Spirax Sarco PN9120 User manual

IM-P357-29 CTLS Issue 14
1
PN9100
PN9300
PN9200
PN9400
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
© Copyright 2017
Printed in France
IM-P357-29
CTLS Issue 14
3579049/14
PN9000 Series
Pneumatic Actuators
Installation and Maintenance Instructions

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1. Safety information
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11) in
compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of tools
and safety equipment must also be complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use / application.
Please note that these products are out of the scope of the European Pressure
Equipment Directive 97 / 23 / EC.
i) The products have been specifically designed for use on compressed air, which
is in Group 2 of the above mentioned Pressure Equipment Directive. The products’
use on other fluids may be possible but, if this is contemplated, Spirax Sarco
should be contacted to confirm the suitability of the product for the application
being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections and protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.

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1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.

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1.12 Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In some cases the product is provided with pre-compressed springs. Any operation
to open the spring housing is to be carried out strictly following the correct procedure
given in the Installation and Maintenance Instructions.
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost
damage in environments where they may be exposed to temperatures below freezing
point.
1.15 Disposal
This product is recyclable and no ecological hazard is anticipated with its disposal
providing due care is taken, however the following list of exception will require
individual disposal in line with local health and safety regulations:
- PTFE
- Viton 'O' rings
- Nitrile
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on any
hazards and the precautions to be taken due to contamination residues or mechanical
damage which may present a health, safety or environmental risk. This information
must be provided in writing including Health and Safety data sheets relating to any
substances identified as hazardous or potentially hazardous.

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2.1 General information
The PN9000 series actuators are a compact range of linear actuators that are available
in four sizes. This range of actuators comprise of four diaphragm sizes for matching the
requirements of valves at various differential pressures.
Each actuator has a mechanical travel indicator fitted and incorporates a fully-rolling
diaphragm, except size 4, which provides good linearity over the operating stroke.
Available options
PN
PNP
=
=
Standard
Electroless nickel plated
Suffix E =Spring-extend
Suffix R =Spring-retract
(not available for the PN9400)
Optional extra
Manual handwheel Suffix H
Stainless steel bolting Suffix S
Important note: Throughout this document, reference has been made to a PN actuator.
With exception of some component materials all actuators are identical.
2.2 Technical data
Temperature range - 20 °C to + 110 °C
Maximum operating inlet pressure
PN9100 6 bar g
PN9200 6 bar g
PN9300 4 bar g
PN9400 4 bar g
Air supply connection
PN9100 ¼" NPT
PN9200 ¼" NPT
PN9300 ¼" NPT
PN9400 2 x ½" NPT
Actuator travel
PN9100 20 mm
PN922_ and PN932_ 20 mm
PN923_ and PN933_ 30 mm
PN9400 80 mm
2. General product information

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2.3 Spring ranges
Actuator types Spring range Travel
PN9120 0.2 to 1.0 bar 20 mm
PN9120 0.4 to 1.2 bar 20 mm
PN9125 0.4 to 2.0 bar 20 mm
PN9126 1.0 to 2.0 bar 20 mm
PN9123 2.0 to 4.0 bar 20 mm
PN9220 0.2 to 1.0 bar 20 mm
PN9230 0.4 to 1.2 bar 30 mm
PN9220 0.4 to 1.2 bar 20 mm
PN9226 1.0 to 2.0 bar 20 mm
PN9223 2.0 to 4.0 bar 20 mm
PN9233 0.4 to 1.2 bar 30 mm
PN9236 1.0 to 2.0 bar 30 mm
PN9320 0.2 to 1.0 bar 20 mm
PN9320 0.4 to 1.2 bar 20 mm
PN9330 0.4 to 1.2 bar 30 mm
PN9336 1.0 to 2.0 bar 30 mm
PN9337 2.5 to 3.5 bar 30 mm
PN9483 1.8 to 3.0 bar 80 mm
PN9486 0.9 to 1.5 bar 80 mm

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2.4 Materials - PN9100, PN9200 and PN9300
No. Part Material
1Yoke SG iron
2Upper diaphragm housing Carbon steel (plated)
3Diaphragm plate Aluminium
4Diaphragm Reinforced NBR
5Spring Spring steel
6Spindle Stainless steel
7Washer Carbon steel (plated)
8Spacer Carbon steel (plated)
9'O' ring Viton
10 Connector Stainless steel BS 970 431 S29
11 Adaptor Stainless steel BS 970 431 S29
12 Collar
PN9000 Carbon steel
PNP9000 Stainless steel
PN9000S Stainless steel 316L
13 Clamp front Stainless steel
14 Clamp rear Stainless steel
15 Scale Stainless steel
16 Vent plug Brass
17 Bearing PTFE / steel composite
18 Seal Polyurethane
19
20
Pan head screw
Nyloc nut
PN9000 Carbon steel (plated)
PNP9000 Stainless steel A2 - 70
PN9000S Stainless steel A2 - 70
21 Bolt Carbon steel (plated) Gr. 8.8
22
23
24
Hex. head screw (short)
Hex. head screw (long)
Nut
PN9000 Carbon steel (plated) Gr. 8.8
PNP9000 Stainless steel A2 - 70
PN9000S Stainless steel A2 - 70
25 Lock-nut
PN9000 Carbon steel (plated)
PNP9000 Stainless steel A2 - 70
PN9000S Stainless steel A2 - 70

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Fig. 1 PN9200E
5
4
2
18
17
29
8
24
22
and
23
28 21
16
1
26 and 27
19 and 20
15
6
31
7
3
12
13 and 14
10
30
25
9
11
32
26
27
Socket head screw
Nut
PN9000 Carbon steel (plated) Gr. 8.8
PNP9000 Stainless steel A2 - 70
PN9000S Stainless steel A2 - 70
28 Washer Carbon steel (plated)
29 Screw Carbon steel (plated) Gr. 8.8
30 Gasket Reinforced graphite
31 Lower diaphragm housing Carbon steel (plated)
32 Lifting eye
PN9000 Cast steel
PNP9000 Cast steel
PN9000S Stainless steel 316L

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2.5 Materials - PN9400
No. Part Material
1Yoke SG iron
2Bearing and seal insert Carbon steel
3Bearing PTFE / steel composite
4Seal Polyurethane
5Gasket Reinforced graphite
6Housing lower Carbon steel
7Spindle Stainless steel
8Diaphragm protection plate Carbon steel
9Diaphragm Reinforced NBR
10 Spacer Carbon steel
11 Spring Carbon steel
12 Housing upper Carbon steel
13 Lock-nut Carbon steel
14 Up guide Carbon steel
15 Screw Carbon steel
16 Screw Carbon steel
17 Screw Carbon steel
18 Nut Carbon steel
19 Connector Stainless steel
Parts 20 to 38 are on page 12

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Fig. 2 PN9400E
12
1
14
4
3
2
7
13
18
16
17
11
10
9
15
6
8
5
19

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2.5 Materials - PN9400
No. Part Material
20 Adaptor Stainless steel
21 Collar Stainless steel
22 Clamp Stainless steel
23 Scale Stainless steel
24 Lock-nut Carbon steel
25 Screw Carbon steel
26 Nut Carbon steel
27 Screw Carbon steel
28 Nut Carbon steel
29 Screw Carbon steel
30 'O' ring Viton
31 Vent plug Brass
32 Washer 'O' ring Carbon steel
33 Intermediate plate Carbon steel
34 Diaphragm guide plate Carbon steel
35 Spring plate Carbon steel
36 Spring guide plate Carbon steel
37 Cap protection Plastic
38 Washer Carbon steel
Parts 1 to 19 are on page 10

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Fig. 3 PN9400E
37
28 +29
25 +26
23
36
33
31
35
33
34
32
30
23
24
21
19
20
38

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3. Installation
See separate Installation and Maintenance Instructions for the control valve. For details of
differential pressures associated with the Spira-trolTM valves refer to the relevant actuator
Technical Information (TI) Sheet.
The actuators should be installed in such a position as to allow full access to both actuator
and valve for maintenance purposes. The preferred mounting position is with the actuator
and valve spindle in the vertical position above or below the horizontal pipework. The air
supply to the actuator must be 'dry and free from oil'. For high temperature conditions,
insulate the control valve and pipework to protect the actuator.
Note: If the actuator is to be fitted onto an older style valve, an adaptor ring will be required.
Contact Spirax Sarco for further information.
Warning: The actuator housing must only be pressurized on the opposite side of the
diaphragm holding the springs. The housing vent cap must be left unrestricted.
3.1 Fitting the PN9100E, PN9200E, PN9300E or PN9400E
actuator to a valve (Figures 4 and 5):
-Remove the front and rear clamp (13 and 14). Then remove the valve adaptor (11).
-Fit the valve adaptor (11) onto the valve spindle then manually push the valve plug to
its closed position. Caution: Two female threads must be visible inside the adaptor
when fitted to the valve spindle.
-Apply the control signal pressure required to bring the spindle to mid-travel position
(Figure 5). Place the actuator yoke over the valve spindle and locate it onto the bonnet
shoulder. Hand tighten the mounting nut.
-Apply the minimum signal pressure + 0.1 bar maximum to the bottom of the actuator,
and then adjust the connector (10) so that it touches the valve adaptor (11), then tighten
the lock-nut (25).
-Release the control air signal. Fit the front and rear clamps (13 and 14) as shown in
Figure 5.
-Fit the locking screws and nuts (26 and 27) loosely - 2 Nm (1.5 lbf ft).
-Operate the actuator and valve over its full travel four times to ensure alignment.
-Tighten the mounting nut to the recommended torque:
For the M34 nut: 70 Nm (52 lbf ft) and 80 Nm (59 lbf ft) for the stainless steel valve.
For the M50 nut: 100 Nm (74 lbf ft)
For the M70 nut: 160 Nm (119 lbf ft)
-Tighten the lock-nut to the recommended torque:
For the M8 stem: 10 Nm (7.5 lbf ft)
For the M12 stem: 20 Nm (15 lbf ft)
For the M30 stem: 40 Nm (30 lbf ft)

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Fig. 4
Fig. 5
Front and rear clamps (13 and 14)
Clamp locking screws (26 and 27)
25
Mid travel
Actuator mounting nut
10
11

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4. Commissioning
If the actuator / valve has been supplied with a positioner, reference should be made to the
separate Installation and Maintenance Instructions supplied with the product.
4.1 Adjusting the spring
The actuator spring range and lift-off-pressure will be indicated on the name-plate.
Should it be necessary to check or adjust the lift-off-pressure the procedure is described
in Sections 4.1.1 and 4.1.2.
4.1.1 PN9100E, PN9200E, PN9300E or PN9400E spring-extend actuators
only
Note: Adjustment of the spring will only alter the pressure of the control signal air at which
the valve commences to move off its seat (set point) and will not alter the spring pressure
range required to move the valve through its full travel. i.e. 0.2 to 1.0 bar spring (range
0.8 bar) set to commence to lift at 0.4 bar will require a 1.2 bar air pressure (0.4 + 0.8) to
obtain valve full travel.
To adjust set point, refer to Figure 6 and proceed as follows:
-Ensure the control valve has been isolated and the actuator housing is pressure free.
-Loosen and remove the clamp nuts and screws (26 and 27, see Figure 7) and remove
the valve adaptor (11).
-Using two spanners whilst holding the actuator spindle (6) loosen the adaptor lock-nut (25).
-Apply the control signal pressure required to commence the lifting of the actuator spindle.
-With the valve plug remaining on its seat adjust the valve connector (10) until it presses
tightly against the valve adaptor (11). Tighten the lock-nut (25). See Figure 6 for correct
installation.
Caution: Two female threads must be visible inside the adaptor when fitted to the valve
spindle.
-Release the control air signal. Fit the front and rear clamps (13 and 14) across the
connector and valve adaptor (10 and 11). Ensure that the screws (26) and the nut (27)
are not damaged. Fit the locking screws and nuts (26 and 27) and loosely tighten.
Operate the unit over its full travel four times to ensure alignment. Tighten the locking
screws and nuts to 2 N m (1.5 lbf ft). Re-check that the valve just commences to move
off its seat at the right spring range minimum pressure and is fully open at the spring
range maximum pressure.
-After the test check the position of the travel indicator against the 'arrow' of the connector
and adjust its position accordingly
.
Warning: To prevent damage to the valve seat, please ensure the plug does not turn while
pressing on the seat during assembling or adjustment.
To prevent damage to the diaphragm, ensure the actuator spindle (6) is not allowed
to rotate when the diaphragm is assembled within its housing.

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Fig. 6 Assembly of actuator adaptor, valve adaptor and connectors
Actuator spindle (6)
Lock-nut (25)
Connector (10)
Front and rear clamps
(13 and 14)
Collar (12)
Valve spindle
Valve adaptor
(11)

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4.1.2 PN9100R, PN9200R, PN9300R or PN9400R spring-retract actuators
only
Note: Adjustment of the spring will only alter the pressure of the control signal air at which
the valve commences to move off its seat (set point) and will not alter the spring pressure
range required to move the valve through its full travel. i.e. 0.2 to 1.0 bar spring (range
0.8 bar) set to commence to lift at 0.4 bar will require a 1.2 bar air pressure (0.4 + 0.8) to
obtain valve full travel.
To adjust the set point refer to Figure 3 and proceed as follows:
-Ensure the control valve has been isolated and the actuator housing is pressure free.
-Loosen and remove the clamp nuts and screws (26 and 27, see Figure 8) and remove
the valve adaptor (11).
-Using two spanners whilst holding the actuator spindle (6) loosen the actuator connector
lock-nut (25).
-Apply the control signal pressure required to complete the full travel of the actuator
spindle.
-With the valve plug remaining on its seat adjust the valve adaptor (11) until it presses
tightly against the connector (10). See Figure 7 for correct installation.
Caution: Two female threads must be visible inside the adaptor when fitted to the valve
spindle.
-Fit the front and rear clamps (13 and 14) across the collar (12) and valve adaptor (11).
-Ensure that the screws (26) and the nut (27) are not damaged.
-Fit the clamp locking screws and nuts (26 and 27) and loosely tighten. Operate the unit
over its full travel four times to ensure alignment. Tighten the locking screws and nuts
to 2 N m (1.5 lbf ft).
-Release the air control pressure and recheck that the valve just commences to move
toward the seat at the right spring range (minimum pressure), and is fully closed at the
spring range (maximum pressure). After the test check the position of the scale travel
indicator against the 'arrow' of the connector and adjust its position accordingly.
Warning: To prevent damage to the valve seat, please ensure the plug does not turn while
pressing on the seat during assembling or adjustment. To prevent damage to the
diaphragm, ensure the actuator spindle (6) is not allowed to rotate when the
diaphragm is assembled within its housing.

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Fig. 8
Front and rear clamps (13 and 14)
Clamp locking screws (26 and 27)
Fig. 7 Assembly of actuator adaptor, valve adaptor and connectors
Actuator spindle (6)
Lock-nut (25)
Connector (10)
Front and rear clamps
(13 and 14)
Collar (12)
Valve spindle
Valve adaptor
(11)

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5. Maintenance
The PN9000 series pneumatic actuators (and variants) are maintenance free. To ensure
satisfactory operation it is strongly recommended that the control signal air is filtered and
supplied dry and free of oil. Should it be necessary to replace spare parts the following
procedure should be used.
CAUTION!
The diaphragm housing contains powerful springs under compression.
Exercise great care when dismantling.
Read this Maintenance section thoroughly prior to commencing any work.
5.1 Removing the actuator from the valve:
-Drive the actuator into approximately mid-travel position with the air supply.
-Loosen and remove the clamp nuts and screws (26 and 27, see Figure 10) and remove
the valve adaptor (11).
-Loosen and remove the actuator mounting nut (see Figure 9) and lift the actuator off
the valve.
-Reduce the air supply pressure until the housing is pressure free. Disconnect the air
supply from the actuator.
Fig. 9
25
Mid travel
Actuator mounting nut
10
11