rotork RH Series Guide

RH Range
Hydraulic Actuator
Single-Acting and Double-Acting Configuration
Installation, Commissioning and
Maintenance Manual
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RH Range Installation, Commissioning and Maintenance Manual
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Section Page Section Page
Contents
Section Page Section Page
This manual contains important safety information.
Please ensure it is throughly read and understood before
installing, operating or maintaining the equipment.
Rotork reserves the right to modify, amend and improve
this manual without notice.
Due to wide variation in the terminal numbering of
actuator products, actual wiring of the device must
follow the print supplied with the unit.
1. Introduction 3
2. Standards & Regulations 3
3. General Information 4
4. Health & Safety 4
4.1 Residual Risks 4
4.2 Thermal Risks 4
4.3 Noise 4
4.4 Health Risks 4
4.5 Mechanical Risks 4
4.6 Magnetic Risks 5
5. Labels & Nameplates 5
6. Operating Limits 6
6.1 Allowed Fluid Types 6
6.2 Expected Lifetime 6
6.3 Tightening Torque Chart 6
7. Handling & Lifting 7
7.1 Lifting Recommendations 7
7.2 Lifting Instructions 7
8. Storage 9
9. Long Term Storage 9
10. Installation on Valve 10
10.1 Preliminary Actions 10
10.2 Instructions 10
11. Removal from Valve 11
12. Operation 12
12.1 Description 12
12.2 Operating Description 14
12.3 Actuator Code and Design 14
12.4 Manual Override 14
12.5 Angular Stroke Setting 14
12.6 Hydraulic Power Supply 18
12.7 Hydraulic Connections 18
12.8 Electrical Connections 19
12.9 Start Up 19
13. Dismantling and Disposal 20
14. Rotork Sales and Service 20
15. Troubleshooting 21
16. Periodic Maintenance 22
17. Part List 51
18. Grease & Hydraulic Oil Specification 55
18.1 Grease 55
18.2 Hydraulic Oil 56
Single-acting actuator (body sizes 015, 030, 060, 120, 240)
Double-acting actuator
(body sizes 090, 105, 125, 145, 155, 185, 225, 250, 280)
Double-acting actuator (body sizes 015, 030, 060, 120, 240)
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1. Introduction 2. Standards & Regulations
This manual covers maintenance aspects and instructions
specific to the RH range of actuators. General information
on Rotork actuators are described in the User Manual,
delivered separately.
In this manual, warning indications are represented by icons,
per ISO 7010 Safety Signs:
Generic danger
Hand crush / pinch point
Electrocution
Explosive material
Actuators destined for European member states have been
designed, built and tested per the Quality Control System, in
compliance with the EN ISO 9001:2015 standard and with the
following regulations/directive.
• 2006/42/EC: Machinery Directive
• 2014/68/EU: Pressure Equipment Directive (PED)
• 2014/34/EU: Directive for safety equipment and systems
to be used in potentially explosive atmospheres (ATEX)
• 2014/30/UE: Electromagnetic Compatibility Directive
• EN ISO 12100: Machinery Safety Directive
• EN 60079-14: Explosive atmospheres - Part 14: Electrical
installations design, selection and erection
• ISO 80079-36: Non-electrical equipment for explosive
atmospheres - Basic method and requirements
• EN 1127–1: Explosive atmospheres – Explosion prevention
and protection
• ISO 80079-37: Non-electrical equipment for explosive
atmospheres - Non-electrical type of protection
construction safety "c", control of ignition sources "b",
liquid immersion "k"
• UNI EN ISO 7010: Safety Signals
Customer Service
For technical assistance, please contact
Rotork Customer Service:
E-mail: [e-mail]
Rotork Fluid Systems, Porcari,
Lucca, IT tel: [phone]
Rotork plc, Brassmill Lane, Bath, UK. Tel [phone]
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RH Range Installation, Commissioning and Maintenance Manual
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3. General Information
This manual is produced to enable a competent user to install,
operate and maintain Rotork RH single and double-acting
actuators.
The mechanical installation must be carried out as outlined
in this manual and in accordance with any relevant national
standard codes of practice.
Maintenance and operation must be carried out in
accordance with the National Legislation and Statutory
Provisions relating to the safe use of this equipment,
applicable to the site of installation.
Any inspection or repair in a Hazardous Area must not be
undertaken unless it conforms to National Legislation and
Statutory Provisions relating to the specific Hazardous Area.
Only Rotork approved replacement parts should be used.
Under no circumstances should any modification or alteration
be carried out on the equipment, as this could invalidate the
conditions under which certification was granted.
Only trained and experienced operators can install, maintain
and repair Rotork Actuators. Work undertaken must be
carried out in accordance with instructions in this manual.
The user and those persons working on this equipment
must be familiar with their responsibilities under any
statutory provisions relating to the Health and Safety of their
workplace.
Operators must always wear appropriate Personal Protection
Equipment (PPE) in line with the existing plant regulations.
Appropriate usage
Rotork RH range actuators have been specifically developed
to motorize ¼ turn valves, such as ball valves, butterfly valves
or plug valves installed on pipelines for oil & gas transport
and distribution.
Improper use can damage the equipment or cause
dangerous situations for health and safety. Rotork
declines any responsibility for damage to people and/
or objects resulting from the use of the equipment
for applications different from those described in the
present manual.
Before installing the equipment, verify it is suitable for the
intended application. If unsure consult Rotork.
4.1 Residual Risks
Residual risks resulting from equipment risk evaluation
performed by Rotork.
4.2 Thermal Risks
Risk Hot/Cold surface during normal operation.
Preventive measures Operators should wear protective gloves.
4.3 Noise
Risk Noise >85 dB during operation.
Preventive measures Operators must wear ear protections.
Operators must not stand near the
equipment during operation.
4.4 Health Risks
Risk Pressurized fluid ejection during
normal operation.
Preventive measures All fittings must be properly sealed.
All fixing clamps must be correctly
tightened and sealed.
Risk Risk of intoxication (per the type of
medium utilized).
Preventive measures Operators must use P.P.D.s and any
other equipment (breathing apparatus)
based on the type of supply medium.
4.5 Mechanical Risks
Risk Uncontrolled movement (remote
operation). (This risk is applicable
only for actuators provided with
control panel).
Preventive measures Assure that the actuator cannot be
operated remotely. Prior to starting,
remove Hydraulic supply, vent all pressure
vessels, and remove electrical power.
Risk Presence of moving parts (centre body,
valve adapter).
Preventive measures Do not perform start-up or test the
actuator if the cylinder tube is removed.
Risk Loss of stability with possible parts
projection.
Preventive measures Do not disassemble the actuator
in case of malfunctioning. Follow
instructions in the present manual and
contact Rotork.
Preventive measures Foresee periodic maintenance
procedure to verify tightening.
4. Health & Safety
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Risk Presence of potential energy during
dismantling.
Preventive measures Do not disassemble the actuator
during dismantling. Follow instructions
in the present manual and contact
Rotork.
4.6 Magnetic Risks
Risk Risk of magnetic field/disturbance and
exothermic reactions.
Preventive measure The End User shall assure that actuator
and its components are installed
far from magnetic field, electro-
magnetic field, radioactive source,
electroacoustic transducer which could
modify its behaviour.
(This mitigation is applicable only for
actuators provided with control panel)
Avoid maintenance operations with
acid/basic solutions.
The following label is applied externally to the actuator:
1370 LUCCA ITALY
L
CYLINDER CODE:
SERIAL NUMBER :
TESTING PRESS. (PT):
DESIGN PRESS. (PS):
MAX WORKING PRESS.:
bar
bar
bar
L
MIN./MAX DESIGN TEMP.(TS):
CĀ
PED CAT.
:
FLUID:
VOLUME (V):
MONTH/YEAR:
Fig 5.1 Actuator label
The TX surface temperature class is not provided since
the actuator has no internal heat source. Maximum
actuator temperature is the environmental or exercise fluid
temperature, whichever is the greater. Normal operating
temperature range is -30 to +100 °C (-22 to +212 °F).
Temperature range must be specified within the project
specific technical documentation. Special applications beyond
the standard temperature range are available upon request.
ATEX plate does not indicate the maximum environmental
and/or exercise fluid temperature; this information is reported
within the project specific technical documentation.
For CE (PED) marked actuator the following label is also used:
Fig 5.2 Actuator PED label
Label removal is not allowed.
4. Health & Safety 5. Labels & Nameplates
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6. Operating Limits
Temperature: -30 to +100 °C (-22 to +212 °F) for
standard applications
-20 to +100 °C (-4 to +212 °F) for PED
applications
-40 to +100 °C (-40 to +212 °F) for low
temperatures
-60 to +100 °C (-76 to +212 °F) for ultra-
low temperatures
Design pressure: up to 250 Barg, refer to job
documentation.
Operating pressure: refer to job documentation.
Do not use the equipment outside its operating
limits. Verify operating limits on the nameplate.
Prevent external surface temperature to reach the ignition
point in potentially explosive environments.
The actuator surface temperature is strictly dependent on the
temperature of the process fluid used and by the irradiation’s
conditions. The end-user must check the surface temperature
of the assembly, so that this cannot go over the minimum
gas ignition’s temperature, which classifies the area with the
explosion’s risk.
Dust and debris accumulated on the actuator will slow down
its cooling and contribute to the increase of its external
temperature.
6.1 Allowed Fluid Types
RH actuators are designed to be operated with hydraulic oil
ISO 4406 class 16/14/11.
Do not use the actuator in presence of naked flames.
6.2 Expected Lifetime
Expected Lifetime greater than 25 years, in normal service
conditions and with planned maintenance.
6.3 Tightening Torque Chart
RECOMMENDED TIGHTENING TORQUE
(Class 8.8 bolts)
Bolt Size Nm Ft. Lbs
M6 8.5 6
M8 20 15
M10 40 30
M12 55 40
M14 110 81
M16 220 162
M20 430 317
M22 425 313
M24 585 431
M27 785 579
M30 1250 921
M33 1400 1030
M36 1750 1290
M48 5000 3688
M64 9200 6786
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Only trained and experienced personnel should
handle/lift the actuator.
The actuator is supplied packed on pallets suitable for normal
handling.
Handle the actuator with care. Never stack pallets.
7.1 Lifting Recommendations
• The lifting device and the sling must be suitably rated
for the actuator weight and dimensions
• Do not use damaged sling(s)
• The sling must not be shortened with knots or bolts or
any other makeshift device
• For lifting purposes, use only suitable lifting tools
• Do not drill holes, weld eye bolts or add any other type
of lifting device on the actuator external surface
• Do not lift the actuator and valve combination with the
actuator lifting lugs
• Every assembly must be estimated separately for a safe
and correct lifting
• Avoid pulls or abrupt movements during lifting.
Avoid pushing the load
• During lifting operations, do not handle the slings
and/or the actuator
Do not step underneath suspended load.
7.2 Lifting Instructions
Note: Indication of Weight, Centre of gravity,
lifting points are reported within specific project
documentation.
For non-horizontal actuator orientation, please consult
project specific documentation before lifting.
• Prior to lifting the actuator, remove electrical power and
vent all pressure vessels (if present).
• For single-acting actuators, hook the double chain slings
on the lifting lugs, as shown in Fig 7.1.
• For double-acting actuators, hook a double chain sling on
the lifting lug on the Hydraulic cylinder and a textile sling
on the centre body closure flange as shown in Fig 7.2.
The actuator must remain horizontal; balance the load .
• Angle βmust be between 0° and 45° as shown below.
Direction
of Pull
Fig 7.1 Lifting single-acting RH body sizes 015, 030,
060, 120, 240.
7. Handling & Lifting
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RH Range Installation, Commissioning and Maintenance Manual
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Fig 7.2 Lifting double-acting RH body sizes 015, 030,
060, 120, 240.
Fig 7.3 Lifting double-acting RH body sizes 090, 105,
125, 145, 155, 185, 225, 250, 280.
7. Handling & Lifting
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8. Storage
Rotork actuators have been fully tested before leaving
the factory.
Actuators must be kept in good condition until installation.
Follow the measures below:
• Check presence and assembling of dust plugs
• Keep the actuator on shipping pallet until installation
Never put the actuator directly on the ground.
• Actuator must be positioned with the centre body cover
upwards
• Protect the valve coupling area (adapter flange
and coupling joint, etc.) with rust preventive oil
e.g. Mobilarma LT or equivalent
• Protect against weather, cover the actuators with
appropriate polyethylene sheets
• Check the actuator condition every 6 months and verify
the above protection measures remain in place
Remove package only at the installation time.
If long term storage is necessary, further operations must
be carried out to maintain the actuator in a good working
condition:
• Replace the plastic plugs with metal plugs
• Stroke the actuator every 12-months
• Cycle the actuator with a hydraulic supply to the working
pressure indicated on the name plate
• Cycle the actuator with all the existing controls
(i.e. two complete strokes - one open, one closed) at
least 5 times
• Cycle the actuator fitted with hydraulic manual
override by means of the override for 4 complete
strokes
• Disconnect the hydraulic and electric (if present)
supply from the actuator, and carefully close all the
threaded connections of the actuator
• Remove electrical components covers (if present) to
ensure control terminals are clean and free from oxidation
and humidity. Reassemble the covers
• In case of storage for over 12 months prior to installation,
it is recommended to operate the actuator to verify
correct operation
9. Long Term Storage
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10. Installation on Valve
Before proceeding, read and understand the Health and
Safety information.
Note: Prior to performing the following operations, the
valve must be properly secured per Valve Manufacturer
instructions.
Prior to performing any operations check the
operating drawings and TAG numbers.
Consult Rotork for any additional information.
10.1 Preliminary Actions
Verify the ATEX classification of the actuator is
compatible with the plant zoning. Refer to actuator
nameplate.
• The centreline of the cylinder is usually aligned to the
centreline of the associated pipe work
• Ensure all fasteners are adequately tightened, to avoid
loosening during operation, considering the vibrations
induced by the dynamics of the pipeline
• Piping used to provide power to the actuator must be
free from contaminants and debris. Ensure tubing runs
are adequately fastened and supported to minimize
repetitive stress induced the dynamics of the pipeline.
Ensure there are no leaks from any gas connections.
Tighten as required
10.2 Instructions
The actuator assembly on valve can be performed by:
• Mounting directly using the actuator housing flange with
threaded holes
• Using an adapter and a coupling joint between the
actuator and the valve
The assembly position of the actuator must be in accordance
with the actuator design, plant requirements and the valve
model.
To assemble the actuator onto the valve, proceed as follows:
• Verify the coupling dimensions of the valve flange and
stem; they must meet the actuator coupling dimensions
(See document pub019-001)
• Actuator is supplied in the fail position (for single-acting).
Set the valve in the right position per the actuator fail
position. Check the position of the actuator by means of
the position indicator on the centre body or on the limit
switch box (if present)
• Clean the coupling flange of the valve and remove
anything that might prevent adherence to the actuator
flange. Grease shall be completely removed
• Inspect, clean and apply grease on the coupling hole
(valve side of coupling joint)
• Lubricate the valve stem with oil or grease, to facilitate
assembling
• Lift the actuator according to instructions reported in
Handling & Lifting , page 7
• If possible, place the valve stem in a vertical position to
facilitate assembling - in this case the actuator must be
lifted while the coupling flange is kept in the horizontal
position
• If the assembly is done using an adapter and a coupling
joint, assemble the coupling joint onto the valve stem
before proceeding with the assembly of the actuator
• Do not exert any force while lowering the actuator onto
the valve
Installation must be performed by qualified personnel.
Keep hands away from the coupling area.
• Secure the actuator to the valve by means of threaded
fixings (bolts, stud bolts and nuts)
• Tighten bolts or nuts of the connecting stud bolts to the
correct torque, in accordance with the size and material
characteristics of the bolts installed
Support the actuator until fully installed and fixing
bolts are correctly tightened.
Attention: Do not pressurize the actuator/valve
adapter.
• Check for possible damage to the paint-work and repair if
necessary, per painting specification
Fig 10.4 Actuator/valve assembling example
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11. Removal from Valve10. Installation on Valve
The End user oversees removing the actuator from the valve.
Removal shall be performed only by qualified
staff, wearing/using appropriate personal protection
equipment.
Do not remove the actuator if the valve is blocked
in the intermediate position. Contact Rotork Customer
Service.
To disassemble the actuator from the valve, proceed as
follows:
• Isolate electrical power supply
• Isolate hydraulic supply
• Release any pressure from the control group
• Remove the supply pipes from the actuator
• Remove control and signal lines from electric components
(if any)
• Sling the actuator in line with the instructions given in
Lifting Instructions , page 7
• Unscrew fixings between the actuator and the valve
• Lift and remove the actuator from the valve
Fig 10.5 Actuator/valve assembling example
Fig 10.6 Actuator/valve assembling example
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12. Operation
The following instructions must be integrated into the user
safety program when installing and using Rotork products.
Read and save all instructions prior to installing, operating
and servicing this product.
Follow all warnings, cautions and instructions marked on and
supplied with the product.
Install equipment as specified in Rotork installation
instructions and as per applicable local and national
codes of practice. Connect all products to the proper
pipeline gas sources.
When replacement parts are required, ensure that the
qualified service technician uses only replacement parts
specified by Rotork.
Substitutions will invalidate any hazardous area certification
and may result in fire, electrical shock, other hazards or
improper operation.
12 .1 Description
RH/S actuators are hydraulic single-acting – spring return
actuators specifically designed to provide efficiency and
reliability in heavy duty services.
RH/S actuators can be assembled in a ‘spring to open’ or
‘spring to close’ configuration and can include an emergency
manual override suitable to operate the actuator in the event
of fluid supply failure.
Main components of an RH/S actuator (body sizes 015, 030,
060, 120, 240) are:
• A Rack and pinion mechanism (single rack), which
transforms the linear movement of the hydraulic cylinder
into a rotary movement suitable for operating quarter
turn valves, such as ball valves, butterfly valves or plug
valves.
The rack and pinion mechanism is situated in a perfectly
sealed cast iron housing, providing protection against
corrosion and ensuring safety of personnel during
operation.
• A hydraulic cylinder , made of Ductile Iron.
The dynamic floating piston seal reduces friction and
avoids stick-slip effect even after prolonged periods
without operation. The PTFE sliding ring guides the piston
in the cylinder and ensures a good radial loading capacity.
• The spring cartridge (single-acting actuators), consisting
of a container for assembled spring package that
prohibits over extension of the spring.
• Two mechanical stop bolts to enable adjustment of valve
angular stroke.
• A mechanical visual position indicator directly
connected to the valve stem that shows position of the
valve through full actuator stroke.
Upon request, RH/S actuators can be equipped with
additional accessories (limit switches box, positioner, position
transmitter, control panel, etc.).
Use only control devices supplied by Rotork.
Installation of any accessory on the bare actuator
must preserve the actuator Ingress Protection level.
5 3
6
2 4 1
Fig 12.7 RH/S single-acting (body sizes 015, 030, 060, 120, 240)
main components
Table 1: RH single-acting Parts list
IT DESCRIPTION QTY
1 Mechanical stop bolt 1
2 Centre body 1
3 Spring cartridge 1
4 Hydraulic cylinder 1
5 Mechanical stop bolt 1
6 Mechanical Visual Indicator 1
RH/D actuators are hydraulic double-acting actuators
specifically designed to provide efficiency and reliability in
heavy duty services:
• RH/D2 (body sizes 015, 030, 060, 120, 240) have two
hydraulic cylinders
• RH/D4 (body sizes 090, 105, 125, 145, 155, 185, 225,
250, 280) have four hydraulic cylinders for extremely high
torque output
Actuator general features are the same as the single-acting
version, except the spring canister is replaced by the centre
body closure group.
Main components of an RH/D2 (body sizes 015, 030, 060,
120, 240) actuator are:
• A Rack and pinion mechanism (single rack), which
transforms the linear movement of the hydraulic cylinder
into a rotary movement suitable for operating quarter
turn valves, such as ball valves, butterfly valves or plug
valves.
The rack and pinion mechanism is situated in a perfectly
sealed cast iron housing, providing protection against
corrosion and ensuring safety of personnel during
operation.
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12. Operation
• Two hydraulic cylinders , made of Ductile Iron.
The dynamic floating piston seal reduces friction and
avoids stick-slip effect even after prolonged periods
without operation. The PTFE sliding ring guides the piston
in the cylinder and ensure a good radial loading capacity.
• Two mechanical stop bolts to enable adjustment of valve
angular stroke.
• A mechanical visual position indicator directly
connected to the valve stem that shows position of the
valve through full actuator stroke.
Upon request, RH/D2 actuators can be equipped with
additional accessories (limit switches box, positioner, position
transmitter, control panel, etc.).
Only use control devices supplied by Rotork.
1 123 34
Fig 12.8 RH/D2 double-acting (body sizes 015, 030,
060, 120, 240) main components
Table 2: RH double-acting (2 cylinders) parts list
IT DESCRIPTION QTY
1 Mechanical stop bolt 2
2 Centre body 1
3 Hydraulic cylinder 2
4 Mechanical Visual Indicator 1
Main components of a RH/D4 (body sizes 090, 105, 125, 145,
155, 185, 225, 250, 280) actuator are:
• A Rack and pinion mechanism (double rack), which
transforms the linear movement of the hydraulic cylinder
into a rotary movement suitable for operating quarter
turn valves, such as ball valves, butterfly valves or plug
valves.
The rack and pinion mechanism is situated in a perfectly
sealed carbon steel housing, providing protection against
corrosion and ensuring safety of personnel during
operation.
• Four hydraulic cylinders , made of carbon steel.
The dynamic floating piston seal reduces friction and
avoids stick-slip effect even after prolonged periods
without operation. The PTFE sliding ring guides the piston
in the cylinder and ensure a good radial loading capacity.
• Four mechanical stop bolts to enable the adjustment of
valve angular stroke.
• A mechanical visual position indicator directly
connected to the valve stem that shows the position of
the valve through full actuator stroke.
Upon request, RH/D4 actuators can be equipped with
additional accessories (limit switches box, positioner, position
transmitter, control panel, etc.).
Only use control devices supplied by Rotork.
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Fig 12.9 RH/D4 double-acting (body sizes 090, 105, 125, 145,
155, 185, 225, 250, 280) main components
Table 3: RH double-acting (4 cylinders) parts list
IT DESCRIPTION QTY
1 Mechanical stop bolt 4
2 Centre body 1
3 Hydraulic cylinder 4
4 Mechanical Visual Indicator 1
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12. Operation
12.2 Operating Description
Please refer to the Operating Diagram supplied for the
specific actuator.
Where RH actuators are used in SIL applications the System
Integrator must fulfil all requirements reported in par. 11.2.11
of standard IEC61511-1.
Do not use the actuator beyond 85° - 95° operating
range.
12.3 Actuator Code and Design
Actuator build code shown below:
R H - 060 - 045 F / C1 - HPB
Example
Model
Number
ACTUATOR TYPE
R = Rack and Pinion
SUPPLY TYPE
H = Hydraulic
CENTRE BODY SIZE
015, 030, 060, 090, 105,
120, 125, 145, 155, 185,
225, 240, 250, 280
CYLINDER SIZE
TEMPERATURE
F = Standard
G = High
H = Low
L = Extreme low
CYLINDER / SPRING CANISTER
CONFIGURATION
C0 ÷ C9 = Spring-Return Fail Close -
Spring set # 0-9
O0 ÷ O9 = Spring-Return Fail Open -
Spring set # 0-9
D2 = Double-Acting - Two Cylinders
D4 = Double-Acting - Four Cylinders
(only with body sizes 090, 105, 125, 145,
155, 185, 225, 250, 280)
MANUAL OVERRIDE TYPE
HPB, HPC (not applicable for D4)
Body sizes 015, 030, 060, 120, 240 are available in both
single and double-acting configuration, max torque
3,400Nm (2,508 lbf.ft).
Body sizes 090, 105, 125, 145, 155, 185, 225, 250, 280 are
available in double-acting configuration only, max torque
700,000 Nm (516,293 lbf.ft).
12.4 Manual Override
RH/S and RH/D2 (body sizes 015, 030, 060, 120, 240) can
be fitted with an emergency manual override to operate the
actuator in the event of fluid supply failure.
This device is of hydraulic type, using a hydraulic hand pump.
A maximum operating time of the manual
override of 24 hours, for maintenance or testing, is
recommended.
Note: The use of manual override is not recommended
in SIL applications. If it is necessary, strictly follow
instructions reported in the following paragraphs.
Before operating the manual override, ensure that
the cylinder is not pressurized and that the actuator is in
the fail position.
For installation and operation procedures for the hydraulic
manual override, refer to PUB016-004-00.
For RH/S with hydraulic HPB override, refer to section 5 of
PUB016-004-00.
For RH/D with hydraulic HPC override, refer to section 4 of
PUB016-004-00.
The drawings shown in this manual refer to a single hydraulic
cylinder supplied from both the left and right side of the
piston. A RH/D has two independent cylinders/pistons, one
supplied to the right side, the other supplied to left side.
After each use, verify that the manual override is
disengaged.
Due to the extremely high torque output, no manual override
is available for RH/D4.
12.5 Angular Stroke Setting
Certain valves incorporate their own travel stops.
Rotork recommend the actuator stop bolt positions
match the valve stop positions.
Contact the valve manufacturer to adjust the valve
mechanical stops.
An incorrect setting of angular stroke could cause
damage to the actuator, valve and/or personnel.
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12.5.1 Single-acting actuator RH/S (body sizes 015, 030,
060, 120, 240), cylinder stop bolt setting
Set the cylinder stop bolt first. Where shown, tools may be
required.
123
4
Adjust the stop bolt in the end flange of the cylinder as
follows:
A. Verify the absence of pressure
B. Remove cap nut (1) and seal washer (2)
C. Loosen stop nut (4)
D. Slowly pressurize the cylinder to detach the stop bolt (3)
from the piston
3
4
E. Hold the stop nut (4)
F. Rotate the stop bolt (3) to adjust stroke. Clockwise will
decrease angular stroke, anti-clockwise will increase
angular stroke
G. Depressurize the cylinder
H. Verify the new position with one operating stroke
I. Repeat operations D to G, until the desired angle is
obtained
3
2 4
J. Re-position the seal washer (2) between the cylinder and
the stop nut (4)
4
K. Hold the stop bolt (3) and carefully tighten the
stop nut (4)
12
L. Reinstall the seal washer (2) and cap nut (1)
12. Operation
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12.5.2 Single-acting actuator RH/S (body sizes 015, 030,
060, 120, 240), spring cartridge stop bolt setting
Where shown, tools may be required.
Adjust the stop bolt in the spring cartridge as follows:
5 6 8 7
A. Pressurize the cylinder to the open/close position and
verify the actuator stroke stop
B. Depressurize the cylinder to adjust the angular stroke
setting
8 7
C. Remove protection plug (5) and seal washer (6)
D. Hold stop bolt (8) and loosen stop nut (7)
E. Hold the stop nut (7)
F. Rotate the stop bolt (8) to adjust stroke. Clockwise will
decrease angular stroke, anti-clockwise will increase
angular stroke
G. Verify the new position with one operating stroke
H. Repeat operations E to G until the desired angle is
obtained
5 6 8 7
I. Hold the stop bolt (8) and carefully tighten the stop nut (7)
J. Reinstall the seal washer (6) and protection plug (5)
12.5.3 Double-acting actuator RH/D2 (body sizes 015,
030, 060, 120, 240), cylinder stop bolt setting
Set the cylinder stop bolt first.
Instructions assume operating direction is in accordance with
conventions detailed in ISO 5211. Clockwise to close and
anticlockwise to open.
Set stop bolts of cylinder X1 for the close position. Set stop
bolts of cylinder X2 for the open position.
X2 X1
Fig 12.10 RH/D2 (body sizes 015, 030, 060, 120, 240)
cylinder identification.
Adjustment of the stop bolts on cylinder X1 and cylinder X2
is the same as adjusting the stop bolts on a single-acting
actuator RH/S. Refer to the single-acting actuator RH/S
cylinder stop bolt procedure described earlier in this manual.
12. Operation
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12.5.4 Double-acting actuator RH/D4 (body sizes 090,
105, 125, 145, 155, 185, 225, 250, 280), cylinder
stop bolt setting
Set the cylinder stop bolts first.
Instructions assume operating direction is in accordance with
conventions detailed in ISO 5211. Clockwise to close and
anticlockwise to open.
Set stop bolts of cylinder X1 and cylinder X3 for the close
position.
Set stop bolts of cylinder X2 and cylinder X4 for the open
position.
X4X3
X2 X1
Fig 12.11 RH/D4 (body sizes 090, 105, 125, 145, 155, 185,
225, 250, 280) cylinder identification.
Adjust the stop bolts located in the end flange of each
cylinder:
11 10 9
A. Verify the absence of pressure
B. Remove cap nut (9) and O-rings (10 and 11)
C. Slowly pressurize the cylinder to detach the stop bolt (12)
from the piston
D. Rotate the stop bolt (12) to adjust stroke. Clockwise will
decrease angular stroke, anti-clockwise will increase
angular stroke
E. Depressurize the cylinders
F. Verify the new position with one operating stroke
G. Repeat operations D to F, until the desired angle is
obtained
11 10 9
H. Replace the O-rings (10, 11) and the cap nut (9)
All four cylinders must be set before operating the actuator
in normal service conditions. Always adjust the close (X1
and X3) or open (X2 and X4) stop bolts together to ensure
contact is equal on both stop bolts.
12. Operation
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12.6 Hydraulic Power Supply
Check the supply pressure range on actuator label.
Verify medium composition. Contact Rotork to check
the compatibility with the supply medium.
12.7 Hydraulic Connections
Preliminary Operations
A. Confirm the size of pipes and fittings per applicable plant
specifications
B. Clean the inside of the connection pipes by washing them
with a suitable detergent and blowing air into them
C. The connecting pipes must be properly shaped and
secured to prevent stress or loosening of threaded
connections
Note: For tapered-thread fluid connections, apply a
thin layer of thread sealing product (Loctite 577 or
equivalent) to ensure a good seal.
Connect the Hydraulic power source in accordance
to the applicable operating diagram, refer to specific job
for details.
Hydraulically powered actuators may exhaust the
power supply gas into the atmosphere during normal
operation. This may present an unacceptable hazard.
Inlet port
Fig 12.12 Inlet port for single-acting actuator RH/S
(body sizes 015, 030, 060, 120, 240)
Inlet portInlet port
Fig 12.13 Inlet port for double-acting actuator RH/D2
(body sizes 015, 030, 060, 120, 240)
Inlet port Inlet port
Fig 12.14 Inlet port for double-acting actuator RH/D4
(body sizes 090, 105, 125, 145, 155, 185, 225, 250, 280)
12. Operation
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12.8 Electrical Connections
Check supply voltage of electrical components.
Access to live electrical conductors is forbidden in
hazardous areas unless done under a special permit. All
power must be isolated and the unit moved to a non-
hazardous area for repair.
Prevent electrostatic charges in potentially explosive
areas.
Electrical connection can be performed as follows:
• Isolate the power supply
• Remove plastic cable entry protection plugs
• Only use appropriately certified reduction fittings, cable
glands, fittings and explosion-proof cables
• The cable glands must be tightened in the threaded
inlets, to guarantee the waterproof and explosion proof
protection
• O-rings must be correctly installed on the cable glands
to prevent water and debris infiltration inside electric
components
• The size of the electric supply cable must be suitable for
the electric power demand
• Insert the connection cables through cable glands and
perform assembly per the cable gland manufacturer’s
instructions
• Connect the cable wires to the terminal block as per the
applicable wiring diagram
• Electric connections must be made by using rigid conduits
and trailing cables to prevent mechanical stresses in the
cable entries
• Any unused conduit entries must have the plastic plugs
replaced with approved metal plugs to comply with
explosion safety protection codes
• Assemble electric enclosure covers with appropriate seals
• Always check electrical component functionality after
commissioning
The actuator and electrical components must be
protected from electrical sparks, lightning, magnetic or
electro-magnetic fields.
12.9 Start Up
Check the following during start-up of the actuator:
• Medium supply pressure is correct
• The supply voltage for electrical components (solenoid
valves coils, limit switches, pressure switches etc.) is
correct
• All actuator controls (remote control, local control,
emergency control, etc.) work correctly
• Remote signals are correct
• The control unit meets plant requirements
• Hydraulic connections show no leakage
• The painted parts have not been damaged during
transport, assembly or storage. Repair the damaged parts
following applicable painting specifications
• Actuator and connected parts work as expected
• Operating time meets requirements
The user must provide appropriate grounding and
ensure equal voltage potential between the valve and
actuator. The user shall indicate and maintain grounding
connections on the actuator.
12. Operation
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13. Dismantling and Disposal
The actuator and all connected components must be
depressurised before dismantling can begin.
For single-acting actuators.
The spring cartridge module contains a compressed
spring. After removing the spring cartridge from the
centre body, the spring cartridge must be returned to
Rotork.
Grease and oil must be disposed of safely in
accordance with local environmental laws and
regulations.
• Dismount the actuator and separate the various parts per
the type of material
• Dispose of the pieces of steel, cast iron and aluminium
alloys as metal scraps
• Dispose of the rubber, PVC, resins etc. separately, in
accordance with existing national and regional regulations
• Electric components are to be separately disposed of on
specialized disposal sites
Should you require technical assistance or spares, Rotork
guarantees the best service in the world. Contact your local
Rotork representative or the factory direct at the address on
the nameplate, quoting the actuator type and serial number.
Some actuators have a special spare parts list. Refer to the
project specific documentation for further details.
14. Rotork Sales and Service
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