Yarway Pneumatic diaphragm actuator model 20 IOM Owner's manual

Brand: Yarway

Model: Pneumatic diaphragm actuator model 20 IOM

Type: Owner's manual

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

UNPACKING

The Yarway pneumatic diaphragm actuators

are mostly delivered in combination with

Desuperheaters for use on low-, medium- and

high pressure steam applications and packed

with the greatest care in wooden boxes or

cartons for protection during handling and

transit to site. If it is found, however, that

damage has occurred during shipment, then

this should be reported immediately to your

forwarder or Yarway representative.

Particular care should be taking when

removing the pneumatic diaphragm actuators

(including Desuperheaters) from the packing

and your special attention is required to

check carefully that no damage has occurred

to the actuators, accessories as: pneumatic

positioner, electric/pneumatic positioner,

position transmitter, air filter regulator, booster

relay, lock-in relay, limit switches, solenoid

valves and the standard piping with stainless

steel pipe and fittings.

Warning: the hoisting lug is for the actuator

only, NOT for a total assembly!

Before installation these instructions must be fully read and understood

PRINCIPLE OF OPERATION

In a direct acting diaphragm actuator,

increasing loading pressure moves the actuator

stem downward, compressing the spring. When

the loading pressure is decreased, the spring

moves the actuator stem upward.

In the event of failure of the loading pressure

or the operating medium pressure to the

controller, the actuator stem moves to the

upward position.

Warning: be certain that the diaphragm casing

pressure does not exceed the limits listed in

the specification table (see table 1).

20 - 55 20 - 55 20 - 90 20 - 90

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

TABLE 1 - FUNCTIONAL SPECIFICATIONS

Type 20 - 55 (see fig. 1) 20 - 90 (see fig. 3)

Type Direct acting Direct acting

Action Stem extends with air pressure Stem extends with air pressure

Diaphragm 950 cm

950 cm

Air displacement 5225 cm

8550 cm

Max. thrust 11 kN (48.800 lbf) 10 kN (44.400 lbf)

Spring range 1.0 to 3.8 bar (15 to 55 psi) 1.0 to 2.2 bar (15 to 32 psi)

Travel 55 mm (2⅛”) 90 mm (3½”)

Travel speed Depending on spring range, air supply

pressure, piping arrangement and air

capacity of auxiliary devices

Depending on spring range, air supply

pressure, piping arrangement and air

capacity of auxiliary devices

Travel indicator Integrated pointer and stainless steel

travel scale

Integrated pointer and stainless steel

travel scale

Air connection ½” NPT female ½” NPT female

Air supply 6.0 bar (max. 87 psi) 6.0 bar (max. 87 psi)

Ambient temperature (std)* -29°C to +70°C (-20°F to +158°F) -29°C to +70°C (-20°F to +158°F)

Weight 46.0 kg (102 lbs) 68.0 kg (150 lbs)

Handwheel Side mounted (see fig. 2) Side mounted (see fig. 4)

Weight 19.0 kg (42 lbs) 19.0 kg (42 lbs)

Protection level (std)** IP55 IP 55

FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4

NOTE

* = Optional temperature: -40°C to +80°C [-40°F to +158°F]

** = Optional protection level: IP66

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

Assembly of a ‘Yarway’ standard duty A.T.-Temp Desuperheater

Air filter regulator

E/P-postioner

Water inlet

Water outlet

FIGURE 5

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

ACTUATOR/DESUPERHEATER DISASSEMBLY

(SEE FIG. 6 AND 7)

Before any maintenance operation on the

Yarway Desuperheater fitted with a Yarway

actuator model 20 - 55/20 - 90, please

carefullyfollow these instructions:

• Isolate or bypass the steam supply.

• Check steam line is cooled down and

pressure free.

• Shut-off Desuperheater water supply.

1. Cut-off the air supply to the positioner

via the air filter regulator. Disconnect the

pneumatic connections and the electrical

connections of the positioner on the

network. Disassemble on the actuator side

the pneumatic connections to the positioner.

2. Disconnect the lever of the positioner from

the stem coupling (mechanical linkage).

3. Slightly supply the actuator to lift the

Desuperheater piston from the seat.

Disassemble the upper and lower

couplings(27) (see fig. 6 and 7) through

the screws. Cut-off the air on the

diaphragmcasing.

4. Unscrew the lock nut (see Installation,

Operation and Maintenance Manual of the

A.T.-Temp Desuperheater) and lift the entire

actuator from the Desuperheater.

DISASSEMBLY

This operation is only needed for:

• To change the diaphragm.

• To change one or several springs.

TABLE 2 - SPARE PARTS

Model 20 - 55 (fig. 6) Model 20 - 90 (fig. 7)

Item Quantity Name Part no. Item Quantity Name Part no.

3 1 Plate bolt M14 x 100 mm HN-3283

3 1

Plate bolt M14 x 100 mm HN-3283

5 1 Diaphragm ø 420 3N-1299-20

5 1

Diaphragm ø 420 3N-1299-20

6 1 Spring plate 3N-2336

6 1

Spring plate 3N-2286-20

19, 20, 21 Set

4 x bolts M8 x 100 mm /

HN-3118 19, 20, 21 Set

4 x bolts M8 x 160 mm /

HN-3117

4 x nuts M8 / 8 x washers / 8 x nuts M8 / 8 x washers /

4 x protecting tubes 8 x protecting tubes

7, 8 1 Spring ø 59, 6 black, total 5

required per actuator

4N-2900-20 7, 8 1 Spring ø 100 (inner), total 3

required per actuator

4N-3017-20

1 Spring ø 59, 6 red, total 5

requiredper actuator

4N-3416-20 1 Spring ø 140 (outer), total 3

required per actuator

4N-3016-20

13 1

Bushing M35 x 1.5 mm brass 4N-2764-20

13 1

Bushing M35 x 1.5 mm brass

4N-2764-20

Bushing M35 x 1.5 mm GGGN60 4N-3858-20

Bushing M35 x 1.5 mm GGGN60

4N-3858-20

Make sure that the identification number (indicated on the nameplate) is verified and specified when ordering spare parts.

Diaphragm exchange

• Cut-off the air supply to the positioner via the

air filter regulator. Disconnect the pneumatic

connections and the electrical connections of

the positioner on the network. Disassemble

on the actuator side the pneumatic

connections to the positioner.

• Remove all short bolts (18), rings (21) and

nuts (20) on the bolt circle. Progressively

unscrew the 4 long bolts (19), located on

a quadrangle on the circle, to unload the

springs. After having released the 4 bolts,

take the upper casing (1) away.

• Unscrew plate bolt (3) whilst avoiding

the actuator stem (10) rotation by using

the square located on the half upper

coupling(27). Take diaphragm plate (4)

away. Withdraw diaphragm (5) and replace

it by a new one. Tighten diaphragm plate by

applying160 Nm on bolt (3).

• Reassemble the upper casing by using the

4 bolts (19), load the springs until complete

tightening of the diaphragm and complete the

short bolts circle in a clockwise, criss-cross

pattern with a max. torque of 40 Nm.

Exchange of one or more springs

• Same instructions as for diaphragm

exchange, except spring plate (6) has to

betaken away.

• Change damaged springs (7/8) and

reassemble in the opposite way.

•

ø 420

ø 360

9544400

•

19 27

•

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

Model 20 - 55

FIGURE 6

TABLE 3 - STANDARD MATERIALS

Item Qty. Name Material Dimension Item Qty. Name Material Dimension

1 1 Upper housing C-steel 16 1 ½” NPT socket A105 / C22.8

2 1 Limit block C-steel 17 1 Hoisting lug C-steel

3• 1 Bolt 12.9 M14 x 100 mm 18* 16 Bolt 8.8 M8 x 30 mm

4 1 Diaphragm plate C-steel 19*• 4 Bolt 8.8 M8 x 100 mm

5• 1 Diaphragm Rubber 20* 16 Nut Steel M8

6 1 Spring plate Aluminium 21* 4 Washer C-steel

7• 5 Spring right 22 1 Cushioning plate Rubber

8• 5 Spring left 23 1 Support plate Aluminium

10 1 Stem A182 F316 24 2 Connector air snubber St. steel

12 1 Lower housing C-steel 25* 1 Washer C-steel M14

13• 1 Bushing Brass / GGGN60+ 26 2 Air snubber Brass

14* 3 Yoke pillar C-steel 27* 4 Nut 3D 8.8 M8

15 1 Yoke plate actuator A105 / C22.8 28 3 Bolt 8.8 M12 x 40

NOTES

- Dimensions may be subject to change without prior notification.

- Yarway will provide a certified dimensional drawing upon request.

- Bolts nr. 19 are used for disassembly of actuator and provided with protection tube.

* Zinc plated parts

+ Optional

• Recommended spares

•

ø 420

ø 360

9544

225

400

•

19 27

•

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

Model 20 - 90

FIGURE 7

NOTES

- Dimensions may be subject to change without prior notification.

- Yarway will provide a certified dimensional drawing upon request.

- Bolts nr. 19 are used for disassembly of actuator and provided with protection tube.

* Zinc plated parts

+ Optional

• Recommended spares

TABLE 4 - STANDARD MATERIALS

Item Qty. Name Material Dimension Item Qty. Name Material Dimension

1 1 Upper housing C-steel 16 1 ½” NPT socket A105 / C22.8

2 1 Limit block C-steel 17 1 Hoisting lug C-steel

3• 1 Bolt 12.9 M14 x 100 mm 18* 16 Bolt 8.8 M8 x 30 mm

4 1 Diaphragm plate C-steel 19*• 4 Stud 8.8 M8 x 200 mm

5• 1 Diaphragm Rubber 20* 16 Nut Steel M8

6 1 Spring plate Aluminium 21* 8 Washer 8.8 M8

7• 3 Spring inside 22 1 Cushioning plate Rubber

8• 3 Spring outside 23 1 Support plate Aluminium

10 1 Stem A182 F316 24 2 Connector air snubber St. steel

11 1 Stroke limiter A106 Gr. B / ST.35.8 25* 1 Washer 8.8 M14

12 1 Lower housing C-steel 26 2 Air snubber Brass

13• 1 Bushing Brass / GGGN60+ 27* 4 Nut 3D 8.8 M8

14* 3 Yoke pillar C-steel 28 3 Bolt 8.8 M12 x 40

15 1 Yoke plate actuator A105 / C22.8

•

ø 200

104

150

21 25

2 17

7 16

280

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

TABLE 5 - STANDARD MATERIALS

Item Qty. Name Material Dimension Item Qty. Name Material Dimension

1* 1 Mounting plate (upper) SA 105 14 1 Parallel key C 45 5 x 5 x 20 mm

2* 1 Mounting plate (lower) SA 105 15• 1 Circlip Steel

3* 1 Mounting plate (handwheel) St 37 K 16• 1 Plain bearing PTFE

4• 1 Drive shaft Al. bronze / GGGN60 17• 1 Bearing bushing Nylon

5 1 Shaft left 1.4057 18* 1 Eye bolt St 37.2

6• 1 Shaft right 1.4057 19 1 Padlock

7*• 1 Helical gear C-steel 20* 2 Pillar SA 105

8* 1 Parallel key C 45 8 x 7 x 24 mm 21 2 Screw St. steel M5 x 10 mm

9*• 1 Pinion C-steel 22 1 Nameplate St. steel

10 1 Cover St. steel 23 1 Handwheel Aluminium

11* 8 Bolt 10.9 M12 x 40 mm 24* 1 Gear bushing SA 106 Gr. B

12* 1 Bushing (handwheel) SA 105 25 2 Ring St. steel M5

13*• 1 Spindle (handwheel) SA 105

FIGURE 8 - Side-mounted handwheel

NOTES

* Zinc plated parts

• Recommended spares

YARWAY MODEL 20 PNEUMATIC DIAPHRAGM ACTUATOR

InstallatIon, operatIon and MaIntenance InstructIons

MAINTENANCE

Maintenance of the Yarway actuator is straight

forward and does not require any special tools

or training.

Care should be taken during any maintenance

operation, particularly when working with

grinders, compressed air and rotating

machinery. It is imperative that safety

glasses and protective workwear are used in

accordance with standard safety procedures.

In case of doubt, consult your supervisor or

safety officer before commencing any work

ontheequipment.

STORAGE PROCEDURE

Upon receipt, check both the pneumatic

actuator and the packing case for any transit

damage. Any damage to the pneumatic

actuator should be reported immediately to

Yarway or their local agent. Any damage to

the packing container should be rectified to

prevent the ingress of dust or water, prior to

placing the equipment into storage. Check

the information contained on the identification

plate (tagplate) and documentation and return

the unit to its packing with protective covers in

place (seefig.5).

For short term storage, up to 6 months

duration, no additional preservation measures

are necessary. Retain the unit in its original

packing in a clean, dry indoor location.

If outdoor storage is unavoidable, then

the packing case should be enclosed in a

waterproof covering.

For long term storage use a dry indoor location

only. Retain pneumatic actuator in its original

packing and inspect at 3 monthly intervals to

ensure that no deterioration has occurred.

Before placing the pneumatic actuator into

service, inspect all components, to ensure

correct functioning. Follow the procedure for

installation as detailed in the operating and

maintenance instruction manual.

MANUAL OPERATOR

• The Yarway manual operator is side-mounted

between the actuator and the Desuperheater.

• The manual operator is intended to be used

for emergency only.

• The handwheel (23) is locked by means of

apadlock (19).

• The handwheel will not turn during actuated

operation of the actuator assembly and/or

Desuperheater assembly.

• By unlocking the padlock, clockwise turning

the handwheel will move the 2 spindle

parts(5)(6) away from each other, opening

the valve.

• Turning counter clockwise, the valve

willclose.

After using the manual operator, the system

shall be set back to the original position. Failing

to do so may lead to improper valve response

and/or damaging of the piston/spray cylinder.

TABLE 6 - SPARE PARTS

Item Qty Name Part number

7, 9 + 13, 15, 16, 17 1 Spares SM handwheel 4N-4307-20

4, 5, 6 1 Spindle kit SM handwheel Al Bronze 4N-4308-20

4, 5, 6 1 Spindle kit SM handwheel GGGN60 4N-4310-20

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.

Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

Yarway is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson

and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be

construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by

our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without

notice.

Emerson.com/FinalControl

NOTES

- Apply some general purpose grease on the gear

wheel (7)(9) once a year.

- Make sure no dirt is trapped between the drive shaft

(4) and the wheel large (7).

- This may obstruct free movement between these

parts.

WARNING

The hoisting lug is for the actuator only, NOT for

atotal assembly!