Air Torque AT045U Manuale di servizio
Original instructions
EB AT-RP-4GU EN
4th Generation Upgrade Series
Rack&Pinion actuators
AT045U → AT801U models
Edition November 2020
Note on these mounting and operating instructions
These mounting and operating instructions assist you in
mounting and operating the device safely. The instructions
are binding for handling AIR TORQUE devices. The images
shown in these instructions are for illustration purposes only.
The actual product may vary.
ÎFor the safe and proper use of these instructions, read
them carefully and keep them for later reference.
ÎIf you have any questions about these instructions, con-
tact AIR TORQUE‘s After-sales Service Department
The mounting and operating instructions for
the devices are included in the scope of
delivery. The latest documentation is avail-
able on our website at .airtorque.
Definition of signal words
Hazardous situations which, if not avoided, will result in death
or serious injury
Hazardous situations which, if not avoided, could result in
death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB AT-RP-4GU EN
EB AT-RP-4GU EN
Contents
1 Safety instructions and measures ................................................................................................................. 1-1
1.1 Notes on possible severe personal injury ....................................................................................................... 1-2
1.2 Notes on possible personal injury ................................................................................................................. 1-2
1.3 Notes on possible property damage ............................................................................................................. 1-2
2 Markings on the device ............................................................................................................................... 2-1
2.1 Actuator nameplate sample .......................................................................................................................... 2-1
3 Design and principle of operation ................................................................................................................ 3-1
3.1 Direction of action and fail position .............................................................................................................. 3-1
3.2 Complementary/accessory parts .................................................................................................................. 3-2
3.3 Technical data ............................................................................................................................................. 3-2
4 Shipment and on-site tranport ..................................................................................................................... 4-1
4.1 Accepting the delivered goods ...................................................................................................................... 4-1
4.2 Removing the packaging from the actuator .................................................................................................... 4-1
4.3 Transporting and lifting the actuator .............................................................................................................. 4-1
4.3.1 Transporting the actuator .............................................................................................................................. 4-1
4.3.2 Lifting the actuator ....................................................................................................................................... 4-1
4.4 Storing the actuator ..................................................................................................................................... 4-2
5 Mounting and assembly .............................................................................................................................. 5-1
5.1 Preparation for installation ........................................................................................................................... 5-1
5.2 Control and signal devices assembly ............................................................................................................. 5-1
5.3 Mounting the actuator over the valve ............................................................................................................. 5-1
6 Start-up ...................................................................................................................................................... 6-1
7 Operation ................................................................................................................................................... 7-1
8 Malfunctions ............................................................................................................................................... 8-1
8.1 Troubleshooting ........................................................................................................................................... 8-1
8.2 Emergency action ........................................................................................................................................ 8-1
9 Service ....................................................................................................................................................... 9-1
9.1 Preparation for servicing .............................................................................................................................. 9-1
9.2 Part list ....................................................................................................................................................... 9-2
9.3 Disassembly ................................................................................................................................................ 9-4
9.4 Service operations ....................................................................................................................................... 9-6
9.5 Reassembly ................................................................................................................................................. 9-6
10 Decommissioning ........................................................................................................................................ 10-1
11 Removal ..................................................................................................................................................... 11-1
12 Repairs ....................................................................................................................................................... 12-1
13 Disposal ..................................................................................................................................................... 13-1
14 Certificates ................................................................................................................................................. 14-1
15 Annex ........................................................................................................................................................ 15-1
15.1 Tools ........................................................................................................................................................... 15-1
15.2 Tightening torque ......................................................................................................................................... 15-3
15.3 Lubricants .................................................................................................................................................... 15-4
4 EB AT-RP-4GU EN
EB AT-RP-4GU EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The AIR TORQUE 4th Generation Upgrade Series actuators
are designed for the automation and operation of quarter-
turn valves such as butterfly valves, ball valves and plug
valves in both indoor and outdoor applications. Depending
on the configuration, the actuator is suitable for on/off or
modulating duties. The actuator can be used in process and
industrial plants.
The actuator is designed to operate under exactly defined
conditions (e.g. temperature, pressure, travel). Therefore,
operators must ensure that the actuator is only used in
operating conditions that meet the specifications used for
sizing the actuator at the ordering stage. In case operators
intend to use the actuator in other applications or conditions
than specified, contact AIR TORQUE.
AIR TORQUE does not assume any liability for damage
resulting from the failure to use the device for its intended
purpose or for damage caused by external forces or any
other external factors.
ÎRefer to the technical data and nameplate for limits and
fields of application as well as possible uses.
Reasonably foreseeable misuse
The actuator is not suitable for the following applications:
−Use outside the limits defined during sizing and by the
technical data.
−Use outside the limits defined by the accessories connected
to the actuator.
Furthermore, the following activities do not comply with the
intended use:
−Use of non-original spare parts.
−Performing service and repair work not described in these
instructions.
Qualifications of operating personnel
The actuator must be mounted, started up, serviced and re-
paired by fully trained and qualified personnel only; the ac-
cepted industry codes and practices are to be observed. Ac-
cording to these mounting and operating instructions, trained
personnel refers to individuals who are able to judge the work
they are assigned to and recognize possible hazards due to
their specialized training, their knowledge and experience as
well as their knowledge of the applicable standards.
Personal protective equipment
We recommend wearing the following personal protective
equipment when handling the AIR TORQUE actuators:
−Protective gloves and safety footwear when mounting or
removing the actuator.
−Eye protection and hearing protection while the actuator is
operating.
ÎCheck with the plant operator for details on further protec-
tive equipment.
Revisions and other modifications
Revisions, conversions or other modifications of the product
are not authorized by AIR TORQUE. They are performed at
the user‘s own risk and may lead to safety hazards, for ex-
ample. Furthermore, the product may no longer meet the re-
quirements for its intended use.
Safety devices
The AIR TORQUE pneumatic actuators alone do not have any
special safety equipment.
Warning against residual hazards
To avoid personal injury or property damage, plant operators
and operating personnel must prevent hazards that could be
caused in the actuator by the signal pressure, stored spring
energy or moving parts by taking appropriate precautions.
They must observe all hazard statements, warning and cauti-
on notes in these mounting and operating instructions.
Responsibilities of the operator
The operator is responsible for proper operation and compli-
ance with the safety regulations. Operators are obliged to
provide these mounting and operating instructions as well as
the referenced documents to the operating personnel and to
instruct them in proper operation.
Furthermore, the operator must ensure that operating person-
nel or third persons are not exposed to any danger.
These instructions should not supersede or replace any custo-
mer’s plant safety or work procedures. If a conflict arises bet-
ween these instructions and the customer’s procedures, the dif-
ferences should be resolved in writing between an authorized
end user‘s representative and an authorized AIR TORQUE re-
presentative.
Responsibilities of operating personnel
Operating personnel must read and understand these moun-
ting and operating instructions as well as the referenced docu-
ments and observe the specified hazard statements, warnings
and caution notes. Furthermore, the operating personnel must
be familiar with the applicable health, safety and accident
prevention regulations and comply with them.
Referenced standards and regulations
−AIR TORQUE actuators are designed, produced and clas-
sified according to the European Atex directive 2014/34/
EU. Before using the actuators in potentially explosive at-
mosphere areas, verify the actuator compliance with the
required ATEX classification.
ÎRefer to the nameplate and the ATEX safety instructions.
−4th Generation Upgrade Series actuators are SIL certifica-
ted.
ÎRefer to the SIL Certificate available from AIR TORQUE for
the 4th Generation Upgrade Series actuators SIL capabili-
ty.
−Referring to Machine Directive 2006/42/EC, actuators
are classified as “partly machinery” (see Declaration of
incorporation).
Therefore, the actuator cannot to be put into service until
1-2 EB AT-RP-4GU EN
Safety instructions and measures
the machinery and/or the final system, where the actuator
is incorporated, will be declared in compliance with the
requirements of the Directive.
−The AIR TORQUE pneumatic actuators are designed ac-
cording to the criteria of Article 1, paragraph 2. j) ii) of
the Pressure equipment directive (PED) 2014/68/EU.
Therefore, according to the directive 2014/68/EU they
are not to be considered pressure equipments.
ÎRefer to the EU Declaration of Conformity available from
AIR TORQUE.
−The AIR TORQUE actuators are in compliance with the TR
CU 10/2011 and TR CU 12/2011.
Referenced documentation
The further documents apply in addition to these mounting
and operating instructions:
−Mounting and operating instructions for the valve, availa-
ble from the valve manufacturer,
−Mounting and operating instructions for control and signal
devices (positioner, solenoid valve, etc.) available from de-
vices manufacturer,
−ATEX safety manual,
−SIL safety manual for use in safety-instrumented systems.
1.1 Notes on possible severe personal in-
jury
DANGER
!
Risk of bursting due to incorrect opening of pressurized
equipment or components.
Pneumatic actuators are pressure equipment that may burst
when handled incorrectly. Flying projectile fragments or com-
ponents can cause serious injury or even death.
ÎBefore starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
Risk of severe personal injury due to suspended loads fal-
ling.
ÎStay far from suspended or moving loads.
ÎClose off and secure the transport paths.
1.2 Notes on possible personal injury
WARNING
!
Risk of lifting equipment tipping over and risk of damage to
lifting accessories due to exceeding the rated lifting capa-
city.
ÎUse only approved lifting equipment and accessories who-
se maximum lifting capacity is higher than the actuator
weight (including the packaging, if applicable).
Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or ngers.
ÎDo not touch or insert hands or nger into moving parts.
ÎBefore starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
ÎDo not block the movement of the pinion and the pistons
by inserting objects into the actuator.
Risk of personal injury during actuator air exhaust.
In case of pneumatic version the actuator is operated with air.
As a result, air is exhausted during operation.
ÎInstall the air exhaust components in such a way that
exhaust ports are not located at eye level and the actuator
does not discharge at eye level in the working position.
ÎUse suitable silencers and vent plugs.
ÎWear eye and hearing protection when working near the
actuator.
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could re-
sult in serious injury.
ÎBefore starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
ÎMake sure that the actuator is in the closed position (0°)
while disassembling the end caps and the stop screws ha-
ve been correctly removed.
ÎDo not disassemble individual spring cartridges.
ÎFor spring cartidges service contact AIR TORQUE.
Risk of personal injury through incorrect operation, use or
installation as a result of information on the actuator being
illegible.
Over time, markings, labels and nameplates on the actuator
may become covered with dirt or become illegible in some
other way. As a result, hazards may go unnoticed and the
necessary instructions not followed. There is a risk of personal
injury.
ÎKeep all relevant markings and inscriptions on the device
in a constantly legible status.
ÎImmediately renew damaged, missing or incorrect name-
plates or labels.
1.3 Notes on possible property damage
NOTICE
!
Risk of actuator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the travel stop.
Risk of actuator damage due to the use of inappropriate
tools.
Certain tools are required to work on the actuator.
ÎDo not use damaged tools. Refer to section 15.1 ‘Tools‘.
EB AT-RP-4GU EN 1-3
Safety instructions and measures
Risk of actuator damage due to excessively high or low tigh-
tening torques.
Observe the specied torques on tightening actuator compo-
nents (bolts and nuts). Excessive tightening torques lead to
parts wearing out quicker. Parts that are not tightened enough
may loosen.
ÎRefer to section 15.2 ‘Tightening torques‘.
Risk of actuator damage due to the use of unsuitable lubri-
cants.
The lubricants to be used depend on the actuator material and
operating temperatures. Unsuitable lubricants may corrode
and damage the components.
ÎUse only lubricants approved by AIR TORQUE . Refer to
section 15.3 ‘Lubricants‘.
1-4 EB AT-RP-4GU EN
Safety instructions and measures
EB AT-RP-4GU EN 2-1
Markings on the device
2 Markings on the device
2.1 Actuator nameplate sample
Fig. 2-1
15
14
13
16
11
10
03
04
05
06
07
08
09
02
12
Maximum 8 bar
AA2
Torque at 5,5 bar
Model / Type:
EN ISO 5211:
Operating Press.:
Max. Nm Min. Nm
Operating Temp.:
Ancillary Attach.:
Pressure Conn.:
Serial Number:
IEC 61508:
AT451U D A
F10+F12-N-27DS
478
-40°C to +80°C
G 1/4"
90° Rotation - ASST
SIL 3 - Capable
Made in Italy
www.airtorque.de
19303249
ATEX 2014/34/EU:
n° INERIS-EQEN 034870/19
II 2 G Ex h IIC T6...T5 Gb X
II 2 D Ex h IIIC T85°C...T95°C Db X
17
01
Table 2-1
Position Description
01 Manufacturer name and trade mark
02 Country of origin
03 Actuator model
04 Standard reference and actuator attachment designation
05 Maximum operating pressure
06 Output torque at specified supply pressure
−for Double acting: Max. output torque = Nominal torque at 5,5 bar (Nominal pressure)
−for Single acting: Max. output torque = Air Start output torque at specified supply pressure
Min. output torque = Spring End output torque
07 Operating temperature range
08 Ancillary attachment, interface according to actuator size
09 Pressure connections and interface
10 Air connections (Port 2 and Port 4 identification)
11 Action and Rotation
−for Double acting: direction of rotation while the actuator is pressurized through Port 2 or Port 4
−for Single acting: direction of rotation while the actuator is pressurized through Port 2 and indication of fail safe direction
for spring action
12 QR code
13 Angle of rotation and assembly type
14 Actuator serial number
15 SIL marking - IEC 61508
16 ATEX marking - 2014/34/EU Directive
17 CE marking
Refer to the Catalogue 4THGU-E for actuators available options and ordering codes.
Note
2-2 EB AT-RP-4GU EN
Markings on the device
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