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Air Torque AT045U Mounting And Operating Instructions

4th generation pneumatic actuator
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EB AT-RP-4GU EN
Original instructions
4th Generation Upgrade Series
Rack&Pinion actuators
AT045U → AT801U models
Edition November 2020

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Summary of Contents for Air Torque AT045U

  • Page 1 EB AT-RP-4GU EN Original instructions 4th Generation Upgrade Series Rack&Pinion actuators AT045U → AT801U models Edition November 2020...
  • Page 2 Note on these mounting and operating instructions These mounting and operating instructions assist you in mounting and operating the device safely. The instructions are binding for handling AIR TORQUE devices. The images shown in these instructions are for illustration purposes only. The actual product may vary.

  • Page 3: Table Of Contents

    Contents Safety instructions and measures ......................... 1-1 Notes on possible severe personal injury ....................... 1-2 Notes on possible personal injury ......................... 1-2 Notes on possible property damage ......................1-2 Markings on the device ..........................2-1 Actuator nameplate sample .......................... 2-1 Design and principle of operation ........................
  • Page 4 EB AT-RP-4GU EN...

  • Page 5: Safety Instructions And Measures

    AIR TORQUE actuators: ted. − Protective gloves and safety footwear when mounting or Î Refer to the SIL Certificate available from AIR TORQUE for removing the actuator. the 4th Generation Upgrade Series actuators SIL capabili- − Eye protection and hearing protection while the actuator is operating.

  • Page 6: Notes On Possible Severe Personal Injury

    Î Refer to the EU Declaration of Conformity available from AIR TORQUE. Risk of personal injury during actuator air exhaust. − The AIR TORQUE actuators are in compliance with the TR In case of pneumatic version the actuator is operated with air. CU 10/2011 and TR CU 12/2011.
  • Page 7 Risk of actuator damage due to the use of unsuitable lubri- cants. The lubricants to be used depend on the actuator material and operating temperatures. Unsuitable lubricants may corrode and damage the components. Î Use only lubricants approved by AIR TORQUE . Refer to section 15.3 ‘Lubricants‘. EB AT-RP-4GU EN...
  • Page 8 Safety instructions and measures EB AT-RP-4GU EN...

  • Page 9: Markings On The Device

    Markings on the device 2 Markings on the device 2.1 Actuator nameplate sample ATEX 2014/34/EU: n° INERIS-EQEN 034870/19 II 2 G Ex h IIC T6...T5 Gb X II 2 D Ex h IIIC T85°C...T95°C Db X www.airtorque.de Model / Type: IEC 61508: AT451U D A SIL 3 - Capable...
  • Page 10 Markings on the device EB AT-RP-4GU EN...

  • Page 11: Design And Principle Of Operation

    (A and B). angle, with travel stop allowing adjustment (Fig. 3-3) for -5° up to +15° on the close position and for +5° up to -15° on the open position. For AT045U stroke adjustment is only available on request. Available stroke 90°...

  • Page 12: Complementary/Accessory Parts

    Î More informations are available in the actuator model in case of any emergency situation. The actuator and the technical data sheet available from AIR TORQUE. valve are operated rotating a handwheel. (Fig. 3-4) Power operating media Î...

  • Page 13: Shipment And On-Site Tranport

    The actuator can be transported using proper lifting equip- 2. Check the shipment for transportation damage. Report ment (e.g. crane or forklift). any damage to AIR TORQUE and the forwarding agent Î Leave the actuator in its transport container or on the pal- (refer to delivery note).

  • Page 14: Storing The Actuator

    Î Observe the storage instructions. Î Observe the rubber components storage instructions (T 3.3.3.1 EN). Î Avoid long storage times. Contact AIR TORQUE in case of different storage conditions or long storage periods. Note It is recommended to regularly check the actuator and the pre- vailing storage conditions during long storage times.

  • Page 15: Mounting And Assembly

    GU Series actuators can be controlled by by inserting objects into the actuator. directly mounted devices or remote control systems. Therefore AIR TORQUE actuators have direct mounting interfaces (Fig. 5-1) in order to allow control and signal devices assembly WARNING (e.g.
  • Page 16 Mounting and assembly − When fitting accessories over the actuators, assemble Before mounting the actuator over the valve, make sure the following conditions are met: them in such a way that the emergency controls are easily accessible for emergency manual operation. −...
  • Page 17 Mounting and assembly 6. Place the bracket, if any, over the valve flange, tighten all bolts and nuts and apply the correct tightening torque. 7. Assemble the coupling at first into the valve stem before the assembly of the actuator. 8.
  • Page 18 Mounting and assembly EB AT-RP-4GU EN...

  • Page 19: Start-Up

    Start-up 6 Start-up The work described in this section is only to be performed by fully trained and qualified personnel. WARNING Risk of personal injury during actuator air exhaust. In case of pneumatic version the actuator is operated with air. As a result, air is exhausted during operation.
  • Page 20 Start-up EB AT-RP-4GU EN...

  • Page 21: Operation

    Operation reduced supply pressure (e.g. “Max. supply pressure limi- 7 Operation ted to ... bar“). The work described in this section is only to be performed by fully trained and qualified personnel. WARNING Risk of personal injury during actuator air exhaust. In case of pneumatic version the actuator is operated with air.
  • Page 22 Operation EB AT-RP-4GU EN...

  • Page 23: Malfunctions

    In case of actuator mounted over the valve, check the valve documentation Faulty valve and contact the manufacturer. Note Contact AIR TORQUE after-sales service ( @airtorque. ) for malfunctions not listed in the table. 8.2 Emergency action The plant operator is responsible for emergency action to be taken in the plant.
  • Page 24 Malfunctions EB AT-RP-4GU EN...

  • Page 25: Service

    3. Remove the actuator from the valve referring to section 11 prior agreement by AIR TORQUE‘s After-sales Service. ‘Removal‘. − Only use original spare parts by AIR TORQUE, which com- ply with the original speci cations. EB AT-RP-4GU EN...

  • Page 26: Part List

    19.6 19.2 60.1 Fig. 9-1 Table 9-2 PART N° UNIT Q.TY NOTE DESCRIPTION N.A. for AT045U OCTI-CAM (Stop arrangement) N.A. for AT045U STOP CAP SCREW N.A. for AT045U WASHER for models with extra travel stop adjustment WASHER N.A. for AT045U...
  • Page 27 Components included in spare part kits are indicated as follows: ◊ included in complete spare parts kit • included in o-rings kit 2) 8 for AT045U ÷ AT101U; 12 for AT701U ÷ AT751U; 16 pcs for AT801U 3) Available on request. EB AT-RP-4GU EN...

  • Page 28: Disassembly

    Service 9.3 Disassembly 9.3.2 Stop cap screws removal Î Refer to the Fig. 9-1 and Table 9-2 for parts list. Note In case of special actuators functions / features (R&P) refer to the corresponding instructions: - Fail mid “FM“ → EB AT-RP-4GU-FM, - 180°...
  • Page 29 DISASSEMBLY: dicated in Table 9-3, the spring cartridge may have been PER ACTUATOR: damaged or the pistons are not completely closed: stop the disassembly and contact AIR TORQUE. Table 9-3 − 8 ACTUATOR MODEL NUMBER OF TURNS FOR SCREWS (13) AT045U 16 ÷18 turns...

  • Page 30: Service Operations

    Î In case of spiral spring clip (18) refer to the disassembly - 180° SR → EB AT-RP-4GU-180SR, and reassembly instructions available from AIR TORQUE. - HCD → EB AT-RP-4GU-HCD, − Remove the spring clip (18) by means of snap-ring pliers - 3P / 3PD →...
  • Page 31 Risk of actuator damage due to the use of unsuitable lubri- cants. The lubricants to be used depend on the actuator material and operating temperatures. Î Only use lubricants approved by AIR TORQUE. Refer to section 15.3 ‘Lubricants‘. 9.5.1 Drive shaft reassembly Refer to Fig.
  • Page 32 0° up to 5°, for models AT051U to AT801U – strictly about over 0° up to 0.5° for model AT045U. − With pistons completely closed (0° position) as per Fig. 9-15 the dimension “A“ must be the same on both sides...
  • Page 33 Service Side B Side A models AT101U to AT801U Fig. 9-17 Side A Table 9-4 SPRING TYPE FOR MODELS AT045U Spring set Side B Side A S1-1 1 (green) 1 (green) S1-2 1 (green) 2 (red) S2-2 2 (red) 2 (red)
  • Page 34 Service TOTAL QUANTITY OF SEQUENCE OF CAP SCREWS (13) ASSEMBLY: PER ACTUATOR: − 8 Fig. 9-23 − 12 9.5.5 Stop cap screws reassembly Refer to Fig. 9-1 and Fig. 9-24. − Insert onto both stop screws (02), the nut (04), the washer (03) and the o-ring (11).
  • Page 35 Service − Holding the stop screw (02) in position, tighten the stop adjustment nut (04) to lock the stop screw (02). Î Refer to the section 15.2 ‘Tightening torques‘. (Table 15.3) Open position − With the actuator in open position (90° position), screw or unscrew the left stop screw (02) 1 turn at a time until the desired stop position is achieved.

  • Page 36: Decommissioning

    Decomissioning To decommission the actuator for service work or before re- 10 Decomissioning moving it from the valve, proceed as follows: The work described in this section is only to be performed by 1. Put the valve and its accessories out of operation in a safe fully trained and qualified personnel.
  • Page 37 Decomissioning 10-2 EB AT-RP-4GU EN...

  • Page 38: Removal

    Removal 11 Removal WARNING Risk of personal injury due to preloaded and compressed The work described in this section is only to be performed by springs. fully trained and qualified personnel only. End caps are under tension due to compressed springs. Before removing from the valve, make sure the actuator is put Furthermore incorrect spring cartidges disassembly could re- out of operation.
  • Page 39 Removal Proceed as follows to remove the actuator from the valve re- ferring to Fig. 11-1, making sure to not expose the plant to any risk: 1. Disconnect any electrical/pneumatic/hydraulic power supply from the actuators and make sure the actuator itself is depressurized.

  • Page 40: Repairs

    NOTICE Risk of actuator damage due to incorrect repair work. Î Do not perform any repair work on your own. Î Contact AIR TORQUE after-sales service @airtorque. ) for repair work. EB AT-RP-4GU EN 12-1...
  • Page 41 Repairs 12-2 EB AT-RP-4GU EN...

  • Page 42: Disposal

    Disposal 13 Disposal At the end of their life cycle AIR TORQUE actuators can be completely disassembled and disposed sorting the compo- nents by the different materials. Î Observe local, national and international refuse regula- tions. All materials have been selected in order to ensure minimal...
  • Page 43 Disposal 13-2 EB AT-RP-4GU EN...

  • Page 44: Certificates

    Certificates 14 Certificates The following certificates and documents are available from AIR TORQUE: − EU Declaration of Conformity (page 14-2), − ATEX Directive 2014/34/EU, − SIL Certificate, − Machine Directive 2006/42/EC, − DNV Type Approval − IP67 and IP68 Degree of protection, −...
  • Page 45 14-2 EB AT-RP-4GU EN...

  • Page 46: Annex

    − TORQUE WRENCH − ALLEN KEY − SCREWDRIVER Fig. 15-1 15.1.2 Tools dimensions − Stop screws (02) and nuts (04); end cap screws (13). ACTUATOR MODEL Ch 1 (mm) Ch 2 (mm) AT045U AT051U AT101U AT201U AT251U AT301U AT351U AT401U AT451U...
  • Page 47 Annex − Extra travel stop adjustment screws tools (50% and 100% adjustment) Ch 4 ACTUATOR 221G/222G MODEL TYPE Ch 3 (mm) Ch 4 (mm) AT051U AT101U AT201U AT251U AT301U AT351U − Type A Ch 3 AT401U AT451U AT501U AT551U 221G 222G AT601U AT651U...

  • Page 48: Tightening Torque

    Table 15-1: End cap screws (13) Table 15-2: Extra travel stop adjustment nuts (04R) ACTUATOR MODEL THREAD TIGHTENING TORQUE (Nm) ACTUATOR MODEL THREAD TIGHTENING TORQUE (Nm) AT045U AT051U 4 ÷ 5 8 ÷ 9 AT051U AT101U AT101U AT201U 18 ÷ 20 AT201U 7 ÷...

  • Page 49: Lubricants

    Annex Table 15-5: Ancillary attachments SIZE THREAD TIGHTENING TORQUE (Nm) AA 0 AA 1 AA 2 4 ÷ 5 AA 3 AA 4 AA 5 8 ÷ 9 NOTE: 1. Refer to section 2.1 ‘Actuator nameplate sample‘. 15.3 Lubricants The 4 GU actuators are factory lubricated for the life of the actuator in normal working conditions.
  • Page 50 Annex EB AT-RP-4GU EN 15-5...
  • Page 51 15-6 EB AT-RP-4GU EN...
  • Page 52 EB AT-RP-4GU EN 15-7...
  • Page 53 EB AT-RP-4GU EN Air Torque GmbH Im Katzentach 16-18 • DE-76275 Ettlingen Tel. +49 (0)7243 5934-0 • Fax +49 (0)7243 5934-34 info@airtorque.de • www.airtorque.de...

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