Maintenance MR / ACTELEC -- MAINTENANCE€¦ · 5 Actuator dismantling ... please consult the AUMA and/or BERNARD multiturns servomotors documentation. 1 ... MR / ACTELEC -- MAINTENANCE

Maintenance

8505.13/3--10 MR / ACTELEC -- MAINTENANCE

INSTALLATIONMAINTENANCE

MR 400 to 1600ACTELEC 200 to 1600

1 General over view

2 Recommended tool

3 Installation

4 Adjustment of closing adjustable end stops

5 Actuator dismantling

6 Actuator greasing and re--assembly

7 Actuator valve coupling

8 Kit sheets : MR 400 / ACTELEC 200 / ACTELEC 400 Ref. 8507.8400/.--90MR 600 Ref. 8507.8600/.--90MR 800 / ACTELEC 500 / ACTELEC 800 Ref. 8507.8800/.--90MR 1200 Ref. 8507.8120/.--90MR 1600 / ACTELEC 950 / ACTELEC 1600 Ref. 8507.8160/.--90

9 Trouble shooting

KSB est certifié ISO 9001

MR / ACTELEC -- MAINTENANCE

2

This purpose of this document is to describe the installation/maintenance procedures and actions to be carried out in case ofbreakdowns or faulty operations of the manual actuators MR 400 to 1600 and electric actuators ACTELEC 200 to 1600.For ACTELEC electric servomotors, please consult the AUMA and/or BERNARD multiturns servomotors documentation.

1 -- General over viewManufacture range -- Characteristics

Type Manual actuatorOutput torque

NmIntput torque

NmNumber of turns for the

operating screw

ACTELEC 200 MR 400 2000 60 47

ACTELEC 400 MR 400 4000 110 47

ACTELEC 500 MR 800 5000 60 135

ACTELEC 800 MR 800 8000 110 135

ACTELEC 950 MR 1600 9500 60 285

ACTELEC 1600 MR 1600 16000 110 285

Manual actuators MR 400, 600 and 1200Handwheel control

970.2

Item Designation Item Designation Item Designation

103 Gear housing 412.3 O’ring 900.4 Screw

142 Cap 412.4 O’ring 901.1 Screw

160 Cover 412.5 O’ring 901.2 Screw

176 Bottom 412.6 O’ring 904 Screw

20--1 Operating screw 412.7 O’ring 916.2 Plug

310.1 Self--lubricating bearing 486 Ball 920.1 Operating screw

310.2 Self--lubricating bearing 554.1 Washer 920.2 Nut

310.3 Self--lubricating bearing 554.2 Washer 940 Woodfrut key

314 Thrust washer 59--40 Chuck + pointer shaft 961 Handwheel

325 Needles thrust 629 Pointer 970.1 Identity plate

32--5 Counter plate 81--68 Pressure pad 970.2 Position plate

412.1 O’ring 991 Grease


3

Manual actuators MR 800 and 1600Control by handwheel and input primary reduction gear

970.2

Item Designation Item Designation

103 Gear housing 554.2 Washer

142 Cap 59--40 Chuck + pointer shaft

160 Cover for adaptation motor F10 629 Pointer

176 Bottom 81--68 Pressure pad

20--1 Operating screw 872 Toothed wheel

310.1 Self--lubricating bearing 877 Pinion--shaft

310.2 Self--lubricating bearing 900.4 Screw

310.3 Self--lubricating bearing 901.1 Screw

310.4 Bearing 901.2 Screw

314 Thrust washer 901.3 Screw

325 Needles thrust 904 Screw

32--5 Counter plate 916.2 Plug

412.1 O--ring 920.1 Operating nut

412.2 O--ring 920.2 Nut

412.3 O--ring 940.1 Woodfrut key

412.4 O--ring 940.2 Parallel key

412.5 O--ring 961 Handwheel

412.6 O--ring 970.1 Identity plate

486 Ball 970.2 Position plate

554.1 Washer 991 Grease


4

2 -- RECOMMENDED TOOL (not supplied)

-- Pneumatic screwing machine-- Open ended spanner 16, 24-- Allen key 6 pans 4, 5 and 8-- 2 brushes for grease: the brushes must not loose its hair (one for cleaning out the old grease and one for greasing)

CONSUMABLES-- Grease Multi MS2 (Total), EPEXELF MO2 (Elf) or RETINAX AM (Shell) or equivalent.You need a quantity of 250 to 450ml. If you have a surplus in grease, it is not a problem for the correct operation of thesemanualactuators.

-- Glue Loctite 242 or equivalent.-- Flange sealant Loctite 58--14 or 58--31, Omnifit FD30 or equivalent-- KSB spare parts kits, according to the actuator size (see kit sheets at the end of the document).

3 -- INSTALLATION

BEFORE ANY ACTION

-- Index the mounting position of the actuator onto the valve-- Index the position of the pointer 629 or of the flag. Pointer position or flag position show the valve position.

ADAPTATION ONTO THE VALVE

In case of thick paint on the valve, put washers to avoid the nut to damage the paintThe adaptation onto the valves is achieved either directly or through adaptors parts:

Interchangeable inserts manufacturedto the size and the shape of the differentshafts output

Flange sealant

FIGURE 1 FIGURE 2Direct fitting Adaptor flange fitting

••

•Glued •

Glued •• ••

Flange sealant

•

Adaptor flange

•

••

POSITION OF THE ACTUATOR ONTO THE VALVE

If the opened or closed position are not known, it is necessary to apply air pressure to obtain clockwise position : the actuator isin a closed position.The actuator can be positioned in 4 positions, at 90° intervals.Standard arrangement is the arrangement N , position 1

Arrangement N Arrangement M

Position 1 Position 1Position 2 Position 2

Flow direction


5

TRANSFORMATION Arrangement N Arrangement M

-- Close the valveIn the case of offset disc valve, empty the pressure of the pipe

-- Uncouple the actuator from the valve,-- Remove the plug 916.2, the screw 900.4 and the pointer 629 or other accessories such as box, flag, etc...,-- Remove the two balls 486 out of their grooves using a screwdriver, pin punch, . . .-- Insert in the groove at 90 ° the balls 486 of the spare part kit,-- Refit the position plate 970.2 (if any, in case of pointer or flag) at 90° from its initial position and retighten its screws.-- Mount the plug 916.2, the screw 900.4 and the pointer 629 or other accessories such as box, flag, e.g. in its initial position andscrew the screw 900.4,

-- Clean the surface and use sealant paste.-- Refit the actuator onto the valve at 90° of the initial position .

CAUTION : if a limit switch box is fitted onto the actuator, the adjustments must be modified following the instructions given in theuser guide document of the correspondant box.

486


6

4 -- ADJUSTMENT OF CLOSING ADJUSTABLE END STOPS

Adjusting: Closing ± 2,5°The adjustable end stops are factory--preset and require no adjustment on site.For a perfect tightness of the valve, this adjustment is of an essential importance .

FOR MANUAL ACTUATOR

After any intervention on the actuator, it is necessary to check the correct adjustment of the adjustable end stops.CAUTION: Never put the valve in over--closing.

Such adjustment may have to be retouched if need be by following the procedure below:Adjustment to be performed on the coupled valve + manual actuator-- Bring the actuator and the valve into closed position,-- Unlock the 2 nuts 920.2,-- Adjust the 2 adjustable end stops 904 until it contacts the operating nut 920.1, ensure that the desired position is obtained rotating

the valve, then lock the adjustable end stops 904 and the nuts 920.2.CAUTION : Take care not to damage the O--rings 412.4 or 412.6 during the adjustment steps (change these O--Rings).

FOR AN ELECTRICAL ACTUATOR

In normal operation, the whole unit must be stopped in closed or open position via the limit switches of the servomotor.The mechanical thrusts must not to be in contact.

After any intervention on the actuator, it is necessary to check the correct adjustment of the adjustable end stops.CAUTION: Never put the valve in over--closing.

Such adjustment may have to be retouched if need be by following the procedure below:Adjustment to be performed on the coupled valve + electrical actuator-- Bring the actuator and the valve into closed position,-- Adjust the limit switches of the servomotor, ensure that the desired position is obtained rotating the valve-- Unlock the 2 nuts 920.2,-- Adjust the 2 adjustable end stops 904 until it contacts the operating nut 920.1-- Unscrew by one turn the 2 adjustable end stops 904,-- Screw the 2 nuts 920.2 holding the adjustable end stops 904CAUTION : Take care not to damage the O--rings 412.4 or 412.6 during the adjustment steps (change these O--Rings).

554.1

412.4 ou 412.6 920.2904

For a manual actuator

Adjustable end stop 904 in contactwith operating nut 920.1

For an electrical actuator

No contact

920.1


7

NOTE: Factory greased, they do not need any maintenance. For a normal use, it needs no intervention.

Never try to operate an actuator not completely dismantled.-- First note the pointer’s position or flag and the fitting position of the actuator onto the valve.

-- Close the valve. In the case of offset disc valve, empty the pressure of the pipe.-- Uncouple the actuator and its accessories onto the valve and place them on the work bench-- Remove all the actuator’s accessories-- Remove the sub--unit plug 916, screw 900 and pointer 629 or the flag, but do not remove the balls 486

5 -- ACTUATOR DISMANTLING

Unscrew the 4 screws 901.1

Remove the cap 142, the O--ring 412.5,the self--lubricating bearing 310.2 and theO--ring 412.7

HANDWHEEL OR SERVOMOTOR SIDE: COVER 160 DISMANTLING

Remove the handwheel or the servomotor

Unscrew the 4 screws 901.1 and remove the cover 160

Case of manual actuators 800 / 1600

CAP 142 DISMANTLING

BOTTOM 176 DISMANTLING

Unscrew the 4 screws 901.1 andremove the bottom 176 .

Remove the old grease with a brush.Do not use solvent or a rag.


8

6 -- GREASING AND RE--ASSEMBLY

In all the following pages, take off the old grease and clean the parts before greasing and re--assembly.

Special grease may be used for special applications.

OPERATING SCREW 20--1 and OPERATING NUT 920.1 GREASING

Handwheel side:Pull the operating screw 20--1 and make 10 turnsGrease thickly the nut 920.1 up and down side and theoperating screw 20--1 using the brush (50ml of greaseregularly deposed).

Grease the underpart of the operating screw 920--1

Bottom 176 side:

Pull the operating screw 20--1Grease thickly the nut 920.1 up and down side and theoperating screw 20--1 using the brush (50ml of greaseregularly deposed).

For specific applications with considerable and frequent temperature changes, it is strongly recommended to brush with thebrush all the internal areas (gear casing, cap, cover, bottom, chuck, thrust washer, ...) with grease (200 ml) -- Specific greasemay also be used.


9

-- Change the 2 O--rings 412.1 (bottom 176 and cover 160)

-- Grease the O--rings and the grooves

-- Remove the needles thrust 325, Grease them and fit themCAUTION : the counter plates and the rings of the radial roller bearingmust be fitted in the same direction and same order as initial position.

-- Mount the bottom176 and screw it with the screws 900.1

-- Grease all contact areas of the O--rings in the gear casing-- Grease the cylindrical parts of the operating screw 20--1-- Grease the bearing of the bottom 176

PREPARATION OF THE PARTSAll the parts included in the spare parts kit must be used.Only, some O--rings for specific applications can be not used.The O--rings and the bearings must be greased before its fitting (grease defined in the chapter: consumable) (quantity: 100 mlof grease).

BOTTOM 176 SIDE


10

-- Remove the shaft--pinion 877, the needles thrust 325 and its counter plates.

CAUTION : the counter plates and the rings of the radial roller bearing must be fittedin the same direction and same order as initial position.

MR 800 and 1600: HANDWHEEL or SERVOMOTOR SIDE

-- Grease the 3 self--lubricating bearings inside the cover 160 andthe areas in contact with the O--rings

-- Remove and grease the needles thrust 325 and its counterplates in the same order as initial position (20 ml of grease)

-- Change the O--ring 412.3 and grease it

-- Remove the shaft--pinion 877 in the cap

-- Grease all contact areas of the O--rings in the gear casing-- Grease the cylindrical parts of operating screw 20--1,toothed wheel 872 and pinion 877 (20 ml of grease)

-- Grease the self--greased bearing of the bottom 176


11

MR 400, 600 and 1200 : HANDWHEEL SIDE

-- Grease the cylindrical parts of operating screw 20--1-- Remove the bottom176 and screw it with the screws 900.1

CAP 142

-- Lubricate and remove the O--ring 412.7 and the upper part ofthe chuck 59--40 (5 ml of grease).

-- Replace carefully the cap.

-- Take care not to damage the O--rings and the bearing

-- Screw the 4 screws 901.1

-- Ensure that the cap is clean.-- Grease the housing of the bearing 310.2 (5 ml of grease)and insert in place.

-- Insert the O--ring 412.5 and lubricate it on the cap 142


12

7 -- ACTUATOR/VALVE COUPLING

Fit the pointer 629 and/or the accessories on the actuator in their initial position.

DIRECT FITTING following figure 1 § 3Put some drops of glue on the threads of tie--bolts and screwCover all the area of the base plate Actuator / Valve with flange sealant

or

ADAPTOR FLANGE FITTING following figure 2 § 3Actuator side, cover all the area of the base plate Actuator / Valve with flange sealantFit the flange onto the actuatorPut some drops of glue on the threads of screws and screw themPut some drops of glue on the threads of tie--bolts and screw themValve side, cover all the area of the base plate Actuator / Valve with flange sealant

For a better protection of the actuator, it is recommended to clean, dry and paint all the interfaces after fitting (interfaces gear casing/ bottom, gear casing / cover and gear casing / cap).

-- Couple the actuator onto the valve in its initial position,

-- Check the correct operation of the unit Valve/Manual actuator--Electric actuator / Accessories.

-- If necessary, re--adjust the adjustable end stops: see § 4 Adjustment of closing adjustable end stops.


13

8 -- Kit sheets

MR 400 / ACTELEC 200 / ACTELEC 400 Ref. 8507.8400/.--90

MR 600 Ref. 8507.8600/.--90


MR 1200 Ref. 8507.8120/.--90


8507.8400/1--90KIT technical sheet KITMR400 / ACTELEC200 / ACTELEC400

CODING

CODIFICATION

KODIERUNG

Specifities

Spécificités

Spezifikationen

42 095 212

ACTELEC200 / ACTELEC400

412.1 412.1 412.3

412.6

412.1

MR400

486

412.4310.2

412.5

412.3412.1

412.6

Item Qty Designation Désignation Benennung Materials / MatériauxWerkstoffe

Dimensions(mm)

310.2 1 Self lubricating bearing Bande autolubrifiante oberes Lager Stainless steel + PTFE

412.1 2 O--ring Joint torique O-Ring Nitril Ø 110,72 x 3,53





486 2 Ball Bille Kugel Stainless steel

10/10/06

8507.8600--90KIT technical sheet KITMR600

CODING

CODIFICATION

KODIERUNG

Specifities

Spécificités

Spezifikationen

42 095 213


Dimensions(mm)








07/07/06

8507.8800--90KIT technical sheet KITMR800 / ACTELEC500 / ACTELEC800

CODING

CODIFICATION

KODIERUNG

Specifities

Spécificités

Spezifikationen

42 095 214

412.1 412.1 412.3

412.6

MR800

486

412.4310.2

412.5

412.1412.1 412.3

412.6ACTELEC500 / ACTELEC800


Dimensions(mm)








07/07/06

8507.8120--90KIT technical sheet KITMR1200

CODING

CODIFICATION

KODIERUNG

Specifities

Spécificités

Spezifikationen

42 095 215

412.4412.1


Dimensions(mm)




412.4 2 O--ring Joint torique O-Ring Nitril Ø 23 x 3,60




07/07/06

8507.8160--90KIT technical sheet KITMR1600 / ACTELEC950 / ACTELEC1600

CODING

CODIFICATION

KODIERUNG

Specifities

Spécificités

Spezifikationen

42 095 216

412.1 412.1 412.3

412.6

MR1600

412.3412.1412.1

486

412.4310.2

412.5

412.6ACTELEC950 / ACTELEC1600


Dimensions(mm)








07/07/06


18

Notes

KSB S.A.S4, allée des Barbanniers • 92635 Gennevilliers Cedex (France)Tél. : +33 1 41 47 75 00 • Fax : +33 1 41 47 75 10 • www.ksb.fr


9 -- TROUBLE SHOOTING

Non operation

Incomplete operation

Reverse operation

Reverse or incorrecte indication

Impossible connection, valve side

Impossible connection, accessories side

Blocked valves Check the valve and/or the interface with thepipe

Rupture of internal components Consult the manufacturer for technical advicesWrong actuator choice Consult type series booklet N° 8505.12

Consult type series booklet of the valve

No driving between the handwheel and the operating shaft Remove the handwheel and check the keyNo driving between the operating shaft and the servomotor Remove the servomotor and check the keyWrong adjustment of limit switches or adjustable end stops Adjust the limit switches and the thrustsServomotor in overtorque Adjust the limit switches and the thrustsNo electrical power Check the electrical connection or

contact your electrical supplier

Inadequat electrical voltage Contact your electrical supplierWrong adjustment of adjustable end stops Refer to § adjustment of closing adjustable end

stops

Overtorque of the valve Contact the manufacturerWrong interface Check the driving and/or adaptor flanges

Consult type series booklet MR N° 8505.12 orcontact the manufacturer

Closed actuator / Opened valveor Closed valve / Opened actuator

Put valve and actuator in the sameposition

Wrong assembly of the actuator onto the valve Check arrangement positions on type seriesbooklet MR N° 8505.12

Wrong adjustment of limit switches cams Check the adjustment according to type seriesbooklet of the limit switches box

Accessories or signalling not compatible Check the type series booklet of theaccessories

concerned

27.09.10

Thisleafletisnotcontractual.

andmay

beam

endedwithoutnotice.

8505.13/3--10

Documents

Maintenance MR / ACTELEC -- MAINTENANCE€¦ · 5 Actuator dismantling ... please consult the AUMA and/or BERNARD multiturns servomotors documentation. 1 ... MR / ACTELEC -- MAINTENANCE