ProtACT PRY Series User manual

Series PRY
PNEUMATIC ACTUATORS
Documentnr.: BWA.PRY.200116| Issue: Jan. 2020
MANUAL AND
MAINTENANCE GUIDELINES

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
BWA.PRY.200116
January 2020
2

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
BWA.PRY.200116
January 2020
3
Content:
Chapter1: Preparaon
1.1 Marking of safety instrucons Page 4
1.2 Safety fundamentals Page 4
1.3 Instrucons for storage Page 4
Chapter 2: Preliminary
2.1 Design descripon Page 5
2.2 Intended use Page 6
2.3 Technial informaon Page 6
2.4 Typecode Page 7
Chapter3: Installaon
3.1 Remarks Page 8
3.2 Installaon instrucons Page 9
3.3 Seng the end posions Page 10
3.4 Assembly to a valve Page 11
3.5 Tightening torques for screw connecon Page 11
Chapter 4: Maintanance
4.1 General Page12
4.2 Safety instrucons Page12
4.3 Disassembly and maintenance of the modules Page13
4.3.1 Spring module Page13
4.3.2 Pneumac module Page14
4.3.3 Center module Page14
4.3.4 Manual hydraulic module Page15
4.3.5 Mechanical manual module Page16
4.4 Field reversion Page17
4.4.1 Changing the direcon of spring acon Page17
4.4.2 Conversion from double-acng to single-acng Page18
4.4.3 Conversion from single-acng to double-acng Page18
4.5 Components Page19
Copyright
This document is protected by copyright. We reserve all rights to this manual before proceeding, even the reproduc-
on and / or duplicaon in any thinkable form, e.g. photocopying, prinng, on data medium or in translated form.
Reproducon of this manual only with wrien permission of ProtACT GmbH. The technical state at the me of deliv-
ery of device and manual is decisive, if no other informaon is given. We reserve the right to make technical modi-
caons without specic noce. Earlier instrucons then become invalid.

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
BWA.PRY.200116
January 2020
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Chapter1:Preparaon
Content:
• Marking of safety instrucons
• Safety fundamentals
• Instrucons for storage
1.1Markingofsafetyinstrucons
1.2 Safety fundamentals
The installaon, assembly, commissioning, maintenance and any other work on pneumac actuators must be
performed by qualied personnel.
This manual is part of the device and must be available for the operang personnel at all mes. This manual must
be read and understood before operaon.
The device may only be operated in perfect condion. No safety devices are removed or deacvated. A rebuilding
or modicaon of the device is strictly prohibited.
1.3 Transport, storage and packaging
The devices must be carefully handled, transported and stored.
The devices should be transported to the end desnaon in their original packaging and unpacked immediately
before installaon.
The actuators are to be stored in a clean, dry storage, which is neither exposed to excessive vibraon nor to rapid
temperature changes.
Prevent ingress of dirt or moisture into the actuator. Close or ghten both air connecons.
Proper disposal of packaging is the customer´s responsibility.
Thissymbolindicatessafetyinstruconswhichcancausepersonalinjuryifnotrespected.
This symbol indicates an important note
Rotaryactuatorsmustbeisolatedbothpneumacallyandelectricallybeforeanyintervenon.
Failuretofollowthesafetybasicscanvoidthewarrantyclaims.
Installaon,operaonandmaintenanceoftheproductsarestrictlysubjecttothelocalsafetyand
accidentprevenonregulaons!
Failuretocomplymayvoidthewarrantyclaims.

MANUAL & MAINTENANCE GUIDELINES
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Chapter 2: Preliminary
Content:
• Design descripon
• Intended use
• Technical informaon
• Type code
2.1Designdescripon
Pneumac actuators of the PRY series are designed for the automaon of rotary valves with a 90° rotaon angle.
They have a modular structure and, depending on the applicaon, consist of one or two pneumac modules, a
center module, a spring module and an oponal module for manual actuaon. In the single-acng version, the spring
module ensures closing or opening in the event of a control media failure (spring-closing or spring-opening).
Two characterisc torque proles are available for generang a drive torque that is adapted to the valve torque.
These are created using either a symmetrical or a canted yoke.
The PRY actuator series oers a torque range of 1000 – 250.000 Nm (double-acng) and 300 – 150.000 Nm (single-
acng). The standard version of the actuators provides valve mounng interfaces according to ISO 5211 and an
accessory interface according to VDI/VDE 3845.
The maximum operang pressure of the pneumac Scotch-Yoke actuators of the PRY series is between 3 and 10 bar
depending on size and conguraon. The maximum operang pressure is specied on the typelabel of the respecve
actuator.

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2.3TechnicalInformaon
Construconprinciple: Pneumac heavy-duty rotary actuator in Scotch-Yoke design; double and single
acng version
Materials See secon 4.5
Temperature range
Standard
Low temperature version
High temperature version
-20°C to +80°C
-40°C to +80°C
-15°C to +150°C
Control pressure 3 … 10 bar (depending on the actuator version, check typelabel!)
Pressure media
dry, ltered air or inert gases in respect of remaining oil-,
dust and water-content according to DIN ISO 8573-1 / class 4,
maximum parcle diameter 30µm,
dew point minimum 10°C below ambient temperature
Nominalrotaonangle 90°, adjustable in both end posions +/-6°
Torque range double-acng: up to 250.000Nm
single-acng: up to 150.000Nm
Standards
Interface actuator/control-unit: VDI/VDE 3845 resp. NAMUR
Interface actuator/control media supply: G- or NPT-Thread
Interface actuator/valve: ISO 5211
2.2 Intended use
Actuators of the PYR series are primarily used for the automaon of quarter-turn valves such as ball valves, buery
valves or plug valves, but can also be used for other applicaons. Contact our qualied personnel where required.
The specied operang and liming values for temperature, pressure, control medium, etc. must be observed.In
operaon of valves high kinec energies may arise, which are transmied to the actuator. Make sure that the drive
is protected from damage by complying with the minimum travel mes safely. Control speed can be reduced by the
use of throle valves, which can be purchased from our sales department.
For valve types with high ywheel mass and low torque requirements the operang condions of the actuator must
be coordinated with us in advance.
The actuator may only be used:
• in perfect condion
• as spulated
• safety- and danger-conscious in consideraon of the operang instrucons
• if all safety devices are in place and funconing
Anyusenotpre-approvedbythemanufacturerisconsideredimproper!

MANUAL & MAINTENANCE GUIDELINES
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PRY .C1 .50 1 S .04 .1625 S 55 .P R S .00
Type
Body size
Cylinder size
Quantycylinders(1or2)
Funcon
D: double-acng
S: single-acng
Spring set
ISOvalveinterface
14: F14 1625: F16 + F25
16: F16 2530: F25 + F30
25: F25 3035: F30 + F35
30: F30 4048: F40 + F48
35: F35 4860: F48 + F60
40: F40
48: F48
60: F60
Stemconnecon
S: Square acc. to ISO 5211 or DIN 3337
D: Double-D
K: Key connecon
Stemconnecondimension
Dimension in mm (not applicable for key connecon)
Mounngdirecon
P: Parallel to pipe
T: Transversal to pipe
Springrotaonsense
R: Clockwise CW (Normally closed)
L: Counterclockwise CCW (Normally open)
Temperatureversion
S: Standard (-20°…+80°C)
H: High temperature version (-15°…+150°C)
T: Low temperature version (-40° … +80°C)
Manualoperaon
00: without
01: Screw manual
02: Gear manual
03: Hydraulic manual
2.4 Typecode

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Chapter3:Installaon
Content:
• Remarks
• Installaon instrucons
• Seng the end posions
• Assembly to valve
• Tightening torques for screw connecons
3.1 Remarks
1. Onlylithedriveusingsuitableliingstraps.Theholesprovidedfortheeyeboltsareonlyfor
liingtheactuatorandnotforliingtheenreassemblyincl.valve.
2. Toachievethedesiredservicelifeoftheactuator,onlytherecommended,lteredcontrolmedia
may be used
3. Theactuatormustnotbeinstalledinpotenallyexplosiveareasthatarenotcompablewith
thespeciedgasgroupsandtemperatureclasses.
4. Whenusingaseparatemanualemergencygearbox,itmustbeensuredthatthegearboxoersa
rotaonanglethatcorrespondsatleasttothatoftheactuator.
5. Theactuatorscanbeinstalledinanyposion.However,caremustbetakentoensurethatsome
accessories,suchaslterregulangunits,reservoirsforhydraulicoverrideunits,etc.,whose
properfunconingdependsongravity,arerealignedappropriately.
6. Thespringcontainerandtheendcoverofthespringmoduleprotectthespring.Duetothe
preloadforceofthespring,itisstrictlyforbiddentocutopentheendcoverorthespring
containerinordertoavoidseriousinjuries.

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3.2Installaoninstrucons
1. Ensure that the pneumac module is completely depressurized by venng it into the atmosphere and discon-
necng all power sources from the accessories.
2. Make sure that the valve and the actuator are aligned in the same posion (i.e. valve closed - actuator in the
closed posion or both open). In the case of actuators with spring return, align the valve to the safe posion of
the actuator. If a manual override is used, it must also be ensured that it corresponds to the valve and actuator
posion.
3. Posion the valve, aach the mounng bracket and then mount the coupling sha on the valve sha (when
using a mounng kit). Check the posion of the actuator and valve, align the valve sha (or sha coupling)
with the actuator sha and slide the actuator onto the mounng surface of the mounng bracket (or onto the
ISO ange of the valve if no mounng bracket is used).
4. When using an emergency manual gearbox between actuator and valve, the gearbox must rst be aached
and fastened to the valve according to the prescribed procedure. Then turn back the stop screws on the gear-
box. Mount the actuator with the coupling sha on the gearbox and x the actuator on the gearbox ange.
5. To align the screw holes, the valve mounng screws on the mounng bracket may need to be loosened slightly.
The actuator xing screws should be easy to screw into the threaded holes of the actuator interface without
the mounng bracket (or the ISO ange of the valve) being loaded by transverse forces. If necessary, turn the
drive a lile and/or adjust the adjusng screws of the drive. Fasten the actuator to the mounng bracket/on
the gearbox ange/on the head ange of the valve.
6. Before operang the actuator, the manual override (if available) must be disengaged.
7. Adjust the adjusng screws of the quarter turn actuator correctly for open and closed valve posions according
to the recommendaons of the valve manufacturer. The adjusng screws of the quarter turn actuator should
dene the end stops, not that of the gearbox.
8. Tighten the lock nuts on the stop screws aer adjusng the stop screws. Make sure that the screws on the
gearbox (if present) are now set and locked so that they are slightly behind the end posion of the drive.
9. Make sure that the manual actuaon modules are unlocked before you start up the actuator.
10.Pneumacally operate the actuator several mes to check that it is operang correctly and smoothly. If the
actuator is equipped with a switch box or other accessories, set it now.

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3.3Sengtheendposions
Sengtheendposionclockwise(CW):
1. Turn the actuator clockwise unl it reaches the end
stop and check the seng.
2. Loosen lock nut "X"
3. Vent the actuator and turn the adjusng screw
in the desired direcon (unscrewing expands the
swivel angle, screwing in reduces the swivel angle)
4. Vent the actuator and check the seng again.
5. Repeat the seng procedure (steps 2 to 4) if
necessary.
6. Tighten the lock nut again.
Sengtheendposioncounterclockwise(CCW):
1. Turn the actuator counterclockwise unl it reaches
the end stop and check the seng.
2. Loosen lock nut "Y"
3. Vent the actuator and turn the adjusng screw
in the desired direcon (unscrewing expands the
swivel angle, screwing in reduces the swivel angle)
4. Vent the actuator and check the seng again.
5. Repeat the seng procedure (steps 2 to 4) if
necessary.
6. Tighten the lock nut again.
Stop screws
By adjusng the stop screws, both end
posions can be adjusted by +/- 6° for
ne adjustment of the valve end posi-
on. The respecve seng posion is
secured by ghtening the lock nut.
X
Y

MANUAL & MAINTENANCE GUIDELINES
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3.4Assemblytoavalve
• The valve bore (for ball and plug valves) resp. the valve disc (for buery valves) must correspond to the
groove on the top of the actuator pinion sha during installaon in order to make signal- or control units work
correctly. The groove symbolizes the valve posion (acc. to VDI/VDE 3845).
• Make sure that the valve sha corresponds to the connecon in the drive pinion in shape and size. Dierences
can be compensated by using adaptaon inserts. These can be ordered separately via our sales department.
• Check whether valve and actuatorhave corresponding ISO interfaces. If not, an addional mounng kit will be
required. It can be ordered separately via our sales department.
• Fasten the actuator to the valve by using matching screws. We recommend using stainless steel screws to
ensure appropriate corrosion resistance. The number of screws is relevant for the stability of the assembly and
power transmission. Therefore, do not miss any aachment point. Take the correct ghtening torques into
account during xaon.
3.5Tighteningtorquesforscrewconnecon
Tightening torques in Nm
Nominal size Nm
M16 220
M20 430
M22 425
M24 585
M27 785
M30 1250
M33 1400
M36 1750
M48 5000
M64 9200

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
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1. Rotaryactuatorsmustbepneumacallyandelectricallyisolatedpriortoanyintervenon.
2. Rotaryactuatorsandtheconnectedvalvecanmovewhenthecontrolpressuregets
disconnectedand/oranelectricalcontrolsignalisswitchedo.
3. Insingle-acngactuatorswithanincompletespringstroke,thereisahighspringforcethatcan
triggerasuddenrotarymovementwhentheactuatorisdisassembled.Thiscancauseserious
injuriesordamages.
4. Intervenonsinelectricalinstallaonsmayonlybecarriedoutbyappropriatespecialists.A
switchedopowersupplymustbesecuredagainstunintenonalrestart.
Chapter 4: Maintenance
Content:
• General
• Safety instrucons
• Disassembly and maintenance of the modules
• Field reversions
• Components
4.1 General
Actuators of the PRY series are designed to be maintenance-free and supplied with sucient lubricaon for their
normal service life. The normal lifespan depends on the size and applicaon condions and is subject to EN 15714-3.
Carry out regular inspecons to ensure a failure-free operaon. Check whether there are visible or audible defects.
Regular maintenance and exchange of seals and bearings extends the normal lifespan. Corresponding spare part
sets are available from our sales department.
4.2Safetyinstrucons

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4.3 Disassembly and maintenance of the modules
4.3.1 Spring module
Disassembly of the spring module
1. Shut o the air supply and ensure that the control
media has been completely vented from the actua-
tor into the atmosphere.
2. Release the spring module from the center module.
3. Carefully pull the spring module away from the
center module in order not to damage the threads
on the spring rod and the stud bolts of the adapter
plate.
4. The spring module is welded as an integral com-
ponent and the internal components cannot be
disassembled.
Maintenance of the spring module
1. Clean and lubricate the spring rod and push it back in.
2. Replace the O-ring between the spring module and the
center body module.
1. Beforedismantlingtheactuator,disconnectallairandpowerfromtheactuator,removeall
accessoriesfromtheactuator,andremovetheactuatorfromthevalve(ordisablethegearbox,
ifpresent).
2. Iftheactuatorisequippedwithamanualoperaonmodule,rstmakesurethattheoverrideis
completelyresettorelieveitofanyspringforce.
Toavoidinjuries,pleasereadtherelevantoperangandmaintenanceinstrucons.Before
removingordisassemblingthespringmodule,makesurethattheactuatorisdepressurized,the
strokelimitaondevicesaredeacvatedandtheendstopposionsarefullyreached.Donot
manipulatefactory-weldedpartsofthespringtank!

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4.3.2Pneumacmodule
Disassemblyofthepneumacmodule
1. Remove the pneumac module from the quarter
turn actuator.
2. Loosen the e rod nuts and remove the end plate
from the pneumac module.
3. The e rods can be unscrewed from the adapter
plate.
4. Remove the cylinder.
Maintenance of the cylinder module
1. Clean the cylinder and grease the inside of the
cylinder.
2. Replace the piston and the O-ring on the cover.
Makesurethatthecontrolmediahasbeencompletelyventedfromtheactuatorintothe
atmospherebeforeyoudisassemblethepneumacmodule.Otherwise,seriousinjuriescanresult.
Toremovethepneumacmodulefromthespring-resetactuator,rstdisassemblethespring
moduleasdescribedinsecon4.3.1.
4.3.3 Center module
Disassembly of the center module
1. Remove the posion indicator, if applied.
2. Loosen and remove the top cover screen.
3. Loosen the screws on the housing cover and open
it.
4. Turn the yoke to the appropriate posion, loosen
the screw on the cover plate of the pin roller and
take out the cover and the drive pin.
5. Take out the yoke.
Eitherthespringmoduleorthepneumacmodulemustberemovedfromthecentermodule
before it can be disassembled.

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
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4.3.4 Manual hydraulic module
Instrucons
1. Aer installaon, the hydraulic unit must be vented
rst.
2. For the single-acng pump, open the relief valve and
quickly move the operang lever a few mes.
3. With the single-acng pump, the hydraulic cylinder
remains in the original posion aer stopping opera-
on. When the relief valve is opened, the hydraulic
cylinder is slowly reset under the spring force. When
the reset process is nished, close the relief valve
again to make the hydraulic unit ready for the next
process.
4. In case of a double-acng pump, the threaded
connector that is connected to the oil line must be
loosened. Move the operang lever up and down
several mes unl hydraulic oil seeps out of the
thread and then ghten the thread again.
5. Before operang the double-acng pump, the
compensaon valve of the hydraulic cylinder must
be closed. If the reversing lever is on the le side,
the le connecon builds up oil pressure, while the
hydraulic oil on the other side ows back to the oil
tank via the right connecon and vice versa.
6. In the case of double-acng actuators it must be en-
sured that the compensang valve is open and there
is no pressure dierence between the le and the
right side of the hydraulic cylinder, before canceling
manual operaon and returning to automac mode
via the pneumac control.
Pleaseusemineraloilorphosphateesterhydraulicoilinthehydraulicunit.Thehydraulicoillter
shouldhaveaporesizeofmax.20μm.Thedegreeofpolluonofthehydraulicuidisnotbelow
requirementsofISO19/16(NAS10).Oilpolluonleadsdirectlytodamageofthepumpandvalve
funcon.Thehydraulicuidcanbeanenvironmentallyharmfulproduct.Donotpourhydraulic
uidintocollecontanksandprotectyourselfagainstaccidentalleakageandspillageofthe
hydraulicuidwithoil-absorbingproducts.
hydraulic module single-acng
hydraulic module double-acng

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January 2020
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4.3.5 Mechanical manual modules
The manual modules are either a screw- or a gear-module for double-acng and single-acng actuators.
Instruconsforthespindleandgearmodules
1. ForactuatorswithspringaconCW:
If there is a loss of compressed air, turn the handwheel counterclockwise to move the actuator in the CCW
direcon. The handwheel must be turned clockwise to the starng posion before the drive resumes automac
operaon.
2. ForactuatorswithCCWspringacon:
If there is a loss of compressed air, turn the handwheel clockwise to move the drive in the CW direcon. The
handwheel must be turned counterclockwise to the starng posion before the drive resumes automac opera-
on.
Thepushrodofthegearmodulemovesbackandforthinnormaloperaon.Donotremove
protecvecoverswithoutensuringthattheairsupplyisinterruptedandtheautomacoperaon
oftheactuatorisdeacvated.
screw module double-acng screw module single-acng
Themanualmodulesarenotusedasastrokelimitaondevice.Forautomacoperaon,the
manualactuaonunitmustbemovedcompletelyintothebasicposion.
double-/single-acng gear module

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
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4.4Fieldreversions
4.4.1Changingthedireconofspringacon(forsingle-acngactuators)
The safety posion of the single-acng actuator can be changed from CW to CCW and vice versa. This requires
swapping the pneumac and spring modules.
1. Follow the steps to remove the spring and pneumac modules from the actuator as described in secons
4.3.1 and 4.3.2.
2. Change the posions of the two modules and rst assemble the pneumac module. Make sure that the
module seal O-ring is properly seated in the groove.
3. Mount the actuator back on the valve/gearbox and adjust the adjusng screws as required for the correct
operaon of the valve. Tighten the lock nuts on the stop screws.
4. Check the actuator for correct operaon at the nominal operang pressure.
Neveraempttounscrewandremovethespringbarwithoutcompletelyrelievingthesprings.
Mounng
version Actuatorconguraon Safetyrotaon
PR CW
PL CCW

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PNEUMATIC ACTUATORS SERIES PRY
BWA.PRY.200116
January 2020
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4.4.2Conversionfromdouble-acngtosingle-acng
1. To convert a double-acng actuator to single-acng (fail-CW mode), a spring module must be mounted
opposite on the center module. If the CCW mode is to be achieved, the pneumac module must rst
be dismantled and mounted on the opposite side of the center module. Then the spring module can be
mounted at the previous posion of the pneumac module.
2. If the pneumac module needs to be enlarged for the required conguraon of the single-acng actuator,
rst carry out the complete replacement of the pneumac module. Follow the instrucons in secon 4.3.2 to
remove the pneumac module. Then mount the new pneumac module accordingly.
3. Connect the spring module and the center module with stop screws, insert the O-ring of the module into the
adapter groove of the spring module.
4. Reassemble the actuator.
5. Adjust the stop screws to ensure correct installaon with the valve.
4.4.3Conversionfromsingle-acngtodouble-acng
1. Remove the spring module from the actuator (see secon 4.3.1).
2. Aach the end cover with the O-ring to the spring module side of the center module.
3. Adjust the adjusng screws if necessary.

MANUAL & MAINTENANCE GUIDELINES
PNEUMATIC ACTUATORS SERIES PRY
BWA.PRY.200116
January 2020
19
4.5 Components
Item Designaon Quanty Material
Center module
5 Bear Seat 1 Carbon Steel
7 Screw n Carbon Steel
8 Indicator 1 Carbon Steel
9 Screw n Carbon Steel
10 Center Body Cap 1 Ducle Iron
11 Yoke 1Ducle Iron
12 Center Body 1 Ducle Iron
13 Cap O-ring 1 Rubber
14 Drive Mechanism 1 Alloy Steel
Spring module
1 Flange Cap 1 Carbon Steel
2 Spring Seat 1 Carbon Steel
3 Spring 1 Spring Steel
4 Spring Body 1 Carbon Steel
6 Spring Stem 1 Alloy Steel
Pneumacmodule
15 Cylinder Seat 1 Ducle Iron
16 O-ring 1 Rubber
17 Piston 1 Carbon Steel
18 Guide Ring 1 Resin
19 Cylinder Body 1 Carbon Steel
20 Cylinder Cap 1 Ducle Iron
21 Screw n Carbon Steel
22 Nut n Carbon Steel

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