HABONIM POWER-COMPACT SY Owner's manual
POWER-COMPACT SY-4PistonsPneumatic Actuator
Valves Series
Installation, Operation & Maintenance
POWER-COMPACT SCOTCH YOKE
4 Pistons Pneumatic Actuator
EN-COMPACT REV00-12/21
POWER-COMPACT SY-4PistonsPneumatic Actuator
Valves Series
Contents
1.
General........................................................................................................................... 1
2.
SIL ............................................................................................................................. 2
3.
Storage ...................................................................................................................... 2
4.
Installation...................................................................................................................... 3
4.1.
General ...................................................................................................................... 3
4.2.
Identification.............................................................................................................. 4
4.3.
Lifting data ................................................................................................................. 4
4.4.
Mounting on a valve ................................................................................................... 5
4.5.
Travel adjustment....................................................................................................... 7
4.6.
Solenoid valve mounting............................................................................................. 8
4.7.
Recommended tubing sizes ........................................................................................ 8
5.
Operation ....................................................................................................................... 9
5.1.
Operating conditions .................................................................................................. 9
5.2.
Principle of operation ............................................................................................... 10
5.3.
Operating media ...................................................................................................... 12
5.4.
Supply pressure........................................................................................................ 12
5.5.
Speed control ........................................................................................................... 12
6.
Maintenance................................................................................................................. 13
6.1.
Maintenance frequency ............................................................................................ 13
6.2.
Lubrication ............................................................................................................... 13
6.3.
Parts replacement .................................................................................................... 13
6.4.
Actuator configuration conversion............................................................................ 14
7.
Disassembly & Assembly Manual ..............................................................................
15
POWER-COMPACT SY-4Pistons Pneumatic Actuator
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COMPACT - 4 Pistons Pneumatic Actuator
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1.
General
This Installation, Operation & Maintenance manual covers the instructions required for safe use of the
Compact Scotch Yoke (SY) pneumatic actuator. Read the entire IOM before using this product.
Warnings & safety instructions
The user of this product must know and follow all applicable industry specifications for the safe installation
and use of these types of actuators. Improper use of the product may result in injuries or property damage.
Refer to the Habonim Compact SY catalogue for additional product safety information or contact Habonim.
1. Assure that the actuator is isolated from the air supply or electrical ancillaries before attempting to
perform any maintenance.
2. Before disconnecting the actuator from a valve, always be sure the line has been depressurized and
drained. Cycle the valve a few times to relieve any pressure that could be trapped in the body cavity.
3. Utmost caution must be taken when handling the actuator. Only trained and qualified maintenance
personnel who have read these instructions should disassemble or assemble the actuator.
4. Before operating an actuator which is connected to a valve in the pipeline make sure you know the
valve function.
5. Do not attempt to remove the actuator pistons by use of air pressure when the covers have been
removed.
6. Do not leave any grip key or shaft connection attached to the actuator, or try to manually operate the
actuator while it is still connected to the air pressure.
7. Use the actuator within the pressure and temperature limits indicated on the nameplate or as specified
in the product catalogue and IOM.
8. The operator must follow and observe any national or local safety laws and regulations.
9. Any product warranty will be invalidated in the case of improper operation resulting from
misapplication or faulty maintenance.
10. The warranty does not cover high cycle installations. High cycle applications is defined as 1 cycle/minute
on average measured on an hourly basis.
11. Every 500,000 cycles you should replace all the soft parts of the actuator with original Repair Kits.
12. Habonim bears no responsibility for external accessories attached to the Compact SY actuator.
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2.
SIL
Under normal operating conditions the COMPACT SY actuator should be inspected for proper functioning and
signs of deterioration every 50,000 cycles or 6 months (whichever comes first). Under severe operating
conditions inspection should be more frequent; detected defects should be repaired promptly.
Severe operating conditions can be defined as:
•Application temperature less than -20 °C (-4 °F)
•Application temperature higher than +80 °C (+176 °F) for standard applications
•Application temperature higher than +110 °C (+230 °F) for HT applications
Habonim recommends a proof test interval of 12 months; in case of Fail to Open ESD system, a partial stroke is
acceptable to confirm that the installation is functioning properly.
For ESD systems with a Fail-To-Close demand, it is necessary to plan a system shut-down; de-energize the
system and inspect the actuator turning to its fully closed position.
It is essential to log-in the following parameters on site QA records as a proof for preserving SIL capabilities:
date, hour, name and signature of the responsible engineer, air pressure on site, time to close the valve, time to
open the valve.
Habonim recommends actuator full maintenance operation every 500,000 cycles or 4 years, whichever comes
first (refer to clause 6 in this IOM for maintenance instructions). The combined corrosion and erosion allowance
for the actuator’s body wall thickness is 1 mm. When this allowance has been eroded or corroded, mechanically
removed or otherwise, the actuator should no longer be used. Inspect the actuator’s wall thickness every time
the actuator is maintained.
Maintenance team must read and understand the Habonim product IOM before starting the operation. In case
of a doubt please consult the Habonim engineering team.
When an actuator has been repaired or any maintenance was performed, check the actuator for proper
function (proof testing). Any failures affecting functional safety should be reported to the Habonim factory.
Client should consult the Habonim factory in order to obtain the product assessment, FMEDA report, and other
associated statistical data to satisfy SIL level.
3.
Storage
The Compact SY actuator has been packaged to provide protection during shipment, however, it can be
damaged in transportation. Prior to storage, inspect the actuator for shipping damage. Keep the actuators in
their original packing box during storage. It is recommended to keep the actuators in a clean and dry
environment until ready for use. The actuator has two air ports, which should be plugged during storage to
prevent liquids or other materials from entering the actuator during storage. If the actuators are to be stored
for a long period of time before installation, it is recommended to cycle them periodically to prevent setting of
the seals. Store the actuators indoors to protect them from humidity and dust.
POWER-COMPACT SY-4Pistons Pneumatic Actuator
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COMPACT - 4 Pistons Pneumatic Actuator
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4.
Installation
The installation procedure for COMPACT SY actuator is critical to ensuring both long life and satisfying
performance. Actuators stored on site, awaiting installation, should be kept in their original packing, in dry
conditions, where damage will not occur (see clause 3).
Before carrying out the installation, read all the installation and operation instructions in this manual.
4.1.
General
4.1.1. Carefully unpack the actuatorand check that there are no visible damages.
4.1.2. Check the nameplate for identification (see clause 4.2) and note any special warning tags or plates
attached.
4.1.3. The Compact SY can be installed in any appropriate potentially explosive hazardous area as listed on
the identification nameplate on the actuator. The Compact SY is certified to category 2 according to the
ATEX Directive 94/9/EC (Equipment intended for use in Potentially Explosive Atmospheres).
4.1.4. Actuators that may be located in Zone 1 or Zone 21 potentially explosive atmospheres must be installed
such that they are protected from risk of impact.
4.1.5. Pressurized air supplied to this equipment shall be taken from a source known to be non-hazardous and
free from ingress of foreign objects or liquids.
4.1.6. Make sure there are no air and/or electrical power supplies connected to the actuator each time you
transfer the actuator.
4.1.7. Check the actuator’s weight and use appropriate lifting device to lift the actuator when the transfer is
needed. There are threaded holes on the top surface of the actuator. Refer to the technical data in the
clause 4.3 to find the actuator weights and sizes of the threaded holes. They should be used only for
lifting the actuators, not for lifting the valves and actuators together.
4.1.8. Operate the actuator before the mounting on a valve and inspect any functionally significant features.
POWER-COMPACT SY-4Pistons Pneumatic Actuator
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4.2.
Identification
Compact SY actuators are supplied with a nameplate located on the side of the body. The information
includes actuator size, model, type, spring set, threads, indicator, additional options, date of manufacture,
protection rating, pressure limits and company logo.
The Temperature Class ‘T’ of the apparatus is determined by the process fluid.
4.3.
Lifting data
Actuator
Weight, kg
Lifting bolts thread
C100M - DA
117
M16
C100M - SR
185
Threaded hole for
lifting eye bolt
Threaded hole
for lifting eye bolt
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4.4.
Mounting on a valve
The actuator can be attached by a bracket (indirect mount) or mounted directly onto the valve.
The actuator bottom interface is in accordance with ISO 5211 and may come with square or with keyways
drive slots to fit various valve shafts.
Before mounting the actuator, make sure that the actuator and the valve rotate in the same direction and
are in the same operation position (open or closed).
Indirect mount
1. Attach the bracket to the valve’s top flange and secure it by tightening bracket bolts.
2. If stem adaptor is necessary, place it on the valve stem.
3. Position the actuator over the valve and lower it to engage the valve stem/stem adaptor with the
actuator yoke. Continue to lower until the actuator seats on the bracket surface.
4. To align the bolt holes, it may be necessary to turn or stroke the actuator a few degrees and/or adjust
the actuator’s stop screws (29).
5. Make sure that yoke drive, adaptor and valve stem are centered and concentric to prevent any side
loading to the yoke lower slide bearing (14) and to the valve stem packing.
6. Secure the actuator to the bracket by tightening the bolts.
Ensure proper tightening of fasteners to avoid loosening during operation.
Direct mount
Indirect mount
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4.5.
Travel adjustment will
quickly result in loss of bolt strain and subsequent leakage.
The actuator comes factory adjusted to produce a 90° rotation. The rotation is restricted by the yoke
stopping surfaces and two or four stop screws (29) which are threaded into the actuator body.
Adjustment screws are locked in place by LOCTITE® SF 7649 and HERNON Nuts N’ Bolts® 420.
Any change of screws position must be repeated with renewal of the glue over the screws thread.
Stroke
2 stop screws
4 stop screws
CCW stroke
CW stroke
The standard stop screws allow adjustment of +/-3° in
the travel limits.
Other Intermediate positions can be achieved with a
longer set of stop screws which will enable travel from
0° to 20° and from 90° to 70° rotation.
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4.6.
Solenoid valve mounting
Connection of the air supply is accomplished by mounting a solenoid valve directly onto the NAMUR
block (24) which has a mounting pad conforming to the NAMUR standards. (Only solenoids made to the
NAMUR standard can be mounted in this way.)
The Compact SY actuator can also be piped with solid or flexible tubing from remote solenoid valves.
4.7.
Recommended tubing sizes.
Actuator
Port thread
Tube size
C100M
G-1/2" ISO
1/2" NPT
16 mm
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5.
Operation
5.1.
Operating conditions
Work temperatures
The standard temperature limits for the Compact SY actuators are -20°C (-4°F) to +80°C (+176°F).
For temperatures below or above these figures special preparation and materials are required such as
grease, O-rings, yoke bearings and pads.
The Compact SY maximum work temperature is 120°C (248°F) when used with Viton O-rings and HT grease.
The Compact SY minimum work temperature is -40°C (-40°F) when used with LT O-rings and LT grease.
Maximum operating pressure
Do not exceed the following supply pressures:
DA and SR actuators: 8 barg (120 psig).
Explosive environments
The Compact SY can be used in any appropriate potentially explosive hazardous area as listed on the
identification nameplate on the actuator. The Compact SY is certified to category 2 according to the ATEX
Directive 94/9/EC (Equipment intended for use in potentially explosive atmospheres).
Conditions for safe use:
1. Layers of dust shall not be permitted to build upon the actuator.
2. Process fluid temperatures shall not approach the layer ignition temperature (LIT) or cloud ignition
temperature (CIT) of the dust atmosphere in which the equipment is to be used with a degree of safety
of 50K.
3. Actuators that may be in Zone 1 or Zone 21 potentially explosive atmospheres must be installed such
that they are protected from risk of impact. Actuators shall be subject to routine inspection and
replaced or repaired should any damage to the surface coating be noted.
4. Pressurized air supplied to this equipment shall be taken from a source known to be non-hazardous
and free from ingress of foreign objects or liquids.
5. User shall ensure any lubrication medium used has an auto- ignition temperature greater then 50K
above the maximum surface temperature of installed equipment and be resistant to carbonization.
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5.2.
Principle of operation
The Compact SY actuator is a pneumatic quarter-turn (90°) scotch yoke actuator. Air pressure applied to
the piston surface area generates thrust which transforms linear motion to rotary motion of the yoke. The
Compact SY has four pistons centrally located around one yoke. When the pistons move away from the
yoke, the yoke rotates counterclockwise (CCW) –CCW stroke. When the pistons move towards the yoke,
the yoke rotates clockwise (CW) –CW stroke.
Air connections
The operating air inlet and outlet occur via two ports of the NAMUR block (24). The ports are marked 2 (A
in this manual) and 4 (B), where port A is above the port B.
Port A is connected to the center chamber, while port B is connected to all the four pistons chambers via a
series of holes.
CCW Stroke
CW Stroke
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Actuator configurations
The actuator has two configurations: Double Acting (DA) and Spring Return (SR).
In DA actuator in CW and CCW strokes the pistons are pushed by air pressure.
In SR actuator in CCW stroke the pistons are pushed by air pressure and in CW stroke the pistons are
pushed by springs, which are located at the piston’s chambers.
Stroke
DA Actuator
SR Actuator
CCW stroke
Port A - pressure inlet to the center
chamber.
Port B –pressure release from the piston’s
chambers.
Port A - pressure inlet to the center
chamber.
Port B –pressure release from the spring’s
chambers.
CW stroke
Port B - pressure inlet to the piston’s
chambers.
Port A –pressure release from the center
chamber.
Springs push the pistons.
Port A –pressure release from the center
chamber.
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5.3.
Operating medium
Use clean dry air according to ISO 8573-1 class 4. Other inert gases may be used such as nitrogen, argon
and sweet natural gas. Thin hydraulic oil can also be used.
Do not use water, oxygen, or hydrogen as a supply medium.
•The operating medium is to be filtered to a particle size of 30 microns or less.
•When used in sub-zero temperatures it is essential to use an air dryer on the air supply line to prevent
moisture.
•In corrosive environments or in high humidity environments it is recommended to use a Breather
Block to avoid contaminated air from the environment entering the actuator.
Always consult with a representative of Compact SY for suitability and recommended practice.
5.4.
Supply pressure.
The supply pressure ranges for the Compact SY actuators are as follows:
DA actuator: 3-8 barg (30-120 psig).
SR actuator: 3-8 barg (40-120 psig).
When sizing an actuator to the available air supply, make sure you have adequate power in the actuator
to allow the valve to complete its operation and leave enough power for safety margin.
5.5.
Speed control
Habonim recommends using reducers to properly control the opening / closing speed of Compact SY
actuators, especially if mounted on butterfly valves or dumpers.
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6.
Maintenance
6.1.
Maintenance frequency
Under normal operating conditions the Compact SY actuator should be inspected for proper functioning
and signs of deterioration every 50,000 cycles or 6 months (whichever comes first). Under severe
operating conditions inspection should be more frequent; detected defects should be repaired promptly.
Severe operating conditions can be defined as:
•Application temperature less than -20 °C (-4 °F)
•Application temperature higher than +110°C (+230 °F)
Any failures affecting functional safety should be reported to the
Habonim factory.
Habonim recommends actuator full maintenance operation every 500,000 cycles or 4 years, whichever
comes first. Maintenance team must read and understand the Habonim product IOM before starting the
operation. In case of a doubt please consult the Habonim engineering team.
Caution: disconnect the actuator from all pneumatic and electrical power
supply before carrying out any assembly and disassembly activities.
6.2.
Lubrication
The actuators come lubricated from the factory and under normal operating conditions do not require
relubrication. In the event of actuator maintenance, it is recommended to use the following lubricants:
6.3.
Parts replacement
When carrying out maintenance a repair kit may be used to replace seals, bearings and other
nonreusable parts. The repair kit is same for DA and SR actuators. The repair kit is available from
Habonim or its stocking distributors. For detailed instructions of disassembly and assembly process refer
to the Disassembly and Assembly Manual.
Actuator type
O-ring type
O-ring working
temperature range
Lubricant type
Lubricant working
temperature range
Standard, LT, HC
NBR
-55 °C (-67 °F) to
+80 °C (+176 °F)
Berulub FR 16 B
-50 °C (-58 °F) to
+140 °C (+284 °F)
HT
Viton
-20 °C (-4 °F) to
+150 °C (+302 °F)
Berulub FR 16 B
-50 °C (-58 °F) to
+140 °C (+284 °F)
Nuclear
EPDM
-40 °C (-40 °F) to
+150 °C (+266 °F)
Novagard G662
-54 °C (-62 °F) to
+200 °C (+392 °F)
POWER-COMPACT SY-4Pistons Pneumatic Actuator
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Springs sets replacement
For SR actuator there are loaded spring cartridge sets for each model. The loaded cartridges are replaced
entirely with new ones. For disassembly and assembly instructions refer to the sections 2 and 3 of the
Disassembly and Assembly Manual.
Warning: Under NO circumstances should the springs cartridge
be cut or disassembled in order to change the springs set. The
only way to change the springs set is by changing to a different
springs cartridge.
6.4.
Actuator configuration conversion
Compact SY actuator can be converted from SR configuration to DA and vice versa.
DA to SR conversion
1. Disassemble the DA covers following the instructions in clauses 2.1-2.3 of the Disassembly and
Assembly Manual.
2. Assemble the springs cartridge and SR covers following the instructions in clause 3.4 of the
Disassembly and Assembly Manual.
SR to DA conversion
1. Disassemble the SR covers following the instructions in clauses 2.1-2.2, 2.4 of the Disassembly and
Assembly Manual.
2. Assemble the DA covers following the instructions in clause 3.3 of the Disassembly and Assembly
Manual.
POWER-COMPACT SY-4Pistons Pneumatic Actuator
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Disassembly & Assembly Manual
POWER-COMPACT SCOTCH YOKE
4 Pistons Pneumatic Actuator
Seriesincluded:
C100M
POWER-COMPACT SY-4Pistons Pneumatic Actuator
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Contents
1.
General......................................................................................................................... 17
2.
Disassembly............................................................................................................. 1
7
2.1.
Before starting
..................................................................................................... 17
2.2.
Identification
........................................................................................................ 17
2.3.
Disassembly of the double action covers
................................................................ 18
2.4.
Disassembly of the spring return covers
................................................................. 18
2.5.
Disassembly of the scotch yoke mechanism
............................................................ 20
2.6.
Disassembly of the drive shaft insert
...................................................................... 24
3.
Assembly ................................................................................................................. 25
3.1.
Before starting ......................................................................................................... 25
3.2.
Assembly of the scotch yoke mechanism .................................................................. 25
3.3.
Assembly of the double action covers....................................................................... 32
3.4.
Assembly of the spring return covers ........................................................................ 33
3.5.
Assembly of the drive shaft insert............................................................................. 33
3.6.
Fasteners tightening sequence.................................................................................. 34
3.7.
Fasteners tightening torques .................................................................................... 34
4.
Exploded drawing and BOM
............................................................................................35
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1.
General
•Before beginning, it is strongly recommended to review both the disassembly and assembly chapters.
•For stop screws use LOCTITE® SF 7649 and HERNON Nuts N’ Bolts® 420.
•For O-ring seals use lubricants indicated in the clause 6.2 table of the Maintenance manual.
•Equivalent agents may be applied, when approved by Habonim engineering.
•For any discrepancies, please contact Habonim
2.
Disassembly
2.1.
Before starting
2.1.1. Make sure you read all the warnings and safety instructions in this manual.
2.1.2. Disconnect the actuator from the valve and from any ancillary device.
2.1.3. Place the actuator in a clean area, free of dust, debris, grease, corrosives, and moisture. For security and
comfort perform disassembly on a table equipped with the necessary fixture and an available air supply.
2.1.4. Verify that the actuator is not pressurized. Check that the air ports are vented and that spring return
actuators are in the fail close position.
2.1.5. Secure the body of the actuator to the worktable, so that it could not move under applied loads.
2.1.6. Identify the model of the actuator according to the clause 2.2.
2.2.
Identification
Identify the model type of the actuator according to the following:
1. By the attached tag.
2. SR actuators can be identified by the longer cup cover and by "tensioned springs" warning on the
covers. DA actuators have flat covers without "tensioned springs" warning.
After identifying the actuator type, use the following disassembly instructions:
•
For DA actuators
follow the instructions in clause 2.2
•
For SR actuators
follow the instructions in clause 2.3
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2.3.
Disassembly of the double action covers
2.3.1. Before disassembly mark the covers (10) with the body. This is recommended so as to reassemble each
cover to its original position when re-assembling the actuator.
2.3.2. Remove the cover bolts (11). If initially the screws are jammed, strike the head lightly with a flat pin to
loosen them.
2.3.3. Remove the covers making sure not to damage the O-ring seals (8).
2.3.4. Remove cover O-ring (8) from its groove.
2.4.
Disassembly of the spring return covers
2.4.1. Before disassembly mark the covers (9) with the body. This is recommended to reassemble each cover to
its original position when re-assembling the actuator.
2.4.2. Open a gap of 10 mm maximum between the cover and the actuator body, releasing the cover bolts (11)
in sequence by turning each opposing bolt two rotations at a time. After opening the gap there should be
no tension on the cover, make sure the cover can be moved freely.
Warning: If after opening a 10 mm gap the cover is still under tension, close the cover by retightening
the bolts and contact Habonim. DO NOT release the cover completely.
Caution: springs in the actuator are under tension.
2.4.3. Only after ensuring that the cover is loose, release the cover bolts and remove the cover.
Table of contents
