Gemini Valve A500 Series, A512D, A522D, A522SR, A512SR Technical Data Sheet

TECHNICAL DA T A SHEET

MATERIALS OF CONSTRUCTION

BODY: Aluminium with T eflon® Imprenated Hard Anodized (PolyLube®) Sufaces
EXTERNAL HARDW ARE: (Pinion Shaft, Driver , End Cap s) 300 Series S tainless Steel
SPRING MODULES: A512SR Zytel ® Housing, A522SR Aluminium with Teflon® Imprenated

Hard Anodized (PolyLube®) Sufaces, 300 Stainless Hardware

EXTERNAL TRIM: 300 Series St ainless Steel

RATINGS / SPECIFICATIONS

TEMPERATURE: -20 F to 350 F
POWER: 50 - 125 psi air . Sufficient air delivery must be available at the actuator to ensure depend-

able operation. The following precautions should be observed: Air supply should be clean and free of
moisture. When dirty or wet air is a problem; a filter / separator should be specified; these units are
most effective when installed as closely as possible to the actuator . A filter , when used, should permit
a minimum flow of 4 scfm at an upstream pressure of 60 psi. Eliminate severe restrictions to air flow
(certain solenoid valves & fittings). The most restricted passage must have an area no smaller than
.012 inches square, the area of 1/8” diameter orifice. If more than a single actuator is to be supplied
by an individual pilot, the minimum passage requirement applies per actuator .

TUBING: For short runs up to 5 feet 5/32” I.D. is suitable, 1/4” I.D. will serve up to 30 feet. For
longer runs, use 3/8” I.D. or larger.

DESCRIPTION

500 Series pneumatic actuators are the latest in compact rack

and pinion valve automation from Gemini V alve. The A500 fea­tures 50 psi operation on all models and sizes and includes
many industry standards features such as NAMUR interfaces
and ISO mounting options.

A500 Series Pneumatic Actuators

2 Otter Court, Raymond, New Hampshire 03077 Tel. [phone] FAX [phone] www.geminivalve.com

TDS009-0710

RATINGS / SPECIFICATIONS (continued)

DUTY CYCLE: 100%
CYCLE TIME: (T o Open or Close) Approximately 1/2 to 1 second*

* - Dependent upon actuator model, air pressure and delivery

TORQUE OUTPUT

MAINTENANCE

Gemini A500 Series Pneumatic Actuators are designed to be maintenance free and normally are replaced
vs. repaired.

Double-Acting Models: For double-acting models, rebuilding of the actuator by our Factory Authorized
Service Center may enable the actuator to be returned to service depending on the duty cycle the actuator

has seen. The cost to rebuild the actuator is generally 50% of the cost of a new actuator . For details on this
service please contact us. Additionally, for those customer desiring to replace 0-rings, gasket(s) and lubri­cant, we offer o-ring kits which contain these genuine factory components.

Spring-Return Models: For the A500 Series spring-return models, rebuilding of the actuator by our Fac-
tory Authorized Service Center may enable the actuator to be returned to service depending on the duty

cycle the actuator has seen. The cost to rebuild the actuator is generally 50% of the cost of a new actuator .
For details on this service please contact us. O-rings kits are not available for the A500 Series S pring Return
models.

* - Approximate

CAUTION: Care must be taken to assure the output torque of the A500 Series Actuator selected is adequate
to turn the valve or device to be operated. Note: Does not apply for mounting of Gemini V alves to A500 Series
Actuators. Gemini V alve offers a selection chart for your convenience. See our literature for details. Note
also; special sizing considerations should be given when a valve is handling suspended solids, abrasives,
dirty media, oxygen and dry gasses.

T orque Output - in. - lbs.*

ACTUATOR TO VALVE MOUNTING INSTRUCTIONS

76, 82, 86 & 96 SERIES VALVES

These instructions detail the procedure for installing a Gemini A500 Series actuator on a drive-key equipped Gemini
76, 82, 86 & 96 Series ball valve. V alves may be purchased with the drive-key assembled or may be retrofitted with
a drive-key conversion kit.

Instructions:

Assemble Bracket to Actuator

1. Position the actuator upright with

driver and the A & B ports oriented
as shown in Figure 1.

2. With the counter sunk holes ex­posed, position the bracket to
achieve an inline or cross mounted
actuator orientation as described
below. Table 1 lists the valve condi­tion at rest with respect to the Ac­tuator Model # (See actuator name­plate to determine model number

a. Inline- (standard mounting for
most actuators) The long axis of the
actuator is in-line with the piping.
The bracket should be oriented per­pendicular to the actuator body.
(See Figure 2)

b.Cross mounted- the long axis of
the actuator is perpendicular to the
piping. The bracket should be
mounted parallel to the actuator
body . (See Figure 3)

Figure 1

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Table 1

3. Install the 4 hex flat socket head

mounting screws to

A510 and 75 inch lbs. for A520 actuators)

(60 inches lbs. for

secure bracket to the actuator body .
Important: To ensure positive fasten­ing mounting screws and bracket
counter sunk holes must be clean
and dry .

Figure 2

Figure 3

ACTUATOR TO VALVE MOUNTING INSTRUCTIONS

76, 82, 86 & 96 SERIES VALVES(continued)

Assemble Valve to Actuator

IMPORTANT Note the red OPEN/
SHUT indicator mounted on top of
the actuator shaft and the position
of the ball in the valve. The actua­tor should be mounted such that
the red indicator is in-line with the
valve body when the ball is in the
open position, or across the valve
body when the ball is in the closed
position.

1. Rotate the valve stem so that it
is in the corresponding closed or
open position with regards to the
actuator. The drive key on the
valve should be perpendicular to
valve body when valve is open and
parallel when in the closed posi­tion.

2. Confirm proper position of the
locator screws on the bottom of
the bracket based on the size and
series of the valve being mounted
as Listed in Table 2.

3. Place the actuator, with the
bracket attached, atop the valve
so that the 12 point socket en­gages the stem nut, the shaft
notch engages the drive-key and
locator screws straddle the valve
body hex (see Figure 4). If the lo­cator screws do not span the valve
properly (i.e. interfere with eye­brows or do not engage valve) turn
valve 180 degrees.

Actuator

Series

A510

A520

76 82 86 96
1/2 1/4, 3/8, 1/2 1/4 & 3/8 - 1
3/4 3/4 1/2 - 2

113/41/2 3
1-1/4 - 1 3/4 4
1-1/4 - 1 3/4 4
1-1/2 - 1-1/4 1 5

2 - 1-1/2 1-1/4 6

--21-1/27

Valve Size & Series

Table 2

Figure 4

Loc a to r S c re w

Mounting

Pattern

4. Position the valve retaining strap
over the valve and align with
bracket holes. Secure strap with
two hex head cap screws. Alter­nate tightening the strap bolts to
obtain even tension on the strap
and to avoid skewing. Do not over
tighten. A gap should remain be­tween strap and bracket when

ACTUATOR TO VALVE MOUNTING INSTRUCTIONS

89 SERIES VALVES

These instructions detail the procedure for installing a Gemini A500 Series actuator on a drive-key equipped
Gemini 89 Series ball valve.

Instructions:

Assemble Bracket to Actuator

1. Position the actuator upright with

driver and the A & B ports oriented
as shown in Figure 1.

2. With the counter sunk holes ex­posed, position the bracket to
achieve an inline or cross mounted
actuator orientation as described
below. Table 1 lists the valve condi­tion at rest with respect to the Ac­tuator Model # (See actuator name­plate to determine model number).

a. Inline- (standard mounting for
most actuators) The long axis of the
actuator is in-line with the piping.
The bracket should be oriented per­pendicular to the actuator body.
(See Figure 2)

b. Cross mounted- the long axis of
the actuator is perpendicular to the
piping. The bracket should be
mounted parallel to the actuator
body . (See Figure 3)

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Table 1

Figure 1

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3. Install the 2 hex flat socket head
mounting screws to

A510 and 75 inch lbs. for A520 actuators)

(60 inches lbs. for

secure bracket to the actuator body .
Important: To ensure positive fas­tening, mounting screws and
bracket counter sunk holes must be
clean and dry .

Figure 2

Figure 3

ACTUATOR TO VALVE MOUNTING INSTRUCTIONS

89 SERIES VALVES (continued)

Assemble Valve to Actuator

IMPORT ANT! Note the red OPEN/
SHUT indicator mounted on top of
the actuator shaft and the position
of the ball in the valve. The actua­tor should be mounted such that
the red indicator is in-line with the
valve body when the ball is in the
open position, or across the valve
body when the ball is in the closed
position.

1. Rotate the valve stem so that it
is in the corresponding closed or
open position with regards to the
actuator. The drive key on the
valve should be perpendicular to
valve body when valve is open and
parallel when in the closed posi­tion.

Figure 4

2. Place the actuator, with the

bracket attached, atop the valve
so that the 12 point socket en­gages the stem nut, the shaft
notch engages the drive-key and
locator screws straddle the valve
body hex (see Figure 4).

3. Install two socket head cap
screws to secure valve to mount­ing bracket.

ACTUATOR TO VALVE SELECTION DATA

Actuator Models

Su ita ble for

Valve S eries & Size

76 82 86 96

1/2 1/4 & 3/8 1/4& 3/8 - 0.5 1/2

89

(Port)

309

A512D (Double-Acting)

A512SR (Spring-Return)

A522D (Double-Acting)

A522SR (Spring-Return)

3/4 1/2 1/2 - 0.6 3/4

1 3/4 3/4 1/2 0.8 ­1-1/4 1 1 3/4 - ­1-1/2 - 1-1/4 1 1.0 -

2 - 1-1/2 1-1/4 1.2 -

--21-1/21.5-

DIMENSIONS

76, 86 & 96 SERIES VALVES

Valve Size & Series

76 86 96

1/2 1/4 & 3/8 ­3/4 1/2 - 4.06 1.18 2.22 2.61

1 3/4 1/2 4.38 1.50 2.76 2.94
1-1/4 1 3/4 6.44 2.00 3.02 3.32
1-1/2 1-1/4 1

- 2 1-1/2 8.47 3.00 - 4.57

Actuator

Model

Spring
Return

A512SR A512D 1.36 1.00 1.53 .31 3.06 4.67

A522SR A522D 1.87 1.55 2.25 .50 4.50 5.18

Double

Acting

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Approximate Dimensions, Inches

76 86/96

3.88

.32 3.00

7.59

1.10 4.75

1.00 2.18 2.18

2.12 3.45 3.70

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309 SERIES VALVES

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3.62 8.31 2.81 .57

5.28 11.23 3.50 .822 1-1/2 1-1/4 8.09 2.62 4.04 4.25

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DIMENSIONS

89 SERIES VALVES

82 SERIES VALVES

Tube

Size

Spr ing Retur n D oub l e Ac t ing A B B1 C D E F G H I J K L M N O
1/4
3/8 4.51 1.00 3.70 11/16
1/2 4.61 1.00 3.94 7/8
3/4 4.91 1.19 4.17 1-1/8

1 5.37 1.50 4.92 1-1/2

Actuator Model Approximate Dimensions - Inches

4.51

A512SR A512D 1.46 1.00 1.53 .31 3.06 4.67

.32 3.00

1.00 3.72

9/16

3.62 8.31 2.81 .57