Spirax Sarco TN2000RH User manual

IM-P327-02 CH Issue 3 1
1. Safety information
2. General
product information
3. Installation
4. Maintenance
5. Spare parts
IM-P327-02
CH Issue 3
3270049/3
© Copyright 2015
Printed in France
TN2000 Series
Pneumatic Piston Actuators
Installation and Maintenance Instructions

IM-P327-02 CH Issue 3
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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 this product is out of the scope of the
European Pressure Equipment Directive 97 / 23 / EC.
i) This product has been specifically designed for use compressed air. 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) 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.
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.
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 opened and closed progressively 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.

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1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the 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.
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 as
detailed in this document.
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 should not be dismantled without first releasing the compression on the
spring (if fitted). 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
- Polythene
- PVC
- Composite tube
- Fluorocarbon 'O' rings.
Warning: 'O' rings must not be incinerated, as hydrofluoric acid will be formed.
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. General product information
2.1 Description
TN2000 series pneumatic piston actuators are suitable for use with DN125 to DN200
Spira-trolTM control valves of which three versions are available; Single acting (with spring),
Double acting (with spring) and Double acting (no spring). The availability of these three
versions meets the requirements of valves at various differential pressures and in a variety
of applications.
2.2 Technical data
Temperature range -15°C to +110°C
Maximum operating inlet pressure 10 bar g
Air supply connection " NPT
Actuator travel 70 mm
2.3 Materials
No. Part Material
1Yoke SG iron
2Lower cylinder end cap SG iron BS EN 1563 GJS 400 18U-LT
3Upper cylinder end cap SG iron BS EN 1563 GJS 400 18U-LT
4Cylinder Composite tube
5Piston SG iron
6Spring Chrome vanadium steel
7Spindle Stainless steel
8Spindle sleeve Carbon steel (plated)
9Lock-nut M27 Carbon steel (plated)
10 Bearing and seal insert Carbon steel (plated)
11 Indicator plate Stainless steel
12 Top connector Carbon steel (plated)
13 Bottom connector Carbon steel (plated)
14 Connector Stainless steel
15 Rod seal wiper Polyurethane
16 DU plain bearing PTFE / steel composite
17 Long nut Carbon steel (plated)
18 Nut and threaded bar Carbon steel (plated)
19 Threaded bar M12 Carbon steel (plated)
20 " NPT vent plug (not shown) LD Polyethylene
21 Cover PVC
22 Scale Stainless steel
23 Nut M12 Carbon steel (plated)
24 Lock-nut M20 Stainless steel
25 Cap screw Carbon steel (plated)
26 Bolt M12 Stainless steel
27 Pan head screw Carbon steel (plated)
28 Nut M2.5 Carbon steel (plated)
29 'O' ring Fluorocarbon rubber (Viton)
30 'O' ring Fluorocarbon rubber (Viton)
31 'O' ring Fluorocarbon rubber (Viton)
32 Spring washer M12 Carbon steel (plated)
33 Spring washer M10 Carbon steel (plated)

IM-P327-02 CH Issue 3 5
21
31
15
10
19
17
29
30
10
16
15
22, 27, 28
24
14
11
23
3
16
9
18
8
4
6
5
31
2
26
7
25
13
Fig. 1
32
1
33
12
Note: When lifting the actuator only use a lifting sling through X1 to X4.
X1 X4
X2 X3

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3 73
3. Installation
Caution: Sling eyes (X, see Figure 2) are not to be used for lifting an actuated valve
assembly.
Sling eyes can only be used to stabilise the assembly. Suitable support of the valve and
actuator will be required.
See separate Installation and Maintenance Instructions for the control valve. For details of
differential pressures associated with the Spira-trolTM KE and KEA control 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 the actuator
and the valve for maintenance purposes. The preferred mounting position is with the actuator
and valve spindle in the vertical position or horizontal to the pipework (it is essential that
support is provided when the installation is in the horizontal position), see Figure 2).
Fig. 2
Vertically
above pipework
Horizontal
(it is essential that support is provided when
the installation is in the horizontal position)
Vertically
below pipework
Optimum
The air supply to the actuator must be ‘dry and free from oil’. Contact Spirax Sarco for more
details with relation to composite tube / media compatibility. For high temperature conditions,
insulate the control valve and pipework only to protect the actuator.
Note: The actuator cannot be fitted onto an older style control valve.
Caution: If the complete assembly is installed horizontally then the air supply must be
connected at the lowest point of the actuator.
Warning: The actuator cylinder must only be pressurized on the opposite side of
the piston holding the spring. The housing vent cap must be left unrestricted. If the
assembly is to be mounted horizontally then it is essential to provide suitable support
for the actuator.
3.1 Fitting the TN2000 SE, DE and DA actuators to the valve
-Remove the bottom connector (13).
-Ensure that the indicator scale (22) is facing the same way as the valve name-plate.
-Apply the control signal pressure to the bottom of the actuator to bring the spindle (7) to
the mid-travel position.
-Manually push the valve spindle down to ensure that the valve plug is on the valve seat.
-Locate the actuator yoke on the valve bonnet and fit the securing screws A to a torque
of 40 Nm.
-Screw the lock-nut B down to the lowest part of the valve spindle.
-Screw the bottom connector (13) onto the valve spindle, caution there must be no valve
spindle threads above the bottom connector.
-Loosen the lock-nut (24) and screw the connector (14) upwards 3 turns, then remove the
air supply.

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Fig. 3
A
B
25 and 33
13 22
24
7
12
14
Actuator yoke
Valve spindle
Valve bonnet
11
-Adjust the connector (14) until it is touching the bottom connector (12 and 13).
-Re apply air to the actuator (to lift the actuator spindle (7)), screw the connector (14) down
by 180°.
-Remove the air supply allowing the connectors to touch (this provides a pre-load on the
valve seat).
-Fit the cap screws (25), spring washers (33) and indicator plate (11) and tighten to 40 Nm.
-Raise the spindle (7) to its mid travel position.
-Tighten the spindle lock-nut B to 40 Nm.
-Tighten the lock-nut (24) to 40 Nm.

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3.2 Fitting the TN2000 SR or DR actuator to the valve:
-Remove the bottom connector (13).
-Manually push the valve spindle down to ensure the valve plug is on the valve seat.
-Ensure that the indicator scale (22) is facing the same way as the valve name-plate.
-Locate the actuator yoke on the valve bonnet and fit securing screws
Ato a torque
of 40 Nm.
-Screw the lock-nut
Bdown to the lowest point of the valve spindle.
-Screw the connector (13) onto the valve spindle, caution there must be no valve spindle
threads above the connector.
-Loosen the lock-nut (24) and screw the connector (14) upwards until the bottom is
level with the spindle, then apply air pressure onto the top of the actuator.
-With the actuator fully extended, adjust the connector (14) until it touches the bottom
connectors.
-Reduce the air supply to the actuator (to lift the actuator stem), screw the connector (14)
down by 180°.
-Re apply air to enable the connectors to touch again, fit and tighten the cap screws (25),
spring washers (33) and indicator plate (11) to 40 Nm.
-Reduce air pressure and tighten lock-nut (24) to 40 Nm.
-Tighten the spindle lock-nut
Bto 40 Nm.
4. Maintenance
Note: Before actioning any maintenance programme
observe the 'Safety information' in Section 1.
Warnings:
1. Actuator support will be required due to weight.
2. The actuator contains a pre-compressed spring.
3. Special assembly tool required.
4. POLYLUB GLY 801 (lubricating grease) only.
TN2000 series pneumatic actuators 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.
4.1 Removing the actuator from the valve:
Note: Remove the handwheel first, If fitted, by following the instructions in Sections 4.6 or 4.7.
-Apply air supply to the drive actuator to move it to its mid-travel position.
-Loosen the lock-nut
Band remove the bottom connector (13).
-Loosen and then remove the cap screws and spring washers (25 and 33). Note: The
valve stem and the bottom connector will move down until the valve head is on the seat.
-Remove the bottom connector (13).
-Remove the air supply.
-Loosen and then remove the securing screws
A.
-Remove the actuator from the valve.

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Fig. 4
A
B
25 and 33
13 22
24
7
12
14
Actuator yoke
Valve spindle
Valve bonnet
11

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4.2 Replacing the 'O' rings (SE and DE actuators)
Note: Remove the actuator from the valve as described in Section 4.1.
Note: There are 5 long securing nuts that must be removed last to ensure that the spring
tension is removed.
-Loosen and remove the 5 securing nuts and washers (23 and 32) on the threaded bar (19).
-Loosen then remove the remaining long securing nuts (17), see note above.
-Remove the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Remove the spring (6) (not applicable for DA).
-Remove the cylinder (4).
-If the bearing seals are to be replaced remove the spindle (7) to fit the lower seal (15).
-Replace the 'O' rings (29,30 and 31).
To rebuild the actuator follow the next procedure:
Caution: POLYLUB GLY 801 must be used to ensure smooth operation of the piston.
-Replace the spindle (7) if previously removed.
-Apply grease to the internal of the cylinder (4) and the bearings (10) (approximately 100 mm
to be in contact with piston).
-Lower the cylinder (4) onto the lower cylinder end cap (2).
-Fit guiding tool over the end of the spindle.
-Replace the spring (6).
-Replace the upper cylinder end cap (3) over the guiding tool, taking care not to damage
the bearing (16) and seal (15).
-Fit the 5 long securing nuts (17) onto the threaded bar (18) making sure that the spring
washer (32) is in place and tighten the nuts (23) evenly to pull the cylinder (4) onto the
lower cylinder end cap. Then tighten to 30 Nm.
-Fit all remaining securing screws, washers and nuts (19, 23, 32) and tighten to 30 Nm.
-Re-attach the actuator to the valve as described in Section 3.1.
Fig. 5 TN2000E
23
3
4
6
31
15
30
7
19
10
2
18
5 x long
securing nuts 17
29
31
32
16

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4.3 Replacing the 'O' rings (SR and DR actuators)
Note: Remove the actuator from the valve as described in Section 4.1
Note: There are 5 long securing nuts that must be removed last to ensure that the spring
tension is removed.
-Loosen and remove the connector (14), see Figure 4.
-Loosen and remove the 5 securing nuts and washers (23 and 32) on the threaded bar (19)
-Evenly loosen and remove the remaining long securing nuts (17), see note above.
-Remove the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Remove the piston assembly (5, 7, 8 and 9).
-Remove the cylinder (4).
-Replace the 'O' rings (30 and 31).
To rebuild the actuator follow the next procedure:
Caution: POLYLUB GLY 801 must be used to ensure smooth operation of the piston.
-Apply grease to the internal of the cylinder (4) and the bearings (10) (approximately 100 mm
to be in contact with the piston).
-Lower the cylinder (4) onto the lower cylinder end cap (2).
-Lower the piston assembly into the actuator (5, 7, 8 and 9), taking care not to damage
the bearing (16) and seal (15).
-Replace the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Fit the long 5 securing nuts (17) onto the threaded bar (18) making sure that the spring
washer (32) is in place and tighten the nuts (23) evenly to pull the piston assembly into
the cylinder (4) and the cylinder (4) onto the cylinder end caps (2and 3). Then tighten
to 30 Nm.
-Fit all the remaining securing screws, washers and nuts (19, 32 and 23) and tighten
to 30 Nm.
-Re-attach the actuator to the valve as described in Section 3.2.
Fig. 6 TN2000R
4
6
8
5
3
19
2
18
9
31
30
7
31
23
32
17 5 x long
securing nuts
15 and 16
15 and 16

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4.4 Conversion of a TN2000E to a TN2000R actuator
Warning: It is not recommended to reverse this actuators operation outside of a controlled
area. Lifting equipment will be required.
Note 1: Remove the actuator from the valve as described in Section 4.1.
Note 2: If a handwheel is fitted, a new adaptor kit will be required.
Note 3: There are 5 long securing nuts that must be removed last to ensure that the spring
tension is removed.
Note 4: A new product label will be required and fitted over the existing label if a conversion
has been done.
Contact Spirax Sarco with the new product details, and a new label can be supplied. As a
temporary measure amend the existing label with a permanent marker stating failure mode
and suffix lettering (E or R).
Dismantle:
-Loosen and remove the connector and lock-nut (14 and 24).
-Loosen and remove the 5 securing nuts and washers (23 and 32) on the threaded bar (19).
-Evenly loosen and remove the remaining long securing nuts (17), see note 3 above.
-Remove the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Remove the spring (6).
-Remove the cylinder (4).
-Using a spanner hold the upper part of the spindle and remove the lock-nut (9).
-Remove the spindle sleeve (8).
-Cover the thread on the main spindle under lock-nut (9).
-Remove the piston (5).
-Remove the spindle (7), taking care not to damage the bearing (16) and seal (15).
Reassembly:
-Fit the spring (6).
-Apply grease to the internal of the cylinder (4) (approximately 100 mm to be in contact
with piston).
-Lower the cylinder (4) onto the lower cylinder end cap (2).
-Assemble the piston and the spindle assembly (5, 7, 8and 9):
-Fit the spindle sleeve (8) to the spindle (7).
-Fit the protective cover to threads on the spindle for the lock-nut (9).
-Fit the piston (5) to the spindle (7), ensure the spring location lugs are facing the
spindle sleeve (8).
-Remove the protective cover from the threads.
-Apply low strength nutlock to the lock-nut threads on spindle (7).
-Replace the lock-nut (9) and tighten to 100 Nm.
-Lower the piston assembly (5, 7, 8 and 9) into the actuator, taking care not to damage
the bearing (16) and seal (15).
-Replace the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Fit the 5 long securing nuts (17) onto the threaded bar (18) making sure that the spring
washer (32) is in place and tighten the nuts (23) evenly to pull the piston assembly into
the cylinder (4), and the cylinder (4) onto the cylinder end caps (2and 3). Then tighten
to 30 Nm.
-Fit the remaining securing screws, nuts and washers (19, 23 and 32) and tighten to
30 Nm.
-Re-attach the actuator to the valve as described in Section 3.2.
C

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5 x long
securing nuts 17
Fig. 7 TN2000E
23
3
4
6
24
7
19
9
8
2
5
21
18
Fig. 8 TN2000R
4
6
8
5
3
21
19
2
18
C
32
14
C
9
17 5 x long
securing nuts
7
23
15 and 16
15 and 16
15 and 16
32
15 and 16

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4.5 Conversion of a TN2000R to a TN2000E
Warning: It is not recommended to reverse this actuators operation outside of a controlled
area. Lifting equipment will be required.
Note 1: Remove the actuator from the valve as described in Section 4.1.
Note 2: If a handwheel is fitted, a new adaptor kit will be required.
Note 3: There are 5 long securing nuts that must be removed last to ensure that the spring
tension is removed.
Note 4: A new product label will be required and fitted over the existing label if a conversion
has been done.
Contact Spirax Sarco with the new product details, and a new label can be supplied. As a
temporary measure amend the existing label with a permanent marker stating failure mode
and suffix lettering (E or R).
Dismantle:
-Loosen and remove the connector and lock-nut (14 and 24).
-Loosen and remove the 5 securing nuts and washers (23 and 32) on the threaded bar (19).
-Evenly loosen and remove the remaining long securing nuts (17), see note 3 above.
-Remove the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Remove piston assembly (5, 7, 8 and 9), taking care not to damage the bearing (16)
and seal (15).
-Remove the cylinder (4).
-Remove the spring (6).
-Using a spanner hold the upper spindle C and remove the lock-nut (9) from the piston
assembly.
-Cover the thread on the main spindle under lock-nut (9).
-Remove the piston (5).
-Remove the spindle sleeve (8).
Reassembly:
-Assemble the piston and spindle assembly
-Fit protective cover to the threads on the spindle for lock-nut (9)
-Fit the piston (5) to the spindle (7), ensure the spring location lugs are facing the
lock-nut (9) end.
-Fit the spindle sleeve (8) to the spindle (7).
-Remove protective cover from the threads.
-Apply low strength nutlock to lock-nut threads on spindle (7)
-Replace the lock-nut (9) and tighten to 100 Nm.
-Lower the piston assembly into the actuator (5, 7, 8 and 9), taking care not to damage
the bearing (16) and the seal (15).
-Fit the spring (6).
-Apply grease to the internal of the cylinder (4) (approximately 100 mm to be in contact
with piston).
-Lower the cylinder (4) onto the piston (5).
-Replace the upper cylinder end cap (3), taking care not to damage the bearing (16)
and seal (15).
-Fit the 5 long securing nuts (17) onto the threaded bar (18)making sure that the spring
washer (32) is in place and tighten the nuts (23) evenly to pull the cylinder (4) onto the
piston (5), and the cylinder (4) onto the cylinder end caps (2 and 3). Then tighten to 30 Nm.
-Fit the remaining securing screws, nuts and washers (19, 23 and 32) and tighten to 30 Nm.
-Re-attach the actuator to the valve as described in Section 3.1.

IM-P327-02 CH Issue 3 15
Fig. 9 TN2000R
4
6
8
5
3
21
19
2
18
C
9
17 5 x long
securing nuts
7
23
5 x long
securing nuts 17
Fig. 10 TN2000E
23
3
4
6
24
7
19
9
8
2
5
21
18
32
14
C
15 and 16
15 and 16
15 and 16
32
15 and 16

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4.6 Fitting the handwheel to TN2000RH actuators
-Remove the cover (21) from the actuator, see Figure 11.
-Remove the dust cap from the top of the handwheel assembly C .
-Insert the plunger E and tighten the securing bolt B .
-Ensure the indicator is at the highest point.
-Fit the handwheel assembly A over the upper spindle.
-Fit and tighten the securing bolts D to a torque of 50 Nm.
-Fit the dust cap C .
Fig. 11 TN2000RH
D
A
B
C
4.6.1 Removal of handwheel TN2000RH
-Ensure indictor is at the highest position.
-Loose and remove 4 securing bolts D .
-Remove handwheel assembly.
E
Indicator

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D
A
B
C
Fig. 12 TN2000EH
4.7 Fitting the handwheel to TN2000 EH actuators
-Remove the cover (21) from the actuator, see Figure 12.
-Remove the dust cap from the top of the handwheel assembly C .
-Fit the handwheel spacer F over the spindle and locate it on the bearing and seal insert.
-Ensure the indicator is at the lowest point.
-Fit the handwheel assembly A .
-Fit and tighten the securing bolts D to a torque of 50 Nm.
-Insert and tighten the securing bolt B .
-Fit the dust cap C .
F
Indicator
4.7.1 Removal of handwheel TN2000EH
-Ensure indictor is at the lowest position.
-Remove dust cap
C.
-Loosen and remove securing bolt
B.
-Loose and remove 4 securing bolts
D.
-Remove handwheel assembly.

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18
5. Spare parts
The spare parts available are common across the range of actuators detailed in this document.
No other parts are available as spares.
Available spares
'O' ring kit 15,29,30,31
Travel indicator kit 22,27,28
Spring 6
Handwheel A
EH kit B
RH kit C
How to order spares
Always order spares by using the description given in the column headed 'Available
spares' and state the actuator model.
Example: 1 - ' O ' ring kit for a Spirax Sarco TN2277SE pneumatic piston actuator.
A
A
B
C
Fig. 14
Fig. 13

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Fig. 15
6
22, 27 and 28
15, 29, 30 and 31

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