MANUAL AND MAINTENANCE GUIDELINES

PRD/PREPNEUMATIC ACTUATOR

Documentnr.: BWA.PRD.201201| Issue: Dec. 2020

MANUAL AND MAINTENANCE GUIDELINES

BWA.PRD.201201 December 2020

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Manual and maintanance GuidelinesPneumatic actuator Type PRD/PRE

BWA.PRD.201201December 2020

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Contents:

Chapter 1: Preparation 1.1 Marking of reference Page 4 1.2 Safety fundamentals Page 4 1.3 Transport, storage and packaging Page 4

Chapter 2: Preliminary

2.1 Description Page 5 2.2 Intended use Page 5 2.3 Technical data Page 6

2.4 Type code Page 6

Chapter 3: Function

3.1 Fundamentals Page 7 3.2 Mountingversions Page 8

Chapter 4: Installation

4.1 Attachmenttoavalve Page 10 4.2 Pneumaticconnection Page 11

4.3 End stop adjustment Page 12

Chapter 5: Maintenance

5.1 General Page 14 5.2 Safetyinstructions Page 14 5.3 Tighteningtorquesforscrewconnections Page 14 5.4 Components Page 14 5.5 Arrangement of safety springs Page 15

Copyright

Thisdocumentisprotectedbycopyright.Wereserveallrightstothismanualbeforeproceeding,eventhereproductionand/orduplicationinanythinkableform,e.g.photocopying,printing,ondatamediumorintranslatedform.ReproductionofthismanualonlywithwrittenpermissionofProtACTGmbH.Thetechnicalstateatthetimeofdeliveryofdeviceandmanualisdecisive,ifnootherinformationisgiven.Wereservetherighttomaketechnicalmodificationswithoutspecificnotice.Earlierinstructionsthenbecomeinvalid.


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Chapter 1: Preparation

Content: - Markingofsafetyinstructions- Safety fundamentals- Instructionsforstorage

1.1 Marking of safety instructions

1.2 Safety fundamentals

The installation,assembly, commissioning, maintenance and any other work on pneumaticactuators must be performed byqualifiedpersonnel.

This manual is part of the deviceandmustbeavailable fortheoperating personnelatalltimes. This manual must be read and understoodbeforeoperation.

Thedevicemay only be operated in perfectcondition. No safety devicesareremoved ordeactivated. A rebuilding or modificationofthedevice is strictly prohibited.

1.3 Transport, storage and packaging

Thedevicesmustbe carefully handled, transported and stored.

Thedevicesshould be transported to the enddestination in their original packaging and unpacked immediately beforeinstallation.

The actuators are to be stored in a clean, dry storage, which is neither exposed to excessive vibrationnorto rapid temperature changes.

Prevent ingress of dirt or moisture into the actuator. Close or tighten both airconnections.

Proper disposal of packaging is the customer´s responsibility.

This symbol indicates safety instructions which can cause personal injury if not respected.

This symbol indicates an important note

Rotary actuators must be isolated both pneumatically and electrically before any intervention.

Failure to follow the safety basics can void the warranty claims.

Installation, operation and maintenance of the products are strictly subject to the local safety andaccident prevention regulations!

Failure to comply may void the warranty claims.


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Chapter 2: Preliminary

Content:• Designdescription• Intended use• Technicalinformation• Type code

2.1 Description

ActuatorsofthePRD/PREseriesarepneumaticdouble-pistonrotaryactuators.Theyaregenerallyusedintwodifferentmodes:singleactinganddouble-acting.

Doublepistonprinciplemeansthattwopistonscreatetwopressurechambers.Byinflatingoneofthesechambersthepistonsaremovedintooppositedirectionseithertowardsorawayfromeachother.Theresultingforceisprovidedtothecentralactuatorpinionviatoothedrackswhichareconnectedwiththepistonsandsocreatesaconstanttorqueovertheentirepivotingangle.

TheactuatorseriesPRD/PREoffers18sizeswithatorquerangeof3-15880Nm.Standardizedinterfacesformountingaccessories(VDI/VDE3845,NAMUR,ISO5211,DIN3337)areavailable.

Inthesingleactingtypeintegratedspringsensuretheclosingoropeningintheeventofafailureofthecontrolmedium(“springtoclose”or“springtoopen”).

2.2 Intended use

ActuatorsofthePRD/PREseriesareprimarilyusedfortheautomationofquarter-turnvalvessuchasballvalves,butterflyvalvesorplugvalves,butcanalsobeusedforotherapplications.Contactourqualifiedpersonnelwhererequired.

Thespecifiedoperatingandlimitingvaluesfortemperature,pressure,controlmedium,etc.mustbeobserved.

Inoperationofvalveshighkineticenergiesmayarise,whicharetransmittedtotheactuator.Makesurethatthedriveisprotectedfromdamagebycomplyingwiththeminimumtraveltimessafely.Controlspeedcanbereducedbytheuseofchokevalves,whichcanbepurchasedthroughoursalesdepartment.

Forvalvetypeswithhighflywheelmassandlowtorquerequirementstheoperatingconditionsofthedrivemustbecoordinatedwithusinadvance.

The actuator may only be used:• inperfectcondition• asstipulated• safety-anddanger-consciousinconsiderationoftheoperatinginstructions• ifallsafetydevicesareinplaceandfunctioning

Inparticularfaultswhichmayaffectsafetyaretobeeliminated!

Any use not pre-approved by the manufacturer is considered improper!


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PR D -

049 / 90 - 08 - V11 - A - BEType

Function D=double-acting E=single-acting Double end-stop adjustment

Size Mounting direction

Rotation angle

Stem connectionZ= double DV=Squareacc.toISO5211andDIN 3337

Spring set

2.4 Type code

2.3 Technical Data

Construction principle Pneumaticdouble-pistonrotaryactuatorinrack&pinion-designwithself-centeringpistons;double-andsingle-actingexecution

Temperature range Standard: Lowtemperature: Hightemperature:

-50°Cto+70°C(NBR) -15°Cto+160°C(Viton) -60°Cto+80°C(Silikon)

Control pressure 2 to 8 bar

Pressure media dry,filteredairorinertgasesinrespectofremainingoil-,dustandwater-contentaccordingtoDINISO8573-1/class4,maximumparticlediameter30µm,dewpointminimum 10°C below ambient temperature

Nominal rotation angle 90°,120°, 180° resp. 240° Adjustableinoneendposition+/-5°(optional100%strokeadjustment) VersionBE:Adjustableinbothendpositions

Torque range to6.400Nm(double-acting) to4.157Nm(single-acting)

Standards ISO5211,VDI/VDE3845resp.NAMUR

Materials Housing:AnodisedaluminumASTM6083,UNI4522Cap:AluminumUNI5076,epoxyresincoatedPiston:AluminumUNI5076Pinion:Steel,nickel-plated(optional:stainlesssteel)Bearings:POMSealings:NBR,optional:FKMorsilicone


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Chapter 3: Function

Content:• Fundamentals• Mountingversions(mountingdirection/springrotationsense)

3.1 Fundamentals

Generalruleisthatvalvesareclosedclockwise(CW)andopenedcounterclockwise(CCW).Theangleofviewistobeunderstoodas“fromthetopontothevalveshaft.”Allstatementsinthismanualarebasedonthisruleandhavetobetakenintoaccountaccordingly

Closing process clockwise (CW)

Opening process counter-clockwise (CCW)

3.2 Mounting versions

Dependingontheorientationoftheactuatortothepipeline(parallelortransverse)andtheswitchingfunction(clockwiseorcounterclockwise),thereare4resultingmountingversionswhichneedtobedifferentiated.


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Mounting version F

Actuator parallel to pipelineSpring rotation sense clockwise (CW)

SPRING TO CLOSE

double-acting

Port„A“pressurized,actuatormovesinswitchedposition90°,valveopens

Port„B“pressurized,actuatormovesininitalposition0°,valvecloses

Valve position

single-acting


Port„A“vented,actuatormovesininitalposition0°,valvecloses

Mounting version H

Actuator parallel to pipelineSpring rotation sense counter-clockwise (CCW)

SPRING TO OPEN

double-acting

Port„A“pressurized,actuatormovesinswitchedposition90°,valvecloses

Port„B“pressurized,actuatormovesininitalposition0°,valveopens

Valve position

single-acting


Port„A“vented,actuatormovesininitalposition0°,valveopens


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Mounting version E

Actuator transversal to pipelineSpring rotation sense clockwise (CW)

SPRING TO CLOSE

double-acting


Port„B“pressurized,actuatormovesininitalposition0°,valvecloses

Valve position

single-acting


Port„A“vented,actuatormovesininitalposition0°,valvecloses

Mounting version G

Actuator transversal to pipelineSpring rotation sense counter-clockwise (CCW)

SPRING TO OPEN

double-acting


Port„B“pressurized,actuatormovesininitalposition0°,valveopens

Valve position

single-acting


Port„A“vented,actuatormovesininitalposition0°,valveopens


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Chapter 4: Installation

Content:• Attachmenttoavalve• Pneumaticconnection• End stop and stroke adjustment

4.1 Attachment to a valve

• Duringtheinstallationoftheactuatorthetaphole(withballandplugvalves)respectivelythedisc(butterflyvalves)mustcorrespondwiththegrooveatthetopofthedrivepinioninordertoensuretheproperfunctionoffurtheradaptedsignal-orcontrolunits.Thegroove(accordingtoVDI/VDE3845)symbolicallyrepresentsthevalveposition.

• Aftercorrectinstallationoftheactuatortothevalveensurethatthevisualpositionindicatorisalsoprogrammedcorrectlybyadjustingthesignalplates. Thesemustcorrespondtothepiniongrooveandthuswiththevalveposition.

• Makesurethatthevalveshaftcorrespondstotheterminalintheactuatorpinionintermsofshapeanddimension.Fordirectmountingpossibledifferencescanusuallybecompensatedbytheuseofreductioninserts.Thesecanbeorderedviaoursalesdepartmentseparately.

• Checkwhethervalveandactuatorhaveacorrespondingadaptioninterface.Ifnot,anadditionalmountingkitisrequired,whichcanbeorderedviaoursalesdepartment.

• Securethedrivewithscrewsonthevalve.Werecommendusingstainlesssteelscrewstoensureacorrespondingcorrosionresistance.Thenumberofscrewsisrelevantforthestabilityofthemountingandpowertransmission.Therefore,don´tleaveanyfixationpointunused.Takeintoaccountthetighteningtorquesinsection5.3whenfixingthescrews.

Perform any kind of installation work on rotary actuators exclusively when the device is fully vented!

Verify that the maximum actuator torque is below the maximum valve torque (MAST) to avoid further damage.


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4.2 Pneumatic connection

ActuatorsofthePRD/PREseriescaneitherbecontrolledviaarigidorflexibletubesystem,withthecontrolvalvemountedapartfromtheactuator,orbyacontrolvalvethatisdirectlymountedtotheNAMURinterfaceaccordingtoVDI/VDE3845inthebodyoftheactuator.

Bythedesignandmountingdirectionofthecontrolvalvesecurityfunctionsfortheeventofapowerfailurecanbepresetindoubleactingapplications.Forspringreturnactuators,theinitialpositionisinprincipleunderstoodasasafetypositionincaseofpowerfailureorfailureofthecontrolmedia.

Single-actingactuatorsarefactorywiseequippedwithasilencerinport“B”.Priortoanyinstallationofadirectlymountedcontrolvalvethatsilenceristoberemoved.

Pneumatic controls

Double-acting Single-acting

Control via 5/2-way valveSample safety function:

power-off in initial position

Control via 3/2-way valve


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Drehmomenttabelle doppeltwirkend

4.3 End stop adjustment

Version "Standard"

AA

A

A B

B

Byturningtheend-stopadjustmentscrews„A“,bothendpositionscanbeadjustedby+/-5°foraprecisesettingofthefinalvalveposition.Theac-cordingsettingsaresecuredbytighteningthelocknuts.

Withtheoptionalversion"BE"bothendpositionscan be independently adjusted by turning the adjustmentscrews"A"and"B".

Version "BE"

AA


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5. Maintenance

Content:• General• Safetyinstructions• Tighteningtorquesforscrewconnections• Actuator components and spare parts• Dismountingfromavalve• Disassembly/assemblyofanactuator

5.1 General

ActuatorsofthePRD/PREseriesaredesignedfor“noneedofmaintenance”duringthenormallifecycleandaresuppliedwithsufficientlubricationfortheirnormalspanofduty.ThenormalspanofdutydependsontheactuatorsizeandissubjecttoEN15714-3.

Performperiodicinspectionstoensuretrouble-freeoperation.Checkwhethervisibleoraudibledefectsarepresent.Regularreplacementofthesealsandbearingsintheactuatorextendthenormalspanofduty.Appropriatesparepartskitcanbeorderedviaoursalesdepartment.

5.2 Safety instructions

5.3 Tightening torques for screw connections

Tightening torques in NmNominal size min. max.

M5 4,9 6M6 8 10M8 20 25

M10 40 49M12 69 86M16 170 210M18 235 290M20 330 410

Rotary actuators must be isolated both pneumatically and electrically before any work is performed.

Actuators and the connected valve can move when the control pressure and/or an electrical control signal is removed.

Single acting actuators with incomplete spring stroke contain a high spring force that can trigger a sudden rotation during dismounting of the actuator. This can cause serious injuries or property damage.

Work on electrical installations must be carried out exclusively by suitably qualified persons. A disabled supply must be protected against accidental reconnection.


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20

21

22

23

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25

4 5 6

7

8 29 10 11 12

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Set 1 = Seitendeckel , komple� Set 2 = Kolben ohne Durchgangsbohrung, komple�Set 3 = Kolben mit Durchgangsbohrung, komple�Set 4 = R itze l , komple� / Set 5 = Innere Hubeinste l lschraube, komple�Set 6 = Äußere Hubeinste l lschraube, komple�Set 7 = DichtungssatzSet 8 = Verschle ißtei lsatz

Pos Beschreibung Menge

1211222211111221111111118

0 - 12

Ersatzteilset

Set 1

-1-----1----1111--------4-

Set 2

--1-111-------------------

Set 3

---1111-------------------

Set 4

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1

1

1

1

1

1

1

-

-

Set 7

----2--2-1---2-----1------

Set 8

-----22-----------1-1-1---

Set 6

-

-

-

-

-

-

-

-

-

-

-

-

1

1

1

1

-

-

-

-

-

-

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-

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Set 5

--------1111----1---------

GehäuseSeitendeckelKolben ohne DurchgangsbohrungKolben mit DurchgangsbohrungO-Ring-KolbenFührungsring-KolbenGleitelement-KolbenO-Ring-GehäusedeckelInnere HubeinstellschraubeO-Ring für innere HubeinstellschraubeGleithülse für innere HubeinstellschraubeScheibe-Hubeinstellschraube-InnenÄussere HubeinstellschraubeO-Ring für äussere HubeinstellschraubeO-Ring-ScheibeKontermu�er-Hubeinstellschraube aussenKontermu�er-Hubeisntellschraube innenSeegeringAnlaufscheibeO-Ring-Ritzel-obenFührungsring-Ritzel-obenRitzelFührungsring-Ritzel-untenO-Ring-Ritzel-untenSchrauben-SeitendeckelRückstellfedern

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No. Description Quantity Spare parts setSet 1 Set 2 Set 3 Set 4 Set 5 Set 6 Set 7 Set 8

1 Actuator body 1 - - - - - - - -2 Actuator end cap 2 1 - - - - - - -3 Blind piston 1 - 1 - - - - - -4 Drilled piston 1 - - 1 - - - - -5 PistonsealingO-Ring 2 - 1 1 - - - 2 -6 Piston guide ring 2 - 1 1 - - - - 27 Piston guide skate 2 - 1 1 - - - - 28 EndcapsealingO-Ring 2 1 - - - - - 2 -9 Internaltravelstoprod 1 - - - - 1 - - -

10 InternaltravelstoprodsealingO-Ring 1 - - - - 1 - 1 -11 Internal stop rod guide bush 1 - - - - 1 - - -12 Rodguidebushstopwasher 1 - - - - 1 - - -13 Externaltravelstopscrew 1 1 - - - - 1 - -14 StopsealingO-Ring 2 1 - - - - 1 2 -15 O-Ringstopwasher 2 1 - - - - 1 - -16 External stop nut 1 1 - - - - 1 - -17 Internalstopnut(yellow) 1 - - - - 1 - - -18 Pinion stop circlips 1 - - - 1 - - - -19 Upperpinionwasher 1 - - - 1 - - - 120 UpperpinionO-Ringsealing 1 - - - 1 - - 1 -21 Upperpinionguidering 1 - - - 1 - - - 122 Pinion 1 - - - 1 - - - -23 Lower pinion guide ring 1 - - - 1 - - - 124 LowerpinionO-Ringsealing 1 - - - 1 - - - -25 End cap screws 8 4 - - - - - - -26 Spring cartridges 0 - 12 - - - - - - - -

Set 1 = Cap, completeSet 2 = Blind piston, completeSet 3 = Drilled piston kit, completeSet4=Shaftcomplete

Set 5 =Internal stop kit, completeSet 6 = External stop ki t, completeSet 7 = Seal kitSet 8 = Guide kit

5.4 Components


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5.5 Arrangement of safety springs

Thedrive pistons are not symmetrical due to the attached racks. In order toensureoptimal flowofforce and minimize internal wear, the springs must be installed accordingtothefollowinginstallationschemes.

Payattentionthat inthefollowingillustrationthespring pocket, which is aligned with the piston, is highlighted with a point.

Piston left/right Piston left/right

5 springs 6 springs

7 springs 8 springs

9 springs 10 springs

11 springs 12 springs

ProtACT GmbHMärkerstraße 18

56307 Dernbach

Tel:+49(0)2605962519-0Fax:+49(0)2605962519-6

Email: [email protected]

Website: www.protact-gmbh.de

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MANUAL AND MAINTENANCE GUIDELINES