Samson BR 31a Series, BR 31a SRP, BR 31a DAP Operating, Assembly And Maintenance Instructions
Specifications subject to change without notice
Edition
EN
The device may only be mounted and started
Operating, assembly and maintenance instructions
BR 31a Rack-and-pinion Actuator,
SRP and DAP
1. General
These instructions are intended to support the user in the
assembly, maintenance, and repair of BR 31a Rack-and-
Fig. 1 - Rack-and-pinion actuator
0. Contents
1. General 1
2. Design, principle of operation, and dimensions 1
3. Actuator designation and nameplate 1
4. Operating conditions 2
4.1 Design 2
4.2 Warnings 2
4.3 Operating media 3
4.4 Supply pressure 3
4.5 Operating temperatures 3
4.6 Response time 3
4.7 Rotation and travel limitation 3
4.8 Lubrication 3
4.9 Coating and corrosion protection 3
4.10 Function and direction of rotation 4
4.11 Fail-safe position 4
5. Actuator design und mounting instructions 4
5.1 Principle of operation 4
5.2 Important safety instructions 5
5.3 Control and connections 5
5.4 Mounting accessories 5
5.5 Mounting the actuator onto valves 6
5.6 Changing the direction of action/fail-safe position 6
5.7 Alternative mounting options 6
6. Maintenance and assembly instructions 7
6.1 Fourth generation of rack-and-pinion actuators
(version manufactured from 2000)
6.2 Third generation rack-and-pinion actuators 13
7. Storage instructions 18
8. Customer inquiries 18
1 of 18
pinion Actuators.
Before operating the unit, please read this manual thor ough l y
and retain it for future reference.
Technical specifications, as a result of further development of
valves mentioned in these instructions are subject to
alteration without notice.
The text and illustrations do not necessarily display the scope
of supply or any ordering of spare parts.
Drawings and graphics are not to scale. Customer-specific
designs not in accordance with our standard product range
are not shown.
Parts subject to wear are not covered by the warranty.
up by skilled staff who are familiar with the
assembly, start-up, and operation of this
product.
In these maintenance and assembly instructions, the term
skilled staff refers to individuals who are able to judge the
responsibilities assigned to them as well as recognize
potential hazards due to their specialized training,
knowledge, and experience as well as their special
knowledge of the relevant standards.
These instructions apply to the actuator only. In addition,
refer to the instructio ns of the moun ted valv e.
2. Design, principle of operation, and dimensions
Design, principle of operation, and dimensions including all
further details and technical data can be found in the Data
Sheet <TB 31a>.
3. Actuator designation and nameplate
The actuator type, size, operating pressure, output torque,
direction of rotation, fail-safe action, operating temperature,
and type of attachment are determined by the actuator
designation.
: August 2017 Maintenance EB 31a-01_
Specifications subject to change without notice
Edition
EN
• Maxi mum per mis si ble pr ess ur e (fixed)
6 Always 10 bar for BR 31a
• Pr inciple of opera tion (variable)
7 Actuator function: Single-acting/double-acting
8 Direction of action : CW = Clockwise
CCW = Counterclockwise
9 Schematic diagram of the spring function with the air
connection. Schematic diagram of NAMUR interface
with identification for ports 2 and 4
• Exact type designation (variable)
10 Series: BR 31a
11 Type: SRP / DAP
12 Actuator size: 6 to 10000
13 Spring design ation: 2,5 to 6 (bar)
• Opening angle (fixed, depending on actuator size)
14 0-90° +5/-15°; 0-120°+/+5/-15°; 0-180° +5/-15°;
• Article number (variable)
15 Pfeiffer article number
• Version acc. to EN (fixed, depending on actuator size)
Example: F07-Y-D-17
16 Flange F07
17 Spigot ( Y )
18 Diagonal square drive ( D )
19 Square drive, width across flats 17
• Torques (variable)
20 Specification of the actuator torque depending on
supply pressure.
Fig. 2 – Name plates
Rack-and-pinion actuators have nameplates, which show the
following information:
• Unique identification (variabel)
1 Order number
2 Position number in the order
3 Serial number (automatically assigned)
• Connection for accessories (fixed, depending on
actuator size)
4 AA1 to AA5 (VDE/VDI actuator size 1 to 4)
• Pressure connection (fixed, depending on actuator size)
5 PC1 = G 1/8“ PC3 = G 3/8“
PC2 = G 1/4“ PC4 = G 1/2“
2 of 18
4. Operating conditions
4.1 Operating conditions
The rack-and-pinion actuator is suitable for use in closed and
open environments without additional weather protection.
4.2 Warnings:
• Referring to the Machinery Directive 2006/46/EU, the
actuators can be classified as “partly completed
machinery” (see declaration of incorporation).
As a result, the actuator cannot put into service until the
machinery and/or the system, into which the actuator is to
be incorporated, has been declared in conformity with the
provisions of the Directive 2006/42/EU.
• Actuators are designed, produced, and classifi ed
according to the ATEX Directive 2014/34/EU.
The use of the actuators in potentially explosive
atmosphere zones must comply with the ATEX
classification indicated on the actuator nameplate and
according to the ATEX safety regulations.
• It is important that the actuator is used only within the
working limits permitted in the technical specifications.
: August 2017 Maintenance EB 31a-01_
Specifications subject to change without notice
Edition
EN
Manufacturer
Lubricant
Tennex
TS 2066/2
• Do not operate the actuator outside the temperature
limits: this could damage internal and external
components (disassembly of single-acting actuators may
be dangerous).
• Do not operate the actuator outside the pressure limits:
this could damage internal parts as well as cause damage
to the housing and end caps.
• D o not use the actuator in corrosive environments with
insufficient protection: this could damage internal and
external parts.
• D o not disassem ble ind iv idua l sprin g cartridges; this may
result in personal injury. If maintenance to springs is
necessary, send them to Pfeiffer.
• C lose and disco nne ct all air su pply lines and ma ke sure
that pneumatic connections are vented during
maintenance and when mounting the actuator onto the
valve.
• Do not disassemble the actuator or remove the end caps
while the actuator is pressurized.
• The actuators are designed to be used only on valves.
• Bef ore mou ntin g the actuator onto the valve, make sure
that the direction of rotation and the position indicator are
in the correct position.
• If the actuator is incorporated into a system or must be
used in safety devices or circuits, the operator must
ensure that the national and local safety laws and
regulations are observed.
4.3 Operating media:
Dry or lubricated air or inert gases, provided that they are
compatible with the actuator’s internal parts and lubricant
used.
Note: The operating media must have a dew point
equal to -20 C (-4°F) or at least 10°C below the
ambient temperature. The maximum particle size
contained into the operating media must not
exceed 30 μm.
Note: For operation at low and high temperatures,
special lubricant is required. Please contact
Pfeiffer. A low or high temperature can slightly
influence the torque of the actuator.
4.6 Response time:
Refer to the corresponding data sheets for the response
times.
Note: The response time depends on several
factors, e.g. supply pressure, supply capa city of
the operating medium (pipe diameter, flow
capacity of pneumatic accessories), valve type, valve torque
and characteristics, applied safet y factor, o perat ing fr equ enc y
and temperature etc.).
4.7 Rotation and travel li m itation:
Refer to the data sheet for the travel of the rack-and-pinion
actuators:
Standard actuator: 90° rotating angle, with end stop
setting at 0° and 90°, +5/–15°
adjustable
120° actuator: 120° rotating angle with end stop
setting at 0° and 120°, +5/–15°
adjustable
180° actuator: 180° rotating angle with end stop
setting at 0° and 180°, +5/–15°
adjustable
4.8 Lubrication:
The actuators are delivered ready lubricated for the service
life of the actuator under normal operating conditions. The
standard lubricant is approved for the temperature range from
-40°C (-40°F) to +80 C (+176°F).
For low (SLT) and high (HT) temperatures, a special lubricant
is required. Contact Pfeiffer in this case.
4.4 Supply pressure:
The maximum supply pressure is 10 bar (145 psi).
For double-acting and single-acting actuators, the operating
pressure range is 2.5 bar (36 psi) to 10 bar (145 psi).
4.5 Operating temperatures:
• Standard actuator:
from -40°C (-40°F) to +80°C (+176°F).
• Low-temperature version SLT with silicone O-rings:
from -55°C (-67°F) to +80°C (+176°F).
• High-temperature version HT with FPM O-rings:
from -15°C (+5°F) to +150°C (+300°F).
3 of 18
: August 2017 Maintenance EB 31a-01_
Table 1 - Lubricant recommendation
4.9 Coating and corrosion protection:
All actuators are protected against corrosion under normal
weather conditions. The different types of coating are
described in the data sheet
Note: Before mounting the actuator in a corrosive
environment, make sure that the correct type of
corrosion protection has been chosen.
Specifications subject to change without notice
Edition
EN
4.10 Function and direction of rotation:
The actuator is a pneumatic component for remote actuation
of valves. For the actuation (90°, 120° or 180° rotation), there
are different actuator versions:
• Direct mounting of a solenoid valve (5/2 or 5/3-way for
double acting, 3/2-way for single acting) for connecting to
ports 2 and 4.
• Hook-up (to ports 2 and 4) with a separate control unit.
• The standard direction of rotation is the clockwise
direction to close a mounted valve. The counterclockwise
direction for double-acting actuators is achieved by
applying air pressure to port 2.
• For actuat ors mar ked “CCW”, the direction of rotation to
close the valve is counterclockwise, the clockwise
direction of rotation (CW) is achieved by applying air
pressure to port 2.
4.11 Fail-safe position:
• Fail-close: clockwise (SRP only)
• Fail-open: counterclockwise (SRP only)
Fig. 4 - CCW direction
If the shaft of the actuator is to turn in a clockwise direction
when the valve opens, the pistons must be installed in the
opposite way to the standard version (see Fig. 4).
The shaft turns from the start position OPEN to the end
position CLOSED in clockwise direction (SRP only). The
actuator is delivered in the start position.
Fig. 3 - CW direction
The standard version of the Series 31a Actuators is mounted
in the direction of the media flow.
When pressure is applied to port 2, the shaft turns from the
start position CLOSED to the end position OPEN in the
counterclockwise direction.
In case of pressure loss at port 2, the shaft turns clockwise to
the start position CLOSED (SRP only). The actuator is
delivered in the start position.
Note: If mounted diagonal to the media flow, make
sure that the position indicator is set correctly (turn
90°, see mounting instructions
4 of 18
5. Actuator design und mounting instructions
The BR 31a Actuator operates with a 90° (optionally 120° or
180°) angle of rotation to open and close different types of
valves
Note: All the necessary technical information to
correctly mount the actuator onto a valve, e.g.
dimensions, output torque, air volume, travel
adjustment, response time, operating temperature, and
direction of rotation are clearly stated on the nameplate, in
the catalog and/or data sheets.
Read the technical information carefully before proceeding
with mounting the actuator.
5.1 Principle of operation:
• Double-acting actuator (standard direction of rotation)
Fig. 5
Fig. 6
: August 2017 Maintenance EB 31a-01_
Specifications subject to change without notice
Edition
EN
Screw
M5
M6
M8
M10
M12
M14
M16
M20
M24
M30
Tightening
in NM
5
6
10
11
23
25
48
52
82
86
132
138
200
210
390
410
675
705
1340
1400
Air supplied to port 2 (Fig. 5) forces the pistons apart and
towards the end positions. Air is vented at port 4. This is
based on a clockwise direction of rotation.
Air supplied to port 4 (Fig. 6) forces the pistons together. Air
is vented at port 2. This is based on a clockwise direction of
rotation.
• Single-a cting actuat or (standard direction of rotation)
Fig. 7
Fig. 8
Air supplied to port 2 (Fig. 7) forces the pistons apart and
towards the end positions. The springs are compressed. Air is
vented at port 4. This is based on a clockwise direction of
rotation.
A loss of air pressure at port 2 (Fig. 8) allows the pistons to
return to the start position. Air is vented at port 2. This is
based on a clockwise direction of rotation.
5.3 Control and connecti o ns:
Fig. 9 – Connections
5.4 Mounting accessories
5.2 Important safety instr u ctions
• For safety reasons, the actuator must not be pressurized
when mounting the actuator onto the valve. Risk of injury.
• When connecting the air pressure to the actuator, it is
important that all connecting parts are clean and free from
dirt, especially the thread connections, pipe screw fittings,
and gaskets.
• When fitting accessories to the actuator, make sure that
the emergency operator control of the solenoid valve and
the top end of the shaft are easily accessible for possible
manual operation of the actuator.
• Before mounting the actuator onto the valve, make sure
that the actuator is correctly aligned based on the direction
of rotation required.
• For single-acting actuators, make sure dan ger ou s and/or
corrosive substances in the working environment cannot
enter the spring chambers through the use of suitable
filters and/or solenoid valves.
• Remove plugs from the actuator’s pneumatic connections
during installation and operation. Protect any unused
pneumatic connections of actuators.
5 of 18
Fig. 10 - Mounting accessories
• Mounting the solenoid valve:
Before mounting the solenoid valve, check that the
actuator is in the initial posit ion (closed position, pistons
retracted). For standard mounting and clockwise rotation
(closing): The groove on the shaft or position indicator (2)
must be in the closed position, at a right angle to the
longitudinal axis of the actuator. Mount the solenoid valve
(4) onto the actuator (3) using the suitable screws (see
Table 2 for max. tightening torque).
• Mounting the limit switch box:
Fit the limit switch box and bracket (1) onto the actuator
(3) using suitable screws (see Table 2 for max. tightening
torque).
torque
Table 2 - Tightening torque
bis
bis
bis
bis
bis
bis
bis
bis
bis
bis
: August 2017 Maintenance EB 31a-01_
Specifications subject to change without notice
Edition
EN
5.5 Mounting the actuator onto valves:
Fig. 11 - Mounting the actuator onto valves
Note: Before mounting the actuator onto a valve,
ensure that the actuator turns in the required
direction of rotation and that the valve and actuator
are correctly aligned with each other.
Caution: When mounting a single-acting actuator
(with spring) with a defined fail-safe position,
ensure upon pneumatic or electric power failure
that the direction of rotation is according to your application.
(clockwise to close).
Mount the actuator ( 3 ) onto the valve ( 5 ). The actuator
must be in the initial position (CLOSED position).
There are two different mounting versions:
• Direct mounting:
Insert either the square drive, flat head drive or key drive
of the valve shaft directly into the actuator shaft. Fasten
them using the ISO flange onto the actuator. See Table 2
for max. tightening torque.
• Mounting using a bracket:
Mount the bracket (6) onto the valve (5) and place the
coupling (7) onto the actuator shaft.
Note: Make sure that the position indicator of the
coupling corresponds with the switching position of
the valve.
Place the actuator onto the shaft and fasten the unit. See
Table 2 for max. tightening torque.
6 of 18
5.6 Changing the direction of action/fail-safe position
Note: For the exact procedure for disassembly and
assembly, refer to section 6 (maintenance and
assembly instructions).
• Move the actuator to the fail-safe position to release the
spring compression.
• Remove the screws ( 24 ) (see Fig. 15).
• Pull the position indicator ( 19 ) off the end of the shaft. If
necessary, use a screwdriver to lever it off.
• Remove both adjusting screws ( 2 ) with washers ( 4 ) and
lock nuts ( 3 ) (see Fig. 16).
• Remove the O-ring ( 11 ).
• Unscrew the screws ( 13 ) of the end caps (see Fig. 17).
• Remove end caps ( 22 und 23 ) from the housing.
• For single-acting actuators, remove the spring cartridges
( 17 ).
• Remove the gaskets ( 14 ) of the end caps.
• C lamp the hou sing ( 29 ) in a vise or similar. Turn the
shaft ( 30 ) until the pistons ( 25 ) are released
(see Fig. 18).
• Turn both pistons ( 25 ) in axial direction by 180° and
reassemble.
• Press both pistons ( 25 ) simultaneously into the housing
( 29 ) until they engage and turn the housing until the
travel end position is reached.
• Check that the pistons are in the end position. Turn the
shaft 4° over the center line (0°) (see Fig. 25).
• For single-acting actuators, insert the spring cartridges
into the end caps (see Fig. 27).
• Insert the gasket ( 14 ) into the groove of both end caps.
• Mount the end caps on the housing ( 29 ).
• Tighten the screws ( 13 ) by hand. Observe the tightening
sequence (see Fig. 28).
• Insert the adjusting screws ( 2 ), lock nuts ( 3 ), washers
( 4 ), and O-rings ( 11 ).
• Screw the adjusting screws ( 2 ) into the housing.
• Observe the end position setting.
• Place the position indicator ( 19 ) onto the shaft. Make
sure that it is in the correct position (see Fig. 30).
• Tighten screw ( 24 ).
5.7 Alternative mounting opti o n s:
• Alternative mounting options
(in clockwise direction to open)
: August 2017 Maintenance EB 31a-01_
Loading...