ATI Technologies IOM1030 Instruction manual

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IOM1030 REV A
INSTALLATION, OPERATION & MAINTENANCE MANUAL - IOM1030
ATI SCOTCH YOKE MODULAR-SERIES ACTUATOR

IOM1030 ATI Scotch Yoke M-Series Actuator
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Table of Contents
1Introduction ....................................................................................................................... 3
1.1 Company Background .............................................................................................................................3
1.2 Scope & Purpose of Manual ....................................................................................................................3
1.3 Company Contact ....................................................................................................................................3
2Reference Documents ........................................................................................................ 4
3Definitions ......................................................................................................................... 4
4Product Description........................................................................................................... 5
4.1 General Description & Typical Applications...........................................................................................5
4.2 Theory of Product Operation ...................................................................................................................5
4.3 Scotch Yoke Actuators ............................................................................................................................5
4.4 Product Specifications .............................................................................................................................6
5Safety Warnings ................................................................................................................ 8
5.1 Personnel Requirements ..........................................................................................................................8
5.2 Potential Hazards .....................................................................................................................................9
6Handling and Storage.......................................................................................................10
6.1 Receiving the Product............................................................................................................................10
6.2 Storage and Preservation .......................................................................................................................10
7Installation Instructions...................................................................................................11
7.1 Scotch Yoke/Quarter-Turn Actuators ....................................................................................................11
7.2 Setting the Stroke Length ......................................................................................................................11
8Preparation for Start-up...................................................................................................12
8.1 Hydraulic Oil Use ..................................................................................................................................12
8.2 Hydraulic & Pneumatic Connections.....................................................................................................12
8.3 Limit Switch Instructions.......................................................................................................................12
8.4 Start-up ..................................................................................................................................................12
9Maintenance & Operation ................................................................................................13
Safety Reminder..................................................................................................................................................13
9.1 Routine Maintenance .............................................................................................................................13
9.2 Double Acting Disassembly ..................................................................................................................14
9.3 Spring Return Disassembly ...................................................................................................................14
9.4 Seal Replacement...................................................................................................................................14
9.5 Double Acting Reassembly ...................................................................................................................15
9.6 Spring Return Reassembly.....................................................................................................................16
9.7 Double-Acting Operation ......................................................................................................................16
9.8 Spring Return Operation........................................................................................................................17
9.9 Lubricating Mechanism .........................................................................................................................17
9.10 Parts Ordering........................................................................................................................................18
10 Disposal.............................................................................................................................19
11 Terms and Conditions/Warranty .....................................................................................20
12 Revision Record ................................................................................................................22
Appendices

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1 Introduction
1.1 Company Background
Automation Technology was founded in 1995 as a manufacturer of pneumatic and hydraulic valve actuators. With
products in a wide range of applications such as petrochemical, pipelines, refineries, pulp and paper, agriculture,
pharmaceutical, municipalities, mining, power plants and marine transportation, ATI has succeeded in becoming a
global leader in valve automation technology.
1.2 Scope & Purpose of Manual
This manual is intended to assist those who are involved with the installation, operation and maintenance of ATI
Scotch Yoke M-series Actuators. This manual should be reviewed and thoroughly understood PRIOR to installing,
operating or providing maintenance on the device. Refer to separate instruction manuals for details regarding
optional accessories and other equipment used with these actuators.
Failure to read and comply with all applicable installation, operation and maintenance instructions may result in
bodily injury or equipment damage and will void the Product warranty.
1.3 Company Contact
For any questions or clarifications, contact ATI or your nearest ATI Authorized Representative.
Email: [e-mail]
Web: http://www.ATIactuators.com/
ATI Global Headquarters – Customer Support, Design & Manufacturing
Cypress, Texas, USA
Phone: [phone]
US Toll Free: 800-924-8037

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2 Reference Documents
The following documents are referenced within this publication. These address options and accessories, and one
or more of these documents may be required to complete installation, operation or maintenance of the as-built
Product.
•DS1001 – Dimensional Data Sheets Scotch Yoke M-Series Actuator
•DS1002 - Torque Table Data Sheets Scotch Yoke M-Series Actuator
3 Definitions
Term/Abbreviation
Definition
ATI
Automation Technology LLC, the manufacturer of the Product.
Cycle
Operating the actuator from full open to full close and back to full open, or from close to
open, back to close. When mounted to the valve, this is 2 full stroke operations, one time in
each direction.
Hydraulic Actuator
A hydraulic actuator uses compressed liquid as the power medium to produce mechanical
motion.
Pneumatic Actuator
A pneumatic actuator uses air, gas, nitrogen or other compressible fluid as the power
medium to produce mechanical motion.
Fluid
A substance, such as a liquid or gas, that can flow, has no fixed shape, and offers little
resistance to an external stress.
MAWP
Maximum Allowable Working Pressure, or Maximum Allowable Operating Pressure
(MAOP). The maximum design pressure for the Product model.
SMAWP
Standard Maximum Allowable Working Pressure, or Standard Maximum Allowable
Operating Pressure (MAOP). The standard maximum design pressure for the Product.
Product
Product refers to all Scotch Yoke M-Series Actuators.
Stroke
Measure of valve openness. Full stroke is the travel distance to move the valve from its full
closed to its full-open position. In control valve applications, stroke is often described in
percentage terms—full closed is 0%, full open is 100%--and stroke is generally proportional
to the amount of flow through the pipe.

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4 Product Description
4.1 General Description & Typical Applications
The ATI Scotch Yoke M-Series Actuator is designed for use with both hydraulic and pneumatic power to operate a
quarter-turn valve.
Controls may include both local and remote control with selector switches. The control systems may be designed
for hazardous areas up to Class 1 Division 1/Zone 1 or Zone 1 with certified electrical components.
This system is capable of providing precise quarter-turn valve control for ON/OFF and modulating valve
applications.
4.2 Theory of Product Operation
ATI Scotch Yoke Actuators are suitable for many quarter turn applications including ball, plug, butterfly
valves or dampers, in both On-Off and modulating heavy-duty service.
4.3 Scotch Yoke Actuators
The Scotch Yoke unit works in the following general way:
•For a double-acting configuration, pressure is supplied to pressure port on either the inside or outside
end cap of the power module which will rotate the yoke/valve stem up to 100°.
•For a spring-return configuration pressure is supplied to the outside end of the power module which
will rotate the yoke as it compresses the spring of the spring module.
•The actuator stroke of the yoke is adjustable between 90°and 100°by means of the external
mechanical stops screwed into body of the actuator.
•The cover of the scotch yoke mechanism is arranged for the assembly of the required accessories
(positioner, signaling limit switches, position transducer, etc.) by means of proper matching units.
The above-mentioned accessories are operated by the yoke indicator plate.
•The housing of the scotch yoke mechanism is machined with a threaded hole flange pattern to fix the
actuator to the valve directly or, if required, with an adapter flange or mounting bracket.
•The actuator yoke has a bore with keyways suitable for the dimensions of a valve stem or a drive slot
suitable for a coupling device.
•ATI may supply different types of control systems following customer’s requirements.

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4.4 Product Specifications
4.4.1 Operating
Pressure
The working pressure range for a standard ATI Scotch Yoke Power Cylinder is as
follows:
HYDRAULIC:
-MINIMUM: 500 psig (34.5 bar)
-STANDARD MAXIMUM (SMAWP): 1,500 psig (103.4 bar)
PNEUMATIC:
-MINIMUM: 50 psig (3.45 bar)
-STANDARD MAXIMUM (SMAWP): 150 psig (10.24 bar)
The minimum pressure may be lower than 500 psig and 50 psig, for hydraulic
and pneumatic cylinders, respectively, due to backpressure in control circuits.
For use with Higher or Lower pressures consult with ATI Representative.
NOTE: The maximum pressure is in reference to just the power modules. When
assembled onto the body module the maximum pressure for system may
decrease. Please reference DS1002 Scotch Yoke Torque Table Data for
maximum pressures for specific actuator models.
4.4.2 Temperature
Limits
Operating Temperature
System
Operating Temperature*
standard
-40℉to +212℉(-40℃to +100℃)
*For temperatures outside standard consult with an ATI Representative.
4.4.3 Duty Cycle &
Cycle Speed
The Product is capable of intermittent duty and continuous duty when
operated within recommended temperature limits with properly filtered fluid.
The stroke speed is controlled by the control circuit for fluid supply and typically
varies between 5 seconds to 60 seconds.
For required speeds outside range, please consult with an ATI Representative.
4.4.4 Fluid Type
The Product is designed and constructed of heavy-duty materials for operation
in systems using petroleum-based fluids for hydraulic power. Pneumatic
operation is designed for filtered nitrogen and compressed air.
For use with other fluid types please consult with an ATI Representative.
4.4.5 Service Life
ATI Scotch Yoke Systems can be operated with petroleum-based hydraulic
fluids or filtered pneumatic fluid for up to 5 years without maintenance. In
harsh environments and safety critical applications, more frequent
maintenance intervals and a proper fluid monitoring program should be
considered to ensure reliable Product performance. With regular maintenance
and monitoring of the fluid, the service life for this actuator will extend well
beyond 5 years.
4.4.6 Lubrication
For normal duty, the actuator is self-lubricated for the life of the Product.
The hydraulic fluid should be filtered and monitored for cleanliness to a
contamination threshold of 20/18/15 per ISO 4406 (NAS 9). Lower
contamination thresholds are recommended to maximize service life.
4.4.7 Lifting Point
Load Ratings
Use lifting straps or chains rated for a minimum of 2000 lbs.

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4.4.8 Pressure
Connections
Per assembly drawing
•Hydraulic and Pneumatic connections will be located on the outside
and inside end cap of power module. Size of connection will vary
based on Scotch Yoke Model size and can be viewed in data sheet
DS1001 Scotch Yoke M-Series Dimensional Data.
4.4.9 Torque
Rating
Torque Ratings for each SYM model.
Model Torque Capacity (in*lbf)
SYM1
80,000
SYM2
190,000
SYM3
375,000
SYM4
750,000
SYM5
1,250,000
Torque Rating is based on springless Double-Acting actuator. For specific spring
return torque capacities please refer to DS1002 SYM Torque Table Data or
consult with an ATI Representative.
4.4.10 Warranty
Complete warranty terms and conditions are included in section 11 of this
manual.
ATI Scotch Yoke Systems, if handled, installed, used, and maintained according
to this manual, are guaranteed to be without defects in material and
workmanship. The warranty period is two (2) years after the date of factory
shipment. Refer to Product nameplate for serial number to confirm date of
shipment. The warranty does not cover accessory components installed by
others or materials that are installed inappropriately, used inappropriately, or
modified or repaired without approval by ATI.
NON-WARRANTY CLAUSE: Contents of this publication are periodically checked
for compliance with the associated Products, and corrections are made as
necessary for subsequent publications. ATI also modifies the Product in this
publication (within limits of Optional Certifications) to meet special
requirements for specific customer orders. Therefore, ATI cannot exclude the
possibility of discrepancies between this publication and the Product and
special documentation that is prepared for a particular shipment, and ATI does
not accept liability for discrepancies between information in this publication
and the Product.

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5 Safety Warnings
THIS MANUAL COVERS GENERAL INSTRUCTIONS AND DOES NOT CLAIM TO ADDRESS ALL SAFETY FACTORS
ASSOCIATED WITH ATI PRODUCTS OR THE ACCESSORIES THAT MAY BE MOUNTED TO ATI PRODUCTS.
FOLLOWING THESE INSTRUCTIONS AND GUIDELINES WILL HELP IN PREVENTING PERSONAL INJURY, PROPERTY
DAMAGE, AND DAMAGE TO THE PRODUCT.
ACTUATORS AND VALVES COME INTO CONTACT WITH CAUSTIC GASES AND FLUIDS IN MANY APPLICATIONS. AS A
RESULT, ALL TOXIC OR FLAMMABLE FUMES MUST BE VENTED AND LIQUIDS MOVED TO A SAFE LOCATION TO
ENSURE SAFETY.
FOR GENERAL SAFETY REQUIREMENTS AND RISK ASSESSMENTS OF HYDRAULIC POWER SYSTEMS, REFER TO
BS EN 982, ISO 4413, AND ISO 12100.
5.1 Personnel Requirements
DO NOT INSTALL, OPERATE, OR MAINTAIN AN ATI PRODUCT UNLESS TRAINED AND QUALIFIED IN PRODUCT AND
ACCESSORY INSTALLATION, OPERATION AND MAINTENANCE.
PROPER INSTALLATION OF THE PRODUCT IS CRITICAL TO PERFORMANCE AND SAFETY. DUE TO THE MANY
VARIATIONS OF ACTUATORS, VALVES, AND RELATED CONTROLS, THE GENERAL INSTRUCTIONS IN THIS MANUAL
MAY NOT ADDRESS SPECIFIC ISSUES AT A PARTICULAR INSTALLATION. EACH TECHNICIAN FOLLOWING THESE
INSTRUCTIONS MUST BE COMPETENT, TRAINED, AND HAVE A WORKING KNOWLEDGE OF VALVES, VALVE
ACTUATORS, ACTUATOR CONTROLS, AND THE SPECIFIC APPLICATION FOR THE INTENDED PRODUCT(S).
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE PROPER SAFETY. ALWAYS TAKE NECESSARY PRECAUTIONS
AND UTILIZE PROPER PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN DEALING WITH COMPRESSED GAS,
PRESSURIZED HYDRAULIC FLUID, PINCH POINTS, AND ELECTRICITY. IT IS THE USER’S RESPONSIBILITY TO UTILIZE
APPROPRIATE PROTECTION AGAINST HEARING DAMAGE WHEN WORKING NEAR THE ACTUATOR AND
CONTROLS.

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Figure 2. Lifting Points, Double Acting
5.2 Potential Hazards
The Product has been designed in accordance with best practices for operational reliability, but as an industrial
machine, it bears the risk of hazards if handled or operated improperly. Only trained, qualified personnel should
work on or near the Product.
Some potential risks from installation include rigging & lifting. Risks during maintenance and operations include
stored energy hazards, pinch points, overpressure conditions, and ignition hazards.
Rigging & Lifting
The user must ensure that the package weight including this Product does not exceed the rated limit of
crane/hoist/lifting hardware. For cases where this limit is exceeded, the actuator and valve or other equipment
must be rigged and lifted separately.
Before rigging, ensure the crane/hoist/rigging hardware lifting capacity can safely accommodate the desired load.
Dropping the Product and any attached accessories or the attached valve may cause personal injury and/or
equipment damage. For all mounting procedures, use adequately rated chain(s) & sling(s) with an adequately
rated hoist or crane to lift and maneuver the Product. Use caution during lifting and handling to prevent
uncontrolled movement or sudden shock loads. The brackets on the body and eye bolt on the spring cartridge
provide adequate support for lifting if used properly.
Figure 1. Lifting Points, Spring Return
Ignition Hazard in Hazardous Areas
The Product may be designed for Class I Division 1, Class I Zone 1, or Zone 1. DO NOT OPEN ELECTRICAL
ENCLOSURES WHEN HAZARDOUS FLAMMABLE GAS IS PRESENT AS THIS MAY CAUSE AN EXPLOSION. EVEN WITH
ELECTRICAL COMPONENTS DEENERGIZED, CAPACITORS IN THE ELECTRICAL COMPONENTS WILL STILL HAVE
STORED ENERGY.

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6 Handling and Storage
6.1 Receiving the Product
Proper care and precautions should be taken when unloading and handling the Scotch Yoke System, especially
when rigging and lifting.
6.2 Storage and Preservation
ATI Products leave the factory in excellent working condition and with an excellent finish. These conditions are
documented by individual inspection certificate. To maintain these characteristics until the Product is installed, it is
necessary to take appropriate measures during the storage period.