Airpower twintorque® instruction
Operating instructions | Pneumatic actuator twintorque
Safety Notes
The mounting, compressed air connections and commissioning of these actuators may only be carried out by suitably trained and qualified persons and in strict accordance with these operating instructions. Incorrect handling or non adherence to the designed use leads to annulment of the guarantee.
Pneumatic actuators can produce extremely large torques. For this reason alone, it is absolutely necessary to adhere to the valid national and international safety regulations, in order to avoid accidents and injury.
Always make sure the compressed air supply is isolated before doing any mounting or mainte-nance work.
Before installing, i.e. commissioning the actuator, make sure that the technical parameters, espe-cially the pressure, torque and temperature are compatible between actuator, valve and air sup-ply.
Make sure that the actuator rotates in the correct direction.
Make sure that the maximum pivoting angle is set so that travel to the valve seals is not exceeded past the seals, otherwise they can be destroyed.
Table of contents
- Introduction
- Technical data
- Spare parts
- Mounting the actuator onto a valve
- Pneumatic connection to the actuator
- End position settings
- Dismantling and assembly
- Screws and tools
- Safety
Introduction
The pneumatic actuators twintorque from ape are designed for use in the automation of valves with a rotating angle of 90° or 180°. These can have either purely 90 / 180° pivoting movement or a regulating application.
The actuator is available in either double-acting (APD) or as single-acting (APS) with spring return for both rotational directions. The rack & pinion movement is especially suited for this type of force transmission onto rotational valves.
Housed in a cylindrically pressed profile, the pistons are arranged opposite each other. Driven by
compressed air (standard air) they move towards or away from each other, transmitting their force via rack to the pinion which in turn provides the rotary movement required.
The pairing of materials here is selected especially to secure balanced operation and therefore long working life.
During design, attention and adherence to the technical fundamentals and specifications for the safety of machines have been fulfilled. In line with the European Guidelines, the danger analyses have been performed and are correspondingly included as warnings in the operating instructions.
The manufacture of the actuator was carried out by a company certified under and according to ISO 9001.
Technical Data
Standard version | Option | |
Construction features | Double cylinder actuator acc. to the rack & pinion principle with selfcentering piston guide inside a housing. Single-acting: with captive springs | |
Design | Pneumatic double-piston pivoting action Type APD = double-acting Type APS = single-acting | 3-position actuator (3P) |
Mounting position | Arbitrary | |
Standards | Interface actuator-signal unit: acc. to VDI/VDO3845 (Namur) and VDI/ VDO3847 | Different dimensions possible |
Materials | Housing: Al alloy, hard anodized, | Other housing coatings possible |
Ambient temperature | -35° to +80° | High temp.: -15 - +150°C |
Rated pivoting angle | 90°, from +5° to -5° adjustable | 180° drive: 180°-120° adjustable |
Torque | 2.4 Nm to 2105Nm | High torques |
Control pressure | 2 – 8 bar | Higher control pressures upon request |
Control medium/Quality | Filtered air min. acc. to DIN/ISO 8573-1, class 4 | Other non-aggressive, gaseous or liquid mediums |
List of single parts
1 screw | 8 sliding bush | 15 lock-nut | 22 springs |
2 visual display | 9 shim | 16 O-ring | 23 O-ring |
3 scuring ring | 10 end-stop cam | 17 guide segment | 24 cover |
4 washer | 11 pinion | 18 plug | 25 end-cap screw |
5 slide ring | 12 sliding bush | 19 piston | 26 threaded pin |
6 housing | 13 O-ring | 20 O-ring | 27 locknut |
7 O-ring | 14threaded pings | 21 piston guide | 28 O-ring |
Spare parts
Spare parts set No. 1 seals- wearing parts | Spare parts set No. 2 piston, complete | Spare parts set No. 3 pinion, complete | Spare parts set No. 4 cover, complete |
Mounting the actuator onto the valve
Before mounting onto the valve following is to be performed:
Check whether the valve spindle and the drive pinion are parallel. Check whether the mounting flange on the valve adapts to the actuator housing with regard to the need for additional adaptors ( bridges, shaft, adopters, reduction pieces). Insert the screws provided and tighten accordingly. Important: check rotational direction and the model type is correct before commissioning.
Pneumatic Connection of the Actuator
- Solenoid valve acc. to NAMUR direct onto the flange.
- Connections 2 and 4 from the actuator correspond to connections 4 and 2 on the solenoid valve.
- Single-acting actuators are fitted with a silencer (connection 4).
- This is to be removed before fitting a NAMUR control valve.
- If the control valve is to be mounted separately in the switching cabinet, then the airway leads (4 and 2) from the control valve are to be fitted to connections 2 and 4 on the actuator.
- Please note here that the connection 2 is standard for opening with the actuator, and connection 4 for closing.
Actuator
Setting the end positions
- Isolate the actuator from the air supply before adjusting the end positions.
- Never use the adjusting screws to press against the operating pressure.
- Adjustment of the end positions is performed via screws “F” and “B” in the housing.
- Take the pistons together in which pressure is applied to connection 4. The actuator is now in position basic position 0°.
- Loosen the locknut at the side and then turn the end position screw “F” inwards until the desired
- position is reached.
- Secure the position by tightening the locknut.
Basic position 0°
- Isolate the actuator from the air supply before adjusting the end positions.
- Never use the adjusting screws to press against the operating pressure.
- Adjustment of the end positions is performed via screws “F” and “B” in the housing.
- Take the pistons together in which pressure is applied to connection 4. The actuator is now in position basic position 0°.
- Loosen the locknut at the side and then turn the end position screw “F” inwards until the desired
- position is reached.
- Secure the position by tightening the locknut.
Switch position 90°
Setting the stroke limits
- Isolate the actuator from the air supply before adjusting the end positions.
- Never use the adjusting screws to press against the operating pressure.
- Adjustment of the stroke limitation is performed via screws “E” in the cover.
- Take the pistons apart in which pressure is applied to connection 2. The actuator is now in position switch position 90°.
- Loosen the locknut “D” (at one end cover) and then turn the end position screw “E” inwards
- until the desired end position of the actuator is reached.
- Secure the position by tightening the locknut.
- Hold the actuator in this position as you apply air pressure to connection 2 (2 bar max.), or use an open-ended spanner which fits perfectly to the pinion.
- Loosen the locknut “D” (at the other end cap) and then turn the end position screw “E” inwards
- until the screw just begins to apply pressure to the piston inside.
- Secure this position of the screw by tightening the locknut.
Switch position 90°
Actuator - Dismantling and Assembly F B
- Attention! Danger of Injury!
- Before doing any work whatsoever on the actuator- isolate it from the air supply.
- Never use compressed air to push the pistons out of the housing.
- For single-acting actuators- remove the springs first.
- The circlip must not be stretched.
Removing the piston
- Unscrew and remove the end position adjustment screws (“F” and “B”) from the housing.
- Remove the end cover from the actuator. For single-acting actuators, remove the springs.
- Rotate the pinion shaft to push out the cylinders.
Removing the pinion shaft
Dismantle the visual display | Remove the circlip and the 2 below-lying washers | Press the pinion shaft downwards and out of the housing | Remove the stop-dog and the distance washer from the housing |
Assembly with the pistons
- Place the pistons inside the housing. Take care to ensure that the teeth on each of the piston racks fit in with the teeth on the pinion, so that both pistons are taken inwards together.
- Place the end covers in position, insert the screws and tighten in position.
- Take care here to see that the “O” rings are correctly positioned.
Inserting the springs
- Mount the cover only in a pressure-free situation
- Remove the cover from the actuator.
- Place the selected number of springs into the holes in the piston. The positioning in the holes is done according one of the systems shown in illustration “1”.
- Place the end covers in position, insert the screws and tighten in position.
- When tightening the screws, make sure to keep to the tightening sequence as shown in illustration “2” (for tightening torques- please consult page 13).
Screws and tools for the twintorque® actuator
Safety in general
The operating instructions contain essential details about installation, maintenance and operation, which have to be adhered to. These instructions have to be read and fully understood by operators (mechanics, electricians and maintenance personnel) before the actuator is commissioned.
Actuators are customer-specific and designed for special applications, which means they are exclusively designed for specific purposes.
Not only the details about safety in general, contained in the chapter “Safety” but also those in other safety-related situations are to be read, understood and implemented, even those also contained in product-specific safety regulations.
Safety Note
Mounting, dismantling and maintenance work may only be carried out by suitably trained and certified personnel.
In the case of newly-installed compressed air systems, the technical requirements recommended are to be adhered to and the newly-installed pipework is to be thoroughly cleaned before connection to the actuator. This ensures that there is no grease, foreign bodies or other material which could impair the operation of the actuator. Finally, the compressed air supply system is to be organised so that there is no possibility for the formation of condensed water.
General safety notices contained in the operating instructions, which indicate that there is a possibility of danger, if the persons do not take heed of the warnings indicated.
Sign to be always used where maintenance or repair work is being carried out.
Wear personal protection
Dangers of non-adherence to the Safety Instructions
Not keeping to the safety instructions can lead to the loss of every protection the guarantee offers.
The most important disadvantages of not keeping to the safety instructions are:
- Loss of the most important functions
- Danger to the lives of persons through the effects of electrical, pneumatic and mechanical forces
Sources of Danger
If you keep to the instructions for mounting, maintenance and operation, then there can normally
be no causes for danger involved with the machine.
Isolate compressed air & electricity supplies and lock in them position before starting maintenance and/or cleaning work.
Do not forget that there is a real danger of injury when testing the function of mounted actuators, especially when switching.
Operators
Operators are only allowed to commission the actuator, when they have read and fully understood the contents of the operating instructions
Owner/Operator The owner/operator commits himself to only allow persons to work on the actuator, who have read and are familiar with the fundamental stipulations laid down in the laws regulating safety at work and the prevention of accidents.
Additionally, the owner/operator is to ensure that all maintenance, mounting & assembly as well as other ancillary activities concerned with the actuator are carried out by qualified and authorized skilled persons, who have proved their ability to carry out such activities via successfully completed training in all implications and consequences of these operating instructions.
- The owner/operator has to ensure that the operating instructions and protective clothing are permanently available to operators
- Regularly check the safety-related work of the operating personnel.
Independent & Unauthorized Changes and Spare Parts
Alterations and changes to actuators are only possible, i.e. permitted under express permission from the company airpower Europe GmbH.
These conditions are concerned purely and simply with safety. Those who use non-authorized components lose the protection of our warranty- they are responsible themselves.
Transport & Storage
Instructions for transport
Actuators arrive from the factory packaged & protected against shock. It is best they remain packaged until usage, i.e. mounting and commissioning.
Preparation for mounting, i.e. usage can be best carried out on a wooden object, usually a pallet. This avoids unnecessary damage.
Storage & Long-term Storage
Actuators are to be stored dry and free from dust. It is best to store the actuator in the packaging it was delivered in until the time of use.
If these rules are kept to, then no other measures are necessary.
