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Summary of Contents for Air Torque AT1001U
- Page 1 EB AT-RP-X01 EN 4th Generation Upgrade Series → AT1001U Power Technology Upgrade Series → PT1000 U Rack&Pinion actuators 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.
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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-X01 EN...
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Page 5: Safety Instructions And Measures
AIR TORQUE actuators: − AIR TORQUE actuators are SIL certificated. − Protective gloves and safety footwear when mounting or Ë Refer to the SIL Certificate available from AIR TORQUE for removing the actuator. the actuators SIL capability. -
Page 6: Notes On Possible Severe Personal Injury
Ë Make sure that the actuator is in the closed position (0°) AIR TORQUE. while disassembling the end caps and the stop screws ha- − The AIR TORQUE actuators are in compliance with the TR ve been correctly removed. CU 10/2011 and TR CU 12/2011. - Page 7 Safety instructions and measures Risk of actuator damage due to incorrectly attached slings. Ë Do not attach load-bearing slings to the travel stop. EB AT-RP-X01 EN...
- Page 8 Safety instructions and measures EB AT-RP-X01 EN...
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Page 9: Markings On The Device
Markings on the device 2 Markings on the device 2.1 Actuator nameplate sample a) 4th Generation Upgrade series K048':);*/7*/4+3 1'654567/4945')7*(0)/;4 66':'2'4#'&'66''0($$$09'2)'8 66':','4#'&'666''0(91'$$$0491'',)'8 www.airtorque.de !!!"# ** 6!!'*3!" 64''(;9)(3 !+,-.'/'012-3 766'7'/''"2").- + ),+,-,+-*.0.--/' 45'678'9:;;3 7-*$".'5&%)-*3 ,******* 82-*"<$ !'"*-##$3 !"#$%&%'(')"* 4)1'5+<"<$+ '/'K770 !"#$'5% !$ $'5% !"#$%&'()'*+,'-(# 22-2... - Page 10 Markings on the device b) Power Technology Upgrade series K048':);*/7*/4+3 1'654567/4945')7*(0)/;4 66':'2'4#'&'66''0($$$09'2)'8 www.airtorque de 66':','4#'&'666''0(91'$$$0491'',)'8 !+,-.'/'012-3 !!!## ***! !&*3!( 64''(;9)(3 766'7'/''"2").- + ),+%&,+-*.*.&&/, 45'678'9:;;3 7-*$".'5&%)-*3 %******* !"#$%&%'(')"* 82-*"<$ !'"*-##$3 4)1'5+<"<$+ '/'K770 !"#$'5% !$ $'5% 34567809:0-;&0<95 --&- -*& =>859:?!"038B>%D /*)1''<+'.()1' .!&?FF95G0.::9&'%D ..&...
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Page 11: Design And Principle Of Operation
3 Design and principle of operation − direct mounting of control devices (for example a solenoid The AIR TORQUE rack and pinion actuators are devices for valve or a manifold) with NAMUR interface, remote operation (on/off or modulating duties) of different in- −... -
Page 12: Complementary/Accessory Parts
Ë More informations are available in the actuator model in the safe position when the supply pressure is not available 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 Ë... -
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 Ë Leave the actuator in its transport container or on the pal- (refer to delivery note). -
Page 14: Storing The Actuator
Ë Observe the storage instructions. Ë Observe the rubber components storage instructions (T 3.3.3.1 EN). Ë 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
5.2 Control and signal devices assembly pressure from the actuator. Ë Do not impede the movement of the pinion and the pistons The AIR TORQUE actuators can be controlled by directly by inserting objects into the actuator. mounted devices or remote control systems. Therefore AIR TORQUE actuators have direct mounting interfaces (Fig. - 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-X01 EN...
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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-X01 EN...
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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-X01 EN...
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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-X01 EN...
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Page 25: Service
− The product warranty becomes void if service or repair ‘Removal‘. work not described in these instructions is performed without prior agreement by AIR TORQUE‘s After-sales Service. − Only use original spare parts by AIR TORQUE, which com- ply with the original speci cations. EB AT-RP-X01 EN... -
Page 26: Part List
Service 9.2 Part list 19.2 60.1 19.1 19.0 02.1 221G 222G 09.1 19.6 19.5 60.1 13.1 11F* Fig. 9-1 EB AT-RP-X01 EN... - Page 27 Service Table 9-2 UNIT Q.TY NOTE DESCRIPTION PART N° OCTI-CAM (Stop arrangement) ANTI BLOW-OUT STOP CAP SCREW 02.1 SPRING CLIP (Stop screws) WASHER (Anti blow-out stop cap screw) WASHER (External cap screw) for special “R“ construction models WASHER (Internal cap screw) for models with extra travel stop adjustment WASHER (Extra travel Stop adjustment screw) NUT (Stop screw)
- Page 28 Service PART N° UNIT Q.TY NOTE DESCRIPTION BODY DRIVE SHAFT 60.1 INTEGRAL DRIVE SHAFT 221G for models with 50% extra travel stop adj. STOP SCREW (extra travel Stop adjustment) 222G for models with 100% extra travel stop adj. STOP SCREW (extra travel Stop adjustment) NOTES: 1) * Suggested spare parts.
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Page 29: Disassembly
Service − unscrew partially the stop screw (221G/222G/24) out 9.3 Disassembly from the actuator, making sure that the stop screw (221G/222G/24) is not in contact anymore with the pis- WARNING ton assembly. Risk of personal injury due to unsuitable workbench and in- correct handling. - Page 30 Ë In case of spiral spring clip (18) refer to the disassembly Ë If there is still force on the end cap (30/30R/32) after and reassembly instructions available from AIR TORQUE. uscrewing the end cap screws (13) for 4/5 turns the spring cartridge may have been damaged or the pistons are not −...
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Page 31: Service Operations
(20). The lubricants to be used depend on the actuator material and operating temperatures. Ë Only use lubricants approved by AIR TORQUE. Refer to section 15.3 ‘Lubricants‘. 9.5.1 Drive shaft reassembly Refer to Fig. 9-1, Fig. 9-9, Fig. 9-10 and Fig. 9-11. - Page 32 Ë In case of spiral spring clip (18) refer to the disassembly and reassembly instructions available from AIR TORQUE. − Place the spring clip (18) by means of by means of snap- ring pliers or a screwdriver for spiral rings.
- Page 33 Service 9.5.3 End caps reassembly WARNING Risk of personal injury due to unsuitable workbench and in- correct handling. Heavy components can cause personal injuries and or get da- maged if not handled carefully. Ë Operate in a safe area on a workbench suitable for the actuator size and weight.
- Page 34 Service Ë Assemble the end caps as shown in Fig. 9-21 keeping a constant distance (A = B) between the actuator body and the end cap interface. 09.1 Ë Observe the speci ed sequence shown in Fig. 9-22. A = B Fig.
- Page 35 Service Open position 9.5.5 Stop cap screws reassembly − With the actuator in open position (90° position), screw or Refer to Fig. 9-1, Fig. 9-24 and Fig. 9-25. unscrew the left stop screw (02) 1 turn at a time until the −...
- Page 36 Service 9-12 EB AT-RP-X01 EN...
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Page 37: 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 38 Decomissioning 10-2 EB AT-RP-X01 EN...
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Page 39: Removal
Removal 11 Removal WARNING The work described in this section is only to be performed by Risk of personal injury due to preloaded and compressed fully trained and qualified personnel only. springs. 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 40 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.
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Page 41: Repairs
NOTICE Risk of actuator damage due to incorrect repair work. Ë Do not perform any repair work on your own. Ë Contact AIR TORQUE after-sales service @airtorque. ) for repair work. EB AT-RP-X01 EN 12-1... - Page 42 Repairs 12-2 EB AT-RP-X01 EN...
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Page 43: 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. Ë Observe local, national and international refuse regula- tions. All materials have been selected in order to ensure minimal... - Page 44 Disposal 13-2 EB AT-RP-X01 EN...
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Page 45: Certificates
Certificates 14 Certificates The following certificates and documents are available from AIR TORQUE: − EU Declaration of Conformity, − ATEX Directive 2014/34/EU, − SIL Certificate, − Machine Directive 2006/42/EC, − DNV Type Approval − IP67 and IP68 Degree of protection, −... - Page 46 14-2 EB AT-RP-X01 EN...
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Page 47: Annex
Annex 15 Annex 15.1 Tools 15.1.1 Tools list − WRENCH − CIRCLIP PLIER − TORQUE WRENCH − ALLEN KEY − SCREWDRIVER Fig. 15-1 15.1.2 Tools dimensions − Stop screws (02) and nuts (04); end cap screws (13). Ch 1 (mm) Ch 2 (mm) Ch 3 (mm) Fig. - Page 48 Annex − Extra travel stop adjustment screws tools (50% and 100% adjustment). Ch 5 221G/222G Ch 4 (mm) Ch 5 (mm) 221G 222G Ch 4 Fig. 15-3 − Special “R“ construction. Ch 9 Ch 7 Ch 6 Ch 10 Ch 6 (mm) Ch 7 (mm) Ch 8 (mm) Ch 9 (mm)
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Page 49: Tightening Torque
Annex 15.2 Tightening torques − All the tightening torques are intended in Nm. − Tightening torque tolerance: ±10%. − The tightening torques are based on a friction coefficient of 0.12 with a lubricated fixing elements (bolts or nuts) threads. − After long operating times or use at temperatures above 80°C, the breakaway torque may be significantly higher. Table 15-1: End cap screws (13) or nuts (13.2) Table 15-2: Extra travel stop adjustment nuts (04R) THREAD... -
Page 50: Lubricants
Annex 15.3 Lubricants The AIR TORQUE actuators are factory lubricated for the life of the actuator in normal working conditions. Ë Refer to the data sheet [U00501E] for Lubricant type in re- lation to the different working temperature ranges. 15-4... - Page 51 EB AT-RP-X01 EN 15-5...
- Page 52 EB AT-RP-X01 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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