APV TORQTURN RP Series Instruction manual

www.australianpipelinevalve.com.au
INSTALLATION, OPERATION & MAINTENANCE MANUAL
QUARTER TURN RACK &
PINION ACTUATORS
PNEUMATIC
RP SERIES
AS 4629

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AUSTRALIAN PIPELINE VALVE BRAND RANGE -CATALOGUES
APV FAMILY OF BRANDS RANGE - CATALOGUES
COMPLETE
PRODUCT LINE
“Australian Pipeline Valve
produces isolation,
control and flow reversal
protection products for
severe and critical service
media in utility, steam,
pipelines, oil & gas
and process industries.
APV valves and pipeline
products form the most
competitive portfolio
in the market.”
Oilfield Products
Valves & Wellheads
Gate, Globe & Check
Valves - Forged Steel
Plug Valves Lubricated,
Sleeved & Lined
Gate, Globe & Check
Valves - Cast Steel
Diamond Gear
Gearboxes
Flowturn Gate, Globe
& Check Valves
Flowturn
Instrument Valves
Flowturn Ball Valves
Multiway & Deadman
Flowturn Strainers
& Sight Glasses
Supercheck
Wafer Check Valves
Superseal
Butterfly Valves
Steamco
Steam Valves
Superseal
Industrial Ball Valves
TwinLok Tube Fittings Uniflo Check ValvesTorqturn Actuators
Ball Valves Floating
& Trunnion Mounted
Ball Valves
Floating Small Bore
Ball Valves
Special Service
Product Brochure
Contact us for your local stockist/distributor

INDEX
ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 1
Overview 2-4
Safety Information 4-5
1.0 Warning 5
2.0 Working Conditions and Technical Data 5-6
3.0 Storage and Handling 7
4.0 Installation 7-12
4.1 Installation, tube & fittings 7-8
4.2 Operation 8
4.3 Manual over-ride operation 8
4.4 Actuator sizing 9-11
4.5 Actuator installation instructions 11-12
5.0 Commissioning 13
6.0 Maintenance 13-18
6.1 Disassembly 14-15
6.2 Assembly 15-17
6.3 Storage 18
7.0 Operation 18-22
7.1 Operating function and direction of rotation 18-19
7.2 Operating specifications 19-22
8.0 Spare Parts Supply 23
9.0 Design Features 24
Appendix A - Parts & Materials RP50 ~ RP400 25
Appendix B - Dimensions 26-27

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual2
OVERVIEW
This instruction manual is for rack & pinion pneumatic actuators. The RP Series rack &
pinion pneumatic actuator has been designed, developed and tested incorporating the
latest technology and materials available, with some innovative design features. As a
result of this product research we have obtained a high grade product with the following
characteristics:
• Reliability
• High performance
• Wider product range permitting a more economical sizing
selection.
• Innovative and patented universal drive shaft and multifunction
position indicator
• Full compliance with latest worldwide specifications
• A wide selection of highest levels of corrosion protection
technology
• Aesthetically compact and modern style with no external cavities
to avoid deposit build up.
Product Code
Chamber 50, 100
Acting Way
“DA” double acting (DA)
“SR” Single acting (spring return)
Operating temperature
Normal temperature NT (Slightly) temperature-20°C~+80°C
Low temperature LT temperature -40°C~+80°C
High temperature HT temperature -15°C~+150°C
Operating media:
Dry or lubricated air or inert /non-corrosive gases on condition that
they are compatible with internal actuator parts and lubricant. The
operating media must have a dew point equal to -20°C (-40°F) or at
least 10°C below the ambient temperature. The maximum particle size
must not exceed 30 μm
Supplying Pressure:
For Double Acting and spring Return actuators the maximum supply
pressure is 8 Bar (116PSI). Minimum supply pressure is 2.5 Bar (36PSI)
Operating Temperature:
• Standard product from -20°C (-4°F) to +80°C (+176°F)
• Low temperature LT actuator with VMQ ‘O’ Rings from -40°C (-40°F)
RP
AS 4629

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 3
to +80°C (+176°F)
• High temperature HT actuator with FPM ‘O’ Rings from - 15°C (+5°F) to +150°C (+302°F)
Stroke
There is ±5° adjustable angle at the position of open and end of
close.
Operating Time:
See Technical Data Sheet
Lubrication:
Actuators are factory lubricated for the life under normal operating
conditions.
The standard lubricant is suitable for use from -20°C (-4°C) +80°C
(+176°F)
Construction:
Twin piston rack and pinion actuator design suitable for both indoor and outdoor installation.
Protection and Corrosion Resistance:
Actuators are supplied with corrosion protections for normal environments. For severe duties select from
the protection level table or contact APV.
RESPONSIBILITY FOR VALVE & ACTUATOR APPLICATION
The User is responsible for ordering the correct valves & actuators. The user is responsible for ensuring
APV Valves & Actuators are selected and installed in conformance with the current pressure rating and
design temperature requirements. Prior to installation, the nameplates and drawings should be checked
for proper identification to ensure the valve & actuator is of the proper type, material and is of a suitable
pressure class and temperature rating to satisfy the requirements of the service application.
Note
We recommend that this entire document be read prior to proceeding with any
installation. Do not attempt to repair this actuator, send it to APV or an APV
approved repair facility. Australian Pipeline Valve and it’s parent company take no
responsibility for damage or injury to people, property or equipment. It is the sole
responsibility of the user to ensure only specially trained actuator repair experts
perform repairs under the supervision of a qualified supervisor.
For low and high temperature service. Special lubricant is required. Please contact
APV for each application. High and low temperature will vary changing the output
torque of the actuator.

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual4
RECEIVING INSPECTION AND HANDLING
Valves & Actuators should be inspected upon receipt to ensure:
- Conformance with all purchase order requirements.
- Correct type, rating, size, body and materials and end connections.
- Any damage caused during shipping.
SAFETY INFORMATION
The following general safety information should be taken in account in addition to the specific warnings
and cautions specified in this manual. They are recommended precautions that must be understood and
applied during operation and maintenance of the equipment covered in this I.O.M.
This manual provides instructions for storing, general servicing, installation and removal of actuators.
APV and it’s resellers refuses any liability for damage to people, property or plant as well as loss of
production and loss of income under any circumstances but especially if caused by: Incorrect installation
Do not use valves & actuators in applications where either the pressure or
temperature is higher than the allowable working values. Also, actuators should not
be used in service media if not compatible with the material of construction, as this
will cause chemical attacks, leakage and failure.
The User is advised that specifying an incorrect valve or actuator for the application
may result in injuries or property damage. Selecting the correct valve and actuator
type, rating, material and connections, in conformance with the required
performance requirements is important for proper application and is the sole
responsibility of the user.
To avoid injury, never attempt disassembly while there are pressures either
upstream or downstream. Furthermore, actuators with spring packs can rapidly
close or open the valve on failure of air supply with extreme force. Also, entrapped
dangerous fluids can be rapidly expelled, this can still happen when working on the
actuated valve once it is removed from the line.
Spring packs are factory sealed and can be dangerous. Don not attempt to
disassemble spring pack, send to an APV approved repairer.

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 5
or utilisation of the actuator or if the actuator installed is not fit for intended purpose. It is the sole
responsibility of the user to ensure the valve type and materials are correctly specified.
1.0 WARNING
• It is important that the actuator is used only within the working limits indicated in the technical
specifications.
• 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 Torqturn.
• Close and disconnect all air supply lines and make sure that air connections are vented during
maintenance and installation on valve.
• Do not disassemble the actuator or remove end caps while the actuator is pressurised.
• Torqturn 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.
2.0 WORKING CONDITIONS
AND TECHNICAL DATA
Operating media: -
Dry or lubricated air or inert gases, provided that they are compatible with the actuator’s 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 7 or 8 bar as an indication.
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).

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual6
Rotation and stroke adjustment: -
The stroke for actuators is as follows:
Standard construction: 90° rotation with stroke adjustment at 0° and 90° (+ or - 4°)
Type 120° stroke: 120° rotation with stroke adjustment at 0° and 120° (+or-4°)
Type 180° stroke: 180° rotation with stroke adjustment at 0° and 180° (+or-4°)
Lubrication: -
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 (LLT) and high temperature (HT) service, special grease is required: please
contact us.
Construction: -
Rack & pinion actuator design suitable for both indoor and outdoor installations.
Water Ingress Protected
O-Rings are fitted on body caps and all joints. This ensures an effective seal to prevent ingress of water.
ISO Valve Mounting
The RP Series Actuators interface meets ISO standard, and meets the dimensional requirements of ISO defined
for each torque range.
Standardised Interface
The shaft driven accessory interface conforms to NAMUR and are identical on all RP Series, allowing
standardisation of accessory mounting hardware and installation practices.
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.
For low and high temperature service, special grease and special components are
required. Please contact us. Working at high or low temperature can affect the life
and the output torque of the actuator.
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 figure, applied safety factor, cycle frequency, temperature, etc.

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual 7
3.0 STORAGE & HANDLING
To ensure the seals remain flexible, and the actuator itself free moving during times of storage or
intermediate services, air or nitrogen pressure should be cycled through the actuator at a minimum of
three (3) times a month. Indoor storage is recommended for actuators in an environment where resilient
seals can be preserved. To help keep out foreign particles and moisture; cylinder ports, control valve
parts and body parts should be kept sealed.
4.0 INSTALLATION
Remove any existing manual gearing from the valve and move into the same position as the actuator
(either both open or both closed). Inspect the stem adapter, valve stem, valve and actuator mounting
surfaces for proper direction and any inconsistencies. In cases where the valve includes a lubricator
fitting, this should be removed and a lubricator extension nipple installed. Refit the lubricator fitting into
the extension nipple. If furnished loose, install the bushing for the stem adaptor over the valve stem,
correctly position the set screw and mount actuator over bushing (parallel to the pipe). All nuts and bolts
should be fastened evenly, ensuring the actuator is centred on the valve stem. Note: whilst the mounting
bolts are loose the actuator can be cycled to help centre itself.
There are many actuator and valve variations, therefore it’s not practical to list instructions for all kinds.
The design of the mountings are kept simple for ease of installation. Actuators are factory shipped with
the travel stops regulated for 90° revolution. However once the actuator is installed on the valve it will
still require further stop adjustments. Reference should be made back to the valve manufacturer’s
recommendations for particular requirements. For valves that contain internal stops, the actuator must be
adjusted at the same points. The “stopping” should be performed by the actuator itself. For valve without
internal stops, adjust the actuator to the full open setting. Using this as a reference point, position the
valve closed and adjust to the specifications recommended by the valve manufacturer for total rotation.
High strength grades of steel like 410, F6, F51, 303, S31803, XM-19, 4140 and 17-4 PH are preferred for
stem adaptors.
4.1 INSTALLATION, TUBE & FITTINGS
a. Use brass or 316 stainless steel tubing, try to avoid vibration, secure piping to avoid leakage. In case of
any vibration or impact during transportation, check tubing and fittings for leakage.
Avoid high temperature, low temperature, high moisture and corrosive applications
unless the actuator has been designed for the application.

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual8
b. Different pneumatic actuators have different air inlet sizes from 3/8” to 2” NPT. Using a smaller size
piping (or reduce orifice valves, solenoids, etc.) will reduce opening speeds. Table 1 - Air Inlet sizes
c. To ensure quick operation of the actuator, do not use a smaller tube or fitting size than the inlet size
provided. Also valves with reduced orifices will reduce air flow.
d. Operating media is filtered dry air, if dew point is over -15°C use a dryer.
4.2 OPERATION
4.2.1 Auto-Operation on/off
On/off operation for pneumatic & hydraulic actuated valve:
A) The valve is open when solenoid valve is energised (fail close type)
B) The valve is close when solenoid valve is de-energised (fail close type)
C) The valve is close when solenoid valve is energised (fail open type)
D) The valve is open when solenoid valve is de-energised (fail open type)
4.2.2 Modulating-Control Operation
Modulating control pneumatic & hydraulic actuated control valve:
a) Input 4~20mA electric signals to the electro-pneumatic positioner, valve’s open degree is
proportionally regulated in 0°~90° stroke through different current size the positioner achieves.
b) Input 0.02~0.1MPa air signals to the pneumatic-pneumatic positioner, valve’s open degree is
proportionally regulated on 0‚~90° stroke through different air pressures the positioner supplies.
4.3 MANUAL OVER-RIDE OPERATION
Declutchable Worm Gear Manual Over-ride - DA Actuators
Double acting actuators are optionally available with a
declutchable worm gear manual over-ride (refer Figure 1 & 2).
Manual operating steps: firstly open the equalising valve on the
pneumatic actuator, draw out the pull pin of the gear operator
with one hand, simultaneously, use another hand to
turn the clutch lever counter clockwise, until the worm and the
worm gear engages, then release the pull pin. After the pin has
returned into the eccentric sleeve, you can then operate the
valve manually. Turn the handwheel clockwise to close the
valve, turn the handwheel counter clockwise to open the valve.
To return to automatic mode, first draw out the pull pin in the
gear operator with one hand, simultaneously use another hand
to turn the clutch lever clockwise until the worm and worm
gear
engages, then release the pull pin. After the pin has returned
into the eccentric sleeve, close the equalising valve.
Pneumatic Actuator
Open
Close
Manual Override
Figure 1
Lock Pin
Clutch Lever
Figure 2

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 9
4.4 ACTUATOR SIZING
4.4.1 General Sizing Rules for Soft Seated Ball Valves
Valve and actuator torque values published are theoretical, however where required APV will perform a
torque test prior to despatch. The real valve torque value can be higher depending upon the following
listed factors as these factors can drastically increase (or decrease) the torque of soft seated ball valves.
These factors will have a similar effect on soft seated butterfly valves. Metal to metal seated ball,
butterfly and plug valves will also be effected but the torque implications will vary.
1) Fluid carrying dust, powder, abrasive particles (+50% to 125%). In extreme cases can be higher. i.e. Up
to 200%.
1a) Slurry, pulp, resins, paste (+50%) can be much higher in some cases.
2) Dry service (Dry Gas) (+30%).
3) High or low temperature (consult us).
4) Infrequent use (+30-50%) *1 - *2.
5) If a higher minimum air supply than used in the calculation is available more torque will be produced
in the air operation phase, (do not exceed maximum air capacity of the actuator).
6) Torque is based on a maximum Delta P for class. If your actual working pressure is lower please
advise as a smaller actuator may be possible.
7) Lubricated service (clean oil or other high lubricity fluid) (+15%).
*1 PTFE/RPTFE seats can require more torque to unseat after a period of time due to it’s fluidity &
‘memory’. For Devlon/Nylon Seat the valve torque is higher and PEEK® is even higher (of course this should
be factored into torque of valve where applicable), however as these are harder materials (especially
PEEK®) infrequent use has a lesser effect on the increase in torque.
*2 Where set fail closed, additional infrequent use safety factor only needs to be applied to spring stroke
torques. Allow additional 50% safety factor if valve is being operated less than once per month.
4.4.2 Actuator Sizing for Ball Valves
Use the following ‘ready reckoner’ rough estimating guide* to calculate the torque values required to
turn a ball valve through it’s 90° travel. Consider torque requirements at these five basic positions:
BTO - Break open torque: the torque required to unseat the closed valve. 100% of the stated torque.
RTO - Opening torque: the torque needed to move the valve to the fully open position. Average 70% of
stated BTO torque*.
ETO - Open breakout torque: the torque required to move the valve from the fully open position. 70% of
All factors shown in section 4.4.1 to 4.4.3 are only estimating guides and are based
more on common smaller sizes valves. It is impossible to accurately estimate the
effect on torque all the below factors will have. However, section 2.5.1 to 2.5.3
provide a rough guide and serve as a warning to ensure users are aware of the
dramatic affect all the below factors can have on torque.

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual10
stated BTO torque*.
ETC - Closing torque: the torque required to reseat a closing valve. 85% of stated BTO torque*.
RTC - Running torque: the torque needed to keep the ball moving through it’s travel. 50% of stated BTO
torque*.
MAST- Maximum stem torque - refer to manufacturer.
*Average guide based on floating ball and smaller size trunnion ball valves. Large trunnion ball valves
have slightly different ratios. Butterfly and plug valves have totally different ratios.
4.4.3 Elements that Effect Soft Seated Ball Valve Operating Torque
The below factors are only for use as a rough estimating guide only and apply to smaller diameter ball
valves. Furthermore, the effects the following factors have will vary for trunnion ball valves, even in
smaller sizes. For trunnion ball valves it is impossible to provide accurate multipliers, however the below
factors will effect all types of soft seated valves in all sizes to a certain degree and should be taken into
account when specifying safety factors.
For a particular size and differential pressure, the torque of soft seated ball valves depend on many
factors. Use the torque multipliers stated below with the selected valve’s stated ‘break’, ‘end to close’
and ‘end to open’ torques as needed for your application.
Seat Material: The friction force or degree of holding force depends on the seat material type.
Fluid Type: Torque values depend on media type. Torque will become higher with dry, gasses or liquids
with solids and lower with oils. Torque multipliers are shown in the table (based on normal
temperatures).
Frequency of Operation: When a valve remains in closed position for extended periods of time, the
breakout torque increases.
Seat Material Seat Type Multiplier
*
1
15% - 25% Glass RPTFE 1.0
Virgin PTFE 0.8
Carbon Graphite RPTFE 1.0
PEEK 2.3
Delrin 2.0
*1
- For floating ball valves up to 175 NM. For larger valves consult us.
Fluid Fluid Type Multiplier
Gas or superheated steam, clean / dry1.2 - 1.3
Viscous fluid 1.4 - 1.6
Liquids containing abrasive solids 1.3 - 2.0* 2
Clean / non-lubricating 1.0
Clean / lubricating 0.8
*2 - Can be higher.
FrequencyFrequency Multiplier
Once per day or greater 1.0
Once per week or greater 1.3
Once per month or greater 1.4
Once per 4 months or greater 1.5
Critical ESD services1.8

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual 11
Temperature Effect: For operating temperature from 80°C to 130°C, use the torque multiplier given. For
0°C to 80°C no temperature multiplier is required. For operating temperatures less
then 0°C and above 140°C consult Australian Pipeline Valve.
The above is an approximate guide only, for estimating purposes.
4.5 ACTUATOR INSTALLATION INSTRUCTIONS
The Torqturn 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 the valve i.e. dimensions, output torque, supply pressure, air volume, stroke adjustment,
operating time and operating temperature.
• For safety reasons, the actuator must not be pressurised at any time during
installation as it may result in injury.
• The utmost cleanliness is required during air supply connection 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 operation 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 dangerous and/or corrosive substances in the
working environment enter into the external chambers by using adequate filters
and/or solenoid valves.
• Remove plugs from actuator air connections during installation and operation.
Protect the air connections of actuators not being used immediately.
Temperature Multiplier = Te mp °C ÷ 100
Ancillaries attachment
Position indicator
Pressure connections
Valve actuator attachment
Figure 3
Interfaces for actuator control and connections

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual12
Solenoid valve mounting
Before mounting a solenoid valve, ensure that the
actuator is in it’s 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 the closed position.
Fit the solenoid valve (4) onto the actuator (3) using the
provided screws (max. tightening torque see Table 1).
Switchbox mounting
Fit the switchbox and bracket (1) onto the actuator (3)
using four screws provided (max. tightening torque see
Table 1).
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.
It is important to note 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
onto the female connection of the actuator (3) and
bolt together through the valve ISO pad (max.
tightening torque see Table 1).
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 1).
Assembly of accessories:
solenoid valves and switchboxes
Figure 4
1
2
3
4
3
5
7
6
Figure 5
Assembly of valve
M. Nm M. Nm
M5 5 - 6 M14 132 - 138
M6 10 - 11 M16 200 - 210
M8 23 - 25 M20 390 - 410
M10 48 - 52 M24 675 - 705
M12 82 - 86 M30 1340 - 1400
Tightening torque Table 1

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual 13
5.0 COMMISSIONING
If the unit has been left in the same position for long periods, the packings and seals may have set. This
means that when the actuator is again operated, possible leakage may come from the piston seals or rod
packings. Cycling the unit several times will activate the packings and seals to work efficiently.
Many factors will effect the rate of operation:
a) how far away it is from the source of pressure
b) the diameter and pressure of the supply line
c) the size of the airline supply valve orifice
d) the torque requirements of the valve
e) the actuator size
f) impurities in the valve stem seat
g) temperature and viscosity of media
As any one of these factors effects the other, a typical operating time is difficult to forecast. However,
operating time can be decreased as follows:
a) larger diameter and higher pressure of the supply line
b) larger airline control valve orifice size
c) high speed exhaust valves
Flow control valves may be used to indicate the flow of exhaust however this will reduce running time.
We do not recommend measuring the incoming source or exhaust flow to great lengths as this may cause
inconsistent operation.
6.0 MAINTENANCE INSTRUCTIONS
The following provides the end user with all the required information
necessary for maintenance. Under normal operating conditions the
actuator requires only periodic observation to ensure proper adjustment.
Rebuilding of the actuators is only permitted by personnel of Australian
Pipeline Valve, or to personnel which are properly instructed. By
contravention the guarantee expires.
Spare kits for maintenance are available to replace
all seals and bearings (soft components listed in
Table 2) that may be necessary between 300,000
and 1,000,000 cycles depending on operating and/
or environment conditions and actuator size.
Spare Parts Components Table 2
Model EX1 mm EX2 mm ø dmm Model EX1 mm EX2 mm ø dmm
50 10 8 14 145 22 17 45
63 10 10 16 160 22 19 48
75 13 10 22 180 24 19 52
88 13 10 25 200 30 22 58
100 17 13 26 240 30 24 68
115 19 13 36 265 36 22 80
125 19 17 38 330 46 24 90

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual14
6.1 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 before disassembling.
6.1.1 Removal of position indicator (Part No. 19), Figure 06
• Remove cap screw (39) if fitted
• Lift position indicator (19) off shaft, it may be necessary to pry gently with a screwdriver.
6.1.2 Removal of stop cap screws (Part No. 02), Figure 07
• Remove both stop cap screws together with nut (04) and washer (03)
• Remove stop screw o-rings (11) and discard if replacing all soft parts.
6.1.3 End caps disassembly (Part No. 30 right and 31 left) for model 180 to 330 the 2 end caps
(30) are symmetric, Figure 08
• Remove cap screw (End cap 13) in the sequence shown in the Figure 08.
• For spring return actuators, always remove spring cartridge
• Remove end cap o-rings (14) and discard if replacing all soft components.
6.1.4 Pistons disassembly (Part No. 40), Figure 09
• Holding the body (50) in a vice or similar device, rotate the drive shaft (60) until the pistons (40) are
released.
When disassembling a spring return actuator, the end cap (30 and 31) should be
loose after unscrewing end cap bolts (13) 4 - 5 turns. If there is still force on the
end cap after 4 -5 turns of the end cap bolts, this may indicate a damaged spring
cartridge and any further disassembly should be discontinued. Further disassembly
of the end caps may result in injury. Return the actuator to Australian Pipeline Valve
for further maintenance.
Figure 06 Figure 07 Figure 08 Figure 09

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual 15
• Remove piston o-rings (16) using a small screwdriver, remove the piston back (05) and piston head (15)
bearings. Discard bearings when replacing all soft components.
6.1.5 Pinion shaft disassembling (Part No. 60), Figure 10
• Remove spring clip (18) carefully, using nap-ring pliers, remove the external
thrust bearing (08) and thrust washer (10).
• Apply downward force to the top of drive shaft (60) until it is partially out of
the bottom of the body when it is possible to remove the octi-cam (01) and
internal thrust bearing (08), then push the pinion (60) completely out of the
bottom of the body. If pinion does not remove freely gently tap the top of the
shaft with a plastic mallet.
• Remove the top and bottom pinion bearings (06) and (07) and top and bottom
pinion o-rings (20 and 21).
• Discard bearings (06) and (07), internal and external thrust washer (08) and o-rings (20) and (21) if
replacing all soft components.
When all components are disassembled, those not being replaced should be properly cleaned and
inspected for wear prior to being greased and re-assembled.
6.2 ASSEMBLY
Prior to assembly, ensure all components are perfectly clean and free from damage. Please see point 3
for recommended lubricants.
6.2.1 Drive shaft assembly (Part No. 60), Figures 11 and 12
• Install top and bottom pinion bearings (06) and (07) and top and bottom
pinion o-rings (20) and (21) onto the shaft.
• Grease the outside surface of the drive shaft (60) in the body (50), install the
octi-cam (01) in the correct position as shown in Figure 12 related to the
bottom and top of the drive shaft and the rotation of the actuator when
Only a trained actuator specialist should attempt any disassembly or conversion.
Actuators can be under high spring loads and are dangerous devices. Valves can be
rapidly slammed shut, possible safety threat. Entrapped dangerous fluid can be
rapidly expelled.
Air pressure should not be used to remove the pistons from the body
Figure 10
Figure 11

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual16
energised and install internal thrust bearing (08). Insert
completely the drive shaft in the body.
• Fit external thrust bearing (08), thrust washer (10) and
then external circlip (18) using snap ring pliers.
6.2.2 Pistons assembly (Part No. 40), Figures 13, 14,
15 and 16
• Install piston o-rings (16), the piston skirt (05) and
piston head (15) bearings.
• Grease the internal surface of the body (50) and the piston (40) rack teeth.
• Hold the body (50) in a horizontal position by inserting the top of the shaft into a
vice or the bottom of the shaft connection into a mal drive fitted in a vice as
shown in Figure 13.
• Ensure that the octi-cam is in the right position as shown in Figure 14.
• For standard rotation assembly (clockwise to close) rotate the body (50) about
40-45° counterclockwise from bottom view or clockwise from top view
depending on which way the shaft has been linked as shown in Figure 15.
• Press the two pistons (40) simultaneously inside the body (50) until the pistons
are engaged and rotate the body clockwise from the bottom view or
counterclockwise from top view until the stroke is complete.
• Ensure that when the pistons are inserted that they both mesh at the same time.
Check fully closed and open positions as shown in Figure 16.
6.2.3 End cap (Part No. 30 right and 31 left) and spring cartridge (17) assembly (for model 180
to 330 the 2 end caps 30 are symmetric), Figures
17, 18 and 19
• Lubricate the body.
• For spring return actuator insert the proper quantity of spring
cartridge according to the pattern shown in Figure 17
(referring to the total number of springs). Insert spring
cartridge (17) as shown in Figure 18.
• Fit end cap o-ring seal (14) into the groove in the end cap, on
both end caps.
Figure 12
Figure 13
Figure 14 Figure 15 Figure 16
Figure 17

ACTUATORS - RP SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 17
• Fit end caps onto the body (50), verifying that the o-ring remains in the groove.
• Insert all the cap screws (13) and tighten each only partially. Complete tightening by following the
sequence indicated in Figure 19.
6.2.4 Assembly of stop cap screws (Part No. 02), and stroke adjustment Figure 20
• Insert on both the stop cap screw (02), the nut (04), the washer (03), and the
o-ring in (11).
• Fit the stop cap screw (02) in the body.
6.2.5 Stroke adjustment for standard rotation actuator (Clockwise to
close)
• 0° (Close) position stroke adjustment with actuator in close position, screw or
unscrew the right (from top view) stop cap screw (02) until the desired stop
position is achieved. Then tighten the stop adjustment nut (04) to lock it in place.
• 90° (open) position stroke adjustment with actuator in open position, screw or
unscrew the left (from top view) stop cap screw (02) until the desired stop
position is achieved, then tighten the stop adjustment nut (04) and lock it in
place.
6.2.6 Assembly of position indicator (Part No. 19 and 39), Figure 21
• Fit position indicator (19) on the shaft verifying that it indicates the correct
actuator position.
• Then fit cap screws (39) where fitted.
Suggested* spare parts for maintenance
Part No Unit QTY Part Description
01 1 Octi-Cam (Stop arrangement)
02 2 Stop Cap Screw
03 2 Washer
04 2 Nut (Stop screw)
05* 2 Bearing (Piston back)
06* 1 Bearing (Piston top)
07* 1 Bearing (Piston bottom)
08* 2 Thrust Bearing (Pinion)
09* 2 Plug
10 1 Thrust Washer (Pinion)
11* 2 O-ring (Stop screw)
12 2 Piston Guide
13 8/12/16(A) Cap Screw (End cap)
14* 2 O-ring (End cap)
15* 2 Bearing (Piston head)
16* 2 O-ring (Piston)
17 min.5 max.12 Spring (Cartridge)
18 1 Spring Clip (Pinion)
19 1 Position Indicator
20* 1 O-ring (Pinion bottom)
21* 1 O-ring (Pinion top)
30(B) 1 Right End Cap
31(B) 1 Left End Cap
39 1 Cap Screw (Indicator)
40 2 Piston
41 1 Actuator Indentication Label
42 2 End Cap Label
43 1 Spigot (Only on request)
50 1 Body
60 1 Drive Shaft
Note (A): 12 pcs for model 265
*Suggested spares
Figure 20
Figure 21

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual18
6.3 STORAGE
6.3.1 Storage Instructions
If the actuator is not for immediate use, the following precaution must be taken for storage:
• Store the actuator in a clean and dry environment and at a temperature between -20°C (-4°F) and
+40‚C (+104°F).
• It is recommended that the actuator be stored in its original box.
• Do not remove the plastic plugs on air supply ports.
6.3.2 Lifting and Handling
It is recommended to lift the actuators with proper, adequate and permitted systems in relation to the
actuator weight and by following the ruling laws in terms of safety and health protection. The weight of
the actuators is indicated on the Torqturn catalogue and on the related technical data sheets. During the
lifting and the handling of the actuators, it is recommended to avoid clashes and/ or accidental falls in
order to avoid irreparable damages to the actuators and to compromise the functionality.
Contact APV for any information and technical data sheets.
7.0 OPERATION
Typical operation of the actuator involves applying pressure to the appropriate pressure inlet(s) of a
double acting or spring return cylinder by means of a suitable control valve. APV-Torqturn actuators are
sized to ensure the required valve torque is produced at the supply pressure selected by the customer.
All APV-Torqturn actuators feature a fully enclosed body cavity which ensures protection for all moving
parts and eliminates the possibility of injury to operating personnel. APV-Torqturn pneumatic actuators do
not require additional lubricants.
When using APV-Torqturn actuators manually, the supply pressure is required to be vented or equalised
on either side of the power piston (with some provision for handling the minor difference in displacement
of opposing sides of the cylinder position).
a) When operation is a ‘declutchable’ gearbox, move the lever until the mechanism is engaged. With this
done, the gearbox then operates actuator and valve.
7.1 OPERATING FUNCTION AND DIRECTION OF ROTATION
The actuator is a pneumatic device for remote operation 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.