Remote Control Twin Power User manual

Twin Power
Pneumatic Multiturn actuator in Standard andATEX design
Manual No. 661
Manual
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1
Valve designed with rising stem and handwheel.
Instead of the handwheel a driving bush with keys is
fitted on the stem end. The driving bush rises axially
corresponding to the valve rise. In this case an actuator
must be chosen with a hub length corresponding to the
rise of the bush.
Valve with rising stem and non rising handwheel.
A flange is mounted on the valve, and a driving bush
with keys fitted in the place of the hand-wheel for
transmission of the turning movement to the stem unit.
ASSEMBLYEXAMPLE
MOUNTING
The Twin Power actuator works beyond reproach in
all positions. Valves with fluid media should if
possible be fitted in such a way that fluid leakage
from the packing box is not led from the packing box,
through the stem, into the stem nut and the actuator.
It is desirable that the valve stem should be
assembled in an upright position. If this cannot be
done care should be taken to tighten the gland
regularlyand change thebox packing when
necessary.
Grease the drive bush carefully and ensure that
there is no radial or axial diffraction between the
drive bush and hub. Check that the numbers of turns
not exceed the permitted turns on the chosen
indicatingbridge
The last three numbers in the type denomination
inside the actuator cover, specifies the type of
Indicator Bridge
Indicator Bridge Maximum turns
175 3,5 - 18
100 18 - 32
050 32 - 65
175S 65 - 155
100S 155 - 275
050S 275 - 550
In cases where the Twin Power actuator will be
assembled on valves with rising stem and rising
handwheel, the length of the hub must be minimum
the length of the drive bush axially movement.
Some practical advice
Ensure that the 3/8” air connections are positioned
so as to prevent dirt and liquids entering the motor.
If necessary, a short length of pipe should be fitted
into each port, with the end pointing downwards.
Driving
bush
Driving
bush
Stem nut
Machined stem
end with key
®

Pressure control
The Remote Control Twin PowerActuator is desig-
ned for a normal working pressure of 7 bar (100 psi),
but it can be satisfactorily operated between 4-8 bar
(60-140 psi). The supply air shall be dust and oil free.
The air dew point shall be -20 oC or 10 oC below the
ambient temperature. The maximum particle size
must not exceed 40 µm.
The Twin Power actuator specified torque is direct
depending on the air supply pressure. In order to
produce a constant power output from the motor, an
even air pressure is required.
The starting torque of the Twin Power is approx. 50
% higher than the tightening torque. If the tightening
of the valve takes place at an air pressure of 6 bar
and the air pressure at opening is 5 bar, gives a
decreasing of the starting torque at a given relation
to the decreasing air pressure.
If the air supply pressure fluctuates, a constant
pressure regulator should be fitted in the system.
The regulator should be set so it gives a pressure
output equivalent to the lowest incoming pressure.
Oil mist lubrication
To increase the reliability of the Twin Power actuator,
an oil mist lubricator should be fitted as close as
possible to the actuator.
For lubrication of the diaphragm motor, control
valve, and the moving parts of the operating cylinder,
an oil mist unit should be fitted not more than one
meter under the Twin Power actuator. At pneumatic
operation where the distance between the actuator
and control panel sideways and at falling pipe
exceeding 10 meters, an oil mist lubricator shall be
fitted on the air supply pipe for clockwise operation.
The oil mist lubricator should be filled with low
viscosity oil. The guideline value for adjustment of
the oil mist lubricator is 1-2 drops/minute.
Before the air pipes connects to the actuator they
should be cleaned by air, so that no particles will
cause operational disturbance. To entirely avoid this
risk an air cleaner can be fitted.
Important!
By new installations all of the air supply pipes
shall carefully be cleaned by air before
connection to the actuator and accessories.
Before testing of the actuator:
Remove the two plastic caps that covers the
breathing and exhaust hole on the air motor.
2
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INSTALLATION
Plastpluggar
borttages
OPERATING
Check that the connection for incoming air supplies
is correct when the actuator operates with auxiliary
valves, e.g. solenoid valves.
When choosing auxiliary valve, i.e. pneumatic 3-
way valves, solenoid valves or hand operated
valves, shall these always be vented after
completed operation
When changing operation direction, the air pipe
between the auxiliary valve and operating unit
must be vented before a new operation starts.
When manually operating with 3-way solenoid
valves, these shall be operated with 3-position
switches with neutral centricity. If other equipment is
used, the same function shall be obtained.
At momentary impulse changes, i.e. when the
rotation direction must be changed rapidly, it is
recommended to use the connection according to
alternative on page 3.
Remove the plastic caps
Connection for clockwise rotation
Connection for anticlockwise
rotation

5
4
3
2
1
5
1
4
89
10
11
6 7
2
3
1
2
3
4
5
6
Impuls för stängning
Impuls för öppning
Inkomm. matning
3
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Terminal No. 5 has breaking function at
open valve.
The solenoid valve for opening
position shall be connected to
terminal 5 for travel limit function
in open position.
1. Microswitch, travel control
2. Microswitch, closed valve
3. Microswitch , open valve
4. Connection terminal
5. Signal lamp, closed valve
6. Signal lamp, travel control
7. Signal lamp, open valve
8. Switch
9. Solenoid valve, for closing
10. Solenoid valve, for opening
11. Oil mist lubricator
Alternative 1. Connection example with solenoid valve and standard indicator bridge
Alternative 3. Piston operated 3-way valve for increased operating speed
Alternative 2. Pneumatic operating and indicating
1. Filter, regulator and oil mist lubricator
2. Manually operated pneumatic 3-way valve
with spring return for closing NC
3. Manually operated pneumatic 3-way valve
with spring return for opening NC
4. Pneumatic signal lamp for open valve
5. Pneumatic signal lamp for closed valve
Air supply
Impulse for closing
Impulse for opening

45
6:S1/5
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Figure 4
The function of the Indicator Bridge
The indicator bridge has several functions. First, the
latches (3:S1/26) accomplish the by 50 % increased
starting torque in both end positions. Secondly, the
micro switches of the bridge give signals which,
when coupled up to signal lamps, indicate ”open”,
”closed” and ”running” condition. Further, it is
possible to fit, as options, pneumatic switches for
open and closed position as well as pneumatic or
electric continuous indication.
The increased starting torque is obtained by a
restriction of the console movement (2:S1) when
changing the rotary direction, figure 1. By support of
the catch (2:S1/12) in the console this is kept in
such a position of the latch (3:S1/26) on the
indicator bridge, that the effect will be the increased
starting torque in relation to the normal torque.
The latch (3:S1/26) is connected to the slide rod
(3:S1/41), figure 2. This slide rod is sliding in an
axial direction by the slide-block (3:S1/9-10), figure
2, in the last stage of the valve operation.
Both the adjustable stops No. 1 and 2 are fastened
by screws in such a position of the slide rod, that
they will be affected by the slide-block about 3 mm
before this one has reached its final position.
When the valve now is driven from the end
positions the latch will return into the neutral position
by support of the centering springs. When the latch
has released the catch, the operating cylinder (5:S1)
will complete its stroke, and the normal torque will be
connected. The increased starting torque will be
obtained by the fact that the motor shaft (6:S1/5)
changes point of attack on the operating levers
(2:S1/5). Figure 3 shows the position of the levers at
the ”Starting” Torque and figure 4 shows the position
at the normal or a ”Running” Torque. The increased
starting torque will be obtained only during the initial
spindle revolutions counting from each end position.
To make sure that the setting are sufficient it is
recommended to operate the actuator a few times.
Figure 3
Figure 1
4
Figure 2
2:S1/12
3:S1/26
2:S1 3:S1/9-10 3:S1/14
4 3 2 1
3:S1/41
2:S1/5 2:S1/5
6:S1/5 6:S1/5
2:S1/5
2:S1/5

WARNING!
Risk for injuries caused by crushing/squeezing
and electrical shocks when the actuator is
energized by air pressure and electricity with its
cover off.
1. Remove the cover.
2. Close the valve entirely.
3. Undo the two stops No. 1 & 2 closed to the
slide block (3:S1/9-10), so that it can move
freely within the whole range. Figure 6
shows the adjustment of the stops.
Damage could occur if the slide block
runs against the stops 1 & 2 moving them
more than 3,2 mm. .
4. Make sure that the slide-block stands close
to the bracket (3:S1/14), so that there is
space enough on bridge spindle for valve
to open, figure 6.
5. Bring over the shaft (3:S1/41) about 3 mm
against bracket (3:S1/14), so that the latch
(3:S1/26) Figure 1, is turned in a suitable
position to grasp the catch (2:S1/12).
Suitable tool: Seeger circlip pliers.
6. Bring the stop No.1 between the slide-
block and the bracket (3:S1/14) towards
the slide-block and screw on tightly.
7. Put the bridge gear (3:S1/52) in place.
8. Open the valve entirely, and check that the
slide-block can move freely within the
whole range, Figure 2 shows the slide-
block (3:S1/9-10) in open valve position.
9. Bring over the shaft (3:S1/41) in the
opposite direction (about 3 mm) and
fasten the stop No.2 by screws after having
been brought towards the slide block.
10. Adjust the other two stops, (3 & 4), so that
the microswitches are actuated at the
end positions of the valve.
above have been carefully observed.
The actuator is now synchronized to the valve.
Should the actuator ever be removed from the valve,
synchronization must be checked after re-installation
11. Fit the cover and tighten the screws.
Indicator Bridges 175S, 100S och 050S
These indicator bridges will be delivered without the
screw (3:S1/31), and the bridge turned so that the
the bridge gears (3:S1/48 and GDS1:1+GDD2:1/5)
do not mesh. The bridge is fastened by screws in
place, after the valve is closed entirely and the
instructions given for the types 175, 100 and 050
Figure 5
Figure 6
Adjustment of the Indicator Bridge
After the actuator has been mounted on the valve,
the indicator bridge must be synchronized to the
valve ends, not only to get the latches to mesh and
get indications of signals, but also in order to prevent
damages to the bridge. Figure 5 shows the unit with
the cover off, and the bridge gear (3:S1/52) tied to
the lead screws (3:S1/7-8). The actuator will be
delivered with the bridge gear tied to the lead screw,
unless the actuator is delivered mounted on the
valve, when bridge mechanism and indicating
switches are set before dispatch.
5
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3:S1/7-8
3:S1/52
Indicator bridge 175, 100 and 050
Note.
The bridge is just an indicating and control device
and is not intended to ”stall out” the actuator.
3:S1/9-10 3:S1/41
1 2 3 4
3:S1/14

MAINTENANCE
The actuator is provided with two lubrication nipples
for a grease gun. When the actuator is in regulary
daily operation, lubrication should be performed at
intervals of some weeks. It is to be borne in mind
however that the invervals of lubrication are
dependent on local conditions, for example, the
frequency of operation, the temperature and
surrounding atmosphere etc.
If the actuator is used only infrequently, it should be
lubricated with grease which doesn´t get hard, or
change viscosity when in contact with the
surrounding atmosphere. The lubrication of the
actuators in this case could be carried out during
normal maintenance on the other equipment. It is
recommended that the actuator is inspected at
regular intervals for preventative purposes. It is not
possible to give general instructions as to the
intervals of inspection, as these are dependent on
local conditions.
We would suggest the following points could be
checked, and if necessary, lubricated with some
drops of oil.
1) Spindle thread and axle journals of the
indicator bridge.
2) The oil holes of the axle journals, 2:S1/ 4+21
3) The pin for the draw-spring, 2:S1/6
4) The case for the ratchet spring, 2:S1/2
5) The stop shoulder, 2:S1/18
TROUBLE SHOOTING
WARNING!
6
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Risk for injuries caused by crushing/squeezing
and electrical shocks when the actuator is
energized by air pressure and electricity with its
cover off.
1.
Check that air supply is available at the actuator and
that the pressure does not vary too much (See Page
2, INSTALLATION)
2.
Check the actuator for functional faults.
Remove the cover and make an ocular inspection.
Open and close the valve. It is very important that the
increased starting torque is correctly adjusted. Check
that the console (2:S1) operates accordingly to the
torque diagram (see technical data sheet). The motor
shaft shall actuate outer part of the operating lever.
3.
If the motor (6:S1, 7:S) does not operate:
Disconnect the air pipe between motor and steering
valve (4:S).
If air flow to the motor is blocked: Check the steering
valve. Push the levers (4:S/10 &13) and at the same
time pressurize the inlet port (4:S/9). The shafts
(4:S/3) should be pushed in about 1,5 mm when the
turning direction changes. If not, then the setting
position of the levers on the shafts should be
adjusted with screw 4:S/7.
4.
If the levers (2:S1/5) hook up on the motor shaft
(6:S1/5 or 7:S/5) by a change over operation, this
depends on an instantaneously change over
operation.The operating cylinder (GDS1:1/12) has
started to change over the turning direction from
open to close or vice versa, before the motor has
vented and the shaft fully returned to its outer
position.
This can be cured like this:
a) Try to avoid instantaneously change over
operations, by allowing a mean time of 1 to
2 seconds to vent the control valves.
b) Fit the motor with a quick exhausting
valve.
c) Introduce some kind of a change over
signal time delay.
5.
If air blows through the front port of the diaphragm
casing (6:S1/1), the diaphragm is bursted. Change
diaphragm according to instruction.
6.
If the motor operates very quick but with short
strokes: Close the needle valve (GDS1:1/19). Then
slowly open until the motor operates normal. If this
doesn’t help, there is probably dirt in the valve
mechanism (6:S1/ and 7:S/17-30). Unscrew the
valve casing (6:S1 and 7:S/31). Carefully take out
and clean the valve mechanism. Be careful when
cleaning the rubberized valve seats. If the motor
does not operate and air blows through the rear
exhaust port, carry out the same procedure as
described above for cleaning the valve mechanism.
7.
Try to manually operate the valve and make sure it
does not seize or jam. Eventually the valve stem
might have seized or the stem gland is over
tightened.
If not, seeAdjustment of Indicator Bridge (Page 5).

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7
TWIN POWER ACTUATORS IN ATEX
EXECUTIONS
0575 II 2 GD
TwinPowerisATEXcertified intwo executions.
One with mechanic indicator bridge and switch box
1990and one withoutindicator bridge butwith gearbox
and switch box 1990.
SURFACE TEMPERATURE
Ambient temperature oC Temperature class
70 T6
90 T5
125 T4
150 T3
TWIN POWER WITH GEARBOX AND
SWITCH BOX 1990
Control and fine adjustment of box 1990
The limit switches are the primary indication of the
box. In cases where limit switches are not used, the
position transmitter of the box is the primary
indication. In cases where visual indication is used,
caution shall be taken to avoid the hand to exceed
the endpoints of the scale in any occasion. If this
happens the hand and the through shaft can be
damaged.
Fine adjustment of box with limit switches:
1. Make sure the valve is fully closed.
2. Attach suitable indication equipment to
the limit switch in the box indicating the
closed position (view wiring diagram sent
with the box).
3. Turn the input shaft of the gearbox anti-
clockwise to the position where the limit
switch start to indicate. View Figure B,pos 1.
4. Mount the gear on the input shaft of the
gearbox. View fig C pos 2.
Fine adjustment of box without limit switches:
1. Make sure the valve is fully closed.
2. Attach suitable indication equipment to
the position transmitter (view wiring
diagram sent with the box).
3. Turn the input shaft of the gearbox anti-
clockwise to the position where the
position transmitter starts to indicate
closed position (normally 4.00 mA). View
Figure B pos 1.
4. Mount the gear on the input shaft of the
gearbox. View Figure C pos 2.
Whenthe actuator is mounted on the valve,possible
limit switches of the switch box, position transmitter
and visual indication shall be synchronised with the
openand closed valveposition.
If the customer, at the registration of the order, has
specified the number of turns of the valve, this will
be factory pre set. Only control and fine adjustment
has to be done in this case.
If the number of turns is not specified, or if factory
pre set is unwanted, the equipment will be delivered
with only a functional test done.Acomplete
adjustment has to be done.
Switch Box 1990
TWIN POWER WITH MECHANIC
INDICATOR BRIDGE AND SWITCH BOX 1990
1. Dismount the lid.
2. Movethesmall gear wheel(seeFig above)
sideways.
3. Follow point 2 to 9, page 5.
4. Closethevalve.
5. Adjust the limit switch (for closed position) of
the switch box according to the instruction
forthe 1990box.
6. Movethe smallgear wheel back.
7. Openthevalve.
8. Adjust the limit switch (for open position) of the
switch box according to the instruction for
the 1990 box.
9. Remountthe lid.
Gear wheel

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8
Complete adjustment of box 1990:
The limit switches are the primary indication of the
box. In cases where limit switches are not used, the
position transmitter of the box is the primary
indication. In cases where visual indication is used,
caution shall be taken to avoid the indicator to
exceed the endpoints of the scale in any occasion.
If this happens the indicator and the through shaft
can be damaged.
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A
B
C
D
1. Make sure that the valve is fully closed.
2. To adjust the limit switches, the position
transmitter need to be dismounted. If limit
switches are not used, please continue at
point 13.
3. Dismount the position transmitter by un-
screwing the two screws holding the
connection terminal in the box. Move the
connection terminal sideways with the
cables still attached. Pull the position
transmitter carefully straight out until it is
released.
4. Attach suitable indication equipment to the
limit switches in the box indicating the
closed and open position (view wiring
diagram sent with the box).
5. In cases where visual indication is used,
turn the input shaft of the gearbox (Figure
B) to the position where the red indicator
points at closed position, i.e. 0%.
6. Adjust the cam of the limit switch indicating
closed position by loosening the socket
head cap screw (figure D pos 3) and
turning the cam anti-clockwise to the
position where the limit switch starts to
indicate. Fasten the cam in this position.
7. Mount the gear on the input shaft of the
gearbox in the way that it is free to rotate
without touching the hub of the actuator.
Mark the position of the gear with a
marker.
8. Rotate the gear clockwise the number of
turns the valve need to open, times two.
10.25 turns of the valve gives 20.5 turns of
the gear etc.
9. Adjust the cam of the limit switch indicating
open position by loosening the socket
head cap screw (Figure D pos 3) and
turning the cam clockwise to the position
where the limit switch start to indicate.
Fasten the cam in this position.
Pos 1
Pos 2
Pos 3

We reserve the right to alterations without previous notice .
Ref No. 661/ Art No. 980661
9
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Kontrollvägen 15
SE-791 45 FALUN
Sweden
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Unit 40, Trent Valley Works
Station Road, Rugeley
Staffordshire WS15 3HB
England
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67 Ubi Crescent, #01-07
Techniques Centre
Singapore 408560
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Gutenbergstr. 22
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10. In cases where visual indication is used,
the hand should now be pointing at open
position, i.e. 100%.
11. Rotate the gear anti-clockwise back
to the exact closed position and check
the number of turns of the valve.
12. Make sure that the marks on the backside
of the position transmitter are lined up
(FigureA). Put the position transmitter back
into the box by pushing its shaft into the
O-ring provided hole in the shaft of the box.
Remount the terminal block and check that
the position of the position transmitter has
not changed.
13. The position transmitter shall be adjusted
with its marks lined up (Figure A) and
possible limit switches and visual indication
shall show closed position.
14. Attach suitable indication equipment to the
position transmitter and possible limit
switches (view wiring diagram sent with the
box).
15. Adjust the output signal from the position
transmitter for closed position (i.e. 4.00 mA)
by turning the screw underneath the
protection plug marked with ”ZERO” on the
position transmitter (Figure A). Use a small
flat screwdriver.
16. See point 7.
17. Rotate the gear clockwise to the position
where the limit switch indicate open
position. In cases where limit switches are
not used, see point 8.
18. Adjust the output signal from the
position transmitter for open position
(i.e. 20.00 mA) by turning the screw
underneath the protection plug marked
with ”SPAN” on the position transmitter
(FigureA).
19. Repeat point 15 and 18 a couple of
times until a stable output signal is
received from the position transmitter.
20. Rotate the gear to closed position and
mount it according to Figure C.
21. Try to manually operate the actuator
and check the signals.
.