Alphair PNEUMATIC ROTARY ACTUATORS INSTRUCTION MANUAL FOR INSTALLATION, USE AND MAINTENANCE 2001 ALPHA POMPE SPA VIA MOLINO EMILT 16 25030 MACLODIO - BS - ITALYAlphair CONTENTS. Introduction Device identification Identification nameplate Model identification Type of working Dal = SR ‘Working principle of assembly variations = Mechanical assembly Construction parts, materials, assembly scheme Directions for installation, use and maintenance Applications Actuator’s installation — General principles Adjustments ~ Regulation in actuator closing (0°) — ball valves Regulation in actuator closing (0®)~ butterfly valves ~ _ Regulation in actuator opening (90°) ~ butterfly and ball valves Maintenance ~ Substitution of spare-parts aipne pompe moline emil) 16 25030 me (+39) 030 - 978,661/2 rox. 978 odie - BS - 663Alphair ‘The manufacturer of ALPHAIR pneumatic rovary actuators and the drawer of this “INSTRUCTION MANUAL FOR USE AND MAINTENANCE is ALPHA POMPE SPA - Via Molino Emili, 16 — 25030 Maclodio (BS Phone (+39) 030 978661/2 Fax (+39) 030 978663 Italia ‘The present publication “INSTRUCTION MANUAL FOR USE AND MAINTENANCE” is owned by ALPHA POMPE SPA. It is combined only to the supply of “Alphair” products, and represents illustrative literature. It refers only to standard pneumatic actuators by us manufactured. All rigts on the information included in this publication are reserved No part of this publication can be copied. diffused or published without the written permission of ALPHA POMPE SPA. ALPHA POMPE SpA is not responsible for any damage whatsoever arising from the use of its devices, from mistakes or inaccuracies during installation or in using the information here contained ALPHA POMPE SpA reserves itself the right to introduce changes both to its devices and to this publication in any moment, without giving prior notice Siphs pormpe spa Vv. moline emill 16 25030 maciodio - BS — tel. (+39) 030 - 978.66172 fox. S78.663Alphair = DEVICE IDENTIFICATION. [GPRER AUXILIARY CONNECTION INTERFACE FOR SWITCH-BOXES, POSITION INDICATORS, ETC. —- __| peaenegence | St et s vote vO-W0e 3845 awe [note 1s0 sets = on 397 aIphapermpe Spe 7 anne erm 16 25050 mociowio ~ 65 - 5 01 0058) a0" —"Sre. 001% one o78 663Alphair - IDENTIFICATION NAMEPLATE. prone. IDENTIFICATION. ] PISTONS MOVEMENT DEPENDING (ON SUPPLIED FEEDING. ' See eel [so]? EE OS mmr(oe 0729 31) of _js(7)} ARTF Alphair "(Sel Se SERIAL NUMBER, DA = OPENING AND CLOSING eee MOVEMENTS BY AIR. SR ~ OPENING MOVEMENT BY AIR, CLOSING MOVEMENT BY SPRING “OA~ nove. “se novel. C cipha _pempe spe a] ‘malig emit 16 25030 macioaio — 85 — tor "088) 30' —“S70.08 1/2 fox '970.603 C3)Alphair = MODEL IDENTIFICATION. “| °C. MODEL[AP_050 GAS | Port DAL | SRI / q N°OF SPRINGS ONLY ON EACH SIDE 6/6 re | PART OF IDENTIFICATION NAMEPLATE. size ROTATION THREAD OF HOLES TYPE OF INTERNAL ANGLE FOR FEEDING WORKING SPRINGS AP 032 ‘STANDARD = NPT CONICAL, 0A 202 leaner a°-s0" a e ‘AIR OPENS a [AP ose (wor PINCHED! GAS CYLINDRICAL Arr cLoses _| oe AP O63 Y= 0-320" | rages oF SIE AL SR a3 on 180" AIR OPENS [AP @75 X = Q°-180 cwcstcioee 3\4 AP 085 | ceive suart TYPE OF WORKING “Ne AP 100. | ROTATION FIELD AIR/SPRINGS, aS AP 11S 5S AP 125 | S\6 AP 145 6\6 ap 160 | NUMBER OF | SPRINGS FOR AP 180 EACH SIDE. ‘AP 200 AP 270 DEVICE size, CORRESPONDING TO INTERNAL CYLINOER DIAMETER IN MM, cipha pompe spa Moline emili 16 25030 mociodio - 83 - Tel. (+391 030 - 978.6672 fox. 976.663—_— ee 2 ee leeeelraeerllUmrerlUmUrerlUmU rel Umer mUmmelUmCce cece = TYPE OF WORKING Alphair A ~ OPENING AND CLOSING MOVEMENTS BY AIR, EXAMPLE FOR “AT ASSEMBLY VARIATION (STANDARD), FEEDING BY PORT “A™ OPENS PISTONS AND CAUSES SHAFT’S ROTATION. FEEDING BY PORT “B CLOSES PISTONS AND CAUSES SHAFT’S COUNTER-ROTATION. Gipha_ pompe spa vo moline eraui 16 25030 macioaio - BS — jel. (+39) 030 - 978.66172 fox. 978 663Alphair = TYPE OF WORKING SR - OPENING HOVE! @Y AIR, CLOSING MOVEMENT BY SPRINGS. * ASSEMBLY VARIATION (STANDARD). FEEDING BY PORT “A” OPENS PISTONS AND CAUSES SHAFT’S ROTATION. FALL ON FEEDING PRESSURE IN PORT "A" CLOSES PISTONS AND CAUSES SHAFT’S COUNTER-ROTATION. a 1 EXHAUST AIR. ww ‘SPRINGS. ” Ginna pompe spa vo moline emir 16 25030 meciodio ~ BS S tel. (+39) 030 - 978.661/72 fox. 978.663asennad Sole otal rertadlcomnionntl Remmi, Apes peace tye cee ee fe, ae Alphair = WORKING PRINCIPLE OF ASSEMBLY VARIATIONS. THE PRESENCE OF SPRINGS INSIDE THE BODY, THAT CLOSE PISTONS WHEN AIR FEEDING PRESSURE OF THE DEVICE {5 INTERRUPTED; THE POSITION OF THE ACTUATOR AS TO THE AUTOMATED VALVE, REQUIRE FOUR ASSEMBLY VARIATIONS IN ORDER THAT THE FOLLOWING CONDITIONS CAN BE RESPECTED: VALVES ROTATION SENSE IS CLOCKWISE (SO 5211 - DIN 3337) ~ AXIS ON STEN MUS} INDICATE THE POSITION OF VALVE"S DIAPHRAGM (VDI/VOE 3845 WAMUR)) a suet | suart 8 axis Bl as 8 g Q 3 4 89 g s g Ze 6 2 ad e 3 @ 83 & $e £ < N > aa > 2% z rz g a VALVE =] wave G | osapreacw B | ovsprmacw 9 8 2 x Ny 4 =) sae =| suet 2 $ 2 ‘ 2] ans a) xs & & 8 a g g A i 5 % eB : g g a N > > a x 2 2 Bl vauve BY) vauve B | oispeacu B | viapieexcu g & p 2 P cipha _pempe spe v moline emi 16 25030 mociodio - 85 ~ tel. {+381 030 - 976.66172 fox. 978.663Alphair = WORKING PRINCIPLE OF ASSEMBLY VARIATIONS MECHANICAL ASSEMBLY. MECHANICAL ASSEMBLY SCHEMES OBSERVED IN ORDER TO OBTAIN THE FOUR DESCRIBED ASSEMBLY VARIATIONS. "AT ASSEMBLY VAR, (SPRINGS CLOSE) “B" ASSEMBLY VAR, (SPRINGS CLOSE) ALPHAIR STANDARD —— “C” ASSEMBLY VAR. (SPRINGS OPEN) "D" ASSEMBLY VAR, (SPRINGS OPEN) Giphe pomee Spe Tmoline emit 16 25030 maciogio - BS — (+39) 030 - 97866172 fox, 978.663 8or “BABHOS ATENRESY ~ SIWIRBLWH ~ Stava HOTLONGLSNOD aeudiyAlph, = DIRECTIONS FOR INSTALLATION, USE AND MAINTENANCE. ‘This part of our Instruction Manual contains notes for storage, installation and maintenance of the actuator Duration and safety use of actuators and plants, forall operators within their range of action, also depends on the attention paid to the following directions ‘+ Move without crashes + Keep actuators in their original packaging, that contain the relevant contents slips *# Stock in warehouse between 0° C and + 40° C also for long periods of time + Installation of the device is forbidden before the plan i declared in accordance to CE norms oF to eventual technical norms that must regulate the plant's working * Construction materials, surface treatments and paintings are physically steady and chemically inactive only under the conditions whicb ae indicated oa the identification nameplate + Because ofthe possible arising of oily fogs inside the device, you cannot freely discharge exhaust feeding air: trate oF reeycle by means of specifi electro-valves + Device lubrication is made in our plants, its working warrant, this means the numberof movements that can be made without further maintenance, is reported on our ALPHAIR general catalogue and refers to standard models only ‘+ Springs’ working is guaranteed for 100.000 movements (opening and closing movement) before their testing: they have tobe substixuted when they bear marks of corrosion, wear or side yield ‘© For model AP 032 standard, all 120° and 180° actuators, drive shaft ejection ffom the body may occur, in presence of air feeding and without mounted valve, because there is no antiejection key, just a seeger ring '* To move model AP 270, that weights more than 60 kg, please use suitable threaded holes for fastening to male eyebolts, made onthe upper part of device's body. Giphe _pompe spe v. moling emit 16 25030 mociodio - BS - yer. tr38) 030 - 978.661/2 fox. 978.663 iBEE EE Alphair = APPLICATIONS. ACTUATOR. SWITCH-BOX. ELECTRO-VALVE, S t S AOMPrER, le 2 yy VALVE. Slpha___pornpe spa v meline emit 16 25030 maciodio = 85 - TT fei. "(+39) 030 ~"978.661/2 rox. 978,663- ACTUATOR’S INSTALLATION WARNING: ConoITIONS. | acruaror IN ORDER INSTALLATION MENT ANO MAINTENANCE MUST BE E% ‘avOIO ANY FAL T BE PREVIOUSLY OISCONVECTE: iE HOVE, Fro ELECTRICAL 1 = BE sure THAT BOTH VALVE - ASSEMBLY BRACKET AND ADAPTER LOWING THE INDICATED SCHEME BRACKET. CLOSED VALVE. ADAPTER, CLOSED ACTUATOR. = "SR" MODELS NORMALLY CLOSED. = "DAT MODELS, FEED BY PORT "8° TO REACH THE CORRECT POSITIONING (GEE IDENTIFICATION NAMEPLATE). Siphe Pompe vo marine emit: 16 25030 mociodio - BS — tel. (+39) 030 - 978.66 172 fox. 978.663Alphair = ACTUATOR’S INSTALLATION 3 = ASSEMBLY ACTUATOR OW 4. = COMECT EVENTUAL ACCESSORIES AND Top OF BRACKET ano | ane SURE OF TH CORRESPONOENCE ADAPTER FOLLOWING THE | BETMCEN THE REAL AND THE INDICATED INDICATED SCHEME. POSITION OF THE VALVE. ACTUATOR. 5 = NOW THE COMPLETE SET 15 READY TD BE CONNECTED PNEUMATICALLY AND ELECTRICALLY FOR WORKING TEST. THE SAME SAFETY RULES AS FOR THE INSTALLATION ARE VALIO, IN CASE OF DIFFICULTY, D0 NOT MECHANICALLY FORCE THE ELEMENTS, BECAUSE THEY HAVE TO COUPLE WITHOUT STRESS, BUT GET SURE THAT THE COUPLING FOLLOWS A PRECISE AXIS, THAT THE SUPPLIED AIR FEEDING 1S CORRECT, AND THAT THE DIMENSIONING OF VALVE AND ACTUATOR IS RIGHTLY MADE. (POSSIBLY GET IN TOUCH WITH YOUR SUPPLIER.) DISASSEMBLY IS MADE FOLLOWING ALL DESCRIBED OPERATIONS IN OPPOSITE DIRECTION 4, 3,2, — Gipho pompe Sma ] v. meting emmii 16 25030 meciodio - 85 - ter. (+39) 030 - 978.66172 fox. 978.663 13 —S a ee ee ee Se SS SS SS Se eS a 2s SUD= ADJUSTMENTS. REGULATION IN ACTUATOR CLOSI { Giphe pombe spe vo meline eri) 16 25030 maciodio - BS — tel. (#39) 030 - 978 66172 fox. 978.663a Se lULeSellUlULreerlUCUCrcreLhlUUC reer Umer hl Urea cree ee ee Alphair ~ ADJUSTMENTS, REGULATION IN ACTUATOR CLOSING (@" - BALL VALVES, | 3 =necema me sre suioknLy iv TENSION, REGULATE THE ROTATION | oF THE ACTUATOR IN CLOSING @°) OW ONE SIDE, ADJUSTING PISTONS - TRAVEL THROUGH THE REGULATION c ower. — 4+ WHEN REACHING THE WANTED POINT OF CLOSURE, KEEP THE REGULATION DOWEL. IN POSITION AND TIGHTEN THE COUNTER-B9L T. REPEAT THIS OPERATION ALSO ON THE OTHER SIDE OF THE ACTUATOR a a ees RE-ASSEMBLY SPRINGS, IF THERE IS ANY, AND COVERS FOLLOWING IN OPPOSITE DIRECTION OPERATIONS IN POINT 1. SCREWS ON COVERS HAVE TO BE TIGHTENED FOLLOWING THE MUMERATION, A LITTLE AT A TIME. NOW THE COMPLETE SET 15 READY TO BE CONNECTED PNEUMATICALLY AND ELECTRICALLY FOR WORKING TEST. aipha_ pompe spa v. meting emili 16 25030 mecioaio - BS — TS tel. (+39) 030 - 978,.661/2 fox. 978.663Alphair ~ ADJUSTMENTS REGULATION IN ACTUATOR CLOSING (@) - BUTTERFLY VALVES [ vam: INSTALLATION, ADJUSTHENT AND WAINTENANCE MUST BE EFFECTED UNDER SAFETY Conbrnfons, ACTUATOR bust BE PREVIOUSLY DISCENNECTED PRON PAEUMATIC AND ELECTRICAL FEEDING, IN ORDER TO AVOID ANY FALSE Bove | THE FIRST REGULATION IN ACTUATOR CLOSING (@*) 15 MADE BY ALPHA POMPE Spa, | aur For purrewet valves auTonaricn «new REGU ATION THROUGH SPECIA.GYNAMOMETRICAL EY 18 NECESSARY, FOLLOWNG THE OIECTION OF THE VALIE"S MAMUACTURER 1 ~ TAKE OFF COVERS LOOSENING SCREWS AS PER INDICATED NUMERATION; PULL OUT SPRINGS, IF 15 ANY, FROM 15 SEATS. 2 = UNSCREW THE COUNTER-BOLT ‘ANDTHE DOWEL FOR REGULATION OF THE PISTON'S TRAVEL FROM BOTH SIDES OF THE ACTUATOR. Gipha pompe spe Vv. moline emi) 16 25030 maciodio ~ 85 — tei "fn39) 030 - 978.6612 fox 978.663 16mE Em ESE EE Ee eS SS SS eS ee Se eS Alphair ~ ADJUSTMENTS. REGULATION IN ACTUATOR CLOSING (@") - BUTTERFLY VALVES. 3 ~ KEEP THE STEM IN TENSION, THROUGH THE SPECIAL DYNAMOMETRICAL KEY, Ti OBTAIN THE PERFECT VALVE CLOSURE, ACCORDING TO VALVE"S MANUFACTURER'S DIRECTIONS. 4 = SOFTLY SCREW REGULATION DOWEL FOR PISTON'S TRAVEL UNTIL IT BEATS, RE-ASSEMBLY SPRINGS, IF THERE 15 ANY, AND COVERS FOLLOWING IN OPPOSITE DIRECTION | OPERATIONS IN POINT 3. SCREWS ON COVERS HAVE TO BE TIGHTENED FOLLOWING THE NUMERATION, A LITILE AT A TIME, NOW THE COMPLETE SET 15 READY TO BE CONNECTED PNEUMATICALLY AND ELECTRICALLY FOR WORKING TEST. alpha _pompe spe Y. moline eran 16 25030 mociodio — 55 - fer P30) 030 ~"S78.60 142 fon ore. 603 teal= ADJUSTMENTS. TUATOR OPENING (90°) - SUTTERELY AND BALL VALVES, Gipha Bomps spe vo meline emili 16 25030 maciodio - BS - tel. (#39) 030 - 978.661/2 fox. 978.663ee ee ee i ee i - ADJUSTMENTS. Alphair REGULATION IN ACTUATOR OPENING (907) - BUTTERFLY AND BALL VALVES. REGULATION NO TIGHTEN THE NOW THE COMPLETE FOR WORKING TEST, GIpRa pombe sBe w meling ernit 18 25030 maciodio = BS - 11. R36) O30. - 978.66 142 ton. "978 863 3)Alphair - MAINTENANCE. SUBSTITUTION OF SPARE-PARTS, Giphapompe spa vo motine emill 16 25030 mociodio - 8S — 0 fel. (+39) 030 - 978.651/2 fox. 978 663Alphair = MAINTENANCE, SUBSTITUTION OF SPARE-PARTS. 2 = TAKE OFF COVERS LOOSENING SCREWS AS PER INDICATED NUMERATION; PULL OUT SPRINGS, IF THERE 15 ANY, FROM | Pistons seats 3 - ROTATE THE STEM IN ORDER TO RELEASE THE PISTONS FROM SHAFT’S RACK. TAKE OFF PISTONS THROUGH A PAIR OF PINCERS. GIpha Pompe Spe v. moline emi) 16 25030 mociogio - BS - DT tel. (+39) 030 - 978.661/2 fox. 978.663 mm Ee EB ES 2 SS S82 SS SS SS Sf a2 SS SS 8 2 2S =Alph = MAINTENANCE. SUBSTITUTION OF SPARE-PARTS, 4 ~ RELEASE SEEGER RING PART, 10) FROM STEM AND TAKE AWAY! = PINION THRUST WASHER (PART. 23 = ANTIERICTION WASHER (PART. 24) BECAUSE THEY HAVE TO BE SUBSTITUTED. 5 - EXTRACT SHAFT FROM ACTUATOR’S BODY AND TAKE OFF? = UPPER PILOT RING FOR SHAFT (PART. 261 = UPPER O-RING FOR SHAFT (PART, @7) = LOWER O-RING FOR SHAFT (PART. 06) = LOWER PILOT RING FOR SHAFT (PART. 25) THEY HAVE TO BE SUBSTITUTED. eipne pampe spe v_ moline emi’ 16 25030 maciodio - 8S — z re. C39) 030' ~ 978.66 172 fox. 978.663 2:Alphair - MAINTENANCE. SUBSTITUTION OF SPARE-PARTS, 6 ~ FROM BOTH PISTONS TAKE OFF: ~ PISTON BEARING «PART. 27) ANTI-EJECTION KEY (PART. @Si = O- RING FOR PISTON (PART. 12) = PISTON HEAD BEARING (PART. 13) = O-RING (PART. 19) BECAUSE THEY HAVE 50 BE SUBSTITUTED. P.N, SUBSTITUTION OF O-RING (PART. 13) MAY REQUIRE ANEW REGULATION OF THE ACTUATOR’S ROTATION IN CLOSING. YOU CAN TAKE NOTE OF THE PROJECTION OF THE DOWEL BEFORE DISASSEMEL ¥. 2 = FROM BOTH COVERS TAKE OFF: = COVER GASKET (PART. 14) = DARING (PaRT. 19) BECAUSE THEY HAVE TO BE SUBSTITUTED. PLN, SUBSTITUTION OF O-RING PART. 19) MAY REQUIRE A NEW REGULATION OF THE ACTUATOR’S ROTATION IN OPENING. YOU CAN TAKE NOTE OF THE PROJECTION OF THE GOWEL BEFORE DISASSEHAL Y, 2 Gipna pormpe spe vo moline emi) 16 25030 meciogio - BS - tel. (+39) 030 - 978.66172 fox. 976.663Alphair - MAINTENANCE. SUBSTITUTION OF SPARE-PARTS. WARNING: AFTER DISASSEMBLY ALL PARTICULARS TO BE SUBSTITUTED, AND BEFORE PROC: ITH THEIR REPLACEMENT, CAREFULLY CLEAN ALL COMPONENTS, WHEN ASSEMBLY, WE SUGGEST LUBRICATING WITH MOLYBDENUM BISULPHIOE GREASE ESSO MOLY EP-2 8 = LIGHTLY LUBRICATE WHERE INDICATED BY ARROWS. aisha pombe spe v. meting emili 18 25030 maciogio = 8S - 7 301 P58) S30| -"S78. 6612 fon p76. 663 (24)Alphair + MAINTENANCE SUBSTITUTION OF SPARE-PARTS. 1 ~ ASSEMBLY NEW SPARE-PARTS ON SHAFT: ~ UPPER PILOT RING FOR SHAFT (PART. 26) = UPPER O-RING FOR SHAFT (PART, @7) 26) AND REPLACE SHAFT INTO ACTUATORS BODY. 2 THEN REPLACE SEECER-RING (PART. 10) IN ITS SPECIAL SEAT. =a ae e = LO oe ra ee a $ é “ 10 ~ SLIP NEW SPARE-PARTS ON STEM 10 = PINION THRUST WASHER (PART. 23) 2 + ANTI-FRICTION WASHER (PART. 24) alpha pempe spa | vo molting emill 16 25030 macioaio - BS — | tel. (+39) 030 ~ 978.661/2 rox. 978.663Alphair ~ MAINTENANCE SUBSTITUTION OF SPARE-PARTS: 11 ~ ASSEMBLY NEW SPARE-PARTS ON PISTONS! Giphe pompe spe vo moline emi 16 25030 meciodio - BS - tel. (+39) 030 - 978.661/2 fox. 978.663~ MAINTENANCE. Alphair SUBSTITUTION OF SPARE-PARTS. EXAMPLE OF "A* STANDARD ALPHAIR ASSEMBLY VARIATION. 19 ~ REPLACE PISTONS IN THE BODY IN ACCORDANCE 10 THE REQUIRED ASSEMBLY VARIATION (SEE PAGE 7 AND 8) 14» GET SURE THAT PISTONS ARE "IN RIGHT PHASE™, THIS MEANS THEY ARE ENGAGED WITH THE SAME TOOTH ON THE SHAFT. MaKe SURE THAT THE SHAFT’S ROTATION FIELD 1S THE REQUIRED ONE. EXAMPLE OF 7A" STANDARD ALPHAIR ASSEMBLY VARIATION. 2 eipha_pormmpe spa vo molne emil) 16 25030 maciosio - 8S - tel. (+39) 030 - 97866172 fox. 975.663Alphair - MAINTENANCE. SUBSTITUTION OF SPARE-PARTS. 1S = REPLACE EVENTUAL SPRINGS, Ft 16 - ASSEMBLY COVERS TIGHTENING SCREWS - FOLLOWING STATED KUMERATION. a SET 1S READY TO BE CONNECTED PNEUMATICALLY AND ELECTRICALLY Gipha pompe spe Vv. meline emili 16 25030 mociedio - BS — 38 fel. (+39) 030 - 978.66172 fox. 978,663