobleshooting of the TORQMAX pneumatic actuators Please read the instructions carefully before operating the actuator.
WARNINGS & SAFETY INSTRUCTIONS
It is important that the actuator should only be used within the pressure limits indicated in our technical specifications. Operating the actuator over temperature limits will damage internal and external components (disassembly of spring retturn actuator may become dangerous). Operating the actuator over pressure limits will damage internal parts as well as case damage to the housing. Operating the actuator in corrosive environments with incorrect protection may damage the internal and external parts. Isolate all airlines and make sure that actuator air connection is vented before installation aor servicing othe actuator. Do not remove end caps or dissassemble the actuator while the actuator is pressurised. Before installing into a valve, make sure that the rotation of the valve and the actuator are the same and that the position indication orientation also correct. If the actuator is in a system or used within safety devices or circuits, the customer shall ensure that the national and local safety laws and regulations are observed. Do not attempt to remove the actuator pistons by use of air pressure when the covers have been removed. Any product warrenty will be invalided in the case of improper operation resulting from misapplication or faulty maintenance.

Spering Return Open (90)

Spering Return Close (0)

Double Acting Open (90)

Double Acting Close (0)

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2. TCHNICAL DATA:

INSTALLATION OPERATION AND MAINTENANCE MANUAL

Operating Media: Dry or lubricated air, non-corrosive and inert gas, or light hydraulic oil. Air Supply: 8 bar (116 PSI) Maximum. Temperature: Standard: -4F to 175F (-20C to 80C) Viton O Rings:-4F to 300F (-20C to 150C) Silicon O Rings: -40F to 175F (5C to 80C) Lubrication: Factory lubricated for the life of the actuator under normal conditions. Cunstruction: Suitable for indoor and outdoor use. External Travel Stops: 5 adjustments on 90 strokes. 3. INSTALLATION: Ensure that the desired failure mode is correct (refer to figure.). The TORQMAX actuator typically operates counter clockwise to open and clockwise to close, it is possible to change this style of operation. If the spring return actuator is not set up in the configuration desired, follow the disassembly procedure section 5.2. Reverse the orientation of the pistons, and then reassemble following the assembly procedure, section 5.3. Mount the actuator to the valve as per the desired orientation (parallel or perpendicular to the pipeline). Connect a regulated air supply to the BSP fitting on the actuator housing. Caution: the maximum operating pressure is 116 psi (8 bar). Adjust the stroke adjustment bolts following assembly section 5.3.4 Stroke adjustment bolts can be adjusted by up to 5.

4. OPERATION: The TORQMAX actuators have simple operational characteristics. Port A (facing the ports and reading right left) is connected to the interior cavity between the pistons directing the airflow into/out of the interior cavity. Port B is connected to the endcap cavities directing airflow into/out of the endcap area. 1. DOUBLE ACTING: Air supplied through port A forces the piston away from eatch other casing the piston to rotate counter clockwise (with exhaust air existing through port B). Air introduced through port B forces the piston towards each other causing the pinion to rotate clockwise (with exhaust air existing through port A). 2. SPRING RETURN: 2.1 Fail to Close (CW) (Standard scope of supply): Air introduced through port A forces the piston away from each other, compressing springs and causing the pinion to rotate counter clockwise (with exhaust air exiting through port B). Upon loss/release of air pressure, a spring forces the piston towards center position causing pinion to rotate clockwise (with exhaust air exiting through port A). 2.2 Fail to open (CCW): Air introduced through port A forces the piston away from each other, comperessing springs and causing the pinion to rotate clockwise (with exhaust air existing through port B). Upon loss/release of air pressure, a spring forces the piston towards center position

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

causing pinion to rotate counter clockwise (CCW) (with exhaust air exiting through port B). 5. MAINTENANCE: 5.1 General: TORQMAX actuator can be supplied with Metric /UNC fasteners. Under normal operating conditions, the actuator requires only periodic observation to ensure proper adjustment. Service kits are available to replace seals and bearings (soft parts). These parts are identified in figure... And listed in Table... Table... lists kit numbers.

1. Removal of local Position indicator

a) Remove the socket head screw (18) if fitted b) Remove the local position indicator (16) from the position. It may be necessary to pry gently with a align key. 2. Removal of Stroke adjustment Bolts

5.2 Disassembly: When disassembly of the actuator is required for maintanence, remove the actuator from the valve. Ensure proper lifting procedures are followed when moving or carrying actuators. Caution: Do not M VDI/VDE mounting holes for lifting the actuator. When disassembly the TORQMAX actuators, use caution and be certain that the actuator is free from accessories and the air supply is disconnected. When the actuator is a spring-return unit, make sure that the actuator is failed position before disassembling.

a) Remove both the stroke adjustment bolts (21) together with nut (22) washer (23) and O Ring (24). Replace the stroke adjustment bolts (21) in case of excessive wear observed on the bolt surface.

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2. End Cap Disassembly:

INSTALLATION OPERATION AND MAINTENANCE MANUAL

a) Hold the body (1) in a vice or similar device. Rotate the pinion (3) until the pistons (2) reach the end positions (i.e. the piston rack teeth disengages with pinion teeth). Caution: Air pressure should not be used to remove the pistons from the body. Clean and inspect the piston teeth for signs of wear. Replace pistons, if wear seems excessive. b) Remove piston O rings (7), piston guide band (5). Discard the O rings and guide band, if replacing the soft parts.

a) Remove the end cap bolts (9) by using align key. Caution: When disassembling a spring return actuator, the end cap (8) should be loose after unscrewing end cap bolts (9) 45 turns. If there is still force on the end cap bolt (9), this may indicate a damaged springs and any further disassembly should be discontinued. Further disassembly of the end caps may result in serious personal injury. Return the actuator to TORQMAX for further maintenance. b) For spring return actuators, remove springs (6) c) Remove end cap O rings (7) and discard if replacing all soft parts. 4. Piston (2) Disassembly:

5. Removal of Pinion (3) cam (19) and bearings (11, 12) a) Remove the circlip (15) using a circlip plier. b) Remove top thrust bush (14). c) Apply a downward force to top of the pinion (03) so that the pinion will move out of the center of the body (1) and remove the cam (19), it may be necessary to pry gently to cam with screw driver. Observed the cam surface for excessive wear, where the stroke adjustment bolts are resting and the cam ID (Square c/s) replace the cam, if excessive wear is observed.

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

d) Apply a downward force to top of the pinion (3) so that the pinion will move completely out of the bottom of the body (1). If the pinion (3) does not move freely, gently tap with a plastic mallet. e) Remove the top and bottom bearings (10, 11) and top and bottom O rings (12, 13). Discard if replacing all soft parts. 6. Cleaning and inspection: When all components are disassembled those not being replaced should be properly cleaned and inspected for wear prior to re-assembly. 5.3 ASSEMBLY: Prior to assembly, ensure that all components are clean are clean and undamaged. It is recommended to use the following lubricants: For NBR O-rings use EP1 The lubricant is suitable for use from -20C (4F) to +80C (+176F) with AIT/Flash point > (T-Class +50K). For Viton O-rings use Molykote 111 or OKS 1110 The lubricants are suitable for use from -40C (-40F) to +140C (+284F) For EPDM O-rings use only silicone grease (i.e. Molykote 111 or OKS 1110) The lubricants are suitable for use from -40C (-40F) to +140C (+284F) 1. Pinion (3) Assembly

a) Install the top and bottom bearings (11, 12) and O rings (10, 13) on to the pinion (3) b) Apply grease to the pinion bearings (11, 12), shaft O rings (20, 21) using general-purpose grease listed as above the assembly instruction.

Insert the pinion (3) in to body from the bottom side up to body center. d) Insert the stop (19) & bottom thrust bush (11) on the pinion (3).

c)

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

e) Insert the pinion (3) into the body (1) from the bottom side. Ensure that bottom surface of the pinion should be around 0.5mm inside the body bottom face and the pinion top slot orientation is as shown in the above figure. f) Insert the top thrust bush (12) & circlip (15) (using the Circlip Plier) on the pinion 93). 3. Piston (2) Assembly: a) Fit piston pad (23), piston guide band (5), and piston o-rings (4) on the pistons (2) b) Apply grease to the internal bore of the body (1) & to the piston rack teeth using recommended general purpose grease listed in assembly instruction (5.3). c) Press the two pistons simultaneously in the body bore until the pinion racks are engaged and rotate the pinion until the stroke is completed. Take care that the pistons are oriented correctly as per the fail position of the actuator (the standard fail action of actuator is fail clockwise). Refer the below figure.

gerease in the cylinders behind the pistons. g) Temporarily install the local position indicator (16, 17, and 18) onto the pinion (3) to determine whether to correct stroke is obtained. Ensure that the arrow in the local position indicator will rotate a minimum of 5 beyond the 90 vertical centerline of the actuator body as shown. If the proper stroke is not obtained remove the pistons and repeat from step 2c. Once proper stroke is obtained, remove the local position indicator. 4. Cover Assembly: a) Assemble the DA covers. Make sure the covers are put back according to your marking during disassembly. b) Assemble the SR covers with the spring set. The screws are long enough to engage to the thread before the springs start to compress. Tighten the screws in sequence only two turns at a time. c) Finally torque the screws to the set figures in the table below. Actuator Screws Torque Figures: Atuator size V25 - V45 V70-V150 V210 V480 V925 V2100 Screw M5 M8 M10 M12 M16 M16 NM 3.5 9.0 18.0 40.0 40.0 40.0 Lb-in 30 80 160 360 360 360

d) To ensure that the piston (2) teeth are evently engaged, fully compress both the pistons, two adjustment screws that were pulled away and screw them back until they both toch the stop. Adjust them until you visually see that the pinion flats are parallel with the body plane. e) Rotate the body back to get the pistons running smoothly in the cylinders. f) Bring the pistons in to thre close position and once again apply the

5. Local position indicator Assembly: Fit local position indicator (16) assembly on to the pinion (3). Ensure that it indicates the cotrrect actuator position. Tighten the socket head screw to secure the local position indicator.

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

6. ACTUATOR TESTING: After completion of actuator assembly it is required to follow these testing procedures to ensure the actuator has been assembled correct and to minimize the risk of personal. I) Pneumatic Leak Test The pneumatic test checks there is no leakage across the pistons or to environment. Use commercial leak testing solution to check leakage to atmosphere. Is acceptable to allow a small amount of leakage to atmosphere. A bubble which breaks every 10 seconds is considered acceptable. The leak test testing pressure will be 80psi (5.5 bar). Use a calibrated pressure regulator to apply pressure to the actuator. WARNING: Do not exceed the maximum operating pressure rating listed on the name plate. Cycle the actuator atleast 5 times to allow the seals to find their position before commencing with the leak test. II) Piston Leakage Any leakage across the piston is not acceptable. Apply the pressure to port A and leave port B open. Apply a leak testing soap solution to port B and check for leakage. For DA actuators repeat this applying pressure port B and check port A for leakage. If leakage is absorbed, disassemble the actuator again and check the seals, surface finish and cleanliness of the internal parts to find the cause of leakage. After doing the repair work, the leakage test must be performed again. III) External Leakage For SR actuators apply the pressure to port A and leave port B open. For DA actuators apply the pressure to port A and B.

After applying the pressure, wait a few seconds to let the pistons stabilize and then check for leakage. Apply the leak testing solution to the pinion output. For DA actuators apply the leak testing solution to the covers. 7. AIR SUPPLY: Use clean dry air. Other inert gases may be used such as nitrogen, argon and natural gas. Thin hydraulic oil can also be used. Do not use water as supply media. Oxygen or hydrogen must NOT BE USED The operating medium is to be filtered to 30 microns particle size or less. Always consult with a representative of TORQMAX for suitability and recommended practice. Piping connected to the actuator or accessories should be fitted according to recommended instrumentation piping practice Prior to connection make sure all lines have no loops and are free of water, oil or other condaminants that may be trapped in the pipes. Pipes must be flushed with air to clean the passages. Where sealants are been used for threaded connections, care must be taken to avoid excess material been forced in to the actuator parts. Supply Pressure: The supply pressures for the TORQMAX actuators are as follows: Double Acting: 2-8 bar (30-120psi) Spring return: 3-8 bar (40-120psi) 8. STORAGE: All the TORQMAX actuators are factory lubricated for one million cycles under normal operating conditions. The ports are plugged to prevent material from entering the actuator during the shipment. If the actuators are not for immediate use, the following precautions must be taken during storage. a) Store in a dry environment. b) It is recomended that the actuator be stored in its original box. c) Do not remove the plastic plugs on the air supply ports.

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

9. EXPLODED VIEW

10. PARTS LIST SL. DESCRIPTION NO

1. 2. 3. 4. 5. 6 7 8. 8a. 9. 10. 11.. BODY PISTON PINION PISTON O-RING PISTON BUSH SPRING COVER O-RING SR COVER DA COVER COVER SCREW PINION O-RING-1 PINION BUSH-1

QTY MATERIAL
1 2 1 2 2 4 2 2 2 8 1 1 ASTM B221. 6063-T6 LM-24 STEEL E.N.P COATED BUNA N, VITON, EPDM DELRIN SPRING STEEL , PAINTED BUNA N, VITON, EPDM LM-24 LM-24 STAINLESS STEEL BUNA N, VITON, EPDM DELRIN

SL. DESCRIPTION NO
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24 PINION BUSH-2 PINION O-RING-2 CIRCLIP WASHER CIRCLIP INDICATOR INDICATOR PIN INDI ASSY SCREW STOP STOP WASHER STOP SCREW LOCK NUT LOCK NUT STOP O-RING

QTY MATERIAL
1 1 1 1 1 1 1 1 1 2 2 2 2 DELRIN BUNA N, VITON, EPDM DELRIN SPRING STEEL PLASTIC PLASTIC STAINLESS STEEL STAINLESS STEEL DELRIN STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL BUNA N, VITON, EPDM

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