Johnson Controls MP8 20 Series User manual

SDI No.: 111 6138 050 E

Issue date: 01/2003

A 17

MP8xxxxx20 (MP8000)

Pneumatic Valve-Actuator

JCI Regelungstechnik GmbH

Westendhof 8 ♦D-45143 Essen

Tel.: +49(0)201-2400-0 ♦Fax: +49(0)201-2400-351

www.johnsoncontrols.com

General

These service and data information (in brief SDI)

are operating instructions and contain instructions

for the safe installation and operation of the

pneumatic actuator. Should difficulties occur,

during installation, which cannot be solved with the

help of this SDI please ask your supplier for further

information.

These SDI are in accordance with the relevant

safety standards and regulations of the EU. When

operating the positioner outside the Federal

Republic of Germany, it is the responsibility of the

control system administrator or operator to ensure

that valid national control standards are met. The

manufacturer maintains all rights for technical

changes and improvements at any time Operators

are to receive instructions in accordance with this

SDI.

Qualified personnel

These are persons conversant with the erection, installation, commissioning, operation and service of the

product and in possession of the respective qualifications through their activities and functions, e.g.:

• Instruction about and obligation to maintain adherence to all operative regional and factory-internal

directives and requirements, conditional to application.

• Training or instruction in accordance with standards of safety in maintenance and utilisation of adequate

safety- and protective equipment.

• Training in first aid, etc. (See TRB 700).

Application:

Diaphragm actuators in conjunction with control valves serve to regulate the flow of fluids in heating systems,

cooling systems and cold water systems. The stroke action distinguishes between direct or reverse action

actuators. Decreasing actuator air pressure allows the stem to be retracted by spring force. The term

“reversible actuator” means that it is possible to change the action of the actuator in-situ, with a conversion

kit. When converting the action of an actuator with hand wheel, the action of the hand wheel must be taken

into account. A pneumatic positioner (PR 10) can be used to regulate the stroke.

Valve and actuator application, are the responsibility of the control system administrator. Particular markings

on the valve with actuator such as flow directional arrow are to be observed.

Dry compressed air is an absolute requirement during usage in below zero temperatures!

Valve and actuator may be supplied as single units or as valve / actuator combinations, factory mounted and

tested.

Technical data

• Diaphragm area 160 cm2Stroke 13-mm • Diaphragm material EPDM

• Ambient temperature -4 to +80°C • Housing material Ck 10 (1.1121)

• Max. operating pressure 160 kPa • Stem material 9SMnPb36 (1.0737)

• Air quality requirements in accordance with DIN ISO 8573-1

• Air quality class: 3 – 2 – 3

2 111 6138 050 E

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Additional equipment

• Hand wheel

• Pneumatic positioner

• (2) end position indicators + 2kΩ-feedback potentiometer

Storage:

• Storage temperature -4°C to +80°C, dry and free of dirt.

• Do not damage the lacquer. The lacquer is a foundation intended only as a protection against corrosion

while in storage and during transport.

• In rooms where moisture or condensation are present use heating or a drying agent to maintain a

moisture-free atmosphere.

Transport:

• Transport temperature -4°C to +80°C.

• Protect against external forces (shock, vibration etc.).

• Do not damage the protective lacquer.

Air pressure (kPa) to close-off force (N)

Diaphragm

Area (cm2)

Stroke

(mm)

Spring range

(kPa)

Spring close-off

force (N) 120 140 160

20 – 50 320 1120 1440 1760

160 13 60 – 90 960 480 800 1120

Air supply connection:

The diaphragm actuator is equipped with a tube connection permitting connection with 4 x 6-mm plastic

tubing.

Mounting orientation

It is recommended that the valves be mounted

within 90° of the upright position, in an easily

accessible location.

Caution:

When mounting in an inclined to

horizontal position, the yoke

should be fitted such that the

stanchions are aligned vertically

one above the other as is

depicted.

O.K.

90° Max.

Caution:

Remember to take tubing temperature limits into account.

Stanchions

111 6138 050 E 3

A 19

Danger:

Safe operation of the valve is only ensured if the valve is installed, commissioned and

serviced by qualified personnel in compliance with warning references in this SDI. In

addition, the general installation and safety regulations for piping, installation construction

and the professional use of tools and safety equipment must be guaranteed. Observe

unconditionally during all work on the control valve. Ignoring this information may cause

physical or material damages.

Pre-installation precautions:

• Provide protection against adverse weather conditions, e.g. moisture; (otherwise use drying agent).

• Suitable protective action prevents damage.

Installation site information:

The valve installation site should be easily accessible and provide sufficient room for service and removal of

actuators. Manual shut-off valves should be located up and downstream of the control valve, to facilitate

service and repairs without drainage of the piping system. The control valve should preferably be installed in

vertical position with actuator installed in the upright position. Inclined to horizontal installation without

support is only permissible for actuators with a low specific weight.

The permitted actuator weight when installed in the horizontal position, relative to valve stem, without

additional support at site is:

7kg for DN 15 - 40

Pipes should be insulated to protect actuators against high temperatures; here sufficient room is to be left for

servicing the stem seal pack. For trouble free function of the control valve the pipe immediately upstream of

the valve should be straight for the length of at least 2x DN and the pipe immediately downstream for the

length of at least 6x DN.

Pipes should be insulated to protect actuators against high temperatures; here sufficient room is to be left for

servicing the stem seal pack. For trouble free function of the control valve the pipe immediately upstream of

the valve should be straight for the length of at least 2x DN and the pipe immediately downstream for the

length of at least 6x DN.

Actuator mounting and removal information:

The control valve is normally supplied complete with actuator. It is not permitted to remove or replace an

actuator on systems in operation, under operating temperature and pressure. For conversion or service, the

actuator mounting procedure should follow the actuator SDI.

During mounting procedure care should be taken NOT to rotate the plug with downward pressure.

The maximum valve operating force0 must be observed when replacing the actuator. This is:

2000N for DN 15 – 40

Commissioning:

• Prior to commissioning check information on material, pressure, temperature and flow-direction are

in conjunction with the installation piping system plan.

• Follow TRB 700.

• Impurities in the piping system and valves, such as dirt, welding beads etc. will cause the system to

leak.

• Prior to commissioning a new installation, or re-commissioning after repairs or service, ensure that:

 Correct installation- and assembly work has been completed.

 Only qualified personnel carry out commissioning.

 Correct functional position of the valve is ascertained.

 Maintenance of existing protective facilities is carried out

4 111 6138 050 E

A 20

Abbreviations:

DA Actuator:

Actuator stem extends (spring-return up).

RA Actuator:

Actuator stem retracts (spring-return down).

Single item delivery

DA and RA actuator construction details.

• Screw the stem extension as far as possible into the actuator stem.

• Always: Pull the valve stem up to connect to DA actuators.

Push the valve stem down to connect to RA actuators.

• Place the actuator with yoke onto the valve bonnet and tighten the ring nut.

• Connect the air supply and impinge the diaphragm with initial start pressure (see table below).

Spring range Impinging pressure

[kPa]

Operating pressure

[kPa]

20 - 50 20 50

60 - 90 60 90

• Unscrew the stem extension until it abuts the valve stem; observe the machined surfaces (see fig

below).

• Fit the coupler.

• Fix the stroke position indication plate.

• Fit other accessories e.g. positioner, position feedback indicator etc in accordance with the device by-

pack.

Replacing the actuator and changing the DA or RA mode

• Remove accessories e.g. positioner, position feedback indicator etc.

• Remove cover when fitted and remove the hand wheel assy. in accordance with paragraph Fitting and

removing DA hand wheel.

• Remove coupler.

• Remove ring nut.

• Remove the actuator

• When replacing the actuator observe paragraph Single item delivery

• When changing the action mode, remove the yoke by removing the 4 bolts. Turn the actuator body

upside down (180°) refit the yoke to the new position i.a.w. paragraph Single item delivery. When

necessary, refit the hand wheel i.a.w. Fitting and removing DA hand wheel.

Machined surfaces

Note:

The pressure equipment directive (PED) and also the VDI/VDE 2174

from October 1967 for pneumatic actuators, have been observed

111 6138 050 E 5

A 21

Fitting and removing DA hand wheel.

To fit carry out the following sequence

1. Remove cover.

2. Screw the four spacer-studs (1) into actuator casing and place cover (11) in position.

3. Position the bearing (3) on the threaded spindle (4) as in diagram.

4. Now place the plate (2) and then the lock washer (5) on to the spindle and align the holes with the holes

in the hand-wheel (6), then, fix with spring dowel (7).

5. Place O-ring (9) into the plate (2) groove.

6. Screw in the threaded bush (8) until it hits the stop (don’t forget to grease).

7. Fit the pre-assembled unit onto spacer-studs (1) so that the threaded bush (8) is guided by the

spacer-studs (1), also the cap fits into the plate (2) groove with O-ring (9).

8. Fasten the assembly onto the spacer-studs (1) with Allen screws (10).

9. Fix ID Plate on cover (11)

Test for trouble free function by operating the hand-wheel manually through one full stroke

To remove follow the procedure in reverse

Caution:

To ensure correct function during operation the hand

wheel must be turned anti-clockwise till it hits the stop.

Caution:

It is necessary to grease the threaded bush (8) and threaded

spindle (4). With the grease (in tube) provided.

6 111 6138 050 E

A 22

Hand wheel DA

MP822

( M = 10Nm )

111 6138 050 E 7

A 23

Fitting and removing RA hand wheel.

To fit carry out the following sequence

1. Remove cover.

2. Screw the four spacer-studs (1) into actuator casing.

3. Remove transport lock from threaded bush (2). Push the Allen key through the threaded bush into the

7/16th UNF bolt (X) and connect to actuator stem. Ensure that the threaded bush (2) is guided by the

spacer-bolts (1).

4. Connect the hand wheel (4) to the threaded spindle (3) with the spring dowel (5)

5. Position the bearing (6) in the plate bore (7) as in diagram.

6. Place the hand wheel (4) with the threaded spindle (3) through the plate (2) as in diagram.

7. Place the corrugated washer (8) and washer (9) onto the threaded spindle (3). Carefully fit the circlip

(10).

8. Place O-ring (11) into the plate (7) groove.

9. Place the cover (12) onto the actuator.

10. Screw the (don’t forget to grease) threaded spindle (3) into the threaded bush (2) until it the plate (7) lays

on the cover and the spacer-studs (1). Observe that the cover (12) fits into the plate (7) groove with O-

ring (11).

11. Fasten the assembly onto the spacer-studs (1) with Allen screws (13).

12. Fix ID Plate on cover (12)

Test for trouble free function by operating the hand-wheel manually through one full stroke

To remove follow the procedure in reverse.

Caution:

To ensure correct function during operation the hand

wheel must be turned clockwise till it hits the stop.

Caution:

It is necessary to grease the threaded bush (2) and threaded

spindle (3). With the grease (in tube) provided.

8 111 6138 050 E

A 24

Hand wheel RA

MP832

( M = 10Nm )

( M = 40Nm )

111 6138 050 E 9

A 25

To replace the hand-wheel gasket of a direct action device (DA):

• Remove the hand-wheel assembly and cap. For refit see: Fitting and removing hand wheel.

• Remove the circlip, then the nylon spacer and replace the gasket.

• Refit nylon spacer and circlip then refit hand-wheel etc.

To replace the hand-wheel gasket of a reverse action device (RA):

Condition: The actuator is in-situ.

• Remove actuator as in paragraph: Replacing the actuator and changing the DA or RA mode.

• Replace the gasket as in paragraphs To replace the hand-wheel gasket of a direct action device (DA)

• For refit, carry out in reverse order.

Replacing the diaphragm of a Direct Action or Reverse Action device:

• Remove the hand-wheel assembly and cap. For refit see paragraphs:Fitting and removing hand wheel.

• Remove the nuts and bolts around the circumference of the actuator.

• Remove the housing top half.

• Slowly unscrew the spindle and remove the pressure disc.

• Carefully! Replace the diaphragm.

• Reassemble and refit the actuator.

Pressure disc

Stem

Housing top half

Diaphragm

Caution:

The replacement gasket must be greased before use. Use

only silicone free lubricants.

10 111 6138 050 E

A 26

Removing the control valve (valve with actuator)

Additional to the general installation guidelines and the TRB 700, the following

points must be observed:

• Pressure free pipe system

• Sufficiently cooled fluid

• Drained system

• Sufficiently ventilated pipe system where aggressive and corrosive fluids are

concerned

• Only qualified personnel are to be allowed to carry out installation.

Tools and spares

MP8x2

Ring nut wrench: 111 6235 010

For gasket and diaphragm

replacement:

Circlip Pliers 111 5330 010

Lubricant:

Silicone free actuator grease (60g tube) 111 5520 010

Repair kits:

Diaphragm MP8000-6325

Gasket 02-857-23

Ring nut wrench

Accessories: Order No. Weight

Pneumatic positioner (PR10) PY - 1010 – 3000 1.0kg

(2) auxiliary switches and 2kΩ(ER2) PQ - 1000 – 3020 1.0kg

Universal accessory kit PQ - 2713 – 3011 0.4kg

(Every accessory device requires an accessory kit)

Hand wheel retro-fit kits Order No. Weight

Hand wheel DA (for MP822...) 111 6128 011 2.0kg

Hand wheel RA (for MP832...) 111 6129 011 2.4kg

Device code:

MP8 20

Action mode Accessories

Direct Acting = 2

0 = Standard

Reverse Acting = 3

2 = (2) aux. switches and 2kΩposition feedback

Stroke Positioner+handwheel

13 mm = 2

5 = None

6 = DA (PY1010)

7 = RA positioner (PY1010) + hand wheel

Spring range

8 = Hand wheel

20 – 50 kPa = C

60 –90 kPa = E

Danger

This manual suits for next models

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