Emerson AW Series, AWN13, AWN Series, AW17, AW28 Installation And Operation Manual

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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
Please read through this manual completely before operating the actuators
SECTION 1 - SAFETY PRECAUTIONS
Precautions for using AW, AWN type actuators safely are highlighted with the following two warning signs to indicate the level of danger posed. Please read the postscript carefully to ensure safety and prevent any damage from occurring before starting to use the product.
WARNING
A potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
A potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
ACTUATOR USE
AW, AWN Type Actuators are suitable for operating ball valves and V-port valves. Please use the actuators according to warnings and cautions described in this document. Failure to do so could result in an accident (due to wrong storage, installing, operation, maintenance and disassembling) and/or serious damage. Please keep this manual in a handy place for immediate reference; be sure to provide it to purchaser, contractor, piping designer, user, operator or maintenance technician.
KTM reserves the right to discontinue the manufacture of, change or modify design and/ or construction of any KTM product during the manufacturing procedure, without incurring any obligation to accept for credit, to replace or furnish or install such changes or modifications on products previously or subsequently sold. This document is subject to change without notice.
SECTION 2 - SPECIFICATION
The performance and safety of AW, AWN type actuators and conformity with your equipment or system should be checked by the design engineer or the person specifying your system based on our catalog or specification data. Upon arrival, the applicable conditions (double acting, direct acting, reverse acting, operating pressure, etc.) should be first checked to make sure they are correct.
SECTION 3 - STORAGE
CAUTION
The following items should be strictly followed in order for the actuators to be installed and operated properly.
1. Do not unpack the actuator from shipping package until just prior to installing it.
2. Store the package in dry and non-corrosive atmosphere.
3. When unpacked, plug or cap inlet and outlet port and direct these ports in horizontal and downward position to protecting from entering rain and dust.
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 4 - MODEL IDENTIFICATION
Example: AW 17 S Q HW Actuator type AW (AWN only applicable for size 13)
Actuator size 13 20 17 28 Operation type Description (Supply pressure) Blank Double acting type (0.3 to 0.7 MPa) S Spring return type - Standard (0.4 to 0.7 MPa) L Spring return type - Low pressure type (0.3 to 0.4 MPa) Special (Option) Description Blank No specials A Direct-acting spring return
(Counter-clockwise rotation under supply pressure loss)
B Stainless steel external bolts and nuts K For high temperature (0ºC to 120ºC) T For low temperature (-45ºC to 60ºC) Q High speed / frequency (500,000 cycles): Available for double acting type
High speed: Available for spring return type
S High torque type (spring return)
Accessories (Option) Description Blank Without any accessories CO ESDV of CO H For double acting type with manual override handle lever:
Available for AWN13 only
HG For double acting type with manual gear operator:
Available for AW17 through AW28
HW For spring return type with manual override handle:
Available for AWN13S through AW28S
L With lift-limiting unit PS Partial stroke test
gas type
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 5 - RANGE OF APPLICATION
Operating mechanism Operation Model no. Pressure (MPa)
Double acting AWN13 0.3 - 0.7
AW17 AW20 AW28
Single acting AWN13S 0.4 - 0.7 Scotch York (Para-arm piston rod pin)
(Spring return) AW17S
AW20S
AW28S Single acting AWN13L 0.3 - 0.4 for low pressure range AW17L 0.2 - 0.4
AW20L 0.3 - 0.5
AW28L 0.2 - 0.4
CAUTION
Use Torque Cylinders within operating pressure ranges only. Operation outside the specified range may cause damage to the cylinder or malfunction.
SECTION 6 - CONSTRUCTION
Spring return
Spring return
Double acting
Double acting
FIGURE 1
NOTE
Only AWN13 has an oval-shaped upper stem and a square-shaped lower stem.
PARTS LIST
No. Parts Nme
1 Body 2 Stem 3 Para-arm 4 Key 5 Set screw 6 O-ring 7 O-ring 8 Thrust bearing 9 Thrust bearing 10 Snap ring 11 Snap ring 12 Piston rod 13 Pin 14 Roller 15 Bearing 16 Snap ring 17 Adapter 18 Gasket 19 Bearing 20 O-ring 21 O-ring 22 Piston 23 O-ring 24 O-ring 25 Nut 26 Cylinder 27 Cap screw 28 Stopper bolt 29 Gasket 30 Cap Nut 31 Spring retainer 32 Cylinder 33 Spring case 34 Spring (Outer) 35 Spring (Inner) 36 Spring cover 37 Long bolt 38 Nut 39 Stopper bolt 40 Nut 41 Pipe
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 7 - MOUNTING OF ACTUATOR TO VALVE
Ensure the following items before mounting the actuator to the ball valve.
1. Cleanse flanges of actuator and valve of dust and foreign substances.
2. When mounting, make sure that the valve opening (fully open or fully closed) coincides with the indicator position of the actuator.
Caution
Mismatching between indication of actuator and valve opening may result in operation trouble, which will cause accidents. Check the indication matching once more.
3. Use the following bolts for connection, which should be fastened in “criss-cross” pattern.
Stainless steel: JIS: SUS304 (AISI 304) with
strength class more than 70
Carbon steel: JIS: S45C (AISI 1045) with
strength class more than 8.8
SECTION 8 - ADJUSTMENT OF VALVE OPENING
After mounting the actuator to the valve, adjust fully open and fully closed position according to the following manner.
CAUTION
Since the adjusting procedure is performed during supplying compressed air, do not touch the moving parts of the actuator. Doing so may cause injury.
8.2 Procedure for Single Acting Actuator
(including the model with manual operator “HW”)
1. Supply compressed air to the inlet port to the valve open and check fully open position of the valve.
2. If the position is not correct, exhaust the compressed air letting the valve to close the valve. Then perform the following steps 3 and 4.
3. Loosen hexagon nut for locking open side stopper bolt, turn the stopper bolt in respective direction by using hexagon bar wrench. Clockwise turning of the bolt reduces travel angle of the actuator, and counterclockwise turning widen the range of the travel angle.
4. After ensuring correct position of the valve by supplying compressed air to the actuator, tighten the locking nut of the stopper bolt.
5. With no compressed air in the actuator, check the fully closed position of the valve.
6. If the position is not correct, loosen the hexagon nut for locking stopper bolt on closed side, then perform the following procedures 7 and 8.
7. Turn the stopper bolt in the respective direction by using hexagon bar wrench. Clockwise turning of the bolt reduces travel angle of the actuator, and counterclockwise turning widen the range of the angle.
8. After ensuring the correct position of the valve, tighten the locking nut of the stopper bolt.
SECTION 9 - PIPING AND INSTALLATION
CAUTION
In piping work, care should be taken for fragments of the sealing tape not to enter in the pipe. Foreign matters in the tube will cause malfunctions of accessories.
WARNING
Never climb on the actuator or accessories in field working, which will cause failure in adjustment or human injury.
For supplying the compressed air, refer to Section 9 “Piping and Installation”. The procedure explained below applies to the combination of actuator and valve, when turning the stem clockwise operates the valve to closed position.
8.1 Procedure for Double Acting Actuator
1. Supply compressed air to inlet port to open the valve and check fully open position of the valve.
2. If the position is not correct, exhaust the compressed air and perform steps 4 and 5.
3. Loosen hexagon nut for locking stopper bolt on open side, turn the stopper bolt in respective direction by using hexagon bar wrench. Clockwise turning of the bolt reduces travel angle of the actuator, and counterclockwise turning widens the range of the travel angle.
4. After ensuring correct position of the valve by supplying compressed air to the actuator, tighten the locking nut of the stopper bolt.
5. Supply compressed air to inlet port to close the valve and check the fully closed position.
6. If the position is not correct, perform the above described procedure for closed side stopper bolt.
When operating actuator in piping work, please pay attention to the following points.
1. Avoid installing the actuators in a place where they are exposed to seawater, chemicals, and high- and/or low­temperature (above 80ºC, under -20ºC). If it is inevitable, protect the actuators by appropriate covering, or protect sufficiently with anticorrosive painting.
2. Usually, copper tubes are used for connecting attachments. When the joints loosen by intensive vibrations, air leakage may occur. Additional tightening will be necessary accordingly. In vibrational environments, use Nylon tubing.
3. Since accessories have been adjusted already in the factory, further adjustments are not necessary.
4. For air piping of accessories, use Φ8 xΦ6 tube or larger for AWN13~AW20, and Φ10 xΦ8 tube or larger for AW28. If quick operation is required, use large size tube according to the desired speed.
5. For air piping from compressor or air tank to supply port of actuator (or inlet port of attachment device, if equipped), use steel pipe of size not smaller than the air supply port of the actuator.
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
6. When using the actuators outdoor in cold or snowy areas moving parts of accessories (positioner, limit switches, etc.) may be frozen. Protect the devices by proper covering in such cases.
7. When installation orientation of actuator is changed for convenience of positioning, the following caution should be taken.
1. Exhaust port of the actuator and
accessories (solenoid valve, air operate valve, quick exhaust valve, etc.) should be directed downward by attaching elbows. If doing so is difficult due to surrounding area environment, use elbow for exhausting downward.
2. Since attaching orientation of filter
regulator or lubricator is limited, drains should be directed downward.
CAUTION
Do not position single acting torque cylinders in such orientation that springs are facing upward. By doing since, the inside of the cylinder may be corroded by entering of water, which may cause malfunctions.
8. In piping for operating actuator work, care should be taken as follows.
1. Clean joint and tubing sufficiently by using
compressed air before piping.
2. When sealing tape is used, apply tape to
thread starting two threads back from end of fitting in order for the fragments of the tape not to enter inside of the pipe.
3. Since copper tubes are regularly used for
connecting accessories, avoid vibrational place for installing. In severe vibrational environments, use Nylon tubing. (The copper tube loosen by vibration may cause leakage.)
4. Do not tighten the joint excessively to the
supply port of the actuator.
9. Pneumatic diagram for actuator and accessories Schematic diagrams of piping for solenoid valve to actuator are shown below. Select appropriate mode according to the operating purpose.
NORMALLY CLOSE (ENERGIZED TO OPEN) NORMALLY OPEN (ENERGIZED TO CLOSE)
• Double Acting type
AWN13 AW17 AW20 AW28
(4-Way solenoid valve)
(Filter Regulator)
FIGURE 3
Actuator
(Equalizing Valve)
Supply air
0.4 MPa
• Double Acting type AWN13 AW17 AW20 AW28
(Equalizing Valve)
(4-Way solenoid valve)
(Filter Regulator)
FIGURE 5
Actuator
Supply air
0.4 MPa
CAUTION
Excessive fastening of joint may cause cracking of supply port leading air leakage.
ca. two threads
Wind tape in this area
FIGURE 2
• Single Acting type
AWN13S AW17S AW20S AW28S
Actuator
(Pluged) (Pluged)
(Filter Regulator)
Supply air
0.4 MPa
• Single Acting type AWN13S AW17S AW20S AW28S
FIGURE 4 FIGURE 6
Actuator
(Filter Regulator)
Supply air
0.4 MPa
(Filter Regulator)(Filter Regulator)
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 10 - AIR SUPPLY FLOW RATE
The volume of air necessary for cylinder operation is determined to obtain the following two types of flow rates:
1. Momentary Flow Rate QD, QS Calculation of the momentary flow rate
is necessary to determine operating time. The shorter the operating time with the same cylinder size, the larger the momentary flow rate. In order to obtain the desired operating time, the supply source capacity, piping diameter, pressure reducing valve capacity, solenoid valve orifice diameter (C
value), etc. are
v
necessary. This enables the momentary flow rate to be determined by the following formulas (1) and (1’). If multiple cylinders are operated simultaneously, then the capacity of each devices used, multiplied by the number of cylinders will provide the momentary flow rate.
Momentary flow rate of Double Acting cylinder: ( )
Momentary flow rate of Spring Return type Cylinder: ( )
2. Air consumption VD, VS This shows the volume of air consumed
in a period of time. For the same size cylinder, air consumption increases in direct proportion to the operating time. The consumption is determined by the following formula. Incidentally, the total air consumption is identical to a sum value obtained for the total units.
Remarks
Q
D = Momentary flow rate in Double Acting
cylinder ( )
Q
S = Momentary flow rate in Spring Return
type cylinder ( )
V
D = Air Consumption of the Double Acting
cylinder ( )
V
S = Air Consumption of the Spring Return
A, B = Cylinder capacity ( ) P = Operating pressure (MPa) T = Operating time (Sec) n = Operating cycles in a time period
(One cycle means one reciprocating action)
type cylinder ( )
Cylinder model
AWN13 3.10 3.10 6.20 AW17 6.70 6.70 13.40 AW20 14.80 14.80 29.60 AW28 34.60 34.60 69.20
A B A + B
SECTION 11 - CAUTIONS PRIOR TO OPERATION
1. Check air leakage in pipeline from compressor or tank to supply port by using soap liquid or leak check liquid.
2. Be sure that supplying compressed air pressure is within the range specified in Section 5 “Range of Application”.
3. Check electric power supply voltage of solenoid valve.
4. Check air pressure of filter regulator outlet
Cylinder capacity (ℓ)
SECTION 12 - CAUTIONS DURING OPERATION
1. Use clean and dry compressed air through dryer and filter. (Dew point below -15ºC). Drain sufficiently to prevent freezing especially in cold areas.
2. Periodical draining of filter or filter regulator should be performed.
3. Supply lubricating oil (turbine oil JIS K2213, ISO VG32 with additives) periodically to lubricator.
port if attached.
5. Check speed of speed controller or quick exhaust valve if attached.
6. Ensure that the actuator and valve travel
CAUTION
Do not use machine oils and spindle oils, which may cause troubles.
smoothly by operating accessories (solenoid valve, air operate valve, positioner, etc.).
7. Ensure that electric wiring of solenoid valve
4. Manual operation is inhibited while automatic operation.
or limit switches are shielded by cable gland, cable protection tube, etc. Wiring port should be directed in horizontal and downward position.
WARNING
Never place or leave lever handles, spanners and wrenches at the upper portion of the stem. They are driven while operation and cause human injury and equipment damages.
Air Consumption of Double Acting cylinder: ( )
Air Consumption of Spring Return type cylinder: ( )
a1 a2
A
b1 b2
B
FIGURE 7
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 13 - MANUAL OPERATION
WARNING
Manual operation must only be done after stopping the air supply for both double and single acting actuators. Manual operation while air supply will cause injury. In operating single acting actuator, use manual operating device “HW” for single acting actuator. Never use spanners or wrenches. Doing so may cause injury.
1. Manual operation of double acting actuators (lever handle) AWN13
1. Stop compressed air supply.
2. Open equalizing valve if attached.
Otherwise, loosen the joint of supply port of the actuator to purge air in the actuator.
3. Apply lever handle at the upper portion of
stem to turn it. The turning range should be within 90 degrees.
4. After manual operation, recover air supply
by closing equalizing valve or retighten the joint at supply ports.
2. Double Acting (Manual Gear HG) AW17 to AW28
3. Single acting actuator (Manual operator HW) AWN13S to AW28S
The HW Type Side Handle can be used as
manual valve operation device when loss of air supply occurs in single acting actuator. The procedure of manual operation with HW Type Side Handle is as follows.
1. Equalize pressure between inside of
cylinder and atmosphere by respective methods according to the piping configurations around the actuator.
For example: Switch the power off of
solenoid valve used for operating the actuator. Manipulate pressure-exhausting valve.
WARNING
1. After manual operation, be sure to remove the lever handle. Pneumatic operation while leaving the tools will cause injury.
2. Operate the valve with stable posture from a set direction. Make sure that the handle is reliably inserted into the stem’s end. Insufficient insertion and forced operation of the handle may result in damage or injury if the handle slips out.
3. Excessive handle operation may break the lever and injure the operator.
CAUTION
1. When valve is open or closed, indicator nut moves toward “OPEN” side or “SHUT” side. Return the nut to “AUTO” position correctly by turning Handle . Incorrect positioning of nut deviating from “AUTO” position will cause insufficient opening or closing in automatic operation or operation malfunctions.
2. After resetting the nut to correct “AUTO” position, lock the Handle by chain and lock to prevent misoperation.
CAUTION
Manual operation with side handle without equalizing pressure between inside of cylinder and atmosphere will bring extreme increase in required operating force, which may cause disabling operation or failure of actuator.
2. Operate valve by turning the side handle manually
Reverse Acting type: Turning the handle
counterclockwise opens the valve.
Direct Acting type: Turning the handle
counterclockwise closes the valve.
CAUTION
Over winding by applying excessive force after the valve is fully opened will cause failure of the actuator. Never use pipe or such things to lengthening the handle arm.
3. Be sure to turn the handle clockwise until it stops to reset manual operation mode before returning to pneumatic operation.
CAUTION
Leaving the handle halfway will cause trouble in automatic operation, and the valve does not open or close completely.
Padlock
Chain
Gear Case
Indicator
SHUT AUTO OPEN
Nut
Handle
FIGURE 8
a. Unlock Padlock of Manual operator and remove chain ➄. b. Turning Handle ➁ enables operation of valve to open or close. Turning the handle clockwise operates to valve closing, and counter clockwise operates valve opening.
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 14 - TROUBLESHOOTING
Trouble examples Causes Measures
Valve does not operate Failure in electric power source or control signal. Check and repair of electric power source and/or control devices.
No or insufficient supply air. Check and repair of air source and attachments
(compressor, filter, reducing valve, etc.) Failure of attachments (solenoid valve, air actuated control valve, positioner, etc.) Failure in actuator. After operating actuator separately, disassemble and repair. Failure of valve. Check and disassemble valve, and repair or replace it.
Unstable operation of valve Fluctuation or low supply air pressure
(insufficient supply or fluctuation).
Failure of attachments (solenoid valve, air actuated valve, positioner, etc.) Leakage at or failure of piston. Replace piston O-ring. Wear or damage of piston bearing. Replace piston bearing. Seal leakage in stem. Replace sealing O-ring. Insufficient power of actuator. Replace actuator with larger one.
Unstable valve operating torque or increase of valve operating torque. Disassembling and checking valve.
After checking each attachment separately, repair or replace it.
Increase capacity of compressed air supply.
Install accumulator.
Increase pipe diameter.
After trying each attachment separately, repair or replace it.
Increase supply pressure.
Repair or replace valve parts.
Replace actuator with larger one.
Increase supply pressure.
CAUTION
SECTION 16 - WARRANTY
If there are any troubles in valve, read the Installation and Maintenance Instructions of the valve thoroughly and disassemble the valve carefully.
The warranty period is one year from the date of installation by the first use of the goods, or eighteen (18) months from the date of shipment to the first user, whichever occurs first.
SECTION 15 - MAINTENANCE
Regular maintenance period depends on the operating environment and conditions. Generally maintenance after 100,000 operations or after 24 months from initial operation, (whichever comes earlier), is recommended. Replacing of spring units of single acting actuator after 200,000 operations or 60 months from first operation, (whichever comes earlier), is recommended. Consumption supplies should be replaced with new ones at the same time regardless the degree of wear and deterioration. For purchasing spare parts, please consult a Service Company affiliated with Emerson or a branch office of Emerson.
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
KTM is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.
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. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
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