Biffi Morin HP Hydraulic Actuator Metric Installation & Maintenance Instructions
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Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Introduction 1. Installation General application Biffi actuators are designed for ‘on-off’ or modulating control of any quarter-turn ball, butterfly, rotary plug or damper style valve application. The actuator is factory lubricated and does NOT normally require periodic lubrication while in service. The actuator can be mounted parallel or perpendicular to pipeline. The actuator can be installed in any convenient position including vertical, horizontal or upside down. A. Bolt mounting bracket to actuator hand tight. DO NOT tighten yet. B. Install coupling on valve. Be sure rotary stops on valve are removed or adjusted to allow actuator stops to do the stopping. C. Install actuator and bracket to valve being sure to leave all fastener connections hand tight. If possible, stroke valve and actuator to a half open position 45° and physically shift actuator back and forth until coupling and all fasteners are relaxed then tighten all bolts and nuts. This procedure will accurately align valve stem to actuator output shaft and prolong valve stem seal life. D.Cycle valve / actuator assembly and observe for smooth operation. E. Adjust travel stops for perfect alignment in both open and closed positions. F.TUBING CONNECTIONS – Tubing connections for the hydraulic supply are to be attached as shown in Figures 1, 2, and 3. Note that on a two cylinder actuator the inboard endcap (adaptor) is vented and must not be connected to the hydraulic or high pressure gas supply. Technical data Supply pressure: Max operating pressure 27.6 to 155 bar (400 to 2250 psig) or as specified by nameplate. Max shell pressure 2250 psig or as specified by nameplate. Supply medium: Any gas or hydraulic fluid compatible with materials of construction. Temperature rating: standard range: -28°C to +98°C (-20°F to 210°F) optional range: -54°C to +149°C (-65°F to 300°F) Angular rotation: 90 degrees ± 8 degrees Figure 1 - Single acting, two cylinders Supply Solenoid or positioner Exhaust Figure 2 - Double acting, two cylinders Supply Solenoid or positioner Exhaust Figure 3 - Double acting, single cylinder Supply Solenoid or positioner www.pentair.com/valves Exhaust © 2012 Pentair plc. All Rights Reserved. VCIOM-01952-EN 15/03 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Single acting spring return one piston All models except: HP60 series HP65 series HP80 series Double acting air to air two pistons All models except: HP60 series HP65 series HP80 series Double acting air to air one piston All models except: HP60 series HP65 series HP80 series Yoke shown at mid-stroke pointer omitted for clarity Section A - A, Models HP15 Section A - A, Models HP25 - HP30 2 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Single acting spring return two pistons Model: HP65 series Single acting spring return two pistons Model: HP80 series Double acting air to air two pistons Models: HP65 series HP80 series Double acting air to air one piston Models: HP65 series HP80 series HP65 and HP80 series Yoke shown at mid-stroke pointer omitted for clarity 3 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Single acting spring return two pistons Model: HP60 series Double acting air to air two pistons Model: HP60 series Double acting air to air one piston Model: HP60 series Note HP60 non-guide bar design only offered in stainless steel. HP60 series Yoke shown at mid-stroke pointer omitted for clarity 4 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Materials of construction (continued next page) 1 2 3 4 5 6a 6b 7 8 9 10 11 12 12a 12b 13 13a 13b 13c 14 15 16 17 Item Housing Yoke Output shaft Piston rod Bushing - output shaft Yoke pin Key - yoke Bushing - piston rod Retaining ring - output shaft Thrust pin Roller bearing Retaining ring - pin Seal, thrust plate Set screw Retaining ring - lower bearing Pointer adaptor Position indicator Thrust plate Gasket, thrust plate Hex head bolt Lock washer Pointer Round head screw HP15 316 SS 17-4 PH 17-4 SS 316 SS PTFE 18-8 SS PTFE 15-7 MO 440C SS 440C SS 15-7 MO 18-8 SS 304 SS 18-8 SS 18-8 SS Soft PVC 18-8 SS S material HP25 and HP30 316 SS 17-4 PH 17-4 SS 316 SS PTFE composite 17-4 PH PTFE 15-7 MO 440C SS 440C SS 15-7 MO NBR 18-8 SS Nylon 316 SS Fiber 18-8 SS 18-8 SS Soft PVC 18-8 SS HP15 Ductile iron 17-4 PH 4140 CPO Bronze Steel Bronze Steel 440C SS 440C SS Steel 18-8 SS 18-8 SS 18-8 SS Soft PVC 18-8 SS B material HP25 and HP30 Ductile iron 17-4 PH 4140 CPO PTFE composite Steel Bronze Steel 440C SS 440C SS Steel NBR Steel Nylon Ductile iron Fiber Steel Steel Soft PVC Steel C material HP25 and HP30 Ductile iron 17-4 PH 4140 CPO PTFE composite Steel Bronze Steel 440C SS 440C SS Steel NBR Steel Nylon Ductile iron Fiber Steel Steel Soft PVC Steel 18 19 20 21 22 23 24 25 26 26b 27 28 29 29a 30 31 32 33 Cover - housing Hex head bolt Lock washer Pointer washer Thrust washer Gasket - cover Cylinder Piston Adaptor HP adaptor End cap Rod cover Seal - piston rod U cup seal - piston rod Seal - piston bolt Seal- piston Gasket - housing Piston bolt 316 SS 18-8 SS 18-8 SS 18-8 SS Fiber 316 SS 316 SS 316 SS 316 SS 316 SS 316 SS NBR Urethane NBR NBR Fiber 18-8 SS 316 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS Fiber 316 SS 316 SS 316 SS 316 SS 316 SS 316 SS NBR Urethane NBR NBR Fiber 18-8 SS Steel 18-8 SS 18-8 SS 18-8 SS Fiber 316 SS Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron NBR Urethane NBR NBR Fiber 18-8 SS Steel Steel Steel Steel Steel Fiber 316 SS Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron NBR Urethane NBR NBR Fiber Steel Steel Steel Steel Steel Steel Fiber Steel /XYLAN Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron NBR Urethane NBR NBR Fiber Steel 34 35 36 36a 37 37a 38 38a 39 41 41a 42 43 44 44a Lock washer Bearing - piston Thread seal Cap nut seal Travel stop bolt HP adjustment screw Jam nut Cap nut Socket head cap screw Tie rod Nut - tie rod Seal - output shaft Lock washer Hex head bolt Socket head cap screw 18-8 SS PTFE SS/EPDM NBR 18-8 SS 304 SS 18-8 SS 316 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS PTFE SS/EPDM NBR 18-8 SS 304 SS 18-8 SS 316 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS 18-8 SS PTFE SS/EPDM NBR 18-8 SS Ductile iron 18-8 SS Ductile iron 18-8 SS 18-8 SS 18-8 SS NBR 18-8 SS 18-8 SS Steel PTFE SS/EPDM NBR Steel Ductile iron Steel Ductile iron Steel Steel Steel Steel Steel Steel PTFE SS/EPDM NBR Steel Ductile iron Steel Ductile iron Steel Steel Steel Steel Steel 45 46 47 48 Stato-seal Cylinder gasket or O-ring Label - nameplate Seal - output shaft bushing NBR NBR MYLAR - NBR NBR MYLAR - 18-8 SS NBR NBR MYLAR NBR Steel NBR NBR MYLAR - Steel NBR NBR MYLAR - 5 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Materials of construction (continued) 49 50 51 52 53 54 55 56 57 58 Item Cylinder - spring side Tie rod - spring side Hex head bolt Travel stop bolt Flat washer End cap - spring side Spring - outer Spring - inner Breather Label - spring HP15 316 SS 316 SS 18-8 SS 18-8 SS 18-8 SS 316 SS Steel Steel 18-8 SS LEXAN S material HP25 and HP30 316 SS 316 SS 18-8 SS 18-8 SS 18-8 SS 316 SS Steel Steel 18-8 SS LEXAN HP15 316SS 316 SS 18-8 SS 18-8 SS 18-8 SS Ductile iron Steel Steel Steel LEXAN Materials of Construction (continued next page) 1 2 Item Housing Yoke S material HP60 316 SS 17-4 PH 4 Piston rod 316 SS 5 Bearing - yoke PTFE composite 7 Bushing - piston rod Bronze 9 10 11 12 Thrust pin Slide block Retaining ring - pin Plug - thrust pin access 440C SS Bronze 15-7 MO 18-8 SS 13 14 Pointer adaptor Drive bar Nylon Steel 16 17 18 19 20 21 22 Pointer Round head screw Cover - housing Hex head bolt - cover Lock washer - cover Pointer washer Vent valve Soft PVC 18-8 SS 316 SS 18-8 SS 18-8 SS 18-8 SS Brass 24 25 26 Cylinder Piston Adaptor 316 SS 316 SS 316 SS 26b 27 28 29 29a 30 HP adaptor Endcap Rod cover Seal - piston rod Seal - piston rod Seal - piston bolt 316 SS 316 SS 316 SS NBR Urethane NBR 1 2 3 4 4a 4b 4c 5 6 6a 6b 7 8 9 10 11 12 12a 12b 13 14 15 15a 15b 16 17 18 19 20 21 22 23 24 25 26 26a 26b 27 28 29 29a 30 Item Housing Yoke Guide block Piston rod - left Piston rod - right Jam nut - piston rod Piston rod - extension Bearing - yoke Bearing - thrust pin Bearing - guide bar Thrust bearing - thrust pin Bushing - piston rod Guide bar Thrust pin Seal, bearing Retaining ring - accessory drive Seal - guide bar Seal, cap Seal, accessory drive Accessory drive Drive bar Cap Washer, cap Screw, cap Pointer Round head screw Cover - housing Hex head bolt - cover Lock washer - cover Pointer washer Vent valve Cup, spring Cylinder Piston Adaptor Spacer plate (1485-2385 only) HP adaptor Endcap Rod cover Seal - piston rod Seal - piston rod Seal - piston bolt B material HP25 and HP30 316 SS Steel Steel Steel Steel Ductile iron Steel Steel Steel LEXAN B material HP65 and HP80 Ductile iron Ductile iron Ductile iron CPO CPO Steel CPO PTFE composite Steel Steel Nylon Bronze CPO 440C SS NBR Steel NBR NBR NBR Steel Steel Ductile iron Steel Steel Soft PVC 18-8 SS Ductile iron Steel Steel Steel Brass Ductile iron 316 SS Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron NBR Urethane NBR C material HP25 and HP30 Steel /XYLAN Steel Steel Steel Steel Ductile iron Steel Steel Steel LEXAN C material HP65 and HP80 Ductile iron Ductile iron Ductile iron CPO CPO Steel CPO PTFE composite Steel Steel Nylon Bronze CPO 440C SS NBR Steel NBR NBR NBR Steel Steel Ductile iron Steel Steel Soft PVC Steel Ductile iron Steel Steel Steel Brass Ductile iron Steel / XYLAN Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron Ductile iron NBR Urethane NBR 6 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Materials of Construction (continued) 31 32 33 34 35 36 36a 37a 38 38a 39 41 41a 42 43 44 44a 45 46 Item Seal - piston Gasket - housing Hex head bolt - piston Lock washer - piston Bearing - piston Thread seal Cap nut seal HP adjusment screw Jam nut Cap nut Socket head cap screw Tie rod Nut - tie rod Seal - yoke Lock washer Hex head bolt Socket head cap screw Stato-seal Cylinder O-ring S material HP60 NBR Fiber 18-8 SS 18-8 SS PTFE SS/EPDM NBR 304 SS 18-8 SS 316 SS 18-8 SS 18-8 SS 18-8 SS NBR 18-8 SS 18-8 SS 18-8 SS NBR NBR 47 48 49 50 51 52 53 54 55 56 57 58 Label - nameplate Seal - output shaft bushing Cylinder - spring side Tie rod - spring side Hex head bolt Travel stop bolt Flat washer Endcap - spring side Spring - outer Spring - inner Breather Label - spring MYLAR NBR 316 SS 316 SS 18-8 SS 18-8 SS 18-8 SS 316 SS Steel Steel 18-8 SS LEXAN 31 32 33 34 35 36 36a 37a 38 38a 39 41 41a 42 43 44 44a 45 46 Item Seal - piston Gasket - housing Hex head bolt - piston Lock washer - piston Bearing - piston Thread seal Cap nut seal Seal - piston rod Jam nut Cap nut Socket head cap screw Tie rod Nut - tie rod Seal - yoke Lock washer Hex head bolt Socket head cap screw Stato-seal Cylinder O-ring B material HP65 and HP80 NBR Fiber Steel Steel PTFE Steel/EPDM NBR Ductile iron Steel Ductile iron Steel Steel Steel NBR Steel Steel Steel NBR NBR C material HP65 and HP80 NBR Fiber Steel Steel PTFE Steel/EPDM NBR Ductile iron Steel Ductile iron Steel Steel Steel NBR Steel Steel Steel NBR NBR 47 Label - nameplate MYLAR MYLAR 49 50 51 52 53 54 55 56 57 58 Cylinder - spring side Tie rod - spring side Hex head bolt Travel stop bolt Flat washer Endcap - spring side Spring - outer Spring - inner Breather Label - spring 316 SS Steel Steel Steel Steel Ductile iron Steel Steel Steel LEXAN Steel / XYLAN Steel Steel Steel Steel Ductile iron Steel Steel Steel LEXAN 2. Manual handpump override (see Figure 4) A. ALWAYS VENT THE HYDRAULIC FLUID SUPPLY TO THE ACTUATOR BEFORE USING THE OVERRIDE. Failure to do so may damage the actuator or hydraulic power supply. B. Maintain fluid level to 25.4 mm (1”) high with piston rod extended line using ISO-22 hydraulic fluid. Use Chevron Hydraulic Oil AW or equal. C.Open reservoir air vent when operating pump. D.The selector control valve is set in center position for remote operation. Select left or right positions for manual open or manual close as shown on pump label. E.Store and lock handle to keep pump plunger closed. Do not remotely operate actuator with handle on plunger. Manual hand pump specifications 1.Reservoir fill volume = 0.20 dm3 (12.20 in3) 2. Pump volume/stroke = 0.01 dm3 (0.66 in3) 3. Handle length = 610 mm (24 in) Figure 4 - Hydraulic override Reservoir Handle Remote position Selector valve Manual open position Manual closed position 7 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions 3. Proximity switch mounting Morin actuators are available with drilled and tapped ports to accept any proximity switches with 5/8-18 UNF, 12-1 mm and 18-1 mm threads. Mounting brackets are not required. A.Remove plastic plugs from proximity ports located on the back of the actuator housing. B.Insert switch and turn clockwise until switch touches ferrous activator on yoke, then back off approximately 1.6 mm (1/16”). C.Test switch by stroking actuator and verifying make and break of switch. D.Repeat procedure for second switch if required. 4. Spring conversion Consult factory for spring conversion. Some spring conversions can be done in the field and others will require a new spring cylinder. 5. Failure mode change (Model HP15) Conversion from ‘fail close’ to ‘fail open’ is accomplished by flipping the actuator over. The top and bottom of the center housing have identical mounting flanges and output shaft dimensions. Remove the vinyl pointer and indicator plate and mount them on opposite side of actuator. (Models HP25, HP30, HP65, HP80) Fail open and fail closed must be specified at time of order. 6. Removal of actuator from valve Caution Do not attempt to remove mounting bolts between actuator and valve until supply pressure has been disconnected and vented. If spring return, be sure that valve is completely in failed position. If valve is frozen in a position causing the spring to be compressed, removal of bracket bolts would allow spring to stroke, resulting in the actuator rotating over bracket causing possible injury or damage. A.Loosen bracket to actuator bolts to hand tight position. B. Physically shift actuator back and forth to be sure there is no strain (or shear stress) on the bracket bolts. Once it has been determined that there is no pressure or spring load remaining on the actuator, remove bolts and remove bolts and actuator from valve. C.In the event the valve is frozen or locked in place, resulting in spring energy remaining in the actuator, replace HP adjustment screw (37a) on end of actuator opposite spring end with length of ‘all thread’ rod of sufficient length and turn clockwise until it contacts the piston. This procedure will safely secure the piston and spring assembly and allow actuator removal. Be sure to carefully remove ‘all thread’ rod prior to actuator disassembly. Figure 5 7. Disassembly - Symmetric yoke actuators A.Remove endcap(s) (27 and 54); tie rods (41 and 50) and cylinder (24 and 49). Remove rod cover (28) if applicable. B.Remove piston bolts (33) and pistons (25) and springs if applicable (55 and 56). C. Remove adaptor (26) and piston rod seals (29). D.Remove housing cover (18), pointer (16) and position indicator (13) (where applicable). (Model HP15) E.Disengage yoke (2) from roller bearing assembly by pulling piston rod to extreme right, as in Figure 5, and swing yoke mechanism clear of roller bearing as in Figure 6. F.Rotate piston rod 90° to allow access to retaining ring (11) as shown in Figure 7. G.Remove retaining ring (11) and bearing (10). Then rotate piston rod (4) 180° and remove the bearing (10) and thrust pin (9) assembly. H.Remove piston rod (4) and piston rod bushings (7). I.Remove plug (12a) from back of housing. J.Using a punch or suitable dowel pin, insert through clearance hole and press yoke pin (6a) out. K.Remove retaining ring (8) from output shaft (3). Remove output shaft (3) and yoke (2). L.Remove bushings (5) from housing. (Models HP25 and HP30) E. Disengage yoke (2) from roller bearing assembly by pulling piston rod (4) to extreme right, as in Figure 5, and swing yoke (2) clear of roller bearing (10) assembly. See Figure 6. B.Rotate piston rod (4) 90° to allow access to retaining ring (11) as shown in Figure 7. C.Remove retaining ring (11) and bearing (10). Then rotate piston rod (4) 180° and remove the bearing and thrust pin assembly. D.Remove piston rod (4) and piston rod bushings (7). I.Remove retaining rings (8) and (12b) on both ends of output shaft. J.Remove thrust plate (13b) and thrust washers (22) from the output shaft (3). K. Position the yoke (2) in the fully clockwise position (viewed from the thrust plate (13b) side). L.Using a soft hammer, drive output shaft (3) out through top of housing (1). M.Withdraw yoke (2) from housing (1). N.Remove the output shaft bushings (5) from the housing (1). Figure 6 Figure 7 8 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions (Models HP60) F. Remove all cover bolts (19). Three of these bolts occupy ‘jack bolt’ holes and are threaded into the cover (18). Screw three long cover bolts into these ‘jack bolt’ holes and turn them sequentially ½ turn at a time to pry the cover off. See Figure 6A. G.Remove the thrust pin access plug (12). (Figure 5A) H. Push the yoke (2) using the piston rod (4) until the thrust pin (9) is centered over the thrust pin access hole (See Figure 5A). Remove the upper thrust pin retaining ring (11) from the thrust pin (9) (Figure 7A). I. Push the thrust pin (9) and lower retaining ring (11) out through the thrust pin access hole allowing the slide blocks (10) to fall free. Remove the slide blocks (10). J.Remove the piston rod (4), piston rod bushings (7), yoke (2). Remove yoke bearings (5), and yoke seals (42) from the housing (1) and cover (18). Remove the upper and lower vent valves (22) from the back of the housing. (Models HP65 and HP80) D.Remove adaptor spacer (26a) (installed on models HP65 only, see Figure 7B). E.Remove cap (15) by removing the cap bolts (15a). F.Remove all cover bolts (19) and cover (18). Three of these bolts occupy ‘jack bolt’ holes and are threaded into the cover (18). Screw three long cover bolts into these ‘jack bolt’ holes and turn them sequentially ½ turn at a time to pry the cover off. See Figure 6B. K.Swing the yoke (2) to one side to expose the guide block (3). L.Unscrew the piston rod jam nuts (4b) and remove the piston rods (4 and 4a). M.Remove the guide bar (8), thrust pin (9), guide block (3) and yoke (2). N.Remove the yoke bearings (5). Disassembly - Canted yoke actuators Canted yoke actuators are disassembled the same way as the symmetric yoke actuators except for the following additional instructions for specific models: (Models HP15) These actuators are disassembled using the same procedure as the symmetric actuators. However, the thrust pin (9) is removed from the housing (1) via access plugs on the upper and lower housing mounting flanges. (Models HP25 and HP30) F.Remove the pointer (16), pointer adaptor (13) and pry out the thrust plate seal (12) (if fitted). G.Remove the thrust plate (13b) and thrust washers (22) from the output shaft (3). H. Position the yoke (2) in the fully clockwise position (viewed from the thrust plate (13b) side). I.Using a soft hammer, drive output shaft (3) out through the thrust plate side of the housing (1). This will drive out the upper output shaft bushing (5) and yoke key (6b). J.Remove the piston rod bushings (7) from the housing (1). K.Shift the yoke (2) around in the housing (1) so that the thrust pin (9) and roller bearing (10) assembly can be moved out of the yoke slot. Remove the thrust pin retaining rings (11) and withdraw the roller bearings (10), thrust pin (9), piston rod (4) and yoke (2). L.Remove the lower output shaft bushing retaining ring (12b) and lower output shaft bushing (5). Figure 5A Thrust pin access Figure 6A Jack bolts Figure 7A Slide block and thrust pin Yoke Figure 6B Jack bolt Jack bolt Jack bolt 9 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions 8. Assembly - Symmetric yoke actuators (Model HP15) A.Insert piston rod bushings (7) and output shaft bushings (5) in housing. Lube output shaft bushings O-rings (48) with ‘Dow Corning #55’ lubricant. Push one O-ring halfway on each bushing and install bushings in housing. B. Place yoke (2) in position in housing. Lubricate with ‘WD40’ or similar lubricant and install output shaft (3). Lube output shaft O-rings (42) with ‘Dow Corning #55’ lubricant. Install one O-ring on one end of output shaft and insert through housing and yoke. Install second O-ring on opposite end of output shaft and push output shaft back into housing.) Secure output shaft with retaining rings (8). C. Lubricate and press yoke pin (6) into yoke and output shaft assembly from open side of housing. Be sure pin is pressed flush in yoke to prevent interference with piston rod (4). (Models HP25 and HP30) A.Insert yoke key (6b) into output shaft (3). B.Install yoke (2) in housing (1). Slide output shaft (3) through top of housing (1) into the yoke (2). Install lubricated upper and lower bearings (5a). C.Install lower thrust washer (22), thrust plate (13), upper thrust washer (22), retaining ring (8) and thrust plate seal (12) (if fitted). Install lower bearing retaining ring (12b). (Models HP15, HP25, HP30) D.Lubricate with ‘WD40’ and install piston rod (4) being careful not to scratch sealing surfaces when sliding through yoke assembly. E.Swing yoke clear toward left side of housing as shown in Figure 7. F.Sub-assemble thrust pin (9) with one roller bearing (10) and one retaining ring (11). Pre-lubricate sub-assembly with high temperature grease such as ‘Whitmore’s Omnitemp II’. G.Install roller bearing sub-assembly per Figure 7. Rotate piston rod 180° and assemble second roller bearing and retaining ring. Place ample amount of high temperature grease on roller bearing and inside wear area of yoke. H.Engage roller bearing in yoke assembly as shown in Figure 7, 6, and 5. I.Install plug (12a) in back of housing if applicable. Use ‘Loctite 222 Thread Locker’. (Models HP60) A.Install yoke seals (42) using O-ring lube and yoke bearings (5) using WD-40 into the cover (18) and housing (1). B.Inspect the housing upper and lower vent passages and clear any blockage. Install new vent valves (22). C.Lubricate the bearing surfaces of the yoke (2) with WD-40 and install the yoke (2) in the housing (1). Install the yoke with the marking and the pointer drive bar visible through the cover hole. D.Install the piston rod bushings (7) and the piston rod (4). E.Install the lower retaining ring (11) on the thrust pin (9) and lubricate the pin with Whitmore grease. Lubricate the slide blocks (10) with Whitmore grease inside and out and position them in the yoke (2) slots. Insert the thrust pin (9) through the thrust pin access hole (Figure 6A) and slide it through the lower slide block (10), piston rod (4), and upper slide block (10). Install the upper retaining ring (11) on the thrust pin (9). F. Place joint compound on the sealing surface of the cover (18), install the cover on the housing (1), and torque the cover bolts (19) to 41 Nm (30 ft-lb). Install the short cover bolts (19) into the jack bolt holes of the cover (18). Figure 7B Canted yoke actuator Symmetric yoke actuator Figure 7C The canted yoke piston rod is not symmetrical. It must be positioned as shown. The symmetrical yoke piston rod can be installed either way. Curved arm of yoke Short dimension Short dimension Canted yoke actuator Closed position - top view Equal dimension Equal dimension Symmetric yoke actuator Open position - top view 10 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Figure 8 Install U-cup into adaptor with the O-ring side facing the pressure. (Models HP65 and HP80) A.Install new guide bar bearing (6a) and thrust pin bearings (6b) in the guide block (3). B.Install new yoke bearings (5) and thrust bearings (6) in housing (1) and cover (18). Position the bearing seal (10) in the yoke bearings (5) toward the inside of the housing (1). C.Use Valvoline multi-purpose grease /GM (or equal) to lubricate all bearings including a generous amount on the thrust bearings (6). D.Insert the yoke (2) into the housing (1). E.Insert the guide block (3) into the housing (1) and slide the guide bar (8) through the housing (1) and through the guide block. Install the guide bar seals (12), lubricate the seals with grease, and then finish sliding the guide bar into the housing. F.Install the piston rod bearings (7) in the housing (1). G.Install the jam nuts (4b) on the piston rods (4) and (4a) and install the piston rods. Symmetric yoke piston rods are equal length and can be installed on either side. See Figure 7C. H.Swing the yoke (2) over the guide block (3) and install the thrust pin (9). I.Insert a bead of Dow Corning 732 silicone sealant on the cover (18) sealing surface and install the cover (18) on the housing (1) torquing the bolts to 8 Nm (6 ft-lb). J. Install the cap seal (12a) and cap (15). (Cylinder and rod cover assembly all models) J. Assemble bolt (33) on end of piston rod before installing rod cover when rod cover is required. K.Install rod cover (28) if applicable. Actuators utilizing one piston only require a rod cover. Bolt rod cover and gasket in place with socket head screws (39). Use ‘Locktite 222 Thread Locker’. L.Install piston rod lip seal (29a), by lubricate O-ring with ‘Dow Corning #55’ lubricant, and then inserting cup end into deeper recess of HP adaptor (26b). The open lips of the cup must face the cylinder so that the lip seal expands under operating pressure (shown in Figure 8). If spring return lubricate piston rod O-ring (29) with ‘Dow Corning #55’ lubricant and install on piston rod (4, 4a). M.Lubricate piston bolt O-ring (30) with ‘Dow Corning #55’ lubricate and put on piston rod (4). N. Assemble adaptor (26, 26b) to housing. The seal must slide over the lubricated piston O-ring (30) on the piston rod (4) to avoid damage to the seal lips. A gasket (32) must be used between adaptor and housing. If actuator is spring return model be sure to insert long tie rod bolts (51) with washer into adaptor prior to bolting adaptor to housing. Insert socket head cap screws (44) from housing into HP adaptor (26b) using Loctite. If spring return, insert hex head bolts (44) with stato-seals (45) through spring side adaptor (26) into housing (1). Use ‘Locktite 262 Permanent Thread Locker’. Uniformly tighten bolts. Refer to Assembly torque requirements chart (Table 1) for proper bolt torque. O. Assemble piston (25) to piston rod with bolt (33) and lock washer (34). Use ‘Loctite 262 Permanent Thread Locker’ on bolt threads. Rotate piston before tightening piston bolt to ensure proper seating of O-ring. Refer to Assembly torque requirements chart (Table 1) for proper bolt torque. P.Install lubricated O-ring (46) in HP adaptor (26b) groove. Q.Lubricate piston O-ring (31) with ‘Dow Corning #55’ lubricant and install on piston (25). R.Lubricate piston bearing (35) with ‘Dow Corning #55’ lubricant and install on piston (25). Assemble bottom two tie rods (41) on HP adaptor (26b). Lubricate cylinder (24) with ‘Dow Corning #55’ lubricant and slide cylinder over piston (25) until cylinder is in contact with O-ring (46) in HP adaptor (26b) groove. Assemble top two tie rods (41) on HP adaptor (26b). S.Insert cylinder O-ring (46) in endcap (27) groove and place endcap over tie rods (41) and on cylinder (24). T. Assemble lock washers (43) and nuts (41a) on tie rods (41) and uniformly tighten. Do not exceed torque values shown in Assembly torque requirements chart (Table 1). U.Install position indicator (13) and pointer (16), where applicable. Assemble HP adjusting screws (37a), cap nuts (38), and cap nut seals (36a). For rod cover assemble adjusting screw (37) with jam nut (38) and install on rod cover (28). V.Stroke actuator with rated supply air and check for leaks. 11 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions Table 1 - Assembly torque requirements (Nm) Model no. HP15-2 HP15-3 HP25-3 HP25-4 HP30-4 HP30-6, HP60-6 HP30-8, HP60-8 HP65-6, HP80-6 HP65-8, HP80-8 Figure 9 - Tie rod tightening sequence Adaptor bolt (44) Piston bolt (33) Tie rod (33) Tie rod bolt spring side (51) 40.7 40.7 203.4 203.4 203.4 339.0 339.0 339.0 339.0 54.2 203.4 203.4 203.4 203.4 339.0 339.0 339.0 339.0 40.7 203.4 203.4 339.0 339.0 339.0 339.0 339.0 339.0 33.9 33.9 135.6 339.0 339.0 339.0 339.0 339.0 339.0 Spring return only All models W.Lubricate piston bolt O-ring (30) with ‘Dow Corning #55’ lubricant and put on piston rod. Assemble piston (25) to piston rod with bolt (33) and lock washer (34). Use ‘Loctite 262 Permanent Thread Locker’on bolt threads. Rotate piston before tightening piston bolt to ensure proper seating of O-ring. Refer to Assembly torque requirements chart (Table 1) for proper bolt torque. X.Install lubricated cylinder O-ring (46) in adaptor (26) groove. Y.Lubricate piston seal (31) with ‘Dow Corning #55’ lubricant and install on piston (25). Z.Lubricate piston bearing (35) and cylinder (24) with ‘Dow Corning #55" lubricant. Hold piston bearing (35) in place on piston (25) and slide cylinder (49) over piston and bearing until cylinder is in contact with O-ring (46) in adaptor (26) groove. AA.Place cylinder O-ring (46) in endcap (54). Insert long bolts (51) with flat washer (53) in endcap (54). AB.Place springs against piston, being sure to nest in contours. AC.Mount endcap over extended spring(s) and fasten to hollow tie rods (50) with bolts (51). To prevent galling, lubricate bolts (51) with ‘Whitmore’s Omnitemp II’ grease or equal. Alternately and uniformly tighten bolts (51) in hollow tie rods. Tighten each bolt approximately 6.4 - 12.7 mm (¼” - ½”) following the sequence shown in Tie rod tightening sequence (Figure 9) until spring is completely compressed. Be sure that each hollow tie rod slides into the counterbore in the endcap. Do not over tighten bolts. Refer to Assembly torque requirements chart (Table 1). AD.Install position indicator (13) and pointer (16), where applicable. Assemble adjusting screws (52), thread seals (36) and jam nuts (38). AE.Stoke actuator with rated supply air and check for leaks. Assembly – Canted yoke actuators Canted yoke actuators are assembled the same way as the symmetric yoke actuators except for the following additional instructions for specific models. 1 3 Canted yoke actuators have a non-symmetrical piston rod as well as a non-symmetrical yoke. It is important to orient the piston rod with the longer dimension in relation to the yoke as shown in Figure 7C. Note that the finished housing assembly is used for both fail open and fail closed actuators. 4 2 (Models HP25 and HP30) A.Insert the yoke (2) into the housing (1) and position the yoke in the fully clockwise position (viewed from the thrust plate (13b) side). B.Insert the piston rod (4) correctly oriented with the longer dimension as shown in Figure 7C. C.Install the thrust pin (9) and roller bearings (10) using generous amounts of Whitmore Omnitemp grease and install both pin retaining rings (11). D.Shift the yoke (2) and piston rod (4) so that the thrust pin (11) and roller bearing (10) assembly can be inserted into the yoke slot. The absence of the piston rod bushings (7) and output shaft bushings (5) allows just enough room for this process. E.Insert the lower output shaft bushing (5) and retaining ring (12b). This bushing must have a press fit. The integral seal O-ring must be oriented toward the yoke. F.Insert the yoke key (6b) into the output shaft (3), then insert the output shaft into the housing (1) and yoke (2) and lower output shaft bushing (5). G.Install the upper output shaft bushing (5) over the output shaft and into the housing (5). The bearing must have a press fit. The integral seal O-ring must be oriented toward the yoke. H.Install output shaft thrust washer (22), thrust plate gasket (13b) thrust plate (13b), thrust washer (22) and retaining ring (8). 1 3 4 2 5 3 1 5 4 3 6 2 I.Install Pointer adaptor (13) using two socket head cap screws. J.Install the thrust plate seal (12), pointer (16) and pointer washer (21). (Models HP65 and HP80) Assembly for these canted yoke actuator models is identical to the symmetric yoke models. However, the yoke (2) must be oriented as shown in Figure 7B. The left and right piston rods are different lengths. Refer to Figure 7C to assure the correct orientation. 12 Biffi Morin HP Model High Pressure Actuators Operation and Maintenance Instructions 9. Operating instructions Operate the actuator in accordance with the pressure and temperature limits specified on the nameplate. See the appropriate Morin Catalog for technical information. 10. Important safeguards Caution: To reduce the risk of injury: •Read the entire operation and maintenance instruction manual before installing, operating, or servicing this actuator. •Inspect the actuator regularly for signs of corrosion and repair immediately. •Always remove pressure and disconnect power supply before servicing the actuator. •Keep hands and feet clear of an actuator that is in service. •Do not disassemble the actuator without reviewing the disassembly procedure in this manual first. This is particularly important that the proper procedure be followed to avoid injury from internal spring power. •Before attempting to remove an actuator from the equipment it is assembled to, always be sure that spring is in the ‘failed’ or extended position. Remove any accessory equipment that may cause the spring to be cocked. If there is any doubt that the actuator is in the ‘failed’ position, remove the air pressure from the actuator and install a long threaded bolt (a bolt that exceeds the length of the cylinder) in place of both travel stops. Once the actuator has been removed from the equipment the long bolts must be removed first before the actuator can be disassembled. •Repair or replace a damaged actuator immediately. •Inspect the vent valves on models HP60-HP80 during regular maintenance periods. The valves should allow leaking fluids to escape but prevent contaminates from the surrounding atmosphere from entering the actuator. Fluid leaking from the lower valve indicates a valve stem seal leak. Fluid leaking from the upper valve indicates a leaking cylinder seal. If leakage is observed from either valve disassemble and repair the source immediately. Never replace the vent valves with plugs. •Operate the actuators within the pressure and temperature ranges specified on the nameplate. Otherwise the actuator life may be reduced or serious safety hazards may develop. 11. Additional safety instructions for actuators used in emergency shut-down service or IEC 61508 safety integrity level (SIL) compliant installations 13. The technician performing a proof test should be trained in Safety Integrated Systems (SIS) operations including bypass procedures and actuator maintenance. No special tools are required. 1.The actuator will move a valve to the designated safe position per the actuator design within the specified safety time. 2.The actuator has met the systematic requirements for SIL-3. 3.The actuator is a Type A device with a hardware fault tolerance (HFT) = 0. 4.If the automated partial valve stroke test (PVST) diagnostics is used, the diagnostics time is the PVST test interval. 5.Customer is required to confirm the actuator is operated within the listed temperature limitations shown on page 1. 6.Customers may voluntarily register their actuator by contacting Morin Actuator sales department. 7. Actuators should be inspected for proper functioning and signs of deterioration every 100,000 cycles or annually (whichever comes first) under normal operating conditions. Inspect more frequently under severe operating conditions. Defects should be repaired promptly. 8.Normal operating conditions are: hydraulic oil compatible with actuator materials of construction and clean to ISO 4406 standards; operating temperature and pressures consistent with the actuator nameplate and catalog limits; environment free from excessive particulates; operating environment consistent with the actuator materials of construction. Under these conditions, actuator life can exceed a million cycles. 9.The recommended minimum operating interval is six months and a partial stroke is acceptable to confirm that the installation is functioning. 10.When an actuator has been repaired or any maintenance is performed, check the actuator for proper function (proof testing). Any failures effecting functional safety should be reported to the Pelham facility. 11.IEC 61508 (SIL) installations should consult the Morin factory to obtain the assessment and FMEDA report, which include failure data, PFDAVG, and other associated statistical data to establish or satisfy SIL level or requirements. This information is available in report MOR 12\04-064 R001 V1 R1 FMEDA. 12.Proof testing of the actuator shall be performed on the interval determined per IEC 61508 / IEC 61511 requirements. A suggested proof test is included in report MOR 12\04-064 R001 V1 R1 FMEDA. No special tools are needed. The report includes the achieved proof test coverage. 13 PENTAIR VALVES & CONTROLS www.pentair.com/valves All Pentair trademarks and logos are owned by Pentair plc. All other brand or product names are trademarks or registered marks of their respective owners. Because we are continuously improving our products and services, Pentair reserves the right to change product designs and specifications without notice. Pentair is an equal opportunity employer. © 2015 Pentair plc. All rights reserved. 14 ">
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