rotork gp series Installation & Maintenance Manual
Established Leaders in Valve Actuation
GP RANGE
PNEUMATIC SCOTCH YOKE ACTUATORS
INSTALLATION
AND
MAINTENANCE
MANUAL
Publication F130E
Date of issue 04/08
CONTENTS
GP RANGE
INSTALLATION AND MAINTENANCE
SECTION
1
2
3
4
5
6
7
Appendix
CONTENT PAGE
Introduction
Installation
Maintenance
Grease and Hydraulic Oil Specifications
Cylinder Seal Replacement
Fault Detection
Actuator Drawing / Parts List
3
3
5
6
7
8
9
A
B
Stop Bolt Adjustment
MB1 Switchbox Setting Procedure
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INTRODUCTION
1.0 Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems GP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of GP range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.
INSTALLATION
GP RANGE
INSTALLATION AND MAINTENANCE
2.0 Installation
2.1 Electrical Considerations
2.1.1 Any electrical connections required are the responsibility of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.
2.1.2 Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.
2.1.3 Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.
2.1.4 The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.
2.2 Motive Power Supply (pneumatic, hydraulic)
2.2.1 Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.
2.2.2 Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium.
2.2.3 Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.
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Publication F130E
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INSTALLATION
GP RANGE
INSTALLATION AND MAINTENANCE
2.3 Maximum Allowable Temperature
2.3.1 The maximum temperature allowable for standard build actuators is 100°C (212°F).Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.
2.3.2 Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.
2.4 Operating Environment
2.4.1 The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.
2.4.2 If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.
2.5 Mechanical Considerations
2.5.1 It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.
2.5.2 Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.
2.5.3 Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.
2.54 All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.
2.5.5 When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.
2.5.6 Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.
2.5.7 Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
2.5.8 Once in position, the actuator should operate the valve with a smooth continuous action. If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
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Date of issue 04/08
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