Installation, Operation & Maintenance Manual

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 Contents

1. INTRODUCTION ....................................................................................................................................... 3

1.1. PURPOSE ............................................................................................................................................ 3

1.2. SAFETY NOTICES ........................................................................................................................ 3/4
1.3. PRODUCT IDENTIFICATION...................................................................................................................... 4
1.4. INITIAL INSPECTION ............................................................................................................................... 4
1.5. STORAGE ............................................................................................................................................ 4
1.6. INSTALLATION .................................................................................................................................. 4/5
1.7. MAINTENANCE ............................................................................................................................................ 5
1.8. LUBRICATION REQUIREMENTS............................................................................................................. 5/6
1.9. TOOL INFORMATION ............................................................................................................................. 6
1.10. CONVEYANCE ...................................................................................................................................... 6
1.11. WEIGHTS and DIMENSIONS .................................................................................................................... 6
2. MATERIALS OF CONSTRUCTION ....................................................................................................... 7

3. MOUNTING AND OPERATING ................................................................................................................. 8

3.1. ACTUATOR MOUNTING ................................................................................................................................ 8

3.2. OPERATING PRESSURE AND METHOD....................................................................................................... 8
3.3. PRINCIPLES OF OPERATION.................................................................................................................. 8/9
4. ASSEMBLY ....................................................................................................................................... 10

4.1. ASSEMBLY OF ACCESSORIES & VALVE.................................................................................... 10/11/12

4.2. OPEN/CLOSE ADJUSTMENT ................................................................................................................. 12
4.3. HP SERIES SPRING SETS ....................................................................................................................... 12
5. DISASSEMBLY .................................................................................................................................. 13

5.1. ACTUATOR TESTING ............................................................................................................................ 13

6. TROUBLE SHOOTING GUIDE .................................................................................................................. 14

7. DIMENSION ................................................................................................................................................... 14

7.1. TOP MOUNTING CONNECTION ............................................................................................................. 14

7.2. BOTTOM MOUNTING CONNECTION ....................................................................................................... 14

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1. Introduction
The manufacturer owns the present publication.
This instruction manual contains important information regarding the installation, operation,
maintenance and storage rack and pinion pneumatic actuators.
Unox Pneumatic actuators are compact, high cycle, high quality pneumatic double rack & pinion
pneumatic actuator specifically designed to meet the demanding needs of the quarter turn valve
automation market.
The actuators provide a wide range of torque outputs to suit quarter turn ball, butterfly, plug and
damper valves, together with a full range of valve position monitors for complete valve automation
solutions.
Quality has been our primary concept in actuator development, the latest manufacturing technologies
have been employed to provide both quality and performance on every actuator produced.

1.1. Purpose
This installation, operation and maintenance manual explains how to install, operate and
maintain the pneumatic actuators.
1.1.1. The normal recommended service interval for the pneumatic actuators is one years.
1.1.2. This procedure is applicable when all electrical power and pneumatic pressure has been
removed from the actuator.
1.1.3. Remove all piping and mounted accessories that may interfere with the module(s) that are
to be worked on.
1.1.4. This procedure should only be implemented by a technically competent technician who
takes care to observe good workmanship practices.
1.1.5. Products supplied by U n o x in t h e i r "as shipped" condition, are safe if the instructions
contained within this Service Instruction are strictly adhered to and executed by well-
trained, equipped, prepared and competent personnel.
1.1.6. When removing seals from seal grooves, use a commercial seal removing tool or a small
screwdriver with sharp corners rounded off.
1.1.7. Use a non-hardening thread sealant on all pipe threads.
1.1.8. WARNING: Apply the thread sealant as per the manufacturer’s instructions.
1.1.9. Unox recommends that actuator disassembly should be performed in a clean area on a
workbench where possible.
1.2. Safety Notices
1.2.1. Safety notices in this manual outline precautions the user must take to reduce the risk of
personal injury and damage to the equipment. The user(s) must read these instructions
before the installation, operation or maintenance of pneumatic actuators.

DANGER: This refers to Personal Safety, and

alerts the user to Personal Danger or Harm.
The Hazard or Unsafe Practice will result in
Severe Injury or Could Cause Death

WARNING: Refers to Personal Safety. Alerts the User to

Personal Danger.
Failure to Follow Warning Notices could result in Personal
Injury or Death.

CAUTION: Directs the User’s attention to the general

precautions that, if not followed, could result in personal
injury and / or equipment damage

Notes: Highlighted information is critical to the user’s

understanding of the actuator’s installation and operation

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 DANGER:

For the protection of personnel working on actuators, this procedure should be reviewed and
implemented for safe disassembly and reassembly. Close attention should be noted to the Warnings,
Cautions and Notes contained within this procedure.
This procedure should not supersede or replace any customer’s plant safety or work procedures. If a
conflict arises between this procedure and the customer’s procedures, then the differences should be
resolved in writing between an authorized customer representative and an authorized seller
representative.
Do not attempt to remove the pistons from the actuator body by using air pressure when the end caps
have been removed.

1.3. Product Identification

The actuator name plate is located on the up side of the body. The name plate contains the
following:
1.3.1. Marking
① General
Logo (trade mark), Model, Type, Fail position, Manufactured year & month, Fluid, Design
pressure & temperature, Operating air pressure, Hydrostatic test pressure, Manufacturer
address & telephone number. If the markings are not applicable on the label, the marking
can be substituted to indicate on the test report.
② CE/PED certified body code
1.3.2. Applied directive and Standard
① 2014/68/EU Annex. III, / 97/23/EC
1.3.3. Certification range
② Applicable ambient t e m p e r a t u r e
③ Design Pressure: Operation pressure: 8 bar max.
1.4. Initial Inspection
Upon receipt of the actuator, the user should inspect the condition of the product and ensure
that product specification stated in the name plate matches with the order sheet.
1.4.1. Remove the packing wrap or wooden box carefully. Inspect the product for any physical
damage that may have occurred during shipment.
1.4.2. Check the product specification with product ordered. If a wrong product has been shipped,
immediately inform us.
1.5. Storage
Actuators must be stored in a clean, cool and dry area. The unit should be stored with the air-
port openings sealed. Storage must be off the floor, covered with a sealed dust protector. When
actuators are to be stored outdoor, they must be stored off the ground, high enough to prevent
from being immersed in water or buried in snow.
1.6. Installation
1.6.1. During the installation, be careful so that dust and metal pieces do not enter the actuator
through Inlet / Outlet port.
1.6.2. When connecting air pipe to NPT tap, be careful so that excessive power cannot be given
to the PF tap in the starting point of the screws because the PF tap can be worn easily.
1.6.3. Speed controllers have to be used only for controlling speed in opening / closing. Regulator
cannot be used for the same purpose.
1.6.4. In case of air supply in the product, it is a general rule to use dry air without any dust.
1.6.5. The temperature around the actuators must be below 80°C. If the temperature is over
80°C, smooth operation cannot be guaranteed. For use in low temperatures, consult the
manufacturer prior to order.
1.6.6. Shock and overpower from external forces should not be applied to the actuators.
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 1.6.7. It is a general rule to use separate lubricate oil in the actuators but not excessively. To
protect the actuators, the ISO VG32 recommended as the lubricant oil.
1.6.8. Check all the bolts and correctly tighten them if necessary.
1.6.9. Close checking and cleaning should be carried out over once a year periodically, not only
during operation but also during shutdown.
1.6.10. If air is let out inside/ outside for a long time, the O-ring sliding parts can be damaged. So,
in case of air leakage, replace or repair immediately on discovery.
1.7. Maintenance
For the maintenance of the actuators, there should not be any air or electrical leaks. Periodical
checking should be carried out regardless of whether joints always seemed fastened. For optimal
working life of the actuators, it is necessary to use enough lubrication oil. The inner seal should
be replaced periodically. When there is a need for repairing tools (including seals), they can be
purchased through agreed representative(s). In the case of spring return actuators, as repeated
condensed power is added on the spring, output torque is reduced due to change of spring
length in long term operation.
The spring set can be purchased at any time via our sales representative or partners.
Table 1-1. Unox Valve Company Ltd. Contact Information
Tel. +90 262 502 1148

Homepage www.unox.com.tr
Email [email protected]
Address Gebze San, Sit. No. 67. Cumhuriyet Cd
Gebze / Kocaeli, Turkey

CAUTION:

Turn off All Power services before Attempting to Perform Any Service on the actuator.
The actuator is a POTENTAI HIGH PRESSURE VESSEL. Before removing or disassembling
your actuator, ensure that the valve or other actuated devices are isolated and not under
pressure.

Perform maintenance procedures, under normal conditions, in six-month intervals. But when
conditions are more severe, more frequent inspections is advised.
1.7.1. Ensure that the actuator is properly aligned with the valve or other actuated device
1.7.2. Ensure that all screws are present and tight
1.7.3. Ensure that air supply connections are installed properly
1.7.4. Check that the supply pressure of the operating media is in the required range
1.7.5. Check the enclosure of O-ring seals and verify that the O-rings are not pinched between
flanges
1.7.6. Visually inspect the open/close cycle
1.7.7. Inspect the identification labels for wear and replace it if necessary
1.8. Lubrication Requirements

CAUTION: For Safety Reasons, alternative lubricants should

not be used without the consent of the manufacturer of the
actuator.
The a ctuators a re a totally enclosed unit with permanent lubrication in the actuator. Once
installed, lubrication should not be required. However, periodic preventative maintenance will
extend the operating life of the actuator.
1.8.1. Lubrication Points
① Cylinder Body
② Piston S e a l s

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③ End Cover Seals

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 Additional grease is required on the following conditions (see Table 1-3).

Table 1-3. Additional Grease

1. Humidity Moisture found inside pipeline (water ingress and/or condensation)
2. Cycle Frequency of operation is
- over 100,000 cycle times per year
- less than 3 cycle times per year
3. High Temp. Over 80℃ ambient temperatures

1.9. Tool Information

1. Allen key set 6. L-screwdrivers
2. Oblate spanner set 7. Adjustable monkey wrench
3. Snap ring clip 8. Impact end wrench set
4. Rubber or leather mallet 9. Impact socket
5. Air impact wrench

Note: Hexagons are Metric Standard Bolts

1.10. Conveyance
1.10.1. Ensure the actuator is fully vented and decontaminated before operation.
1.10.2. Pay attention in shock.
1.10.3. Ensure all power supplies are removed before operation.
1.11. Weights and Dimensions
Technical Dimensions(mm)
Model L D A B c e h g J I M b a Air supply
U 40 121 81 40 36 18 15 80 30 50 36 9 M5x8 M6x10 G 1/4"
U 52 148 92 30 42 18 15 80 30 50 36 9-11 M5x8 M6x10 G 1/4"
U 63 172 106 37 47 18 19 80 30 70 50 9-11-14 M6x10 M8x10 G 1/4"
U 75 185 119 42 53 18 19 80 30 70 50 11-14 M6x10 M8x13 G 1/4"
U 83 204 129 46 57 18 21 80 30 70 50 14-17 M6x10 M8x13 G 1/4"
U 92 262 137 50 59 18 21 80 30 70 50 14-17 M6x10 M8x13 G 1/4"
U 105 268 153 58 64 18 26 80 30 102 70 17-22 M8x13 M10x16 G 1/4"
U 125 296 175 68 75 18 26 80 30 102 70 22 M8x13 M10x16 G 1/4"
U 140 390 191 75 77 18 31 80 30 125 102 27 M10x16 M12x20 G 1/4"
U 160 454 217 87 87 18 31 80 30 125 102 27 M10x16 M12x20 G 1/4"
U 190 525 260 103 103 30 40 130 30 140 36 M16x25 G 1/4"
U 210 532 285 113 113 30 40 130 30 140 36 M16x25 G 1/4"
U 240 610 318 130 130 30 50 130 30 165 46 M20x25 G 1/4"
U 270 722 356 147 147 30 50 130 30 165 46 M20x25 G1/4"-G1/2"

Actuator Weights(kg/pcs)
Model U 40 U 52 U 63 U 75 U 83 U 92 U 105 U 125 U 140 U 160 U 190 U 210 U 240 U 270

Single Acting 1,5 2,180 2,9 3,65 5,6 6,6 10,4 14,5 23,3 46 53,3 73,3 116

Double Acting 0.69 1,35 2,08 2,75 3,35 5,1 5,8 9 12 19 39 44,2 59 93,5

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2. Material of Construction

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3. Mounting and Operating
3.1. Actuator Mounting
CAUTION: Do not attempt to work on your actuator without
first shutting off the incoming power, compressed air and
related internal piping fluid.
Prior to Mounting, the part turn actuator must be checked for
damage and damaged parts must be replaced by original
spare parts only.

3.1.1. Mounting is most easily done with the valve shaft pointing vertically upward. But mounting
is also possible in any other position; the actuator may be mounted in any position.
3.1.2. The pneumatic actuators are supplied with a female drive output. The ISO5211 bolt
patterns are provided for actuator mounting. The actuator drive bush is removable for ease
of machining.
3.1.3. It is mandatory for the actuator to be firmly secured to a sturdy mounting bracket or directly
mounted to the valves’ ISO mounting pad. High tensile bolts or studs with spring locking
washers should be used.
3.1.4. The valve output shaft must be in lined with the actuator output drive to avoid side- loading
the shaft. To avoid any backlash, flexibility in the mounting bracket or mounting should
not be allowed.
3.2. Operating Pressure and Method
3.2.1. The maximum operating Air supply pressure should not exceed 8 bar (115psi). The air
supply should be clean, dry and lubricated.

CAUTION: Before using an alternative air supply, the is not of

instrument quality, please consult with us.

3.3. Principles of Operation

3.3.1. Air connections double acting
OPEN Air to port 2: counter clockwise/open

CLOSE Air to Port 4: clockwise/close

* Pistons must be inverted to reverse actuator rotation

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 3.3.2. Air connections of spring return

Air to port 2: counter clockwise / open

Spring to Close

Spring to Open

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4. Assembly
4.1. Assembly of accessories & valve
4.1.1. Assembly of valve (Direct mounting)

4.1.2. Assembly of accessories

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FIG 3 Connect eventual accessories, making sure of the real position of the valve.
Connect pneumatic/electric feeding and verify correct operation.

Tightening torque table

Metric Tightening torque
Screw table (Nm)
M5 5~6
M6 10~11
M8 23~25
M10 48~52
M12 82~86
M14 132~138
M16 200~210
M20 390~410
M24 675~705
M30 1340~1400

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 4.1.3. Valve mounting

Before proceeding with the assembly of a valve onto an actuator be sure that the actuator
operates in the desired direction of rotation and both actuator/valves are correctly
orientated.
Important: When using a spring return actuator for a fail-safe operation, ensure that when
air or electricity failure occurs the direction of rotation is correct for your application.
There are two types of valve assembly onto the actuator:
① Bracket-mount: Mounting with a bracket and coupling the bracket is bolted to the actuator
/ valve to join them together and the coupling is used to connect the actuator output
drive to the valve stem (max. tightening torque see table).
② Direct-mount: Fit the square of the valve directly into the square of the actuator and bolt
together through the valve ISO pad (max. tightening torque see table above).

4.2. Open/close adjustment

OPEN/CLOSE Adjustment

OPEN/CLOSE Adjustment of END STOPPER TYPE

4.2.1. Adjustment CLOSE

If, After the valve and actuator are assembled, you need additional adjustment for the closed
position, please contact us.

4.2.2. Adjustment for OPEN

If, after the valve and actuator are assembled, you need additional adjustment for the
open position, please contact us.

4.3. Spring Sets

If advice is required on Spring Sets, please contact us for further information.

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 5. Assembly / Disassembly of the Pneumatic Actuator

Assembly and disassembly of the actuator is not recommended a there are no serviceable parts within the actuator. If the
actuator fails, please contact your sales representative who will be please to recommend the best possible course of action
under warranty.

5.1. Actuator Testing

DANGER:

Pressure applied to the actuator is not to exceed the maximum operating pressure rating listed on the

actuator name tag. Test the actuator using a properly adjusted self-relieving regulator with gauge

CAUTION:

If excessive leakage is experienced across the pistons, the actuator must be disassembled and the cause of

the leakage determined. As this procedure is not recommended, please contact your sales representative

to determine the best course of action under warranty.

5.1.1. Leakage Testing: All areas where leakage to the atmosphere may occur are to be checked
using a commercial leak testing solution.
5.1.2. Cycle the actuator 5 times at the nominal operating pressure (NOP) as listed on the actuator
name tag or the user default actuator supply pressure. If excessive leakage across the
pistons is noted, generally a bubble which breaks three seconds or less after starting to
form, cycle the actuator five times as this will allow the seals to seek their proper
service condition.
5.1.3. Check the piston for leaks.
5.1.4. The cover, drive shaft and air ports should be tested by pressurizing each port in turn and
applying the test procedure.
5.1.5. Remove pressure from the pressure inlet port
5.1.6. If an actuator was disassembled and repaired, the above leakage test must be performed
again.

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6. Trouble Shooting Guide

Table 6-1 provides solutions for the most commonly encountered issues during installation and start-up.

Issue Reason Solution

Air pressure is low Raise the air supply

Pipe is obstructed by foreign

Remove the substance in pipe
substance

Valve open/close does

Locked speed controller Open speed controller
not operate smoothly

Air is escaping from cylinder /

Replace piston O-ring
piston

a) Raise the air supply

Working torque of valve is too big
b) Replace valve

Stopper setting is incorrect Perform stopper settings again

Valve does not open or
close correctly
a) Raise the air supply
Working torque of valve is too big
b) Replace valve
The open/close valve
The setting of speed controller is
operates too quickly or Reconfigure the speed controller
not calibrated correctly
slowly
O-ring of piston or cover bushing
Air is escaping Replace O-ring
is worn out

7. Dimension

Please refer to general brochure or request drawings for the actuator that you are ordering or have
received. It may be possible to provide these including all of the accessories required.

7.1. Top Mounting Connection

Please refer to general brochure or request drawings for the actuator that you are ordering or have
received. It may be possible to provide these including all of the accessories required.
7.2. Bottom Mounting Connection
Please refer to general brochure or request drawings for the actuator that you are ordering or have
received. It may be possible to provide these including all of the accessories required.

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