Johnson Controls MP8 20 Series User manual

SDI No.: 111 6138 050 E
Issue date: 01/2003
A 17
MP8xxxxx20 (MP8000)
Pneumatic Valve-Actuator
JCI Regelungstechnik GmbH
Westendhof 8 ♦D-45143 Essen
Tel.: [phone] ♦Fax: [phone]
www.johnsoncontrols.com
General
These service and data information (in brief SDI)
are operating instructions and contain instructions
for the safe installation and operation of the
pneumatic actuator. Should difficulties occur,
during installation, which cannot be solved with the
help of this SDI please ask your supplier for further
information.
These SDI are in accordance with the relevant
safety standards and regulations of the EU. When
operating the positioner outside the Federal
Republic of Germany, it is the responsibility of the
control system administrator or operator to ensure
that valid national control standards are met. The
manufacturer maintains all rights for technical
changes and improvements at any time Operators
are to receive instructions in accordance with this
SDI.
Qualified personnel
These are persons conversant with the erection, installation, commissioning, operation and service of the
product and in possession of the respective qualifications through their activities and functions, e.g.:
• Instruction about and obligation to maintain adherence to all operative regional and factory-internal
directives and requirements, conditional to application.
• Training or instruction in accordance with standards of safety in maintenance and utilisation of adequate
safety- and protective equipment.
• Training in first aid, etc. (See TRB 700).
Application:
Diaphragm actuators in conjunction with control valves serve to regulate the flow of fluids in heating systems,
cooling systems and cold water systems. The stroke action distinguishes between direct or reverse action
actuators. Decreasing actuator air pressure allows the stem to be retracted by spring force. The term
“reversible actuator” means that it is possible to change the action of the actuator in-situ, with a conversion
kit. When converting the action of an actuator with hand wheel, the action of the hand wheel must be taken
into account. A pneumatic positioner (PR 10) can be used to regulate the stroke.
Valve and actuator application, are the responsibility of the control system administrator. Particular markings
on the valve with actuator such as flow directional arrow are to be observed.
Dry compressed air is an absolute requirement during usage in below zero temperatures!
Valve and actuator may be supplied as single units or as valve / actuator combinations, factory mounted and
tested.
Technical data
• Diaphragm area 160 cm2Stroke 13-mm • Diaphragm material EPDM
• Ambient temperature -4 to +80°C • Housing material Ck 10 (1.1121)
• Max. operating pressure 160 kPa • Stem material 9SMnPb36 (1.0737)
• Air quality requirements in accordance with DIN ISO 8573-1
• Air quality class: 3 – 2 – 3

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Additional equipment
• Hand wheel
• Pneumatic positioner
• (2) end position indicators + 2kΩ-feedback potentiometer
Storage:
• Storage temperature -4°C to +80°C, dry and free of dirt.
• Do not damage the lacquer. The lacquer is a foundation intended only as a protection against corrosion
while in storage and during transport.
• In rooms where moisture or condensation are present use heating or a drying agent to maintain a
moisture-free atmosphere.
Transport:
• Transport temperature -4°C to +80°C.
• Protect against external forces (shock, vibration etc.).
• Do not damage the protective lacquer.
Air pressure (kPa) to close-off force (N)
Diaphragm
Area (cm2)
Stroke
(mm)
Spring range
(kPa)
Spring close-off
force (N) 120 140 160
20 – 50 320 1120 1440 1760
160 13 60 – 90 960 480 800 1120
Air supply connection:
The diaphragm actuator is equipped with a tube connection permitting connection with 4 x 6-mm plastic
tubing.
Mounting orientation
It is recommended that the valves be mounted
within 90° of the upright position, in an easily
accessible location.
Caution:
When mounting in an inclined to
horizontal position, the yoke
should be fitted such that the
stanchions are aligned vertically
one above the other as is
depicted.
O.K.
90° Max.
Caution:
Remember to take tubing temperature limits into account.
Stanchions

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Danger:
Safe operation of the valve is only ensured if the valve is installed, commissioned and
serviced by qualified personnel in compliance with warning references in this SDI. In
addition, the general installation and safety regulations for piping, installation construction
and the professional use of tools and safety equipment must be guaranteed. Observe
unconditionally during all work on the control valve. Ignoring this information may cause
physical or material damages.
Pre-installation precautions:
• Provide protection against adverse weather conditions, e.g. moisture; (otherwise use drying agent).
• Suitable protective action prevents damage.
Installation site information:
The valve installation site should be easily accessible and provide sufficient room for service and removal of
actuators. Manual shut-off valves should be located up and downstream of the control valve, to facilitate
service and repairs without drainage of the piping system. The control valve should preferably be installed in
vertical position with actuator installed in the upright position. Inclined to horizontal installation without
support is only permissible for actuators with a low specific weight.
The permitted actuator weight when installed in the horizontal position, relative to valve stem, without
additional support at site is:
7kg for DN 15 - 40
Pipes should be insulated to protect actuators against high temperatures; here sufficient room is to be left for
servicing the stem seal pack. For trouble free function of the control valve the pipe immediately upstream of
the valve should be straight for the length of at least 2x DN and the pipe immediately downstream for the
length of at least 6x DN.
Pipes should be insulated to protect actuators against high temperatures; here sufficient room is to be left for
servicing the stem seal pack. For trouble free function of the control valve the pipe immediately upstream of
the valve should be straight for the length of at least 2x DN and the pipe immediately downstream for the
length of at least 6x DN.
Actuator mounting and removal information:
The control valve is normally supplied complete with actuator. It is not permitted to remove or replace an
actuator on systems in operation, under operating temperature and pressure. For conversion or service, the
actuator mounting procedure should follow the actuator SDI.
During mounting procedure care should be taken NOT to rotate the plug with downward pressure.
The maximum valve operating force0 must be observed when replacing the actuator. This is:
2000N for DN 15 – 40
Commissioning:
• Prior to commissioning check information on material, pressure, temperature and flow-direction are
in conjunction with the installation piping system plan.
• Follow TRB 700.
• Impurities in the piping system and valves, such as dirt, welding beads etc. will cause the system to
leak.
• Prior to commissioning a new installation, or re-commissioning after repairs or service, ensure that:
 Correct installation- and assembly work has been completed.
 Only qualified personnel carry out commissioning.
 Correct functional position of the valve is ascertained.
 Maintenance of existing protective facilities is carried out

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Abbreviations:
DA Actuator:
Actuator stem extends (spring-return up).
RA Actuator:
Actuator stem retracts (spring-return down).
Single item delivery
DA and RA actuator construction details.
• Screw the stem extension as far as possible into the actuator stem.
• Always: Pull the valve stem up to connect to DA actuators.
Push the valve stem down to connect to RA actuators.
• Place the actuator with yoke onto the valve bonnet and tighten the ring nut.
• Connect the air supply and impinge the diaphragm with initial start pressure (see table below).
Spring range Impinging pressure
[kPa]
Operating pressure
[kPa]
20 - 50 20 50
60 - 90 60 90
• Unscrew the stem extension until it abuts the valve stem; observe the machined surfaces (see fig
below).
• Fit the coupler.
• Fix the stroke position indication plate.
• Fit other accessories e.g. positioner, position feedback indicator etc in accordance with the device by-
pack.
Replacing the actuator and changing the DA or RA mode
• Remove accessories e.g. positioner, position feedback indicator etc.
• Remove cover when fitted and remove the hand wheel assy. in accordance with paragraph Fitting and
removing DA hand wheel.
• Remove coupler.
• Remove ring nut.
• Remove the actuator
• When replacing the actuator observe paragraph Single item delivery
• When changing the action mode, remove the yoke by removing the 4 bolts. Turn the actuator body
upside down (180°) refit the yoke to the new position i.a.w. paragraph Single item delivery. When
necessary, refit the hand wheel i.a.w. Fitting and removing DA hand wheel.
Machined surfaces
Note:
The pressure equipment directive (PED) and also the VDI/VDE 2174
from October 1967 for pneumatic actuators, have been observed

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Fitting and removing DA hand wheel.
To fit carry out the following sequence
1. Remove cover.
2. Screw the four spacer-studs (1) into actuator casing and place cover (11) in position.
3. Position the bearing (3) on the threaded spindle (4) as in diagram.
4. Now place the plate (2) and then the lock washer (5) on to the spindle and align the holes with the holes
in the hand-wheel (6), then, fix with spring dowel (7).
5. Place O-ring (9) into the plate (2) groove.
6. Screw in the threaded bush (8) until it hits the stop (don’t forget to grease).
7. Fit the pre-assembled unit onto spacer-studs (1) so that the threaded bush (8) is guided by the
spacer-studs (1), also the cap fits into the plate (2) groove with O-ring (9).
8. Fasten the assembly onto the spacer-studs (1) with Allen screws (10).
9. Fix ID Plate on cover (11)
Test for trouble free function by operating the hand-wheel manually through one full stroke
To remove follow the procedure in reverse
Caution:
To ensure correct function during operation the hand
wheel must be turned anti-clockwise till it hits the stop.
Caution:
It is necessary to grease the threaded bush (8) and threaded
spindle (4). With the grease (in tube) provided.

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Hand wheel DA
MP822
11
8
3
2
5
6
1
9
( M = 10Nm )
10
7
4

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A 23
Fitting and removing RA hand wheel.
To fit carry out the following sequence
1. Remove cover.
2. Screw the four spacer-studs (1) into actuator casing.
3. Remove transport lock from threaded bush (2). Push the Allen key through the threaded bush into the
7/16th UNF bolt (X) and connect to actuator stem. Ensure that the threaded bush (2) is guided by the
spacer-bolts (1).
4. Connect the hand wheel (4) to the threaded spindle (3) with the spring dowel (5)
5. Position the bearing (6) in the plate bore (7) as in diagram.
6. Place the hand wheel (4) with the threaded spindle (3) through the plate (2) as in diagram.
7. Place the corrugated washer (8) and washer (9) onto the threaded spindle (3). Carefully fit the circlip
(10).
8. Place O-ring (11) into the plate (7) groove.
9. Place the cover (12) onto the actuator.
10. Screw the (don’t forget to grease) threaded spindle (3) into the threaded bush (2) until it the plate (7) lays
on the cover and the spacer-studs (1). Observe that the cover (12) fits into the plate (7) groove with O-
ring (11).
11. Fasten the assembly onto the spacer-studs (1) with Allen screws (13).
12. Fix ID Plate on cover (12)
Test for trouble free function by operating the hand-wheel manually through one full stroke
To remove follow the procedure in reverse.
Caution:
To ensure correct function during operation the hand
wheel must be turned clockwise till it hits the stop.
Caution:
It is necessary to grease the threaded bush (2) and threaded
spindle (3). With the grease (in tube) provided.

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Hand wheel RA
MP832
9
8
7
6
4
10
3
12
11
1
2
13
5
X
( M = 10Nm )
( M = 40Nm )

111 6138 050 E 9
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To replace the hand-wheel gasket of a direct action device (DA):
• Remove the hand-wheel assembly and cap. For refit see: Fitting and removing hand wheel.
• Remove the circlip, then the nylon spacer and replace the gasket.
• Refit nylon spacer and circlip then refit hand-wheel etc.
To replace the hand-wheel gasket of a reverse action device (RA):
Condition: The actuator is in-situ.
• Remove actuator as in paragraph: Replacing the actuator and changing the DA or RA mode.
• Replace the gasket as in paragraphs To replace the hand-wheel gasket of a direct action device (DA)
• For refit, carry out in reverse order.
Replacing the diaphragm of a Direct Action or Reverse Action device:
• Remove the hand-wheel assembly and cap. For refit see paragraphs:Fitting and removing hand wheel.
• Remove the nuts and bolts around the circumference of the actuator.
• Remove the housing top half.
• Slowly unscrew the spindle and remove the pressure disc.
• Carefully! Replace the diaphragm.
• Reassemble and refit the actuator.
Pressure disc
Stem
Housing top half
Diaphragm
Caution:
The replacement gasket must be greased before use. Use
only silicone free lubricants.

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Removing the control valve (valve with actuator)
Additional to the general installation guidelines and the TRB 700, the following
points must be observed:
• Pressure free pipe system
• Sufficiently cooled fluid
• Drained system
• Sufficiently ventilated pipe system where aggressive and corrosive fluids are
concerned
• Only qualified personnel are to be allowed to carry out installation.
Tools and spares
MP8x2
Ring nut wrench: 111 6235 010
For gasket and diaphragm
replacement:
Circlip Pliers 111 5330 010
Lubricant:
Silicone free actuator grease (60g tube) 111 5520 010
Repair kits:
Diaphragm MP8000-6325
Gasket 02-857-23
Ring nut wrench
Accessories: Order No. Weight
Pneumatic positioner (PR10) PY - 1010 – 3000 1.0kg
(2) auxiliary switches and 2kΩ(ER2) PQ - 1000 – 3020 1.0kg
Universal accessory kit PQ - 2713 – 3011 0.4kg
(Every accessory device requires an accessory kit)
Hand wheel retro-fit kits Order No. Weight
Hand wheel DA (for MP822...) 111 6128 011 2.0kg
Hand wheel RA (for MP832...) 111 6129 011 2.4kg
Device code:
MP8 20
Action mode Accessories
Direct Acting = 2
0 = Standard
Reverse Acting = 3
2 = (2) aux. switches and 2kΩposition feedback
Stroke Positioner+handwheel
13 mm = 2
5 = None
6 = DA (PY1010)
7 = RA positioner (PY1010) + hand wheel
Spring range 8 = Hand wheel
20 – 50 kPa = C
60 –90 kPa = E
Danger

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Close-off Pressures [kPa] with VG Valves
DA Actuator
Spring-return up
PDTO Valve
Mixing: Inlet 1 – Outlet
Diverting: Inlet – Outlet 2 (Bypass)
RA Actuator
Spring-return down
PDTC Valve
Mixing: Inlet 2 – Outlet
Diverting: Inlet – Outlet 2 (2-way)
DA Actuator
Air Pressure closes
PDTO Valve
Mixing: Inlet 1 – Outlet
Diverting: Inlet – Outlet 2 (Bypass)
RA Actuator
Air Pressure closes
PDTC Valve
Mixing: Inlet 2 – Outlet
Diverting: Inlet – Outlet 2 (2-way)
120 kPa 140 kPa 160 kPa
Spring Range
[kPa] Spring Range
[kPa]
Spring Range
[kPa]
Spring Range
[kPa]
20 - 50 60 - 90 20 - 50 60 - 90 20 - 50 60 - 90 20 - 50 60 - 90
Spring ID No. Spring ID No. Spring ID No. Spring ID No.
DN Kvs
Coefficient Actuator
23 63 23 63 23 63 23 63
VG8000N PN 16 Valves
15 4.0 + 2.5 600 1600 1600 1600 1600 1600 1600 1600
15 0.1 – 1.6 1600 1600 1600 1600 1600 1600 1600 1600
20 4.0 / 6.3 200 1600 1600 890 1600 1600 1600 1600
25 6.3 / 10 90 1600 1600 560 1600 1510 1600 1600
32 10 / 16 - 1000 1250 230 1600 740 1600 1250
40 16 / 25
MP8x2
- 580 740 100 1060 420 1380 740
VG8300N PN 16 Valves
40 16 / 25 MP8x2 - 1600 1600 1600 1600 1600 1600 1600
VG8000H PN 25 Valves
15 4.0 + 2.5 30 2500 2500 1330 2500 2500 2500 2500
15 0.1 – 1.6 820 2500 2500 2500 2500 2500 2500 2500
20 4.0 / 6.3 - 2500 2500 590 2500 1940 2500 2500
25 6.3 / 10 - 1780 2250 350 2500 1300 2500 2250
32 10 / 16 - 880 1140 120 1650 630 2160 1140
40 16 / 25
MP8x2
- 510 670 30 990 350 1320 670
VG8300H PN 25 Valves
40 16 / 25 MP8x2 - 2500 2500 2500 2500 2500 2500 2500

12 111 6138 050 E A 28
Close-off Pressures [kPa] with VBD Valves
DA Actuator
Spring-return up
PDTO Valve
Mixing: Inlet 1 – Outlet
Diverting: Inlet – Outlet 2 (Bypass)
RA Actuator
Spring-return down
PDTC Valve
Mixing: Inlet 2 – Outlet
Diverting: Inlet – Outlet 2 (2-way)
DA Actuator
Air Pressure closes
PDTO Valve
Mixing: Inlet 1 – Outlet
Diverting: Inlet – Outlet 2 (Bypass)
RA Actuator
Air Pressure closes
PDTC Valve
Mixing: Inlet 2 – Outlet
Diverting: Inlet – Outlet 2 (2-way)
120 kPa 140 kPa 160 kPa
Spring Range
[kPa] Spring Range
[kPa]
Spring Range
[kPa]
Spring Range
[kPa]
20 - 50 60 - 90 20 - 50 60 - 90 20 - 50 60 - 90 20 - 50 60 - 90
Spring ID No. Spring ID No. Spring ID No. Spring ID No.
DN Kvs
Coefficient Actuator
23 63 23 63 23 63 23 63
VBD PDTC Two-Way Valves
15 4.0 1340 2500 2500 2250 2500 2500 2500 2500
15 0.6 – 1.0 2430 2500 2500 2500 2500 2500 2500 2500
15 1.6 – 2.5 2500 2500 2500 2500 2500 2500 2500 2500
25 6.3 / 10 540 1850 2170 870 2500 1520 2500 2170
40 16 / 25
MP8x2
60 570 700 190 950 440 1210 700
VBD Mixing Valves
15 4.0 - 2500 2500 1150 2500 2500 2500 2500
15 0.6 – 1.0 370 2500 2500 2500 2500 2500 2500 2500
15 1.6 – 2.5 2500 2500 2500 2500 2500 2500 2500 2500
25 6.3 / 10 - 900 1330 - 2150 480 2500 1330
40 16 / 25
MP8x2
- 130 270 - 550 - 830 270

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Dimensions in mm
416
266
160
102
Ø54
+0.15
219
25
M
Ø54
+0.15
M
25
219
102
372
160
416
160
25
219
83.5
416
M
Ø54
+0.15
266
416
83.5
219
372
Ø54
+0.15
25
M
160
Stroke
Stroke
RA actuator without hand wheel RA actuator with hand wheel
DA actuator without hand wheel DA actuator with hand wheel
Stroke
Stroke
Approx. 38
Approx. 38
Approx. 38 Approx. 38

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JCI Regelungstechnik GmbH
Westendhof 8 ♦D-45143 Essen
Tel.: [phone] ♦Fax: [phone]
www.johnsoncontrols.com
Rights to make technical changes
without warning reserved
Causes and remedies when malfunction occurs
When experiencing malfunction please check that the installation and adjustments were carried out in
accordance with these operating instructions. Properly qualified personnel (see: Qualified personnel) must
always be present during maintenance or repair. The TRB 700 is to be observed.
Compare information regarding materials, pressure, temperature, flow direction, actuator action, spring range
and controller, with installation plans of the piping system. The conditions of usage must also correspond to
these operating instructions, the data sheet and the technical information given on the ID plate.
Danger
Troubleshooting
Malfunction Possible cause Remedial action
No air pressure Check air pressure system
Split diaphragm Replace membrane
Actuator does not move valve
stem Valve plug stuck Clean plug and valve seat or when
necessary replace
Actuator adjustment incorrect Carry out new adjustment
Control signal does not correspond to
spring range
Check control and spring range
Start-point incorrect
High back pressure in valve Use positioner
Valve plug etched by sticking dirt
particles
Clean internal parts, smoothen
damaged areas
Valve stem moves jerkily
Positioner setting incorrect Re-set positioner
Worn seals and gaskets
High air consumption Leaky tubes Replace
Unstable control, oscillation in control
system
Check amplification factor or time
constant at the controller
Stem moves constantly
Positioner setting incorrect Re-set positioner
Sealing surfaces of the seat edge or
plug washed away or worn
Replace plug (when necessary
with stem) and / or seat ring
Seat and plug dirty Clean valve internal parts
Pressure balance chamber leaking Replace circlip
Leakage rate is too high when
valve closed
Actuator thrust too low Use actuator with more thrust
Valve stem „knocking““ Flow through valve in wrong direction Correct the flow direction
During troubleshooting, safety regulations must be observed unconditionally. If the problem
cannot be solved using the following troubleshooting table please contact the
supplier/manufacturer.
See paragraphs: “Actuator mounting and removal information” and “Removing the
control valve (valve with actuator)”for any work to be carried out on the valve.