MANUAL FOR INSTALLATION AND OPERATING
Contents
1. or opening of the valve in case of malfunction in the automatic actuator system 1 2 3 The gearbox is operated by handwheel The valve is closed by turning the handwheel clockwise Stop turning when the required valveposition is achieved The number of rotations of the handwheel needed to turn the valve from fully opened to fully closed position is listed in table 2 When the valve can not be totally closed first detect and solve the cause of failure In case of malfunction of the gearbox this has to be replaced see chapter 2 for dismounting Return the gearbox to your supplier for repair When you do the repair in house all replacement parts must be obtained from the manufacturer to assure proper operation ofthe gearbox The gearbox is self braking Therefore no fixation is needed to retain the valveposition When the cause of the malfunction is solved turn the handwheel until blocked for correct stand of the gearbox see chapter 2 installation The system is ready for use a Option is a fixation of the the inputshaft to prevent not allowed turning J J Deutschland GmbH Auf der Hackelmasch 1 31061Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de ILG S gearbox manual Figure 5 ILG S gearbox neuer number of turns es number of oe to close ype amp turns to close ILG ssso 9 5 ILG S 6800 SP4 79 25 ILG S 1250 13 75 ILG S 250 SP9 table2. to the valve with nut and ring In case of use of bolts for the maximum screwdepth see table 1 For tightening refer to standard VDI 2230 table 1 maximum screwdepth per pitch center diameter 13 The fail close spring return actuator can be mounted on top see chapter 3 14 The assembly is ready for adjustment see chapter 3 15 For another kind of actuator operation above mentioned points may not apply to the situation When the valve has to opened with the gearbox in case of malfunction of the actuator system position the gearbox in opened position and the driveshaftkey at 12 o clock Be sure the driveshaft can be freely turned by the actuator from close to open v v without interfering with the wormwheel 3 Adjustment of the stopscrews The gearbox is already mounted on top of the valve see installation This manual only applies to fail close clockwise actuators 1 Be sure gearbox and valve are in fully closed position If not turn the gearbox in opened position by turning the handwheel clockwise 2 Turn the valve in the fully closed position 3 Mount the spring clockwise return actuator Do not pressurize the actuator Be sure the actuator is ready for use stopscrews are adjusted 4 Check if the valve is in fully closed position If not then adjust the setscrews either of the gearbox or the actuator 5 Turn the handwheel counterclockwise to put the gearbox and valve in fully opened position Whe
3. 2 number of turned for totally opening closing 5 Maintenance Under normal conditions the gearbox is maintenance free The Rotork Gears gearboxes can be used at ambient temperatures from 20 to 110 C The standard gearbox reaches IP65 dust and waterspray proof Cleaning can be done with a waterhose not a high pressure waterjet J J Deutschland GmbH Auf der Hackelmasch 1 31061 Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de
4. MANUAL FOR INSTALLATION AND OPERATING for the gearbox model ILG S ILG S gearbox manual 1 Preface usage ni EIER Te RR RE RER EER Technical data 1 2 Handling and safety precautions 22 2 2 s28 2 22 EN BSRRE sctlsecasaiossedsse opbosseaastiaa osnscssdecsesesessuespevaninsen 3 3 Adjustment of the StOPSCreWS cccesessssesessesesesesesseseececeneaeavsuesesesseusucseseecsusacaeansseseeceususscseeseessasaeaneseseeseesesesaeeses 6 4 Operalingz un uses nisse ie E REE E EENT EEEE 7 5 M intenance 22 224232 saleteats sh deed l savant ccessasadts E AE E 8 J J Deutschland GmbH Auf der Hackelmasch 1 31061 Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de ILG S gearbox manual 1 Preface Rotork Gears bv produces gearboxes of different types and sizes The ILG S gearbox of Rotork Gears is a sandwich manual override quarter turn gearbox for single acting actuators It is intended to be used for the manual operation of valves in pipelines in case of failure of the of the automatic actuator system NB This manual is valid only for the standard ILG S gearboxes of Rotork Gears bv For special versions the specifications and model can differ Rotork Gears bv is not responsible for any damage caused by incorrect use of the gearbox 1 1 Technical data Specifications The maximum allowable input and outputtorque are listed in table 1 connection to connecti
5. eved by turning the handwheel clockwise 6 Incase of use of studbolts for fixing the gearbox to the valve it is recommended to screw them into the bottomflange of the gearbox prior to mounting the gearbox on top of the valve 7 The use of a gasket between the flange of the valve and gearbox is recommended ur J J Deutschland GmbH Auf der Hackelmasch 1 31061Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de ILG S gearbox manual 8 Put the driveshaft from the bottomside into the gearbox see figure 1 The size and shape of the connections of the driveshaft and the gearbox can differ from figure 1 figure 1 assembly of driveshaft into gearbox ILG S 9 For fail close actuators clockwise close be sure the driveshaft can make a free quarter turn clockwise seen from the bottomside from its endposition refer to figure 2 the position of the free run can differ from the figure By this the gearbox can open the valve in case of actuator or power supply failure BOTTOMVIEW figure 2 Position of driveshaft 10 Put the gearbox on top of the valve 11 The gearbox is mounted perpendicular to the valve see figure 3 J J Deutschland GmbH Auf der Hackelmasch 1 31061 Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de ILG S gearbox manual figure 3 Gearbox perpendicular to the valve 12 Fix the gearbox
6. n the full open position can not be achieved loosen the stopscrew open of the gearbox see figure 4 and check the travel stop adjustment of the actuator Continue turning the handwheel until the valve is fully opened 6 Turn the screw back into the gearbox until blocked handtight Secure the stopscrew open with the counternut J J Deutschland GmbH Auf der Hackelmasch 1 31061 Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de ILG S gearbox manual 10 11 12 4 STOPSCREW CLGSE STOPSCREW OPEN figure 4 ILG S gearbox stopscrew adjustment Put the gearbox into the fully cbsed position by turning the handwheel clockwise The actuator must also return the valve to its fully closed position When the fully closed position can not be achieved loosen the stopscrew close of the gearbox see figure 4 and check the travel stop adjustment of the actuator Turn the stop screw back into the gearbox until blocked handtight Secure the stopscrew open with the counternut If still no return to closed position is achieved check if any obstacles prevent the valve from returning back into its closed position Be sure the gearbox and valve are in fully closed position Adjustment completed The assembly is ready for automatic operation Operating Under normal circumstances the valve is operated by an automatic actuator The ILG S gearbox allows manual operation closing
7. ns are observed correct operation of the gearboxes can be garanteed Disposal Never refuse a gearbox at a general disposal unit The gearbox has to be offered to a disposal depot for recycling The iron parts can be used for recycling The seals are of nitrile and can be used for plastic recycling The grease may not be discharged to sewer or surface water It has to be disposed according to local regulations for incineration 2 Installation mounting to the valve The ILG S is a sandwich manual override quarter turn gearbox for single acting quarter turn pneumatic or electric actuators For maximum allowable input and outputtorque refer to table 1 or the not included datasheet This manual describes the installation of the gearbox and its parts The intention is to open a valve with the gearbox in case of a failing actuator system If the power supply fails the spring returns the actuator and valve to the secure closed position 1 The gearbox is standard delivered in closed position It is recommended to mount a handwheel on the inputshaft prior to assemble the gearbox to the valve 3 Check if the boltcircle of the flanges of gearbox and valve coincide Also check if the valvestem and the bore of the driveshaft match Make sure the valve is in the fully closed position If not close the valve before continuing For fail close actuators 90 clockwise close the gearbox has to be positioned fully closed This is achi
8. on to aed actuator valve Max Torque Nm table 1 Connectiondata of the gearboxes The Rotork Gears gearboxes can be used at ambient temperatures from 20 to 110 C For more specified information you can contact our sales departement 1 2 Handling and safety precautions Be sure to read and understand this manual before installation and use of our ILG S gearbox Storage The gearboxes need to be stored in a safe way to avoid accidents Also avoid storage in areas subjected to high temperature extremes and or areas subjected to large amounts of humidity and dust Handling Never drop the gearbox or otherwise subject it to strong impact J J Deutschland GmbH Auf der Hackelmasch 1 31061 Alfeld fon 4951816017 Fax 4951816032 mail info juj deutschland de homepage www juj deutschland de ILG S gearbox manual Correct use Prior to installation be sure the gearbox will NOT be overloaded during normal use For this convince yourself the valvesize and needed opening and closing torque do not exceed the values given for the gearbox For the maximum allowable torque of the gearbox see table 1 Rotork Gears bv is not responsible for any damage caused by incorrect use of the gearbox Installation en operating Not observing and following the rules as stated in this manual can lead to damage and or personal injuries The qualified personel must be fully aware of the instructions as descibed in this manual Only when the instructio
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