ARCA ARCAPAQ 812-DWK Series Operating instructions

Operating and maintenance manual
ARCAPAQ® pneumatic piston actuator
Series 812-DWK
03.2020 / 1.0

Original instructions
© ARCA Regler GmbH. All rights reserved.
Cover picture background: Freepik.com

Table of contents
1 General data...........................................................................................................................5
1.1 Validity of the manual ..............................................................................................................5
1.2 Contact details.........................................................................................................................5
1.3 Other applicable documents....................................................................................................5
1.4 Place of storage of the manual................................................................................................5
1.5 ARCA ONSITE ........................................................................................................................5
2 Safety......................................................................................................................................7
2.1 General safety information ......................................................................................................7
2.2 Explanation of symbols and notices ........................................................................................7
2.3 Structure of the warning notices..............................................................................................7
2.4 Intended use............................................................................................................................8
2.5 Inappropriate use ....................................................................................................................9
2.6 Use in potentially explosive areas (optional) ...........................................................................9
2.7 Residual risks ........................................................................................................................12
2.8 Qualification of the personnel................................................................................................12
2.9 Operator's duty of care..........................................................................................................13
2.10 Personal protective equipment..............................................................................................14
3 Transport, storage and packaging ....................................................................................15
3.1 Transport ...............................................................................................................................15
3.2 Storage..................................................................................................................................15
3.3 Packaging..............................................................................................................................15
4 Nameplate ............................................................................................................................16
5 Type key ...............................................................................................................................17
6 Sectional drawings..............................................................................................................19
6.1 Parts list.................................................................................................................................19
6.2 812-*****-DWK0.....................................................................................................................20
6.3 812-*****-DWÖK0..................................................................................................................21
7 Functional description........................................................................................................22
8 Installation ...........................................................................................................................23
9 Commissioning ...................................................................................................................24
9.1 Adjustment ............................................................................................................................24
9.2 Actuating signal connection...................................................................................................24
9.3 Positioner installation ............................................................................................................25
10 Maintenance.........................................................................................................................26
10.1 Care.......................................................................................................................................26
10.2 Maintenance..........................................................................................................................26
11 Disassembly / assembly of the actuator ...........................................................................27
11.1 Procedure..............................................................................................................................27
ARCA Regler GmbH Table of contents
Series 812-DWK 3 / 3203.2020 / 1.0

11.2 Guide and sealing element....................................................................................................27
11.3 Piston ....................................................................................................................................27
11.4 Springs ..................................................................................................................................28
12 Torque tables - bolted connections...................................................................................29
12.1 Screws according to DIN EN ISO 4017/4014, DIN 939 ........................................................29
12.2 Screws according to ASME B16.5 ........................................................................................29
12.3 Sealing plug (39) ...................................................................................................................29
12.4 Bushing (4) ............................................................................................................................29
12.5 Hex nut (18)...........................................................................................................................29
13 Fault removal .......................................................................................................................30
14 Disposal and recycling .......................................................................................................31
Table of contents ARCA Regler GmbH
4 / 32 Series 812-DWK03.2020 / 1.0

ARCA Regler GmbH 1 General data
Series 812-DWK 5 / 3203.2020 / 1.0
1 General data
This operating manual contains instructions that enable the product to
be safely and properly installed, put into operation and maintained.
The target group for this operating manual is exclusively specially
trained and authorised technical personnel.
Please contact the manufacturer if you encounter problems that cannot
be solved with the aid of this operating manual.
The product is subject to technical changes at any time.
1.1 Validity of the manual
This operating manual applies to the product in the version described in
the device pass.
1.2 Contact details
Further information about the product can be obtained from:
Manufacturer's address ARCA Regler GmbH
Kempener Str. 18
D-47918 Tönisvorst
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.arca-valve.com
1.3 Other applicable documents
The product can be delivered as part of an actuator and equipped with
additional components that are described in their own operating manu-
als. The instructions as well as the warning and safety information con-
tained therein must also be observed.
Furthermore, the following documents apply in addition to this operating
manual.
▪ Device pass
▪ Installation drawing
1.4 Place of storage of the manual
The operating manual and all other applicable documents are part of the
product.They must be kept in the immediate vicinity of the product and
must be accessible to the personnel at all times.
1.5 ARCA ONSITE
Acceptance documents (if ordered) and operating documentation for this
product can be downloaded from the ARCA ONSITE portal.
Two options are available here:
1. Scan the QR Code¹ on the product. Further entries are not required.

1 General data ARCA Regler GmbH
6 / 32 Series 812-DWK03.2020 / 1.0
2. Visit the website https://onsite.arca-valve.com/search and enter
the ARCA order no. and ARCA serial no. The order no. and serial no.
can be found in the device pass and in our order confirmation.
Entry example
Illustration1: ARCA ONSITE
¹ QR Code is a registered trademark of DENSO WAVE INCORPOR-
ATED

ARCA Regler GmbH 2 Safety
Series 812-DWK 7 / 3203.2020 / 1.0
2 Safety
2.1 General safety information
The operating manual contains detailed descriptions for the safe installa-
tion, commissioning and maintenance of the product.
▪ Read this operating manual attentively in its entirety in order to famili-
arise yourself with the product.
▪ Particular attention must be paid to the information in this chapter.
2.2 Explanation of symbols and notices
Safety and warning instructions are intended to avoid hazards to the life
or health of operating or maintenance personnel, and to avoid material
damage. It is emphasised through the use of the special terms defined
here. Additionally, their location is marked by warning symbols (picto-
grams). The signal terms used have the following meanings:
DANGER
means that death, serious injuries and/or considerable damage to
property will occur if the corresponding preventive measures are
not taken and maintained.
WARNING
means that death, serious injuries and/or considerable damage to
property can occur if the corresponding preventive measures are
not taken and maintained.
CAUTION
means that minor injuries and/or damage to property can occur if
the corresponding preventive measures are not taken and main-
tained.
NOTICE
indicates an important item of information about the product itself
or how the product should be handled, to which special attention
should be paid.
2.3 Structure of the warning notices
Section-related warning notice Section-related warning notices refer to the entire chapter, sections or
several paragraphs within this operating manual. Section-related warn-
ing notices are structured as follows:

2 Safety ARCA Regler GmbH
8 / 32 Series 812-DWK03.2020 / 1.0
DANGER
Type and source of the danger
Possible consequences of disregard
► Measure to avoid the danger
► Further measures
Embedded warning notice Embedded warning notices refer to a certain area within a section. They
apply to smaller information units than the section-related warning no-
tices. Embedded warning notices are structured as follows:
DANGER!Instructions for avoiding a dangerous situation.
2.4 Intended use
The product complies with laws, regulations and standards valid at the
time of delivery.
The product does not pose a danger to people, property or environment
if it is used for its intended purpose and the warning notices contained in
this operating manual and attached to the product are observed. This
applies to the entire lifetime, from the delivery, assembly and operation
to the disassembly and disposal.
The following is deemed to be used for the intended purpose:
▪ Operate the product exclusively in accordance with this operating
manual and in accordance with the specification in the order confirm-
ation and the device pass.
▪ Use exclusively original ARCA spare parts for the maintenance of the
product.
DANGER
Risk of death and serious injuries as well as damage to property
and the environment!
Risk of death and serious injuries as well as damage to property and the
environment due to hazardous operating media, high temperatures and
pressures as well as moving parts.
► The following requirements and conditions must be complied with
without fail.
► Observe warning notices.
Maintenance Ensure or observe the following before performing any maintenance
work:
▪ Depressurise the actuator and the attached valve.
▪ If necessary, cool the actuator down or heat it up to ambient temper-
ature.
▪ Disconnect electrical connections, if any.
▪ The actuator springs are inserted with a high preload; it is imperative
to follow the disassembly instructions according to the chapter en-
titled Diaphragm.
▪ Ensure that the system cannot be started up by third parties.

ARCA Regler GmbH 2 Safety
Series 812-DWK 9 / 3203.2020 / 1.0
▪ You are expressly directed to observe the regulations for potentially
explosive equipment where necessary. Refer also to the chapter Use
in potentially explosive areas (optional).
Limits of use Operate the actuator only within the following limits of use.
Max. operating pres-
sure [bar]
Min. operating tem-
perature [°C]
Max. operating tem-
perature [°C]
6 -20 / Low temperature
version -40
+80
The actuator is designed for a maximum number of switching cycles of 1
million full strokes.
The max. permissible switching cycle frequency is 1 full stroke per
second.
2.5 Inappropriate use
Inappropriate use is use of the product other than as described is the
chapter entitled [2.4] Intended use.
In the addition, the following applies:
▪ Unauthorised modifications to the product can lead to injuries, dam-
age to property and malfunctions. The user alone bears this risk.
Warranty and liability claims are excluded.
2.6 Use in potentially explosive areas (optional)
The product can also be used in potentially explosive areas if fitted with
the optional additional "EX" equipment.
WARNING
Unsuitable product for potentially explosive areas
Risk of explosion!
► Use only products that are approved for use in Ex-zones and are
marked accordingly.
► Make sure that the product is suitable for the area of use.
WARNING
Impermissible accessories and impermissible spare parts
Risk of explosion or damage to the product!
► Use exclusively original accessories and original spare parts.
► Observe all relevant installation and safety instructions described in
the manuals for the product, accessories and spare parts.

2 Safety ARCA Regler GmbH
10 / 32 Series 812-DWK03.2020 / 1.0
WARNING
Exceeding the maximum ambient or media temperature
Risk of explosion due to high surface temperature!
The temperature class of the product is no longer valid if the maximum
permissible ambient or media temperature is exceeded!
► Make sure that the maximum permissible ambient or media temper-
ature of the product is not exceeded.
WARNING
Contaminated operating medium
Risk of explosion and damage to the product due to clogging up with fine
dust or solid contents!
► Install a pre-filter or fine filter
► Clean the filter after 100,000 switching cycles or at least twice annu-
ally.
WARNING
Heat radiation
Risk of explosion due to high surface temperature as a result of heat ra-
diation from additionally attached products!
► Make sure that the maximum permissible surface temperature is not
exceeded.
► Insulate or decouple any attached products that radiate increased
heat.
WARNING
Dust deposits
Risk of explosion due to raised product temperature as a result of dust
deposits!
► Remove dust deposits that are thicker than 2 mm.
► Avoid electrostatic charging of the surface; remove dust deposits
properly without rubbing the surface.
WARNING
Damaged surface coating
Risk of explosion due to damage to the surface coating in conjunction
with corrosion and aluminium!
► Make sure that the surface coating is not damaged and that there is
no corrosion.

ARCA Regler GmbH 2 Safety
Series 812-DWK 11 / 3203.2020 / 1.0
WARNING
Exceeding the layer thickness of the surface coating
Risk of explosion due to electrostatic charging of the electrically non-
conductive surface coating!
► Make sure in case of overpainting that the surface coating does not
exceed a total thickness of 0.2 mm.
WARNING
External impact effect
Risk of explosion due to generation of sparks caused by an impact!
► Avoid external impact effects on the product.
WARNING
Dismantling the product
Risk of explosion due to the ingress of an explosive atmosphere!
üThe product may only be opened after it has been proven that no ex-
plosive atmosphere exists in the area around the product
► Ensure through ventilation that there is no explosive atmosphere. If
this is not possible, take the product to an area where there is no risk
of explosion.
WARNING
Non-conductive materials with pipe-laying work
Risk of explosion due to potential differences when using non-conduct-
ive materials!
► When using non-conductive materials for piping or sealing, care must
be taken that they are bridged with conductors.
WARNING
Non-conductive lubricants
Risk of explosion due to potential differences when using non-conduct-
ive lubricants!
► Use only electrically conductive lubricants to lubricate the compon-
ents.
WARNING
Exceeding the max. surface temperature at bearing points
Risk of explosion due to raised surface temperature in case of inad-
equate lubrication and dust deposits at the bearing points!
► Make sure that the maximum permissible surface temperature is not
exceeded.
► The lubrication and dust deposits at the bearing points must be in-
spected after 100000 operating cycles or at least twice annually.

2 Safety ARCA Regler GmbH
12 / 32 Series 812-DWK03.2020 / 1.0
ATEX nameplate
1
523
7
4 6
Illustration2: ATEX nameplate
1 Manufacturer
2 Type designation
3 ATEX marking for gas atmosphere
4 ATEX marking for dust atmosphere
5 Serial no.
6 "X" marking – the actuator can be used for an ambient temperat-
ure of -40 °C up to a surface temperature of +80 °C.
7 "X" marking – the actuator can be used for an ambient temperat-
ure of -40 °C up to a surface temperature of +80 °C.
2.7 Residual risks
There may still be residual risks even if the product is used for its inten-
ded purpose.
▪ Danger of being crushed by unsecured actuators
In case of negligent use of personal protective equipment:
▪ Danger due to noise resulting in hearing loss
▪ Thermal hazards (burning, scalding, etc.)
▪ Danger due to escape of the operating medium
Furthermore, there may be unapparent residual risks despite all precau-
tions taken.
Residual risks can be minimised if the notes on safety and commission-
ing as well as the operating manual as a whole are observed.
2.8 Qualification of the personnel
The product is exclusively intended for use in plants and installations in
which trained technical personnel carry out the necessary work. Tech-
nical personnel are persons who are entrusted with the installation, com-
missioning and operation of this product and who have the appropriate
qualifications for their work activities, such as, for example:
▪ training or instruction in accordance with current technical safety
standards in the maintenance and usage of appropriate safety equip-
ment.
▪ Training in First Aid.

ARCA Regler GmbH 2 Safety
Series 812-DWK 13 / 3203.2020 / 1.0
▪ In the case of systems with explosion protection: training or instruc-
tion and authorisation to carry out work on potentially explosive sys-
tems.
Repair work may be carried out only by trained and qualified technical
personnel.
Work on electrical equipment may be carried out only by trained electri-
cians or persons who have received electrotechnical instruction.
Persons
Activity
Instructed
persons
Persons
with a recog-
nised tech-
nical educa-
tion
Persons
with a recog-
nised elec-
trotechnical
education
Superiors
with relevant
skills
ARCA ser-
vice person-
nel
Transport X X X X X
Installation X X X X X
Commissioning X X X X
Maintenance X X X X X
Fault finding X X X
Mechanical
troubleshooting
X X
Electrical
troubleshooting
X X
Repairs X X X X
Disposal X X X X X
2.9 Operator's duty of care
To avoid accidents, malfunctions and environmental impacts, the re-
spective person responsible for the transport, commissioning, operation,
maintenance and disposal of the product must ensure the following:
▪ Observation of all warning and danger notices.
▪ Regular instruction of personnel on all applicable questions of work
safety, the operating manual and in particular the safety instructions
that it contains.
▪ Regulations and work instructions for safe working as well as the cor-
responding instructions for the conduct of the personnel in case of
accidents and fire are to be kept at the ready at all times and hung
up in the plant if necessary.
▪ Operate the product only if it is in perfect working order.
▪ Use only spare parts, lubricants and operating resources approved
by the manufacturer.
▪ Observe the specified operating conditions and requirements at the
place of installation.
▪ Provide all necessary devices and the personal protective equipment
required for the respective task.
▪ Refer to the chapter entitled Maintenance for the prescribed mainten-
ance intervals and comply with the corresponding regulations.
▪ Allow installation, commissioning and maintenance of the product to
be carried out only by qualified and trained personnel in accordance
with this operating manual.

2 Safety ARCA Regler GmbH
14 / 32 Series 812-DWK03.2020 / 1.0
▪ The operator must ensure that the product is used for its intended
purpose.
▪ Before commissioning the product the operator must carry out a risk
assessment and define appropriate inspection and maintenance in-
tervals according to the operating conditions.
2.10 Personal protective equipment
Personal protective equipment must be worn during work in order to
minimise health risks.
▪ During work, always wear the protective equipment necessary for the
respective work
▪ Follow the notices about personal protective equipment displayed in
the working area.
Always wear
Protective clothing
Tight-fitting work clothes with a low tear
resistance, with narrow sleeves and
without protruding parts. They primarily
serve to protect against being caught up
by moving machine parts.
Do not wear rings, chains or other jew-
ellery.
Safety shoes
To protect against heavy falling parts and
slipping on smooth floors.
Wear in case of particular
environmental conditions
Special protective equipment is neces-
sary in particular environmental condi-
tions.
It is to be selected according to the
environment.
Safety glasses
To protect the eyes against flying parts
and splashes of liquids.
Helmet
To protect against falling and flying parts
and materials.
Hearing protection
To protect against hearing damage.

ARCA Regler GmbH 3 Transport, storage and packaging
Series 812-DWK 15 / 3203.2020 / 1.0
3 Transport, storage and packaging
3.1 Transport
WARNING
Tipping or falling load!
Danger of death and danger of damage to property due to load tipping
over or falling!
► Only suitable and approved means of transport and lifting equipment
may be used for transporting the product.
► Lifting equipment must generally be attached to the housing of the
product, not to attachments.
► Allow only instructed persons to select and attach the lifting equip-
ment.
► Do not stand under suspended loads.
Transport at a temperature lower than -40 °C or higher than +80 °C is
not permissible.
The attachment points on actuators (lifting eyes, ring bolts, etc.) are de-
signed solely for transporting the actuator. Under no circumstances may
these attachment points be used if the actuator is coupled to a valve.
3.2 Storage
NOTICE
Improper storage!
There is a danger of the product and in particular the attached electronic
accessories no longer functioning if stored improperly.
► Storage at a temperature lower than -40 °C or higher than +80 °C is
not permissible.
► It must be stored in roofed-over storage places and that are weather-
proof.
To protect against contamination and to protect the sealing surfaces,
openings such as nozzles, flanges, etc. must be sealed using suitable
means. These should be removed by technical personnel at the place of
installation.
3.3 Packaging
The product is packed in a PE film inside the outer packaging (card-
board box, wooden crate, pallet, lattice box).
If the packaging, in particular the PE film, has been opened, the product
must be stored immediately in a heated room.
The product must be packed in weatherproof or seaworthy packaging for
transport by ship, airplane, rail or truck.

4 Nameplate ARCA Regler GmbH
16 / 32 Series 812-DWK03.2020 / 1.0
4 Nameplate
Illustration3: Nameplate
1 App. no. / Serial no.
2 Type designation / Year of manufacture
3 Valve design
4 Nominal size
5 Nominal pressure
6 Flow coefficient, characteristic curve
7 Seat diameter
8 Valve stroke
9 Material of housing / trim
10 Actuator function
11 Actuator type
12 Max. actuation pressure
13 Actuation pressure range
14 Actuator type key
Place of installation The nameplate is attached to the actuator yoke or the actuator head.

ARCA Regler GmbH 5 Type key
Series 812-DWK 17 / 3203.2020 / 1.0
5 Type key
812 - 2 2 3 _ N - DWK 0
[1] [2] [3] [4] [5] [6] [7] [8]
1. Series
812
2. Actuator size
2 MFI piston area 284 cm²
3. Yoke (Ø = mounting in mm)
0 without
1 Ø40
2 Ø48
3 Ø56
9 Special version
4. Stroke
3 20 mm
4 30 mm
5. Spring set
_ no springs
3 3 springs
6 6 springs
6. Diaphragm head / yoke material
N Steel / Steel
A Steel / Stainless steel
V Stainless steel / Stainless steel
7. Function
DWK Double-acting
DWÖK Double-acting with safety position
"closed"
8. Additional equipment
0 none
4 Low temperature version max.
-40°C (incl. 6)
5 Air connection G½
6 Screws, stainless steel (long)
AP External stainless steel parts, pas-
sivated (incl. 6)
EX Explosion-proof version
SD Stem 1.4462 (incl. 6)
X Peripheral bolts XYLAN
Z Peripheral bolt ASME

5 Type key ARCA Regler GmbH
18 / 32 Series 812-DWK03.2020 / 1.0
Example of type designation 812-223 N-DWK-0
MFI pneumatic piston actuator ─ mounting diameter 48 mm ─ stroke 20
mm ─ diaphragm head / yoke material steel / steel ─ double-acting func-
tion ─ no additional equipment.

ARCA Regler GmbH 6 Sectional drawings
Series 812-DWK 19 / 3203.2020 / 1.0
6 Sectional drawings
Some versions of the actuator are illustrated below. Further versions are
possible by combining the different components.
Connections Z1, Z2, Z3 see [9.2] Actuation signal connection
6.1 Parts list
Item Name
1 Stem
2 Pin
3 * Sealing ring
4 Bushing
5 * Plain bearing
6 * O-ring
7 Filter
14 * Compression spring
18 * Hex nut
21 Hex screw
22 Washer
23 Hex nut
24 * Sealing
25 Screw sleeve
26 * O-ring
28 * O-ring
29 Sealing plug
30 Stroke plate
31 Cylinder head bolt
32 Washer
34 Lantern
38 * Sealing
39 Sealing plug
43 * Pipework, compl.
46 Thread adapter
47 Nameplate Ex
69 * O-ring
76 Intermediate ring
77 Piston
78 * Guide band
79 * Sealing ring
108 bottom cover
118 top cover
119 Washer
* recommended spare part / wearing part

6 Sectional drawings ARCA Regler GmbH
20 / 32 Series 812-DWK03.2020 / 1.0
6.2 812-*****-DWK0
Function: Double-acting
Illustration4: 812-*****-DWK0