| Вид документа | Інструкція з монтажу |
|---|---|
| Виробник | JCI |
| Код документа | mp8000-6325-and-mp8000-6350-diaphragm-and-seal-kits-for-mp8000-series-actuators |
| Група обладнання | MP8000-6012 Diaphragm and Seal Repair Tool Kit |
| Сторінок | 8 |
| Мова документа | англійська |
| Розмір файлу | 0.1 МБ |
О чём документ
Инструкция по ремонту пневматических пружинных приводов серии MP8000 (MP82–MP87) с помощью сменных комплектов мембран и уплотнений MP8000-6325 и MP8000-6350. Описан состав каждого комплекта, необходимый инструмент и пошаговые процедуры замены мембраны и уплотнения с последующей установкой привода на клапан. Пригодится сервисным специалистам при восстановлении герметичности и хода привода.
Ключевые характеристики
| Параметр | Значение |
|---|---|
| Комплект MP8000-6325 | для приводов MP82 и MP83: уплотнение 5/8 in. I.D. × 7/8 in. O.D. × 1/8 in., пластиковая втулка 41/64 in. I.D., мембрана эффективной площадью 25 sq in. |
| Комплект MP8000-6350 | для приводов MP84, MP85, MP86, MP87: уплотнение 5/8 in. I.D. × 7/8 in. O.D. × 1/8 in., пластиковая втулка 41/64 in. I.D., мембрана эффективной площадью 50 sq in. |
| Расход комплектов | для ремонта MP86 и MP87 требуются два комплекта MP8000-6350 |
| Специальный инструмент | MP8000-6012 — ремённый ключ, ключ для штока, шестигранник 7/16 in. |
| Момент затяжки штока | 144…168 lb·in (16…19 N·m) |
| Момент затяжки фланцевых болтов | 115…125 lb·in (13…14 N·m), крест-накрест |
| Момент затяжки болта штока привода | 95…105 lb·in (11…12 N·m) |
| Давление для страгивания уплотнения/проверки | 15 psig (103 kPa); проверка после монтажа — до 20 psig (138 kPa) |
Что внутри документа
- Состав комплектов MP8000-6325 (MP82/MP83) и MP8000-6350 (MP84–MP87).
- Перечень необходимого инструмента, включая ремённый и динамометрический ключи.
- Процедура замены уплотнения и мембраны для приводов MP82 и MP84 (spring-return-up).
- Процедура замены для двухподовых приводов MP86 (и MP87) с двумя комплектами MP8000-6350.
- Снятие привода с клапана и обратный монтаж для приводов MP83, MP85, MP87 (spring-return-down).
- Иллюстрации компонентов MP84, MP86 и привода spring-return-down.
- Предупреждения: не повреждать шток и уплотнение, фиксировать шток ключом при затяжке.
Быстрый старт
- Снимите подачу воздуха к приводу; при наличии снимите защитный кожух штока.
- Снимите E-кольцо съёмником стопорных колец; подайте медленно 15 psig (103 kPa) на вход — привод стронется и ослабит уплотнение с тефлоновой шайбой.
- Снимите тефлоновую шайбу и уплотнение (шайбу сохраните), отверните восемь фланцевых болтов и снимите верхний корпус.
- Замените мембрану и латунную шайбу, затяните шток моментом 144…168 lb·in (16…19 N·m), фланцевые болты крест-накрест — 115…125 lb·in (13…14 N·m).
- Наденьте пластиковую втулку и новое уплотнение (канавкой к приводу), сняв втулку так, чтобы уплотнение осталось на штоке; установите тефлоновую шайбу и E-кольцо.
- Подайте 15 psig (103 kPa) для проверки хода; при некорректном ходе повторите процедуру установки уплотнения.
- Для MP86/MP87 используйте два комплекта MP8000-6350 и обработайте оба пода.
Частые вопросы
- Какой комплект нужен для моего привода?
- MP8000-6325 — для MP82 и MP83 (мембрана 25 sq in.); MP8000-6350 — для MP84, MP85, MP86 и MP87 (мембрана 50 sq in.). Для MP86 и MP87 нужны два комплекта MP8000-6350.
- Какое давление подать, чтобы ослабить уплотнение перед заменой?
- Медленно подайте 15 psig (103 kPa) на вход привода — он стронется и ослабит уплотнение и тефлоновую шайбу. Затем давление нужно снять.
- С какими моментами затягивать шток и фланцевые болты?
- Шток — 144…168 lb·in (16…19 N·m), фланцевые болты — 115…125 lb·in (13…14 N·m) крест-накрест, болт штока привода при монтаже на клапан — 95…105 lb·in (11…12 N·m).
- Почему нельзя царапать шток при замене уплотнения?
- Повреждение (риски) штока приведёт к утечкам — в инструкции это выделено как важное предупреждение.
- Каким инструментом удерживать шток при затяжке?
- Используйте ключ для штока из комплекта MP8000-6012: он надевается на шток над разъёмом, где есть две плоские грани. Вращение штока при затяжке может сморщить мембрану и ухудшить работу привода.
- Какие ключи нужны для антиротационного штифта и гаек?
- Штифт на MP82/MP83 — ключ 3/16 in., на MP84–MP87 — 1/4 in.; контргайки 1/4 in. на MP82/MP83 — ключ 7/16 in., контргайки 3/8 in. — 9/16 in., болт штока и гайки 3/8 in. на MP84–MP87 — 5/8 in.
Текст документа
MP8000-6325 and MP8000-6350 Diaphragm and
Seal Kits for MP8000 Series Actuators
Contents of the MP8000-6325 Diaphragm and Seal Kit for MP82 and
MP83 Actuators
• One seal, 5/8 in. Internal Diameter (I.D.) x 7/8 in. Outside Diameter (O.D.)
x 1/8 in.
• One plastic sleeve, 41/64 in. I.D.
• One diaphragm, 25 sq in. effective area
Contents of the MP8000-6350 Diaphragm and Seal Kit for MP84,
MP85, MP86, and MP87 Actuators
• One seal, 5/8 in. I.D. x 7/8 in. O.D. x 1/8 in.
• One plastic sleeve, 41/64 in. I.D.
• One diaphragm, 50 sq in. effective area
Note: Two MP8000-6350 kits are needed to repair MP86 and MP87 actuators.
Tools Required
• MP8000-6012 Diaphragm and Seal Repair Tool Kit:
- Strap wrench (polyester strap and strap handle)
- Stem wrench
- 7/16 in. hex tool
• Retaining ring pliers
• 3/8 in. ratchet wrench
• 7/16 in., 10 mm, and 13 mm sockets
• 7/32 in. Allen wrench
• 200 lb·in torque wrench with socket to fit a 7/16 in. hex
• 3/16 in. open-end wrench for anti-rotation pin on the MP82 and MP83
• 1/4 in. open-end wrench for anti-rotation pin on MP84, MP85, MP86 and
MP87 actuators
• 7/16 in. open-end wrench for 1/4 in. jam nut on MP82 and MP83 actuators
• 9/16 in. open-end wrench for the 3/8 in. jam nuts on the MP82 and MP83
• 5/8 in. open-end wrench for stem bolt and 3/8 in. jam nuts on MP84, MP85,
MP86, and MP87 actuators
• 3/8 in. open-end wrench for the flange bolts
© 2000 Johnson Controls, Inc. 1
Part No. 14-1161-33, Rev. — Printed in U.S.A.
Seal and Diaphragm Repair Procedure for MP82 and MP84
Spring-Return-Up Actuators
Refer to Figure 1 and proceed as follows:
E-ring
Teflon Washer
Seal
Stem
Brass Washer
Upper Diaphragm
Housing
Flange
Bolts
Pneumatic
Input
Lower
Housing
Figure 1: Components of the MP84 Actuator
1. Remove air pressure input to the actuator.
Note: If the optional stem cover is present, remove it.
2. Remove the E-ring with the retaining ring pliers and set aside.
3. Apply 15 psig (103 kPa) slowly to the actuator input. The actuator will
stroke, which will loosen the seal and Teflon® washer.
4. Remove the air pressure from the actuator.
5. Remove the Teflon washer and seal, and retain the washer. (The second
stainless steel washer below the seal should remain on the stem.)
IMPORTANT: Be careful not to score the stem or leakage may result.
6. Remove the eight flange bolts from the top actuator housing, using a
7/16 in. socket and 3/8 in. ratchet and 3/8 in. open-end wrenches.
7. Lift off the upper housing. (The stainless steel washer should remain with
the housing.)
8. Roll the diaphragm to the top of the piston.
2
9. Use the strap wrench and the 3/8 in. ratchet wrench to hold the piston in
place.
Note: To prevent the strap handle from scratching the piston, wrap the strap
around the piston once before inserting the end of the strap into the
handle.
10. Insert the 7/16 in. hex tool into the top of the stem, and use the
7/16 in. open-end wrench to remove the stem.
11. Remove the brass washer and the diaphragm.
12. Install the new diaphragm and the brass washer, making sure the
diaphragm O-ring seal bead is against the piston.
13. Use the strap wrench and 3/8 in. ratchet wrench to hold the piston in place.
1. Insert the 7/16 in. hex tool into the top of the actuator stem and tighten the
stem between 144 and 168 lb·in (16 and 19 N·m), using the torque wrench.
15. Roll the diaphragm back into place over the piston.
16. Replace the upper housing and the stainless steel washer, and tighten the
flange bolts in a cross pattern between 115 and 125 lb·in (13 and 14 N·m),
using the torque wrench.
17. Place the plastic sleeve over the stem, and slide the new seal over the
sleeve (both supplied in the kit).
Note: Make sure the groove side of the seal is facing the actuator.
18. Hold the seal on the stem, while pulling the plastic sleeve off the stem, so
the seal remains on the stem.
IMPORTANT: Be careful not to damage the seal on the flats located on the
upper part of the stem.
19. Install the Teflon washer on the stem.
20. Place the plastic sleeve over the stem, and push down firmly to seat the
washer and seal.
21. Install the E-ring, using the retaining ring pliers.
Note: If the E-ring cannot be installed, the seal is not completely seated.
Repeat Step 20.
22. Apply 15 psig (103 kPa) to stroke the actuator and to ensure the air seal is
properly installed. If the actuator does not stroke correctly, repeat Steps 2
through 4 and 20 through 22.
23. If the actuator has the optional stem cover, install it now.
3
Seal and Diaphragm Repair Procedure for MP86 Spring-Return-Up
Actuators
Two MP8000-6350 Seal Kits are required for the MP86 and MP87 actuators.
Refer to Figure 2 and proceed as follows:
E-ring
Teflon Washer
Seal
Stem
Brass Washer
Upper
Diaphragm
Upper
Housing
Upper
Flange Pod
Bolts
Flare
Nut
Upper Tubing
Piston Lower
Lower Diaphragm
Housing
Upper
Housing Pneumatic
Input
Lower
E-ring, Pod
Teflon Washer,
and Seal
Lower Lower
Housing Piston
Figure 2: Components of the MP86 Actuator
1. Remove the air pressure input to the actuator.
Note: If the optional stem cover is present, remove it.
2. Unscrew the flare nut from the copper tubing at the upper pod.
3. Remove the eight flange bolts from the upper housing of the upper pod,
using a 7/16 in. socket and 3/8 in. ratchet and 3/8 in. open-end wrenches.
4. Lift off the upper housing. (This will also disconnect the copper tubing from
the upper pod.)
5. Insert the 7/16 in. hex tool into the top of the upper pod stem, and use the
7/16 in. open-end wrench to remove the stem assembly (includes the
piston, diaphragm, and stem).
4
6. Remove the eight flange bolts from the lower pod, and lift off the connected
housing halves.
7. Roll the diaphragm to the top of the lower piston.
8. Use the strap wrench to hold the lower piston in place and use the 7/16 in.
hex tool with the 7/16 in. open-end wrench to remove the lower stem.
Note: To prevent the strap handle from scratching the piston, wrap the strap
around the piston once before inserting the strap end into the handle.
9. Remove the brass washer and the diaphragm from the lower piston.
10. Install the new lower pod diaphragm, brass washer, and the stem. Make
sure the O-ring seal bead seats against the top of the piston.
11. Use the strap wrench and the 3/8 in. ratchet wrench to hold the piston in
place.
1. Insert the 7/16 in. hex tool into the top of the actuator stem, and tighten the
stem between 144 and 168 lb·in (16 and 19 N·m), using the torque wrench.
13. Replace the connected housing halves, and tighten the flange bolts in
a cross pattern between 115 and 125 lb·in (13 and 14 N·m), using the
torque wrench.
14. Remove the E-ring with the retaining ring pliers and retain.
15. Block the open end of the tubing (end disconnected from the upper pod) to
temporarily seal it.
16. Apply up to 15 psig (103 kPa) pressure slowly to the lower pod. The
actuator will stroke, which will loosen the seal and the Teflon washer.
17. Remove the air pressure from the actuator.
18. Remove the Teflon washer and seal, and retain the washer. (The second
stainless steel washer below the seal should remain on the stem.)
IMPORTANT: Be careful not to score the stem or leakage may result.
19. Place the plastic sleeve over the stem, and slide the new seal over the
sleeve (both supplied in the kit).
Note: Make sure the groove side of the seal is facing the actuator.
20. Hold the seal on the stem, while pulling the plastic sleeve off the stem, so
the seal remains on the stem.
IMPORTANT: Be careful not to damage the seal on the flats located on the
upper part of the stem.
21. Install the Teflon washer on the stem.
22. Place the plastic sleeve over the stem, and push down firmly to seat the
washer and seal.
23. Install the E-ring, using the retaining ring pliers.
Note: If the E-ring cannot be installed, the seal is not completely seated.
Repeat Step 22.
5
24. Check that the air seal is properly installed by applying 15 psig (103 kPa) to
the lower pod to stroke the actuator. If the actuator does not stroke
correctly, repeat Steps 14 through 17 and 22 through 24.
24. Install the piston and diaphragm in the upper pod, and secure the assembly
between 21 and 26 lb·in (2 and 25 N·m), using the 7/16 in. hex tool and the
torque wrench.
26. Roll the diaphragm to the top of the piston.
27. Use the strap wrench to hold the piston in place and use the
7/16 in. hex tool with the 7/16 in. open-end wrench to remove the top stem.
Note: To prevent the strap handle from scratching the piston, wrap the strap
around the piston once before inserting the strap end into the handle.
28. Remove the brass washer and the old diaphragm.
29. Install the new diaphragm and the brass washer, making sure the
diaphragm O-ring seal bead is against the piston.
24. Tighten the top stem between 144 and 168 lb·in (16 and 19 N·m), using the
7/16 in. hex tool and the torque wrench. (Use the strap wrench to prevent
the piston from turning while tightening.)
31. Install the upper housing and the eight bolts, nuts, and lock washers.
Tighten the nuts in a cross pattern between 115 and 125 lb·in
(13 and 14 N·m), using the torque wrench.
32. Reconnect the copper tubing to the upper pod.
33. Remove the E-ring with the retaining ring pliers and retain.
34. Apply up to 15 psig (103 kPa) pressure slowly to the actuator input. The
actuator will stroke, which will loosen the seal and the Teflon washer.
35. Remove the air pressure from the actuator.
36. Remove the Teflon washer and seal, and retain the washer. (The second
stainless steel washer below the seal should remain on the stem.)
IMPORTANT: Be careful not to score the stem or leakage may result.
37. Place the plastic sleeve over the stem, and slide the new seal over the
sleeve (both supplied in the kit).
Note: Make sure the groove side of the seal is facing the actuator.
38. Hold the seal on the stem, while pulling the plastic sleeve off the stem, so
the seal remains on the stem.
IMPORTANT: Be careful not to damage the seal on the flats located on the
upper part of the stem.
39. Install the Teflon washer on the stem.
40. Place the plastic sleeve over the stem, and push down firmly to seat the
washer and seal.
41. Install the E-ring, using the retaining ring pliers.
6
Note: If the E-ring cannot be installed, repeat Step 41.
42. Check that the air seal is properly installed by applying 15 psig (103 kPa) to
the lower pod to stroke the actuator. If the actuator does not stroke
correctly, repeat Steps 33 through 35 and 40 through 42.
43. If the actuator has the optional stem cover, install it now.
Seal and Diaphragm Repair Procedure for MP83, MP85, and MP87
Spring-Return-Down Actuators
Actuator Stop Nut
Brass Bearing 1/32 in. Gap
Holder
Actuator
Supply Air
Actuator Stem
Connection
Metric Nuts
Anti-Rotation Pin and Washers
(through Yoke Slot) Connector
Actuator
Valve Stem
Stem Bolt
Packing Nut
Yoke Nut Jam Nuts
Yoke
Valve Body
Figure 3: Components of a Spring-Return-Down Actuator
Before the seals can be replaced, the actuator will have to be removed from the
valve. Proceed as follows:
1. Remove the stem cover (if present), and the anti-rotation pin using a
3/16 or 1/4 in. open-end wrench.
2. Loosen the yoke nut and the lower jam nut.
3. Remove the upper jam nut from the stem.
4. Apply air pressure to the actuator, and stroke the valve approximately 1/8 in.
5. Loosen the actuator stem bolt.
IMPORTANT: Use the stem wrench to hold the stem in place while loosening
the stem bolt. Rotation of the stem could cause the diaphragm
to wrinkle, affecting the actuator's performance.
Note: The stem wrench fits on the actuator stem just above the connector
where the stem has two flat sides.
7
6. Remove the air pressure, and make sure the valve stem is fully down.
7. Remove the four metric nuts holding the actuator to the yoke. (Use the
10 mm socket for the MP83 and the 13 mm socket for the MP85 and MP87.)
8. Remove the actuator stem bolt and the connector from the actuator stem,
and remove the actuator from the yoke.
To install a seal and diaphragm kit on a MP83 or MP85 actuator, refer to the
Seal and Diaphragm Repair Procedure for MP82 and MP84 Spring-Return-Up
Actuators section. For an MP87 actuator, refer to the Seal and Diaphragm
Repair Procedure for MP86 Spring-Return-Up Actuators section.
After completing the previous procedures, remount the actuator onto the valve
as follows:
1. Make sure the lower jam nut is still on the valve.
2. Attach the connector to the actuator stem using the actuator stem bolt and
lock washer, and hand tighten.
Note: Orient the connector so the anti-rotation pin holes on the connector are
closest to the valve body.
3. Locate the four threaded studs on the bottom of the actuator housing
adjacent to the actuator stem, and install the yoke onto the threaded studs.
4. Secure the actuator to the yoke with the four metric nuts so the valve stem
engages the connector, and tighten the nuts securely.
5. Position the valve stem to fully close the valve.
6. Align the connector with the yoke slot, and insert the anti-rotation pin.
7. Tighten the anti-rotation pin securely with a 3/16 or 1/4 in. open-end wrench.
1. Tighten the actuator stem bolt between 95 and 105 lb·in (11 and 12 N·m).
IMPORTANT: Use the stem wrench to hold the stem in place while tightening
the actuator stem bolt, or rotation of the stem could cause the
diaphragm to wrinkle and affect actuator performance.
9. Thread the lower jam nut against the connector, and tighten it until there is a
1/32 in. gap between the actuator stop nut and the brass bearing holder at
the top of the actuator. (See Figure 3.)
Note: This ensures the valve stem is in the full down position.
10. Thread the upper jam nut against the connector and tighten.
11. Tighten the yoke nut.
12. Apply up to 20 psig (138 kPa) air supply to the actuator to make sure the
unit is operating properly.
13. Remove the supply air.
14. If the actuator has the optional stem cover, install the cover now.
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