INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-48 12-13 MODEL 48 SPRING/DIAPHRAGM ROTARY ACTUATORS SECTION I I. DESCRIPTION AND SCOPE Models 48D and 48R are multi-spring, single acting, spring opposed, rotary actuators used with Cashco rotary control valves. Regardless of final installed failure action, the actuator is always pressurized on “top” of the traveling diaphragm plate.
ACTUATOR MODEL NO. vs. VALVE BODY MODEL (Model 148 included for clarity) Full Actuator Model No. Basic Available Actuator Modifier Bench Settings Model No. Number psig (Barg) 48R or -01 5-15 (.34-1.03) 48D 148R or -01 5-13 (.34-0.90) 148D 148R or -02 10-26 (.69-1.79) 148D 148R or -03 7.5-19.5 (.52-1.34) 148D Air Supply Pressure psig (Barg) 20 (1.4) 20 (1.4) 36 (2.5) 27 (1.
Position A Position A Position B Position B FIGURE 4: Mounting position of Premier EZO or Premier Unlined to Model 48 Actuator with Model 73N-B P/P Positioner FIGURE 5: Mounting position of Premier EZO or Premier Unlined to Model 48 Actuator with Models 9540R or Smart Positioners 3. A 1/4"–NPT female connection for pneumatic LOAD is located on the side of the actuator’s upper diaphragm casing near the casing flange joint. Reference specific Ranger-TB or Premier-TB for location of the connection. 4.
TABLE 2 RANGER QCT ACTUATOR BENCHSET RANGES Actuator Model * Failure Action 48R-01 ATO-FC 48D-01 ATC-FO 3" & 4" (80 & 100) 148R-01 ATO-FC 148D-01 ATC-FO 4", 6" & 8" (100,150, & 200) 148R-02 ATO-FC 148D-02 ATC-FO Valve Body Size In. (DN) 1", 1-1/2" & 2" (25, 40 & 50) Benchset Range psig (Barg) Supply Pressure psig (Barg) Qty of Range Springs 5-15 (.34-1.03) 20 (1.4) 6 5-13 (.34-.90) 20 (1.4) 4 10-26 (.69-1.79) 36 (2.
SECTION V V. MAINTENANCE A. General: 1. Hereafter, all maintenance, disassembly, etc., is assumed to be done in an indoor shop. 2. Most actuators are a sub-assembly that is unitized with a body sub-assembly. Reference should be made to the IOM for the correct body utilized. 3. Where the body is not being disassembled, special care MUST be exhibited to prevent valve stem rotation during any disassembly or reassembly for all types of valves. Following this procedure will ensure not damaging seating surfaces.
4. For ATO-FC valve action, it is necessary to remove the “stem windup”. a. Rotate manual handwheel operator (MHWO) handwheel (58.1) approximately 1-3 revolutions CW (viewed from above handwheel) until interconnecting arm and stem linkage (5, 10) of actuator “relax”. b. Pressurize actuator casing (1) only until the interconnecting arm and stem linkage (5,10) “relax”. DO NOT OVERPRESSURIZE. NOTE: Do not remove the drive coupling ((32)) unless required. 5.
FIGURE 6: ORIENTATION – RANGER QCT ACTUATOR MOUNTING POSITIONS WITH MODEL 73 P/P POSITIONER REVERSE ACTION NOTES: IOM-48 DIRECT ACTION 1. Flangeless valve design indicated; integral flanged units follow same orientation. 2. Dimension tables are included in the Ranger-TB.
FIGURE 7: ORIENTATION – RANGER QCT ACTUATOR MOUNTING POSITIONS WITH MODELS 9540R P/P or 991 or PS2 I/P POSITIONERS REVERSE ACTION NOTES: 8 DIRECT ACTION 1. Flangeless valve design indicated; integral flanged units follow same orientation. 2. Dimension tables are printed in the Ranger-TB.
FIGURE 8 PREMIER ACTUATOR MOUNTING POSITIONS – 73 Position "A" is standard for fail closed action. Position "B" is standard for fail open action. Position "C" and "D" covers vertical piping. FIGURE 9 PREMIER ACTUATOR MOUNTING POSITIONS – 9540R/991/PS2 Position "A" is standard for fail closed action. Position "B" is standard for fail open action. Position "C" and "D" covers vertical piping.
9. Reposition packing flange (Ranger (14)) (Premier Unlined (5)) over packing studs (21) for Ranger and Premier Unlined. Reinstall live-loaded packing components (Ranger (27) (28) (29) 2 sets). Reengage both packing stud nuts (22) for Ranger and Premier Unlined. Set torque level on packing stud nuts as indicated in IOM-Ranger QCT, IOM-Premier EZO, or IOM-Premier Unlined body assembly (BA) instructions. 10. Reorient body assembly (BA) with respect to the actuator assembly (AA).
5. Loosen all casing (1,2) flange bolting (27, 28, 41, 42) two revolutions. Pry apart the casings (1,2) if “stuck” together. CCW-TO-OPEN ATC-FO (DIRECT) Push Down-to-Close CCW-TO-OPEN ATO-FC (REVERSE) Push Down-to-Open NOTE: To switch “action” requires locating actuator stem to opposite side of valve stem. Figure 10 Ranger Plug vs. Lever Arm vs. Actuator Orientation 6. In one revolution increments loosen all opposing nuts (41, 42) until the short bolting (27, 41) disengages and can be removed.
the new diaphragm (6). Place Locktite #242, or equal, thread sealant onto the threads of pivot screw (25); engage and tighten screw (25) to 15-20 ft-lbs (21-27 N-m) torque. NOTE: Piston (3) must be held from rotating to prevent the multiple nested range springs (11) from tilting away from a common vertical centerline between hubs of lower case (2), piston (3) and range spring (11). 15. Fold the diaphragm (6) skirt from its insideout orientation, down and around the piston’s (3) skirt.
Section IV.A.4. for the corresponding actual benchset range of the actuator being serviced, and test for leakage at upper casing (1) to lower casing (2) joint. Also test for leakage at manual handwheel operator (MHWO), rotating handwheel (58) in and out several times during the test. 25. Release all air pressure into actuator upper casing (1); remove air source from 1/4" FPT connection. F. Manual Handwheel Operator: 1.
23. Place heavy duty wheel bearing grease as specified previously onto the stem-end ball (64). Engage the gland (67) into the upper casing (1) female opening. Align tapped opening for self-tapping slotted-head screw (65). 24. Install slotted-head screw (65) fully. G. Adjusting Screw Assembly and Actuator Plug Maintenance: 1. Reference Item Number drawing at end of the IOM. 2. Determine the portion of the text of Subsection F.
9. Inspect clevis (7), upper R.H. rod end (8), clevis pin (48), washers (53) and hairpin (49) for signs of looseness and/or wear; replace any worn parts. Check bolting (26) for looseness; tighten as necessary to 15-18 ft-lbs (20-23 N-m). 12. Reinstall a new diaphragm (6) and reassemble the upper casing (1) as described in this Section, V.E.12 through V.E.24. 13. Using air pressure of V.E.24., pressurize the actuator upper casing (1) to the upper value of the stated benchset range plus 2 psi (0.14 Bar); i.
bearing (18), bearing flanges (19) and cover plate (20) removed) properly oriented and shift laterally over the protruding stem (Ranger (7), Premier (3.2)). Bring the round opening of the arm housing (4) into position against the mounting yoke (12). Raise/lower/tip/rotate the actuator assembly (AA) to align at least one bolt hole of the yoke (12) with one bolt hole in the arm housing (4).
ATO-FC (Reverse) Action ATC-FO (Direct) Action Figure 13: travel indicator (16) to shaft (Ranger (7), Premier (3.2)) with cap screw (32) using a 7/32" allen key wrench until firmly tight. c. Position cover plate (13) over the bearing flanges (19) aligning the cover plate (13) bolt holes with those of the bearing flanges (19). Hold cover plate (13) on outer edge with fingers. NOTE: Ensure that the three tapped holes in the coverplate (13) are near the 1:o'clock, 5:o'clock and 9:o'clock positions. d.
7. In this Section reference will be made to three phrases – a. “lower value of benchset range”, b. “higher” value of benchset range”, c. benchset range. The meaning of these phrases is summarized in the following table. Benchset Range * 5-15 psig (.34-1.03 Barg) Lower Value of Benchset Range 5 psig (0.34 Barg) Higher Value of Benchset Range 15 psig (1.03 Barg) * Identified on nameplate (21) as “Bench” or “Input Range”. RANGER QCT® SERIAL NO.
e. Loosen lower L.H. rod end (9) jam nut (44) by rotating CW (viewed from above); this nut (44) is “left-handed”. Back nut (44) to the root of its threads on push rod (10). f. Using a suitable tool to prevent lower L.H. rod end (9) from rotating, rotate push rod (10) CCW (viewed from above) until upper end of push rod (10) is fully engaged with upper R.H. rod end (8). NOTE: If lower L.H.
dial (15) such that travel indicator (16) shows “0°” travel before fully tightening screws (31). w. Completion to this point completes the benchset range adjustment. Proceed to Subsection VI.C. to adjust 90° travel stop. 6. Units with ATC-FO (Direct) Action: a. Disconnect the lower L.H. rod end (9) from engagement with the lever arms (5) by removing shoulder bolt (40) and lock nut (46). b.
(16) shows “0°” travel (no “bright orange” showing from indicator (16))before fully tightening screws (31). q. Fully release air pressure in actuator (AA). Observe position of valve on travel indicator (16). Travel should be short of “full open”; i.e. 90° rotation. 1. Travel short of 90°. Adjust the push rod (10) by rotating CCW (viewed from above) until the travel reaches 90° as shown by travel indicator (16). 2. Travel beyond 90°.
SECTION VII VII. TROUBLE SHOOTING GUIDE Reference the IOM of the valve body this actuator is unitized with for additional information on Trouble Shooting. 1. Air leakage. Possible Causes A. Leakage at diaphragm-to-upper casing flange. Remedies A1. Overpressure. Check source of air supply and determine if pressure is greater than indicated in Table 1; reset airset pressure as required. A2. Tighten casing flange bolting (27, 28, 41 & 42) B. Faulty O-ring (62); replace O-ring. C.
ADJUSTING SCREW ASSEMBLY Not available on Air to Close-Fail Open Rangers ACTUATOR PLUG Available on Premier Butterfly Valves ONLY BASIC 48 ACTUATOR Shown Air to Open ITEM NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. IOM-48 DESCRIPTION Upper Case Lower Case Piston Arm Housing Arm Diaphragm Clevis Rod End (R.H.) Rod End (L.H.
STOP SCREW 73N-B POSITIONER AIR SUPPLY REGULATOR SOLENOID VALVE 73N-B POSITIONER ITEM NO. DESCRIPTION 72 Feedback Linkage Subassembly 73 Feedback Linkage Spacer 74 Feedback Linkage Pivot Shaft 101 Positioner 102 Range Spring 106 Tube Fittings (Elbow) 107 Output Tube 108 Name Plate SOLENOID VALVE ITEM NO. DESCRIPTION 128 Solenoid Valve 129 Nipple Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: sales@cashco.com Printed in U.S.A.