Spirax Sarco TN203 E Series User manual

IM-P361-02-EN-ISS1 CTLS 1
TN203 _ RH
TN203 _ E
or
TN215 _ E
TN215 _ SRH
IM-P361-02-EN-ISS1
CTLS
3270150/5
TN2000 Series
Pneumatic Piston Actuators
for DN15 to DN100 Spira-trolTM Series Control Valves
Installation and Maintenance Instructions
PREVIOUS REFERENCE NO. IM-P327-07
© Copyright 2018
Printed in France
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Spare parts

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Safe operation of this product can only be guaranteed if it is 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 Pressure Equipment Directive (PED).
i) This product has 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) 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 and solvents.
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. Safety information

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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.
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.

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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
-Nitrile NBR 70 shore 'O' rings and 'X' rings.
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 Description
The TN2000 series of pneumatic piston actuators are suitable for use with DN15 to DN100 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 (5 °F to 230 °F)
Maximum operating inlet pressure
TN203_ 10 bar g (145 psi g)
TN2153 DE/DR
5 bar g (72 psi g)TN2150 DR/DE
TN215N DA
TN2153 SR/SE 8 bar g (116 psi g)
TN2150 SE/SE 7 bar g (101 psi g)
Air supply connection ¼" or "screwed NPT
Actuator travel
TN203 _ 30 mm
TN215 _ 50 mm
2.3 Materials Parts 1 to 14 (See page 8 for parts 15 to 41)
No. Part Material
1Lower cylinder end cap SG iron EN 1563 EN-GJS-400-15 : 5.3106
2Piston SG iron
3Spring Chrome vanadium steel
4Upper cylinder end cap SG iron EN 1563 EN-GJS-400-15 : 5.3106
5Cylinder Composite tube
6'O' ring Nitrile NBR 70 SH
7Threaded bar M8 Carbon steel (plated)
8Nut M8 Carbon steel (plated)
9Screw slotted pan head M2.5 x 12 Carbon steel (plated)
10 Yoke SG iron
11 Front clamp Stainless steel
12 Rear clamp Stainless steel
13 Nut M5 Carbon steel (plated)
14 Formed hex. screw M5 x 16 Carbon steel (plated)
2. General product information

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9
5
7
1
8
13, 14
11, 12
10
4
3
6
6
Fig. 1
2

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2.3 Materials (continued) Parts 15 to 41 (See page 6 for parts 1 to 14)
No. Part Material
15 Nut M12 Carbon steel (plated)
16 Bearing and seal insert Carbon steel (plated)
17 Rod seal wiper Ø20 Polyurethane
18 DU plain bearing Ø20 PTFE/steel composite
19 Spindle Stainless steel
20 Connector Stainless steel
21 Scale Stainless steel
22 Collar Carbon steel (plated)
23 Threaded bar M8 Long Carbon steel (plated)
24 'O' ring 11.6 x 2.4 Nitrile NBR 70 SH
25 Vent plug "NPT Polyamid 6.6
26 'X' ring Nitrile NBR 70 SH
27 Gasket Graphite seal
28 Label blank (Compressed spring warning) Adhesive paper
29 Adaptor Stainless steel
30 Label blank Adhesive paper
31 Sleeve Carbon steel (plated)
32 Formed hex. screw M12 Carbon steel (plated)
33 Formed hex. screw M12 x 25 Carbon steel (plated)
34 Nut M2.5 Carbon steel (plated)
35 Yoke adapter Stainless steel
36 Yoke sleeve Stainless steel
37 Spindle sleeve (TN21 only) Carbon steel (plated)
38 Connector DA Stainless steel
39 Upper clamp DA Stainless steel
40 Adaptor DA Stainless steel
41 Thin valve nut Carbon steel (plated)
42 Grower washer M10 Stainless steel

IM-P361-02-EN-ISS1 CTLS 9
20
22
18
17
34
21
23
25
30
28
19
26
16
29
33
32
24
31
27
Fig. 2
15
35
Only used
with the
TN2_ _ _ _ _ 36
Only used with
the TN2_ _ _ _C
TN21 only
37
37 TN21 only
Only used with the TN215___ C
38
39
40
42
41
41

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Note: When lifting the
actuator only use a
lifting sling through X1
to X4.
X4
X3
X1
X2
Actuator data:
Actuator
range Travel Thrust
Acting
pressure
0 mm
Acting
pressure
20 mm
Acting
pressure
30 mm
Acting
pressure
50 mm
TN2030 and
variants 30 mm 2.5 kN 562 lbf
0.79 bar
11.5 0 psi
1.47 bar
21.31 psi
1.81 bar
26.24 psi
TN2033 and
variants 30 mm 6 kN 1 349 lbf
1.89 bar
27.4 0 psi
4.19 bar
60.80 psi
5.34 bar
77. 4 9 psi
TN2150 and
variants 50 mm 3.6 kN 809 lbf
0.46 bar
6.70 psi
1.12 bar
16.27 psi
1.45 bar
21.06 psi
2.11 bar
30.64 psi
TN2153 and
variants 50 mm 14 kN 3 147 lbf
1.95 bar
28.30 psi
2.73 bar
39.58 psi
3.12 bar
45.23 psi
3.90 bar
56.54 psi
Caution:
Those pressure ranges are estimated and directly related to the springs precision (±10%).
Furthermore, the working pressure with the valve coupled can be a little bit upper because of the friction
inside of it.
Fig. 3

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Caution: Sling eyes (X, see Figure 3) 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 4).
Note : Due to the thrust that the actuator uses, it can deteriorate the valve or the coupling parts,
if the working pressures are exceeded.
Fig. 4
Vertically
below pipework
Vertically
above pipework
Optimum
Horizontal
(it is essential that support is provided when the
installation is in the horizontal position)
3. Installation

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3.1 Fitting the actuator (extend) to the valve
-Remove the screw and nut (13 and 14) then the rear and front clamp (11 and 12).
-Ensure the indicator scale 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 (19) to the mid-travel
position.
-Manually push the valve spindle down to ensure that the plug is on the valve seat.
-Screw the yoke adapter (35) onto the valve and tighten it to 50 Nm (36.9 lbf ft) - (TN2 _ _ _ E_ only).
-Put the yoke sleeve (36) onto the valve bonnet (TN2 _ _ _ EC only).
-Locate the actuator yoke onto the valve bonnet and fit the lock-nut (A).
-Screw the lock-nut of the valve’s spindle down to the lowest part of the valve spindle.
-Screw the bottom connector (29) onto the valve spindle, caution there must be no valve spindle threads
above the bottom connector.
-Loosen the lock-nut and screw the connector (20) upwards 3 turns, then remove the air supply.
-Apply the minimum signal pressure + 0.1 bar (1.45 psi) maximum to the bottom of the actuator, and then
adjust the connector (20) so that it touches the bottom connector (29), then tighten the lock-nut (15).
-Release the control air signal. Fit the front and rear clamps (11 and 12).
-Fit the locking screws and nuts (13 and 14) loosely.
-Operate the actuator and valve over its full travel four times to ensure alignment.
-Tighten the mounting nut to 50 N m (36.9 lbf ft).

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Fig. 5
A
Only used
with the
TN2_ _ _ _ _
Only used
with the
TN2_ _ _ _C
29
13, 14
11, 12
35
20
15
19
36

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3.2 Fitting the actuator (retract) to the valve
-Remove the screw and nut (13 and 14) then the rear and front clamp (11 and 12).
-Ensure the indicator scale is facing the same way as the valve name-plate.
-Apply the control signal pressure to the top of the actuator to bring the spindle (19) to the mid-travel
position.
-Manually push the valve spindle down to ensure that the plug is on the valve seat.
-Screw the yoke adapter (35) onto the valve and tighten it to 50 Nm (36.9 lbf ft) - (TN2 _ _ _ E_ only).
-Put the yoke sleeve (36) onto the valve bonnet (TN2 _ _ _ EC only).
-Locate the actuator yoke onto the valve bonnet and fit the lock-nut (A).
-Screw the lock-nut of the valve’s spindle down to the lowest part of the valve spindle.
-Screw the bottom connector (29) onto the valve spindle, caution there must be no valve spindle threads
above the bottom connector.
-Loosen the lock-nut and screw the connector (20) upwards 3 turns, then remove the air supply.
-Adjust the connector (20) so that it touches the bottom connector (29). Apply the minimum signal pressure
+ 0.1 bar (1.45 psi) maximum to the top of the actuator then unscrew the connector (20) downwards 3
turns, and finally tighten the lock-nut (15).
-Release the control air signal. Fit the front and rear clamps (11 and 12).
-Fit the locking screws and nuts (13 and 14) loosely.
-Operate the actuator and valve over its full travel four times to ensure alignment.
-Tighten the mounting nut to 50 N m (36.9 lbf ft).
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.

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Fig. 6
A
Only used
with the
TN2_ _ _ _ _
Only used
with the
TN2_ _ _ _C
40
39
38
35
15
19
36

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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. Use POLYLUB GLY 801 (lubricating grease) only.
The TN2000 series of 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 4.4 or 4.5.
-Remove the screws and nuts (13, 14) then the rear and front clamp (11, 12).
-Remove the lock-nut (A).
-Remove the air supply.
-Remove the actuator from the valve.
4. Commissioning

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Fig. 7
A
Only used
with the
TN2_ _ _ _ _
Only used
with the
TN2_ _ _ _C
13, 14
11, 12

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Fig. 8 TN2000E
8
4
6
26
6
18
17
23
24
3
5
19
7
4.2 Replacing the 'O' and 'X' rings (SE and DE actuators)
Note: Remove the actuator from the valve as described in Section 4.1.
Note: Depending on the actuator size there is either 3 or 4 short threaded bars which must be removed last
to ensure that the spring tension is removed before taking the actuator apart.
-Depending on the actuator size loosen and remove the 3 or 4 threaded bars (7).
-Loosen then remove the remaining long securing nuts (23), see note above.
-Remove the upper cylinder end cap (4).
-Remove the spring (3) (not applicable for DA).
-Remove the cylinder (5).
-If the bearing seals are to be replaced remove the spindle (19) to fit the lower seal (17).
-Replace the 'O' and 'X' rings (6,26 and 24).
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 (19) if previously removed.
-Apply grease to the internal of the cylinder (5) and the bearings (18) (approximately 50 mm to be in
contact with piston).
-Lower the cylinder (5) onto the lower cylinder end cap (1).
-Replace the springs (3).
-Replace the upper
cylinder end cap (4) over
the springs (3).
-Depending on the
actuator size refit the 3 or
4 long threaded bars (23)
and tighten the nuts (8)
evenly to pull the cylinder
(5) onto the lower cylinder
end cap. Then tighten to
30 Nm (22.1 lbf ft).
-Refit all remaining
securing screws and nuts
(7and 8) and tighten to
30 Nm (22.1 lbf ft).
-Re-attach the actuator to
the valve as described in
Section 3.1.

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Fig. 9 TN2000R
8
6
6
18
17
23
24
5
20
7
A
26
4.3 Replacing the 'O' and 'X' 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 (20), see Figure 9.
-Depending on the actuator size loosen and remove the 3 or 4 short threaded bars (7).
-Evenly loosen and remove the remaining long securing nuts (23), see note above.
-Remove the upper cylinder cap (4).
-Remove the piston assembly (Apart numbers: 2,19,24,26,31 and 32).
-Remove the cylinder (5).
-Replace the 'O' and 'X' rings (17,6,24 and 26).
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 (5) and the bearings (18) (approximately 50 mm) to be in contact
with the piston).
-Lower the cylinder (5) onto the lower cylinder.
-Lower the piston assembly into the actuator (2,19,24,26,31 and 32), taking care not to damage the
bearing (18) and seal (17).
-Replace the upper
cylinder (4).
-Depending on the
actuator size refit the 3 or
4 long threaded bars (23)
evenly to pull the piston
assembly into the
cylinder (5) and the
cylinder (5) onto the
cylinder end caps (1and
4). Then tighten to 30 Nm
(22.1 lbf ft).
-Refit all remaining
securing screws and nuts
(7,8 and 23) and tighten
to 30 Nm (22.1 lbf ft).
-Re-attach the actuator to
the valve as described in
Section 3.2.
1
4

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4.4 TN203_SEH or TN203_SRH (handwheel)
Note: Ensure the handwheel has no comprehessive load on the actuator springs.
-Remove the plastic barrel plug (A), hold the actuator spindle at point (B) with a spanner and
simultaneously loosen and remove the screw (C).
-Remove the handwheel (D), taking care not to displace the internal bearing (F).
To re-attach the handwheel, the above the procedure should be reversed ensuring the correct torques are
used.
Fig. 10 TN203 _ SEH
Fig. 11 TN203 _ SRH
B
E
F
C
D
A
B
E
F
C
D
A
Table 1 - Recommended tightening torques
Screw
(C)
Spindle connector
(E)
N m lbf ft N m lbf ft
20 29.5 40 29.5