Air Torque Upgrade Series Operating and maintenance manual

IMAT 4thGU-E ISSUE: 05/11
INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTION
MANUAL FOR 4TH GENERATION Upgrade Series ACTUATORS
For AIR TORQUE ACTUATORS Model/Type:
“AT045U” ➛ ”AT801U”
Double acti g “D” a d Spri g retur “S”
“90°” ➛ “180° Stroke”
GB

IMAT 4thGU-E
GB
CO TE TS
1) GE ERAL ......................................................................................... pag. 3
2) WAR I G ......................................................................................... pag. 3
3) WORKI G CO DITIO S A D TECH ICAL DATA ....................................... pag. 3
4) OPERATI G FU CTIO A D DIRECTIO OF ROTATIO ............................ pag. 4
5) I STALLATIO I STRUCTIO S ............................................................. pag. 4
6) MAI TE A CE I STRUCTIO S ............................................................ pag. 5
7) STORAGE I STRUCTIO S ................................................................... pag. 11
8) LIFTI G A D HA DLI G ..................................................................... pag. 11

1) GE ERAL
This instruction manual contains important information
regarding the installation, operation, maintenance and
storage for AIR TORQUE rack and pinion pneumatic actuators.
Please read these instructions carefully and keep them
for future reference. It is important that the use and
maintenance of the actuator is made only by properly
trained personnel.
2) WAR I G
• Do not operate the actuator using inflammable,
oxidizing, corrosive, explosive or unstable gases
or liquids (use only not dangerous fluids - group 2
according to 97/26/EC directive). Moreover, for
actuators installed in potentially explosive zones,
make sure that the internal parts of the actuator do
not come into contact with the external atmosphere.
• Referring to the Machinery Directive 2006/46/EC,
the actuators can be classified as “PARTLY
COMPLETED MACHI ERY” (see the DECLARATIO
OF I CORPORATIO ). Therefore the actuator can
not put into service until the machinery and/or the
system, where the actuator is incorporated, will be
declared in compliance with the requirements of the
Directive 2006/42/EC.
• Air Torque actuators are designed, produced and
classified according to the ATEX Directive 94/9/EC
(see actuator label and safety instructions). The use
of the actuators in potential explosive atmosphere
zones has to comply with the ATEX classification
indicated on the actuator label and according to the
ATEX safety instructions.
• The use, the installation and the maintenance of
the Air Torque actuators must be made by adequately
trained personnel. For the use, installation and
maintenance of Air Torque actuators it is recom-
mended to comply to the safety notice and to
use proper equipment to protect health and prevent
accidents.
• It is important that the actuator is used only within
the working limits indicated in the technical specifi-
cations.
• Do not operate the actuator over temperature limits:
this could damage internal and external components
(disassembly of spring return actuator may become
dangerous).
• Do not operate the actuator over pressure limits: this
could damage internal parts as well as cause damage
to the housing and end-caps.
• Do not use the actuator in corrosive environments
with incorrect protection: this could damage the
internal and external parts.
• Do not disassemble individual spring cartridges, this
may result in personal injury. If maintenance to
springs is necessary, send them to AIR TORQUE.
• Close and disconnect all air supply lines and make
sure that air connections are vented during mainte-
nance and installation on valve.
• Do not disassemble the actuator or remove end
caps while the actuator is pressurized.
• The 4TH GE ERATIO Upgrade Series actuators are
designed to be used only on valves.
• Before installing the actuator onto the valve make
sure that the rotation direction and the position
indicator are in the correct position.
• If the actuator is incorporated in a system or used
within safety devices or circuits, the customer shall
ensure that the national and local safety laws and
regulations are observed.
3) WORKI G CO DITIO S A D TECH ICAL DATA
• Operating media:
Dry or lubricated air or inert gases, provided that they
are compatible with the actuator internal parts and
lubricant. The operating media must have a dew point
equal to –20°C (-4°F) or at least 10°C below the ambient
temperature. The maximum particle size contained into
the operating media must not exceed 30 µm.
• Supply pressure:
The maximum supply pressure is 8 bar (116 Psi), only
for AT801U it is 7 bar (101,5 Psi).
For double acting and spring return actuators the working
pressure is from 2.5 bar (36 Psi) to 8 bar (116 Psi).
• Operating temperature:
==> “Standard” actuators from -40°C (-40°F) to +80°C
(+176°F)
==> Actuators for high temperature “HT” from -15°C
(+5°F) to +150°C (+300°F)
==> Actuators for extreme low temperature “LLT” from
-55°C (-67°F) to + 80°C (+176°F)
Caution: for low and high temperature service, special
grease and special components are required. Please
contact AIR TORQUE. Working at high or low temperature
can affect the life and the output torque of the actuator.
• Operating time (see technical data sheet):
Caution: the operating time depends on several factors
such as supply pressure, supply system capacity (pipe
diameter, flow capacity of pneumatic accessories), valve
type, valve torque and figures, applied safety factor,
cycle frequency, temperature, etc.
• Rotation and stroke adjustment (see technical data
sheet):
For standard actuators (90° rotation), 120° actuators
(120° rotation), 135° actuators (135° rotation) and 180°
actuators (180° rotation).
Stroke adjustment at 0°(closed pistons): +15°max/ - 5°.
Stroke adjustment at 90°, 120°, 135° and 180°(open
pistons): +5°/-15°max. For actuator AT045U the stroke
adjustment at 90° (open pistons) is available only on
request.
• ubrication:
The actuators are factory lubricated for the life of the
actuator in normal working conditions.
The standard lubricant type GSTD is suitable for use
from -40°C (-40°F) to +80°C (+176°F).
For extreme low temperature ( T) and high temperature
(HT) service, special grease is required: please contact
Air Torque.
• Construction: rack and pinion actuator design suitable
for both indoor or outdoor installations.
• Protection and corrosion resistance:
All the actuators are supplied with corrosion protection
for normal environments. For corrosion resistance of the
different types of protection see technical data sheet.
Before installing the actuator in aggressive environment,
ensure that the selected protection level is suitable.
IMAT 4thGU-E
3
GB

• Actuator designation and marking (see technical data
sheets):
The actuator type, size, operating pressure, output
torque, direction of rotation, spring action, operating
temperature and type of connections/interfaces are
determined by designation.
• All AIR TORQUE actuators are supplied with an identifi-
cation label showing the serial number and all necessary
information on use, service, operation and product
designation. Where applicable, the label indicates the
classification according to ATEX Directive 94/9/EC.
4) OPERATI G FU CTIO A D DIRECTIO OF
ROTATIO
The actuator is a pneumatic device for remote opera-
tion of industrial valves. The operation (90°,120°,135° or
180° rotation) may be activated by different methods:
• Direct mounting of solenoid valve (5/2 for double acting,
3/2 for spring return) to pressure connections 2 and 4,
connected to supply and control lines.
• Screwed connection (to pressure connections 2 and 4)
with air lines from separate control cabinet.
The standard rotation (when port 4 is pressurized or
for spring action) is clockwise to close. When port 2 is
pressurized, counter-clockwise rotation is obtained.
Air Torque actuators can be supplied with different types
of assembly/rotation direction depending on the type of
required operation and/or installation, see technical data
sheets.
5) ACTUATOR I STALLATIO I STRUCTIO S
The Air Torque actuator is a pneumatic device for the remote
operation of industrial valves. The actuator will operate through
90°,120°,135° and 180° rotation permitting the opening and
closing of many types of valves up to 180° rotation.
All the necessary technical information to install the actuator
correctly and safely onto a valve i.e.:
Dimensions, Output torque, Supply pressure, Air volume,
Stroke adjustment, Operating time, Operating temperature,
Direction of rotation and Weight is stated clearly on the
Actuator label, in the catalogue and technical data sheets.
Please read all technical information before proceeding with
the actuator installation.
5.1) Important safety notice!
• For safety reasons, the actuator must not be pressurized
at any time during installation as injury may result.
• The utmost cleanliness is required during air supply
connection to the actuator i.e. the connecting pipe
thread, fittings and seals must be clean and dirt-free.
• When fitting accessories onto the actuators, assemble
them in such a way that the emergency control of the
solenoid valve and the top of the drive shaft are easily
accessible, should emergency manual operations be required.
• Before fitting onto the valve, make sure that the actuator/
valve are correctly orientated, depending upon which
direction of rotation is required.
• For spring return actuators, avoid that dangerous and/or
corrosive substances in the working environment enter
into the external chambers by using adequate filters
and/or solenoid valves.
IMAT 4thGU-E
4
GB
DOUBLE ACTI G OPERATIO FU CTIO
(STA DARD ROTATIO TYPE “ST”) TOP VIEW
Air supplied to port 2 forces the pistons towards the actuator end caps.
A counter-clockwise rotation is achieved.
Exhaust air exits from Port 4.
Air supplied to Port 4 forces the pistons inward.
A clockwise rotation is achieved.
Exhaust air exits from Port 2.
SI GLE ACTI G OPERATIO FU CTIO
(STA DARD ROTATIO TYPE “ST”) TOP VIEW
Air supplied to Port “2” forces the pistons toward the actuator end caps,
compressing the springs.
A counter-clockwise rotation is achieved. Exhaust air exits from Port 4.
The loss of air pressure (air or electric failure) at Port “2” allows the springs
to force the pistons inward.
A clockwise rotation is achieved.
Exhaust air exits from Port 2.

Tightening torque table:
→
→
M.. Nm
M5 5 6
M6 10 11
M8 23 25
M10 48 52
M12 82 86
M14 132 138
M16 200 210
M20 390 410
M24 675 705
M30 1340 1400
→
→
→
→
→
→
→
→
5
• Remove plugs from actuator air connections during
installation and operation. Protect the air connections of
actuators not being used immediately.
5.2) Interfaces for actuator control and connections, figure A:
5.3) Assembly of accessories: solenoid valves and
switchboxes, figure B:
• Solenoid valve mounting:
Before mounting a solenoid valve, ensure that the
actuator is in its normal position (closed position) with
pistons inwards.
For standard rotation type “ST” (clockwise to close)
assembly: the groove on the drive shaft or on the position
indicator 2 must be horizontal to the longitudinal axis of
the actuator in closed position.
Fit the solenoid valve 4 onto the actuator 3 using the
provided screws (max. tightening torque see table).
• Switchbox mounting:
Fit the switchbox and bracket 1 onto the actuator 3 using
four provided screws (max. tightening torque see table).
5.4) Assembly of valve figure C:
Before proceeding with the assembly of the actuator onto
the valve, be sure that the actuator operates in the desired
direction of rotation when pressurised and both actuator/
valve are in the correct position.
Important: when using a spring return actuator for a fail
safe operation, ensure that when air or electricity failure
occurs the direction of rotation is correct for your application.
Fit the actuator 3 onto the valve 5. It is possible to assemble
the valve onto the actuator in two ways:
• Direct-mount: fit the stem of the valve 5 directly into the
female connection of the actuator 3 and bolt together
through the valve ISO pad (max. tightening torque see table).
• Bracket-mount: mounting with a bracket 6 and coupling
7, the bracket is bolted to the actuator / valve to join
them together and the coupling is used to connect the
actuator output drive to the valve stem (max. tightening
torque see table).
6) MAI TE A CE I STRUCTIO
With the information given below, AIR TORQUE provides
the end user with all the required information necessary
for maintenance. Under normal conditions, the actuator
requires only periodic observation to ensure proper operation.
Maintenance (disassembly, maintenance and rebuilding)
of AIR TORQUE actuators is allowed only to AIR TORQUE
personnel or properly instructed personnel. In case of
controversy the product guarantee will expire!
Spare kits for maintenace are available to replace all
seals and bearings (soft parts indicated into the table),
that may be necessary between 300.000 and 1.000.000
cycles depending on operating and environmental
conditions and actuator size.
IMAT 4thGU-E GB
Fig. A
Fig. B
Fig. C

IMAT 4thGU-E
GB
6.1) DRAWI G WITH ITEMIZED COMPO E TS A D RECOMME DED SPARE PARTS
6
Model Ex1 mm Ex2 mm d mm
AT045U / 8 13
AT051U 10 8 14
AT101U 10 10 16
AT201U 13 10 22
AT251U 13 10 25
AT301U 17 13 26
AT351U 19 13 36
AT401U 19 17 38
AT451U 22 17 45
AT501U 22 19 48
AT551U 24 19 52
AT601U 30 22 58
AT651U 30 24 68
AT701U 36 22 80
AT751U 46 24 85
AT801U 46 24 90
60.1

7
IMAT 4thGU-E GB
* Suggested SPARE PARTS for maintenance
otes: A) 12 Pcs. for models AT701U / AT751U, 16 Pcs. for models AT801U
N
OI
TP
IRCSED TRAP
E
T
O
N
Y
T
.
Q
T
I
NU°
N
T
RAP
)
t
n
e
m
e
g
n
a
rr
a
p
otS
( M
AC
-
I
T
C
OU
5
4
0
TA
r
o
f
A
N
1
10
WERCS
PAC
P
O
TSU
5
4
0
TA
r
o
f
AN2
2
0
REHSAWU
5
4
0
TA
r
o
f
AN2
3
0
)w
e
rcs p
otS
( TUNU
5
4
0
TA
r
o
fAN2
4
0
05* )
k
c
a
b
n
ot
s
iP
(
GN
IRAEB
2
06* ) p
o
t
n
oi
n
iP
(
GN
I
RAEB
1
07* )
m
o
tt
o
b n
oi
n
iP
(
GN
IRAEB
1
08* ) n
oi
niP( GNI
RA
EB TSUR
H
T
U
5
4
0
TA
l
e
d
o
m
r
of
.
scP 1
2
09* GU
LPU
1
0
8
TA
r
o
fA
N
2
09.1* )U 1
0
8TA
r
o
F
(
GN
IR"
O"
2
)
n
oin
iP(
REHSAW
TS
URH
T
1
0
1
11* )
w
er
c
s p
o
tS
(
GN
IR
"
O"U
5
4
0
TA
r
o
f
A
N
2
EDIU
G
N
O
TS
IPU
5
4
0
TA
r
of
AN2
2
1
13 8/12/16 (A) )pa c
dnE(WERCS
PAC
14* )pa c
d
nE(GNIR"O"
2
15* ) d
a
e
h
notsiP
(
GN
IRAEB
2
16* )no
tsiP
(
GN
IR
"
O"
2
17 min.5/max.12 for AT101U ÷
÷
÷
÷
AT801U )egdirt
r
aC
(
GN
IRPS
NA for AT101U AT801U
17.1
max. 2 for AT045U
max. 4 for AT051U
SPRING (For AT045U
17.2 NA for AT101U AT801U SPRING (For AT045U
17.3 NA for AT101U AT801U SPRING (For AT045U
÷
÷
÷
AT051U)
AT051U)
AT051U)
)
n
oiniP(P
I
LCG
N
IRPS
1
81
19 1 POSITION INDICATOR (For AT045U
AT101U)
GN
IR
DE
TAUDAR
G1
0
.
9
1
19.11
NA for AT045U ÷ AT101U ROTACIDN
I
NO
I
TISOP
19.51
NA for AT045U ÷ AT101U R
O
TPADA
POT
19.62
NA for AT045U
only for AT045U, AT751U
÷ AT101U )
r
o
t
p
a
dA
po
T( WE
RCS
T
EK
C
OS .XE
H
20* )mottob
n
oiniP
(
GN
I
R"O"1
21* ) p
o
t
n
oi
n
iP
(
G
NI
R"
O
"1
PACD
NE
2
0
3
)
r
otaci
d
nI
(
WERCSPA
C
1
9
3
N
O
TSIP2
0
4
LE
BAL NOI
TAC
IFITNED
I
ROTAU
T
CA114
LEBA
L
PAC
DNE
2
2
4
)
ts
e
u
q
er
n
oyl
n
O
(
T
O
G
IPS
134
YDOB1
0
5
TFAHSEVI
R
D106
T
FAHSEV
IRD LAR
GE
TN
I
"
F"dna"E"l
ev
el
.c
e
t
orprof
yl
n
o
11
.
0
6
TRESN
ICITSA
LP
156

Fig. 05
Fig. 04
IMAT 4thGU-E
8
GB
Fig. 03
Fig. 01
Fig. 02
6.2) DISASSEMBLY
When disassembly of actuator is required for maintenance,
firstly remove the actuator from the valve. Before
performing any disassembly operations it is important
to verify that the actuator is not pressurised.
Always use caution and double check that the ports 2 and
4 are vented and are free from any accessory and/or
device. When the actuator is a spring return unit, make
sure that the actuator is in the failed position and with
pistons completely inwards before disassembling.
A) Removal of position indicator and graduated ring
(Part ° 19,19.0,19.1), figure 01:
• Remove cap screw (39) if
fitted.
• ift position indicator (19
or 19.1) off shaft, it may
be necessary to pry gently
with a screwdriver.
• ift, if necessary, the
graduated ring (19.0)
off the body, it may be
necessary to pry gently
with a screwdriver.
B) Removal of stop cap screws (Part ° 02), figure 02:
• Remove both stop cap
screws together with nut
(04) and washer (03).
• R e m o v e s t o p s c r e w
o-rings (11) and discard if
replacing all soft parts.
C) End caps disassembly (Part ° 30), figure 03:
• End caps disassembly for spring return actuators
(disassemble one end cap at a time).
Unscrew the end cap bolts (13) in the sequence shown in
figure 03, until the end-caps are free from springs force
(for AT045U and AT051U 20-23 turns of the screws, for
AT101U to AT801U 4-5 turns of the screws).
Then completely unscrew the screws and remove the
end-cap and the springs.
If there is still force on the end-caps after unscrewing as
indicated above, this may indicate that spring cartridge is
damaged or that the pistons are not completely closed,
so any further disassembly should be discontinued.
Further disassembly of the end caps may result in injury.
• End caps disassembly for double acting actuators
(disassemble one end cap at a time)
Unscrew the end cap bolts (13) in the sequence shown in
figure 03, until the screws are completely unscrewed and
the end caps are free.
• Remove the o-rings (14) using a screwdriver. Discard soft
parts if replacing.
• Only for actuators with adjustment 50% or 100%, remove
the nut 04R, the washers 03R and o-rings 11R and
discard soft parts if replacing.
D) Pistons disassembly (Part ° 40), figure 04:
• Holding the body (50) in a vice or similar device, rotate the
drive shaft (60) until the pistons (40) are released. Caution:
air pressure should not be used to remove the pistons from
the body.
• Remove o-rings (16) using a screwdriver. Remove the
piston back (05) and piston head (15) bearings.
• Discard bearings when replacing all soft components.
E) Drive shaft disassembly (Part ° 60), figure 05:
• If necessary, remove the graduated ring (19.0) with a
screwdriver, remove the spring clip (18) using snap-ring
pliers or screwdriver for spiral rings, remove the thrust
washer (10) and the external thrust bearing (08). Apply
downward force to top of drive shaft (60), until it is partially
out of the bottom of the body when it is possible to
remove the internal thrust bearing (08) and the octi-cam
(01), then push the pinion (60) completely out of the
body. If pinion is not easily removed, gently tap the top
of the shaft with a plastic hammer.

Fig. 06 Fig. 08 Fig. 09
9
IMAT 4thGU-E GB
Fig. 10
• Remove top (06) and bottom (07) pinion bearings and top
(20) and bottom (21) pinion o-rings.
• Discard bearings (06) and (07), internal and external thrust
washer (08) and o-rings (20) and (21) if replacing the soft
components.
All the components disassembled and not replaced will
have to be cleaned and inspected for wear and before
reassembly, if necessary, also replace the plugs (09).
6.3) ASSEMBLY:
Prior to assembly, ensure that:
• all the components are perfectly clean and in good
condition.
• the spare parts and the lubricant used are suitable for the
operating temperature of the actuator (see Air Torque
technical data sheets).
• Note: The lubricants suitable for the various operating
temperatures (Standard, HT and T actuators) are
available in Air Torque.
Only for “standard” actuators, for temperature from -40°C
(-40°F) to +80°C (+176°F), it is possible to use lubricant
Dow Corning type Molykote®G-2003.
A) Drive shaft assembly (Part ° 60), figures 06, 07
and 07A:
• Install top (06) and
bottom (07) bearings,
grease and insert the
bottom (20) and top
(21) pinion o-rings
onto the shaft.
• Grease the outside
surface of the drive
shaft as shown in figure
06.
• Insert partially the drive shaft (60) in the body (50),
install octi-cam (01) in the correct position (for standard
assembly or for lock-out) as shown in figures 07 and
07A, related to the bottom and top of the drive shaft and
the rotation of the actuator when energised. Install the
internal thrust bearing (08). Insert completely the drive
shaft in the body.
• Fit external thrust bearing (08), thrust washer (10) and then
external spring clip (18) using snap ring pliers or screwdriver
for spiral rings.
B) Pistons assembly (Part ° 40), figures 08, 09, 10 and 11:
• Grease and install o-rings (16), piston back (05) and
piston head (15) bearings.
• Grease the internal surface of the body (50) and the
piston (40) rack teeth.
• Insert the female connection of the drive shaft (60) in a
properly fixed coupling.
• Ensure that the octi-cam is in the right position as shown
in figure 09.
• For standard rotation assembly type “ST” (clockwise to
close), rotate the body (50) about 40-45° clockwise from
top view, as shown in figure 10.
• Insert and press the two pistons (40) simultaneously
inside the body (50) until the pistons are engaged, then
rotate the body anticlockwise from top view until the
stroke is completed.
• Ensure that with pistons completely closed, the rotation
obtained referred to the axis of the body is about over 0°
Fig. 07A
Fig. 07

for models AT051U→AT801U (0,5° over 0° for AT045U)
and that the dimension “A” on both sides is the same as
shown in figure 11.
C) End cap (Part ° 30) assembly, figures 12, 13 and 14:
• Assemble one end cap at a time.
• ubricate the body.
• For spring return actuators, insert the springs in each
end cap according to the desired configuration, as shown
in figure 12 and related tables. For models
AT101U→AT801U insert spring cartridges as shown in
figure 13.
SPRI G SET CO FIGURATIO
AT045U configuration:
AT051U configuration:
• Fit end cap o-ring seal (14) into the groove on both end caps.
Fig. 12
Fig. 11
IMAT 4thGU-E
10
GB
Spring Set
S1-1
S1-2
S2-2
S2-3
S3-3
Side B
AT045U
Spring type
1 (green)
1 (green)
2 (red)
2 (red)
3 (black)
Side A
AT045U
Spring type
1 (green)
2 (red)
2 (red)
3 (black)
3 (black)
Spring
Set
S1
S2
S3
S4
S5
S6
S7
S8
AT051U
Internal
Spring type
1(green)
------------
------------
------------
------------
1 (green)
1 (green)
1 (green)
AT051U
External
Spring type
------------
2 (black)
2 (black)
3 (red)
3 (red)
2 (black)
2 (black)
3 (red)
AT051U
Internal
Spring type
------------
------------
------------
------------
1 (green)
1 (green)
1 (green)
1 (green)
AT051U
External
Spring type
2 (black)
2 (black)
3 (red)
3 (red)
2 (black)
2 (black)
3 (red)
3 (red)
Side B Side A
Fig. 14
Fig. 13