Metso Quadra-Powr X Operating and maintenance manual

Quadra-Powr® X
Spring Diaphragm Actuators
Installation, Maintenance and
Operating Instructions
IMO-215EN • 6/2013

2 IMO-215EN
Table of Contents
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Handling Quadra-Powr X Actuators . . . . . . . . . . 3
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Parts List/Bill of Materials . . . . . . . . . . . . . . . . . . . . 7
4 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 REPAIR KITS/SPARE PARTS . . . . . . . . . . . . . . . . . . . . 7

3
IMO-215EN
1 GENERAL
This instruction manual contains important information
regarding the installation, operation and troubleshooting
of Jamesbury® Quadra-Powr X Spring-Diaphragm Actua-
tors. This unique spring-diaphragm actuator designed for
rotary valves provides safe, smooth and reliable valve
actuation at minimal pressures and up to 100 psi (6.9 BAR).
Please read these instructions carefully and save them for
further reference.
1.1 WARNING
KEEP HANDS AND CLOTHING AWAY FROMTHEVALVE PORTS AT ALL TIMES.
DO NOT ATTEMPT TO DISASSEMBLE THE SPRING CARTRIDGE.
DISASSEMBLY OF THE SPRING PACKAGE MAY RESULT IN SERIOUS
PERSONAL INJURY. IF MAINTENANCE IS REQUIRED, THE ENTIRE
ACTUATOR MUST BE RETURNED TO JAMESBURY.
SHUT-OFF AND BLEED ALL SUPPLY LINES BEFORE INSTALLATION OR
SERVICING. DO NOT REMOVE DIAPHRAGM CASING HEX HEAD SCREWS
(27), NUTS (29) OR DIAPHRAGM CASING (15) WHILE ACTUATOR IS
PRESSURIZED.
BEFORE INSTALLING THE VALVE AND ACTUATOR, BE SURE THAT THE
INDICATOR POINTER ON TOP OF THE ACTUATOR (AND THE
IDENTIFICATION PLATE IN FEMALE ACTUATORS) ARE CORRECTLY
INDICATING THE VALVE POSITION. FAILURE TO ASSEMBLE THESE
PRODUCTS TO INDICATE THE CORRECT VALVE POSITION COULD
RESULT IN PERSONAL INJURY.
AN ACTUATOR MUST BE SIZED ACCURATELY FOR PROPER OPERATION.
REFER TO INFORMATION ON ACTUATOR END OF STROKE TORQUES
AND THE APPROPRIATE VALVE BULLETIN FOR OPERATING TORQUES.
WHEN SERVICING A VALVE ACTUATOR ASSEMBLY, THE BEST PRACTICE
ISTO REMOVETHE ENTIRE ASSEMBLY FROM SERVICE. IFTHE ACTUATOR
IS REMOVED FROM THE VALVE, IT SHOULD BE REMOUNTED ON THAT
SAME VALVE AFTER SERVICING IS COMPLETED.THE ACTUATOR MUST
BE READJUSTED FOR PROPER OPEN AND CLOSE POSITION EACH
TIME IT IS REMOUNTED.
ACTUATORS ARE NOT TO BE LIFTED USING THE 3/8" NPT IN THE
DIAPHRAGM CASING. HANDLING OFTHE ACTUATOR IS ACCOMPLISHED
BY USING LIFTING STRAPS. SEE SECTION 1.2.
1.2 Handling Quadra-Powr X Actuators
Handling of the actuator is to be accomplished by using
lifting straps. (SeeTable 1) for approximate actuator weights.
Follow (Figure 1) for proper strap lifting technique.
2 INSTALLATION
1. Check to see that the position indicator on the actuator
is assembled correctly for the desired failure mode, either
spring-to-close or spring-to-open. In the spring-to-close
mode, the actuator will cycle clockwise to close upon loss
of pressure. In the spring-to-open mode, the actuator will
cycle counterclockwise to open upon loss of pressure.
2. If the actuator is not set up in the configuration desired,
remove the four hex head screws (33), indicator plate
(12), indicator pointer (24), and remount them on the
opposite mounting surface. In the female actuators,
the fastener identification plate shows the failure
mode of the actuator.
TABLE 1
Handling Quadra-Powr X Actuators
Actuator Series Approximate Weight Lb. (kg)
QPX1 23 (10)
QPX2 42 (19)
QPX3 72 (33)
QPX4 117 (53)
QPX5 235 (107)
Figure 1
SPRING-TO-CLOSE
In this mode, the actuator will cycle clockwise
to close upon loss of pressure
SPRING-TO-OPEN
In this mode, the actuator will cycle counterclockwise
to open upon loss of pressure
Figure 2

4 IMO-215EN
3. Mount the actuator to the valve following the directions
in the AMI (Actuator Mounting Instructions) or valve IMO.
4. Connect a regulated air supply to the 3/8" NPT fitting
in the diaphragm casing (15). CAUTION: The maximum
operating pressure is 100 psi (6.9 BAR).
5. Adjust the stop screws (19) by releasing the jam nut (23)
and turning. Stops can only be adjusted when driver
arm (3) is off the stop screws being adjusted. (Maximum
rotation adjustment ±5˚.) Be sure to retighten jam nut (23).
2.1 Operation
The operating pressure, output torque and drive type is
determined by the actuator designation. Maximum oper-
ating pressure is 100 psi (6.9 BAR). (See Table 2)
Actuator designation example: QPX4C/K40 is a series
QPX4 spring diaphragm actuator that has a 60 psi (4.1
BAR) spring, an end of stroke output torque of 200 FT•LBS
(272 N•m) and uses a 40 mm female key to drive the valve.
Before operating make sure all tapped holes in the body
which are not being used are resealed with fasteners.
3 MAINTENANCE
Before working on a Quadra-Powr X actuator, note that all
fasteners except socket head shoulder screw (8) and hex
head cap screw (88, on QPX4 & QPX5) are metric.
TABLE 2
Actuator
Series Spring Version
Operating
Pressure in
psi (BAR)
End of Spring
Stroke
Torque in
FT•LBS (N•m)
Drive Type
QPX1 C 60 (4.1) 25 (34) K15 - 15 mm Keyed
M - 9/16" Square
QPX2
A**
B
C
D
20* (1.4)
40 (2.8)
60 (4.1)
80 (5.5)
11 (15)
38 (52)
57 (77)
74 (100)
K20 - 20 mm Keyed
M - 9/16" Square
QPX3
A
B
C
D
20* (1.4)
40 (2.8)
60 (4.1)
80 (5.5)
26 (35)
76 (103)
114 (155)
146 (198)
K35 - 35 mm Keyed
M - 3/4" Square
QPX4
B
C
D
40 (2.8)
60 (4.1)
80 (5.5)
153 (207)
229 (310)
294 (399)
K40 - 40 mm Keyed
M - 1" Square
QPX5
B
C
D
40 (2.8)
60 (4.1)
80 (5.5)
305 (414)
458 (621)
587 (796)
K40 - 40 mm Keyed
M - 1" Square
* For Direct Control Applications
** QPX2A only available with QPX1 drive type options.
Under normal operating conditions the actuator requires
only periodic observation to ensure proper adjustment.
Standard replacement of “soft” parts in Quadra-Powr II
actuators consists of items numbered 6, 14, 31, 62 and 64.
See REPAIR KITS/SPARE PARTS Section.
1. When replacing the diaphragm use caution and be
sure the air supply is disconnected. Back off nuts (29)
from the hex head screws (27), holding the diaphragm
casing and spring housing together until the nuts are
flush with the hex head screw ends. Do not remove the
nuts completely from the hex head screws. If tension
still exists on the hex head screws, then the spring
package is not properly contained. Stop disassembly:
retighten nuts and return the actuator to the factory. If
the spring package proves to be intact remove the
nuts (29) and remove the hex head screws (27).
2. Lift off diaphragm casing (15). Remove hex head cap
screw (88) and retaining washer (89). Remove
diaphragm (14).
3. Inspect the inside of both the diaphragm casing (15) and
the spring housing (32) for any rough spots or foreign
matter which may cause abrasion to the diaphragm.
4. Place the new diaphragm (14) on the diaphragm
retainer (10). Do not pinch or stretch the diaphragm.
Attach with washer (89) and cap screw (88). Tighten to
value in (Table 3) keeping spring housing (32) holes
aligned with diaphragm (14) holes. Place the
diaphragm casing (15) on the spring housing (32) and
line up all the holes.
5. Insert hex head screws (27) in all holes. Do not force the
hex head screws through the diaphragm. Install nuts (29)
on screws and tighten uniformly using the standard
practice of tightening diametrically opposite bolts in
sequence with the torque requirements from (Table 3).
3.1 Disassembly
When disassembly of the actuator is required for mainte-
nance, remove the actuator to a clean well lit area. Handling
of the actuator is accomplished by using lifting straps. See
Section 1.2.
Prior to disassembling the actuator, obtain the following
tools: two (2) M10 wrenches, preferably one being a ratchet,
one (1) hex (Allen) wrench, 3 mm for QPX1, 5 mm for QPX2,
3 and 4, 6 mm for QPX5, one (1) screwdriver, one (1) plastic
faced mallet.
1. Remove the cover (5) by removing six (four on QPX1)
socket cap screws (21). If the cover cannot be removed,
tap it with a plastic hammer to break the adhesion of
the paint between the body and cover joint.
2. Use air pressure to remove spring preload by partially
stroking the actuator. If the diaphragm (14) is ruptured,
replace as instructed in the previous section.
3. To remove the socket shoulder screw (8) (or socket cap
screw in QPX1) that holds the clevis (7) to the driver arm
(3), first apply some heat to the lower arm to loosen
the Loctite® on threads of the socket shoulder screw.
4. Slowly increase air pressure until the driver arm (3)
moves slightly off the stop screw (19). Remove the
socket shoulder screw (8).

5IMO-215EN
5. Slowly relieve the air pressure in the actuator. The clevis
(7) should be set against the spring retainer (30), and
positioned symmetrically about the slot in the spring
housing.
6. Shut off and bleed the air pressure to zero. Disconnect
the air lines.
7. Remove the hex head screws (27) and hex nuts (29) holding
the diaphragm casing and spring housing together.
8. Lift off diaphragm casing (15), remove hex head cap
screw (88), washer (89) and diaphragm (14). Inspect the
diaphragm for signs of wear, rupture or mechanical
damage.
9. Inspect the inside of both the diaphragm casing and
spring housing, as well as the outside of the
diaphragm retainer for any rough spots or foreign
matter which may cause abrasion of the diaphragm.
10. Lift the entire spring cartridge out of the unit
WARNING: DISASSEMBLY OF THE SPRING PACKAGE
SHOULD NOT BE ATTEMPTED. SPECIAL EQUIPMENT IS
REQUIRED. DISASSEMBLY OF THE SPRING PACKAGE MAY
RESULT IN SERIOUS PERSONAL INJURY. IF MAINTENANCE
IS REQUIRED SHIP THE ENTIRE ACTUATOR TO JAMESBURY.
It is usually not necessary to remove the spring housing (32)
from the body (1). However, if removal is required, heat must
be used to loosen the Loctite®. When reassembling, the
information in (Table 1), torque and Loctite® recommen-
dations must be met. All fasteners should use Loctite® 271
on the threads. Inspect and clean all components.
Good practice dictates that all bearings should be
removed and replaced. See the SERVICE KIT section of
this IMO for the proper actuator series repair kit number.
3.2 Assembly
To aid assembly, spread light oil or grease on the outside
diameter of the new bearings.
1. Press driver arm bearings (6) into the body (1) and covers
(5). This is best done in an arbor press, but a vise could
be used if care is taken not to damage the bearing. Driv-
er arm bearings are to be pressed in until they are flush
or 0.015 in. (0.38 mm) below the body counterbore or
the inside cover surface. Press clevis bearings (62) into
the clevis (7).
2. Apply lubricant, MOLYKOTE® GN grease on shoulder
screw (8) barrel prior to assembly. Also, apply
MOLYKOTE ® GN grease to driver arm bearings (6).
3. Place the thrust bearing (31) into the counterbore in
the body of QPX1-QPX5 actuators. Slide the other
thrust bearing onto the trunnion of the driver arm (3).
Place the driver in the body.
4. Spring housing (32), diaphragm retainer (10) and
springs shall be lubricated with Kendall L-427 Super
Blu® or Mobilgrease™ XHP 222. Lower the spring car-
tridge into the spring housing (32). Make sure that the
spring package is not resting on the hex head cap
screws (38) which hold the spring housing and body
together. If bearing (64) has separated from
diaphragm retainer (10), hold in place while lowering
spring cartridge into housing.
5. Place the new diaphragm (14) on the diaphragm plate.
Attach diaphragm (14) to diaphragm retainer (10) using
washer (89) and hex head cap screw (88).Torque to the
value specified in (Table 3).
6. Insert the hex head bolt (27) in all holes. Do not force
the bolts through the diaphragm. Install nuts (29) and
tighten uniformly using the standard practice of tight-
ening diametrically opposite bolts in sequence. Follow
(Table 3) for tightening torques.
7. Connect a regulated air supply to the pressure port
and slowly increase the air pressure until the holes in
the clevis and driver arm are aligned. Turn clevis a few
degrees, if required, to align holes.
8. Apply Loctite® 271 on the threads of the shoulder
screw. Insert it through the driver arm and clevis.
Tighten per (Table 3).
9. Back off the nut (74) against clevis (7). Apply Loctite® 271
on the threads of the actuator rod.Tighten nut against
clevis by applying torque from (Table 3), as the nut is
being tightened, firmly hold the clevis with a wrench,
since the unsupported driver arm may tend to tip over.
10. Slowly release air pressure. Assemble cover by using
the socket head screws (21). Apply tightening torque
per (Table 3).
11. Install the indicator pointer (24) if this was previously
disassembled. In female actuators make certain that the
indicator points to the inscribed line in the driver arm. In
male actuators, hold the indicator pointer in place with
a retaining ring (9). NOTE: Refer to Installation instructions
for spring-to-close or spring-to-open configuration.
TABLE 3
Torque Requirements
Required Tightening Torques In FT•LBS (N•m)
For Various Fasteners
QPX1 QPX2 QPX3 QPX4 QPX5
Nuts for Hex Head
Screws through
Diaphragm Casing (29)
24
(32)
24
(32)
24
(32)
24
(32)
24
(32)
Socket Head
Cover Screws (21)
4
(5)
6
(8)
6
(8)
6
(8)
15
( 20)
Socket Head
Shoulder Screw (8)
35
(48)
55
(75)
132
(179)
132
(179)
132
(179)
Nuts on Actuator
Rod (74)
55
(74)
55
(75)
88
(119)
132
(176)
176
(239)
Hex Head Screws
between Body and
Spring Housing (38)
5
(7)
18
(24)
30
(40)
30
(40)
55
(75)
Hex Head Cap Screws
for Attaching Diaphragm
to Diaphragm Retainer (88)
19 IN•LBS
(1)
19 IN•LBS
(1)
27 IN•LBS
(2)
10 FT•LBS
(14)
17 FT•LBS
(23)

6
33
3.3 QPX EXPLODED VIEW
15
88
89
14
45
10
82 64
9 43, 63, 73
12
24 24 For Clarity, 27
33 ISO Spring #1
21 86 ONLY Shown 26
12 30
21 5
5
6
31 3
8
3 4
38
31
62
MALE DRIVE FEMALE 26 53
DRIVE 80 23, 40
29
KEYED 32
7
71
6 23
81 19
Figure 3
IMO-215EN
1

7IMO-215EN
3.4 PARTS LIST AND BILL OF MATERIALS
Bills Of Materials And Parts
ITEM NO. PART DESCRIPTION QPX1C/_ QPX2A/_ QPX2B/_ QPX2C/_ QPX2D/_ QPX3A/_
QPX3B/_ QPX3C/_ QPX3D/_ QPX4B/_ QPX4C/_ QPX4D/_ QPX5B/_ QPX5C/_ QPX5D/_
1 Body 1 1 1 1 1
3 Driver Arm 1 1 1 1 1
4 Actuator Rod 1 1 1 1 1
5 Cover 1 1 1 1 1
6 Bearing-Driver Arm 2 2 2 2 2
7 Clevis 1 1 1 1 1
8 Socket Head Shoulder Screw 1 1 1 1 1
9 Retaining Ring* 1 1 1 1 1
10 Diaphragm Retainer 1 1 1 1 1
12 Indicator Plate 1 1 1 1 1
14 Diaphragm 1 1 1 1 1
15 Diaphragm Casing 1 1 1 1 1
19 Hex Head Cap Screw 2 2 2 2 2
21 Socket Cap Screw 4 4 6 6 6 6 6 6
23 Hex Jam Nut 3 3 4 4 4 2 2 2
24 Indicator Pointer 1 1 1 1 1
26 Washer 16 24 24 32 48
27 Hex Head Cap Screw 8 12 12 16 24
29 Centerlock Hex Nut 8 12 12 16 24
30 Spring Retainer 1 1 1 1 1
31 Thrust Bearing 2 2 2 2 2
32 Spring Housing 1 1 1 1 1
33 Cap Screw 4 4 4 4 4
38 Cap Screw 4 4 6 10 10
40 Hex Jam Nut N/A N/A 2 2 2
43 Spring #1 1 1 1 1 1
45 Caution Plate 1 1 1 1 1
53 Identification Tag 1 1 1 1 1
62 Clevis Bearing 2 2 2 2 2
63 Spring #2 N/A N/A N/A 1 1 N/A 1 1 N/A 1 1 N/A 1 1
64 Bearing Strip 1 1 1 1 1
71 Breather Vent 1 1 1 1 1
73 Spring #3 N/A N/A N/A N/A 1 N/A N/A 1 N/A N/A 1 N/A N/A 1
80 Set Screw 1 1 1 1 1
81 Nameplate 1 1 1 1 1
82 Slotted Pan Head Screw** 2 2 2 2 2
86 Socket Head Set Screw** 8 8 8 8 8
88 Hex Head Cap Screw 1 1 1 1 1
89 Diaphragm Washer 1 1 1 1 1
*MALE ACTUATORS ONLY.
**FEMALE ACTUATORS ONLY.
ACCESSORIES
Quadra-Powr X actuators can be locked in the spring
uncompressed mode. Refer to IMO-30 for more information.
Quadra-Powr X actuators can easily be reworked to have
100% adjustability in air stroke. Consult factory if this fea-
ture is desired.
Quadra-Powr X actuators are designed with one or two
accessory mounting pads; ISO and Jamesbury standard.
Refer to Figure "5". Consult Jamesbury linkage manual for
accessory linkage kits.
5 REPAIR KITS/SPARE PARTS
SERVICE KITS
Model Complete Diaphragm
QPX1 Actuator RKQ-68 RKQ-75
QPX2 Actuator* RKQ-70 RKQ-76
QPX3 Actuator RKQ-71 RKQ-77
QPX4 Actuator RKQ-72 RKQ-78
QPX5 Actuator RKQ-73 RKQ-79
*Note: QPX2A uses complete kit RKQ-69 and diaphragm kit RKQ-76
For further information on spare parts and service or
assistance visit our web-site at www.metso.com/valves.
4

8 IMO-215EN
QPX Actuators
Figure 4
ISO Mount J Mount J Mount
QPX1, 2, 3, 4, 5, 6 QPX1, 2, 4, 5 QPX3
QPX1C-QPX2A Actuators
Figure 5
Subject to change without prior notice.
Metso Automation Inc.
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North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, Massachusetts, 01545-8044, USA, Tel. [phone], fax [phone]
South America, Av. Independência, 2500-Iporanga, 18087-101, Sorocaba-São Paulo, Brazil, Tel. [phone], fax [phone]
Asia Pacific, 20 Kallang Avenue, Lobby B, #06-00, PICO Creative Centre, Singapore 339411, Singapore, Tel. [phone], fax [phone]
China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaiyang Dist, 100022 Beijing, China, Tel. [phone], fax [phone]
Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates, Tel. [phone], fax [phone]
www.metso.com/valves