Summary of Contents for Proval A210 Series
- Page 1 Installation, Operation and Maintenance Manual PROVAL A210-211-212-213-Series Rack and Pinion Pneumatic Actuators...
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Page 2: Table Of Contents
d> /KD E Table of Contents Section 1: Before You Start Installation, Operation and Maintenance Reference Documents ...... 1 Warehouse Storage ......................... 1 On-Site Storage ......................... 2 Section 2: Introduction Identification .......................... 3 Intended Use ..........................4 Specifications ........................4 Section 3: Product Code Configuration code for a default actuator .............. - Page 3 d> /KD E Section 7: Decommission (Out of Service) Before You Start ....................... 22 Removing the actuator from the valve ..............23 Section 8: Disassembly Removing End Caps......................25 Removing Spring Cartridges (Spring-Return) ............. 26 Removing of Limit Stop ..................... 27 Removing Pistons ......................
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Page 4: Section 1: Before You Start
d> /KD E Section 1: Before You Start This section explains: • Base safety procedures • Where to find detailed information relating safety. • Storage guidelines. Installation, adjustment, putting into service, use, assembly, disassembly and maintenance of the pneumatic actuator must be performed by qualified personnel. Failure to follow the above guidelines will void warranty. -
Page 5: On-Site Storage
d> /KD E On-Site Storage • All actuators should be stored in a clean, dry warehouse, free from excessive vibration and rapid temperature changes. • Prevent moisture or dirt from entering the actuator. Plug or seal both air connection ports. EKd/ Failure to follow the above guidelines (Warehouse and On Site Storages) will void warranty. -
Page 6: Section 2: Introduction
d> /KD E Section 2: Introduction This section explains: • How to identify the received product, • The intended use of the product • Construction details • Actuator specifications Identification The A210-211-212-213 Series Rack and Pinion actuators are available as double-acting or spring-return versions. -
Page 7: Intended Use
d> /KD E Intended Use The A210-211-212-213 Series Rack and Pinion actuators are intended for the automation and operation of quarter-turn valves like Butterfly, Ball and Plug valves. Rack and Pinion actuators can also be used to operate dampers or any other quarter-turn applications. - Page 8 A. through port B. The Proval actuators typically operate counter clockwise to open and clockwise to close. The direction of pinion rotation (CCW to CW) can be reversed changing the orientation of pistons as shown in the picture above.
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Page 9: Section 3: Product Code
d> /KD E Section 3: Product Code This section explains: • How to create the configuration code for a default actuator. • How to create the configuration code for an actuator with added integral options. ' , t E End-Cap Color Body Finish Seal Material... -
Page 10: Section 4: Installation
d> /KD E Body / End-Cap Finish RAL.9005 Piano Black RAL.9010 Glossy White RAL.9005 Matte Black RAL.1006 Glossy Yellow RAL.2004 Glossy Orange RAL.9006 Glossy Dark Gray RAL.7035 Glossy Light Gray White Anodized RAL.3000 Glossy Red Black Anodized RAL.6026 Glossy Green PTFE RAL.5005 Glossy Blue AISI304 Stainless Steel... -
Page 11: Position After Failure
d> /KD E Position After Failure The position of the actuator after a failure depends on the: Principle of operation (see paragraph 4.3) Assembly codes (see paragraph 4.4) Kind of failure. Refer to the table below. Table 5. Position After Failure &... -
Page 12: Ingress Protection (Ip) Rating
d> /KD E The table below represents the cycle time (operating time) per different Actuator sizes: Table 6. Operating Speed Cycle time in seconds Spring-Return(12springs) Double-Acting Actuator 0°-90° 90 ° -0 ° 0°-90° 90°-0° size PA32 PA40 0.55 0.47 PA52 2.66 0.44 0.53... -
Page 13: Double-Acting Actuators
d> /KD E Double-Acting Actuators The operating principle, as explained here, is applicable for actuators with assembly code W (direct acting). • Applying supply pressure to port A will move the pistons outward to the "Open" position of the valve. •... -
Page 14: Spring-Return Actuators
d> /KD E Spring-Return Actuators The operating principle, as explained here, is applicable for actuators with assembly code C (direct acting). • Applying supply pressure to port A will move the pistons outwards to the "Open" position of the valve. •... -
Page 15: Actuator Assembly Codes
d> /KD E Actuator Assembly Codes Figure 7 Assembly Code - Double-Acting Assembly code: W Assembly code: C = Standard, Counterclockwise-to-Open = Reverse, Clockwise-to-Open = Fail-to-Close = Fail-to-Open Pinion Pinion Pistons Pistons A = Rotation when central air chamber is pressurized. B = Rotation when end cap air chambers are pressurized. -
Page 16: Actuator To Valve Installation
d> /KD E Actuator to Valve Installation Actuator must be isolated pneumatically and electrically before any (dis)assembly starts. Stay away from moving parts to prevent serious injuries. When test cycling the actuator and valve assembly by applying pressure to the A or B port, be aware that there are moving parts like pinion top, actuator to valve coupling and the valve- blade, ball, plug, etc. - Page 17 d> /KD E When required, check if the insert drive (23) is mounted. If not, use a plastic mallet and tap slightly until the reducer square is in the required position. Be sure that the insert is mounted at 90° or 45°. It is possible to mount the insert turned 22.5°.
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Page 18: Mounting Of Control And Feedback Accessories
d> /KD E Install the actuator to the bracket. Tighten all bolts and apply the correct torque (refer to Table 8). Table 8. Bottom flange torque values Torque (Nm) Torque (lbf.ft) Actuator Size ISO Pattern Thread Min. Max. Thread Min. Max. -
Page 19: Recommended Tubing Sizes
d> /KD E Recommended Tubing Sizes In case the solenoid valve is mounted remotely (i.e. in a central solenoid cabinet) and in order to supply sufficient flow of air supply to the actuator, the following tubing sizes are recommended. Table 9. Tubing Sizes Runs up to Runs over to... -
Page 20: Section 5: Mechanical Stroke Adjustment
d> /KD E Section 5: Mechanical Stroke Adjustment This section explains: • What the mechanical stroke adjustment is. • What the factory settings are. • How to adjust the travel stops. A210-211-212-213 Series actuator sizes 32 to 300 have two stroke adjustment stops for adjusting accurately the stroke of the actuator/valve assembly in open and closed position. -
Page 21: Travel Stop Adjustment
d> /KD E Travel Stop Adjustment Do not turn out the travel stops completely when the actuator is pressurized. When adjusting the travel stops and the actuator is still pressurized, the travel stops can be “shot” away when completely turned out. Double-Acting Actuators Operate valve/actuator assembly to the required "Closed"... - Page 22 d> /KD E Turn the “closed” stop clockwise to reduce or counterclockwise to increase the travel. Consult chapter 5.1.3 (angular displacement of the pinion), to define how far the limit stop must be turned in or out. Remove air supply. Actuator will move to the closed position. Check whether the actuator valve assembly is in the required position.
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Page 23: Section 6: Maintenance
d> /KD E Section 6: Maintenance This section explains: • When and how to do maintenance. Normal maintenance Extraordinary maintenance • What to do when replacing springs. • What the availability is of spare parts, action conversion kits and temperature conversion kits. Actuator must be isolated pneumatically and electrically before any (dis)assembly starts. -
Page 24: Repair
Replacement of internal seals and bearings allows to you extend the normal working life. Service kits, containing all necessary spare parts (like seals, bearings, grease and instructions) can be obtained through authorized PROVAL distributors. Service Kits All soft seals, bearings, and nonreusable parts are included in the recommended service kit. -
Page 25: Section 7: Decommission (Out Of Service)
d> /KD E Section 7: Decommission (Out of Service) This section explains: • How to decommission an actuator in a safe way. Before You Start Actuator must be isolated pneumatically and electrically before any (dis)assembly starts. Before mounting or (dis)assembling the actuator consult the relevant sections of this manual. -
Page 26: Removing The Actuator From The Valve
d> /KD E Removing the actuator from the valve Disconnect all air supply hoses (Ports A and B or solenoid). Disconnect all electrical wirings of the switch box. Disconnect the electrical wiring of the solenoid valve. Remove the bolts and nuts from the valve flange. Remove the bracket from the actuator. -
Page 27: Section 8: Disassembly
d> /KD E Section 8: Disassembly This section explains: • How to disassemble an actuator safely. The instructions of this section can be used for maintenance or reconfiguration like spring set change or maintenance. Reference numbers for components refer to the exploded view in section 11. In case of maintenance, discard all the used soft parts like O-ring seals, guide bands, wear strips and circlip. -
Page 28: Removing End Caps
d> /KD E Removing End Caps For Double-acting actuators, do the following: Loosen the screws (26) of the end caps (25). Remove the o-ring (24) and "B" port seal (14). Discard these parts. Figure 17 Double-Acting End Caps Removal The above end caps (2) are for all Actuator sizes except 32. End caps (2) for Actuator size 32 have limit stop screwed flat end caps (see below). -
Page 29: Removing Spring Cartridges (Spring-Return)
d> /KD E For Spring-return actuators, do the following: Tip: For actuators with assembly code C, turn back the right hand limit stop screw (18) 2 full turns. For actuators with assembly code W, turn back the left hand limit stop screw (18) 2 full turns. -
Page 30: Removing Of Limit Stop
d> /KD E Removing of Limit Stop Remove the limit stop screws (18), limit stop nuts (17), limit stop washers (16) and limit stop o-rings (15). Discard the o-rings. Figure 20 Limit Stop Removal Removing Pistons Use a wrench and turn the pinion counterclockwise (180°) until the pistons (19) comes out of the body. -
Page 31: Removing Pinion
d> /KD E Removing pinion Remove the circlip (3) and thrust washers (4-5) on top of the pinion assembly. Discard if necessary the circlip (3) and thrust washers (4-5). While removing the pinion (11) by pushing it downwards, remove cam(8) and washer(7). -
Page 32: Section 9: Reassembly
d> /KD E Section 9: Reassembly This section explains: • Which parts and how to grease them. • How to reassemble a complete actuator. • How to set the stroke adjustment bolts after reassembly. • How to do a basic function and air leak test. The instructions of this section can be used for maintenance or reconfiguration like spring set change or maintenance. -
Page 33: Grease Instructions
d> /KD E Grease Instructions We recommend using a suitable sized paint brush to apply the required amount of grease on the parts as per Table 13 and Figure 23. Table 13. Grease Instructions Part Section of part Amount of grease O-rings: Completely Light film... -
Page 34: Reassembly Of The Pinion
d> /KD E Reassembly of the pinion Grease the pinion parts according to chapter 9.1. Install the pinion bearings (10-13) and the O-ring seals (9-12) on the pinion (11). While inserting the pinion (11) on the housing install the cam(8) and bearing(7). Install the thrust washers (4-5) and mount the circlip (3) on the pinion top using circlip pliers. -
Page 35: Reassembly Of The Pistons
d> /KD E Reassembly of the pistons EKd/ Before reassembling the pistons, check the required assembly code (see section 4.2). Grease the piston parts according to step 9.1. Install the piston bearings (22), piston rack bearing strips (20) and piston o-ring seals(21) on the pistons. - Page 36 d> /KD E Figure 26 Position of the slot and the cam on the pinion top Assembly code Assembly code (Standard; Spring-to-Close) (Reverse; Spring-to-Open) A = Position of cam B = Position of slot and in dot in pinion C = Final position of pinion dot Note: When the pistons are completely moved inwards, the pinion top will show a 5°...
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Page 37: Reassembly And Settings Of The Limit Stops
d> /KD E Reassembly and settings of the limit stops Install the limit stop screws (18), limit stop nuts (17), limit stop washers (16) and limit stop o-rings (15). Figure 27 Install Limit Stop Bolts Move the pistons inward until the slot in the top of the pinion is perpendicular to centerline of the housing. - Page 38 d> /KD E Figure 28 Double-acting end cap assembly The above end caps (2) are for all Actuator sizes except 32. End caps (2) for Actuator size 32 have limit stop screwed, flat end caps (see below). Table 15. End cap Screw Torque Actuator Torque (Nm) Torque (lbf.ft)
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Page 39: Spring-Return Actuators
d> /KD E Spring-Return actuators Important When replacing spring cartridges in a spring-return actuator, ensure that the cartridges are replaced in their identical position from where they were removed. Check below figure to see where to place the spring cartridges in case of spring set conversion. - Page 40 d> /KD E Grease the O-ring seals (14) and B port seals (16) according to step 9.1. Ensure that O-ring seals (14) and B port seals are kept in place during assembly. Place the spring cartridges in actuator as per required spring set (see Figure 29). Tighten each end cap screw in small equal turns and in the sequence as per Figure 28.
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Page 41: Basic Function And Air Leak Test
d> /KD E Basic function and Air Leak Test Applying pressure to the actuator will cause the actuator/valve assembly to operate. Apply pressure (max. 8 bar/116 psi) to ports A and B. Use some soap suds at the indicated points: around pinion top (1), pinion bottom (2), the end caps (3) and limit stops (4). -
Page 42: Section 10: Troubleshooting
Actuator rotates, valve actuator shaft and between actuator shaft Section 4.5 does not. valve spindle. and valve spindle. Contact nearest PROVAL Broken gearing on representative to replace pistons or pinion. Actuator does not actuator. rotate or does not rotate Contact nearest PROVAL smoothly. -
Page 43: Pneumatic Problems
d> /KD E Pneumatic Problems Problem Possible error Solution Where to find Section 2.3 Actuator does not There is no supply Supply the right Check that the actual react to electrical pressure at the pressure to the supply pressure is higher than the control signal. -
Page 44: Electrical Problems
d> /KD E Electrical Problems Problem Possible error Solution Where to find Control wiring. Power Instructions of the Connect all wiring supply wiring or control or feedback wiring are in the right way. feedback not right connected. accessories Actuator does not The power supply react to control voltage is not is not... -
Page 45: Section 11: Parts List And Spare Parts Recommendations
> d> /KD E Section 11: Parts List and Spare Parts Recommendations Exploded View and Parts List Table 16. Parts List Pos. Description Material Indicator Screw Stainless Steel Indicator Plastic Circlip Stainless Steel Metal Washer Stainless Steel Washer Engineering Plastics Body Extruded Aluminium Alloy Inner Washer... -
Page 46: Appendix A: Spring Load Removal
d> /KD E Appendix A: Spring load removal This section explains: • How to remove the spring load safely of spring-return actuators in case: The valve gets “stuck” in mid position. One of the cartridge spring is broken. A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a high spring load which will cause a sudden rotation of the actuator versus the valve during disassembly. -
Page 47: Appendix B: Tool & Torque Table
d> /KD E Appendix B: Tool & Torque Table This section explains: • Which tools to use for the indicated fasteners • The recommended amount of torque to apply on the indicated fasteners. Table B-1. End cap bolts Actuator Torque (Nm) Torque (lbf.ft) Thread Tool... - Page 48 d> /KD E Table B-3. NAMUR (VDE/VDI 3845) flanges Metric Torque (Nm) Imperial Torque (lbf.ft) Flange Thread Min. Max. Thread Min. Max. Solenoid flange screw threads 10-24UNC Top flange screw threads 10-24UNC Table B-4. Limit stop screws and nuts Bolt Wrench Nut wrench Actuator size Thread...
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