Air Torque AT045U Service manual

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
([email protected]).
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 specied 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

EB AT-RP-4GU EN 3-1
Design and principle of operation
3 Design and principle of operation
The AIR TORQUE 4th Generation Upgrade Series (4thGU) ac-
tuators are devices for remote operation (on/off or modula-
ting duties) of different industrial valves such as ball valves,
butterfly valves and plug valves.
The actuators are available in two configurations: spring re-
turn and double acting.
1. DOUBLE ACTING
Refer to Fig. 3-1.
In case of the double acting configuration air pressure will be
necessary for both strokes (A and B).
Fig. 3-1
“2“ “4“
“2“ “4“
A
B
2. SINGLE ACTING
Refer to Fig. 3-2.
When air pressure is supplied through port “2“ (A‘) into the
actuator body, the linear force applied on the piston surface
generates the pinion rotation, driving the valve to a defined
position. At the same time the actuator springs are compres-
sed.
When air pressure is discharged (B‘), the springs are auto-
matically released, driving the rack and pistons back to the
original position and thus the valve to the fail-safe position.
Fig. 3-2
“2“ “4“
“2“ “4“
A‘
B‘
The actuators can be controlled by different options:
−direct mounting of control devices (for example a solenoid
valve or a manifold) with NAMUR interface,
−threaded connections (to pressurize port “2“ and “4“) wi-
th air lines from separate electro-pneumatic control sys-
tem.
3.1 Direction of action and fail positions
The standard rotating direction for the 4thGU actuators is
clockwise to close.
Standard 4thGU actuators are designed for 90° rotating
angle, with travel stop allowing adjustment (Fig. 3-3) for -5°
up to +15° on the close position and for +5° up to -15° on the
open position. For AT045U stroke adjustment is only available
on request.
Fig. 3-3
0°
90°
95°
-5°
15°
75°
Available stroke
adjustment
For single acting actuators in case of pressure, power or
signal failure the springs drive the actuator in the fail position
that can be FAIL OPEN or FAIL CLOSE.
If the actuator is controlled by a control system the FAIL positi-
on may be different from FAIL OPEN or FAIL CLOSE.
ÎRefer to the actuator model technical data for the FAIL po-
sition.
ÎRefer to section 2.1 ‘Actuator nameplate sample‘ (Table
2-1, position 11) for the fail action and direction of rotati-
on available options.
Note

3-2 EB AT-RP-4GU EN
Design and principle of operation
3.2 Complementary/accessory parts
Gearbox
It is an emergency manual override system designed to
provide manual operation to drive the actuator and the valve
in the safe position when the supply pressure is not available
in case of any emergency situation. The actuator and the
valve are operated rotating a handwheel. (Fig. 3-4)
ÎRefer to the gearbox instruction manual available from
AIR TORQUE.
Risk of actuator damage due to incorrect gearbox stroke
adjustment.
−Make sure that the actuator and the gearbox are correctly
oriented, with reference to the rotation direction required.
−Make sure that the stroke of the gearbox does not exceed
the stroke allowed by the actuator.
Fig. 3-4
GEARBOX
Block and safety lock-out system
The block and safety lock-out system permits to lock the actua-
tor and the valve in specific cases, despite the fail action of
the actuator. (Fig. 3-5)
ÎRefer to technical data T.D.S. 4.3.1.
Fig. 3-5
BLOCK AND SAFETY
LOCK-OUT SYSTEM
NOTICE
!
3.3 Technical data
The nameplate provides information on the actuator configu-
ration.
ÎRefer to section 2.1 ‘Actuator nameplate sample‘.
ÎMore informations are available in the actuator model
technical data sheet available from AIR TORQUE.
Power operating media
−Use dry or lubricated air or inert gas.
−Make sure the operating media is compatible with the ac-
tuator internal parts and lubricant.
−In case of pressure medium different than Group 2 fluids
according to the PED 2014/68/EU, contact AIR TOR-
QUE.
−The operating media must have a dew point equal to
–20°C (-4°F) or at least 10°C (18°F) below the ambient
temperature.
−The maximum particle size contained into the operating
media must not exceed 30 μm.
Supply pressure
−The maximum operating pressure is 8 bar (116 Psi).
ÎRefer to section 2.1 ‘Actuator nameplate sample‘ (Table
2-1, position 05).
−For double acting and single acting actuators the working
pressure is from 2.5 bar (36 Psi) to 8 bar (116 Psi).
ÎRefer to the actuator model technical data for output tor-
que values related to the working pressure range.
Operating temperature
The nameplate provides indication on the operating tempera-
tures.
– “ST” actuators for standard temperatures from
-40°C (-40°F) to +80°C (+176°F).
– “HT” actuators for high temperatures from
-15°C (+5°F) to +150°C (+302°F).
– “LLT2” actuators for extremely low temperatures from
-60°C (-76°F) to +80°C (+176°F).
ÎRefer to the data sheet RP10600E for the soft spare parts
material and lubricant type in relation to the different wor-
king temperature ranges.
Stroking time
The stroking time depends on several factors such as supply
pressure, supply system capacity (tubing diameter, pneumatic
accessories flow capacity), valve type, valve torque, applied
safety factor, cycle frequency, temperatures, etc. Nevertheless,
an indication of the stroking time in clearly defined conditions
is available in the actuator model technical data sheet.

EB AT-RP-4GU EN 4-1
Shipment and on-site transport
4 Shipment and on-site transport
The work described in this section is only to be performed by
fully trained and qualified personnel.
4.1 Accepting the delivered goods
After receiving the shipment, proceed as follows:
1. Check the scope of delivery. Check that the specifications
on the actuator nameplate match the specifications in the
delivery note. See the ‘Markings on the device‘ section for
nameplate details.
2. Check the shipment for transportation damage. Report
any damage to AIR TORQUE and the forwarding agent
(refer to delivery note).
3. Determine the weight and dimensions of the units to be lif-
ted and transported in order to select the appropriate lif-
ting equipment and lifting accessories. Refer to the trans-
port documents and to the actuator model Technical data
sheet.
4.2 Removing the packaging from the actu-
ator
Do not open or remove the packaging until immediately befo-
re mounting the actuator.
Leave the actuator in its transport container or on the pallet to
transport it on site.
Dispose and recycle the packaging in accordance with the
local regulations.
4.3 Transporting and lifting 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 parths.
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).
Risk of actuator damage due to incorrectly attached slings.
Only attach load slings to vertically lift the actuator on its
own.The lifting points must not be used to lift the actuator and
valve assembly.
ÎDo not attach load-bearing slings to the travel stop or to
accessories.
ÎDo not use damaged or defective slings.
DANGER
!
WARNING
!
NOTICE
!
ÎDo not shorten the slings with knots or bolts or other ma-
keshift devices.
ÎObserve lifting instructions (see section 4.3.2).
Our after-sales service can provide more detailed transport
and lifting instructions on request.
4.3.1 Transporting the actuator
The actuator can be transported using proper lifting equip-
ment (e.g. crane or forklift).
ÎLeave the actuator in its transport container or on the pal-
let to transport it.
ÎObserve the transport instructions.
Transport instructions
−Protect the actuator against external influences (e.g. im-
pact).
−Do not damage the corrosion protection (paint, surface
coatings). Repair any damage immediately.
−Protect the actuator against moisture and dirt.
−Observe permissible temperatures (refer to the section 3.3
‘Technical data‘).
4.3.2 Lifting the actuator
Observe the ruling regulations corcerning the lifting opera-
tions.
To mount large actuators onto the valve, use lifting equipment
(e.g. crane or forklift) to lift it.
Do not drill extra holes into the actuator.
Do not use the actuator lifting points to lift the actuator and
valve assembly.
Fig. 4-1
Use appropriate tackles and slings to lift the actuator.
ÎRefer to technical data sheet for the actuator weight.
Tip

4-2 EB AT-RP-4GU EN
Shipment and on-site transport
Lifting instructions
−Secure slings on the object to be transported against slip-
ping.
−Make sure the slings can be removed from the actuator
once it has been mounted on the valve.
−Prevent the actuator from tilting or tipping.
−Do not leave loads suspended when interrupting work for
longer periods of time.
−Use a hook with safety latch to secure the slings from slip-
ping during lifting and transporting.
−For models bigger than AT651U two threaded holes are
available to lift the actuator by means of eyebolts or simil-
ar components as shown in Fig. 4-2. Do not lift the actua-
tor and valve assembly from these lifting points.
Fig. 4-2
a
a
Only for models from
AT651U to AT801U
0°≤ a ≤ 45°
Lifting
point
Lifting
point
4.4 Storing the actuator
Risk of actuator damage due to improper storage.
ÎObserve the storage instructions.
ÎObserve the rubber components storage instructions
(T 3.3.3.1 EN).
ÎAvoid long storage times. Contact AIR TORQUE in case of
different storage conditions or long storage periods.
It is recommended to regularly check the actuator and the pre-
vailing storage conditions during long storage times.
Storage instructions
−Store the actuator in a clean and dry place.
−Temperature limits are defined by the rubber components
material.
NOTICE
!
Note
ÎRefer to the ‘Rubber components storage instruction‘ (T
3.3.3.1 EN).
−When the valve and actuator are already assembled, also
observe the valve storage conditions. Refer to the valve
documentation.
−Protect the actuator against external influences (e.g. im-
pact).
−Secure the actuator in the stored position against slipping
or tipping over.
−Do not damage the corrosion protection (paint, surface
coatings). Repair any damage immediately.
−Protect the actuator against moisture and dirt.
−Make sure that the ambient air is free of acids or other
corrosive media.
−Do not place any objects on the actuator.
−Keep for future references the relevant technical documen-
tation of the actuator.
−Do not remove the plastic plugs from the air connections.
Tip
Our after-sales service (@airtorque.) can provide
more detailed storage instructions on request.

EB AT-RP-4GU EN 5-1
Mounting and assembly
5 Mounting and assembly
The work described in this section is only to be performed by
fully trained and qualified personnel.
5.1 Preparation for installation
If the actuator was shipped already assembled over the valve,
the setting of the actuator and control system (if any) should
have been already done by the valve manufacturer or auto-
mation center.
If the actuator was shipped separately from the valve, the set-
ting of the actuator and control system must be done while as-
sembling the actuator on top of the valve.
The actuator assembly on valve can be performed by:
−Mounting directly the actuator over the valve interface
−Assembling a bracket and a coupling between the actua-
tor and the valve.
5.2 Control and signal devices assembly
The AIR TORQUE 4thGU Series actuators can be controlled by
directly mounted devices or remote control systems. Therefore
AIR TORQUE actuators have direct mounting interfaces (Fig.
5-1) in order to allow control and signal devices assembly
(e.g. solenoid valve, positioner, switchbox, etc) and threaded
connections for remote control systems.
ÎRefer to the documentation available from control and sig-
nal devices manufacturers for mounting and operating in-
structions.
Fig. 5-1
Position
indicator
Solenoid
valve
Ancillary
attachments
Switchbox
and bracket
Top view
5.3 Mounting the actuator over the valve
Risk of bursting in the actuator
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.
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 impede the movement of the pinion and the pistons
by inserting objects into the actuator.
Risk of damage and malfunction due to torque limit viola-
tion.
Considering the maximum actuator output torque, the maxi-
mum air supply pressure and the maximum valve torque, ac-
cording to ISO 5211, the actuator maximum transmissible
output torque must not exceed the torque limit in relation to
the available ISO ange and the drive shaft connection.
ÎRefer to section 2 ‘Markings on the device‘ for nameplate
details.
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°).
Risk of actuator damage due to excessively high or low tigh-
tening torques.
Observe the specied 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‘.
DANGER
!
WARNING
!
WARNING
!
WARNING
!
NOTICE
!

5-2 EB AT-RP-4GU EN
Mounting and assembly
Before mounting the actuator over the valve, make sure the
following conditions are met:
−The actuator is not damaged.
−The type designation, material and temperature range of
the actuator match the ambient conditions (temperatures
etc.). Refer to ‘Markings on the device‘ in section 2 for
nameplate details.
−Check compatibility of the valve stem to the actuator bore.
The length, size and configurations must match.
−Check compatibility of actuator, valve and bracket bolting
pattern.
−Before fitting the actuator over the valve, make sure that
the actuator and the valve are correctly oriented, with re-
ference to the rotation direction and fail action required.
−Make sure that the tubing, fittings and seals connected to
the actuator are cleaned to prevent foreign matter/objects
entering into the actuator’s chambers.
−When fitting accessories over the actuators, assemble
them in such a way that the emergency controls are easily
accessible for emergency manual operation.
−Check that the exhaust ports are not obstructed.
−Remove the plugs from the actuator air connections during
installation and operation, protect and close the air
connections which may not being used immediately.
−Make sure that the operating pressure media composition
used for the actuator operation meets the operating condi-
tions given in this manual and corresponds to what the ac-
tuator was manufactured for. Refer to section 3 ‘Design
and principles‘.
−It is the user responsibility to ensure that actuator and con-
trol components must be protected from electrical spikes,
surge and lightning strikes as well as all magnetic fields.
−Prevent any dangerous and/or corrosive substances in the
working environment enter into the internal chambers by
using adequate filters and/or solenoid valves and/or any
other appropriate system.
Fig. 5-2
Coupling
Bracket
Valve
interface
Actuator
Valve
interface
Actuator
DIRECT MOUNTING MOUNTING WITH BRACKET
Refer to Fig. 5-2 and proceed as follows to mount the actua-
tor over the valve:
1. Disconnect any electrical/pneumatic/hydraulic power
supply.
2. Lay out the necessary material and tools to have them rea-
dy during mounting.
3. The actuator is supplied in the fail position (for single-ac-
ting), so drive the valve in the right position as per the ac-
tuator fail position.
4. Clean the actuator‘s bore and the bottom flange.
5. Clean the valve and the actuator interface to remove com-
pletely any lubricant.

EB AT-RP-4GU EN 5-3
Mounting and assembly
6. Place the bracket, if any, over the valve flange, tighten all
bolts and nuts and apply the correct tightening torque.
7. Assemble the coupling at first into the valve stem before
the assembly of the actuator.
8. Lift the actuator.
Risk of damage due to incorrect alignment
ÎSupport the actuator with the lifting equipment until the
connection bolts are completely tightened.
ÎMake sure to align correctly the dowel pins or the spigot,
if any.
9. Align the valve stem/coupling to the actuator’s bore.
10. Carefully lower the actuator and engage the valve stem/
coupling into the actuator’s bore without forcing and dri-
ving the actuator into the position only with the weight of
the actuator itself.
11. Fix the actuator over the valve flange/bracket with the
connection bolts.
12. Tighten the connection bolts at the correct tightening tor-
que as per ISO 5211.
WARNING
!

5-4 EB AT-RP-4GU EN
Mounting and assembly

EB AT-RP-4GU EN 6-1
Start-up
6 Start-up
The work described in this section is only to be performed by
fully trained and qualified personnel.
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 work position.
ÎUse suitable silencers and vent plugs.
ÎWear eye and hearing protection when working near the
actuator.
WARNING
!
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 state.
ÎImmediately renew damaged, missing or incorrect name-
plates or labels.
Verify the compatibility and connect the actuator to the pres-
sure supply line and/or to the control system, if any, with fit-
tings and pipes as per actuator model and plant specifica-
tions.
WARNING
!

6-2 EB AT-RP-4GU EN
Start-up