rotork AB 210, AB 150, AB 550, AB 215, AB 1250 Manual For Installation And Operation

PUB033-005-00_0219

MANUAL

FOR

INSTALLATION

AND

OPERATING

For gearbox models AB, 242, and 232

model AB, 232, 242 manual

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: [phone] - Fax: [phone]
Mail: [e-mail] - Web: www.rotork.com

PUB033-005-00_0219

2

Table of contents

1 PREFACE .................................................................................................................................................... 3

1.1 Introduction 3

2 TECHNICAL DATA SPECIFICATIONS .................................................................................................. 3

2.1 Maximum allowable input- and output torque 3

3 HANDLING AND SAFETY PRECAUTIONS .......................................................................................... 4

3.1 Qualification of staff 4

3.2 Commissioning 4

3.3 Operation 4

3.4 Protective measures 4

3.5 Maintenance 4

3.6 Storage 5

3.7 Long-term storage 5

3.8 Packing 5

3.9 Handling 5

3.10 IP rating and environmental conditions 5

3.11 Stem shaft water ingress 5

3.12 Paint 6

3.13 Primer 6

3.14 Seals 6

3.15 Grease 6

3.16 Gearboxes for – 60°C operation 6

3.17 Correct use 6

3.18 Installation and operating 6

3.19 Disposal 7

3.20 Identification 7

3.21 Orientation options of gearboxes. 7

3.22 Keyway and drive positions 7

4 INSTALLATION: MOUNTING TO THE VALVE ................................................................................... 8

4.1 Mounting instructions chainwheel 8

4.2 Adjustment of set screws 11

4.3 Operating instruction 12

4.4 Number of turns opening or closing 13

4.5 Handwheel type 14

STANDARD CONDITIONS .............................................................................................................................. 15

5 IP RATING................................................................................................................................................ 17

5.1 Solid Particle protection 17

5.2 Liquid ingress protection 17

6 CERTIFICATES ....................................................................................................................................... 18

6.1 Atex 18

6.2 Certificates of conformity 18

6.3 Other certificates 18

6.4 Reach 19

model AB, 232, 242 manual

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: [phone] - Fax: [phone]
Mail: [e-mail] - Web: www.rotork.com

PUB033-005-00_0219

3

1 PREFACE

1.1 Introduction

The gearbox of the AB, 232, and 242 series is a quarter turn gearbox designed to use for the manual operation
of valves (e.g. butterfly/ball valves) in pipelines.

NB. This manual is valid only for the standard AB, 232 and 242 series gearboxes of Rotork. For special
versions, specifications and model can differ. Rotork is not responsible for any damage caused by incorrect use
of the gearbox.

2 TECHNICAL DATA SPECIFICATIONS

2.1 Maximum allowable input- and output torque

Gearbox

Connection Valve

Max. Manual operating

Torque in [Nm]

type

ISO 5211/1

Input

Output

AB 150

F05-F07

16

150

AB 210(LB)

F05-F07-F10(-F12)

28.5

330

AB 215 (LB)

F05-F07-F10(-F12)

43

500

AB 550 (LB)

F07-F10-F12-F14(-F16)

83

1000

AB 880 (LB)

F10-F12-F14-F16

152

2000

AB 1250 (LB)

F10-F12-F14-F16(-F25)

171

3250

AB 1950(LB)

F12-F14-F16-F25(-F30)

289

5500

AB 1950(LB) HR

F12-F14-F16-F25(-F30)

159

4500

AB 1950(LB)/SP4

F12-F14-F16-F25(-F30)

125

6800

AB 1950(LB/PR4)

F12-F14-F16-F25(-F30)

106

7000

AB2000 (LB)

F12-F14-F16-(F25)

136

4500

AB 3000(LB)

F16-F25(-F30)

305

7000

AB 3000(LB/PR4)
AB 3000(LB/PR6)

F16-F25(-F30)
F16-F25(-F30)

111
104

9000

11000

AB 6800(LB)

F16-F25-F30(-F35)

305

8400

AB 6800(LB)LT/SP4

F16-F25-F30(-F35)

96

9000

AB 6800(LB)/SP4

F16-F25-F30(-F35)

134

12500

AB 6800(LB)/PR4

F16-F25-F30(-F35)

130

12500

AB 6800(LB)/SP6

F16-F25-F30(-F35)

121

17000

AB 6800(LB)/PR6

F16-F25-F30(-F35)

121

17000

AB 6800(LB)/SP9

F16-F25-F30(-F35)

92

17000

A 200/SP9

F25-F30-F35

166

26000

A 200/PR10

F25-F30-F35

124

26000

A 250LT/SP9

F25-F30-F35-F40

116

26000

A 250/SP9

F25-F30-F35-F40

142

32000

A 250/PR10

F25-F30-F35-F40

142

32000

242-10

F05-F07

15

150

242-20

F07-F10-F12

30

300

242-30

F07-F10-F12-F14

65

650

242-40

F10-F12-F14-F16

120

1200

242-50LT

F14-F16-F25

F14-F16-F25

120
140

1800
2100

model AB, 232, 242 manual

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: [phone] - Fax: [phone]
Mail: [e-mail] - Web: www.rotork.com

PUB033-005-00_0219

4

232-05O

F05-F07

13

125

232-05N

F05-F07

12,5

125

232-06

F05-F07

25

250

232-07

F05-F07

21

250

232-08

F07-F10

41,7

500

232-10

F07-F10-F12

39

500

232-11

F10-F12

75

900

232-12

F10-F12-F14

100

1000

232-13

F10-F12-F14

83

1000

232-14

F10-F12-F14

125

1500

232-15

*per application

125

1500

Table 1 : Connection data of the gearbox

For more specified information, you can contact our sales department.

3 HANDLING AND SAFETY PRECAUTIONS

Be sure to read and understand this manual before installation and use of our gearboxes. All personnel working
with this gearbox must be familiar with the instructions in this manual and observe the instructions given.
Safety instructions must be observed to avoid personal injury or property damage.

3.1 Qualification of staff

Assembly, commissioning, operation, and maintenance must be carried out exclusively by suitably qualified
personnel authorised by the end user or contractor. Prior to working on this product, the staff must have
thoroughly read and understood these instructions and, furthermore, know and observe officially recognised
rules regarding occupational health and safety. Work performed in explosive atmospheres is subject to special
regulations which have to be observed. The end user or contractor is responsible for respect and control of
these regulations, standards, and laws.

3.2 Commissioning

Prior to commissioning, it is important to check that all settings are in compliance with the requirements of the
application. Incorrect settings might present a danger to the application, e.g. cause damage to the valve or the
installation. The manufacturer will not be held liable for any consequential damage. Such risk lies entirely with
the user.

3.3 Operation

Prerequisites for safe and smooth operation:

• Correct transport, proper storage, mounting and installation, as well as careful commissioning.

• Only operate the gearbox if it is in perfect condition while observing these instructions.

• Immediately notify Rotork about any faults and damage and allow for corrective measures.

• Observe recognised rules for occupational health and safety. Observe the national regulations.

3.4 Protective measures

The end user or the contractor is responsible for implementing the required protective measures on site, such as
enclosures, barriers or personal safety equipment for the staff.

3.5 Maintenance

To ensure reliable gearbox operation, the maintenance instructions included in this manual must be observed.
Any gearbox modification requires the consent of the manufacturer. A Rotork gearbox requires only little
maintenance. To ensure that the gearbox is always ready to operate, we recommend for gearboxes the
following measures. Three (3) months after commissioning and each year:

model AB, 232, 242 manual

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: [phone] - Fax: [phone]
Mail: [e-mail] - Web: www.rotork.com

PUB033-005-00_0219

5

- Check the bolts on top of the gearbox;

- Check the bolts on the valve flange;

- Perform a test run every six months;

- Check the gearbox for leakage of grease;

- For gearboxes with permanently vibration and exposure above 60ºC, checks should be performed at

shorter intervals.

3.6 Storage

The gearboxes need to be stored inside in a safe way to avoid accidents. Also avoid storage in areas subjected
to high temperature extremes and /or areas subjected to large amounts of humidity and dust. Protect against
floor dampness by storage on a shelf or on a wooden pallet. Apply suitable corrosion protection agent to bare
surfaces.

3.7 Long-term storage

If the Gearbox must be stored for a long period (more than 6 months) the following points must be observed.
Prior to storage:

• Protect uncoated surfaces, in particular the output drive parts and mounting surface, with long-term

corrosion protection agent.

At an interval of approximately 6 months:

• Check for corrosion. If first signs of corrosion show, apply new corrosion protection.

3.8 Packing

Our products are protected and packed by special packaging for the transport ex works. The packaging consists
of environmentally friendly materials which can easily be separated and recycled. We use the following
packaging material: wood, cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.

3.9 Handling

Never drop the gearbox or otherwise subject it to strong impact. Standard gearboxes are delivered without
eyebolts. On request assembled eyebolts are available for the AB gearboxes these need to be ordered in the
preliminary stages of the order. Eyebolts should only be used to lift the gearbox horizontal on the valve. The
input shaft or hand wheel cannot be used for lifting the gearbox. Do not lift the gearbox when it is assembled to
the valve with eyebolts, input shaft or handwheel.

3.10 IP rating and environmental conditions

The enclosure protection IP65, 67 and 68 only refers to the interior of the gearboxes and not to the stem shaft
coupling compartment. (See table. 6 - IP rating)
Suitability for any specific application is not claimed. IP rating is done in accordance to a standard test
protocol. It is recommended that users carry out tailor made tests to prove the product is fit for purpose for the
specific environmental conditions. For example marine environment, tropical conditions, cold or very hot
conditions, chemical sites with acids or salty conditions requires the end user to assess the fit for purpose.
When the product is used in areas with high temperature fluctuations it is recommended to use pressure
compensators to prevent pressure differences between the outside environment and the interior of the gearbox.

3.11 Stem shaft water ingress

Water can enter into the coupling compartment along the valve shaft, this would lead to corrosion. Therefore a
suitable anticorrosive (or sticky grease) must be applied on the inside bore hole of the gearbox and coupling
before mounting. When water ingress protection towards the stem shaft and rotating quadrant in the coverplate
is required, aluminium position indicators with NBR O-ring is needed, which should be mentioned during
order process. Our G and W gearbox type are suitable. A condition that can occur in some areas is snow on top
of the gearbox with melting water on top of the gearbox, in that case the position indicator with O-ring is
recommended. For horizontal outdoor installation also a sealed aluminium position indicator is recommended.
For gas applications with sealed position indicators an air vent in the indicator could be required. In case of
permanent submersion of the gearboxes or for buried service, a protection cover must be fitted instead of a

model AB, 232, 242 manual

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: [phone] - Fax: [phone]
Mail: [e-mail] - Web: www.rotork.com

PUB033-005-00_0219

6

position indicator and should be mentioned in the order. Exchange of the position indicator for the protection
cover is possible.

3.12 Paint

We deliver our gearboxes in different RAL colours, our standard average paint thickness is 60 microns for AB
and 242 gearboxes and 40 microns for the 232 gearboxes, suitable for installation in a clean and dry industrial
indoor environment. Our process consists of a phosphating pre-treatment followed by our standard DTM
(direct to metal) paint system (Polyaspartic) or primer paint. Other paint systems are on customer request. For
submersed, marine conditions, use for buried service or exposed to corrosive outside environment and other
non-standard environments, paint system are to be advised by the customer including IP rating. On request we
can deliver paint systems and thicknesses (see table 4 standard conditions and options)

3.13 Primer

On request we deliver gearboxes in primer. Standard primer is a 1K industry primer which has a maximal
lifetime of 1, 5 month and must be stored only in indoor, clean and dry conditions. On request zinc primer can
be supplied which has a maximal lifetime of 3 months when free from zinc salts and free from contamination
and stored in a clean exterior. In industrial or marine conditions this should be reduced to the practical
minimum.

3.14 Seals

Rotork is using a silicone low volatile liquid seal between cover lid and body. Loosening the top bolts of the
cover plate from the gearbox can break the seal resulting to leakage. Rotork will not be held liable when the
top bolts are opened without notification. Once opened a new liquid sealing must be applied. Liquid seals kits
may be obtained from Rotork. During the order process it should be mentioned when gearboxes are exposed to
high- or low temperatures. Seals made of elastomeric materials are subject to ageing. All NBR seals subject to
rotating parts are lubricated with MI-setral 9-M. Gearboxes up to minus 60 degrees Celsius are built with
special O-rings and an aluminium indicator will be used to prevent water increase into the bore of the gearbox.

3.15 Grease

Rotork is applying grease that is non-self-igniting and do not present an explosion hazard. Dependent on the
environmental conditions different greases can be used such as high temperature grease, silicone free grease,
foodgrade grease or oxygen free grease. Gearboxes for minus 60 degrees Celsius are built with 75% filling
level of grease. Gearboxes are filled for life but on customer request grease nipples are an option to be
mentioned during order process.

3.16 Gearboxes for – 60°C operation

Gearboxes for – 60°C have special O-rings and seals. The AB range has a position indicator with O-ring and
have special closed stainless nuts on the stud bolts with a copper ring and an additional O-ring around the input
shaft. Gearboxes are filled for life with 75% grease. Up to AB1250 the housing is made of cast iron and tested
up to minus 60 degrees Celsius. On request ductile iron is available. For the AB1950 up to the A250 we supply
ductile iron housing for – 60°C as standard. On request the gearboxes will be supplied with stainless steel
name plate.

3.17 Correct use

Prior to installation, be sure the gearbox will NOT be overloaded during normal use. For this, verify that valve
size and required opening torque do not exceed the values given for the gearbox. For the maximum allowable
torque on the gearbox, (see table 1). AB, 232 and 242 gearboxes can only be used for manual operation.

3.18 Installation and operating

Not observing the rules as stated in this manual, can lead to damage and/or personal injuries. Qualified
personnel must be fully aware of the instructions as described in this manual. Only when the instructions are
observed, correct operation of the gearboxes can be guaranteed.