Mesto jamesbury Valv-Powr VPVL Operating and maintenance manual

Valv-Powr® VPVL
Mod D Value-Line®
Double-Opposed Piston Actuators
Installation, Maintenance and
Operating Instructions
IMO 553 EN • 5/2017

2 IMO-553 EN
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about safe handling and operation of the actuator. If you require
additional assistance, please contact the manufacturer or manufacturer’s representative. Addresses and phone
numbers are printed on the back cover. See also www.metso.com/valves for the latest documentation.
SAVE THESE INSTRUCTIONS!
TABLE OF CONTENTS
1 GENERAL................................................................... 3
1.1 Warning............................................................................. 3
2 TECHNICAL DATA ..................................................... 3
3 INSTALLATION ......................................................... 4
3.1 General.............................................................................. 4
3.1 Operation ......................................................................... 4
4 MAINTENANCE......................................................... 4
4.1 General.............................................................................. 4
4.2 Disassembly..................................................................... 4
4.3 Assembly .......................................................................... 6
5 SAFETY LOCKOUT DEVICE..................................... 10
6 ACTUATOR STORAGE ............................................. 11
6 REPAIR KITS/SPARE PARTS .................................... 11
7 EXPLODED VIEW..................................................... 12
Parts list......................................................................................13
Subject to change without notice.
All trademarks are property of their respective owners.

IMO-553 EN 3
1. GENERAL
This instruction manual contains important information
regarding the installation, operation, and troubleshoot-
ing of the Jamesbury® Valv-Powr VPVL Mod D Value-Line
Double-Opposed Piston Actuators. Please read these
instructions carefully and save them for further reference.
1.1 WARNING:
1. KEEP HANDS AND CLOTHING AWAY FROM THE ACTUATOR
PINION AT ALL TIMES.
2. DO NOT ATTEMPT TO DISASSEMBLE INDIVIDUAL SPRING
CARTRIDGES. DISASSEMBLY OF THE CARTRIDGE MAY RESULT
IN SERIOUS PERSONAL INJURY. IF MAINTENANCE OF THE
CARTRIDGE IS NECESSARY, IT MUST BE RETURNED TO METSO.
3. SHUT OFF AND BLEED ALL SUPPLY LINES BEFORE
INSTALLATION OR SERVICING. DO NOT REMOVE END CAPS
WHILE THE ACTUATOR IS PRESSURIZED.
4. BEFORE INSTALLING THE VALVE AND ACTUATOR, BE SURE
THAT THE INDICATOR ON TOP OF THE ACTUATOR CORRECTLY
SHOWS THE VALVE POSITION. FAILURE TO ASSEMBLE THESE
PRODUCTS TO INDICATE THE CORRECT VALVE POSITION
COULD RESULT IN PERSONAL INJURY.
5. AN ACTUATOR MUST BE SIZED ACCURATELY FOR PROPER
OPERATION. REFER TO INFORMATION ON ACTUATOR OUTPUT
TORQUES IN A1115 OR A1114 BULLETIN AND VALVE TORQUE
REQUIREMENTS IN THE APPROPRIATE VALVE BULLETIN.
6. OPERATING THE ACTUATOR OUTSIDE OF THE PUBLISHED
TEMPERATURE LIMITS MAY DAMAGE INTERNAL AND
EXTERNAL COMPONENTS DISASSEMBLY OF SPRING RETURN
ACTUATORS MAY BE DANGEROUS.
7. OPERATING OVER THE PUBLISHED PRESSURE LIMITS MAY
RESULT IN PREMATURE FAILURE AS WELL AS DAMAGE TO THE
HOUSING.
2. TECHNICAL DATA
1. Operating Media: Dry or lubricated air, non-corrosive
and inert gas, or light hydraulic oil.
2. Air Supply: 116 psi (8 bar) Maximum.
3. Temperature:
Standard – NBR; -40° to 176°F (-40° to 80°C)
HT – Viton O-rings: 5° to 302°F (-15° to 150°C)
LX – Silicone: -60°F to 176°F (-51°C to 80°C)
4. Lubrication: Factory lubricated for the life of the actua-
tor under normal operating conditions.
5. Construction: Suitable for indoor and outdoor use.
6. External Travel Stops: -5° up +5° on the Closed posi-
tion and +5° down to -5° in the Open position.
“2” “4” “2” “4”
Double-Acting (Top View)
Air supplied to Port 2 forces pistons apart and toward end
positions with exhaust air exiting at Port 4 (a counterclockwise
rotation is obtained).
Air supplied to Port 4 forces pistons toward center with exhaust
air exiting at Port 2 (a clockwise rotation is obtained).
Figure 1
Spring-Return (Top View) Spring-to-Close
“2” “4” “2” “4”
Air supplied to Port 2 forces pistons apart and toward end
position, compressing springs. Exhaust air exits at Port 4 (a
counterclockwise rotation is obtained).
Loss of air pressure allows springs to force pistons toward center
position with exhaust air exiting at Port 2 (a clockwise rotation is
obtained).
Figure 2

4 IMO-553 EN
3. INSTALLATION
3.1 General
1. Check to see that the desired failure mode is correc
(Figures 1 & 2). In the spring-to-close mode, the actu-
ator will cycle clockwise to close upon loss of pressure.
If the spring-return actuator is not set up in the con-
guration desired, follow the disassembly procedure
section 4.2. Reverse the orientation of the pistons,
then reassemble following the assembly procedure,
section4.3.
2. Mount the actuator to the valve, following the direction
in the linkage AMI or valve IMO.
3. Connect a regulated air supply to the NPT tting in the
actuator housing. CAUTION: The maximum operat-
ing pressure is 116 psi (8 bar).
4. Adjust the stop screws following ASSEMBLY Section
4.3.5.
3.2 Operation
1. The actuator series, size, operating pressure, operating
temperature, output torque, spring directions, and
drive type is determined by the actuator designation.
2. The label lists the actuator series, size, operating pres-
sure, maximum pressure, and serial number.
3. Actuator designation example, VPVL300SR6BD is
a spring-return series, VPVL300 double-opposed piston
actuator that has 80-psi (5.5-bar) springs, a Teon®-
coated anodized housing (protection B), an end-of-
spring-stroke output torque of 44.9 FT•LBS (60.8 N•m).
4. MAINTENANCE
4.1 General
Although Metso’s Jamesbury actuators are designed to work
under severe conditions, proper preventative maintenance
can signicantly help to prevent unplanned downtime and
in real terms reduce the total cost of ownership. Metso rec-
ommends inspecting actuators at least every ve (5) years.
The inspection and maintenance frequency depends on the
actual application and process condition.
NOTE: All VPVL actuator fasteners are metric. Under normal
operating conditions the actuator requires only periodic
observation to ensure proper adjustment. Service kits are
available to replace seals and bearings (soft parts). These
parts are identied in (Figure 23) and listed in (Table 3).
(Table 1) below lists kit part numbers.
4.2 Disassembly
When disassembly of the actuator is required for mainte-
nance, remove the actuator from the valve. Ensure proper
lifting procedures are followed when moving or carrying
actuators. CAUTION: Do not use the M5 VDE/ VDI mount-
ing holes or the M6 hole in the pinion for lifting the
actuator.
When disassembling VPVL actuators, use caution and be
certain that the actuator is free from accessories and the air
supply is disconnected. When the actuator is a springreturn
unit, make sure that the actuator is in the failed position
before disassembling.
1. Removal of Position Indicator (19,20), (Figure 3):
A. Remove cap screw if tted (39).
TABLE 1
Complete Service Kit
Actuator Standard High Temp.
VPVL-01/011 RKP-152 RKP-232
VPVL-050/051 RKP-262 RKP-233
VPVL-100 RKP-263 RKP-234
VPVL-200 RKP-264 RKP-235
VPVL-250 RKP-265 RKP-236
VPVL-300 RKP-266 RKP-237
VPVL-350 RKP-267 RKP-238
VPVL-400 RKP-268 RKP-239
VPVL-450 RKP-269 RKP-240
VPVL-500 RKP-270 RKP-241
VPVL-550 RKP-271 RKP-242
VPVL-600 RKP-272 RKP-243
VPVL-650 RKP-273 RKP-244
VPVL-700 RKP-274 RKP-245
VPVL-800 RKP-275 RKP-246
39
19
Figure 3
02, 04, 03,and 11
Figure 4

IMO-553 EN 5
B. Lift position indicator (19) o shaft; it may be
necessary to pry gently with a screwdriver.
2. Removal of Stop Cap Screws (02), (Figure 4):
A. Remove both stop cap screws (02) together with
nut (04) and washer (03).
B. Remove stop screw o-rings (11) and discard if
replacing all soft parts.
3. End Cap (30) Disassembly, (Figure 5):
A. Remove the end cap bolts (13) in the sequence
shown in (Figure 5). CAUTION: When disassem-
bling a spring return actuator, the end cap (30)
should be loose after unscrewing end cap bolts
(13) 4-5 turns. If there is still force on the end cap
(30) after 4-5 turns of the end cap bolt (13), this
may indicate a damaged spring cartridge and
any further disassembly should be discontinued.
Further disassembly of the end-caps may result
in serious personal injury. Return actuator to
Metso for further maintenance.
B. For spring return actuators, remove spring cartridg-
es (17).
Figure 5
50
60
40
40
Figure 6
C. Remove end-cap o-rings (14) and discard if replacing
all soft parts.
4. Piston (40) Disassembly, (Figure 6):
A. Holding the body (50) in a vice (or similar device),
rotate the drive shaft (60) until the pistons (40)
are released. CAUTION: Air Pressure should not
be used to remove the pistons from the body.
Clean and inspect the piston teeth for signs of wear.
Replace piston if wear seems excessive.
B. Remove piston o-ring seal (16) using a screwdriver.
Remove the piston head (15) and piston back (5)
bearings. Discard bearings if replacing all soft parts.
5. Drive Shaft (60) and Bearing (6, 7) Disassembly,
(Figure 7):
A. Remove spring clip (18) carefully. Remove external
thrust bearing (8) and thrust washer (10).
B. Apply downward force to top of drive shaft (60)
until it is partially out of the bottom of the body
(50) and the octi-cam (1) and internal thrust bearing
(8) can be removed. Remove the octi-cam (1) and
internal thrust bearing (8). Push the drive shaft (60)
completely out of the bottom of the body (50). If the
shaft (60) does not move freely, gently tap with a
plastic mallet.
C. Remove the top and bottom shaft bearings (6, 7)
and top and bottom shaft o-rings (21, 22). Discard if
replacing all soft parts.
6. Cleaning and Inspection.
A. When all components are disassembled, those
not being replaced should be properly cleaned and
inspected for wear prior to re-assembly.
18
1
8
50
8
10
60
Figure 7

6 IMO-553 EN
60 50
TABLE 2
Recommended VPVL Lubricants
General Use Dow Corning type Molykote® G-2003
O-Ring Areas Dow-Corning Silicone 111
(For Standard and High Temperature)
Parker Super-O-Lube
(For LX Option)
60
6
21
20
7
Figure 8
18
8
1
1
8
10
60
60
1
50
Figure 9
4.3 Assembly
Prior to assembly, ensure that all components are clean
and undamaged.
NOTE: (Table 2) lists the recommended Valv-Powr
lubricants.
1. Drive Shaft (60) Assembly, (Figures 8 & 9):
A Install the top and bottom shaft bearings (6, 7)and
o-rings (21, 22) onto the shaft (60).
B. Apply grease to the shaft bearings (6, 7), using a gen-
eral purpose grease listed in (Table 2). Apply grease
to the shaft o-rings (21,22) using the recommended
o-ring-area grease listed in (Table 2).
C. Partially Insert the shaft (60) into the body (50).
Install the octi-cam (1) onto the shaft in the orienta-
tion shown in (Figure 9). The edges of the octi-cam
(1) should align with the edges of the square in the
bottom of the shaft (60). Insert the internal thrust
bearing (8) over the octi-cam (1). Fully insert the
shaft into the body (50).
D. Install the external thrust bearing (8), thrust washer
(10), and the spring clip (18).
2. Piston (40) Assembly, (Figures 10 through 13):
A. Install the piston o-ring seal (16) and the piston head
(15) and piston back (5) bearings.
B. Apply grease to the internal bore of the body (50)
using a recommended o-ring area grease listed in
(Table 2). Apply grease to the piston (40) rack teeth
using a recommended generalpurpose grease listed
in (Table 2).
Molykote is the registered trademark of Dow Corning
Corporations.
Figure 10

IMO-553 EN 7
C. Hold the body (50) in a horizontal position by insert-
ing the top of the shaft in a vice, or inserting the bot-
tom of the shaft connection into a male drive tted
into a vice as shown by (Figure 10).
D. Ensure that the octi-cam (1) is in the correct position
with respect to the stop screw holes as shown by
(Figure 11).
E. For standard-rotation assembly (clockwise to close)
rotate the body (50) 40 – 45° counterclockwise (if
viewing the bottom of the actuator), or clockwise (if
viewing the top of the actuator) as shown in (Figure
12).
F. Press the two pistons (40) simultaneously into the
body (50) until the piston racks are engaged and
rotate the body clockwise (if viewing the bottom of
the actuator), or counter-clockwise (if viewing the
top of the actuator), until the stroke is completed.
G. To ensure that the piston (40) teeth are evenly
engaged, fully compress both pistons (40) inward
and measure the distance from the edge of the body
to the piston (40) face on each side, shown as dimen-
sion “A” in (Figure 12). If a dierent value is obtained
on each side, remove the pistons and repeat from
step 2d.
H. Temporarily install the position indicator (19) onto
the shaft (60) to determine whether the correct
stroke is obtained, Verify that the slot in the top of
the position indicator (19) will rotate a minimum of
5° beyond the 90° vertical centerline of the actua-
tor body (50) and a minimum of 5° beyond the 0°
horizontal centerline of the actuator body as shown
in (Figure 13). If the proper stroke is not obtained,
remove the pistons and repeat from step 2d. Once
the proper stroke is veried, remove the position
indicator (19).
3. End Cap (30) and Spring Cartridge (17) Assembly,
(Figures 14 through 16):
A. For spring-return actuators, insert the proper quan-
tity of spring cartridges (17) according to the pattern
shown in (Figure 14) (referring to the total number
of springs).
AA
40°- 45°
Figure 12
Spring to Close or Clockwise to
Close for Double Acti
n
Close for Double Acting
Octi
Bottom Square
Orientation
-Cam
elohwercspotSelohwercspotS
Bottom Square
Orientation
-Cam
Spring to Open or Counterclockwise
to Open for Double Acting
Octi
elohwercspotSelohwercspotS
Figure 11 (Looking from above)
5°
Figure 13

8 IMO-553 EN
B. Apply grease to the end-cap o-ring seals, using the
recommended o-ring-area grease listed in (Table 2).
Fit the end-cap o-ring seals (14) into the groove in
each end cap (30, 31).
C. Fit the end caps (30) onto the body (50), verifying
that the o-ring seals (14) remain in the grooves.
D. Insert all end-cap screws (13) and hand tighten.
Complete tightening by following the sequence
indicated in (Figure 16), using torques listed in
Table 4.
Figure 14
17
50
4. Assembly of Stop Screws (2) and Stroke
Adjustment. (Figure 17):
A. Insert the nut (4), washer (3), and o-ring (11) onto the
stop screws (2).
B. Screw the stop screws (2) into the body (50).
5. External Travel Stop Adjustment, (Figure 17):
The stop adjustment screw (2) to the right controls the
clockwise end of travel. The stop adjustment screw (2) to
the left controls the counter-clockwise end of travel.
A. Cycle the actuator/valve to the clockwise end of
travel and measure to determine if the valve is in
the proper position. (In most applications this will be
fully closed.)
B. If the valve is not in the correct clockwise position,
turn the right stop adjustment screw (2) IN to reduce
actuator travel, or OUT to increase actuator travel.
C. When the correct clockwise position is obtained,
hold the adjusting screw (2) stationary while tight-
ening the lock nut (4).
Figure 15 2, 4, 3 and 11
Figure 17

IMO-553 EN 9
19.5
19.1
19.6
19
39
Figure 18
D. Cycle the actuator/valve to the counter-clockwise
end of travel and measure to determine if the valve is
in the proper position. (In most applications this will
be fully opened.)
E. If the valve is not in the correct counter-clockwise
position, turn the left stop adjustment screw (2) IN to
reduce actuator travel, or OUT to increase actuator
travel.
F. When the correct counter-clockwise position is
obtained, hold the adjusting screw (2) stationary
while tightening the lock nut (4).
6. Position Indicator (19, 39) Assembly. (Figure 18):
A. Fit position indicator (19) on the shaft (60), verifying
that it indicates the correct actuator position.
B. Tighten cap screw (39) to secure the position indica-
tor.
7. Setting 100% Adjustable Stop (If applicable).
(Figure 19):
To limit the rotation on the stroke beyond the standard ±5°
of a VPVL actuator, a stainless steel 100% adjustable travel
stop option can be added. The stops, located in the end
caps, allow the valve position to be set anywhere between
full closed and full open. This option limits travel of only the
counter-clockwise stroke for standard double-acting and
spring-closed units. Follow the proceeding steps in order to
set the 100% adjustable travel stops.
Figure 19

10 IMO-553 EN
Double Acting Actuators:
A. Back o one travel stop screw, leaving it partially
threaded in the end cap. Entirely remove the other
stop screw from the other end cap.
B. Open valve using air pressure. NOTE: Actuator will
leak due to removed travel stop.
C. Use the indicator pointer on top of actuator to
determine if valve is open to desired position. If not,
repeat steps 1-3, backing o or screwing in stop
screw to attain proper open position of valve.
D. Make sure O-ring is in proper position in counter-
sunk area on end cap and the washer is in place.
Tighten down nut to set stop position.
E. Thread in the other travel stop, making sure the
O-ring and washer are in the correct place. When the
travel stop will not thread any further, tighten nut to
set stop position.
F. The previous steps set the open travel stop. See
section 4.3.5 for instructions on setting the close
position stop.
Spring Return Actuators:
A. Back o one travel stop screw, leaving it partially
threaded in the end cap. Entirely remove the other
stop screw from the other end cap.
B. Open valve using air pressure. Note actuator will leak
due to removed travel stop.
C. Keeping air pressure applied to actuator, use the
indicator pointer on top of actuator to determine if
valve is open to desired position. If not, remove air
pressure and repeat steps 1-3, backing o or screw-
ing in stop screw to attain proper open position of
valve.
D. Make sure O-ring is in proper position in counter-
sunk area on end cap and the washer is in place.
Tighten down nut to set stop position.
E. Thread in the other travel stop, making sure the
Oring and washer are in the correct place. When the
travel stop will not thread any further, tighten nut to
set stop position.
F. The previous steps set the open travel stop. See
section 4.3.5 for instructions on setting the close
position stop.
5. SAFETY LOCKOUT DEVICE
WARNING:
IF THE SERIAL NUMBER OF THE ACTUATOR IS 10136023 OR LOWER
THEN THE ACTUATOR MUST BE DISASSEMBLED AND THE OCTICAM
1 MUST BE ROTATED, SEE FIGURE 9, BEFORE INSTALLING THE
SAFETY LOCKOUT KIT.
1. Removal of Stop Screws:
A. Remove from the Body both the existing Standard
Stop Screws (02) together with Nut (04), Washer (03)
and the O-ring (11), see (Figure 4).
B. Insert on the Adjustment Screw (227) and on the
Blocking Screw (226) the Special Nut (228), the
Washer (03) and the O-ring (11), see (Figure 21).
2. Assembly of Blocking Screw and Adjustment Screw:
A. Before proceeding with the assembly of the
Adjustment and Blocking Screws in the body, check
the requested stop position. If the stop position
is fully close (0°) or fully open (90°), Figure 21.
Attention: when the screws are tted,the actuator
position must be 0° ± 2° or 90° ± 2°.
Figure 20