Proval A210 Series Installation, Operation And Maintenance Manual Download Page 1

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PROVAL A210-211-212-213-Series

Rack and Pinion Pneumatic Actuators

Installation, Operation and Maintenance Manual

Summary of Contents for A210 Series

Page 1: ...PROVAL A210 211 212 213 Series Rack and Pinion Pneumatic Actuators Installation Operation and Maintenance Manual...

Page 2: ...ailure Modes 7 Valve Rotation 7 Position After Failure 8 Principles of Operation 8 Solenoid Valve 8 Ingress Protection IP rating 9 Double Acting Actuators 10 Spring Return Actuators 11 Actuator Assemb...

Page 3: ...ly and settings of the limit stops 34 Reassembly of the end caps 34 Double Acting actuators 34 Spring Return actuators 36 Basic function and Air Leak Test 38 Section 10 Troubleshooting MechanicalProbl...

Page 4: ...g or dis assembly the actuator consults the relevant sections of this manual Installation Operation and Maintenance Reference Documents Before you start read the following documents All chapters in th...

Page 5: ...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 Failure to follow the abov...

Page 6: ...enoid switchbox or positioner mounting VDI VDE3845 NAMUR The valve interface is equipped with an insert in the pinion bottom that allows both ISO5211 or DIN3337 mounting The springs in the spring retu...

Page 7: ...barg 87 to120 psig with maximum spring set 3to8 3 barg 43 5 to120 psig reducedspringquantity Table 2 Operating Media Actuator Type Operating Media Double Acting and Single Acting Air dry or lubricated...

Page 8: ...pinion to rotate counter clockwise while air is being exhausted through port A Air supplied through port A forces the piston away from each other causing the pinions to rotate clockwise while air is...

Page 9: ...ring Type N A Double Acting A 5 B 6 C 7 D 8 E 9 F 10 G 11 H 12 Series 0 A210 1 A211 2 A212 3 A213 4 A214 Stem Connection Size 09 9mm 11 11mm 14 14mm 17 17mm 22 22mm 27 27mm 36 36mm 46 46mm xx Upon Req...

Page 10: ...Rotation For the following paragraphs we assume that valves rotate as indicated in figure 3 Figure 3 Normalvalverotation The valve is closed after a clockwise rotation The valve is open after a counte...

Page 11: ...below Table 5 Position After Failure Principles of Operation Solenoid Valve All actuators can be either piped with solid or flexible tubing with the solenoid valve mounted remotely from the actuator o...

Page 12: ...53 PA300 31 6 16 54 15 14 9 Operating time is average with actuator under load and solenoid valve fitted Test conditions Solenoid with flow capacity 0 6 m3 hr Pipe diameter 6mm Medium clean air Suppl...

Page 13: ...ing Applying supply pressure to port A will move the pistons outward to the Open position of the valve Applying supply pressure to port B will move the pistons inward to the Close position of the valv...

Page 14: ...plying supply pressure to port A will move the pistons outwards to the Open position of the valve Venting the supply pressure from port A will cause the springs to move the pistons inwardsto the Close...

Page 15: ...e C Standard Counterclockwise to Open Reverse Clockwise to Open Fail to Close Fail to Open B A A B Pinion Pistons B A B A Pistons A Rotation when central air chamber is pressurized B Rotation when end...

Page 16: ...and screwdrivers For the removal of inserts a special extractor tool can be supplied on request During assembly to the valve do not hit with hammer on pinion top This can damage the pinion top washer...

Page 17: ...Be sure that the insert is mounted at 90 or 45 It is possible to mount the insert turned 22 5 This way the valve will not open or close the right way Figure 10 InsertdriveInstallation Parallel square...

Page 18: ...9 2 105 125 F07 inner pattern M8 10 5 12 5 5 16 18 7 7 9 2 F10 outer pattern M10 21 0 24 5 3 8 16 15 5 18 1 140 160 F10 inner pattern M10 21 0 24 5 3 8 16 15 5 18 1 F12 outer pattern M12 34 5 43 0 1 2...

Page 19: ...supply sufficient flow of air supply to the actuator the following tubing sizes are recommended Table9 Tubing Sizes Actuatorsize Runs up to Runs over to 1 2 meters 4 feet 1 2 meters 4 feet 32 40 52 6...

Page 20: ...ment stops for adjusting accurately the stroke of the actuator valve assembly in open and closed position The smallest actuator size 32 have limit stops on end caps The factory setting of the stroke i...

Page 21: ...e 14 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...

Page 22: ...ot repeat steps 1 to 5 Remove air supply For adjusting the open position repeat steps 1 to 6 but now for the open position and open stop 1 Table10 Limit stopdimensions Actuatorsize Thread Bolt Wrench...

Page 23: ...g with the rules and regulations of the country of final installation Visually check the entire actuator as well as the control system where foreseen Ensure there are no leaks on the actuator parts un...

Page 24: ...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...

Page 25: ...y ball valve or plug valve assemblies from a pipe system isolate the piping system on which the Actuator is installed and relieve any media pressure that may be trapped in the valve cavities before re...

Page 26: ...cal 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 Remove the switch box and sole...

Page 27: ...gs in a compressed state Follow these instructions to release the spring force safely Normally the end caps of spring return actuators should be free of the spring load after 10 full turns crosswise r...

Page 28: ...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 E...

Page 29: ...reduces the screw out length of the end cap screws Important Apply a strong sudden rotational and downward force to loosen all the end cap screws 26 for maximum 1 4 turn Uniformly loosen the screws 2...

Page 30: ...limit stop o rings 15 Discard the o rings Figure 20 Limit Stop Removal RemovingPistons Use a wrench and turn the pinion counterclockwise 180 until the pistons 19 comes out of the body Remove the pisto...

Page 31: ...d the pinion bearings 9 12 Discard all of these parts Figure 22 PinionRemoval Table 12 Recommended circlip pliers according DIN 5254 or equal for shaft circlips Actuatorsize Pliers according DIN 5254...

Page 32: ...nents refer to the exploded view in section 11 In case of maintenance discard all used soft parts like O ring seals guide bands and wear strips and circlip and replace them with the parts as supplied...

Page 33: ...ghtfilm C Top pinion bore Lightfilm D Bottom pinion bore Lightfilm Piston Parts E O ring bearing groove Lightfilm F Rack teeth Half the teeth depth full with grease G Piston bearing Light film on outs...

Page 34: ...st washers 4 5 and mount the circlip 3 on the pinion top using circlip pliers Install the new circlip onto its mating groove on the top shaft extension and with the non sharp edge B towards the housin...

Page 35: ...For standard or Spring to Close Assembly Code C For reverse or Spring to Open Assembly Code W Slightly push the pinion inward to engage with the pinion Ensure that smooth movement and 90 degree opera...

Page 36: ...pinion top Assemblycode Assembly code 8 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 a...

Page 37: ...avel stop until it comes into contact with the pinion stop face Move the pistons outward until the slot in the top of the pinion is in line with the centerline of the housing Screw in the left hand tr...

Page 38: ...Torque Nm Torque lbf ft Target Min Max Target Min Max 32 M4 Allen key SW3 1 1 0 8 1 3 0 8 0 6 1 0 40 M5 SW4 2 0 1 6 3 0 1 5 1 2 2 2 52 M6 SW5 3 3 2 6 5 1 2 4 1 9 3 8 63 M6 SW5 3 3 2 6 5 1 2 4 1 9 3 8...

Page 39: ...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 Before assembling the spring cartridge...

Page 40: ...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 Refer to...

Page 41: ...1 pinion bottom 2 the end caps 3 and limit stops 4 In case of leakage around The limit stop bolts and or the spring package bolt at spring return models Turn the lock nut of the bolts tighter until t...

Page 42: ...sition Remark Rotate insert to one cam 22 5 Section4 5 Pressure to low Apply pressure as per sizing Sizing is wrong Check valve torque data with actuator torque data Pinion is mounted in the wrong pos...

Page 43: ...Solenoid Valve is locked Unlock manual override on the solenoid valve Instructions shipped with the manual override Air leakage between actuator and solenoid valve Sealing between solenoid valve and...

Page 44: ...tions of the control or feedback accessories The power supply voltage is not is not the same as the voltage of the applicable solenoid Connect the right power supply voltage Instructions of the soleno...

Page 45: ...aring Engineering Plastics 10 1 Pinion Upper O Ring NBR 11 1 Pinion Alloy Steel 12 1 Pinion Lower Bearing NBR 13 1 Pinion Lower O Ring Engineering Plastics 14 2 Sealing Plug NBR 15 2 Adjustment Screw...

Page 46: ...y to personnel or damage to material Spring load relief In case of an actuator valve assembly stuck in mid position leave the actuator on the valve and or mounting bracket during this procedure Figure...

Page 47: ...2 4 9 9 0 105 M8 SW6 8 4 6 7 12 2 6 2 4 9 9 0 125 M10 SW8 15 3 12 2 24 8 11 3 9 0 18 3 140 M10 SW8 15 3 12 2 24 8 11 3 9 0 18 3 160 M12 SW 10 190 210 240 270 300 Table B 2 Bottom flange ActuatorSize...

Page 48: ...size mm size mm 32 M5 20 stay bolt 8 40 M6 25 10 52 M6 30 10 63 M6 30 10 75 M 8 35 13 83 M 8 45 13 92 M 8 40 13 105 M 8 40 13 125 M 10 50 17 140 M 12 60 19 160 M 16 70 24 190 210 240 270 300 Default d...

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