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installation operation maintenance manual virgo engineers ltd virgo series 20 ­ actuators technical data sheet t.d.s no ­ a040r0 issue date jan 2009 installation operation and maintenance manual please read the entire instructions carefully before installation or servicing guarantee our liability in respect of any defect in or failure of the goods supplied or for any loss injury or damage attributable onward is limited to making goods by replacement or repair defects which under proper use appear therein and arise solely from faulty materials and workmanship within a period of 18 calendar months after the original goods shall have been first shipped or 12 calendar months from the date of installation whichever is earlier provided that such defective parts are returned without charge to our factory for examination no other warranty is either expressed or implied table of contents item 1 2 3 4 description general technical data installation operation 1 ­ double acting 2 ­ spring return 5 maintenance 5.1 ­ general 5.2 ­ disassembly 5.3 ­ assembly 5.4 ­ insert 6 7 8 storage exploded view parts list 3 4 7 7 8 page 1 of 1 page no 2 2 2 2 2 2

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installation operation maintenance manual 1 general this manual contains the important information regarding the installation operation and troubleshooting of the `virgo pneumatic actuators please read these instructions carefully before operating the actuator warning · it is important that the actuator should only be used within the pressure limits indicated in our technical specifications · operating the actuator over pressure limits will damage internal parts as well as cause damage to the housing · operating the actuator over temperature limits will damage internal and external components disassembly of spring return actuator may become dangerous · operating the actuator in corrosive environments with incorrect protection may damage the internal and external parts · do not disassemble the individual spring cartridges disassembly may result in personal injury · isolate all airlines and make sure that actuator air connection is vented before installation or servicing of the actuator · do not remove end caps or disassemble the actuator while the actuator is pressurised · before installing onto a valve make sure that the rotation of the valve and the actuator are the same and that the position indicator orientation is also correct · if the actuator is in a system or used within safety devices or circuits the customer shall ensure that the national and local safety laws and regulations are observed 2 technical data operating media dry or lubricated air non-corrosive and inert gas or light hydraulic oil air supply 8 bar 116 psi maximum temperature standard -4 °f to 175°f 20°c to 80°c viton `o rings -4 °f to 300°f 20°c to 150°c siilicon `o rings -40 °f to 175°f 40°c to 80°c lubrication factory lubricated for the life of the actuator under normal conditions construction suitable for indoor and outdoor use external travel stops ±5° adjustment on 90° stroke 3 installation 1 ensure that the desired failure mode is correct refer to figure no 1,2 3 the `virgo actuator typically operates counter clockwise to open and clockwise to close it is possible to change this style of operation if the spring return actuator is not set up in the configuration desired follow the disassembly procedure section 5.2 reverse the orientation of the pistons then reassemble following the assembly procedure section 5.3 2 mount the actuator to the valve as per the desired orientation parallel or perpendicular to the pipeline 3 connect a regulated air supply to the npt fitting in the actuator housing caution the maximum operating pressure is 116 psi 8 bar 4 adjust the stroke adjustment bolts following assembly section 5.3.5 stroke adjustment bolts can be adjusted by up to ±5° 4 operation the `virgo actuators have simple operational characteristics port `a facing the ports and reading right to left is connected to the interior cavity between the pistons directing the airflow into/out of the interior cavity port `b is connected to the end cap cavities directing airflow into/out of the end cap area 4.1 double acting figure 1 air supplied through port `a forces the piston away from each other causing the pinion to rotate counter clockwise with exhaust air exiting through port `b air introduced through port `b forces the piston towards each other causing the pinion to rotate clockwise with exhaust air exiting through port `a 4.2 spring return 4.2.1 fail clockwise fcw standard scope of supply figure 2 air introduced through port `a forces the piston away from each other compressing springs and causing the pinion to rotate counter clockwise with exhaust air exiting through port `b upon loss /release of air pressure springs forces the piston towards center position causing pinion to rotate clockwise fcw with exhaust air exiting through port `a 4.2.2 fail counter clockwise fccw figure 3 air introduced through port `a forces the piston away from each other compressing springs and causing the pinion to rotate clockwise with exhaust air exiting through port `b upon loss /release of air pressure springs forces the piston towards center position causing pinion to rotate counter clockwise fccw with exhaust air exiting through port `a 5 maintenance 5.1 general `virgo actuator can be supplied with metric unc fasteners under normal operating conditions the actuator requires only periodic observation to ensure proper adjustment service kits are available to replace seals and bearings soft parts these parts are identified in figure 22 and listed in table 3 table 1 lists kit numbers table 1 actuator service kit 052 20.sk.052.xx.0 065 20.sk.065.xx.0 075 20.sk.075.xx.0 085 20.sk.085.xx.0 100 20.sk.100.xx.0 115 20.sk.115.xx.0 125 20.sk.125.xx.0 160 20.sk.160.xx.0 210 20.sk.210.xx.0 5.2 disassembly page 2 of 2

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installation operation maintenance manual 5.2.3 removal of stroke adjustment bolts 12 figure 6 when disassembly of the actuator is required for maintenance remove the actuator from the valve ensure proper lifting procedures are followed when moving or carrying actuators caution do not use m5 vde/vdi mounting holes for lifting the actuator when disassembling the virgo actuators use caution and be certain that the actuator is free from accessories and the air supply is disconnected when the actuator is a spring-return unit make sure that the actuator is in the failed position before disassembling 5.2.1 removal of local position indicator 28 figure 4 a remove both the stroke adjustment bolts 12 together with nut 13 and washer 14 replace the stroke adjustment bolts 12 in case of excessive wear observed on the bolt surface 5.2.4 end cap 02,03 disassembly figure 7 a b remove the counter sunk screw 29 if fitted remove the local position indicator 28 from the pinion 05 it may be necessary to pry gently with a screwdriver 5.2.2 removal of top cover plate 19 assembly figure 5 a remove the end cap bolts 15 in the sequence shown in the figure 7 caution when disassembling a spring return actuator the end cap 02,03 should be loose after unscrewing end cap bolts 15 4-5 turns if there is still force on the end cap bolt 15 this may indicate a damaged spring cartridge and any further disassembly should be discontinued further disassembly of the end caps may result in serious personal injury return the actuator to virgo for further maintenance b a b c remove the counter screws 17 remove the top cover plate 19 from the pinion with the help of knurling provided on top cover plate it may be necessary to pry gently with a screwdriver remove the top cover plate `o ring 20 and discard if replacing soft parts c for spring return actuators remove spring cartridges 26 remove end cap `o rings 24 and discard if replacing all soft parts 5.2.5 piston 04 disassembly figure 8 page 3 of 3

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installation operation maintenance manual when all components are disassembled those not being replaced should be properly cleaned and inspected for wear prior to reassembly 5.3 assembly prior to assembly ensure that all components are clean and undamaged it is recommended to use the lubricants as mentioned in table 2 table 2 recommended lubricants general use castrol grease ap3 5.3.1 pinion 05 assembly figure 10 a b hold the body 01 in a vice or similar device rotate the pinion 05 until the pistons 04 reach the end positions i.e the piston rack teeth disengages with pinion teeth caution air pressure should not be used to remove the pistons from the body clean and inspect the piston teeth for signs of wear replace pistons if wear seems excessive remove piston `o rings 23 piston guide band 07 discard the `o rings and guide band if replacing the soft parts 5.2.6 removal of pinion 05 cam 11 and bearings 08,09 figure 9 a b install the top and bottom bearings 08,09 and `o rings 21,22 onto the pinion 05 apply grease to the pinion bearings 08,09 shaft `o rings 21,22 using general-purpose grease listed in table 2 a b c d remove the circlip 25 using a circlip plier remove the cam retaining washer 31 cam 11 cam bearing 10 it may be necessary to pry gently to cam with a screwdriver observe the cam surfaces for excessive wear where the stroke adjustment bolts are resting and the cam id square c/s replace the cam if excessive wear is observed apply a downward force to top of the pinion 05 so that the pinion will move completely out of the bottom of the body 01 if the pinion 05 does not move freely gently tap with a plastic mallet remove the top and bottom bearings 08,09 and top and bottom `o rings 21,22 discard if replacing all soft parts c insert the pinion 05 into the body 01 from the bottom side ensure that bottom surface of the pinion should be around 0.5mm inside the body bottom face and the pinion top slot orientation is as shown in figure 11 5.3.2 piston 04 assembly figure 12 13 a b fit piston pad 06 piston guide band 07 piston o-rings 23 on the pistons 04 apply grease to the internal bore of the body 01 to the piston rack teeth using recommended general purpose grease listed in table 2 5.2.7 cleaning and inspection page 4 of 4

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installation operation maintenance manual c press the two pistons simultaneously in the body bore until the pinion racks are engaged and rotate the pinion until the stroke is completed take care that the pistons are oriented correctly as per the fail position of the actuator the standard fail action of actuator is fail clockwise refer fig 12 fig 13 to ensure that the piston 04 teeth are evenly engaged fully compress both the pistons inward and measure the distance from the edge of the body to the piston 04 face on each side shown as dimension `a in figure 13 if a different value is obtained on each side remove the pistons and repeat from step 2c d 5.3.4 cam 11 assembly figure 15 a b insert the cam bearing 10 and cam 11 ensure that the cam orientation is as shown in the figure 15 insert the circlip 25 using the circlip plier e temporarily install the local position indicator 28 onto the pinion 05 to determine whether the correct stroke is obtained ensure that the arrow in the local position indicator 28 will rotate a minimum of 5° beyond the 90° vertical centerline of the actuator body 01 and a minimum of 5° beyond the 0° horizontal centerline of the actuator body as shown in figure 14 if the proper stroke is not obtained remove the pistons and repeat from step 2c once proper stroke is obtained remove the local position indicator 28 · spring return actuators for spring return actuator insert the proper quantity of the spring cartridges 26 according to the pattern shown in fig 16 referring to the total number of springs insert the spring cartridges 26 as shown in fig 17 apply grease to the end cap `o rings 24 fit the `o rings 24 into the groove in each end cap 02,03 fit the plug · page 5 of 5

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installation operation maintenance manual transfer port 30 inside the body 01 on each side fit the end caps insert all the end cap bolts 15 and hand tighten complete tightening by following the sequence indicated in fig 18 c d when the correct clockwise position is obtained hold the adjusting bolt 12 stationary while tightening the nut 13 cycle the actuator to the counter-clockwise end of travel and measure to determine if the pinion top slot is in the proper position in most of the applications this will be parallel to 0 the actuator body i.e at 0 double acting actuators · apply grease to the end cap `o rings 24 fit the `o rings 24 into the groove in each end cap 02,03 fit the plug transfer port 30 inside the body 01 on each side fit the end caps 02,03 onto the body 01 verifying that the `o rings 24 remain in the groove insert all the end cap bolts 15 and hand tighten complete tightening by following the sequence indicated in fig 18 e if the pinion top slot is not in the correct counter-clockwise position turn the left stop adjustment bolt 12 in to reduce actuator travel or out to increase actuator travel when the correct counter-clockwise position is obtained hold the adjusting bolt 12 stationary while tightening the nut 13 · f 5.3.6 top cover plate assembly figure no 20 · paste the top cover plate gasket 18 to the top cover plate 19 by using suitable paste/solution · fit the `o ring 20 using grease inside the top cover plate · insert the top cover plate 19 onto the pinion 05 · fit the three counter sunk screws 17 on the cover plate 5.3.7 local position indicator assembly figure no 21 · · fit local position indicator 28 assembly onto the pinion 05 ensure that it indicates the correct actuator position tighten the counter sunk screw 29 to secure the local position indicator 5.3.8 actuator lock out arrangement for 052-100 models refer to fig no-23 24 · to lock the actuator at fully closed condition cycle the actuator to clockwise end of travel rotate the right stroke adjustment bolt out left stroke adjustment bolt completely in refer to fig no-23 · to lock the actuator at fully opened condition cycle the actuator to counter clockwise end of travel rotate the left stroke adjustment bolt out right stroke adjustment bolt completely in refer to fig no-24 for 115-270 models refer to fig no-25 26 · to lock the actuator at fully closed condition cycle the actuator to clockwise end of travel till the counter on the cam is inline with backside tapping rotate the right stroke adjustment bolt out insert the locking bolt from backside as shown in fig no 25 · to lock the actuator at fully open condition cycle the actuator to counter clockwise end of travel till the counter on the cam is inline with backside tapping rotate the left stroke adjustment bolt out insert the locking bolt from backside as shown in fig no 26 5.3.4 assembly of stroke adjustment bolts 12 a b insert the nut 13 washer 14 onto the stroke adjustment bolt screw in the bolts 12 into the body 01 5.3.5 external travel stop adjustment figure 19 the stroke adjustment bolt to the right controls the clockwise end of travel while to the left controls the counter-clockwise end of travel a cycle the actuator to the clockwise end of travel and determine if the pinion top slot is in the proper position in most of the applications this will be perpendicular to the 0 actuator body i.e at 90 b if the pinion top slot is not in the correct position turn the right stop adjustment bolt 12 in to reduce actuator travel or out to increase actuator travel page 6 of 6

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installation operation maintenance manual 5.4 mounting of insert following procedure gives a b guidelines for assembly disassembly of serrated pinion and serrated inserts drive by square head refer fig 27 a b drive by double `d flat head refer fig 28 a b reference standard din en iso 5211 2 guide insert removing tool 33 in cavity of insert 32 e.g double `d as shown in figure 29 o 3 turn insert removing tool by 90 through rod 35 and blow hammer 34 upward direction shown in figure 29 4 insert 32 will come out from pinion serration after hammer blow 5.4.2 assembly of insert on pinion 1 as per final output drive requirement match the insert 32 on pinion serration 05 two dots are provided on insert32 one on pinion 05 so that one can perfectly match double `d square drive properly see fig 27 a b fig 28 a b 2 for diagonal square drive make insert s 32 square diagonal i.e diagonal of square actuator axis should be inline see fig 27 b 3 after matching required output drive hammer insert by rubber mallet not shown in figure please follow above orientation for serrated insert and local position indicator as per your requirements 5.4.1 disassembly of inserts 1 mount appropriate insert removing tool 33 on rod 35 as shown in figure e.g for insert 30x22 double `d select insert removing tool of marking 30x22 page 7 of 7

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installation operation maintenance manual 6 storage all the `virgo actuators are factory lubricated for one million cycles under normal operating conditions the ports are plugged to prevent material from entering the actuator during the shipment if the actuators are not for immediate use the following precautions must be taken during storage a store in a dry environment b it is recommended that the actuator be stored in its original box c do not remove the plastic plugs on the air supply ports page 8 of 8

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installation operation maintenance manual elfor controls s.r.l virgo engineers limited via torino 3/5 277,hinjewadi phase ii 20039 varedo mi mulshi maan p iva 05232190966 pune 411057 tel +39.0362.554335 phone 91-2066744000 fax +39.0362.554357 e-mail sales@virgoengineers.com info@elforcontrols.it www.virgoengineers.com document path rev no 00 published on jan 2009 page 9 of 9

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