CVS Rack and Pinion Pneumatic Actuator
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1 CVS Rack and Pinion Pneumatic Actuator Product Manual INTRODUCTION These instructions apply specifically to the CVS Rack and Pinion pneumatic actuator. This manual provides maintenance, operation, installation, and parts ordering information. These actuators may be equipped with valve bodies, ball valves and accessories. Please refer to the appropriate instruction manuals. The CVS Rack and Pinion Actuator has been designed, developed and tested utilizing the latest technology, and materials. This design is a rugged, reliable, high quality performer. The materials used allow for excellent corrosion protection and is NACE compliant. This design matches up to the latest global specifications; Full conformance to the latest specifications: ISO 5211, DIN 3337 and VDI/VDE 3845 NAMUR for product interchangeability and easy mounting of solenoids, limit switches and other accessories. CONSTRUCTION The CVS Rack and Pinion Pneumatic Actuator is constructed of an extruded aluminum body, with both internal and external corrosion protection. This design utilizes a dual piston rack and pinion for compact construction, symmetrical mounting, high cycle life, and fast operation. Reverse rotation can be accomplished in the field by simply inverting the pistons. Two independent external travel stop adjustments permit an easy and precise adjustment of +/-4 in both the open and closed positions for accurate valve alignment. Universal and anti-blowout patented drive shaft with easy conversion from parallel to diagonal square and vice versa. This feature permits a lower and more flexible stock. Figure 1. CVS Rack and Pinion Actuator A compact design with identical body and end caps for double acting and spring return models. This reduces inventory and allows for field conversion, by adding or removing the modular spring cartridge. These units come furnished with a multi-function position indicator with NAMUR slot. This slot aids as a visual indicator, allowing for easy installation, accommodates all accessories, and the most popular sensors. Multiple bearings with guides on racks and pistons for precise operation, low friction, and high cycle life. Modular preloaded spring cartridge design with coated springs for simple versatile range, greater safety and corrosion resistance. Fully machined teeth on piston rack and pinion allows for minimum backlash and pinion engagement for maximum efficiency. Electroless nickel plated blowout resistant bearing guided one-piece pinion for improved safety and maximum cycle life. High quality bearings and seals were selected for low friction, high cycle life and a wide operating temperature range. Internal and external stainless steel fasteners provide long term corrosion resistance.
2 QUALITY MANUFACTURING The CVS Rack and Pinion actuator is manufactured under a quality system independently assessed and approved to ISO 9001: ISO 5211, DIN 3337 and VDI/VDE 3845 NAMUR. Every actuator is factory tested and provided with a serial number for traceability. Each actuator is packed in a special cardboard carton with a full description of the product for easy identification. AVALIABLE ACCESSORIES Connector Brackets Couplings Solenoid valves Switch boxes Proximity sensors Gearboxes Positioners SPECIFICATIONS Position indication: The Actuator/Valve position is shown via a color-coded insert and NAMUR slot. The indicator is suitable for either direction of actuator rotation, and drive shaft size. Actuator drive: The NAMUR drive slot on the position indicator permits direct drive engagement of switch boxes and positioners. Direct mounting of sensors: The indicator can be supplied with metal inserts to allow for easy installation of many types of sensors. Operating media: Dry or lubricated air or inert/non-corrosive gases on condition that they are compatible with wetted internal actuator parts and lubricant. The operating media dew point must equal either -20 C (-40 F) or 10 C below the ambient temperature. The maximum particle size must not exceed 30 microns. Supply pressure: For Double Acting and Spring Return actuators the maximum supply pressure is 8 bar (116 psi). The minimum supply pressure is 2.5 bar (36 psi). Operating Temperature: Low temperature (LT) actuator with nitrile O-rings from 50 C(-58 F) to +80 C(+176 F) High temperature (HT) actuator with FPM O-rings from -15 C(+5 F) to +150 C(+300 F). CAUTION: For high and low temperature service special grease is required. High and low temperature will vary the output torque of the actuator. Please contact a CVS sales representative for each application. Stroke: The stroke of the CVS rack and pinion actuators is as follows (see technical data): Standard construction: 90 rotation with stroke adjustment at 0 and 90 ± 4 Operating time: See Technical Data sheet Lubrication: The CVS Rack and Pinion Actuator comes factory lubricated for the life under normal operating conditions. The standard lubricant is suitable for use from 50 C (-58 F) +80 C (+176 F). For high and low temperature service where special grease is required please contact a CVS sales representative. Construction: Durable twin piston rack and pinion actuator design is suitable for both indoor and outdoor applications. Protection and Corrosion resistance: Actuators are supplied with corrosion protection for normal environments. For severe duties contact your CVS sales representative. OPERATING FUNCTION and DIRECTION OF ROTATION: The standard rotation is clockwise to close; counter-clockwise rotation is achieved when port 2 is pressurized. For an actuator marked LF the rotation is counter-clockwise, clockwise rotation is obtained when port 2 is pressurized. 2
3 Double Acting (standard rotation) TOP View: 1. Air supplied to port 2 forces the pistons to separate and move toward the end caps, with the exhaust air exiting at port 4, a counterclockwise rotation is achieved. 2. Air supplied to port 4 forces the pistons together with exhaust air exiting at port 2, a clockwise rotation is achieved. Single Acting (standard rotation) TOP View: 1. Air supplied to port 2 forces the pistons apart and toward the actuator end caps, compressing the springs, the exhaust air exits though port 4, a counter clockwise rotation is achieved. 2. A loss of air pressure (air or electric failure) at port 2 will allow the springs to force the pistons together exhausting air through port 2, a clockwise rotation is achieved. 3 Product Manual: Electro-Pneumatic Positioner YT-1000L In spring return applications the output torque is obtained in two different operations as shown in fig 2 and 3 (following page), each operation produces two different values in relation to the stroke position (0 or 90 ). For spring return actuators the output torque is produced by multiplying the force (air or springs acting on the pistons) by the lever arm. First condition (fig 2, following page): The output torque is generated by supply air pressure at port 2 after compressing the springs; this is called Output Torque Air Stroke. In this case the air forces the pistons from the 0 to the 90 position and consequently the torque starts at a high value and during the stroke it continually decreases until 90 due to the natural force the springs generate (oppose) when they are compressed (see diagram C) Second condition (fig 3): The output torque is generated by the force the springs release onto the pistons when air fails; this is called Output Torque Spring Stroke. In this case the torque, starting from the 90 position, continually decreases until 0 because the spring extends (see diagram D). The CVS spring return actuator is designed to produce a balanced torque in the two conditions explained above when the number of springs per side is equal to the air pressure supply (4 bar-4 springs each side) as shown in diagram E. For specific applications it is possible to achieve (where desired) the unbalanced torque as shown in diagram F, by changing the relation between the number of springs per side and air pressure supply in bar (for example 6 springs and 5.5 bar or vice versa). In spring return applications two conditions can be achieved: air failure to close or failure to open. The suggested safety factor for spring return actuators in normal working conditions is 25%. Sizing example of AT Spring Return actuator (see also technical data): 1. Spring to close (when air fails) 2. Published ball valve torque in.lbs 3. Safety factor (25%)=708 in.lbs +25%=885 in.lbs 4. Air supply pressure available = 80 psi 5. The spring return CVS actuator selected is: CVS125SR10 because it produces the following values:
4 A. Spring stroke at 0 =930 in.lbs B. Spring stroke at 90 =1459 in.lbs C. Air stroke 0 =1772 in.lbs D. Air stroke 90 =1246 in.lbs (see diagram G) PRODUCT SPECIFICATION CVS 1. Product Code 2. Model 3. Type A. DA (Double Acting) B. SR (Spring Return) 4. Operating Temperature PARTS ORDERING Each Rack and Pinion Actuator is assigned a serial number, which can be found on the front of the actuator. Refer to this serial number when contacting your CVS Controls representative. When ordering replacement parts, specify the serial number, key number, and part description from the following Parts Lists REPAIR KITS Recommended spare parts are available as complete kits. 1. Normal Temperature (NT): -20 C to +80 C 2. Low Temperature (LT): -50 C to +80 C 3. High Temperature (HT):-15 C to +150 C Example: 1. CVS 88SRLT = CVS Model 88 Spring Return, Low Temperature DIAG. G 1522 in.lbs 1460 in.lbs 929 in.lbs 991 in.lbs SPRING STROKE (OUTPUT TORQUE) DIAG. D BALANCED TORQUE DIAG. E Air Stroke UNBALANCED TORQUE DIAG. F Air Stroke 850 in.lbs 443 in.lbs 682 in.lbs 566 in.lbs Spring Stroke Spring Stroke Spring Stroke Safety Factor Torque In.lbs. Torque In.lbs. Torque In.lbs. Torque In.lbs. 0 Actuator Rotation 90 0 Actuator Rotation 90 0 Actuator Rotation 90 0 Actuator Rotation 90 Closed Valve (air failure) Open Valve 4
5 Figure 2. CVS Rack and Pinion Actuator Assembly *9 Dimensional Data See Table 2 5
6 TABLE 1 Part # Spare Parts Qty Description Std. Material Corrosion Resistant 1 Optional Material OCTI-CAM (Stop 1 1 Arrangement) SS (B) Capscrew SS Washer SS Nut (Stop Screw) SS * O 2 Bearing (Piston Back) Polyphthalamide * O 1 Bearing (Pinion Top) Nylon * O 1 Bearing (Pinion Bottom) Nylon * O 2 Thrust Bearing (Pinion) Polyphthalamide * O 2 Plug Nitrile (NBR) - - FPM Silicon 10 1 Thrust Washer SS * O 2 O-ring (Stop Screw) Nitrile (NBR) - - FPM Silicon 12 2 Piston Guide Polyphthalamide+GF (3) Capscrew (End Cap) SS * O 2 O-ring (End Cap) Nitrile (NBR) - - FPM Silicon 15* O 2 Bearing (Piston Head) Polyphthalamide * O 2 O-ring (Piston) Nitrile (NBR) - - FPM Silicon Spring (Cartridge) High Alloy Spring Steel FPM Silicon 18 1 Spring Clip (Pinion) High Alloy Spring Steel Nickel Plated SS 19 1 Position Indicator Polpropylene+GF * O 1 O-ring (Pinion Bottom) Nitrile (NBR) - - FPM Silicon 21* O 1 O-ring (Pinion Top) Nitrile (NBR) - - FPM Silicon 30 (D) 1 Right End Cap Die Cast Aluminum Alloy Polyester Coated (D) 1 Left End Cap Die Cast Aluminum Alloy Polyester Coated Capscrew (Indicator) SS Piston Die Cast Aluminum Alloy Anodized Actuator I.D. Label Polyester-Aluminum End Cap Label Polyester-Aluminum Spigot (Upon Request) Extruded Aluminum Alloy Alodur Body Extruded Aluminum Alloy Alodur Drive Shaft Steel Alloy Nickel Plated SS- Notes: For other protection levels contact your CVS Sales Representative For models CVS115 and bigger the OCTI-CAM material is cast iron For model CVS265 and Model CVS300 the capscrews are 12 pieces For models CVS and bigger the two end caps are symmetrical * - Suggested Spare Parts O - Parts included in spare parts kit Parts included in O-ring Kit 6
7 DIMENSIONS: CVS50 - CVS265 7
8 TABLE 2 - External Dimensions CVS50 - CVS265 (INCHES) Dim. CVS50 CVS63 CVS75 CVS88 CVS100 CVS125 CVS145 CVS160 CVS180 CVS200 CVS240 CVS265 A B C D M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 E F G H I 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 3/8" 3/8" J K L M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M6 M6 M N P R S T Q Q W M5 M6 M6 M6 M8 M8 M10 M10 M16 M16 M20 M20 W1 - - M8 M8 M10 M10 M12 M X X ISO5211 F04 F05 F05/F07 F05/F07 F07/ F10 F07/F10 F10/F12 F10/F12 F14 F14 F16 F16 Z DIMENSIONS: CVS300 - CVS1000 Z D,E S C B Q W,X 8
9 TABLE 2 - External Dimensions CVS300 - CVS1000 (INCHES) Dim. CVS300 CVS350 CVS400 CVS500 CVS600 CVS700 CVS800 CVS900 CVS1000 IS05211 F16 F16 F25/F16 F30 F35 F40 F40 F48 F48 A B C D M5 M5 M5 M5 M5 M5 M5 M5 M5 E F G H I 1/2 1/2 1/2 1" 1" J K L M6 M6 M M N P Q Q R S T W M20 M20 M16 M20 M30 M36 M36 M36 M36 W1 - - M X X Z TECHNICAL DATA TABLE 3 - Test Data Model Piston Diameter (in) Travel 1 /Turn Air Volume OPEN (In 3 ) Air Volume CLOSED (In 3 ) OPEN Time (Seconds) CLOSED Time (Seconds) WEIGHT (Lbs) SR DA SR DA SR DA CVS /6 Turn CVS /6 Turn CVS /6 Turn CVS /5 Turn CVS /5 Turn CVS /5 Turn CVS /5 Turn CVS /4 Turn CVS /4 Turn CVS /4 Turn CVS /4 Turn CVS /4 Turn The above data was obtained using the following test conditions: Room Temperature, 90 Actuator Stroke, Solenoid Valve with a 5/32ø (4mm) Orifice and a flow capacity of 105gpm (400 L/min), Inside Pipe Diameter = 5/16ø (8mm), Clean Air, Supply Pressure (Air) = 79.8psi (5.5 bar), Actuator without external loading CAUTION: When one or more of the above parameters are different, the moving time may vary slightly. 9
10 TABLE 4 - Spring & Torque Ratings: Tables 4, 5, 6, & 7 Spring Return Torque Ratings (in.lbs) Supply Press. 40psi 50psi 60psi 70psi 80psi 90psi 100psi 110psi 116psi Model Spring CVS50SR CVS63SR CVS75SR CVS88SR CVS100SR Spring Stroke Start End Start End Start End Start End Start End Start End Start End Start End Start End Start End S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
11 TABLE 5 Spring Return Torque Ratings (in.lbs) Supply Press. 40psi 50psi 60psi 70psi 80psi 90psi 100psi 110psi 116psi Model Spring Spring Stroke Start End Start End Start End Start End Start End Start End Start End Start End Start End Start End S S S S CVS125SR S S S S S S S S CVS145SR S S S S S S S S CVS160SR S S S S S S S S CVS180SR S S S S
12 Spring Return Torque Ratings (in.lbs) Supply Press. 40psi 50psi 60psi 70psi 80psi 90psi 100psi 110psi 116psi Model Spring CVS200SR CVS240SR CVS265SR TABLE 5 Spring Stroke Start End Start End Start End Start End Start End Start End Start End Start End Start End Start End S S S S S S S S S S S S S S S S S S S S S S S S ** PLEASE NOTE: FORMAT CHANGE Spring Return Torque Ratings (in.lbs) Supply Press. 36psi 44psi 51psi 58psi 65psi 73psi 80psi 87psi 102psi 116psi Spring Stroke S CVS300SR CVS350SR CVS400SR S S S S S S S S S S S S S S S S S S S S
13 ** PLEASE NOTE: FORMAT CHANGE TABLE 6 Spring Return Torque Ratings (in.lbs) Supply Press. 36psi 44psi 51psi 58psi 65psi 73psi 80psi 87psi 102psi 116psi Spring Stroke CVS1000SR CVS900SR CVS800SR CVS700SR CVS600SR CVS500SR S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
14 TABLE 7 Double Acting Torque Ratings (in.lbs) Model 40psi 50psi 60psi 70psi 80psi 90psi 100psi 110psi 116psi CVS 50DA CVS 63DA CVS 75DA CVS 88DA CVS 100DA CVS 125DA CVS 145DA CVS 160DA CVS 180DA CVS 200DA CVS 240DA CVS 265DA Double Acting Torque Ratings (in.lbs) Model 36psi 44psi 51psi 58psi 65psi 73psi 80psi 87psi 102psi 116psi CVS 300DA CVS 350DA CVS 400DA CVS 500DA CVS 600DA CVS 700DA CVS 800DA CVS 900DA CVS 1000DA
15 NOTES: 15
16 Head Office Street Edmonton, Alberta, Canada T6E 0A5 Office: (780) Fax: (780) Calgary Sales Office 205, Avenue NE Calgary, Alberta, Canada T2E 6Z3 Office: (403) Fax: (403) Website: Printed in Canada Rev 2, Mar 08 16
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