Weir Hopkinsons Fig 9052 Manual

Hopkinsons Fig 9052
VALVE ACTUATO
tandard Operating & Maintenance Instructions
CUT-AWAY OF FIG. 9052 GEAR BOX, WITH LIMIT WITCH
& VALVE PO ITION INDICATOR
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HOP 9052 /Jan 2011

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Index
Section 1
1.1 General Page 3
1.2 Motor and Gear Train Page 3
1.3 Torque Limiting Device Page 3
1.4 Manual Operation Page 4
1.5 Limit Switch Assembly Page 5
1.6 Limit Switch and ndicator Unit Assembly Page 6
1.7 Torque Switch Assembly Page 6
1.8 ndicator Unit (When Fitted) Page 6
Section 2
2.1 Limit Switch Page 7
2.2 Commissioning Pedestal Units Page 7
2.3 Commissioning Direct Mounted Actuators Page 7
2.4 Mechanical Valve Position ndicator (When Fitted) Page 8
2.5 Motor Page 8
2.6 Alternating Current Page 8
2.7 Lubrication Page 8
Drawings
Arrangement of Fig 9052 Actuator Page 10
Sectional Arrangement of Gear Box Assembly for
Fig 0052 Actuator Page 11
Cut-Away of Fig. 9052 Gear Box, With Limit Switch & Valve
Position ndicator Page 12
Arrangement of Fig 9052 Actuator - Pedestal Mounted Page 13
Arrangement of Limit Switch Suitable for Fig. 9051, 9052, 9053,
9054, 9055 & 9056 Actuators Page 14
Diagrammatic Cut Away of Limit Switch Assembly Page 15
Arrangement of Torque Switch Page 16
Contact Details Page 17

Hopkinsons Fig 9052
VALVE ACTUATO
ection 1
1.1 GENE AL
The actuator consists of a motor driving an output shaft through an all spur gear train
incorporating a torque indicating mechanism and an automatic mechanical device for changing
the drive from manual to power. The actuator includes a valve travel limit switch unit and a
torque switch unit with combined torque indicator and is of totally enclosed weatherproof
construction, suitable for mounting at any angle or inverted.
1.2 MOTO AND GEA T AIN
A. C. 3 phase motors are of squirrel cage design fitted with 'packed for life' grease lubricated
ball bearings. Dimensions and performance are in accordance with B.S. 2048, B.S. 2960,
B.S. 2613 or B.S.170, whichever is applicable. Class "B" insulation is provided as standard and
the machines are 1/2 hour rated. The windings are terminated on 2 B. A. stainless steel stud
type terminals in an integral terminal box.
The motor is mounted on the top cover of the gear box, and the reduction gear shafts and final
output shaft bearings are located in the main housing and spider plate. The final drive assembly
incorporates a lost motion, or hammer blow device which allows the motor to run up to speed
before transmitting full torque to the valve.
1.3 TO QUE LIMITING DEVICE
The final reduction stage in the actuator drive consists of a single helical spur pinion shaft which is
capable of axial movement against a spring. Upon a predetermined torque being exceeded the
end thrust component causes axial movement of the helical pinion shaft. This movement is
transmitted to the indicator and switches of the torque switch assembly by means of a roller
mounted on the torque switch lever and positioned between flanges on the helical pinion shaft.
The final reduction gear is axially located on the actuator output shaft and the face width of the
helical pinion shaft is sufficient to allow axial movement while remaining in mesh with the gear.
The spring cylinder assembly which is anchored to the spider plate, normally keeps the pinion shaft
in a mid position.
The design of the spring cylinder assembly is such that a limited deflection of the compression
spring is permitted allowing axial movement of the helical pinion shaft in either direction
corresponding to 50% to 110% output torque of the actuator in the opening or closing directions.
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1.4 MANUAL OPE ATION
The actuator is equipped with a handwheel to operate the valve in the event of a power failure.
The handwheel is easily engaged with the output shaft via the gear train by pulling the hand/
auto clutch lever towards the handwheel at the same time turning the handwheel slowly until
the clutch is engaged.
An automatic device is incorporated which transfers the drive from manual to power
immediately the motor pinion starts to rotate. As the clutch is withdrawn completely from
manual before engaging power drive the operator is ensured complete safety should the
actuator be started during hand operation.
A bevel wheel on the handwheel shaft meshes with a bevel pinion on the bevel shaft which also
carries a hand spur wheel. The motor spur wheel is fitted to a fixed clutch member which is
axially located in the spider and is provided with pawls to disengage the catch levers and dog
teeth to engage the sliding clutch. The sliding clutch is mounted on the splined shaft which
forms the second reduction pinion at the lower end and a journal bearing of the fixed clutch at
the upper end. The sliding clutch is provided with a groove for the hand/auto clutch lever roller
and during power operation is held in engagement with the fixed clutch by the clutch return
spring. The hand/auto clutch lever is fixed to a spindle carried in bearings through the wall of
the main housing to the external clutch handle. One arm of the hand/auto clutch lever carries
the roller and the other arm determines the position of the spring loaded catch levers.
To engage hand operation the clutch lever is pulled approximately 30° towards the handwheel
whilst slowly turning the latter to allow the gear of the sliding clutch member to engage with
the hand spur wheel. Do not attempt to force the lever into the manual position as this should
be easily and smoothly attained. With the lever in the manual position the motor pinion and
motor gear are bypassed for hand operation. By this action, the catch levers, which are clear of
the fixed clutch member pawls during power operation, are allowed to make contact with the
fixed clutch member and the sliding clutch is retained in mesh with the hand spur wheel
against the action of the clutch return spring by slots in the catch lever s engaging the free arm
of the clutch lever. Two catch levers are employed, and two pawls positioned at 180° on the
fixed clutch member in order to ensure that one catch lever engages the clutch lever in the
event of the stationary position of the fixed clutch being such that a pawl is directly in line with
a catch lever.
To return to power operation the motor is energised and during the first rotation of the fixed
clutch member the free arm of the clutch lever is released from the slot(s) of the catch lever(s)
by the action of the pawl(s) striking the catch lever(s). As the clutch lever also carries the roller
which positions the sliding clutch member the latter is disengaged from the hand spur wheel
and engaged with the dog teeth of the fixed clutch by the clutch return spring to immediately
take up the power drive. With the clutch engaged the free arm of the clutch lever maintains the
catch levers clear of the fixed clutch pawls with the hand lever in the power position, i.e.
parallel with the output shaft. Do not attempt to disengage the hand/auto clutch when power
driving. As the sliding clutch is clear of the hand spur wheel before engaging the dog teeth of
the fixed clutch, it is impossible to transmit rotary motion from motor to handwheel.
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1.5 LIMIT SWITCH ASSEMBLY
The standard limit switch assembly comprises 4 -'open' position and 4 -'close' position micro
switches, each bank of switches being simultaneously operated by a lever actuated by a cam on
the pinion shaft of a hunting tooth gear train. An intermediate position bank is fitted when
required providing 2 micro-switches operated simultaneously by a switch lever actuated by a
cam on the pinion shaft of an additional hunting tooth train.
The hunting tooth gear trains are so arranged that each bank is independently adjustable to
provide any limit switch setting from zero to 1,000 actuator turns, i.e. valve fully closed to fully
opened, with the 'intermediate' bank set at any position between the open and close limits, the
accuracy of the settings being 0.1 actuator turns.
Each hunting tooth gear train consists of a pinion shaft with a cam pinned to the non-driving
end, 4 pinions on the shaft within the housing and a drive pinion in mesh with the compound
gear train coupled to the limit switch drive spindle. The pinions within the housing are in mesh
with 4 spur wheels each of which embodies a ball drive to a hunting tooth gear mounted on
the spur wheel boss. The bore of the gear is formed to permit the ball drive to be in any of 10
positions corresponding to the numerals on the gear flange, and the spur wheels are mounted
on a hunting tooth spindle. The spindle is provided with a series of grooves, circlips to limit the
engagement and withdrawal, and a knurled end to facilitate withdrawal. A spring loaded ball
axially locates the spindle in the engaged or disengaged positions.
n the normal driving or set position the hunting tooth spindle is engaged and in this position
the ball drive of the hunting tooth gear and spur wheel is locked in position by the spindle.
Resetting of a switch bank is effected by pulling out the hunting tooth spindle to allow the
spring loaded ball in the housing to register the disengaged position and also to bring the
grooves in the spindle in line with the drive ball of each hunting tooth wheel. With the spindle
in the disengaged position the hunting tooth wheels can be turned to any combination of
digits on the flanges as each driving ball is allowed to move clear of the hunting tooth wheel
bore profile into the spindle groove. Reading from left to right or non-driving end to driving
end the flange numbers are in multiples of hundred, ten, unit and tenth turns respectively. t is
important that the digits of the required combination are in a straight line and in line with the
centres of the pinion shaft and hunting tooth spindle, before pressing home the hunting tooth
spindle.
The engaged position of the spindle is attained without the use of excessive force.
f the spindle does not readily snap home the four digits are not lined up correctly.
t is possible to re-set a bank with the tenth counter flange only in any radial position, but it is
essential that when re-set the correct relationship of this hunting tooth wheel and spur wheel is
maintained in respect of the ball drive. This means that the radial position of the tenth digits
must be the same before and after setting irrespective of the actual numerals. As the numerals
of each flange must be adjacent to alternate tooth spaces of the spur wheels it is possible to
inadvertently position a tenth digit opposite the incorrect tooth space which will prevent
engagement of the hunting tooth spindle. f this occurs the tenth digit wheel should be rotated
one tooth space thereby allowing engagement of the spindle.
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1.6 LIMIT SWITCH AND INDICATO UNIT ASSEMBLY
The limit switch and indicator units are mounted on a spider plate which embodies an indicator
take-off spindle and a limit switch drive gear.
The complete assembly is fitted to the top cover of the actuator, the cross pin of the limit switch
drive gear and a slot in the limit switch driven spindle forming the coupling for the gear drive
from the actuator output shaft.
1.7 TO QUE SWITCH ASSEMBLY
The actuator is fitted with a torque switch assembly which incorporates a torque indicator, (the
scale of which is calibrated to indicate 50% to 110% output torque of the actuator) and 'open'
and 'close' torque switches which are fitted with adjusting features easily set to limit the
actuator torque in increments of 5% within the indicated range. The torque switch assembly is
spigot mounted on the torque lever bearing and the main spindle is coupled to the torque lever
spindle. Torque indication in terms of angular displacement of the torque lever spindle is
transmitted via the main spindle to the indicator spindle and the 'open' and 'close' torque
switch operating spindles. An adjusting screw permits the adjusting plate to be set in any of 12
positions from 0.5 to 1.1(50% - 110%) output torque by simply releasing the adjusting screw
sufficiently to allow the teeth of the adjusting plate to clear the teeth of the index plate,
rotating the adjusting plate to the required figure and tightening the adjusting screw. The
driving dog tooth of the adjusting plate is thereby positioned relative to the driven dog tooth of
the switch lever to allow angular displacement of the operating spindle corresponding to the
set torque figure. The switch is normally tripped with circuit closed and retained in this position
by the switch lever and torsion spring. The switch is re-set and the circuit opened at the set
torque figure by the aforementioned action of the adjusting plate dog tooth.
1.8 INDICATO UNIT (WHEN FITTED)
The indicator unit consists of a housing, base, input and output spindles, change gears, range
gears, index plate, pointer and pointer spindle. An indicator unit supplied with an actuator
includes range and change gears of the correct ratio for the number of output turns of the
actuator and no adjustment is required other than setting the pointer to correspond
to the position of the valve.
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ection 2
2.1 LIMIT SWITCH
The limit switch assembly of an actuator fitted direct on to a valve is set for the correct number
of turns before despatch and should not be disturbed.
Pedestal type actuators and actuators for fitting direct on to valves at site are despatched with
each switch bank set at 500.0 turns so that any mal-operation of the handwheel before the
actuator is coupled or fitted to the valve should not disturb the correct relationship of cams to
rollers. After coupling or fitting the actuator to the valve remove the limit switch cover and the
limit switch housing cover. Hand operate the valve to the full shut position, and observe that
the limit switch cams are in the correct re-set position, i.e. maximum cam throw 72° clockwise
of roller assembly. f for any reason the cam is in any other position, the correct position is easily
attained by withdrawing the hunting tooth spindle and rotating only the hunting tooth wheel
which registers multiples of 100 turns in a clockwise or anti-clockwise direction until the correct
cam position is obtained and the spindle re-engaged. This should be carried out without
disturbing the remaining digits. After noting the actual number of turns indicated on the 'close'
bank hand operate the valve in the open direction 0.3 turns of the limit switch counter
mechanism to the nearest 0.1 turn which will give a complete number in a straight line, in line
with the pinion and hunting tooth spindles. Withdraw the hunting tooth spindle of the 'close'
bank and re-set to 0000 turns (in line) and re-engage the spindle. Now set the 'intermediate'
and 'open' banks to the correct number of actuator output shaft turns from zero at which these
switches are required to trip.
Check by hand operation the tripping positions of the switch banks.
2.2 COMMISSIONING PEDESTAL UNITS
First ascertain that the valve is in the full shut position i.e. the stop is resting on the lower
shoulder of the valve pillars. Connect the valve and unit mechanically by the extension spindle
supplied taking care not to move the valve from the full shut position and also ensure that the
universal forks on the intermediate shaft are in line and not at 90° to each other.
2.3 COMMISSIONING DI ECT MOUNTED ACTUATO S
Valves which are to be fitted with direct mounted actuators at site are fitted with a circular
adaptor plate secured to the valve by the pillar nuts.
f a standard hand operated valve is to be motorised by means of a direct-mounted actuator,
remove the existing handwheel, gearing (when fitted) sleeve and bridge, leaving the valve
pillars and spindle only for application of the actuator. Remove the circular adaptor plate from
the base of the actuator and fit this item on the valve pillar ends and secure by means of the
existing pillar nuts. Do not remove any covers at this stage but engage manual operation in
preparation for fitting to the valve.
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Sling the actuator by means of overhead tackle and carefully lining up the actuator with the
valve spindle axially and radially, lower the actuator on to the valve until the output shaft begins
to engage the valve spindle. Rotate the handwheel in the opening direction, and, at the same
time, gradually lower the actuator until the base face within the spigot location is flush with the
top face of the adaptor flange. Fit the nuts to the mounting studs and secure.
2.4 MECHANICAL VALVE POSITION INDICATO (WHEN FITTED)
Set the pointer to the 'shut' index of the scale with the valve in the full shut position after
setting the limit switch.
2.5 MOTO
The adjustment for wear of brushes for D.C. motors is the only attention required.
2.6 ALTE NATING CU ENT
For A. C. 2 and 3 Phase.
It is very important to ascertain that the direction of travel of the valve corresponds to the
'open' and the 'shut' button of the controller.
Carefully check the direction of travel of the valve with the movement of the controller by
having the valve in mid-position. Then press the 'open' or 'shut' operating button and
immediately after that stop the actuator and ascertain whether the valve has moved to
correspond to the button which was operated. f the valve has travelled in the opposite
direction, reverse any two of the supply leads in the contactor.
2.7 LUB ICATION
The actuator requires the minimum of lubrication and the motor bearings are packed for life.
A grease gun nipple is provided for the output shaft thrust bearings on Fig. 9052 actuators.
All other actuators are also fitted with grease gun nipples for journal bearings. Actuators for
mounting direct on to a valve are fitted with a grease gun nipple for valve stem lubrication.
When an actuator is fitted to a valve at site, the latter nipple should be fully charged when
commissioning, with the valve in the full open position, and not excessively lubricated during
service with the valve full shut. t is advisable to lubricate sparingly the limit switch and torque
switch unit gearing and moving parts.
ECOMMENDED LUB ICANTS:
SHELL ALVANlA GREASE No.3 - Grease gun nipples.
SHELL V TREA O L No. 27 - Gears and moving parts of limit switch and torque switch
assemblies.

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ROCOL MOLYGEAR - nternal power and hand gears prelubricated at works sufficient for normal
life of actuator.
Dependent upon usage and operating conditions.

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ARRANGEMENT OF FIG 9052 ACTUATOR

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ECTIONAL ARRANGEMENT OF GEAR BOX A EMBLY FOR FIG 9052 ACTUATOR

12 Weir Power & ndustrial - First choice for power and industrial protection
CUT-AWAY OF FIG. 9052 GEAR BOX, WITH LIMIT WITCH
& VALVE PO ITION INDICATOR

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ARRANGEMENT OF FIG 9052 ACTUATOR - PEDE TAL MOUNTED

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ARRANGEMENT OF LIMIT WITCH UITABLE FOR FIG. 9051, 9052, 9053, 9054, 9055 & 9056 ACTUATOR

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DIAGRAMMATIC CUT AWAY OF LIMIT WITCH A EMBLY

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ARRANGEMENT OF TORQUE WITCH

HOP 9052 /Jan 2011
For spares or service enquiries please contact:
North America
Valve Customer Support Group
Weir Power and ndustrial
2360 Millrace Court
Mississauga, Ontario
L5N 1W2, Canada
Tel: [phone]
Servicecall: (877) 797 WE R (9347)
Fax: [phone]
E-mail: [email protected]
Web: www.weirpowerindustrial.com
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Power & ndustrial
Solutions
est of World
Weir Power and ndustrial
The Harlands
Alloa FK10 1TB
United Kingdom
Telephone: [phone]
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E-mail: [email protected]
Web: www.weirpowerindustrial.com
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