cashco 48 Series, 148D-01, 148R-02, 48R-01, 148D-02 Installation, Operation & Maintenance Manual

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INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

MODEL 48

SPRING/DIAPHRAGM ROTARY ACTUATORS

I. DESCRIPTION AND SCOPE

Models 48D and 48R are multi-spring, single act ing, spring opposed, rotary ac tu a tors used with Cash co rotary control valves. Regardless of ﬁ nal installed fail ure action, the ac tu a tor is always pres sur ized on “top” of the traveling diaphragm plate.

Cashco has adopted a convention as follows in iden ti fy ing its rotary actuators: “D” = Direct Action = ATC-FO Action “R” = Reverse Action = ATO-FC Action

IOM-48

12-13

SECTION I

The Model 48 actuator is ﬁ eld re vers ible by ar range - ment of actuator with respect to valve stem and valve plug/disc orientation. Some dis as sem bly is re quired, but no new parts are re quired.

Reference the technical bulletin of the valve body these actuators are unitized with for operating/in stal la tion/ se lec tion speciﬁ cations; i.e. available bench settings, strokes, etc.

Figure 1

Model 48 Actuator

SECTION II

II. MODEL NUMBERING

The basic Model Number identiﬁ es the actuator size and action. To identify a unique Model Number, an oth er series of 2-character modiﬁ ers is added to the basic number. This number will identify which basic valve body the actuator may be used on. See Table 1.

TABLE 1

Basic Model No.

48 in2 size

Reverse Action

(ATO-FC)

4 8 R - 0 1

Modiﬁ er

Valve Modiﬁ er

Product Series No.

Ranger QCT -00 through -09 Premier EZO -00 through -09 Premier Unlined -00 through -09

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ACTUATOR MODEL NO. vs. VALVE BODY MODEL

(Model 148 included for clarity)

Full Actuator Model No. Basic Available Air Supply Actuator Modiﬁ er Bench Settings Pressure Unitized Products * Model No. Number psig (Barg) psig (Barg)

48R 1"-2" (DN25-50) Ranger QCT or -01 5-15 (.34-1.03) 20 (1.4) 3"-4" (DN80-100) Premier EZO 48D or Premier Unlined 148R 3"-4" (DN80-100) Ranger QCT or -01 5-13 (.34-0.90) 20 (1.4) 6" (DN150) Premier EZO 148D or Premier Unlined 148R 4"-8" (DN100-200) Ranger QCT, or -02 10-26 (.69-1.79) 36 (2.5) 10" (DN250) Premier EZO 148D 148R 8" (DN200) Premier EZO, or -03 7.5-19.5 (.52-1.34) 27 (1.9) 8"-10" (DN200-250) Premier 148D Unlined

* Metric body size in parenthesis.

III. INSTALLATION

A. Orientation:

1. Recommended actuator major axis ori en ta tion with any model of Cashco rotary control valve is upwards with the valve in a horizontal pipe and the valve stem also horizontal; i.e. position “A” for ATO-FC, or position “B” for ATC-FO.

2. Both Ranger QCT and Premier EZO/Unlined control valve products incorporate an ex tend ed

Position A

SECTION III

valve body bon net and a mounting yoke to allow the actuator to be far enough away from the valve body or mounting ﬂ anges to in cor po rate a minimum of 2" (50 mm) thickness of in su la tion. It should not be necessary to install thermal insulation to any portion of Model 48 actuator. The maximum ambient temperature for installation is 180°F (83°C); the minimum ambient temperature is -20°F (-29°C).

Position A

Position B

FIGURE 2: Mounting position of Ranger QCT to

Model 48 Actuator with Model 73N-B P/P Positioner.

FIGURE 3: Mounting position of Ranger QCT to

Model 48 Actuator w/Model 9540R or Smart Positioners.

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Position A

Position B

FIGURE 4: Mounting position of Premier EZO or Pre-

mier Unlined to Model 48 Actuator with Model 73N-B P/P Positioner

3. A 1/4"–NPT female connection for pneumatic LOAD is located on the side of the actuator’s upper diaphragm casing near the casing ﬂ ange joint. Reference speciﬁ c Ranger-TB or Pre mier-TB for location of the connection.

4. Reference the valve body instructions — IOMRang er, IOM-Premier EZO or IOM-Premier Unlined — for ad di tion al instructions on in stall ing unit in the process piping.

B. Air Supply:

1. Recommendation is that a desiccant dried, instrument quality air supply be used. Such a supply is recommended for outdoor in stal la tions, and is required in areas of freezing weather conditions.

Position B

FIGURE 5: Mounting position of Premier EZO or Pre-

mier Unlined to Model 48 Actuator with Models 9540R or Smart Positioners

2. If air supply contains moisture and/or lu bri cat ing oil, the air should be ﬁ ltered with a co- a lesc ing type of ﬁ lter prior to use in stroking the actuator.

3. Connection for the air loading pressure is 1/4" female NPT. A suitable pipe thread sealant is recommended to be used when installing the pipe or tube ﬁ tting. Exhibit care to prevent the sealant from getting inside the tube/pipe.

4. If an alternate gaseous ﬂ uid is used as a source of loading pressure (i.e. natural gas, ni tro gen, etc.), this gas MUST NOT BE COR RO SIVE to the aluminum casing material.

IV. OPERATION

A. General:

1. Actuators supplied with 5-13 psig (0.34-0.90 Barg) benchset range are designed to op er ate with or without a positioner. A 3-15 psig (0.21-

1.03 Barg) instrument output signal would be required to operate without a positioner.

2. On larger valve body sizes the benchset range is essentially 1.5–2.3 times that of the 5-13 psig (0.34-090 Barg); i.e. 7.5-19.5 psig (0.52-1.34 Barg) or 10-26 psig (0.69-1.79 Barg) for Model 148’s. Either a signal booster or a positioner will be required for full rotation (0°–90°) by the actuator.

IOM-48

SECTION IV

3. If an “installed characteristic” other than the “inherent characteristic” is desired, a positioner plus a “char ac ter iza tion cam” is required. The inherent characteristic of Rang er QCT control valves is linear; for Premiers the inherent characteristic is equal percent.

4. See Tables 2 through 4 for available actuator models with benchset ranges per valve type and body size. (Note: Model 148 actuators included for clarity.) Proper MAX I MUM air supply pressures are also indicated.

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TABLE 2

RANGER QCT

ACTUATOR BENCHSET RANGES

Valve Body Size

In. (DN)

1", 1-1/2" & 2"

(25, 40 & 50)

3" & 4"

(80 & 100)

4", 6" & 8"

(100,150, & 200)

Valve Body Size

In. (DN)

3" & 4"

(80 & 100)

(150)

(200)

10"

(250)

Actuator

Model

Failure

Action

48R-01 ATO-FC

48D-01 ATC-FO

148R-01 ATO-FC

148D-01 ATC-FO

148R-02 ATO-FC

148D-02 ATC-FO

PREMIER EZO

ACTUATOR BENCHSET RANGES

Actuator

Model

Failure

Action

48R-01 ATO-FC

48D-01 ATC-FO

148R-01 ATO-FC

148D-01 ATC-FO

148R-03 ATO-FC

148D-03 ATC-FO

148R-02 ATO-FC

148D-02 ATC-FO

Benchset

Range

psig (Barg)

5-15

(.34-1.03)

5-13

(.34-.90)

10-26

(.69-1.79)

TABLE 3

Benchset

Range

psig (Barg)

5-15

(.34-1.03)

5-13

(.34-.90)

7.5-19.5

(.52-1.34)

10-26

(.69-1.79)

Supply

Pressure

psig (Barg)

(1.4)

(2.5)

Supply

Pressure

psig (Barg)

(1.4)

(1.9)

(2.1)

Qty of Range

Springs

Qty of Range

Springs

TABLE 4

PREMIER UNLINED

ACTUATOR BENCHSET RANGES

Valve Body Size

In. (DN)

3" & 4"

(80 & 100)

(150)

8" , 10"

(200, 250)

Actuator

Model

Failure

Action

48R-01 ATO-FC

48D-01 ATC-FO

148R-01 ATO-FC

148D-01 ATC-FO

148R-03 ATO-FC

148D-03 ATC-FO

Benchset

Range

psig (Barg)

5-15

(.34-1.03)

5-13

(.34-.90)

7.5-19.5

(.52-1.34)

Supply

Pressure

psig (Barg)

(1.4)

(1.9)

Qty of Range

Springs

* Model 148 included for clarity.

IOM-48

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SECTION V

V. MAINTENANCE

A. General:

1. Hereafter, all maintenance, disassembly, etc., is as sumed to be done in an indoor shop.

2. Most actuators are a sub-assembly that is unitized with a body sub-assembly. Ref er ence should be made to the IOM for the correct body utilized.

3. Where the body is not being disassembled, special care MUST be exhibited to prevent valve stem rotation during any disassembly or reassembly for all types of valves. Following this procedure will ensure not damaging seat ing surfaces.

4. Remove all instrument tubing and in ter con nect ed electrical wiring. Label “ends” to en sure proper reconnection.

5. All indicated Item Numbers that are with re spect to IOM-Ranger, IOM-Premier EZO or IOM-Premier Unlined will be in parenthesis and underscored; i.e. (20); the same is true for Model 73N-B P/P positioner parts.

6. All Item Numbers that are with respect to this IOM-48 are not underscored; i.e. (19).

7. Item Numbers that relate to the Model 9540 or Smart positioners ((PA)) are in a double set of pa ren the sis and are underscored; i.e. ((3)).

B. Separation of Body Assembly (BA) from Ac-

tu a tor Assembly (AA):

1. Place completely joined valve assembly (AA)

(BA) upon a ﬂ at work surface with suf ﬁ cient room to move the individual sub-as sem blies (AA) (BA) around. Place matchmarks on valve yoke (12), arm housing (4) and ac tu a tor lower casing (2) to use as ref er enc es.

2. Remove cover plate (20) away from arm

hous ing (4) by removing four machine screws (36).

washer (55) se cur ing the bright or angecol ored travel in di ca tor (16) to the upper end of valve stem (Rang er (7)), (Premier (3.2)) using a 7/32" allen key wrench. Re move travel in di ca tor (16) off of pro trud ing lo ca tor pin (51).

c. If equipped with a Model 73N-B P/P po-

sitioner, re move the four cap screws (33) that secure the positioner assembly (PA) to the arm housing (4) using a 3/16" allen key wrench. Remove positioner as sem bly (PA) and feed back range spring (102). Loop a 6" piece of ﬁ ne wire around the feedback linkage subassembly (72). Place one screw (33) back into a tapped open ing. Pull wire taut and wrap around pro trud ing screw (33) to keep the linkage (72) from interfering with further dis as sem bly.

3B. Units with End-of-Shaft Model 9540R Posi-

tioners:

a. Remove clear indicator cover ((22)) by

removing two cap screws ((A3)).

b. Remove red plastic pointer ((34)) by pull-

ing outwards from hub of post-end screw ((23)).

c. Make a matchmark on the char ac ter iza-

tion cam ((24)) at the point where the cam follower ((31)) touches. Using a wrench remove post-end screw ((23)) that se cures characterization cam ((24)). Pull feedback lever ((13)) downwards; re move cam ((24)) and adhered to lock toothed washer ((28)) and shouldered wash er ((27)).

d. Remove the positioner unit ((I/P)) ((P/P))

from the baseplate ((26)) by removing cap screws ((11)) with lock washers ((12)) from side and back of baseplate ((26)).

e. Remove the four cap screws ((78)) se cur-

ing the bracket ((76)), baseplate ((26)) assembly and coverplate (13) to the arm housing (4).

3C. Units with End-of-Shaft Model 991 or PS2 I/P

Positioners:

3A. Units with Model 73N-B P/P Positioner or No

Positioner, and No Travel Limit Switch:

a. Using a 3/16" allen key wrench, remove

the three cap screws (31) securing the dial lens (14), travel indicator dial (15) and coverplate (13).

b. Remove cap screw (32) and lock tooth

IOM-48

a. Remove cap screws (31) securing the

positioner mounting bracket ((9)) to coverplate (13).

b. Set positioner/bracket assembly to the

side.

c. Remove set screw ((16)), washer ((17))

from end of valve stem (Ranger (7)), (Premier (3.2)) securing carrier linkage ((3)) to stem.

d. Remove linkage ((3)) from end of stem.

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4. For ATO-FC valve action, it is necessary to remove the “stem windup”. a. Rotate manual handwheel operator

(MHWO) handwheel (58.1) ap prox i mate ly 1-3 revolutions CW (viewed from above handwheel) until interconnecting arm and stem linkage (5, 10) of actuator “relax”.

b. Pressurize actuator casing (1) only

until the in ter con nect ing arm and stem linkage (5,10) “relax”. DO NOT OVERPRES SUR IZE.

body assembly (BA) from Figures 6-9, fol low ing pages.

2. The valve body/bonnet (1) to valve body yoke (12) can be rotated in four 90° increments around the centerline of the valve shaft (Rang er (7)) (Premier (3.2)).

3. Separate the actuator assembly (AA) from the body assembly (BA) as described in this Sec tion, V.B.1. through V.B.9.

NOTE: Do not remove the drive coupling ((32)) unless required.

5. Remove ball bearing (18), both bearing ﬂ ang es (19) and indicator spacer (17) over shaft-end (Ranger (7)), (Premier (3.2)).

6. For actuator with a handwheel (58), rotate handwheel CW (viewed from above), driving the arms (5) down until the shoulder bolt (40) clears the ears on the arm housing (4). If actuator does not include a handwheel (58), loosen jam nut (44) and, using a 9/16" open end wrench, rotate the hex portion of the push rod (10) until the shoulder bolt (40) clears the ears on the arm housing (4).

7. Remove lock nut (46) that secures shoulder bolt pin (40) through lever arms (5). Remove shoulder bolt pin (40).

8. Grasp lever arms and rotate stem (Ranger (7)), (Pre mier (3.2)) as required to pull down and away from the lower rod end-L.H. (9) to allow clearance to remove arms (5). Slide subassembly consisting of both arms (5), spacer (12) or characterization cam (Model 73N-B (12)), and two spring pins (50) out wards and away from the arm housing (4) and over shaft-end (Ranger (7)), (Premier (3.2)).

9. While securely holding the actuator assembly (AA) with an overhead sling support, and the body assembly (BA) to prevent movement, remove the four bolts (24) that secure the body yoke (12) to the actuator arm housing (4). Slide the actuator assembly (AA) over the stem-end (Ranger (7)), (Pre mier (3.2)). Lay body assembly (BA) aside.

C. Changing Actuator Mounting Position (With

No Change in Failsafe Action).

4. Determine if it is necessary to interchange packing studs (21) on Ranger or Premier Un lined, and yoke (12) attachment hex head cap screws (19) on Rang er or Premier Un lined per fol low ing:

Degrees Packing Studs Rotary Valve Rotation Yoke Attach Studs Position Change Switch of Position

Ranger, 90°, 270° Required Premier Unlined 180° Not Required Premier EZO 90°, 180°, 270° Not Required

5. If required, remove both packing ﬂ ange stud nuts (22) on Ranger or Premier Unlined, and any external live-loaded packing com po nents (Rang er (27) (28) (29)), and set both aside carefully to prevent an “inadvertent mix ing” of the component’s “stack-up”.

6. Place matchmarks between yoke (12) and valve bon net/body (1). While holding yoke (12) with hand, remove two cap screws (19) and pull yoke (12) over end of stem (Ranger (7)) (Premier (3.2)) and set aside.

7. If necessary, remove studs (21) from Ranger or Premier Unlined body assembly (BA) and re lo cate/in ter change as re quired.

8. Reposition yoke (12) back onto body bonnet (1), shifted/rotated the number of degrees re quired (i.e. 90°, 180° or 270°), using the matchmarks to guide to correct position. Se cure yoke (12) to body bonnet (1) by engaging two cap screws (19). Torque per following:

1" & 2" Rangers — 35-40 ft-lbs (47-54

N-m)

3" & 4" Premiers, lined & unlined —

75-80 ft-lbs (101-108 N-m).

1. Determine the desired mounting position of actuator assembly (AA) with respect to valve

IOM-48

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FIGURE 6:

ORIENTATION – RANGER QCT ACTUATOR MOUNTING POSITIONS

WITH MODEL 73 P/P POSITIONER

REVERSE ACTION DIRECT ACTION

NOTES: 1. Flangeless valve design indicated; integral ﬂ anged units follow same orientation.

2. Dimension tables are included in the Ranger-TB.

IOM-48

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FIGURE 7:

ORIENTATION – RANGER QCT ACTUATOR MOUNTING POSITIONS

WITH MODELS 9540R P/P or 991 or PS2 I/P POSITIONERS

REVERSE ACTION DIRECT ACTION

NOTES: 1. Flangeless valve design indicated; integral ﬂ anged units follow same orientation.

2. Dimension tables are printed in the Ranger-TB.

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Page 9

FIGURE 8

PREMIER ACTUATOR MOUNTING POSITIONS – 73

Position "A" is standard for fail closed action. Position "B" is stan dard for fail open action.

Po si tion "C" and "D" covers ver ti cal piping.

FIGURE 9

PREMIER ACTUATOR MOUNTING POSITIONS – 9540R/991/PS2

Position "A" is standard for fail closed action. Position "B" is stan dard for fail open action.

Po si tion "C" and "D" covers ver ti cal piping.

Note: All basic valve dimensions are printed in the Premier-TB

IOM-48

Page 10

9. Reposition packing ﬂ ange (Ranger (14)) (Pre mier Unlined (5)) over packing studs (21) for Ranger and Premier Unlined. Reinstall live-loaded packing components (Rang er (27) (28) (29) 2 sets). Reengage both pack ing stud nuts (22) for Ranger and Premier Un lined. Set torque level on pack ing stud nuts as indicated in IOM-Ranger QCT, IOM-Pre mier EZO, or IOM-Premier Unlined body as sem bly (BA) instructions.

10. Reorient body assembly (BA) with respect to the actuator assembly (AA). Rejoin the body assembly (BA) to the actuator assembly (AA) as described in this section, V.I. Ensure prop er plug (Ranger (6)) or disc (Premier (3.1)) po si tion prior to reinstalling lever arms (5). Ensure that the lever arms (5) are “centered” within the arm housing (4), and with respect to the actuator stem linkage (8) (9) (10) (43) (44).

11. Recalibrate the unit (AA) (BA) and its positioner ((PA)).

D. Changing Failsafe Action:

3. To reverse actuator (AA) failsafe action ba si cal ly requires: a. Moving lever arms (5) from left side of

valve’s stem (Ranger (7)) (Premier (3.2)) to right side, or vice versa. This is ac com plished by removing actuator assembly (AA) from body assembly (BA) and ro tat ing actuator (AA) 180° about the ac tu a tor’s stem linkage (8) (9) (10) (43) (44). See Figure 10 and Figure 11.

b. Rotating plug (Ranger (6)) or disc (Pre mier

(3.1)) by 90°; ie. from “closed” po si tion to “open” position, or vice versa.

c. Reconnecting actuator (AA) to body (BA)

with lever arms (5) also rotated 180°.

NOTE: Valve stem always goes CW to “close”, viewed from stem-end.

4. Separate the actuator assembly (AA) from the body assembly (BA) as described in this Sec tion, V.B.1. through V.B.9.

5. Rotate plug (Ranger (6)) or disc (Premier (3.1)) position 90° to new failsafe position.

1. The Model 48 actuator (AA) is ﬁ eld-re vers ible for failsafe action with no additional parts required.

2. It is possible that both of the following can occur together for the degree of disassembly undertaken: a. Failsafe action reversed. b. Change in actuator mounting position.

NOTE: This section will be limited to the pro ce dures for 2.a. above. If 2.b. is also desired, then it will be necessary to reference Sub sec tion C. here in for the added procedural steps as required.

This subsection will thus be limited as in di cat ed as follows (reference Figures 6 – 9 herein for be gin ning and end graphic orientations).

Product Begin End Position Action Position Action

“A” ATO-FC “B“ ATC-FO “C” ATO-FC “D” ATC-FO “E” ATO-FC “F” ATC-FO Ranger QCT “G” ATO-FC “H” ATC-FO “B” ATC-FO “A” ATO-FC “D” ATC-FO “C” ATO-FC “F” ATC-FO “E” ATO-FC “H” ATC-FO “G” ATO-FC Premier EZO “A” ATO-FC “B” ATC-FO or “C” ATO-FC “D” ATC-FO Premier “B” ATC-FO “A” ATO-FC

Unlined “D” ATC-FO “C” ATO-FC

6. Slide actuator assembly (AA) that has been rotated 180° back over the stem-end (Ranger (7)) (Premier (3.2)). Align bolt holes between arm housing (4) and valve yoke (12).

7. Reengage bolting (24) securing arm housing (4) to yoke (12). Torque bolting (24) to 17-20 ft-lbs (23-27 N-m).

8. Ensure that the reinstalled lever arms (5) are also rotated 180° in the same reference as the actuator as sem bly (AA) was rotated. (NOTE:

The repositioned arms (5) will appear to have only changed relative position by 90° in an oth er plane.) Ensure the lever arms assembly (5)

is “centered” within the arm housing (4), and with respect to the actuator stem (8) (9) (10) (43) (44).

9. Rejoin the body assembly (BA) to the actuator as sem bly (AA) as described in this Section, V.I.

E. Diaphragm Replacement:

1. Place unit assembly (AA) (BA) onto a ﬂ at work bench with actuator upper casing (1) on top side; i.e. handwheel (58), if supplied, on top side.

2. Ensure that all air pressure is released from actuator assembly (AA) casing (1).

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Page 11

CCW-TO-OPEN

ATC-FO

(DIRECT)

Push Down-to-Close

NOTE: To switch “action” requires locating actuator stem to opposite side of valve stem.

CCW-TO-OPEN

ATO-FC

(REVERSE)

Push Down-to-Open

5. Loosen all casing (1,2) ﬂ ange bolting (27, 28,

41, 42) two revolutions. Pry apart the casings (1,2) if “stuck” together.

6. In one revolution increments loosen all op-

pos ing nuts (41, 42) until the short bolting (27, 41) disengages and can be removed. Con tin ue loosening extension nuts (42) in the alternating, one revolution pattern ensuring that the cas ings (1, 2) are being “pushed apart”, until the extension bolting (28, 42) is disengaged and removed.

7. Lift the upper casing (1) upwards and away

from the lower casing (2). Set upper casing (1) aside.

Figure 10

Ranger Plug vs. Lever Arm vs. Actuator Ori en ta tion

CCW-TO-OPEN

ATC-FO

(DIRECT)

Push Down-to-Close

NOTE: To switch “action” requires locating actuator stem to opposite side of valve stem.

CCW-TO-OPEN

ATO-FC

(REVERSE)

Push Down-to-Open

Figure 11

Premier Plug vs. Lever Arm vs. Actuator Ori en ta tion

3. Ensure that manual handwheel (58) operator is fully rotated upwards by loosening locking lever (59) and ro tat ing CCW (viewed from top side) as far as possible.

4. Place a matchmark between actuator casings (1) (2).

WARNING

SPRING UNDER COMPRESSION. Prior to re mov ing ﬂ ange bolting (27, 28, 41, 42) re lieve range spring (11) compression by rotating the handwheel or adjusting screw assembly (58) CCW (viewed from above handwheel (58) until all spring com pres sion is re lieved. Fail ure to do so may result in ﬂ ying parts that could cause personal injury.

8. Remove pivot screw (25) by rotating CCW (viewed from above), and seal (56).

9. Pry diaphragm washer (52) loose. Clean wash er (52) of any rubberized sealant.

10. Prior to diaphragm (6) removal, inspect to see where a diaphragm (6) leak may have been caused by wearing against the upper case (1) at any point. Inspect the upper case (1). NOTE:

The diaphragm (6) is a rolling di a phragm and should NOT touch the upper case (1) at any point of the piston’s (3) up wards/downwards travel. If there is side move ment of the piston (3), further dis as sem bly for inspection of range springs (11) is man da to ry. If there is topside wear, uptravel stop washer (54) is not prop er ly adjusted.

11. Remove diaphragm (6) and discard.

12. Clean surface of piston (3) of any foreign material that could cause a premature failure of diaphragm (6) if cov ered. Turn diaphragm (6) “inside-out”. Place diaphragm (6) onto piston (3) centered over the center bolt hole in piston (3); ensure that the smooth black sur face of di a phragm (6) is on the “pressurized air-side”.

13. Place silicone sealant, Dow-Corning “Silastic” #732 RTV or equal, around the diaphragm’s (6) center bolt hole opening. Lay diaphragm washer (52) onto sealant and centered over bolt hole. Replace seal (56) on top of washer (52).

14. Place a tool around the skirt circumference of the piston (3) to secure during tightening; use tape or similar material to prevent this tool from leaving sharp edges that could damage

IOM-48

Page 12

the new diaphragm (6). Place Locktite #242, or equal, thread sealant onto the threads of pivot screw (25); engage and tighten screw (25) to 15-20 ft-lbs (21-27 N-m) torque. NOTE:

Piston (3) must be held from rotating to pre vent the multiple nested range springs (11) from tilting away from a common vertical centerline be tween hubs of lower case (2), piston (3) and range spring (11).

15. Fold the diaphragm (6) skirt from its insideout ori en ta tion, down and around the piston’s (3) skirt. Using a rounded-end tool, push the diaphragm (6) down between the lower cas ing (2) sidewall and the piston’s (3) skirt, forming a “valley”. Work diaphragm (6) to ensure that all folds or “puckers” are taken away. Press the di a phragm’s (6) lower/outer beaded edge into the groove. Again, smooth out all folds or puckers in diaphragm (6).

16. Place a light coating of graphite powder lu bri cant, (dry mo lyb de num disulﬁ de) on the skirt ed areas of diaphragm (6), and into the “valley”. This lubricant will prevent the di a phragm (6) from “sticking together” or abrad ing itself dur ing piston (3) travel.

17. If actuator (AA) is supplied with a manual handwheel operator (MHWO), place a heavy-duty wheel bearing grease, Lubriplate No. 130-AA, or equal, into the v-notch in the head of the pivot screw (25).

WARNING

1. Elongated extension bolting (28) (42) is a safe ty feature to allow relaxation of range springs (11) to the piston’s (3) mechanical uptravel stop at dis as sem bly.

2. Extension bolting (28) (42) should ONLY be re placed with factory replacements; do NOT sub sti tute con ven tion al bolting.

3. Extension bolting (28) (42) MUST be located 180° opposite of each other in the ﬂ ange bolt- ing array. Failure to heed could cause per son al injury at a later dis as sem bly.

21. Place the same friction-reducing thread lu bri cant into the threaded portion of both ex ten sion nuts (42). NOTE: Only one end of ex ten sion

nut (42) is threaded. It is not possible to engage the extension bolting (28) (42) with the extension nut (42) upside down; the threads of the nut (42) will not engage.) Engage both

extension nuts (42) until they draw tight to the lower casing (2) ﬂ ange’s underneath side. Place one short bolt (27) through a bolt hole of upper ﬂ ange (1) to serve as an indicator. In one-rev o lu tion increments and an al ter nat ing cross-pattern, draw the casing (1) (2) ﬂ anges to wards each other. When there is at least one-half of the indicator short bolt (27) threads exposed through the lower casing (2) ﬂ engage nut (41) until the short bolting (27) (41) is ﬁ nger-tight.

ange,

18. Inspect working of manual handwheel op er a tor (MHWO) located within the upper casing (1) for signs of wear. Go to Subsection F. for maintenance of manual handwheel operator (MHWO).

19. Place properly oriented upper casing (1) down onto the lower casing (2) with matchmarks aligned and all casing ﬂ ange bolt holes cen- tered. NOTE: The casing ﬂ anges (1) (2) will

not touch together.

20. Insert both extension bolts (28) through two upper casing (1) bolt holes that are located 180° across from each other; these bolts should extend through the lower casing (2) ﬂ ange enough to engage its companion ex ten sion nut (42). Place a friction-reducing thread lubricant on the lower exposed threads of the extension bolts (28).

22. Place all short bolts (27) through the re main ing upper casing (1) ﬂ ange bolt holes, and engage each ones nut (41) until the short bolting (27) (41) is ﬁ nger-tight.

23. In an alternating cross-pattern, tighten all ﬂ ange bolt ing (27) (28) (41) (42) in onerev o lu tion increments. When all bolting (27) (28) (41) (42) is hand-wrench tight, torque to levels indicated below:

Item Torque Req’d Nos. Description ft-lbs N-m

27, 41 Short Bolting 15–18 20–24 28, 42 Extension Bolting 8–12 11–16

24. Connect a temporary instrument air source di rect ly to the 1/4" FPT connection in the upper casing (1). Pres sur ize to the “Air Supply Pressure” level as indicated in Table 2-4 of

IOM-48

Page 13

Section IV.A.4. for the corresponding actual benchset range of the actuator being ser viced, and test for leakage at upper casing (1) to lower casing (2) joint. Also test for leakage at man u al handwheel operator (MHWO), ro tat ing handwheel (58) in and out several times dur ing the test.

25. Release all air pressure into actuator upper casing (1); remove air source from 1/4" FPT connection.

F. Manual Handwheel Operator:

1. Reference Item Number drawing at end of IOM for de tails of the man u al handwheel op er a tor (MHWO) sub-assembly.

2. Place unit (AA) (BA) on a ﬂ at work surface with the handwheel (58) on topside.

wheel (58.1) end) back into the handwheel gland (67). When stem (58.2) protrudes far enough through gland (67), re lo cate locking pliers to opposite end and ro tate stem (58.2) until stem (58.2) fully dis en gag es.

12. Remove O-ring (62) from handwheel gland (67).

13. Remove O-ring (63) from handwheel stem (58.2).

14. Place parts (58.2) (59) (60) (64) (67) into a suitable solvent and clean as much as pos si ble, remove parts and allow to dry.

15. Inspect handwheel stem (58.2) with em bed ded ball (64) for wear on ball (64). If ball (64) is worn, or threads of stem (58.2) are dam aged, replace handwheel sub-assembly (58); i.e. parts (58.1) (58.2) and (64).

3. Ensure all air pressure has been released from ac tu a tor casing (1). Ensure handwheel (58) is fully “backed-out” by rotating CCW (viewed from above); i.e. is as “high” as pos si ble.

4. Remove slotted-head screw (65) securing handwheel gland (67) to upper casing (1).

5. Place a smooth-jawed wrench onto handwheel gland (67) and rotate CCW (viewed from above) to removal of the manual handwheel operator sub-assembly (MHWO).

6. Place the sub-assembly (MHWO) into a vise, grasping with leaded jaws on the coarsescrewed handwheel stem (58.2) near the base of the handwheel (58.1), oriented to allow driving-out the rolled pin (66) securing the handwheel (58.1) to the handwheel stem (58.2).

7. Drive pin (66) out using a suitable punch and locking pliers. Set pin (66) aside for reuse. Remove handwheel (58.1) from stem (58.2).

8. Rotate locking lever (59) CCW (viewed from handwheel-end) to removal.

9. Slide washer (60) and threadseal washer (61) off handwheel stem-end (58.2). Discard threadseal washer (61).

16. If handwheel gland (67) shows signs of wear in female threads (i.e. loose gauging), replace handwheel gland (67) and self-tapping slot ted-head screw (65). NOTE: A re place ment handwheel gland (67) will require drilling a new 5/32" x 1-1/16" (4mm x 25.5mm) deep hole into the lip of the upper casing (1).

17. Install new O-ring (63) onto handwheel stem (58.2).

18. Install new O-ring (62) onto handwheel gland (67).

19. Place a thin coat of lithium grease on the handwheel stem O-ring (63) and the im me di ate surrounding area of the handwheel stem (58.2).

20. Engage the handwheel stem (58.2) into the gland’s (67) underneath side. When the handwheel (58.1) end of the stem (58.2) pro trudes through the gland’s (67) upper side, place a new threadseal washer (61) over the stem’s (58.2) upper end. Continue engaging stem (58.2) until the O-ring (63) is pulled into the gland (67).

21. Install washer (60) and locking lever (59) onto stem (58.2).

10. Remove remaining engaged parts (67) (58.2) from vise. Reorient horizontally in vise along ﬂ ats of handwheel gland (67).

11. Place stick punch in drive-pin hole and rotate handwheel stem (58.2) CW (viewed from hand-

IOM-48

22. Place handwheel stem (58.2) into a soft-jawed vise. Position handwheel (58.1) onto stem (58.2) with holes for pin (66) aligned. Insert pin (66) and drive through stem (58.2) and handwheel (58.1) far side. Remove handwheel assembly (MHWO) from vise.

Page 14

23. Place heavy duty wheel bearing grease as speciﬁ ed previously onto the stem-end ball (64). Engage the gland (67) into the upper casing (1) female opening. Align tapped open ing for self-tapping slotted-head screw (65).

24. Install slotted-head screw (65) fully.

G. Adjusting Screw Assembly and Actuator Plug

Maintenance:

1. Reference Item Number drawing at end of the IOM.

WARNING

Do NOT stick hand or ﬁ ngers into the arm housing (4) when the actuator is pressurized. ONLY USE TOOLS WITHIN ARM HOUSING (4).

4. Place a wrench on the hex surface of the ac tu a tor’s stem/pushrod (10). Rotate the push rod (10) CCW (viewed from lower L.H. rod end (9)); keep track of number of revolutions to disengage from upper R.H. rod end (8) in box below.

2. Determine the portion of the text of Sub sec tion F. above that would apply to the adjusting screw assembly (ASA) counterpart of the manual handwheel operator (MHWO) as sem bly, and complete maintenance in a sim i lar procedure. NOTE: Adjusting screw assembly

(ASA) is ONLY applied to reverse-action, ATO-FC Ranger QCT units (AA) (BA).

3. Determine the portions of the text of Sub sec tion F. previous that would apply to the ac tu a tor plug (67) coun ter part of the manual handwheel operator (MHWO) as sem bly, and complete maintenance in a similar procedure. NOTE:

Actuator plug (67) may be applied on all Premier units (AA) (BA) and ONLY direct-action, ATC-FO Ranger QCT units (AA) (BA).

H. Replacement of Range Springs:

1. Replacement of actuator assembly (AA) range springs (11) requires what is essentially a complete actuator (AA) disassembly. It is rec om mend ed that the range spring (11) re place ment should include: a. diaphragm (6) replacement b. O-ring(s) (62) (63) replacement c. threadseal (61) replacement.

2. Separate the actuator assembly (AA) from the body assembly (BA) as described in this Sec tion, V.B.1 through V.B.9.

3. Push piston (3) downwards by: a. manual handwheel operator (MHWO)

being rotated CW (viewed from above handwheel (58.1)) approximately one-half of full travel.

b. pressurize actuator to approximately one-

half of the stated benchset range; i.e. for 5-15 psig (.34-1.03 Barg) pressurize to ap prox i mate ly 10 psig (.69 Barg).

Number of revolutions of push rod (10) re quired to disengage from upper R.H. rod end (8). ___________

5. Allow piston (3) to travel upwards by: a. manual handwheel operator (MHWO)

being rotated CCW (viewed from above handwheel (58.1)) fully out/up.

b. releasing air pressure as applied per 3.b.

above; remove the air supply from ac tu a tor upper casing (1).

6. Orient actuator assembly (AA) with upper casing (1) on top side. Disassemble the ac tu a tor assembly (AA) to the point of di a phragm (6) replacement as described in this Section V.E.1 through V.E.11.

7. Place a matchmark at ﬂ ange of lower casing (2) and correspondingly at piston (3). Lift off piston (3) in a vertical direction to prevent tipping range springs (11) over. Set piston (3) on work surface upside down.

8. Remove all range springs (11) and set in a row side-by-side. Inspect for any difference in the spring (11) height or verticality. Replace any abnormal spring(s) (11). Re place any springs (11) that show cracks, nicks, damaged epoxy coating, corrosion, etc. Inspect springs (11) using data in table below as the “normal”:

Benchset Free Part Range Qty. of Height * Coating Number psig (Barg) Springs in (cm) Color

830-H2-5-R9069-95 5-15 6 5.60 Grey (0.34-1.03) (14.23)

* Acceptable ± 1/8" (± 3 mm)

IOM-48

Page 15

9. Inspect clevis (7), upper R.H. rod end (8), clevis pin (48), washers (53) and hairpin (49) for signs of looseness and/or wear; re place any worn parts. Check bolting (26) for loose ness; tighten as necessary to 15-18 ft-lbs (20-23 N-m).

12. Reinstall a new diaphragm (6) and re as sem ble the upper casing (1) as described in this Section, V.E.12 through V.E.24.

13. Using air pressure of V.E.24., pressurize the actuator upper casing (1) to the upper value of the stated benchset range plus 2 psi (0.14 Bar); i.e. for 5-15 psig (0.34-1.03 Barg) benchset range, pressurize to 15+2 = 17 psig (1.03+0.14 = 1.17 Barg). This pressure level should cause the piston’s (3) lower skirt-edge to bottom out on the lower casing (2).

14. Using only tools (i.e. no ﬁ ngers within arm housing (4)) to grasp the actuator stem/push rod (10), insert push rod (10) with in ter con nect ed parts (9) (43) (43) (44) (54) into arm housing (4) and engage into dangling upper R.H. rod end (8) by rotating CW (viewed from lower L.H. rod end (9)). Count number of revolutions of push rod (10) en gage ment to match those recorded in Article 4., previous, at removal.

Figure 12

Piston & Clevis Close-up

10. Place range springs (11) back onto hubs of lower casing (2) per following table:

NOTE: Every spring (11) has another spring (11) 180°

across/opposite.

Benchset Range Quantity

psig (Barg) of Springs Array

Hub w/NO

Spring (11)

5-15 (0.34-1.03) 6

Hub With

Spring

(11)

11. Aligning matchmarks of Article 7. above, re po si tion piston (3) back onto top side of range spring (11) array. Using a mirror tool and ﬂ ashlight, look through the rect an gu lar open ing in the lower casing (2) from within the arm housing (4) to ensure that the piston (3) hubs are centered within the ID of the range spring (11) coil. It may be necessary to use a tool to move the upper end of the range spring (11) as necessary to be “captured” by a piston (3) hub. Each spring (11) MUST be captured by a hub on top and bottom ends.

15. Release all air pressure into actuator upper casing (1); remove air source from 1/4" FPT connection.

16. Join the actuator assembly (AA) to the body assembly (BA) as described in this Section, V.I.

I. Joining of Body Assembly (BA) to Actuator

As sem bly (AA):

1. Determine proper orientation of actuator (AA)-to-body (BA) for the following considerations:

• failsafe action

• installed piping orientation.

Reference Sub-sections V.C. and V.D. to see

sche mat ics of orientations available.

2. Position body assembly (BA) on a ﬂ at work surface. Orient such that the actuator as sem bly (AA) can be ori ent ed with the top of the actuator upper casing (1) on topside; i.e. man u al handwheel operator sub-assembly (MHWO) stem (58.2) vertically oriented, if supplied.

3. Using an overhead hoist, lift the actuator as sem bly (AA) (with position indicator ap pa ra tus (13,14,15,16,17,31,31,34), lever arm ap pa ra tus (5,5,12,40,46,50,50), end-of-shaft

IOM-48

Page 16

bearing (18), bearing ﬂ anges (19) and cover plate (20) removed) prop er ly ori ent ed and shift lat er al ly over the pro trud ing stem (Rang er (7), Premier (3.2)). Bring the round opening of the arm housing (4) into position against the mounting yoke (12). Raise/lower/tip/rotate the actuator assembly (AA) to align at least one bolt hole of the yoke (12) with one bolt hole in the arm housing (4). Insert one cap screw (24) from behind the yoke's (12) bolt hole and engage with the tapped opening in the arm housing (4); ﬁ nger tighten cap screw (24).

4. Reposition actuator assembly (AA) as re quired to align the remaining bolt holes se cur ing yoke (12) with arm housing (4). In sert the cap screws (24) and ﬁ nger-tighten.

5. (Wrench-tighten in one-half revolution in cre ments and in an alternating cross-pattern the three cap screws (24) securing actuator as sem bly (AA) to body assembly (BA). Final tightening should be by torque wrench to 1720 ft-lbs (23-27 N-m)

6A. For units (AA, BA) with Model 73N-B P/P

positioner: a. Secure characterization cam (12) prop er ly

oriented over the two rolled spring pins (50) stuck into the inner lever arm (5).

b. Place the outer lever arm (5) over the

two spring pins (50) with the bolt holes align ing. Press the apparatus (5,50,50,5) to geth er.

into place. Center-align lever arm apparatus (5,50,12,50,5) transversely within the arm housing (4), directly over stop screw (35).

9A. For units (AA, BA) with Model 73N-B P/P po-

sitioner: Place indicator spacer (17) over end of shaft (Ranger (7), Premier (3.2)) prop er ly oriented for travel indicator (16) to be “located” by spring pin (51).

9B. For units (AA, BA) with Model 9540R P/P

positioner or 991 or PS2 I/P positioner: Reference the IOM-9540R or 991/PS2 IOM for proper instructions on reinstallation of in di ca tor spacer (17) and drive coupling ((32)).

10. Align the bolt holes in lever arms (5) and lower

L.H. rod end (9). NOTE: For units (AA, BA)

with ATO-FC action it will be necessary to offset “stem windup” by – a. Rotating manual handwheel operator

(MHWO) handwheel (58.1) ap prox i mate ly 1-3 rev o lu tions CW (viewed from above handwheel) until the bolt holes of lever arms (5) and lower L.H. rod end (9) are aligned.

b. Pressurize actuator casing (1) only until

the bolt holes of the lever arms (5) and the lower L.H. rod end (9) align.

11. Insert shoulder bolt (40) through the round opening of the arm housing (4) and into the bolt holes of lever arms (5) and lower L.H. rod end (9).

6B. For Units (AA, BA) with no positioner, Model

9540R P/P positioner or 991 or PS2 I/P: a. Similar to 6A. above, except a spacer

wash er (12) replaces the cam (12) of a Model 73N-B P/P positioner.

7. Position valve plug (Ranger (6)) / disc (Pre mier (3.1) in the proper “Full Closed” or “Full Open” position. NOT FOLLOWING THIS ARTICLE

WILL CAUSE ME CHAN I CAL DAMAGE TO THE UNIT’S (AA, BA) LINKAGE MECH A NISM!

8. Place properly oriented lever arm ap pa ra tus (5,50,12,50,5) over shaft’s (Ranger (7), Pre mier (3.2)) square end and push into place while holding lower L.H. rod end (9) “swung” aside so as to not interfere. NOTE: For units

(AA, BA) with 73N-B P/P positioner, it will be nec es sary to “swing” the feedback linkage subassembly ((72)) out of the way as the lever arm apparatus (5,50,12,50,5) is pushed

12. Ensure that lever arm apparatus (5,50,12,50,5) is transversely centered within the arm hous ing (4). Engage lock nut (46) together with shoulder bolt. Wrench-tighten to a torque of 15-20 ft-lbs (20-27 N-m).

13. Position bearing ﬂ anges (19) with retainer ball bearing (18) over the spacer (17). Align the bearing ﬂ anges' (19) bolt holes with the arm housing (4) bolt holes.

14A. Units (AA, BA) with Model 73N-B or without

postioner: a. Insert rolled spring pin (51) into indicator

spacer (17). Pin (51) will protrude ap prox i mate ly 1/16" (1.5 mm).

b. Position travel indicator (16) onto end of

shaft (Ranger (7), Premier (3.2)) impaling over pro trud ing spring pin (51) and align ing with shaft-end tapped opening with hole in travel in di ca tor (16). Align lock-tooth washer (55) on spacer (17) and secure

IOM-48

Page 17

ATO-FC (Reverse) Action

trav el in di ca tor (16) to shaft (Rang er (7), Pre mier (3.2)) with cap screw (32) using a 7/32" allen key wrench until ﬁ rmly tight.

c. Position cover plate (13) over the bearing

ﬂ anges (19) aligning the cover plate (13) bolt holes with those of the bearing ﬂ ang es (19). Hold cover plate (13) on outer edge with ﬁ ngers. NOTE: Ensure that the three

tapped holes in the coverplate (13) are near the 1:o'clock, 5:o'clock and 9:o'clock positions.

d. Position travel indicator dial (15) onto

cover plate (13) properly oriented.

e. Position clear plastic dial lens (14) over

in di ca tor dial (15), aligning bolt holes of lens (14), dial (15) and cover plate (13).

f. Secure lens (14), dial (15), cover plate

(13) and bearing ﬂ anges (19) to arm hous ing (4) by en gag ing the three sock et

VI. CALIBRATION

A. General:

1. This section covers calibration of the actuator as sem bly (AA) to a Ranger QCT, Premier EZO, or Premier Unlined body assembly (BA).

2. Positioner, if installed, requires ref er ence to the spe ciﬁ c positioner model IOM for proper calibration pro ce dure.

3. All indicated Item Numbers that are with re spect to this Model 48 actuator as sem bly (AA) are in pa ren the sis but are not un der scored; i.e. (20). Item Numbers that relate to the body assemblies (BA) are in parenthesis and are underscored; i.e. (7). Item Num bers that re late to the positioners ((PA)) are in a double set of

ATC-FO (Direct) Action

Figure 13:

head cap screws (31) using a 3/16" allen key wrench and tight en ﬁ rmly; do not over-tighten and crack plas tic lens (14).

NOTE: It may be necessary to rotate the actuator manual handwheel operator (58) down wards, or alternately supply a small level of air pressure (5-7 psig (0.35-0.50 Barg) to assist in aligning bolt holes for cap screws (31). Do not tighten one single cap screw (31) until all cap screws (31) are partially thread-engaged.

14B. Units (AA, BA) with Models 9540R or 991 or

PS2 positioners: Reference the IOM-9540R or 991 or PS2 IOMs for proper instructions on re in stal la tion of positioner ((PA)) assembly to shaft-end.

SECTION VI

parenthesis and are un der scored; i.e. ((3)).

4. This Section assumes that the actuator as sem bly (AA) and body assembly (BA) have been interconnected to geth er as recorded in Section V.

5. This Section assumes that the cal i bra tion is performed with the valve unit re moved from its normal pipeline location, and is in a repair shop located on a suitable work bench. Ac tu a tor stem/push rod sub as sem bly (8, 9,10, 43, 43, 43, 44, 54) should be oriented ver ti cal ly.

6. Premier EZO (lined) body assembly (BA) MUST be properly clamped between two ANSI 150# RF weld neck ﬂ anges. NOTE: Flanges MUST be of weld neck type! Clamp ing of liner (Premier (10)) will prevent false move ment of liner (Premier (10)) within body (1).

IOM-48

Page 18

7. In this Section reference will be made to three phrases – a. “lower value of benchset range”, b. “higher” value of benchset range”, c. benchset range.

The meaning of these phrases is sum ma rized

in the following table.

B. Actuator Stem/Push Rod Adjustment:

1. Actuator stem/push rod linkage (8, 9, 10, 43, 43, 43, 44, 54) when properly ad just ed willa. Provide the proper benchset range. b. Provide 90° rotation. c. Provide proper valve stem (Ranger (7),

Premier (3.2)) “windup”.

Benchset Lower Higher Range Value of Value of * Benchset Benchset Range Range

5-15 psig 5 psig 15 psig (.34-1.03 Barg) (0.34 Barg) (1.03 Barg)

* Identiﬁ ed on nameplate (21) as “Bench” or “Input Range”.

RANGER QCT®

SERIAL NO. BODY SIZE BODY RATING CLASS END CON NEC TION

MAX ALLOWABLE WORKING PRESSURE

MAX. MAX. WORKING ∆P PSIG

SEAT MATERIAL

PACKING

INHERENT FLOW CHAR.

RATED TRAVEL

FLOW TOWARD FAILURE POSITION MAX ACTUATOR PRESSURE INPUT RANGE OPTIONS

PRODUCT CODE TAG NO.

WARNING: REFER TO IOM PRIOR TO MAIN TE NANCE

PSIG @ 100°F

90°

CASHCO, INC.

ELLSWORTH, KS.

MATERIAL

PLUGSTEM

RATED Cv

RATED Kv

TRIM NUMBER

OF PLUG

MTG. POSITION

PSIG

U.S.A.

@ 38°C

PSIG

WARNING

Do not pressurize actuator assembly (AA) be yond the “MAX ACTUATOR PRESSURE” level/value in di cat ed on the unit’s nameplate (21). Fail ure to heed may cause catastrophic failure of upper cas ing (1) lead ing to ﬂ ying parts.

2. Ensure that manual handwheel operator (MHWO) has handwheel (58.1) backed fully out by rotating CCW (viewed from above handwheel (58.1)).

3. Remove cover plate (20) by removing four screws (36).

4. Remove travel indicator dial (15), dial lens (14), coverplate (13), bearing ﬂ anges (19) and bearing (18) by removing three cap screws (31) using a 3/16" allen key wrench.

5. Units with ATO-FC (Reverse) Action: a. Disconnect the lower L.H. rod end (9) from

en gage ment with the lever arms (5) by removing shoulder bolt (40) and lock nut (46). It will be necessary to re move stem (Ranger (7), Premier (3.2)) “wind up” as described in Sec tion V.B.4.

b. Swing the lever arms (5) down against

the travel stop screw (35); this “opens” valve plug (6)/disc (3.1).

c. Loosen lower upstop jam nut (43) from

securing upstop washer (54); back nut (43) to the root of its threads on push rod (10).

d. The upper R.H. rod end (8), lower L.H. rod

end (9), and push rod (10) act to geth er as a turnbuckle; the upper end is standard right-hand thread ed while the lower end is left-hand thread ed. To en sure max i mum and equal en gage ment of rod ends (8,9) to the push rod (10), it is rec om mend ed that the link age (8,9,10) be fully en gaged and then re ad just ed as a safety pre cau tion.

CAUTION

Unequal engagement adjustment of rod ends (8,9) and push rod (10) can cause failure of a rod end (8,9)-topush rod (10) connection.

a. If this occurs during bench main te nance, the

parts (8,9,10) could snap apart and cause per son al injury.

b. If this occurs during installed operation, con-

trol func tion would be lost.

IOM-48

Page 19

e. Loosen lower L.H. rod end (9) jam nut (44)

by rotating CW (viewed from above); this nut (44) is “left-handed”. Back nut (44) to the root of its threads on push rod (10).

f. Using a suitable tool to prevent lower L.H.

rod end (9) from rotating, rotate push rod (10) CCW (viewed from above) until up per end of push rod (10) is fully en gaged with upper R.H. rod end (8). NOTE: If lower L.H.

rod end (9) reaches full en gage ment with low er push rod (10) end ﬁ rst, remove tool se cur ing against ro ta tion, and allow lower L.H. rod end (9) to rotate with push rod (10). Once upper end of push rod (10) is

fully en gaged with upper R.H. rod end (8), rotate lower L.H. rod end (9) CW (viewed from above) until it is fully engaged.

g. Provide a temporary air supply with an

inline ad just able airset to the ac tu a tor upper cas ing (1) connection.

h. Reference the name plate (21) at tached

to the cover plate (20) that is fas tened to the arm hous ing (4). De ter mine the bench set ting from the name plate (21).

i. Pres sur ize the ac tu a tor (AA) to the lower

val ue of the benchset range pres sure in di cat ed on the name plate (21).

j. While holding low er L.H. rod end (9) out

of way, lift lever arms (5) up as far as pos si ble (this will close plug (Rang er (5))/ disc (Pre mier (3.1)).

k. Rotate lower L.H. rod end (9) as re quired

to orient the holes of the rod end (9) and the lever arms (5) in the same plane. Swing low er L.H. rod end (9) be tween the lever arms (5).

l. Rotate the push rod (10) CW (viewed

from above) lowering the lower L.H. rod end (9) until it’s hole is centered with the lever arm (5) holes. Center lever arms (5) with in arm housing’s (4) transverse axis; i.e. center over trav el stop screw (35).

m. Reinstall the shoulder bolt (40) through

the lever arm (5) and lower L.H. rod end (9) holes. Finger-tight en lock nut (46) onto shoul der bolt (40). Using a 1/4" allen key wrench to secure the head of shoul der bolt (40), torque wrench-tighten nut (46) to 15-20 ft-lbs (20-27 N-m).

n. Tighten lower L.H. jam nut (44) down until

locked against lower L.H. rod end (9); nut (44) is “left-handed”.

o. Add approximately 6 psig (0.4 Barg) to the

actuator’s (AA) lower value of benchset range. This will extend the actuator stem/ push rod sub-assembly (8, 9, 10, 43, 43, 43, 44, 54) downwards to al low loos en-

ing double jam nuts (43) on top side of uptravel stop washer (54).

p. Release air pressure down to the lower

value of benchset range.

q. Rotate lower jam nut (43) to raise uptravel

stop wash ers (54) until the gap clearance between the lower casing (2) and the top side of the washer (54) is 1/8"±1/16" (3mm±1.5mm).

r. Repressurize actuator (AA) to level as

indicated in Article 5.o. above. Tighten the lower of the two upper jam nuts (43) until it is tight, and secures the uptravel stop washer (54). Tighten the upper of the two upper jam nuts (43) down to secure the double jam nut (43) locking effect. Retighten lower jam nut (43) on un der neath side of washer (54).

s. Release all air pressure from actuator

upper casing (1). Repressurize slowly to conﬁ rm that as the pressure reaches the lower value of the benchset range (see Article 5.i. previous), the actuator stem/ push rod sub-assembly (8, 9, 10, 43, 43, 43, 44, 54) begins to move. If move ment is prematurely occurring (i.e. move ment at less than the lower benchset range val ue), the length of the actuator stem sub-as sem bly (8, 9, 10, 43, 43, 43, 44,

54) must be short ened. Re peat pro ce dure from Article 5.a. through to this Ar ti cle. If move ment is late (i.e. move ment at more than the lower benchset range value), the length of the actuator stem sub-assembly (8,9,10,43,43,43,44,54) must be length ened (i.e. increased). Re peat procedure from Article 5.a. through to this Article. It is recommended that ad just ment of ac tu a tor stem sub-assembly (8, 9, 10, 43, 43, 43, 44, 54) be made in one rev o lu tion of push rod (10) increments. Re peat as nec es sary.

t. Slowly increase air pressure in upper cas-

ing (1) until reaching the higher value of the benchset range; i.e. pres sur ize only until plug (Ranger (5))/disc (Premier (3.1)) is in the full open position.

u. Release all air pressure in actuator upper

casing (1). Repeat Article 5.t above and this article, cycling valve unit (AA, BA) closed-open-closed-open-closed sev er al times.

v. With valve plug (Ranger (5)) / disc (Pre mier

(3.1)) in “full closed” position, re in stall bearing (18), bearing ﬂ anges (19), cover- plate (13), dial lens (14) and dial (15) with three cap screws (31). NOTE: Position

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Page 20

dial (15) such that travel in di ca tor (16) shows “0°” travel before fully tightening screws (31).

w. Completion to this point completes the

benchset range adjustment. Proceed to Subsection VI.C. to adjust 90° travel stop.

6. Units with ATC-FO (Direct) Action: a. Disconnect the lower L.H. rod end (9)

from en gage ment with the lever arms (5) by removing shoulder bolt (40) and lock nut (46).

b. Swing the lever arms (5) down and as

close as possible to the travel stop screw (35); this “closes” valve plug (6) / disc (3.1). Ensure that the “closed” position is reached by observing actual plug (6) / disc (3.1) position.

c. Loosen lower upstop jam nut (43) from

securing upstop washer (54); back nut (43) to the root of its threads on push rod (10).

d. The upper R.H. rod end (8), lower L.H. rod

end (9), and push rod (10) act to geth er as a turnbuckle; the upper end is stan dard right-hand thread ed while the low er end is left-hand thread ed. To ensure max i mum and equal en gage ment of rod ends (8,9) to the push rod (10), it is rec om mend ed that the link age (8,9,10) be fully en gaged and then re ad just ed as a safety pre cau tion.

CAUTION

Unequal engagement adjustment of rod ends (8,9) and push rod (10) can cause failure of a rod end (8,9)-topush rod (10) connection.

a. If this occurs during bench maintenance, the

parts (8,9,10) could snap apart and cause per son al injury.

b. If this occurs during installed operation, con trol

func tion would be lost.

e. Loosen lower L.H. rod end (9) jam nut (44)

by rotating CW (viewed from above); this nut (44) is “left-handed”. Back nut (44) to the root of its threads on push rod (10).

f. Using a suitable tool to prevent lower L.H.

rod end (9) from rotating, rotate push rod (10) CCW (viewed from above) until up per end of push rod (10) is fully en gaged with upper R.H. rod end (8). NOTE: If lower L.H.

rod end (9) reaches full en gage ment with lower push rod (10) end ﬁ rst, remove tool se cur ing against ro ta tion, and allow lower L.H. rod end (9) to rotate with push rod

(10). Once upper end of push rod (10) is

fully en gaged with upper R.H. rod end (8), rotate lower L.H. rod end (9) CW (viewed from above) until it is fully en gaged.

g. Provide a temporary air supply with an

inline ad just able airset to the actuator up per casing (1) connection.

h. Reference the nameplate (21) at tached

to the cover plate (20) that is fastened to the arm housing (4). De ter mine the bench setting from the nameplate (21).

i. Rotate lower L.H. rod end (9) until the rod

end (9) and the lever arm’s (5) holes are in the same plane.

j. Loosen jam nut (45) and rotate downtra-

vel stop screw (35) out by ro tat ing CCW (viewed from below screw’s (35) head) until just barely engaged in arm hous ing (4).

k. Pressurize actuator (AA) to the higher

value of the benchset range pressure in di cat ed on the nameplate (21), while “guid ing” the lower L.H. rod end (9) hub to its proper position between the lever arms (5).

l. Pressurize actuator (AA) to a level as

indicated by “C” pressure in table that follows according to the formula: “A” + “B” = “C”.

Benchset Higher Value Adder Loading Range of Benchset Value – Pressure – Range - “A” “B” “C”

_____ psig ____ psig 2 psig ____ psig

____ Barg ____ Barg .14 Barg ____ Barg

m. Adjust the push rod (10) by rotating CW

(viewed from above) until the holes of the lever arms (5) and the lower L.H. rod end (9) are centered and the valve is in the “closed” position.

n. Reinstall the shoulder bolt (40) through

the lever arm (5) and lower L.H. rod end (9) holes. Finger-tighten lock nut (46) onto shoulder bolt (40). Using a 1/4" allen key wrench to secure the head of shoul der bolt (40), torque wrench-tighten nut (46) to 15-20 ft-lbs (20-27 N-m).

o. Loosen double jam nuts (43,43) on top

side of uptravel stop washer (54).

p. With valve in “closed” position, reinstall

bearing (18), bearing ﬂ anges (19), cov- erplate (13), dial lens (14) and dial (15) with three cap screws (31). NOTE: Po-

si tion dial (15) such that travel in di ca tor

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Page 21

(16) shows “0°” travel (no “bright or ange” show ing from indicator (16))before fully tight en ing screws (31).

q. Fully release air pressure in actuator

(AA). Observe position of valve on travel in di ca tor (16). Travel should be short of “full open”; i.e. 90° rotation.

1. Travel short of 90°. Adjust the push rod (10) by rotating CCW (viewed from above) until the travel reaches 90° as shown by travel indicator (16).

2. Travel beyond 90°. Adjust the push rod (10) by rotating CW (viewed from above) until the travel is reduced to 90° as shown by the travel indicator (16).

r. Rotate lower jam nut (43) to raise uptravel

stop wash ers (54) until the gap clearance between the lower casing (2) and the top side of the washer (54) is 1/8"±1/16" (3mm±1.5mm).

s. Repressurize actuator (AA) to upper val ue

of benchset range. Tighten the lower of the two upper jam nuts (43) until it is tight, and secure the uptravel stop washer (54). Tighten the upper of the two upper jam nuts (43) down to secure the double jam nut (43) locking effect. Retighten lower jam nut (43) on underneath side of wash er (54).

t. Tighten lower L.H. jam nut (44) down until

locked against lower L.H. rod end (9); nut (44) is “left-handed”.

u. For Premier EZO and Premier Unlined

ONLY. Ref er ence VI.C.2. for procedure to adjust downtravel stop screw (35).

v. Release all air pressure in actuator upper

casing (1). Repeat loading-unloading to cycle the valve unit (AA, BA). Repeat adjustments as necessary.

w. Completion to this point completes the

benchset range adjustment. Proceed to the next subsection (VI.C.) to adjust 90° travel stop, if necessary.

b. Rotate downtravel stop screw

(35) CCW (viewed from below screw (35)) until 90° rotation is reached on the travel indicator (16).

c. Retighten jam nut (45).

2. Travel beyond 90°. Hub of lower L.H. rod end (9) may or may not be touch ing on downtravel stop screw’s (35) upper end. a. Loosen jam nut (45) about four

revolutions.

b. Very slowly release air pressure

into actuator (AA) until travel in di ca tor (16) is showing at 90°.

c. Rotate downtravel stop screw

(35) CW (viewed from below screw (35)) until the screw’s (35) upper edge touch es the hub of lower L.H. rod end (9).

d. Retighten jam nut (45).

2. Units with ATC-FO (Direct) Action:

a. Loosen jam nut (45). b. Rotate downtravel stop screw (35) CW

(viewed from below screw (35)).

c. Pressurize actuator (AA) slowly until the

travel in di ca tor (16) indicates that travel is at 0°; the valve should be in the “fully closed” position.

d. Adjust gap between downtravel stop screw

(35) and hub of lower L.H. rod end (9) as indicated in table that follows.

e. Retighten jam nut (45).

Product Gap Between L.H. Rod End (9) Model and Downtravel Stop Screw (35)

Ranger QCT 1/8" ± 1/16" (3.0 mm ± 1.5 mm) Premier EZO 1/16" ± 1/16" (1.5 mm ± 1.5 mm) Premier Unlined No gap; i.e. touching

C. 90° Rotation Adjustment:

1. Units with ATO-FC (Reverse) Action:

a. Pressurize actuator (AA) to the higher

value of benchset range. This pressure should cause 90° rotation as shown by travel indicator (16).

1. Travel short of 90°. Hub of lower L.H. rod end (9) may be touching on downtravel stop screw’s (35) upper end. a. Loosen jam nut (45).

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SECTION VII

VII. TROUBLE SHOOTING GUIDE

Reference the IOM of the valve body this actuator is unitized with for additional information on Trouble Shooting.

1. Air leakage.

Possible Causes Remedies A. Leakage at diaphragm-to-upper casing A1. Overpressure. Check source of air supply and ﬂ ange. determine if pressure is greater than indicated in Table 1; reset airset pressure as required. A2. Tighten casing ﬂ ange bolting (27, 28, 41 & 42) B. Leakage at handwheel gland-to-upper case. B. Faulty O-ring (62); replace O-ring. C. Leakage at manual handwheel threads. C. Faulty seal (61); replace thread seal. D. Leakage around stem on side where yoke D1. Failure of diaphragm (6); replace diaphragm. bolts to arm housing. D2. Faulty seal (56); replace seal.

SECTION VIII

VIII. ORDERING INFORMATION NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"), aparts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code typical format as follows: (last digit is alpha character that reﬂ ects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. With this information they can provide a quotation for a new unit including a complete description, price and availability.

CAUTION

Do not attempt to alter the original construction of any unit without assistance and approval from the factory. All purposed changes will require a new name plate with appropriate ratings and new product code to accommodate the recommended part(s) changes.

–

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. Identify the parts and the quantity required to repair the unit from the "BOM" sheet that was provided when unit was originally shipped.

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” reﬂ ect minimum parts required for inspection and rebuild, - "Soft Goods Kit". Those in column “B” include minimum trim replacement parts needed plus those "Soft Goods" parts from column "A".

If the "BOM" is not available, refer to the crosssectional drawings included in this manual for part identiﬁ cation and selection.

A Local Sales Representative will provide quotation for appropriate Kit Number, Price and Availability.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or speciﬁ cations of such product at any time without notice. Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Cashco, Inc. product remains solely with the purchaser.

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Page 23

ADJUSTING SCREW ASSEMBLY

Not available on Air to Close-Fail Open Rangers

ACTUATOR PLUG

Available on Premier Butterﬂ y

Valves ONLY

BASIC 48 ACTUATOR

Shown Air to Open

ITEM NO. DESCRIPTION

1. Upper Case

2. Lower Case

3. Piston

4. Arm Housing

5. Arm

6. Diaphragm

7. Clevis

8. Rod End (R.H.)

9. Rod End (L.H.)

10. Push Rod

11. Spring

12. Cam

13. Cover Plate

14. Dial Lens

15. Travel Indicator Dial

16. Travel Indicator

17. Indicator Spacer

18. Ball Bearing

19. Bearing Flange

20. Cover Plate

21. Name Plate

IOM-48

ITEM NO. DESCRIPTION

22. Housing Cover

25. Pivot Screw

26. Hex. Head Cap Screw

27. Hex. Head Cap Screw

28. Hex. Head Cap Screw

29. Hex. Head Cap Screw

31. Button Head Cap Screw

32. Button Head cap Screw

33. Socket Head Cap Screw

35. Socket Head Stop Screw

36. Fillister Head Machine Screw

37. Fillister Head Machine Screw

38. Drive Screw

40. Bolt Shoulder

41. Nut

42. Extension Nut

43. Jam Nut

44. Jan Nut (L.H.)

45. Jam Nut

46. Lock Nut

48. Clevis Pin

SECTION “A-A”

ITEM NO. DESCRIPTION

49. Hairpin

50. Spring Pin

51. Spring Pin

52. Diaphragm Washer

53. Washer

54. Stop Washer

55. Internal Lock Tooth Washer

56. Seal

58. Handwheel Subassembly or Adjusting Screw

59. Locking Lever or Nut

60. Washer

61. Thread Seal

62. O-Ring (Gland to Upper Case)

63. O-Ring (Handwheel to Gland)

64. Ball

65. Self-Tapping Screw

66. Pin (Spring)

67. Handwheel Gland or Actuator Plug

Page 24

73N-B POSITIONER

STOP SCREW

SOLENOID VALVE

73N-B POSITIONER ITEM NO. DESCRIPTION 72 Feedback Linkage Subassembly 73 Feedback Linkage Spacer 74 Feedback Linkage Pivot Shaft 101 Positioner 102 Range Spring 106 Tube Fittings (Elbow) 107 Output Tube 108 Name Plate

SOLENOID VALVE ITEM NO. DESCRIPTION 128 Solenoid Valve 129 Nipple

Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: [email protected]

Printed in U.S.A. 48-IOM

Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No. +49 3342 4243136 www.cashco.com Email: [email protected]

Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com Email: [email protected]

AIR SUPPLY REG U LA TOR

AIR SUPPLY REGULATOR ITEM NO. DESCRIPTION 130 Air Supply Regulator 131 Mounting Bracket 132 Supply Tube

GUAGES (Not Shown) ITEM NO. DESCRIPTION 135 Signal Guage 137 Output Gauge 138 Branch Tee 139 Reducing Bushing