RCI200 IOM Manual - Remote Control Inc.

RCI200 IOM Manual - Remote Control Inc.
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REMOTE CONTROL
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02/04
PNEUMATIC ACTUATORS
Installation & Maintenance Instructions
(Including Parts List) MI 0998
P.O. Box 275 * North Kingstown, RI 02852 * Phone: 401-294-1400 ¢ Fax: 401-294-3388
E-Mail: sales(@rciactuators.com * Website: www.rciactuators.com
INTRODUCTION
RC Compact Pneumatic Actuators are intended for on-off and proportional
control on quarter-turn valves. The design features a modern Scotch Yoke.
This instruction covers the following actuators:
RC 210, 230, 250, and 270 (one piston)
RC 220, 240, 260, and 280 (two pistons)
Type DA (Double Acting)
Type SR Single Acting-Spring Return
Type SR actuators can be arranged for valves to "Fail Close"
(CW rotation) or "Fail Open" (CCW rotation)
DOUBLE ACTING (DA) ACTUATOR
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SPRING RETURN (SR) ACTUATOR
Ll For clockwise to close valves,
| pressure to the left port opens the
| о © valve. The right port is an exhaust
port from the spring chamber(s).
E
| For clockwise to close valves, pressure to the
left port closes the valve, pressure to the right
р port opens the valve.
STANDARD SPECIFICATIONS
Ambient Temperature Limits: -4 to+ 175%
Operating Medium: Filtered dry air or inert gas
Maximum Working Pressure: 150 PSI
Pneumatic piping to the actuator and associated accessories should follow
the best practices for instrument pneumatic piping systems, ie: lines free of
all water, oil or other contaminents, etc.
The operating medium is to be filtered dry air or inert gas which is filtered
to 30 micron particle size or less. It is extremely important that the actuator
be powered with an adequate air supply. Inadequate air could cause the
valve to fail to operate.
The Spring housings on SR actuators, if not piped, will breath through the
right hand port, see sketch (above). It's important that it not be exposed
to a corrosive atmosphere. Please contact Remote Control for possible
solutions if this condition exists.
INSTALLATION OF ACTUATOR
RCactuators are adapted to the valve by means of an intermediate bracket
and coupler. The coupler adapts the 1S0 or DIN/ISO female output of the
actuator to the valve shaft.
Standard mounting kits provide for mounting the actuator body in the
direction of the pipe. Pipelines can be horizontal, vertical, or other
postitions. When mounting on a valve, the axis of the actuator drive shaft
and valve shaft must be in line. Intermediate couplings must allow for axial
clearance of .020" to .040", depending on actuater size, between valve shaft
and bottom of drive socket. This axial clearance must be added to any valve
stem rise which may be applicable. After mounting, it may be necessary to
adjust the end of travel limit stop (yoke turning angle).
LUBRICATION
RC actuators are permanently lubricated and additional lubrication is not
normally required. However, for actuators performing 100,000 cycles or
more under a very heavy load, an oil mist lubrication is recommended. Oil
mist lubrication requires a mineral oil type ISO VG32 class 1 for useage in
temperature range 15 to 158°F. Oil mist lubricator must be set at the lowest
possible value. Once begun, the oil mist lubrication cannot be discontinued.
CAUTION: If the actuator is equipped with a pneumatic
or electro pneumatic positioner or pneumatic controller,
oil mist lubricated air cannot be used unless the instrument
manufacturer indicates that the instrument is compatible
with lubricated air.
RECOMMENDED LUBRICATION GREASE
Cylinder bore and
drive shaft with shaft Grease
seals and bearings
RC 200 standard Cargo White Grease
Kliber Isoflex Topas NCA 52
Klüber Isoflex Topas NCA 52
and high temp
RC 200 low temp
Piston Roller (21) Grease
All RC 200 Cargo Red Grease
Kliber Unimoly GL 82
ORIENTATION OF PISTONS
Type DA
The pistons of standard Type DA Actuators are mounted as shown in figure
1. This provides for the highest torque at the "closed" (CW) valve position
for valves that rotate clockwise to dose. The pistons are then in their
outermost position and the end of travel stop (yoke turning angle) can be
fine adjusted +3". To enable this adjustment to be done in the "open"
(CCW) valve position, turn the pistons 180° about their axis as shown in
Figure 3.
Type SR
The pistons of standard Type SR Adtuators are mounted as shown in Figure
3. Although spring force is diminished, the geometry of the mechanism
provides a greater torque at the end of the spring stroke than at mid stroke.
When the actuator is in the "Open" valve position (Springs fully com-
pressed), the end of travel stop, (turning angle), can be fine adjusted = 3°.
Changing from "SPRING CLOSES" to "SPRING OPENS" (or
Vice Versa)
CAUTION!! - STORED ENERGY - This procedure MUST be
followed for safe removal of pretensioned spring hous-
ings. Serious injury or damage could result from failure
to follow these instructions.
Refer to Figures 2 & 3
1. Shut off pneumatic (or hydraulic) supply and vent actuator.
2. Remove actuator from valve.
3. Disconnect any electrical power.
4. Confirm that the springs are fully extended as shown in figure 3. This can
be confirmed by observing that the flats on the top drive shaft are 90°to
the actuator axis on a "Fail Close" {fails CW) when viewed from the top of
the actuator and parallel to the axis on a "Fail Open" (fails CCW) when
viewed from the top of the actuator.
5. Loosen Locknut (29).
6. Rotate tensioning screw (26) counterclockwise until resistance is felt,
then turn one more full turn.
Remove screws (4).
Remove spring pack(s) from actuator. .
. Rotate drive shaft (15) until the pistons are at the end of the cylinder. This
can be done by turning the drive shaft with a wrench on the flats or by
clamping the shaft between soft jaws in a vise and turning the actuator.
Insert two close fitting rods in the holes on the end of the piston and,
squeezing them, pull the piston(s) from the cylinder.
10. Rotate drive shaft 90°.
11.Grease cylinder surface (see table above)
12. Rotate piston(s 180° about their axis and reinstall them as shown in
igure 1.
13.Ensure that pistons are lined up so that roller bearing (21) engages scotch
yoke correctly. Once pistons are in, rotate shaft 90° to draw pistons in and
confirm proper engagement. Pistons should now be in their innermost
position. On sizes RC 230 through RC 280, align spring assembly so that
one of three support points falls between the bosses on the piston and pins
engage holes in the piston.
14. Install screws (4).
] > Rolo tensioning screw clockwise until resistance abates and turn one more
ull turn,
16.Tighten locknut (29).
The adjustment will then take place at the air end position.
ADJUSTMENT OF THE TURNING ANGLE
The +3' adjustment of the end of travel stop described in the section on
Orientation of Pistons is accomplished by loosening the lock nut on the end
plate and turning the adjusting screw dockwise for reduced and counterclock-
wise for increased rotary motion. RC 220, 240, 260, and 280 actuators have
two adjustment screws. It is important that both screws are in contact with their
respective pistons.
MANUAL OPERATION
All actuators have a drive shaft with two flats for manual operation. However,
because of the potential for stored energy in the actuator and the possibility
of injury, it is strongly recommended that actuators size RC 230 and larger be
equipped with M1 Manual Handwheel Override for manual operation.
CAUTION: Actuators must be vented before attempting
manual operation.
MAINTENANCE
CAUTION: Before removing any components of the actuator,
ensure that all pneumatic (or hydraulic) and electrical
power supplies are disconnected.
NO Oo Y
Replacement of Shaft O-Rings
The shaft O-rings (18) & (38) and the support washers (33) & (39) can easily
be replaced. Refer to figure 2.
1. Vent actuator.
2. Remove circlip locking rings (31) & (40).
3. Replace O-rings and support rings.
Note: Use a high quality grease when installing new parts.
(See table on page 1.)
4. Replace dirclip locking rings. The rounded inner edge is to be toward the
center of the actuator. Do not spread more than necessary to get
it over the shaft. It should fit tightly in the groove with no play.
REPLACEMENT OF O-RING AND SUPPORT BAND
FOR DA ACTUATORS
Replacement of the piston O-ring is required if the O-ring is not holding air
pressure.
1. Vent actuator.
2. Remove end hoe 5).
3. Rotate drive shaft (15) until the pistons are at the end of the cylinder.
This can be done by turning the drive shaft with a wrench on the flats or
by clamping the shaft between soft jaws in a vise and turning the actuator.
Insert two close fitting rods in the holes on the end of the piston and,
squeezing them, pull the piston(s) from the cylinder.
Replace O-ring (12).
Replace wear band (14).
Replace the support element (9). It should “pop” off with minimal effort.
Grease cylinder surface before reassembling. See table on page 1.
Install piston. Ensure that pistons are lined up so that roller bearing (21)
engages scotch yoke correctly. Once pistons are in place, turn the drive
shaft to draw pistons in and confirm proper engagement.
9. Mount end plates.
10.Replace O-ring (3) under lock nut (2).
11. Turn drive shaft to extend pistons and fine adjust end of travel stop (1).
12.Tighten lock nut (2)
NOTE: For two piston actuators (RC 220DA, RC 240DA, RC
260DA, RC 280DA), it is important that both travel
stops contact pistons equally.
REPLACEMENT OF O-RING AND SUPPORT BAND FOR
SR ACTUATORS
Refer to figures 2 & 3
1. Loosen lock nut (29).
2. Rotate tensioning screw (26) counterclockwise until you feel
resistance and turn one more full turn.
3. Remove screws (4).
4. Remove spring pack from actuator.
5. Follow steps 3 through 8 for DA actuators.
Assembling
6. Replace O-Ring on spring cartridge(s) and end plate, if applicable.
7. Mount spring assembly with pistons in their innermost position. On sizes
RC 230 through RC 280, turn spring assembly so that one of three support
points lies between bosses on piston and pins engage holes in piston.
8. Install screws (4).
9. Rotate tensioning screw clockwise until resistance abates, and turn one
more full turn.
10.Tighten locknut (29).
CHANGING DA TO SR ACTUATORS
All DA actuators can be changed to SR actuators by adding spring conversion
kits as follows:
1. Pretension spring assembly using item (26). Refer to Table 1
and Figure 4.
Vent actuator.
Remove end plates.
Follow instructions above for removing piston(s) (10).
Rotate shaft 90°.
Grease cylinder surface see table on page 1.
Turn pistons 180° about their axis and reinstall them per figure 3.
Follow instructions above for reinstalling pistons.
Note: Refer to instruction on assembling SR actuators
above for installation of spring paks.
DL. |
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Figure 1 - RC 200-DA from above
7——— = —=\
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Figure 2 - Top Side
Figure 3- RC 200-SR from above
INSTRUCTIONS FOR DISMANTLING OF RC 200-SR
ACTUATORS WITH MANUAL OPERATION UNIT TYPE MI
CAUTION
Do not remove the protective tube (50) and handwheel
from the spring housing as long as the springs are under
tension. This procedure must be followed for safe removal
of pretensioned spring housings.
DISASSEMBLY MUST BE PERFORMED EXACTLY AS FOLLOWS.
SERIOUS INJURY OR DAMAGE COULD RESULT FROM FAILURE
TO FOLLOW THESE INSTRUCTIONS. CONTACT REMOTE
CONTROL IF AT ALL UNCERTAIN.
1. Shut off pneumatic (or hydraulic) supply and vent actuator.
2. Confirm that the springs are fully extended as shown in figure 5. This can
be confirmed by observing that the flats on the top drive shaft are 90°to
the actuator axis on a "Fail Close" (fails CW) when viewed from the top
of the actuator and parallel to the axis on a "Fail Open" (fails CCW) when
viewed from the top of the actuator.
3. Turn the handwheel so that the threaded stem (51) moves toward the
actuator until it stops and the stem can just barely be seen in the plastic
tube (49).
4. For sizes RC 220, 240, 260 and 280 (i.e. actuators with two pistons):
adjust the tensioning screw (26) in the opposite spring housing counter
clockwise until it contacts the spring guide (22). Remove the spring
housing by removing the screws (4).
5. Turn the handwheel until there is resistance and the threaded stem (51)
can be seen slightly to the right of neutral position "N" (see figure 5).
6. Remove the spring housing of the manual override by removing the
retaining screws (4) and turn the handwheel several turns in the direction
which gives the least resistance.
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Figure 4 - Spring Pack
Pretensioning
Actuator Dimension "A"
inches (mm)
210-220 1.61 (41)
230-240 2.44 (62)
250-260 3.43 (87)
270-280 5.39 (137)
Table 1 - Pretensioning
Dimension "A"
Figure 5
MATERIAL TABLE FOR RC 210-280
Item Description Quantity | Quantity | Material Surface
Number RC 200DA |RC 200-SR Treatment
1 Adjusting screw' 1 -- Sizes 210-260: Stainless steel
270, 280: Steel Zinc plated
2 Lock nut' 1 -- Sizes 210-260: Stainless steel
270, 280: Steel Zinc plated
3* O-ring’ 1 -- Nitrile
4 Screw 8-16 8-16 Sizes 210-260: Stainless steel
270, 280: Steel Zinc plated
5 End plate with center hole‘ 1 -- Aluminum Anodized
6* O-ring 2 2 Nitrile
7 Cylinder 1 1 Aluminum Anodized
8 Scotch yoke 1 1 Steel
9* Support element' 1 1 POM/PTFE
10 Piston’ 1 1 Aluminum
11 Roll pin, double?? 1 1 Spring steel
12* O-ring’ 1 1 Nitrile
14* Support band’ 1 1 PTFE filled
15 Drive shaft 1 1 Sizes 210-260: Stainless steel
270, 280: Steel Yellow chromated
16 Bearing, upper 1 1 Polymer material
17 End plate without center hole* 1 1 Aluminium Anodized
18* O-ring, upper 1 1 Nitrile
19 Support ring, upper 1 1 Polymer material
20 Piston pin' 1 1 Steel
21 Piston roller 1 1 Steel
22 Spring guide! = 1 Aluminum
23 Spring external’ -- 1 Sizes 210-260: Alloyed spring steel
270, 280 Spring steel Corrosion protected
24 Spring internal's -- 1 Alloyed spring steel Corrosion protected
25 Spring housing! -- 1 Aluminum Anodized
26 Pre-tensioning screw’ -- 1 Sizes 210-260: Stainless steel
270, 280: Steel Zinc plated
27 Indicator 1 1 Polymer material
28* O-ring’ -- 1 Nitrile
29 Lock nut! -- 1 Sizes 210-260: Stainless steel
270, 280 Spring steel Zinc plated
30 Marking washer’ -- 1 Aluminum Anodized
31* Circlip, upper 1 1 Sizes 210-260: Stainless spring steel
270, 280: Spring steel Corrosion protected
32* Middle Washer 1 1 Sizes 210-260: Stainless steel
270, 280: Steel Corrosion protected
33* Support washer, upper 1 1 Polymer material, chemically resistant
34 Seal’ 1 1 Sizes 210-260: Stainless steel
270, 280: Nitrile
35 Support ring, lower 1 1 Polymer material
36 Bearing, lower 1 1 Polymer material
37 Guide ring 1 1 Polymer material
38* O-ring, lower 1 1 Nitrile
39* Support washer, lower 1 1 Polymer material, chemically resistant
40* Circlip 1 1 Sizes 210-260: Stainless spring steel
270, 280: Spring steel Corrosion protected
1. For actuators sizes 220, 240, 260 and 280: double the quantity. 2. RC 240 has triple roll pins.
3. RC 270-280 have steel pin. 4. Not shown. Does not exist for sizes 220, 240, 260 and 280.
5. Only for sizes 270 and 280.
* = Parts are contained in "Seal Kit" these are "Recommended Spare Parts".
Locknut
TIGHTENING TORQUES FOR SCREWS AND LOCKNUTS Actuator | Actuator | gern DA | SR
The actuators must be screwed onto the mounting brackets Console (4) (2) (29)
with the correct torque in order to be stable during operation. L = 210.229 = e =
Use maximum screw length possible without the threads RC250-260 204 797 310
bottoming. Tightening torque values are expressed in in.-Ib. RC 270-280 673 1062 708
| Lmax Screw Length (mm)
Actuator [DIN Flange| Thread | (mm) | 32 (8) 1.39 (10) | .47 (12) | .55 (14) | .63 (16) | „71 (18) | .79 (20) | .94 (24) [1.10 (28)1.26 (32)
RC 210 F05 1/4" 43 (11) 88 91
RC 220 F05 1/4" 43 (11) 88 91
F07 5/16" 55 (14) 168 186 186
RC 230-240 |" F10 3/8" 67 (17) 283 319 319
F10 3/8" 67 (17) 283 319 319
RC 250-260 F12 1/2" 83 (21) 611 708 761 761
F14 5/8" ‚98 (25) 1018 1151 1274 1522
ВС 270 170 X 110| 5/8" 98 (25) 1018 | 1151 | 1274 | 1522
F12 1/2" 98 (25) 708 761 761 761
RC 280 F16 3/4" 1.26 (32) 2080 2451 2682
F25 5/8" ‚98 (25) 1018 1151 1274 1522
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