OMC AP23 User manual

Installaon, Operaon and Maintenance Manual ManA‐en Rev.03/2018
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OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
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INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
PNEUMATIC ACTUATORS

Installaon, Operaon and Maintenance Manual ManA‐en Rev.03/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
ENGLISH
TABLE OF CONTENTS
1.0 SAFETY INFORMATION
1.01 INTENDED USE
1.02 ACCESS
1.03 LIGHTING
1.04 HAZARDOUS FLUIDS IN THE PIPE
1.05 ENVIRONMENTAL SITUATIONS
1.06 TEMPERATURE
1.07 SYSTEM
1.08 PRESSURIZED SYSTEMS
1.09 TOOLS AND CONSUMABLE PARTS
1.10 PROTECTION CLOTHES
1.11 QUALIFICATION OF OPERATORS IN CHARGE OF THE WORKS
1.12 HANDLING
1.13 FREEZING
1.14 OTHER RISKS
1.15 DISPOSAL
2.0 ACTUATOR CONNECTION
3.01 PNEUMATIC ACTUATOR CONNECTION
3.0 ASSEMBLY
3.01 VALVE/ACTUATOR SEPARATION
3.02 DIRECT ACTUATOR / REVERSE ACTUATOR
3.03 COUPLING TO THE DIRECT ACTUATOR’S VALVE
3.04 COUPLING TO THE REVERSE ACTUATOR’S VALVE
4.0 REPLACEMENT OF THE DIAPHRAGM
5.0 REPLACEMENT OF THE PISTON DISC
6.0 TIGHTENING TORQUES
7.0 AVAILABLE SPARE PARTS

Installaon, Operaon and Maintenance Manual ManA‐en Rev.03/2018
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OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
ENGLISH
1.0 SAFETY INFORMATION
The safe operation of this product is ensured only if it is installed, commissioned, used and maintained in an
appropriate way by qualified personnel in compliance with the operating instructions.
1.01 INTENDED USE
Verify that the actuator is suitable for the intended use and application by controlling:
‐ to have arranged an appropriate safety device which prevents, in case of malfunctioning of the actuator, any
hazardous overpressures or overtemperatures.
The OMC actuators are not intended to withstand external stresses which may be induced by the systems in
which they are inserted. The installer must take account of these stresses and take the appropriate measures.
1.02 ACCESS
Ensure a safe access and, if required, a safe working platform (with a suitable protection) before operating on the
product. Arrange the suitable lifting means, if required.
1.03 LIGHTING
Ensure a lighting which is suitable to the required type of work.
1.04 HAZARDOUS FLUIDS IN THE PIPE
Take account of the content of the pipe or anything it may have previously contained. Be careful to: flammable
materials, substances hazardous for the health, temperature extremes.
1.05 ENVIRONMENTAL SITUATIONS
Take account of: areas at risk of explosion, lack of oxygen (such as tanks, wells, etc.…), hazardous gases,
temperature limits, high or low temperature surfaces, risk of fire (for example during welding operations),
excessive noise, moving machines.
1.06 TEMPERATURE
Wait until the temperature normalizes after the interception to prevent any risks of burn or freezing.
1.07 SYSTEM
Take account of the possible effects on the whole expected working system.
May the intended measure put the other parts of the system or the personnel at risk?
Make sure that the shut-off valves are gradually activated in order to prevent any abrupt variations to the system.
1.08 PRESSURIZED SYSTEMS
Make sure that the pressure is isolated and discharged to the atmospheric pressure in safe conditions. Take
account of a double insulation (double block and vent) and the blocking or the labelling of the closed valves. Do
not consider the system depressurized even if the pressure gauge indicates zero pressure.
During the operation the valve is pressurized. Before performing any maintenance operation or action on
the flanges and closing caps, make sure that the line is depressurized (0 bar) and at ambient temperature.

Installaon, Operaon and Maintenance Manual ManA‐en Rev.03/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
ENGLISH
1.09 TOOLS AND CONSUMABLE PARTS
Before starting the work, make sure to have at your disposal all the tools required to perform it, do not make use
of inappropriate tools. Use only OMC original spare parts.
1.10 PROTECTION CLOTHES
Take account of whether you and/or others need some clothes against the hazards, such as chemical products,
temperatures, radiations, noise, fall of objects, risks for eyes and face.
1.11 QUALIFICATION OF THE OPERATORS IN CHARGE OF THE WORKS
All works must be performed and supervised by some skilled, trained and competent personnel.
1.12 HANDLING
Use suitable lifting means for the handling of the products by assessing all the risks concerning the lifting, the
environment load, the individual and the circumstances of the work which is about to be performed.
CORRECT WRONG
1.13 FREEZING
Protect the products against frozen in environments with temperatures lower than the freezing point of the
process fluid.
1.14 OTHER RISKS
During the operation, the external surface of the product can be at temperatures which are hazardous to touch.
Take account of this risk.
1.15 DISPOSAL
For the disposal respect the legislation in force in the State/Country/Nation where the product should be disposed
of.
CORRECT

Installaon, Operaon and Maintenance Manual ManA‐en Rev.03/2018
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OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
ENGLISH
1
2
4
1 1
2
3
Pic. 5 Pic. 6
2.0 ACTUATOR CONNECTION
2.01 PNEUMATIC ACTUATOR CONNECTION
The pneumatic actuator is provided with two 1/4"NPT connections, one of which is closed by a filter. Connect the
control air pipe to the connection which has remained free. The control air must be clean, de-humidified and free
from oils and greases and must not exceed an allowed maximum pressure. The signal required to control the
valve is provided on the plate fixed on the actuator’s yoke. If the valve is provided with a pilot positioner, refer to
its manual.
3.0 ASSEMBLY
If the valve and the actuator are not supplied already assembled or if the original actuator must be replaced with
one of another Type or another size, perform the operations described in paragraph 4.01.
All above-described operations must be performed and supervised by skilled, trained and competent personnel.
The OMC valves are univocally identified by a serial number fixed on the plate located on the actuator’s yoke. To
order spare parts or for any need, always refer the above-mentioned number.
During the operation the valve is pressurized. Before performing any maintenance operation or
action on the flanges and closing caps, make sure that the line is depressurized (0 bar) and at
ambient temperature.
3.01 VALVE/ACTUATOR SEPARATOR
Referring to Pic. 5 or to Pic. 6, according to the available actuator, perform as follows:
 Set the valve to the 50% stroke
 Fully unscrew the screws (1) and remove the terminals (2)
 Fully unscrew the ring nut (3) or the screws (4).
 Extract the actuator

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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
ENGLISH
3.02 DIRECT ACTUATOR/REVERSE ACTUATOR
In the direct-action actuator the increase of the control signal lets the stem go out (1) (Pic.7 and 9)
In the reverse-action actuator the increase of the control signal lets the stem go in (1) (Pic.8 and 10)
Pic. 7 Direct-action actuator Pic. 8 Reverse-action actuator
Pic. 9 Direct-action ON/OFF actuator Pic. 10 Reverse-action ON/OFF actuator
1 1
1 1

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OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
ENGLISH
3.03 COUPLING TO THE DIRECT ACTUATOR’S VALVE
 Fully lift the stem (2) of the valve Pic. 11
 Position the actuator on the valve Pic.12
 Give air to the actuator by setting the stem (1) to touch the stem (2) Pic.12
 By referring to Pic. 13 or to Pic. 14, according to the available actuator, assemble the terminal (3) by aligning
the stems (1) and (2) Pic.12.
 Remove the air from the actuator
Attention!!! The actuator’s yoke will be pressed against the valve.
Risk of crushing!!!
 By referring to Pic. 13 or to Pic. 14, according to the available actuator, tighten the ring nut (4) or the screws
(5).
For the tightening forces refer to the valve’s manual
2
2
1
3
4 3
5
Pic. 13
Pic. 11
Pic. 14
Pic. 12

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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
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3.04 COUPLING TO THE REVERSE ACTUATOR’S VALVE
 Fully lower the stem (2) of the valve Pic. 15
 Position the actuator on the valve Pic.12
 By acting on the nut (2) set the height “A” (Fig.16) to the value indicated in “Table 1”
 By referring to Pic. 13 or to Pic. 14, according to the available actuator, assemble the terminal (3) by aligning
the stems (1) and (2) Pic.12.
 Give the maximum control signal to the actuator
Attention!!! The actuator’s yoke will be pressed against the valve.
Risk of crushing!!!
 By referring to Pic. 13 or to Pic. 14, according to the available actuator, tighten the ring nut (4) or the screws
(5).
For the tightening forces refer to the valve’s manual
2
2
1
Pic. 15 Pic. 16
A

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OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
ENGLISH
TYPE OF ACTUATOR CONTROL SIGNAL
(psi)
VALVE STROKE
(mm)
DISTANCE “A” Pic.16
(mm)
AP23 / AM23
3÷15 20 mm 6 ÷ 7
6÷18 20 mm 5 ÷ 6
6÷30 20 mm 7 ÷ 8
15÷60 20 mm 8 ÷ 9
AP28 / AM28
3÷15 20 mm 6 ÷ 7
6÷18 20 mm 6 ÷ 7
6÷30 20 mm 4 ÷ 5
15÷60 20 mm 5 ÷ 6
AP34 / AM34
3÷15 20 mm 8 ÷ 9
6÷18 20 mm 11 ÷ 12
6÷30 20 mm 7 ÷ 8
15÷60 20 mm 12 ÷ 13
3÷15 30 mm 6 ÷ 7
6÷18 30 mm 9 ÷ 10
6÷30 30 mm 6 ÷ 7
15÷60 30 mm 9 ÷ 10
AP43 / AM43
AP44 / AM44
3÷15 20 / 30 mm 17 ÷ 18
6÷18 20 / 30 mm 17 ÷ 18
6÷30 20 / 30 mm 12 ÷ 13
15÷60 20 / 30 mm 1 ÷ 2
AP47 15÷60 35 mm 1 ÷ 2
AP45 15÷60 30 mm 1 ÷ 2
AP48
15÷60 50 mm 9 ÷ 10
15÷60 60 mm 1 ÷ 2
AP61 15÷60 50 mm 9 ÷ 10
AP63 15÷60 60 mm 1 ÷ 2
OP10 / OL10 90÷145 20 mm 9 ÷ 10
OP16 / OL16 90÷145 30 mm 9 ÷ 10
AP35 / AM35
TABLE 1

Installaon, Operaon and Maintenance Manual ManA‐en Rev.03/2018
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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
ENGLISH
4.0 REPLACEMENT OF THE DIAPHRAGM
Separate the actuator from the valve as described in paragraph 4.01
By referring to Pic.17 for the direct-action actuators and to Pic.18 for the reverse-action actuators, perform the
following operations:
ATTENTION!!! Tensioned springs
 gradually unscrew the bolts (1) in criss-cross sequence
 extract the lid (2) unscrew the nut (3) which blocks the plate (5) and replace the diaphragm (4).
 if required, replace the v-ring inside the stem-guide (7)
 re-assemble everything by performing the operations in the reverse order.
Attention: for valves provided with bellows, in order to prevent any damages to the bellows, make sure that the
plug stem (6) does not rotate.
For the tightening forces refer to chapter 6
Pic. 17 Direct-action actuator Pic. 18 Reverse-action actuator
7 7

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OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
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5.0 REPLACEMENT OF ON/OFF PISTON DISC
Separate the actuator from the valve as described in paragraph 4.01
By referring to Pic.19 for the direct-action actuators and to Pic.20 for the reverse-action actuators, perform the
following operations:
ATTENTION!!! Tensioned springs
 gradually unscrew the bolts (1) in criss-cross sequence
 extract the lid (2) unscrew the nut (3) which blocks the plate (5) and replace the diaphragm (4).
 re-assemble everything by performing the operations in the reverse order.
Attention: for valves provided with bellows, in order to prevent any damages to the bellows, make sure that the
plug stem (6) does not rotate.
For the tightening forces refer to chapter 6
Pic. 19 Direct-action actuator Pic. 20 Reverse-action actuator

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Our products are manufactured under ISO-9001 Quality Assurance System, approved by CSQ certified under no.9190.OMC2 - FIRST ISSUE 1994/08/04
OMC s.r.l. Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcsrl.com - Tel.: [phone]
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6.0 TIGHTENING TORQUES
TYPE OF
ACTUATOR
NUT (1) Pic. 22 -
Pic.23
Nm ±10%
NUT (2) Fig. 22 -
Pic.23
Nm ±10%
NUT (3) - Pic. 19 -
Pic.20
Nm ±10%
AP23 / AM23 12 35 //
AP28 / AM28 18 35 //
AP34 / AM34
AP35 / AM35 40 35 //
AP47 - AP45
AP48 - AP61 -
AP63
50 35 //
OP10 / OL10 3÷15 // 35
OP16 / OL16 6÷18 // 35
SCREW (1) - Pic. 19 -
Pic.20
Nm ±10%
//
//
//
//
80
80
SCREW (3) - Pic. 22 -
Pic.23
Nm ±10%
70
70
70
70
//
//
Pic. 23 Pic. 22
1 1 2 2
For the tightening forces of the valve’s coupling screws (stem connection terminal, actuator blocking ring nut, etc.
…) refer to the specific valve’s manual.
3
3
7.0 AVAILABLE SPARE PARTS
DESCRIPTION PICTURE POSITION
Diaphragm 17 - 18 4
ON-Off Piston Disc 19 - 20 4
Stem-guide V-ring 17 - 18 7