Emerson Yarway, 20 Installation, Operation And Maintenance Instructions

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

PRINCIPLE OF OPERATION

In a direct acting diaphragm actuator, increasing loading pressure moves the actuator stem downward, compressing the spring. When the loading pressure is decreased, the spring moves the actuator stem upward. In the event of failure of the loading pressure or the operating medium pressure to the controller, the actuator stem moves to the upward position.

Warning: be certain that the diaphragm casing pressure does not exceed the limits listed in the specification table (see table 1).

UNPACKING

The Yarway pneumatic diaphragm actuators are mostly delivered in combination with Desuperheaters for use on low-, medium- and high pressure steam applications and packed with the greatest care in wooden boxes or cartons for protection during handling and transit to site. If it is found, however, that damage has occurred during shipment, then this should be reported immediately to your forwarder or Yarway representative. Particular care should be taking when removing the pneumatic diaphragm actuators (including Desuperheaters) from the packing and your special attention is required to check carefully that no damage has occurred to the actuators, accessories as: pneumatic positioner, electric/pneumatic positioner, position transmitter, air filter regulator, booster relay, lock-in relay, limit switches, solenoid valves and the standard piping with stainless steel pipe and fittings.

Warning: the hoisting lug is for the actuator only, NOT for a total assembly!

VCIOM-03327-EN 16/10

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4

20 - 55 20 - 55 20 - 90 20 - 90

TABLE 1 - FUNCTIONAL SPECIFICATIONS

Type 20 - 55 (see fig. 1) 20 - 90 (see fig. 3)

Type Direct acting Direct acting Action Stem extends with air pressure Stem extends with air pressure Diaphragm 950 cm Air displacement 5225 cm Max. thrust 11 kN (48.800 lbf) 10 kN (44.400 lbf) Spring range 1.0 to 3.8 bar (15 to 55 psi) 1.0 to 2.2 bar (15 to 32 psi) Travel 55 mm (2⅛”) 90 mm (3½”) Travel speed Depending on spring range, air supply

Travel indicator Integrated pointer and stainless steel

Air connection ½” NPT female ½” NPT female Air supply 6.0 bar (max. 87 psi) 6.0 bar (max. 87 psi) Ambient temperature (std)* Weight 46.0 kg (102 lbs) 68.0 kg (150 lbs) Handwheel Side mounted (see fig. 2) Side mounted (see fig. 4) Weight 19.0 kg (42 lbs) 19.0 kg (42 lbs) Protection level (std)** IP55 IP 55

NOTE

* = Optional temperature: -40°C to +80°C [-40°F to +158°F] ** = Optional protection level: IP66

pressure, piping arrangement and air capacity of auxiliary devices

travel scale

-29°C to +70°C (-20°F to +158°F) -29°C to +70°C (-20°F to +158°F)

950 cm

8550 cm

Depending on spring range, air supply pressure, piping arrangement and air capacity of auxiliary devices Integrated pointer and stainless steel travel scale

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 5

Air filter regulator

E/P-postioner

Water inlet

Water outlet

Assembly of a ‘Yarway’ standard duty A.T.-Temp Desuperheater

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

ACTUATOR/DESUPERHEATER DISASSEMBLY (SEE FIG. 6 AND 7)

Before any maintenance operation on the Yarway Desuperheater fitted with a Yarway actuator model 20 - 55/20 - 90, please carefullyfollow these instructions:

• Isolate or bypass the steam supply.

• Check steam line is cooled down and pressure free.

• Shut-off Desuperheater water supply.

1. Cut-off the air supply to the positioner

via the air filter regulator. Disconnect the pneumatic connections and the electrical connections of the positioner on the network. Disassemble on the actuator side the pneumatic connections to the positioner.

2. Disconnect the lever of the positioner from

the stem coupling (mechanical linkage).

3. Slightly supply the actuator to lift the

Desuperheater piston from the seat. Disassemble the upper and lower couplings(27) (see fig. 6 and 7) through the screws. Cut-off the air on the diaphragmcasing.

4. Unscrew the lock nut (see Installation,

Operation and Maintenance Manual of the A.T.-Temp Desuperheater) and lift the entire actuator from the Desuperheater.

DISASSEMBLY

Diaphragm exchange

• Cut-off the air supply to the positioner via the air filter regulator. Disconnect the pneumatic connections and the electrical connections of the positioner on the network. Disassemble on the actuator side the pneumatic connections to the positioner.

• Remove all short bolts (18), rings (21) and nuts (20) on the bolt circle. Progressively unscrew the 4 long bolts (19), located on a quadrangle on the circle, to unload the springs. After having released the 4 bolts, take the upper casing (1) away.

• Unscrew plate bolt (3) whilst avoiding the actuator stem (10) rotation by using the square located on the half upper coupling(27). Take diaphragm plate (4) away. Withdraw diaphragm (5) and replace it by a new one. Tighten diaphragm plate by applying160 Nm on bolt (3).

• Reassemble the upper casing by using the 4 bolts (19), load the springs until complete tightening of the diaphragm and complete the short bolts circle in a clockwise, criss-cross pattern with a max. torque of 40 Nm.

Exchange of one or more springs

• Same instructions as for diaphragm exchange, except spring plate (6) has to betaken away.

• Change damaged springs (7/8) and reassemble in the opposite way.

This operation is only needed for:

• To change the diaphragm.

• To change one or several springs.

TABLE 2 - SPARE PARTS

Model 20 - 55 (fig. 6) Model 20 - 90 (fig. 7)

Item Quantity Name Part no. Item Quantity Name Part no.

3 1 Plate bolt M14 x 100 mm HN-3283 5 1 Diaphragm ø 420 3N-1299-20 6 1 Spring plate 3N-2336 19, 20, 21 Set

7, 8 1 Spring ø 59, 6 black, total 5

1 Spring ø 59, 6 red, total 5

13 1

4 x bolts M8 x 100 mm / 4 x nuts M8 / 8 x washers / 8 x nuts M8 / 8 x washers / 4 x protecting tubes 8 x protecting tubes

required per actuator

requiredper actuator Bushing M35 x 1.5 mm brass 4N-2764-20 Bushing M35 x 1.5 mm GGGN60 4N-3858-20

HN-3118 19, 20, 21 Set

4N-2900-20 7, 8 1 Spring ø 100 (inner), total 3

4N-3416-20 1 Spring ø 140 (outer), total 3

3 1 5 1 6 1

13 1

Plate bolt M14 x 100 mm HN-3283 Diaphragm ø 420 3N-1299-20 Spring plate 3N-2286-20 4 x bolts M8 x 160 mm /

required per actuator

required per actuator Bushing M35 x 1.5 mm brass

Bushing M35 x 1.5 mm GGGN60

HN-3117

4N-3017-20

4N-3016-20

4N-2764-20 4N-3858-20

Make sure that the identification number (indicated on the nameplate) is verified and specified when ordering spare parts.

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 6 MODEL 20 - 55

9544400

ø 420 ø 360

•

19 27

•

TABLE 3 - STANDARD MATERIALS

Item Qty. Name Material Dimension Item Qty. Name Material Dimension

1 1 Upper housing C-steel 16 1 ½” NPT socket A105 / C22.8 2 1 Limit block C-steel 17 1 Hoisting lug C-steel 3• 1 Bolt 12.9 M14 x 100 mm 18* 16 Bolt 8.8 M8 x 30 mm 4 1 Diaphragm plate C-steel 19*• 4 Bolt 8.8 M8 x 100 mm 5• 1 Diaphragm Rubber 20* 16 Nut Steel M8 6 1 Spring plate Aluminium 21* 4 Washer C-steel 7• 5 Spring right 22 1 Cushioning plate Rubber 8• 5 Spring left 23 1 Support plate Aluminium 10 1 Stem A182 F316 24 2 Connector air snubber St. steel 12 1 Lower housing C-steel 25* 1 Washer C-steel M14 13• 1 Bushing Brass / GGGN60+ 26 2 Air snubber Brass 14* 3 Yoke pillar C-steel 27* 4 Nut 3D 8.8 M8 15 1 Yoke plate actuator A105 / C22.8 28 3 Bolt 8.8 M12 x 40

NOTES

- Dimensions may be subject to change without prior notification.

- Yarway will provide a certified dimensional drawing upon request.

- Bolts nr. 19 are used for disassembly of actuator and provided with protection tube. * Zinc plated parts + Optional

• Recommended spares

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 7 MODEL 20 - 90

19 27

•

ø 420 ø 360

•

9544

•

225

400

TABLE 4 - STANDARD MATERIALS

Item Qty. Name Material Dimension Item Qty. Name Material Dimension

1 1 Upper housing C-steel 16 1 ½” NPT socket A105 / C22.8 2 1 Limit block C-steel 17 1 Hoisting lug C-steel 3• 1 Bolt 12.9 M14 x 100 mm 18* 16 Bolt 8.8 M8 x 30 mm 4 1 Diaphragm plate C-steel 19*• 4 Stud 8.8 M8 x 200 mm 5• 1 Diaphragm Rubber 20* 16 Nut Steel M8 6 1 Spring plate Aluminium 21* 8 Washer 8.8 M8 7• 3 Spring inside 22 1 Cushioning plate Rubber 8• 3 Spring outside 23 1 Support plate Aluminium 10 1 Stem A182 F316 24 2 Connector air snubber St. steel 11 1 Stroke limiter A106 Gr. B / ST.35.8 25* 1 Washer 8.8 M14 12 1 Lower housing C-steel 26 2 Air snubber Brass 13• 1 Bushing Brass / GGGN60+ 27* 4 Nut 3D 8.8 M8 14* 3 Yoke pillar C-steel 28 3 Bolt 8.8 M12 x 40 15 1 Yoke plate actuator A105 / C22.8

NOTES

- Dimensions may be subject to change without prior notification.

- Yarway will provide a certified dimensional drawing upon request.

- Bolts nr. 19 are used for disassembly of actuator and provided with protection tube. * Zinc plated parts + Optional

• Recommended spares

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 8 - SIDE-MOUNTED HANDWHEEL

280

•

104

•

2 17

•

7 16

•

21 25

150

1193

•

ø 200

TABLE 5 - STANDARD MATERIALS

Item Qty. Name Material Dimension Item Qty. Name Material Dimension

1* 1 Mounting plate (upper) SA 105 14 1 Parallel key C 45 5 x 5 x 20 mm 2* 1 Mounting plate (lower) SA 105 15• 1 Circlip Steel 3* 1 Mounting plate (handwheel) St 37 K 16• 1 Plain bearing PTFE 4• 1 Drive shaft Al. bronze / GGGN60 17• 1 Bearing bushing Nylon 5 1 Shaft left 1.4057 18* 1 Eye bolt St 37.2 6• 1 Shaft right 1.4057 19 1 Padlock 7*• 1 Helical gear C-steel 20* 2 Pillar SA 105 8* 1 Parallel key C 45 8 x 7 x 24 mm 21 2 Screw St. steel M5 x 10 mm 9*• 1 Pinion C-steel 22 1 Nameplate St. steel 10 1 Cover St. steel 23 1 Handwheel Aluminium 11* 8 Bolt 10.9 M12 x 40 mm 24* 1 Gear bushing SA 106 Gr. B 12* 1 Bushing (handwheel) SA 105 25 2 Ring St. steel M5 13*• 1 Spindle (handwheel) SA 105

NOTES

* Zinc plated parts

• Recommended spares

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

MAINTENANCE

Maintenance of the Yarway actuator is straight forward and does not require any special tools or training. Care should be taken during any maintenance operation, particularly when working with grinders, compressed air and rotating machinery. It is imperative that safety glasses and protective workwear are used in accordance with standard safety procedures. In case of doubt, consult your supervisor or safety officer before commencing any work ontheequipment.

MANUAL OPERATOR

• The Yarway manual operator is side-mounted between the actuator and the Desuperheater.

• The manual operator is intended to be used for emergency only.

• The handwheel (23) is locked by means of apadlock (19).

• The handwheel will not turn during actuated operation of the actuator assembly and/or Desuperheater assembly.

• By unlocking the padlock, clockwise turning the handwheel will move the 2 spindle parts(5)(6) away from each other, opening the valve.

• Turning counter clockwise, the valve willclose.

After using the manual operator, the system shall be set back to the original position. Failing to do so may lead to improper valve response and/or damaging of the piston/spray cylinder.

STORAGE PROCEDURE

Upon receipt, check both the pneumatic actuator and the packing case for any transit damage. Any damage to the pneumatic actuator should be reported immediately to Yarway or their local agent. Any damage to the packing container should be rectified to prevent the ingress of dust or water, prior to placing the equipment into storage. Check the information contained on the identification plate (tagplate) and documentation and return the unit to its packing with protective covers in place (seefig.5). For short term storage, up to 6 months duration, no additional preservation measures are necessary. Retain the unit in its original packing in a clean, dry indoor location. If outdoor storage is unavoidable, then the packing case should be enclosed in a waterproof covering. For long term storage use a dry indoor location only. Retain pneumatic actuator in its original packing and inspect at 3 monthly intervals to ensure that no deterioration has occurred. Before placing the pneumatic actuator into service, inspect all components, to ensure correct functioning. Follow the procedure for installation as detailed in the operating and maintenance instruction manual.

WARNING

The hoisting lug is for the actuator only, NOT for atotal assembly!

NOTE

NOTES

- Apply some general purpose grease on the gear wheel (7)(9) once a year.

- Make sure no dirt is trapped between the drive shaft (4) and the wheel large (7).

- This may obstruct free movement between these parts.

TABLE 6 - SPARE PARTS

Item Qty Name Part number

7, 9 + 13, 15, 16, 17 1 Spares SM handwheel 4N-4307-20 4, 5, 6 1 Spindle kit SM handwheel Al Bronze 4N-4308-20 4, 5, 6 1 Spindle kit SM handwheel GGGN60 4N-4310-20

Materials and data of units supplied, may deviated from this Instruction Manual. Please consult order documents in case of doubt.

The pneumatic actuator is classified under European Directive 2014/68/EC under category I with CE-marking and ATEX 2014/34/ EC. See actuator name plate.

Emerson Yarway, 20 Installation, Operation And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual