Kobold KUP Series Manual de usuario
Operating Instructions
for
Ball Valves
with Pneumatic Actuator
Model: KUP-...
KUP
page 2 KUP K02/0522
1. Contents
1.Contents ........................................................................................................ 2
2.Note .............................................................................................................. 3
3.Instrument Inspection .................................................................................... 3
4.Specific application ....................................................................................... 3
5.Safety notes .................................................................................................. 4
5.1.Safety of personnel .............................................................................. 4
5.2.Safety of machinery ............................................................................. 5
6.Operating principles ...................................................................................... 6
6.1.General information ............................................................................. 6
6.2.Design.................................................................................................. 6
6.3.Function „double-acting“ ...................................................................... 6
6.4.Function „single-acting“........................................................................ 7
7.Rotation Direction .......................................................................................... 8
7.1.Change of the rotation direction ........................................................... 8
7.2.Change of the rotation direction at actuator with function „double-acting“
............................................................................................................. 9
8.Ambient conditions ...................................................................................... 11
9.Assembly Instructions ................................................................................. 11
9.1.Mechanical mounting ......................................................................... 11
9.2.Pneumatically Installation .................................................................. 14
9.3.Disassembly ...................................................................................... 16
10.Adjustment/Starting ..................................................................................... 17
10.1.Adjustments ....................................................................................... 17
10.2.Starting .............................................................................................. 18
11.Emergency Operation ................................................................................. 19
12.Failure ......................................................................................................... 20
12.1.Failure causes ................................................................................... 20
13.Maintenance/Cleaning ................................................................................ 20
13.1.Maintenance ...................................................................................... 20
13.2.Mounting of the spare part kit ............................................................ 21
13.3.Cleaning ............................................................................................. 26
14.Technical details ......................................................................................... 26
15.Device Description ...................................................................................... 27
16.Order Codes ............................................................................................... 28
17.Dimensions [mm] ........................................................................................ 31
18.EC Declaration of Conformance ................................................................. 35
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: +49(0)6192-2990
Fax: +49(0)6192-23398
E-Mail: [email protected]
Internet: www.kobold.com
KUP
KUP K02/0522 page 3
2. Note
Please read and take note of these operating instructions before unpacking and
putting the unit in operation, and follow the instructions precisely as described
herein.
The instruction manuals on our website www.kobold.com are always for currently
manufactured version of our products. Due to technical changes, the instruction
manuals available online may not always correspond to the product version you
have purchased. If you need an instruction manual that corresponds to the
purchased product version, you can request it from us free of charge by email
([email protected]) in PDF format, specifying the relevant invoice number and
serial number. If you wish, the operating instructions can also be sent to you by
post in paper form against an applicable postage fee.
The devices are only to be used, maintained and serviced by persons familiar
with these operating instructions and with the prevailing regulation applying to
operational safety and the prevention of accidents.
When used in machinery, the device may only be placed in operation if the
machine in use complies with the EEC machinery guidelines.
3. Instrument Inspection
Instruments are inspected before shipping and sent out in perfect condition.
Should damage to a device be visible, we recommend a thorough inspection of
the delivery packaging. In case of damage, please inform your parcel service /
forwarding agent immediately, since they are responsible for damages during
transit.
Scope of delivery:
The standard delivery includes:
Ball valve with pneumatic activator model: KUP-…
Optional: solenoid valves, limit switches
4. Specific application
Model KUP pneumatic actuators can be employed to automatically open and
close ball valves with the help of control air. Do not use an aggressive gas as a
control fluid. We recommend, instead, the use of filtered air. The fitting material
and gaskets must be resistant to the medium flowing in the pipe.
KUP
page 4 KUP K02/0522
5. Safety notes
You must pay attention to special safety aspects depending on the prevailing
technical conditions and the time at which you install and adjust the actuator, and
put it into operation!
For example, you will be exposed to much greater risks when placing the device
in operation if you open or close a pipe in an operational chemical plant with the
pneumatically operated ball valve than when you place the device in operation for
test purposes at a "dry" section of the plant in the assembling hall.
Because we cannot predict the conditions that will apply at the time of
installation/adjustment/putting into operation, we have provided a comprehensive
list of risk notes below, some of which may not apply to your particular
application.
Please follow the instructions that apply to your situation only!
5.1. Safety of personnel
5.1.1. Safety notes for installation
We expressly point out that the installation, electrical wiring and adjustment of the
rotary actuator should only be carried out by trained and skilled personnel with
sound mechanical and electrical technical skills!
Shutdown all devices/machinery/plant affected by the installation or repairs!
If necessary, disconnect the devices/machinery/plant from the electrical
supply!
Make sure you do not introduce risk by shutting down devices/machinery/plant
in chemical plant, for example!
You should inform the shift supervisor, the health and safety engineer, or the
plant manager immediately about any fault that occurs with the ball valve with
pneumatic rotary actuator in a running plant. This is to avoid any
discharge/overflow of chemicals or leakage of gases by taking suitable
precautionary measures!
Depressurize pneumatic/hydraulic devices/machinery/plant before installation
and service!
Attach warning labels to devices/machinery/plant to prevent someone from
unintentionally putting them into operation.
Installation and servicing should be carried out in compliance with the
appropriate professional/trade association safety and accident prevention
regulations.
Check that safety devices (e. g. emergency stop buttons, relief valves, etc.) are
working correctly.
Before mounting check, the rotation direction and the position of the actuator.
KUP
KUP K02/0522 page 5
5.1.2. Safety notes for adjustment / starting
As a result of the starting (pneumatic or by hand) of a pneumatic actuator the
position of a flanged slide/valve/flap will be changed!
Therefore, the flow of gases, steam, liquids, etc. may be enabled or interrupted!
Satisfy yourself that, as a result of the starting or the test adjustment no
potential hazards will be produced for the personnel or the environment!
If necessary, set up warning signs in order to prevent the inadvertent starting
up or shutting down of the device/machine/plant!
By ending the adjustment check the correct function and should the occasion
arise the position of the slide/valve/flap.
Check the function of the limit switches (option)!
Check, whether the slide/valve/flap will be closed totally, if the control signals
the appropriate limit stop!
Through suitable measures, prevent actuating links being trapped by moving
actuating elements!
Check the right function of all safety devices (for example emergency push off
buttons / safety valves)!
Carry out the starting and the adjustments only in accordance with the
instructions described in this documentation!
When adjustments are being carried out on a switched-on actuator with
options (e.g. solenoid valves, limit switches) there is the risk that life parts
(230V AC~) can be touched!
Therefore, the adjustments must be carried out only by the electrician or a
person having adequate training, who is aware of the potential hazard!
5.2. Safety of machinery
The rotary actuator s a quality product which is produced in accordance with the
recognized industrial regulations. It left the manufacturers work in a perfect safety
condition!
In order to maintain this condition, as installer/user you must carry out your task
in accordance with the description in these instructions, technically correctly and
with the greatest possible precision.
We assume, as trained specialist you are having mechanical and electrical
knowledge!
The pneumatic actuator must be used only for a purpose corresponding to
its construction!
The pneumatic actuator must be used within the actuator specified in the
technical data!
KUP
page 6 KUP K02/0522
The operation of the pneumatic actuator beyond the admissible temperature
range will overburden or damage the sealings and bearing.
The operation of the pneumatic actuator beyond the admissible working
pressure will damages the internal parts and the body.
Never remove or loosen the caps or accessories, if the actuator will be under
pressure or will be connected with a supply voltage (option).
Satisfy yourself that, as a result of the mounting, the starting or as a result of
the test adjustment on the pneumatic actuator, no potential hazards will be
produced for device/machine/plant!
Do not mount the actuator, start the actuator or carry out any adjustments on it,
if the actuator, the supply lines or the part of the plant on which it is mounted is
damaged!
Before mounting the actuator check the smooth movement of the
slide/valve/flap on which the actuator will be mounted.
By ending mounting check the correct function and adjustment of the actuator
and check the correct function of the options (e.g. solenoid valve, limit switch).
6. Operating principles
6.1. General information
The actuator is a pneumatic twin-piston drive, designed primarily for operating
ball valves and butterfly valves. A double-action and a spring-return (single-
action) type is available. The twin-piston system affords a high torque with
minimum overall dimensions. The rotation angle is adjustable with the standard
settings by ± 6 degrees.
6.2. Design
Due the twin-piston system the force developed by the counter-running pistons is
transmitted to one common pinion via two racks solidly connected with the piston.
This principle ensures a linear torque transmission along the entire stroke.
6.3. Function „double-acting“
Pressure is given through port „P1“ into the actuator between the two piston
surfaces. The pis-tons expand and transfers the force to the pinion which turn
round counterclockwise about 90° -> the actuator moves into position „OPEN“. By
giving compressed air through port „P2“, port „P1“ exhausts, the pressure in both
chambers between the caps and pistons will increase and the pistons will strike
against themselves. Therefore the pinion turns clockwise about 90° ->the
actuator moves into position „CLOSE“ (see Fig.).
KUP
KUP K02/0522 page 7
Description of function, double-acting
6.4. Function „single-acting“
Pressure is given through port „P1“ into the actuator between the two piston
surfaces. The pistons expand against the spring force. The pistons force will be
transfer to the pinion by racks. The pinion turns round counterclockwise about 90°
->the actuator moves into the position „OPEN“. Exhausting the port „P1“ the
pistons will be replaced by the spring force. Therefore the pinion turns clockwise
about 90° -> the actuator moves into the position „Close“. The springs will be able
to adjust to the working conditions (see Fig.).
Description of function, single-acting
KUP
page 8 KUP K02/0522
7. Rotation Direction
The pneumatic actuators are available as „right revolving“ or „left revolving“
actuators.
The standard rotation direction is to turn left. The rotation direction of the pinion of
the pneumatic actuator will be counterclockwise to be open and clockwise to be
close. The rotation direction refers to a view on the top of the actuator (see Fig.).
Before mounting the pneumatic actuator on a slide/valve/flap, take care that the
rotation direction will be practicable in your case. If appropriate, you have to
change the rotation direction by reconstructing the pistons of the actuator.
Rotation direction
7.1. Change of the rotation direction
In the following description we assume, that you have read the former chapters
attentive. We also assume that you will observe the safety advices and warnings
from chapter 5. „Safety advice“ during the mounting / disassembly.
Do not open a pneumatic actuator with the function „single acting“ on no
account!
If you have not read chapter 5.“Safety advices“ until now, read these
important advices now and turn back to this page!
The following description based on the assumption, that the pneumatic actuator is
not been mount-ed on a slide/valve/flap. All accessories have to be removed. The
mentioned rotation direction refers to the standard rotation direction „closed by
rotating clockwise“.
During the working at an opened actuator take care for great cleanness, because
even little pollution should cause a hasten wear or will damage the sealings and
the treads.
KUP
KUP K02/0522 page 9
7.2. Change of the rotation direction at actuator with function
„double-acting“
Loosen the cap bolts (1).
At single-acting pneumatic actuators the changing of the rotation direction
will be permitted only by the manufacturer. Do not loosen or screw out the
cap bolts. There will be a high tension at the caps causes by the resilience.
Remove the caps (2) and put them aside. The caps a symmetrical and therefore
the caps could be mounted both on the left and the right end of body (5).
Turn round the shaft (3) counterclockwise with a spanner until the racks of the
pistons (4) and the pinion at the shaft didn’t mesh anymore.
Do not drive out the pistons with compressed air.
The pistons have to stand out from the body now. Turn back the shaft clockwise
about 90°.
Change of the rotation direction, Removing the caps
KUP
page 10 KUP K02/0522
Turn around the pistons (1) about 180°, don’t take the pistons out of the body (2)
at this (see Fig.)
Insert the piston (1) into the body, so that both racks (3) will mesh into the teeth of
the shaft (4) at the same time. Observe the turning direction of the shaft.
Turn the shaft counterclockwise with a spanner until the groove of the shaft will
be at right angles to the axle of the actuator. The pistons have to strike against
themselves and that the piston will be symmetrically in the body.
If appropriate, repeat the working operations to adjust the shaft.
Put the cap onto the body and align it. Put the cap seals into the sealing groove
of the cap and check the right placement. Screw the cap bolts with the washers
into the body and tighten them crosswise.
Change of the rotation direction, Turning of the pistons
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