Genebre GNP Instruction manual

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es
GENEBRE S.A.
FECHA DE REVISIÓN: 06/07/2020 NUMERO DE REVISIÓN: 2
1
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
GNP
Rack & Pinion Pneumatic Actuators
Ref. GENEBRE: 5800

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es
GENEBRE S.A.
FECHA DE REVISIÓN: 06/07/2020 NUMERO DE REVISIÓN: 2
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INSTRUCTIONS FOR INSTALLATION, OPERATION & MAINTENANCE MANUAL
1. Product Description ............................................................................. 3
2. Transport and Storage Conditions ………………………………… 4
3. Technical Features & Data ............................................................... 5
3.1 Method of Operation ……………………………………………….. 5
3.2 Technical Data & Working Conditions ……………………………. 7
3.3 Special Conditions ………………………………………………… 7
4. Actuators Installation …..................................................................... 8
5. Maintenance Instructions …..……………………………………. 10
6. Repair Instructions …………………………………………………. 11
6.1 Disassembling Procedure ………….………………………………. 11
6.2 Assembly Procedure ........................................................................... 11
6.3 Spring Cartridge Insertion …………………………………………… 14
7. Safety Instructions …………………………………………………… 14

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es
GENEBRE S.A.
FECHA DE REVISIÓN: 06/07/2020 NUMERO DE REVISIÓN: 2
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1. Product Description
1.1) General
Genebre, S.A. offers a broad range of pneumatic rack & pinion actuators.
GNP actuators are designed to operate with dry or lubricated air media, but will function
equally well with non-corrosive and inert gas or light hydraulic oil. The actuators are
offered in two different configurations: double acting and spring return. Each actuator can
be easily converted from double acting to spring return (or vice versa) by insertion (or
removal) of spring cartridges.
GNP actuators are equipped in the standard configurations with the following unique
features:
•Double travel stops (± 5º).
•External open/closed indication
•Pre –loader springs of non –metallic material.
•All bodies are internally lapped.
•All internal and external surfaces are anodized for corrosion resistance.
•External powder polyester painted.
•Angle of rotation: 90°.
•All air line connections are ¼” GAS.
•“NAMUR” VDI/VDE 3845 and ISO 5211 dimensions on all sizes.
1.2) Assembly drawing

Edificio Genebre. Av. de Joan Carles I, 46-48
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1.3) Parts list
Nº
Name
Material
Spare Part Code
1
Spring clip
Stainless steel AISI 304
------
2
Housing indicator
PC+ABS
------
3
Indicator
PC+ABS
------
4
Body
Al 6005-T5
------
5*
Guide piston
Techno - polymer
KGNP
6*
O-ring (pinion top)
NBR
KGNP
7*
Washer (pinion top)
Techno - polymer
KGNP
8*
Bearing (pinion top)
Techno - polymer
KGNP
9
Cam
Al. Steel
------
10
Pinion
Al. Steel
------
11*
Bearing (pinion bottom)
Techno - polymer
KGNP
12*
O-ring (pinion bottom)
NBR
KGNP
13*
Spring
AISI 301
C5800
14*
Ring (Piston)
Techno –polymer
KGNP
15*
O-ring (Piston)
NBR
KGNP
16*
Piston
Al. A380.1
EMB
17*
Plug
NBR
KGNP
18*
O-ring
NBR
KGNP
19
Adjust Nut
Stainless steel AISI 304
------
20
Adjust screw
Stainless steel AISI 304
------
21
Stop screw
Stainless steel AISI 304
------
22
Nut (stop screw)
Stainless steel AISI 304
------
23*
O-ring (End cap)
NBR
KGNP
24
End cap right
Al. A380.1
------
25
End cap left
Al. A380.1
------
26
Cap screw
Stainless steel AISI 304
------
27*
Spring clip
Stainless steel AISI 304
KGNP
28*
Washer
Stainless steel AISI 304
KGNP
29*
Ring
Techno - polymer
KGNP
* Available spare parts
2. Transport and Storage Conditions
The transport and storage of this type of product must be performed in its original
packaging!

Edificio Genebre. Av. de Joan Carles I, 46-48
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VISUAL INSPECTION
Check that the products have not been damaged during transportation, unloading and
placement on site.
During storage it is recommended that the protective packaging not be removed to
prevent any blows or the accumulation of dirt in the interior of the valve. This packaging
should not be removed unless the valve is going to be installed.
Where possible, the actuators must be stored in a dry clean place.
If during any anomaly is noticed during the observance of these guidelines for
receipt , contact GENEBRE urgently in order to resolve the liability for these anomalies.
IMPORTANT NOTE:
Before installing and/or handling these elements, CAREFULLY READ these
instructions for use and OBSERVE all information contained herein. In the event
of not understanding any of this information, please contact GENEBRE, S.A.
The responsibility for the safe use of these products is that of the user in
accordance with the contents of these instructions for use as well as the specific
technical documentation of the device supplied.
3. Technical Features & Data
3.1) Method of Operation
DOUBLE ACTING
Note: The bracketed numbers refer to the actuator exploded view –page 4.

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Rotation occurs when compressed air is supplied to the actuator through Port A,
connected to the interior cavity between the pistons (ref. 16), or through Port B,
connected to the end cap area (ref. 24 & 25).
•Pressure to Port A, as shown in Figure Standard rotation, fills the inboard cavity
pushing both pistons (ref. 16) outward and exhausting air through Port B. As the pistons
extend they rotate the pinion (ref. 10) counter clockwise (when viewed from the top of the
actuator).
•As shown in Figure Standard rotation, pressure to Port B fills the outboard cavities
pushing both pistons (ref. 16) inward and exhausting air through Port A. As the pistons
retract they rotate the pinion (ref. 10) clockwise (when viewed from the top of the
actuator).
Standard Rotation
SPRING RETURN
Note: The bracketed numbers refer to the actuator exploded view –page 9.
In this configuration the closed position occurs with spring cartridges (ref. 13), which are
located between the pistons and end caps.
•Pressure to Port A, see Figure Standard rotation, fills the inboard cavity pushing both
pistons outward and exhausting air through Port B. As the pistons (ref. 16) extend they
rotate the pinion (ref. 10) counter clockwise (when viewed from the top of the actuator)
and compress all the spring cartridges (ref. 13).
A B
A B

Edificio Genebre. Av. de Joan Carles I, 46-48
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•Relieving pressure from the inboard cavity through Port A, as shown in Figure
Standard rotation, allows the spring cartridges (ref. 13) to push both pistons (ref. 16)
inward. As the pistons retract they rotate the pinion (ref. 10) clockwise (when viewed from
the top of the actuator).
Standard Rotation
3.2) Technical Data & Working Conditions
•Operating Media –Dry or lubricated air, non-corrosive and inert gas or light hydraulic
oil.
•Air supply: 2 Bar (30 PSIG) to 8 Bar (120 PSIG) maximum. A safety valve is normally
recommended.
•Temperature: Standard from –20°C a +80°C and –15°C +150°C available on request.
•Lubrication: Factory lubricated for life under normal working conditions with Exxon
CAZAR K2 or equivalent
•Application: Suitable for both indoor and/or outdoor applications.
3.3) Special Conditions
•Operating the actuator beyond its designed temperature limitations may damage
internal and external components and, therefore, could prove potentially dangerous for
operating and maintenance personnel.
•Operating the actuator beyond its designated pressure limitations may result in either an
actuator malfunction or an actuator explosion and, therefore, could prove potentially
dangerous for operating and maintenance personnel.
A B
A

Edificio Genebre. Av. de Joan Carles I, 46-48
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•Note: Do not disassemble the actuator end caps when air pressure is applied to the
actuator.
4. Actuators Installation
GNP actuators can be fitted on many styles of quarter-turn valves, including ball, butterfly
and plug and dampers in accordance with the instructions contained in this chapter.
The flange is an integral part of the body and is designed with ISO 5211 and Namur (see
Table a and Figures 3.a / 3.b).
(*) one of the two options must be chosen
Table a Figure 3.a
On the top face of GNP actuators there is a NAMUR standard mounting pattern for
easy installation of accessories for position survey and/or control devices Micro Switch
Boxes, Positioners, ect. (H=80 / 130 and G=30)
Model
I
J
K
L
M
GNP14
F03*
F04*
M5
M5
11
GNP24
F03*
F04*
M5
M5
11
GNP44
F04*
F05/F07*
M5
M6/M8
14
GNP60
F05
F07
M6
M8
14
GNP94
F05
F07
M6
M8
17
GNP135
F05
F07
M6
M8
17
GNP198
F07
F10
M8
M10
22
GNP300
F07
F10
M8
M10
22
GNP513
F10
F12
M10
M12
27
GNP800
F10
F12
M10
M12
27
GNP1280
F12*
F14*
M12
M16
36
GNP1600
---
F14
---
M16
36
GNP2300
---
F14
---
M16
46
GNP2500
---
F16
---
M20
46

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Figura 3.b
The Ports are NAMUR standard for easy solenoid valve connection
Installation procedure.
1. Check the coupling female pinion drive –valve stem.
2. Make sure that the valve and the actuator are both in the closed position before
proceeding (see Figure 3.b).
3. Install mounting bracket on the valve and hand tighten all fasteners; be sure not to fully
torque bolts until entire assembly is correctly aligned and installed.
Model
G
H
GNP14
30
80
GNP24
30
80
GNP44
30
80
GNP60
30
80
GNP94
30
80
GNP135
30
80
GNP198
30
80
GNP300
30
80
GNP513
30
80
GNP800
30
80
GNP1280
30
80/130
GNP1600
30
80/130
GNP2300
30
80/130
GNP2500
30
80/130
Figure 3.b shows an
actuator in the normal
position (closed) with the
pinion flats and the
indicator –drive milling
perpendicular to the
body

Edificio Genebre. Av. de Joan Carles I, 46-48
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4.
a) Mounting with brackets: Place coupling on valve stem and the actuator on mounting
bracket. Align valve and actuator in order to eliminate forces on the system; tighten all the
assembly fasteners.
b) Direct mounting: Position the actuator on valve; use caution while inserting the valve
stem into the double square female pinion drive. Insert the screws from the bottom side
of flange and manually tighten them and align the assembly in order to eliminate the
forces on the system; tighten all assembly fasteners.
5. Actuate the unit several times to ensure that it works properly. If the unit does not work
properly, disassemble the unit and repeat steps 1 –4. If the problem persists, contact
with Genebre, S.A.
6. After the completion of the mounting operations, it is necessary to set the actuator
stroke through the travel stops to ensure that the valve works properly. GNP actuators
have a regulation range ± 5° in both open and close directions (See Chapter 4 –3 for
information on actuator positioning phase).
5. Maintenance Instructions
The maintenance frequency, place and method will be defined by the user, bearing in
mind the use of this product. However, where necessary, the following checks will aid in
prolonging the useful life and reduce problems on the installation.
Adjustment Closed (0º)
Adjustment Open (MAX)
CAUTION –PLEASE READ CAREFULLY:
•BEFORE CARRYING OUT ANY MAINTENANCE ON GEN - AIR ACTUATORS,
IT IS ESSENTIAL THAT THE ACTUATOR IS NOT UNDER PRESSURE AND IS
FREE OF ANY ACCESSORIES.
•FOR YOUR SAFETY, IT IS ABSOLUTELY NECESSARY, BEFORE
DISASSEMBLING A SPRING RETURN ACTUATOR, THAT THE UNIT IS IN THE
FAILSAFE POSITION (SPRINGS EXTENDED AND NOT COMPRESSED).

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6. Repair Instructions
6.1) Disassembling Procedure
1. Disconnect all electrical and air supplies from the actuator.
2. Remove the actuator from the mounting bracket and place in a clean environment.
3. After removing the end cap screws (ref. 26), remove the end caps (ref. 24 and 25).
4. Remove O-Rings (ref. 23) from the end caps and inspect their wear and lubrication.
5. Remove the regulation screw, Nut and o’rings (ref. 18, 19 and 20), located in the lateral body
(ref. 4).
6. Using a wrench on the appropriate mill on the upper part of pinion (ref. 10), turn the pinion
counter-clockwise until the pistons (ref. 16) protrude further out from the cylinder to be removed.
7. Remove the pistons by hand or with pliers, taking the pistons from the spring grooves and
using caution not to damage the pistons’ surfaces. Note: If actuator is fail counter-clockwise the
pinion must be rotated in the opposite direction.
8. Remove O-Rings (ref. 15), guide ring (ref. 14) and guide piston (ref. 5) from the left and right
pistons.
9. Remove the seeger (ref. 1) and indicator (ref. 2 & 3). Firmly tap the upper part of the pinion on
a wood surface, to prevent damage of the pinion.
10. Remove the cam (ref. 9) and bearing (ref. 8) from the body (ref. 4).
11. Remove the pinion (ref. 10).
12. Remove the O-Rings and the bearings (ref. 6, 7, 11 and 12) from the pinion.
13. Inspect and replace the following wearing parts as necessary.
6.2) Assembly Procedure
1. Insert O-Rings (ref. 6 & 12) and bearings (ref. 7 & 11) on pinion (ref. 10).
2. Insert the pinion into the body (lower hole)
3. Insert the cam (ref. 9) and the bearing (ref. 8) on the pinion (ref. 10), pushing until the pinion is
completely inserted into the body (upper hole).
4. Intermediate test: using a wrench and acting on the appropriate mill on the upper part of the
pinion. Manually rotate the pinion to make sure it freely rotates.

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5. Insert the O-Rings (ref. 15), the guide ring (ref. 14) and the thrust block (ref. 5) on the left and
right pistons (ref. 16).
6. Piston insertion: This operation can be performed in two different ways in order to obtain
either a fail clockwise actuator (mounting A - FCW) or a fail counter clockwise actuator
(mounting B - FCCW).
6a. Mounting A (clockwise rotation for close)
Place the pinion in close position and after move counter clockwise about 95º.
Left piston insertion.
•Place the actuator in a stand up position on its right side with the flange facing you
and the supply holes on your right.
•To obtain the counter clockwise rotation (mounting A) it is necessary to insert the
rack of the piston to the left of the pinion.
•Insert the left piston applying pressure with hands until the piston is completely in
the body.
Right piston insertion.
•Place the actuator in a stand up position on its left side with the flange facing you.
•Insert the rack of the piston to the left of the pinion.
•Insert the right piston applying pressure with hands until the piston is completely in
the body.
6b. Mounting B (counter clockwise rotation for close): follow the same steps as above, but
inserting the rack of both pistons on the right of the pinion
7. Actuator positioning phase:
7a. Place the actuator in a stand up position on a flat surface with the upper part of the
pinion on the right side.
7b. Manually apply pressure to the piston, as this will assist to compress the opposite
piston.
7c. While continuing to apply pressure, use a wrench on the appropriate mill of the upper
portion of the pinion and rotate the pinion counter clockwise. At this point there must
be clicking sound due to the interlocking between the piston rack and the pinion tooth.
Make sure to create an individual sound per tooth.
7d. After each individual sound, rotate the pinion clockwise; verify that the pinion Namur
mill is about 10° beyond the perpendicular to the body axis. If problematic, repeat step
7c.

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7e. Double check the correct assembly of the actuator, confirming that the open position
pistons are of equal distance from the cylinder border.
8. End cap mounting:
8a. Insert the end cap O-Rings (ref. 23) into their grooves by following the shape of the grooves
with a finger to ensure that the O-Rings are properly seated.
8b. Insert the stop bolt, nut and o’ring (ref. 18, 19, & 20) on tha lateral of body (ref. 4).
8c. Insert the indicator (ref. 2 & 3) and the seeger (ref. 1) on the pinion.
8d. Insert the end cap (ref. 25) on the body and tighten the screw (ref. 26) in an alternating order.
9. Adjustment:
•Supply low pressure compressed air to Port B (see drawings). Using a
hex key wrench, turn the regulation screw (right) until the pinion shaft is
perpendicular to the actuator axis (0° position); tighten the nut.
•Next, supply low pressure compressed air to Port A to open the actuator. The pinion
shaft must be at a 90° position (with respect to the 0° position), aligned with the
actuator axis. If it is not aligned, act on the stop bolt (left) and tighten the nut.
B
A

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6.3) Spring Cartridge Insertion
GNP actuators can be easily converted from Double Acting to Spring Return by changing the
spring number and configuration inside the end cap. GNP actuators can accept up to 6 springs
in the right end cap and 6 in the left end cap. We advise the insertion of at least two spring
cartridges in each end cap in order to have a uniform distribution of forces on the pistons. The
number of the springs loaded affects the torque value the actuator will be able to generate during
its working cycle.
Springs Installation Procedure:
1. Remove the four end cap screws (ref. 26) from the right and left end caps.
2. Remove the end caps (ref. 25)
3. Insert the correct number of spring cartridges into each end cap (i.e. GNP44–S4 = 4 + 4
springs). It is strongly advised to insert the plastic part of the cartridge containing the deep hole
into the appropriate end cap seat.
7. Safety Instructions
When operating any kind of element, you must follow the security instructions and it is
recommended to use personal protection gadgets:
1) Protect your eyes.
2) Wear gloves and appropriate working clothes.
3) Wear safety footwear.
4) Wear a helmet.
5) Have running water at hand.