CN 19960 81-M-14 FEB 1981 REV: MAY 2000 Orbit LS Series Double Acting Cylinder Actuators and Accessories Installation and Maintenance Manual DO NOT USE THIS MANUAL FOR ORBIT LG SERIES ACTUATORS - UNEXPECTED PRESSURE COULD BE ENCOUNTERED. Check the nameplate to determine the correct model or ‘contact your Orbit representative. For Orbit LG Series actuators, see Orbit Manual 79-M-1 1 For Orbit Spring Close Cylinder Actuators, sce Orbit Manual 79-M-13 for the LG Series and Orbit Manual 81-M-15 for the LS Series. WARNING BLEED PRESSURE FROM VALVE AND ACTUATOR PRIOR TO ASSEMBLY OR DISASSEMBLY OPERATIONS ORBIT VALVE (A Division of Cooper Cameron Valves) b, ois P.O, Box 193520 Little Rock, AR 72219, U.S.A.EOE Orbit Valve Sealing Effectiveness Cylinder Actuator « Installation . Field Mounting Instructions - Disassenbly Instructions + Assembly Instructions « Mounting Dimensions « Lifting Fyes + Nameplate Gas-Over-041 Tank « Size, Type Fluid and Capacity - Nounting Positions Manual Close! - Installation Disassembly and Reassembly Manual Opener and Closer (for LS-124) « Introduction . Installation . Disassembly and Reassembly Two-May Manual Mechanism (for LS-266) « Introduction + Installation Micro Switch « Introduction « Setting « Installation Visual Position Indicator « Introduction Mlustration 15 19 20 2 a ra) 27 27 34 34 35 33 33ORBIT VALVE SEALING EFFECTIVENESS The stem force required to seal an Orbit valve varies with several factors, including: type of seat, size and type of actuation, and direction of applica- tion of line pressure. The closing forces required are appreciably less with soft seats (Teflon or Nylon insert) as compared to metal-insert seats. Line pressure applied to the PREFERRED PRESSURE END assists sealing, whereas Tine pressure applied to the other end (SEAT END) increases the stem force necessary to effect a seal. The following configurations of Orbit valves are tested to hold with no visible leakage: 1. Soft-seated handvheel-operated valves with pressure from either direction 2. AUT block and bleed valves, both handwheel and actuator-operated, with pressure fron either direction. 3. Soft-seated, actuator-operated valves with pressure applied to ‘the PREFERRED PRESSURE END only. WARNING: If sealing is required with pressure applied.to the SEAT END of actuated, soft-seated valves, the customer must-so specify. The following valves are tested to API 598 leakage rate: 1. Handwheel operated valves with metal-insert seats and pressure from either direction. 2. Actuated valves with metal-insert seats and pressure from the PREFERRED PRESSURE END only. WARNING: If sealing to API $98 leakage rates is required for Pressure applied to the SEAT ENO of actuated valves with metal- insert seats, the customer must so specify.CYLINDER ACTUATOR INTRODUCTION The Orbit Cylinder Actuator is a double acting, linear type, piston actuator consisting of two separate cylinders and pistons used for auto~ matic operation of valves. The opening or closing of the valve core in the body is accomplished by applying pressure to either side of the piston. A typical Orbit Cylinder Actuator is shown in Fig. 11. The Orbit Cylinder Actuator is adaptable to Orbit valves only. Since Orbit Valves are basically on and off type valves and are not generally recommended for throttling services, a constant intensity signal is required to completely stroke the actuator in either direction. The intensity of this constant signal will vary depending on the differential pressure across the valve seat and operating pressure: however, in most cases the intensity will_be the maximum allovable pressure for that specific actuator. WARNING: The loss of air supply pressure from either side of the piston while valve is in service can cause the valve to open or close, so caution all maintenance and operating personnel not to bleed air from the system while valve is in service. (See Pig. 4.) INSTALLATION Wormally, the cylinder actuator is mounted on the valve at the factory In this case, follow the normal procedure for installing the valve in the pipe line. There are two air-connections on the actuator. The air connec- tion for opening the valve is: located on the bottom of the lower cylinder head, and the air connection for closing the valve is. located on top of the actuator gas-over-oil tank. The-sizes of these air connections are shown below. ACTUATOR CLOSING AIR OPENING AIR NOMINAL OPERATING SIZE CONNECTION CONNECTION TIME (OPEN OR CLOSE) ts-124-p-3* | 3/8" - 18 NPT 3/8" - 18 NPT 25-40 sec. ts-124-p-4% | : a : " ts-1z4-p-20 | * « " . " ts-124-d-21 " . " . " [s-124-b-22 " . * . " (s-124-b-23 a . " * " Us-124--24 | i f : Ts-124-0-25 |" 0 a ‘ Us-124--25 | * ‘ 7 7 ts-185-p-5* | . . " US-205-D-6* | 1/2" ~ 14 NPT v2" - 14 NET LS-206-D-19 : 7 - LS-266-D-19 ‘Also applies to cylinder actuators for H-8 valves with suffix -13, -14, =18 and -16.These connections tie into the supply air outlet connections on the pilot valve with either copper tubing or pipe. The length of this connecting piping should be kept as short as possible to avoid any lag in the supply signal. Often, the actuators are shipped with the instrumentation already assenbled at the factory In this case, all that is necessary is to hook up the supply gas to the inlet connection of the four-way valve and connect the signal to the pilot on the four-way valve. For these details refer to the applicable Suggested Piping Arrange- ment. Drawing. AML cylinder actuators are furnished with a Gas-Over-Oi1 system to assure smooth operation and prevent sudden sten movement which would damage the valve mechanism, The sizes and fill levels are shown in the table below. The type of fluid used to Fill Gas-Over-Oil Tanks is Mobil ATF 220 automatic transmission fluid or equivalent. When filling the tank the actuator piston should be in the open (up) position to prevent over-filting the tank. Capacities of the tanks when filled to the proper level are as follows: ACTUATOR TANK FILL LEVEL capacITY ATF-220 | FicuRE SIZE SIZE HOLE TN GALLONS NUMBER ts-1240 10 00 x 1s One Only 3 1 Ls-185D 12 00 x 19 Bottom 6 2 Ls-2050 12 00 x 19 Top 8 2 Ls-206D 14 OD x 27 Bottom 12 2 LS-2660 14 OD x 27 Top 15 2 It is very important that the tank is filled to the proper level because underfilling will allow fluid to blow out the top connection of the tank in the form of spray and fill up all of the instrumentation system with oil. Over~ Filling will do the same thing because there will not be enough volume in the tank to hold'all of the excess fluid from the cylinder when the actuator opens the valve. To drain tank, remove plug in tee at bottom of tank as shown in Figs. Land 2. Important: The tank always has to be mounted in a vertical position for the actuator to function properly. Tilustrations of the different basic position valves can be mounted in are shown in Fig. 3. Untess otherwise stated on the order, all Gas-Over-0i1 Tanks will be mounted as shown in Illustration 1. Therefore, in order to insure that the Gas- Over-0i1 Tank will be mounted properly, a sketch showning the position (vertical or horizontal) of the line, position (vertical or horizontal) of the actuator, Vocation of Gas-Over-0i1 Tank and direction of flow should be subjitted with the order. The foregoing illustrations can be used as guides or references when ordering valves with Gas-Over-0i1 Tanks.REMOVE HYLON SHIPPING PLUG AND REPLACE WITH THE PIPE PLUG (FURNISHED) PRIOR TO GPERAT ~ THE ACTUATOR -—CLOSING AIR CONNECTION REMOVE PLUG FROM IRLLT FOR CORRECT LEVEL INDICATION, FILL TANK WITH | MOBIL ATF 220 AUTOMATIC TRANSMISSION I FLUTO OR EQUIVALENT, 3 GALLONS REQ‘D. ORAIN PLUG r i ain : conticcrion FIG. 1 GAS-OVER-OIL TANK FOR LS-124 ACTUATOR REMOVE NYLON SHIPPING PLUG AND REPLACE WITH THE PIPE PLUG (FURNISHED) PRIOR TO OPERATING THE ACTUATOR. CLOSING ATR CONNECTION FOR 1S-205-D AND LS-266-D REMOVE PLUG FROM UPPER INLET FOR CORRECT LEVEL INDICATION. FILL TANK WITH MOBIL ATF 220 AUTOMATIC TRANSMISSION FLUID OR EQUIVALENT, 8 GALLONS REQ'D. FOR LS-205-D ANO 15 GALLONS REQ'O. FOR US-266-0. FOR LS-185-0 AND LS-206-D REMOVE PLUG FROH LOWER INLET FOR CORRECT LEVEL INDICATION. FILL TANK WITH MOBIL ATF 220 AUTOMATIC TRANSMISSION FLULD OR EQUIVALENT, 6 GALLONS REQ'O. FOR LS-185-0 AND 12 GALLONS REQ'D. FOR LS-206-D. DRAIN PLUG OPENING AIR ‘CONNECTION FIG. 2 GAS -OVER-OIL. TANK FOR LS-185, LS-205, L5-206 AND L5~266 ACTUATORj-Tanm vocation FoR / US" 266 ony PREF. PRES. END facreR TO CATALOG 78-0, ALN TERARCE AND INSTALE™ ATION SECTION. fuusteatiON 1 HORIZONTAL LINE, VALVE STEK VERTICAL Nuusrration 3 VERTICAL LINE VALVE STEM HORIZONTAL, FIG. 3 A VIEW _A-A WwusTRATION 2 WoRIZONTAL LIKE VALVE STEM HORIZONTAL,LIFTING Eves Two lifting eyes are welded onto each upper cylinder head to facilitate lifting and installation. The same size pad is used for all actuator sizes Typical dimensions for this welded-type lifting eye pad are shown below DETAIL A From Page 4 (Tye) 3 nase comer NAREPLATE i The nameplate shown in Fig. 4 is attached to the actuator's middle cylinder head. Nameplate information inicudes actuator figure number, serial number, and maximum operating pressure. -Also included is a warning to use flow controls to regulate the desired operating speed in order. to prevent damage. to equipment. Warning should not be ignored because severe danage can be done to the stem spiral, guide pin, and the valve bonnet if-the valve actuator is allowed to operate too fast. This, in turn, can cause further damage throughout the valve resulting in costly repairs. IRE USE FLOW CONTROLS TO REGULATE. babintea tidied Seen T hs mae sae uo To eau Bi WARNING! rs oss or an pHESsUMe can CAUSE va Oke “10 WADVERTENTeY OPeN OW CLOSE. ° Eeiecrane ee ee Romer aN il i joprosire €No st ® Oger fs 1DO WOT OLECD Alt FROM ACTUATOR, FIG.4GAS OVER OIL TANK NOT SHOWN ¥ 1 -@ wur {| © seesve iB, ie SLEEVE Ly Lygl TYPICAL H-8 VALVE WITH CYLINDER ACTUATOR FIG. 5FACTORY MOUNTED CYLINDER ACTUATOR ON A VALVE (EXLUDING H-8 VALVES} When Orbit valves have cylinder actuators mounted at the factory, Fig. 11 represents a typical assembly. In order to remove the cylinder actuator to perform maintenance on either the valve or the actuator, remove the mounting flange bolts and nuts, Ttems 46 and 47. Lift the actuator, by the lifting eyes, approximately two inches. Rotate the actuator clockwise to unscrew it from the valve stem. For complete actuator dismantling, follow the instructions on Page 13. To replace the actuator after maintenance is complete, follow the mounting procedure outlined on Page 7, titled "To Install a Cylinder Actuator on a Valve in the Field." FACTORY MOUNTED CYLINDER ACTUATOR ON H-8 VALVES When H-8 valves have cylinder actuators mounted at the factory, Fig. 5 represents a typical assembly. In order to remove the cylinder actuator to perform maintenance on either the valve or the actuator, unscrew the top Nuts, Item 1, from the Sleeve Studs, Item 2, and remove the Sieove Studs. Lift the actuator, by the lifting eyes, approximately two inches. Rotate the actuator-clockwise to unscrew it from the valve stem. For complete actuator dismantling, follow the instructions on Page 13. To replace the actuator after maintenance is complete, follow the mounting procedure outlined on Page 9 titled "Installation of Cylinder Actuator on an H-8 Yalve in the Field" Packing gland height dimensions as normally observed after factory pressure tests are also shown in Fig. 9 TO INSTALL A CYLINDER ACTUATOR ON A VALVE IN THE FIELD (EXCLUDING H1-8 VALVES), USE_THE FOLLOWING PROCEDURE: CAUTION! REMOVE THE LINE PRESSURE FROM THE VALVE BEFORE DISASSEMBLY. | Open the valve, then remove the handwheel or gear operator, bonnet nut or gear operator adapter, drive nut, thrust bearings and bearing races Some valves require adapter flanges for mounting cylinder actuators while other valves have integral bonnet flanges sized to accept cylinder actuators. See Figs. 4 and 5. The 10" ANSI 600 and 900 Class, 12" ANSI 150, 300, 600 and 900 Class. and 16" ANSI 150, 300 and 600 Class valves have integral actuator mounting flanges. Also, the 6" ANSE 900 Class, 8" ANST 600 Class, and 10" ANST 150 and 300 Class valves with serial number prefixes* HC or HD have integral actuator mounting flanges However, for the preceeding 6", 8", and 10" valves without the HC or HD serial number prefixes, 8" ANST 150-300 Class and all valve sizes 6" ANSI 600 Class and smaller, it will be necessary to install an actuator adapter flange. See Figs. 7 and 8. *Serial number prefixes are stamped on the valve nameplate and on the valve body.1 CAUIION: For the 8" ANS) 150-300 Class, 6” ANSI 600 Class and smaller valves. ‘without the A or JB serial aunber prefix, the use of the Tock ring is mandatory to provide stem retention and a full open position stem stop Make sure the cylinder actuator is in the full closed position and the valve stem is in the full open position. Apply Lubriplate 930-AA grease to the external stem threads, upper stem and entire length of keyway groove prior to assembly. Now, engage the stem threads with the threads in the Piston Rod and rotate the actuator counterclockwise to screw it onto the valve stem to the dimensions shown for the respective actuator in Fig. 10. When this has been done, lower the actuator until the mounting flanges touch. The flanges may have to be pulled together with long bolts. ATign the bolt holes, insert the flange mounting bolts and tighten the nuts in a criss-cross method. [f air is available, stroke the valve several times to be sure the valve is opening and closing fully. NSTALLATION OF CYLINDER ACTUATOR ON AN H-8 VALVE IN THE FI WAVE PACKING GLAND AND ADJUSTING NUTS OR TOP OF BONNET! LO (VALVES WHICH When cylinder actuators have to be mounted on H-8 valves in the field, First, open the valve with the handwheel, then refer to Fig. 6 and unscrew the top Nuts, Item 1, from the Sleeve Studs, Item 2,and renove the Sleeve Studs Next, remove the gear operator or handuheei as a unit by turning the complete assembly clockwise and unscrewing it from the stem. Leave the Sleeve, Item 3, ‘in place. After the gear operator or handwhec! has been removed, wake sure the actuator piston is in the full closed position and the valve stem is in the full open position. Apply Lubriplate 930-AA grease to the external stem threads, upper stem and entire length of keyway groove prior to assembly. How, engage the stem threads with the threads in the Piston Rod and rotate the actuator counterclockwise to screw it onto the valve stem to the dimensions shown for the respective actuator in Fig. 9. When this has been done, lower the actuator until the flange on the bottom of the actuator seats into the recess in the Sleeve, Item 3, Fig. 5. Line up the bolt holes, insert Sleeve Studs, Item 2, Fig. and screw Nuts, Item 1, Fig. 5 onto Sleeve Studs being sure to tighten evenly all the way around. If air is available, stroke the valve several times to be sure the valve js opening and closing fully. Cylinder actuators for the 8" ANSI 150-300 Class, 6" ANST 600 Class and smaller H-8 valves are mounted the same way as is shown on Pages 8 and 9._-@) SLEEVE cae sTuo —~@ sveeve (B) TYPICAL H-8 VALVE WITH GEAR OPERATOR (A) AND HANDWHEEL (8) FIG.6 -10-FLANGE ASSEAOLY OINENSYON yasisse 0 ———— 1/32 (HI) CLEARANCE. BEFORE TIGHTENING RUTS AND WELDING STUD YO GE ON VALYE CENTER LIME 74.2 3/423/4 WELDING BRIDGE ' (OWE stun over stex curae) UOCKTE BETWEEN BOLTS-REFER TO ASSEMBLY INSTRUCTIONS ITEM 6 Oo Oo a ob&(Cje) ect me S Oo O° ower FLANGE —~ ASSEMBLY INSTRUCTIONS FOR VALVES WITH JA OR JB SERIAL NUMBER PREFIX (ONE-PIECE STEM) 1 2. -) .) SCREW FLANGE ONTO BONNET UNTIL ASSEMBLY OIHENSION (1/4 1/32) 15 acuTEVED AND (2) BOLT HOLES TN FLANGE ARE ALIGNED WITH CENTERLINECOF VALVE BORE. (D0 NOT APPLY LUBRICANTS TO THREADS. ) PLACE ADAPTER PLATE ON VALVE. CHECK ASSEMBLY CLEARANCE (1/32) AND LOCATION OF BOLT HOLES WITH CENTERLINE OF VALVE BORE AND ADJUST IF NECESSARY. INSTALL (4) 1/2-13 BOLTS/STUDS AND NUTS AND TORQUE TO 60 FT-LBS,IN 20 FT-LB INCREMENTS, USING A CRISS-CROSS PATTERN. PLACE CUP-POINT PUNCH (2-3904) IN EACH SET SCREW HOLE AND STRIKE SHARPLY WITH HANMER. INSTALL SLT SCREWS (S-7082) AND TIGHTEN SECURELY. WELD FLANGE 10 BONNET WITH 1/4 x 3/4x 3/4 BRIDGE. NOTE: ORBIT RECOMMENDS WELDING THE FLANGE TO THE BONNET, BUT UNDER NORMAL OPERATING CONDITIONS, THE FLANGE IS ADEQUATELY LOCKED IN POSITION IF ASSEMBLY INSTRUCTIONS 1 THRU 5 ARE CAREFULLY FOLLOWED. FIGURE 7 -u-Tlantenc. Secureey Noyes 10.96 04 & Thee Sie te TACKWELD (2) CLIPS SPACED AT APPROX Ino" Te PosstaLe — 3 ton ts 124-0313 besitos TWO-PIECE STEM VALVES wrTHOUT_He OF 10 SERIAL HUMBER PREEIX Lock RING MUST BF TrowTeWED SECURELY AGAINST TOP OF BONWET i WARNING: This Tock ring fs mandatory { Tock the adapter flange in place, provide the open-position stem stop during operation, and assure stem retention in the event the actuator 1s Subsequently rosoved without depressuring the valve, INJURY CMW RESULT from fatlure to provide this stea retent on Omens Iie 82 MOLE TO 8¢ ow CENTER Une (OF Mave (OME HOLE OVER srcw cue) tacxweto (2}cuPs ve-PHECE STM _vALvES WITHOUT 9A OF 3 SERIAL RUNDER PREFIX FIGURE 8 12-MOUNTING DIMENSIONS FOR CYLINDER ACTUATORS ON_OS&Y_VALVES ‘ Te 3 4i6 tS-185-0- 15 3 ve Zz 36 Ls-124-0-26 tS-183-b- 26 8 1F vo [8 (v.15) 5 3 SS B10 2 w20 HOLYKOTE PASTE APPLIED TO 0.0. 1.0. OF PACKING Sia Ls-124-0-26 Ls -185-0- 15/26 F-7/A6 To 778 (0-19) LS-205-D-16 LS-206-D-19 Ls-207-0-19 LS-266-0-19 LS-267- 0-19 FIG. 9 13. LS-124-0-14 AUG 4 178 15-205-0-16 53/4 21/8 6-1 21/8 5-5/8 418 - eae v8 MOLYKOTE PASTE [APPLIED 10 0.0. 15-206-0-19 1-207-0-19 5-266-0-19 t5-267-0-19 . 1.0, fF PACKING GLADMOUNTING OIMENSLONS FOR CYLINDER ACTUATORS, ON VAL “S_(EXCLUDING MOST OS&Y VALVES) q AEP se5-05 ie 4 5 Bie t8185°0-33 4B ° is-205-0-6 23 US 24-0-2 32 Pesa403, "| LS-124-0-2/3/4/25 Ls-185-0-5, LS-124-0-12/13 OStY BONNET Pe aaeanere LS-185-0-25 2 1/6 £3/32 FOR LS-124-0-21 3-4 3/32 FOR LS-124-D-20 21/2 £3/32 FOR LS-I24-0- 23 3/9/16 £ 3/32 FOR LS-124-0-28,-24 LS-124-D-20/21/23/27 LS-124-D-22/24 OSEY BONNET FIGURE 10 -14-DISASSENBLY INSTRUCTIONS, The following procedure describes how the actuator can be completely disassembled. In order to completely disassemble actuator, it should be removed from valve. This operation will be necessary only in the event internals of the actuator need to be inspected or parts such as O-rings and piston seals need to be replaced. In most cases, as a matter of good practice, the actuator should be completely disassembled, but sone cases may warrant disassembling only as far as is necessary to correct the problen. Preferably, disassenbly and assembly of this actuator should be done in a shop that has a clean work bench where sand, grit or other debris can't get inside and cause damage in the future; aiso, the proper tools must be available to perform the work. REFER TO FIG. 1 OR FIG. 2 1. The actuator must be in the full-up position. This forces ofl from the actuator into the Gas-Over-0it Tank 2. Be sure that all pressure has been bled off the actuator and tank, then drain the fluid from the system. Remove the pipe plug (fill Tevel indicator) in the side of the Gas-Over-0i1 Tank so that a vacuum won't be created while draining tank. REFER TO FIG. 11 3. Remove actuator mounting bolts and nuts, Items 46 and 47 4. Rotate actuator clockwise to-uascrew it from’ the valve stem, 5. Securely bolt or clamp. the actuator to work bench with block under piston rod to hold actuator in full open position. This is necessary to gain access to piston rod nut, Item 16 or Item 18, and restrain actuator while loosening nut. tote high torque requirements for piston rod nut. Alternatively, one may find it is easier ‘to loosen the piston rod nut while the actuator remains attached to valve. Further dismantling should be performed in a shop to prevent dirt and debris from con- taminating actuator interior. 6. Paint, mark or scribe a line from upper cylinder head, across both cylinders and middle cylinder head, to the lower cylinder head. Also, mark top position of cylinders and middle cylinder head. This procedure will facilitate re-assembly. 7. Remove Items 23, 25, 30 and 32 tubing or piping, connections and fittings for top and bottom cylinder inlet connections 8. Remove Item 29, cylinder head cover nut (Item 22 cap screws on LS-124) and take Item 6, cylinder head cover (Item 33 for LS-124), off and inspect Tten 34, O-ring. 9. Take all cylinder stud nuts, [tem 17, off then remove all cylinder studs, Item 19,and take off Item 4, upper cylinder head, and inspect Item 35, O-ring -15-10. Unscrew {tea 16 (Item 18 for LS-124), piston rod nut, then remve item 1, cylinder, and [ten 7, upper piston, together. Take Item 7 out of Item 1 and inspect Tee Seal (Item 36) 11. Remove Item 3, middle cylinder head,and Item 9, piston rod sleeve, together, then take Item 9out of Item 3. Inspect O-rings, Items 35, 37, and 38. 12. Rewove Item 43, gland, from Item 2, lower cylinder head, and inspect. Unscrew Item 44, position indicator rod assembly. Avoid marring rod surface. 13. Remove Item 39, lover piston,and Item 40, lower cylinder, together, then separate and inspect Item 35, O-ring,and Item 36, Tee Seal {During reassembly, tapped hole on bottom of lower piston must be aligned with tapped hole in lower cylinder head so that indicator rod assembly may be installed. Use Z-2886 alignment tool.) 14. Push Item 8, piston rod, out bottom of Item 2, lower cylinder head,and inspect it. Rewove Item 10, key. Remove Item 20, retaining ring, then take out Item §, sealing gland, and inspect. O-rings, Items 41 and 42. ASSEMBLY INSTRUCTIONS Reassenble the-actuator by.referring to Fig. 11 and following the foregoing disassembly procedure in reverse. Be sure and apply 930-AA Lubriplate grease to keyway groove. Final. tightening.of the piston rod nut or cylinder head cover fasteners must be done after the upper cylinder head (Item 4) is securely in place. Tighten the cylinder head nuts (Item 17) evenly using a criss-cross method. When actuator is completely assembled, mount it on the valve using the foregoing installation procedures 'on Page 7. Fill the Gas-Over-Oil Tank with automatic transmission fluid per instructions on Page 4. -16-OPEN/CLOSED. INDICATOR NOT SHOW SHOWN WiTH GAS CONNECTING OIL LINE OVER ON TANK REMOVED AND gy OFFSET SKIVE CUTS TOP ano 3) portom ack -ue RINGS BY “A a WaMMOM OFS @ TEE SEAL i 15-105 Loven Piston Beta ® 6 © 69 © ASPLY UUBRIPLATE LwI23-006_ TO (uonicare EM 45, AUC osmiNGs , O-RING. GROOVES , WITH LUBRIPLATE ‘930-44 BND O-RING. ‘CONTACT “SURFACES. (eiciuoes Tee SEALS) ‘ORBIT CYLINDER ACTUATOR PISTON ROD HEX socKeT Fig, 11 NUT TORQUE WRENCH € ts-t24-0 | 330 FT La. 13/6 “17. ts-105-0 | s20 Fruo:| 2 9/16 ts-205-0 | uso Fr ts. } 2 9/16 Ls-206-0| uso Fr tn 2 on6 ts-266-0| zs00rr..a.| 37816 Vv 18 49 20 21 22 23 25 26 29 31 32 33 34 35 36 37 38 41 42 43 44 45, 46 PARTS REFERENCE FOR FIG. 11 DESCRIPTION CYLINDER (Upper) LOWER CYLINDER HEAD WSIODLE CYLINDER HEAD UPPER CYLINDER HEAD SEALING GLAND CYLINDER HEAD COVER PISTON (Upper) PISTON ROD PISTON ROD SLEEVE key O-RING PISTON ROO HUT CYLINDER STUD NUT PISTON ROD NUT CYLINDER STUD RETAINING RING BUSHING CAP SCREW TUBING MALE CONNECTOR CYLINDER HEAD COVER STUD CYLINDER HEAD COVER NUT Tee NIPPLE FEMALE ELBOX CYLINDER HEAD COVER O-RING O-RING TEE SEAL WITH BACK-UP RINGS O-RING O-RING PISTON (Lower) CYLINDER (Lower) O-RING O-RING GLAND POSITION INDICATOR ROD ASSY. ALEMITE FITTING WITH LUBRTCAP MOUNTING FLANGE BOLTS MOUNTING FLANGE HUTS -18-MANUAL CLOSE. INYRODUCTIOK, The top mounted manual closing mechanism is used to lock the valve in a closed position and to manuaily close the valve in the event of a failure in the instrumentation syste or air supply. Note in Fig.12 and 13 that the jack screw is not attached to the piston red, therefore, the handwheel cannot be used for opening the valve. Rotation of the handuheel in a clockwise direction moves the jack screw down, which makes contact with the piston rod in the actuator. “Further rotation moves the jack screw down, pushing the piston rod down until the valve is closed. Prior to opening the valve, the handwheel must be rotated counterclockwise until the jack screw is in’the full up position INSTALLATION Usually the actuator has the manual closer installed at the factory, how- ever sometimes they may have to be installed later in the field after a valve is already in service. When this happens, be sure all pressure has been bled off the actuator. Refer to Fig. 11 and remove Item 29, cylinder head cover nut, (Item 22 cap screws on LS-124) and take Item 6, cylinder head cover (Item 33 for {S-124) off. Next, remove Item 26, cylinder head cover studs. This applies to the LS-185 and 15-205 piston actuators only. The actuator is now ready for installation of the manual closer. tiow refer to Fig. 12 or 13. Be sure the jack screw is in the full up position. Set the manual closer down on top of the piston act- uator and line up the bolt holes. Apply C-102 to the hex bolts, Item 9, then insert them in the bolt holes and tighten evenly all the way around. MANUAL CLOSER FOR L8-124 ACTUATOR Fig, 12 -19-DISASSEMBLY INSTRUCTIONS i Refer to Fig. 12 Manual Closer for 15-124, and Fig. 13 Manual Closer for LS~185, LS-205, and LS-206. Again, be sure all pressure has been bled off the actuator and also, check Relief Fitting (Item 4) to be sure it ‘isn't plugged and trapping pressure inside the Weather Shield (Item 6) Back off Jam Nut (Item i) and remove handwheel (Item 2). Slip Weather Shield (Item 6) off over top of Jack Screw, Item 3. Remove O-ring (Item 7) from groove in Jack Nut (Item 8) and inspect it. Replace it if it is damaged, Now take all Heavy Hex Bolts (Item 9) out and rewove dack Nut (Item 8) from top of actuator and slip Jack Screw (Item 3) out : the bottom, Remove O-rings, Items 10 and 11, and inspect them, Replace them if they are damaged. On LS-124 only, inspect Thrust Masher (Item 12) If damaged, replace it. REASSEMBLY In order to reassemble the Manual Closer, reverse the foregoing procedure for disassembly. Apply C-102 lubricant to the heavy hex bolts, Ttew 9, before inserting them in the bolt holes. Apply Lubriplate LM123-006 to all O-ring grooves, O-rings, inside surface of weather shield, the external threads on the jack screw and the lower part of the jack screw before inserting it in the jack nut. Apply C-102 to the threads of the jam nut that holds the handwheel . -20-4) 5 LUBRICATE ITEM 5 WITH LUBRIPLATE 930-AA. MANUAL CLOSER FOR LS-185, 18-205 & 13-206 ACTUATORS FIG, 13, PARTS REFERENCE FOR FIGS. 12° AND 13 in DESCRIPTION Jam Nut. Handwheel dack Screw Relief Fitting Alemite Fitting Weather Shield O-Ring Jack Nut Heavy Hex BOLT O-Ring u O-Ring 12 Thrust Washer 13 O-Ring Bowvanson+[s 2i-Two-Way HANA The top mounted two-way manual opener and closer is used only on the 15-124 piston actuator. The purpose of the two-way manual opener and closer is to manually operate the valve either in the case of an emergency as mentioned in the manual closer section or for any other valid reason that may arise. | Two way manual operators have an instruction plate Item 21, Fig. 18 at the location shown. An example of this instruction plate is shown below in Fig. 14. INSTRUCTIONS FOR AIR OPERATION-MOVE ACTUATOR TO FULL OPEN POSITION TREN TURN HANO WHEEL SO THAT LOWER EDGE OF WEATHER SHIELD {S FLUSH WITH TOP. OF GROOVE IN JACK NUT HOUSING, TO CLOSE MANUALLY —TURN HANDWHEEL CLOCKWISE TO OPEN MANUALLY — TURN HANOWHEEL COUNTER CLOCKWISE Fig. 14 INSTRUCTION PLATE Even though the instruction plate generally shows how to operate the two- way manual opener and closer.. the following_detailed. procedure will help eliminate some of the guesswork. Refer to Figures 15, 16, and 17 when-using this procedure. To close the valve manually when valve is open and handwheel is locked in neutral position, first disengage the locking pin so handwheel will turn, then rotate handwheel in clockwise direction until valve is closed, If the valve is not in the neutral position but Tocked in the open position, disengage the lock- ing pin and rotate clockwise as mentioned before. The difference here is that the handwheel has to be rotated approximately 26 turns clockwise for the jack nut to move up and shoulder on the top of the jack nut housing before the jack screw will start moving down to close the valve. When valve is closed, engage the locking pin. To open the valve manually when valve is closed and handwhee! is locked in the neutral position, first disengage the locking pin so handvheel will turn, then rotate handvheel in counterclockwise direction until valve is open. If the valve is not in the neutral position but locked in the closed position, disen- gage the locking pin and rotate counterclockwise. Again, the handwheel has to be rotated approximately 26 turns counterclockwise for the jack nut to move down and shoulder on the bearing ring before the jack screw will start moving up to open the valve. When valve is open, engage the locking pin. For air operation the handvheel has to be in the neutral position. Rotate hand- wheel counterclockwise until valve is open as discussed in #2 above. After valve is open, rotate handwhee! clockwise and move the weather shield up until the Tow- er edge of the shield is flush with the top of neutral position groove in the Jack nut housing, When valve is in neutral position, engage the locking piHANOWHEEL LocxeD AUD DOES NOT MOVE LOCKING. PIN HANOWHEEL LocKED. AND DOES NOT MOVE LOCKING PIN Loci PIN SS NEUTRAL POSITION GRoove [tert nano acme Ti TWO WAY WITH VALVE CLOSED AND LOCKED CLOSED FIG. 16 -23- “NEUTRAL POSITION GROOVE TWO WAY WITH VALVE FULL OPEN AND Locke OPEN FIG. 15, HANDWHEEL MOVES: UP_AND Down WITT ACTUATOR KING. NEUTRAL POSITION Groove READ. TWO MAY IN NEUTRAL POSITION ACTUATOR IN FULL OPEN Fig. 17INSTALLATION i The two-way manual opener and closer is usually installed at the factory, however, there will be times when it has to be installed in the field. After actuator has been placed in a fully open position be sure all pressure has been bled off the actuator. Refer to Fig. 11 and remove Item 22, cap screws, and take Item 33, cylinder head cover off. Now the actuator is ready for installation of the two-way manual opener and closer. With reference to Fig. 18, rotate the jack screw, Item 6, until the bottom extends far enough. below the bottom flange on Item’ 13, jack nut housing to expose the hole drilled through the flared part of the jack screw Now slip the flared end of the jack screw over the end of the actuator piston rod. Cine up the holes and drive Item 10, roll pin, into the hole. Verify that Item 12, O-ring is in place and then rotate the handvheel until Flange of the jack nut housing contacts head of the actuator and line up bolt holes. Insert Ttens 9 and 14, ferry head cap screws, and tighten evenly all the way around. Set the handwheel in neutral position for air operation by using procedure in Fig. 14. DISASSEMBLY Refer to Fig. 18, two-way manual opener and closer, being sure all pressure has been bled off the piston actuator and there is not any pressure trapped inside of the weather shield (Item 3) by checking to see if Item 4, relief fitting is plugged. After these precautions have been taken, back off the jam nut (Item 1) and remove Item 2,-handiheel. -tlext; remove ferry. head cap screw (Item 14) and take off the locking pin assenbly which consists of Ttem 15, bracket, Item 16, handle, Item 17, roll pin, Item 18, roll pin, Ttem 19, pin and Item 20, spring. The locking pin assenbly need. not be disassembled any further unless there is obvious damage to it. Now slip the weather shield, (Item 3) off and inspect O-ring (Item 7). Replace O-ring if damaged. Relief fitting (Itew4), need not be removed unless it is damaged and has to be replaced. Next, remove the remaining three (3) ferry head cap screws (Item 9) and take the remainder of the handwheet assenbly off the piston actuator by rotating the reminder of the assenbly clockwise until the roll pin (Item 10) is exposed. Drive the roll pin out and lift remainder of assembly off the actuator. Slip bearing ring (Item 11) out of jack nut housing (Item 13) and reaoye O-ring (Item 12). Replace O-ring If dasaged. How slip Jack nut (Item 5) and Jack screw (Item 6) out of jack nut housing (Item 13). Inspect.O-ring (Item 8) and replace if damaged. Separate jack nut (Item 5) and jack screw (Ttem 6) by rotating them in opposite directions tintil they are separated. Remove ail bearings and bearing races (Item 22) from flanged end of jack nut (Item §) and inspect them. If they are crushed or otherwise damaged, be sure and replace them. REASSEMBLY Reassenble the two-way manual opener and closer by reversing the foregoing dis- assembly procedure and making sure the piston actuator is in the full open position. Coat all O-rings, O-ring grooves, inside surface of Weather Shield, outside surface of Jack Nut and the external threads of the Jack Screw with Cubriptate LN123-006. Apply C-102 lubricant to the threads on the Ferry Head Cap Screws before inserting them in the bolt holes. Apply C-102 to the threads for the Jan Nut that holds the handwheel -24-wren Bopvansene TWO-WAY MANUAL OPENER AND CLOSER TWO-WAY WITH VALVE OPEN NEUTRAL POSITION GRoovE 2) AND LOCKED OPEN (HANOWHEEL DOES HOT HOVE) Fic. 18 "ARTS REFERENCE FOR FIG. 18 DESCRIPTION ITEM gam Nut u Handhee! 12 Weather Shield 2B Relief Fitting 14 dack Mut 15 Jack Screw 16 V7 18 Ferry Head Cap Screw (3)- 19 Roll Pin 20 21 2 -25- DESCRIPTION Bearing Ring O-Ring Jack Kut Housing Ferry Head Cap Screw Bracket Handle Roll Pin Roll Pin Locking Pin Spring Drive Screw & Instruction Plate Thrust BearingTWO-WAY. MANUAL NECHAWESH FOR:LS=266_ ACTUATOR [a | Li roma fa i an 4 Fi ih i ni f j d lea FIGURE 20 ig = 1 7 a a eee eerie FIGURE 19 -26-INTRODUCTION The top mounted two-way manual mechanism shown in Fig. 19 is used only on the LS-266 piston actuator. The purpose of the two-way wanual mechanisin is to provide a means of opening or closing the valve in the event actuator supply pressure is lost. The two-way manual mechanism cannot be used to over- ride the actuator. For instance, if the actuator is held closed by supply pressure, the manual mechanism cannot be used to open the actuator without damaging the two-way manual mechanism INSTALLATION Field installation requires that the cylinder actuator be partially dismantled to replace the upper cylinder head. Also, the piping.for the upper cylinder head will have to be replaced. The valve and actuator will have to be in the full open position to perform the two-way manual mechanism installation. __ [CAUTIONS —REROVE-PRESSURT_FROM_THE VALVE AND ACTUATOR BEFORE DISMANTLING j [THE “ACTUATOR. | Exercise the utmost care to insure Safety and cleanliness white working on the actuator. REFER TO FIG. 11 1. Hote position of 1/2 NPT port in top of upper cylinder head. New upper cylinder head 1/2 NPT port will be located in same position as original cylinder head 2. Drain Gas-Over-Oil tank. Remove piping to upper cylinder head. Either remove Gas-Over-0i1 tank or restrain it so that when upper cylinder head is removed, the tank will not fall or bend lower piping 3. Remove nuts () from ytinder studs @ . REFER 10 FIG. 20 4, Install O-ring (2) in upper cylinder head. Lubricate O-ring with Lubriplate Lm123-006. 5. Place upper cylinder head (2) on upper cylinder ©... Position 1/2 NPT port in same position as original cylinder head. 6. Replace all cylinder stud nuts @ ‘including those needed to mount Gas-Over-Oi1 tank. Torque nuts to 120 ft Tbs. 7. Serew rod connector (5) onto 2-8UN threaded end of piston rod until drilled hole in connector is aligned with slot in upper end of piston rod and assembly dimension [1 is obtained. 8. Instal1 lower drive stem pin (6) to retain rod connector to piston rod. 9. Screw drive stem ® into rod connector until slot in 2-UN threaded end of drive stem is aTigned with upper hole in rod connector and assenbly dimension L2 is obtained. Check that Keyway in upper portion of drive stem is Tocated on the same side of the actuator as the handwheel or within 4-1/2 cyl stud hole spacings from 1/2 NPT upper air connection. (Dirension L2 may have to be adjusted by 1/2 stem turn to correctly locate drive stem keyway.) -27-10. un. 12. 13. M4. 15. 16. Ww. 18. 19. 20. 2. 22. Install upper drive stem pin (6) to retain drive stem to rod connector. Install O-rings on rod seal upper and Tower flanges Install rod seal (8) with 1/2-13UNC studs and nuts Install adapter spool (9) with 7/8-9UNC studs and auts. Locate T/16 diameter dowel pin holes on centerline of valve bore. REFER TO FIG. 21. saa gear box adapter assembly in ie following ee Install] wiper ring, one thrust bearing » drive nut » second thrust bearing » then bearing retainer Bearing retainer should be made up tYght with spanner wrench. Spanner holes are 1/2" diameter, between centers. Complete sub-assembly by installing lube fitting and relief fitting © 12" Install tapered end of 7/16 diameter dowel pins into top of adapter spool. Install 7/8-9UNC studs in upper flange of adapter spool Install gear box adapter assembly. Locate with dowel pin pilot holes and position lube fitting over preferred pressure end of valve. Install drive nut key i Place gear box (12) on adapter ® with key engaged in gear box keyway. Locate gear box on adapter with handwheel shaft located over upper air connection (1/2 NPT port) in upper cylinder head. Secure gear box with 1/2-13UNC cap screws. REFER TO FIG. 22. Lubricate drive sleeve » Acme thread, and drive stem keyway with Molykote "G" paste. Then position drive steeve onto drive stem @0 and screw sleeve into drive nut ® until key seat in drive sleeve is aligned with keyway in drive stém Install] drive sleeve key » retainer plate @2 (with red stripe visible and located toward top end), and retainer screws i Continue threading drive sleeve until steeve bottoms on drive stem. (Handwheel may be used to drive sleeve to bottom position.) Install cover gasket » plexiglas cov indicator plates 6) coe sree Sta Wanton vate @ © sens Wrear os weather protectar nipple G0) Install 1-3/8-8UN heavy hex nut G1) to drive stem and tighten to assembly dimension L3 after applying Loctite 262 to male thread. 2823. 24. 25. Screw weather protector sub-assembly over drive stem and drive sleeve and into 4x3 NPI hex bustring* G2) installed in upper portion of gear operator. Tighten until red st¥ipe is clearly visible thru plexiglas cover plate. Adjust indicator plates to closely bracket red stripe for neutral position indication. REFER 10 FIG. 21. washer G@) , and cap screw @ Complete assemble by installing new upper cylinder head to Gas-Over- Oil tank piping, Refit] tank per instructions given in Fig. 2 Install handwheel *Some model gear operators do not require a bushing. -29-PREF PRES END OF VALVE, sores D1) aercy coe were ee @® 2 a7Pc¥_Lm123-006 10 o- RINGS AND SURFACES INDICATED, © 2) aoc vocrse 262 Assenace sruo wiry staring UP Aeraoe 0 re. Man) Te? FON a us eH SEARO o Near tives {oO Ee Or, aKa | ‘ . aly ee nenanelih @o-nne 6-200 OF seshed ever gue nto con FIGURE 20 30. SERRATE oN S52696) Se 4-N/e 78 @ conve sreu rts} © oO e1sT0n ROD‘onp scnew y2 «2-1/4 (0) ‘Tonave TO 60 Ft. t86. % — Bee sce (ela none 26-40] @eean ovenaron: | Le wasnen@), ! bg ore sone @onive nur Kev 4 7, q GHeCEt| ; tl I" Hl ‘cPaste © wren eng— OnIVE NUT (2-4/4 =4 REME 26-48} — @ sone -neust oec.cr] | @ aes @azennre cuve evens rir Lune ie DOWEL Pus (21 @ ‘VE He ORE: Gers S135/8 xy tetaner® ores ® 1) mvrty ¢-102 HI-TEHP LUBE. @) 2) APPLY LM1Z3-006 TO O-RINGS AND SURFACES INDICATED, ® 2) avnvy coctrte 262 WIPER FING (REF) DETAIL A FIGURE 21 -31-srmucrion PLATE @9 _—]—Rep strive Locates NEUTRAL POSITION ce oe ® suet wipe WA (wearer -areon a eet / DRIVE STEM(29) DRIVE STEM KEYWAY (APPLY MOLYKOTE. 6 a] Paste) |-wotcaron PLates (2) @) cover sorews (41) ~ pLexicuass cover o-—~ @Q4x3 ner wex ousnine @ NOTES: @ 1) APPLY LUBRIPLATE 930-AA. @ 2) APPLY LOCTITE 262. |—COVER GASKET @ —oRIve SLEEVE KEY @) |-neranen pare @® retainer screws (2@ onIve steeve FIGURE 22 32VISUAL POSITION INDICATOR INTRODUCTION Every current production cylinder actuator has a visual position indicator rod located on the lower cylinder head that is directly connected to the lower piston An open and closed position bracket is also affixed to the lower cylinder head flange. The open and closed position plates are adjusted at the factory to correctly indicate actuator/valve position. Subsequent adjustments of the open position plate should not be necessary. However, when valve or actuator repairs are performed it may be necessary to readjust the closed position plate. APPLY LOCTITE 262 TO THREADS LOWER PISTON ATTACHING FITTING ROLL PIN ZZ HPOSITION INDICATOR ROD LOWER CYLINDER HEAD NOTE O-RING WITH PISTONS DOWN, TORQUE VPI ROD ASSEMBLY INTO ‘PISTON oe TO 40 TH LBS. PISTON HST HOSE CLAMP BE ALIGNED WITH 1"-12. RO IN LOWER CYLINDER HEAD, SEE fon oe STEP 13, PAGE “16. SET SCREW (2) ROD COLLAR (ROD BOOT FLUSH WITH END OF ROD COLLAR) POINTER CLAMP SCREW (4 REQUIRED) POSITION PLATE (OPEN, CLOSED) INDICATOR BRACKET FIGURE 23 33MICRO SWITCH INTRODUCTION ‘The Type CK Micro Switch is a weather tight, explosion proof limit switch with two or four circuits. Open, closed and intermediate positions of the valve can be indicated by adjusting cams on the shaft SETTING OF CX MICRO SWITCH Unscrew cover. Refer to Figure 24. To set "open" position switch, actuator must be in open position and switch actuating arm must be engaged with arm guide. Any or all of the switches in the housing may be set to actuate at the open position. Cam adjustment: lift cam follower and move cam wheel axially to dis- engage teeth on wheel from teeth on shaft disc. Turncam wheel and position so that pointer on cam follower lines up with symbol on the cam wheel. In this position switch will be tripped. Release cam wheel to engage with mating shaft disc and then release cam follower . To set "closed" position switch, actuator must be in closed position and switching actuating arm must be engaged with arm guide. Repeat cam adjustment procedure. CAM FOLLOWER 3E ‘CAM WHEEL MATING SHAFT DISC peaciewtch Fig, 24 CX MICROSWITCH -34-FIELD INSTALL Although the cylinder actuator is factory equipped with a visual position indicator (VPI) per Fig. 23, field installation of the CX Micro Switch will require partially disassenbling the vistial position indicator. See Step 5 below 1. REFER TO FIG. 25. Instat] mounting bracket (1) with cylinder actuator mounting botts (2) as shown, Note location of mounting bracket in respect to visual position indicator. 2. Attach CX Micro Switch (@) to mounting bracket (2) with four (4) 1/4-20 Hex Bolts and Nuts (4). # 3. Assemble arm clamp () and actuating arm (6) on Micro Switch @). Use Loctite 262 on both screws (7). 4. Attach actuating arm guide (8) to actuating clamp @) with shoulder screw @Q. Use Loctite 262 on screw. 5. REFER TO FIG. 23. Remove pointer clamp. Push rod boot away from rod collar to expose set screws (2). Loosen set screws and remove rod collar. 6. Again, REFER TO FIG. 25. To properly align actuating clamp on VPI rod, slide actuator arm guide (8) onto actuator arm (G) and then Fit actuating clamp (9) on VPI rod. Apply Loctite 262 to set screws ({i), thread into actuating clamp @, and tighten against VPI rod 8. Replace rod boot (2) and pointer clamp (3). Note assembly dimensions. 9. Adjust the open and closed position plates (14) to agree with actuator positions. Adjust Micro Switch per instructYons for Fig. 23. -36-Qroregrg sturarne -O ny ae cae A svver vocrite 262 FIGURE 25 MICRO _SWITCH INSTALLATION ON LOWER CYLINDER HEAD 236PARTS REFERENCE FOR FIGURE 25. Item 1, Switch Mounting Bracket 2, Actuator Hounting Bolts (6 for LS-124, 8 for LS-185, 205, 206, and 266) 3. CX Micro switch 4. Hex Bolt and Huts (4) 5. Arm Clamp 6. Actuating Arm Sereus (2) Actuating Arm Guide 9. Actuating Clamp 10. Shoulder Screw Ll. Set Screws (2) 12. Rod Boot 13. Pointer Clamp uM, Position Plates (2) -37-