acto 400 to 1600 -- maintenance › ims_docs › b9 › b9c8314e44335425e... · acto 400 to 1600 --...

Maintenance8506.84--10 ACTO 400 to 1600 -- MAINTENANCE

INSTALLATION

MAINTENANCE

-- General overview

-- Tooling

-- Installation

-- Hydraulic remote control

-- Adjustment of end stops

-- Actuator disassembly

-- Actuator re--assembly

-- Trouble--shooting

KSB is approved by ISO 9001

ACTO 400 to 1600 -- MAINTENANCE

2

The purpose of this manual is to describe the installation/maintenance procedures and actions to be carried out incase of breakdowns or faulty operation of the ACTO 400 to 1600 hydraulic actuators.

Draining and connection of hand pump

Constitutive parts of the spare kits

Section A--A

412.8

412.8

Item Designation Item Designation

59--40 Chuck + pointer shaft 553 Adjustable end stop

81.68 Pressure pad 554.1 Washer

103 Housing 595 Piston

141 Cylinder 629 Pointer

142 Cover 813 Supporting plate

310.1 Self--lubricating strip 900 Cheese head screw

310.2 Bearing 901.1 Hexagon head screw

310.3 Self--lubricating strip 901.2 Hexagon head screw

310.4 Self--lubricating strip 903 Threaded plug

412.1 O--ring 916.1 Check valve plug

412.2 O--ring 916.2 Protection plug

412.4 O--ring 920.1 Operating nut

412.5 O--ring 920.2 Hexagon nut

412.6 O--ring 932 Ring

412.8 O--ring 950 Check valve spring

415 Lip seal ring 970 Identity plate

486.2 Ball Grease

486.2 Ball

NOTE : The identity plate 970 shows the reference data of the unit These data are to be specified for eachNOTE : The identity plate 970 shows the reference data of the unit. These data are to be specified for eachinquiryinquiry.


3

RECOMMENDED TOOLING (not supplied)-- Pneumatic screwdriver-- Mallet-- Open--ended spanner-- Allen key-- Mounting spanner for end stops (see definition on page 7)

TEST EQUIPMENT (not supplied)-- Hydraulic power pack 0--350 bar

CONSUMABLES

-- Oil: Superflux HV46-- Grease EPEXELF MO2 (Elf) or RETINAX HDM (Shell) or RENOLIT MO2 (Fuchs)

INSTALLATION

BEFORE ANY ACTION-- Index the mounting position of the actuator onto the valve before dismantling-- Index the pointer position 629

ADAPTATIONThe adaptation onto the valves is achieved either directly or through adaptor parts :-- interchangeable inserts manufactured to the size and the shape of the different valve shafts-- adaptor flanges for coupling.

ACTUATOR POSITION ONTO THE VALVEThe actuator can be positioned in 4 positions, at 90° intervals.Standard arrangement is N position 1When a manual override is fitted on the actuator, the actuator should be mounted in accordance with M position 2.If the actuator is disconnected, fit it onto the valve following the steps as defined before the uncoupling, then drainthe actuator.

Arrangement N Arrangement MPosition 1 Position 1 Position 2Position 2

Flow direction

The arrangement position can be modified at site. The procedure below should be followed as well as the specificassembly operations as described in the maintenance procedure.

TRANSFORMATION Arrangement N Arrangement M

-- Uncouple the actuator from the valve,-- Remove the screw 900 and pointer 629,-- Remove the ball 486 from its groove using a screwdriver, pin punch, ....-- Insert the ball 486 into the perpendicular groove,-- Refit the pointer at 90° from its original position and retighten the screw 900,-- Refit the actuator onto the valve at 90° from its initial position.


4

DRAINING PROCEDURE

PIPING CONNECTIONAll components and pipework must remain sealed until connected.All openings must be fitted with recommended plugs.Pickling of internal surfaces of pipework is always necessary when pipes and fittings contain scale, corrosiveproducts, magnetic particles or when pipeworks have to be welded or heated.Pickling must be confined only to the pipework. All sensitive components (actuators, solenoïd valves, deck boxes,...) are to be isolated and bypassed.All traces of pickling, neutralising and cleansing solutions must be removed from the system before connection andoil filling.

CLEANING -- FLUSHING

All newly installed hydraulic systems require cleaning to remove foreign matters and any contamination.In order to reduce the circulation time; it is advised to perform a first injectionwith nitrogen under a 30--40 bar pressurefor a 30 second to 1 minute period .All elements, part of the system (hydraulic power pack, distribution panel or stand, actuators) are delivered perfectlyclean, with obturated ends.Therefore, it is most important to flush all the pipe connections to the various equipment :-- hydraulic power pack towards solenoïd valves rack or deck boxes-- solenoïd valves rack or deck boxes towards the actuators.Flushing through KSB AMRI components is not allowed.All components must be disconnected or by--passed.

Flushingunit

P

T

R471--10200

N° 42074021It is recommended to use the KSB--AMRI flexibleconnector R471--10200.This equipment can be connected to the hydraulicblock fitted on the actuator.

All opened lines and parts must be efficiently sealed.

Under no circumstances, process pumps should be used for flushing.The pump used for flushing must be a dedicated unit and be external to the system. The pump capacity should besuch that the flow speed be maintained at a minimum of 5m/s to 8m/s (turbulent flow) throughout the system.Oilmust be introduced through the filling orifice ; it should be properly filtered in accordancewith cleanliness standardsin force.The filter must have the ability to accomodate the high flow rates required for turbulent flow flushing.The required cleanliness class must be minimum ISO 18/15 according to ISO 4406 standards (equivalent to NAS1638 class 9).

SYSTEM FILLINGDuring the filling operations, the flowmeter must be protected, therefore :

V

O C

O

C

F

-- after flushing connect the hydraulic pipes to thecomponents

-- open the flow restrictors F,

-- connect the flexible connector R471--10200 to the hydraulic block fittedon the actuator, valve V closed.


5

-- disconnect flexible connector from the closed connection,-- open the valve V,-- operate the solenoïd valve (4 way 3 position see note) to open direction,

VCO

O

C

F

-- when the oil flows out of the flexible connectorClose the valve V,

-- connect the flexible connector to the open connection and disconnectit from closed connection,

-- Open the valve V,

-- operate the solenoïd valve (4way 3 position see note) to closing direction,-- when the oil flows out of flexible connector close the valve V,-- disconnect the flexible connector from the hydraulic block.

NOTE:-- Before operating the 4 way 2 position solenoïd valve before operating in the required position, closethe valve rack pressure isolating valve

-- To supply oil to the hydraulic pipe open the pressure isolating valve.

DRAINING-- connect the flexible R471--10200 to the actuator, valve V closed,-- open the valve V,-- open the flow restrictors F,-- operate the solenoïd valve to opening direction,-- let the oil circulate for a 15 minute minimum period,-- operate the solenoïd valve to closing direction,-- let the oil circulate for a 15 minute minimum period,-- close the valve V,-- disconnect the flexible from the actuator.

V

OC

O

C

F


6

ADJUSTMENT OF STANDARD CLOSING END STOPS (±2° )

Adjustable end stops are adjusted in the factory and do not need further adjustment at site.This is of utmost importance for the perfect tightness of the valve.

After any intervention on the actuator, the correct adjustment of the adjustable end stops must be verified.

If need be, this adjustment will be modified as per the following procedure:Adjustment procedure for the unit valve + actuator-- Operate the actuator to the closing position and disconnect the oil supply,-- Loosed the nut 920.2 on the closing end stop,-- Adjust the closing end stop 553 andensure that the desired position is obtained by pressurizing the closing chamber,then lock the nut 920.2,

Closing end stop

Opening end stop

Closing chamber Opening chamber

-- Operate the actuator to the opening position and disconnect the oil supply,-- Loosed the nut 920.2 on the opening end stop,-- Adjust the opening end stop 553 and ensure that the desired position is obtained by pressurizing the openingchamber, then lock the nut 920.2,

SPECIAL CASE: ACTUATOR FITTED WITH AN OVERRIDE CONTROL

Adjustment to be performed on the unit valve + hydraulical actuator + manual overrideIn automatic operation under oil pressure, the assembly must be stopped in position against the hydraulic actuatorend stops.

The following adjustment sequence must be strictly followed:-- Operate the actuator to the closing position and disconnect the oil supply,-- Unscrew the 2 adjustable end stops of the override reducer (at least 4 -- 5 ),-- Loosed the nut 920.2 on the closing end stop,-- Adjust the closing end stop 553 andensure that the desired position is obtained by pressurizing the closing chamber,then lock the nut 920.2,

-- Maintain the hydraulic pressure inside the actuator,-- Screw the closing stop of the override control until it contacts the wheel then unscrew it by one quarter (1/4) turnand tighten the corresponding lock nut,

-- Operate the actuator to the opening position and disconnect the oil supply,-- Loosed the nut 920.2 on the opening end stop,-- Adjust the opening end stop 553 and ensure that the desired position is obtained by pressurizing the openingchamber, then lock the nut 920.2,

-- Screw the opening stop of the override control until it contacts the wheel then unscrew it by one quarter (1/4) turnand tighten the corresponding lock nut,

-- Check the good operation of the unit.


7

-- First record the pointer position and the actuator mounting position on the valve.-- Disconnect the oil supply-- Uncouple the actuator with its accessories from the valve and lay it on the workbench-- Remove all accessories from the actuator-- If the actuator is fitted with a pointer 629, remove the sub--unit plug 916, screw 900 and pointer 629

ACTUATOR DISASSEMBLY

Unscrew the 4 screws 901.1

Remove the cover 142, the O--ring412.5, the self--lubricating ring 310.2and the O--ring 412.7

Removal of one cylinder:-- Unscrew the screws 901.2 and remove the supporting plates 813-- Cautiously remove the cylinder 141 taking care not to damagethe piston 595.

-- Cover the piston with a film or a plastic tube plastique in order to protect itagainst impacts

-- Remove the lip seal 412 and the O--ring 412.1

Removal of the other cylinder:-- Follow the same procedure as above

Removal of adjustable end stopsProcedure to be followed for each cylinder:-- Measure and notify the overlength of the adjustable end stops with respectto the cylinder bottom,

-- Remove the adjustable end stops through the inside of the cylinder usingthe mounting key of the adjustable end stop (see definition drawing below)

-- Remove the O--ring 412.2

DISASSEMBLY COVER 142 SIDE

CYLINDERS DISASSEMBLY

520 20

75

dia. 20

6

dia. 18

2

2

dia. 8


8

PREPARATION OF PARTS

All the constitutive parts of the kit must be used.

The O--rings and their respective housings must be lubricated or oiled prior to insertion.

ACTUATOR RE--ASSEMBLY

Ensure that the cylinders 141 are internally clean and remove any impurity.

REFITTING OF CYLINDERS

-- Position the adjustable end stop on themounting key and insert it though the inside ofthe cylinder in its initial position as notifiedprior to removal.

Preparation of each cylinder

-- Place the O--ring 412.2 on the adjustable endstop 553 and lubricate it.

-- Insert the lip seal 415 into its groove by warping it for easierinsertion.Special precaution:The sealing lips must be oriented towards the cylinderbottom

-- Insert the O--ring 412.1 and lubricate it


9

TIGHTNESS TEST FOR THE CYLINDERS

The functional tightness test is to be performed on the actuator without its cover in order to allow the detectionof possible leaks.This operation involves no risk in so far as the actuator is not subjected to any load (resistant torque).This kind of operation must never be done when the actuator is coupled to the valve.

Test to be perfomed on each cylinder:1st cylinder:-- Connect the cylinder to the hydraulic power pack and pressurize:

-- at 40 bar during one minute-- then, at 180 bar during three minutes.

Check the tightnesses at:-- lip seal 415: if leak: visible inside the housing-- O--ring 412.2: if leak: visible at the end adjustable stop 553

If a leak is detected, remove the cylinder and check that the O--rings are in good repair.Replace any defective O--rings and repeat the assembly steps until correct tightness is ensured.

2nd cylinder:-- Disconnect the oil supply and disconnect the first cylinder.-- Disconnect the second cylinder, pressurize and operate the actuator

Caution for the draining of the first cylinder-- Realize the tightness test as defined above.

Remove the protection film from the pistons andlubricate them

If the actuator is equipped with a distributor strip,refit it in its initial position.

Put in place the supporting plate 813 and screws901.2 and tighten diagonally

Reinstall the cylinders by sliding themwith care in order not to damagethe O--rings


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-- Ensure that the cover is clean-- Lubricate the housing of the guide strip 310.2 and install the strip.-- Insert the O--ring 412.5 and lubricate it onto the cover142

-- Refit the O--ring 412.7Lubricate the O--ring and the upper part of the yoke.

COVER REASSEMBLY

Cautiously refit the cover.Take care not to damage the O--ringsand guide strip.If necessary, use a mallet to finish theinsertion and refit the 4 screws 901.1


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-- Connect the actuator to the hydraulic power pack and check the actuator for correct operation (stroke,tightness) under motor oil pressure 120 bar.

-- Refit the pointer 629 and/or the accessories onto the actuator in their initial position.-- Couple the actuator to the valve in its original position,-- Check the good operating of the unit valve/actuator/hydraulical actuator/accessories.-- If necessary, adjust the adjustable end stops as defined on chapter: Adjustment of standard closingadjustable end stops.

ACTUATOR/VALVE COUPLING

KSB S.A.S4, allée des Barbanniers 92635 Gennevilliers Cedex (France)Tel. : +33 1 41 47 75 00 Fax : +33 1 41 47 75 10 www.ksb.com

ACTO 400 to 1600

TROUBLE SHOOTINGAt end adjustable stops 553At plugs 916.1In connection or indication zone External leaksAt hydraulical connection interfaceNon--operationIncomplete operation or overstrokeOperating with jerksReversed operationDevice driftIncorrect or inadequate IndicationImpossible or inadequate coupling

O--ring 412.2 damaged Change O--ring 412.2

Check valve 486.2 defective Change sub--unit adjustable end stop 553 +cylinder cover 916.1 +O--ring 412.2

Lip seal 415 damaged Change lip seal 415 + check the cleanliness ofthe oil in the actuator

O--ring damaged at the strip Change the O--rings of the strip

Manual override engaged or bypassopen

Disconnect the hydraulical pressureDisengage the manual override and/or closeby--pass

Missing or insufficient pressure Check hydraulic power pack and its associatedcomponents

Valve blocked Check valve and/or interfacing with piping

Internal leaks Change O--rings 415Check the cleanliness of the oil

Corrosion :chuck 59--40 blockedMechanical components breakage

Change actuator

Safety box check valve blocked ordefective

Check hydraulic power pack

Wrong actuator selection Consult the leaflet 8506Consult the valve leaflet

Wrong interface Check drive and/or adapter flangeConsult the leaflet 8506 or contact themanufacturer

Wrong adjusting of the adjustable endstops

Refer to chapter “Adjusting of adjustable endstops” of the maintenance leaflet

System improperly drained Drain the actuator according to the procedureof the maintenance manual

Actuator closed / valve openedor closed valve / actuator opened

Put valve and actuator in the same position

Inversed hydraulic connections Vérifier le branchement hydraulique

Hydrodynamiqc torque Check the safe box and its components

Loss of air pressure Pressurize the equipment and keep it underpressure

Wrong assembly of the actuator onto thevalve

Refer to § “transformation arrangement N<----> M in manual maintenance

concerned

15.01.03

Thisleafletisnotcontractual

andmay

beam

endedwithoutnotice.

8506.84--10

acto 400 to 1600 -- maintenance › ims_docs › b9 › b9c8314e44335425e... · acto 400 to 1600 --...

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