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Model A1 / Series TRI-CON

(with Rotork Gearbox)


(Zchng.Nr.: ZUSA1G)

50 80 100 150 200 250 300 350 400 450 500 600 700 750 800 900
DN
2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 30" 32" 36"
ANSI 150 A 190 200 215 250 328 368 387 447 498 548 580 652 778 841 841 873

B 128 143 159 196 224 258 315 349 413 468 501 581 666 748 748 766

C 153 190 229 295 343 405 482 530 597 635 700 810 934 985 1061 1169

D 80 80 80 80 120 120 120 150 150 150 150 150 200 200 200 200

F 43 48 54 57 64 71 81 92 102 114 127 154 229 241 241 241

G - 28,5 28,5 40,5 40,5 42 48 48 55 55 59 59 - - - -

J - 68 68 88,5 88,5 91,5 101 101 111 111 121 121 - - - -

K - 208 208 238 238 335 380 380 475 475 538 538 - - - -

M - 57 57 83 83 101 110 110 142,5 142,5 170 170 - - - -

N - 52 52 71 71 86 104,5 104,5 211 211 263 263 - - - -

O - 137 137 188 188 227 258 258 402,5 402,5 482 482 - - - -

P - 160 160 250 315 400 500 600 400 400 500 500 - - - -

X 120,7 152,4 190,5 241,3 298,5 362 431,8 476,3 539,8 577,9 635 749,3 863,8 914,4 977,9 1085,9

4x 4x 8x 8x 8x 12 x 12 x 12 x 12 x 12 x 16 x 16 x 24 x 24 x 28 x
Y 5/8"-11UNC 5/8"-11UNC 5/8"-11UNC 3/4"-10UNC 3/4"-10UNC 7/8"-9UNC 7/8"-9UNC 1"-8UNC 1"-8UNC 1 1/8"-8UN 1 1/8"-8UN 1 1/4"-8UN 1 1/4"-8UN 1 1/4"-8UN - 1 1/2"-8UN
15mm deep 18mm deep 20mm deep 22mm deep 25mm deep 30mm deep 34mm deep 40mm deep 40mm deep 43mm deep 43mm deep 55mm deep 55mm deep 55mm deep 60mm deep

4x 4x 4x 4x 4x 4x 4x
Z - - - - - - - - 1"-8UNC 1 1/8"-8UN 1 1/8"-8UN 1 1/4"-8UN 1 1/4"-8UN 1 1/4"-8UN - 1 1/2"-8UN
28mm deep 24mm deep 26mm deep 25mm deep 35mm deep 41mm deep 50mm deep

Contents subject to change without notice

Zwick Armaturen GmbH - Egerstrae 25 - D-58256 Ennepetal - Germany - Tel.:023 33/98 56-50 - fax:023 33/98 56-60
260808
E-mail: info@zwick-gmbh.de - Internet: www.zwick-gmbh.de
Operating instructions
Butterfly valves Series TRI-CON
(with gear or actuator)
Operating instruction Butterfly valve TRI-CON with gear or actuator

Table of contents

0 INTRODUCTION 2

1 APPROPRIATE USE 2

2 NOTES ON SAFETY 2

2.1 General notes on safety 2

2.2 Safety precautions for the operator 2

2.3 Special hazards 3

2.4 Marking of butterfly valve 4

3 TRANSPORT AND STORAGE 5

4 INSTALLATION IN THE PIPELINE 6

5 PRESSURE TEST AND ACTIVATION 9

6 NORMAL OPERATION AND MAINTENANCE 9

7 HELP WITH MALFUNCTIONS 10

8 CAUTION WITH USE OF THE BUTTERFLY VALVES THAT ARE SUBJECT TO


-HAZARDOUS ENVIRONMENTS 12

9 FURTHER INFORMATION 12

10 EU DIRECTIVES 13

Zwick Armaturen GmbH, D-58256 Ennepetal 1


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

0 Introduction
This instruction is meant as support for the user of the Butterfly valves Series TRI-CON during
installation, operation and maintenance of valves.
If below listed caution and warning notes are not observed, it could result in
hazards, and the warranty of the manufacturer could become ineffective.
Caution For any queries, please contact the manufacturer. For addresses, see Section 9.

1 Appropriate Use
Butterfly valves of the Series TRI-CON are solely intended to be used in media within the allowed
pressure and temperature limits and to shut off or regulate the flow after installation in a pipe
system (between flanges or through welding) and after connection of the actuator/end switch (if
any) to the controls.
Those butterfly valves are not recommended for medias with more than small amounts of solids,
partially not for those with abrasive solids.
Planning document, the ZWICK brochure <Butterfly valves TRI-CON> (see Section 9
<Information>) describes the allowed pressure and temperature.
Section 2.2 <Safety precautions for the operator> has to be followed when using the valve.
When using a valve with differential pressures greater than approx. 0.15 bar (liquid
media at approximately 20C) for the continuous control operation, the limits for
the use have to be coordinated with the manufacturer. Cavitation has to be
Caution avoided by all means.

2 Notes on safety

2.1 General notes on safety


The same safety regulations that apply for the valves apply also for the piping system, in which
they are build and for the control system, which will be connected to the actuator. The present
instructions provide only those notes on safety for valves that have to be additionally observed.
Additional safety notes for actuator assemblies and/or the end switches are listed in the supplied
documentation of the manufacturer of these assemblies

2.2 Safety precautions for the operator


It is not the responsibility of manufacturer ZWICK to ensure that the valve
is used only in accordance as described in Section 1 and in accordance with the supplied
documentation (see above)
Do not use any valve, if its allowed pressure/temperature area (= "rating") is not
sufficient for the operating condition: this allowed area is described in the ZWICK
brochure <butterfly valves TRI-CON> - see Section 9 <Information>. For materials,
Life- pressures or temperatures that are not listed in the above brochure, it is mandatory
threatening that the operator obtains an approval by the manufacturer for the permitted
hazard pressures above room temperature.
Disregard of this regulation could result in injuries or could endanger lives
and could cause damage to the piping system.
It must be ensured that the selected materials of the parts of the valve - that are in
contact with the media - are suitable for the used media. The manufacturer
assumes no liability for damage that is caused by corrosion through aggressive
media.
Danger Disregard of this regulation could result in injuries or could endanger lives
and could cause damage to the piping system.

Zwick Armaturen GmbH, D-58256 Ennepetal 2


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator
to make sure that a gear or a actuator unit that was attached later to the valve and that was
adjusted to the valve is properly adjusted in both end positions of the valve. In the closing
position, the end stop must take place in the seat of the valve. A stroke limitation within the
actuator unit in closing position must be either turned back or must be neutralized.
that the piping system was professionally installed. With such laid pipes, the measurement
of the wall thickness of the valve's housing allows an additional load Fz in the usual order
of magnitude (Fz = /4DNPS).
(PS = maximum allowable design pressure at room temperature).
Higher values for Fz can be allowed for butterfly valves designed for clamping. The applied
shear force on the valve's housing may not exceed 10% of the above mentioned forces.
that the valve is properly connected with these systems, particularly such valves that were
welded to the pipe
that the actuator/end switch is properly on-site connected to the control system pursuant to
the supplied documentation
that the usual flow speeds within these pipes (e.g. B. 4 m/s for fluids) will not be exceeded
and that abnormal operational conditions as vibration, water hammering, erosion, (e.g.
caused by saturated steam) cavitation, and more, as minor parts of solids in the medium
and particularly such of abrasive nature are clarified with the manufacturer ZWICK
that valves that are operated at an operating temperature of >50C or <-20C are
protected together with the pipe joints against contact
and that only competent personnel operates, maintains and repairs the valves on
pressurized pipes. Competent persons within the meanings of this instruction are
individuals who are able to perform their assigned tasks properly by evaluating correctly
and by identifying potential hazards and by resolving them due to their training, expertise
and experience.

2.3 Special hazards

The valve stem is sealed by a compression gland. Before the nuts on the
compression spacer may be relaxed or loosened, the pressure in the pipeline must
Life-
be completely relieved, so that no media can leak from the compression gland.
threatening
hazard
The pressure in the pipeline must be completely relieved before the screw cap or
the body cover may be safely loosened or before the valve may be disassembled
Life- from the piping to avoid that the uncontrolled medium discharges from the pipe. It
threatening
is important to open the valve approx. 5 - 10 to ensure pressure relief on both
hazard
sides of the valve. If necessary, the actuator may be only dismantled after the
valve has been opened for this purpose and remains in opened position.

For valves that are used as end fitting:


Danger With normal operation, particularly with use of gas, hot and/or hazardous media, a
blind flange or a sealing lid must be assembled on the non-attached connection
part, or the valve must be in "OFF"-position and safely and permanently locked.
Caution when closing such a valve: pay attention to the crushing hazard!

If a valve is an end fitting of a pressurized pipeline and has to be opened, it must


be done very carefully so that the squirting out medium does not cause any
Danger damage. Be careful when closing such a valve. Pay attention to the crushing
hazard!

Zwick Armaturen GmbH, D-58256 Ennepetal 3


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

When a valve needs to be disassembled from a pipeline: the medium might be


discharged from the pipeline or the valve. The piping must be completely empty of
Danger health-damaging or hazardous media before the valve is removed. Caution with
afterflow residues from dead spaces of the valve or the piping that have remained
(under pressure) in the valve.
Beforehand disconnect actuator/end switch according to manufacturer's
documentation.

2.4 Marking of butterfly valve


Any butterfly valve carries a marking with following data (type plate, left column):
EC type plate:
For Marking Note
Manufacturer Zwick Armaturen GmbH Address see Section 9 <Information>
Model no. e.g.: C10125C-AA11CP Key no., see the Zwick Armaturen GmbH catalog
S.-No. e.g.: 02-03-7806 Corresponds to: year month serial production no.
Size DN (and numerical Numerical value in mm, e.g. DN200 or in inch, e.g.
value) 8"
PN / class Numerical value for PN / PN / class = Dimension standard for flanged butterfly
class valves
PS Numerical values in bar = maximum allowable pressure at 20C /
or PSI maximum allowable pressure at max. temperature
TS Numerical values in C = ambient temperature ~ 20C /
or F maximum allowable temperature
P Numerical values in bar Differential pressure
or PSI
ASME type plate:
For Marking Note
Manufacturer Zwick Armaturen GmbH Address see Section 9 <Information>
Model no. e.g.: C10125C-AA11CP Key no., see the ZWICK catalog
S.-No. e.g.: 02-03-7806 Corresponds to: year month serial production no.
Size DN (and numerical Numerical value in mm, e.g. DN200 or in inch, e.g. 8
value)
PN / class Numerical value for PN / PN / class = Dimension standard for flanged butterfly
class valves
CWP / PS Numerical value in bar or = pressure, upper limit of use at 20C
PSI
max. T / TS Numerical value in C or = Temperature, upper limit of use
F
Date Year / month

and marking for the material of parts that are connected to the media (type plate, right column):
for Marking Note
Body Material of the housing
Disc & Cl. Material of the valves disc and clamp ring
Marking after material
Shaft Material of the shaft
standard
Seat Material of the seat in the body
Lamin. Material of the (removable) seat ring in the disc
Date Year / month (Only EC-type plate)
Standards API609B/ B16.34/ CE, etc. Calculation and test standards
The type plate may not be damaged to identify the valve at all times.
An actuator is usually equipped with an additional type plate.

Zwick Armaturen GmbH, D-58256 Ennepetal 4


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

3 Transport and storage


Valves must be carefully handled, transported and stored:
Store the valve in its original packaging and/or with the protective caps at the flange
connections/weld-on ends. The valve should be stored and transported on a pallet (or
supported by something similar). This includes transportation to the installation site.
Store the valve prior to installation in a closed space and protect it from harmful influences
such as dirt or moisture.
In particular, the metallic seat in the valve, the actuator and the flange connection
faces/weld-on ends may not be damaged by mechanical or other influences.
Store valves the same way as they were delivered. Do not operate the gear and/or the
actuator.

Valves supplied without actuator (special case):


Transport the valve particularly careful so that external influences (e.g. vibration)
Danger cannot open an unsecured valve disc that was in the closing position.
Valves with actuator type "safety position ON"
There are valves with short installation length. Their clamp disk usually sticks out
on both sides of the housing: The shipping of such clamps is carried out with
Caution transport safety measures and closed valve disc:
Remove transport safely measures first when installing see Chapter 4.2!

Zwick Armaturen GmbH, D-58256 Ennepetal 5


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

4 Installation in the pipeline


General
For the installation of valves in a pipeline, the same instructions apply as for the connection of
pipes and similar pipeline elements. For valves, the following instructions apply additionally.
For the transport to the installation site, observe also Section 3 (above).
Butterfly valves particularly such with short installation length - must be
transported and installed with closed valve disc. Otherwise, the sealing
Caution element in the disc could be damaged and the valve might no longer be tight.
Crushing hazard exists with non-installed butterfly valves:
Do not connect and operate the actuator before the butterfly valve is installed
into the pipeline.
If the valve is intended as end valve of a pipe section, install either an end cover at
Caution the exit outlet or securely lock the actuator against unauthorized operation to
eliminate the crushing hazard.
The butterfly valve is adjusted for tight closing position:
In the closing position, the end stop of the valve/actuator must take place in the
seat of the butterfly valve. A stroke limitation in the gear/actuator must be either
Note reset or otherwise rendered ineffective.
Do not change the adjustment of the end stop "CLOSE".

If - in an exceptional case a valve has to be installed without a gear/without an


actuator: ensure that such a valve is not pressured.
If a gear/actuator unit is upgraded, the torque, rotational direction, operation angle
Life- and the position of the position of the end stops "OPEN" and "CLOSE" of the valve
threatening must be adjusted according to the operating instructions. Disregard of this
hazard regulation could result in injuries or could endanger lives and could cause
damage to the valve or the piping system.
Valves with electric actuator:
Make sure that the valve is switched off in the "CLOSE"-position through the
signal of the torque switch. In the position "OPEN", the flap has to be switched
Caution off with the signal of the limit switch.
For further references, see documentation for the electric actuator.

Work steps
Transport valve in protective packaging to the installation site and unpack only there.
Inspect the valve/gear/actuator for transportation damages. Valves/gears/actuators with
visible damages may not be installed.
Make sure that only such valves are installed whose pressure class, connection type and
connection dimensions comply with the conditions of use. See type plate on the valve. The
connection data for the actuator must be in accord with the data of the control. See type
plate on the actuator.
Install no valve if its permitted pressure/temperature area (="rating") is not
sufficient for the operation condition: this allowed area is described in the ZWICK
brochure <Butterfly valves TRI-CON> - see Section 9 <Information>. For materials,
pressures or temperatures that are not listed in the above brochure, it is mandatory
Life- that the operator obtains an approval by the manufacturer for the permitted
threatening pressures above room temperature. Disregard of this regulation could result in
hazard injuries or could endanger lives and cause damage to the piping system.
In case of doubts, contact the manufacturer.

Zwick Armaturen GmbH, D-58256 Ennepetal 6


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

If the actuator unit allows manual operation, conduct a test function at the beginning of the
installation: the valve must open and close properly. Recognizable malfunction must be
corrected by all means before the activation. See also Section 7 <Help with malfunctions>.
The position indicator at the gear/at the actuator unit must match the position of the valve
disc.
For the installation, the valve must be in a closed position.
Butterfly valves with short installation length:
Counter flanges and/or pipe ends must have a clearance or inside width/height that allows
sufficient space for the opened valve disc so that the precision sealing element in the valve
disc will not be damaged during panning.
For the protection of the sealing element, the valve and the connecting pipe has to be
thoroughly cleaned prior to the installation and particularly hard foreign bodies must be
removed.
Butterfly valves with short installation length and pneum./electro-hydr. Actuator
"safety position OPEN":
The actuator is blocked with a transport lock in position <CLOSE>.
For the installation
first, the actuator has to be pressurized with the control energy and blocked in
Life- the
threatening closed position, in which it was delivered,
hazard next, the transport safety must be removed,
then, the closed valve must be held constantly under full control pressure in the
"CLOSE" position until it is inserted into the pipe and securely mounted there,
and finally, the control pressure can be slowly released.
Disregard of this regulation could result in injuries or endanger lives and
cause damage to the piping system.

Butterfly valves of the series TRI-CON are generally installed in flow direction. They also
can be installed in the opposed direction, if this had been agreed with the purchaser (for the
sealing in the non-preferred direction, the activity has to be planned with a higher torque).
Install the valve so that the marked arrow on the housing matches the direction that
pressure exercises on a closed disc. This direction may be indeed opposite to the flow
direction with open butterfly valve!
The preferred mounting position is the one with horizontal butterfly valve stem. If possible,
do not arrange the gear/actuator directly below the valve: compression gland leakage could
damage the actuator.

A valve that is mounted to the side of an actuator (electr./electr.-hydraul./pneum.)


must be supported if it causes a non-planned bending effect due to its weight.
Danger
When inserting the valve (and the flange seals) in an already mounted pipeline, measure
the distance between the pipe ends so that all connecting surfaces (and seals) remain
undamaged.
But the gap may not be larger than necessary to generate no additional pressures in the
pipeline during mounting.

Zwick Armaturen GmbH, D-58256 Ennepetal 7


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

Only butterfly valves with flanges:


The counter flanges in the pipeline must be aligned and coplanar.
Butterfly valves with flange ends: the seal faces on the housings with butterfly
valve flange ends are designed for the use of flange seals according to EN1514-1
Caution or ANSI B16.21. Counter flanges must have smooth sealing strips, e.g. form B1 or
B2 according to Standard EN 1092 or stock finish according to ANSI B 16.5.
Other flanges with short installation length must be inserted with closed disc in the
gap between the pipeline ends, otherwise the precision sealing element in the disc
Caution could be damaged and the valve is will be no longer tight.
During the installment, the flanged butterfly valves must be fitted with the flange screws to
the counter flange before the screws are tightened.

Butterfly valves with short installation length require usually screws of different
lengths for the connection to the counter flanges. For the size of these flange
Caution screws, see the ZWICK planning documents <Zw-TriCon-Scr-2002-A1>

Only butterfly valves with weld-on ends:


The weld-on ends of the valve must be aligned, coplanar and of the same kind as the
piping material - see materials in the type plate of the valve. Opposite positioned weld-on
ends must fit together in diameter and edge form.
During welding, earth cable may not be attached to the valve but must be connected to the
pipeline.
Professional welding must ensure that no significant tensions are created in the pipeline
section nor transmitted on the valve. It must be ensured that the butterfly valve is not
damaged by heat. Only temperatures of <300C are permitted, measured on the housing
wall.
Butterfly valves >DN 400:
When welding the valve into the pipe, the welding process must be controlled in a
way that limits added heat energy and to avoid warping of the valve housing. For
example, "crossed" welding must be carried out to avoid tensions on the valve
housing. Disregard of those regulations may cause warping of the valve housing.
Caution Already 1/10 mm of steady warping in the seat area (around the mounting of the
connection pieces) may render the valve useless.
All butterfly valves:
The instruction of the actuator manufacturer applies for the connection of the actuator/end
switch to the control.
In order to complete the installation, conduct a test function with the signals of the controls:
The valve must close and open with the necessary actuator torque in accordance with the
control commands. The signals from end switches/position detectors (if any) must display
properly the position of the valve.
Recognizable malfunctions must be corrected by all means before the activation. See also
Section 7 <Help with malfunctions>.

Incorrectly executed control commands could cause danger to the operating staff
and to the piping system.
Danger

Zwick Armaturen GmbH, D-58256 Ennepetal 8


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

5 Pressure test and activation


The pressure tests of the valves have already been carried out by the manufacturer. For the
pressure test of a pipe section with built-in valves, the following should be noted:
Rinse newly installed pipe systems carefully to remove all contaminant.
Valve opened: the test pressure may not exceed value 1.5 x PS (according to the type
plate). (PS = maximum allowable operating pressure at 20C).
Valve closed: the test pressure may not exceed value 1.1 x P (according to the type
plate).
If a valve should leak, pay attention to Section 7 <Help with malfunctions>.

6 Normal operation and maintenance


Valves that were delivered ex factory with the gear/actuator are precisely adjusted and should not
be adjusted as long as the valve works properly.
For valves with hand wheel, normal hand forces are sufficient. The use of extensions to increase
the actuating torque is not allowed.
Valves with actuators must be operated with signals of the control. For a hand emergency
operation on the actuator (if available), normal hand forces are sufficient. The use of extensions to
increase the actuating torque is not allowed.
Valves do not require regular maintenance work, but during the test of the pipe section no leakage
may occur on the pipe section of a valve particularly not at the compression gland. In such
cases, pay attention to Section 7 <Help with malfunctions>.
It is recommended to cycle the valves 1 to 2 x per year if they continuously remain in one position.

A butterfly valve is usually not self-locking: The gear/ the actuator may not be
dismounted as long there is pressure on the valve.
Danger

A piston actuator is not self-locking

Piston actuators require a constant supply of control pressure for all positions
Note that are approached under control pressure.

Zwick Armaturen GmbH, D-58256 Ennepetal 9


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

7 Help with malfunctions


When troubleshooting, strictly adhere to Section 2 <Notes on safety>.
Note 1:
Order spare parts with all specification on the type plate. Only ZWICK original spare parts may be
installed.
Note 2:
If it is determined after disassembly that housing and/or internal parts are not sufficiently resistant
against the medium, please inform the manufacturer and mention all specification on the type
plate.

Type of the Measure


malfunction

When a spring
Risk of injury
return actuator has
to be removed. The actuator must be disconnected from the supply of the control pressure,
prior removal of the actuator from the valve,
Tighten flange screws.
Leakage from a If leakage cannot be removed by tightening flange screws:
connection to the Repair is necessary: Replace the seal. Pay attention to the notes of Section
pipeline flange or 2.3 <Special hazards> and order the seal for cover and necessary
body cover. instruction from ZWICK.
Examine if valve is 100% closed.
When the valve is in the closed position:
Examine if the gear closes with necessary torque.
Valve with hand wheel: If the gear closes at peak torque.
Open/close valve under pressure several times.
Seat Leakage
If the valve still leaks:
Repair is necessary: Replace the lamella seal. Pay attention to the notes of
Section 2.3 <Special hazards> and order spare parts and get necessary
instructions from ZWICK.
Type of the Measure
malfunction
Examine if valve is 100% closed.
When the valve is in the closed position:
Examine if actuator closes with necessary torque.
If actuator closes at peak torque:
Open/close valve under pressure several times.
Valve with actuator:
If the valve still leaks:
Seat Leakage Increase the torque of the actuator in position "CLOSE" up to maximal 1.1
nominal torque.
If the valve should be still leaky:
Repair is necessary: Replace the lamella seal. Pay attention to the notes of
Section 2.3 <Special hazards> and order spare parts and necessary
instruction from ZWICK.

Zwick Armaturen GmbH, D-58256 Ennepetal 10


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

Danger of injury and life threatening hazard


A larger corrosion than 1.5mm leads to weakening of pressure-bearing
Corrosion within parts and can lead to breakage of the housing wall with sudden discharge
the housing wall of a large amount of the operating medium in very high speed.
According to Section 2.2, it is the responsibility of the operator to coordinate
housing material and the operating medium to eliminate this kind of danger
from the start.
Tighten both nuts on the compression gland alternately clockwise in little by
little turns.
If the leakage does not stop:
Repair is necessary: order spare parts and necessary instructions from
ZWICK.
Leakage of the When the nuts on the gland follower must be loosened or removed
compression gland (counter- clockwise):

Life-threatening hazard
To protect the operation staff from hazards make sure that the pipe on both
sides of the valve were prior depressurized.
Pay attention to Section 2.3 <Special hazards>.
Examine function of the actuator.
If the actuator functions properly:
Valve with hand wheel: Demount and inspect the valve (and by doing so pay attention to the notes
of Section 2.3 <Special hazards>.
Malfunction If the valve is damaged:
Repair is necessary: order spare parts and necessary instructions from
ZWICK.
Examine actuator unit and control command. If actuator and controls
function properly:
Valve with actuator: Demount and inspect the valve (and by doing so pay attention to the notes
of Section 2.3 <Special hazards>.
Malfunction If the valve is damaged:
Repair is necessary: order spare parts and necessary instructions from
ZWICK.

In case of malfunctions of the actuator unit, see documentation of the actuator's manufacturer.

Zwick Armaturen GmbH, D-58256 Ennepetal 11


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

8 Caution with use of the butterfly valves in -hazardous environments


Caution for the valve (without the electro-/hydraulic-/pneumatic actuator):
Below is a summary of the results of the ZWICK ignition analysis, carried out in accordance with
EN 13463-1:

Source of hazard Measure


Valve (without The valve has no own source of ignition, if the user pays
actuator/accessories) attention to below measures.
Sparks when installing a
Mounting / dismounting / service is only allowed in non-
butterfly valve in the pipe
ignitable environmental atmosphere.
section
The manufacturer of the valve is not liable for damage
Heating of the valve's housing resulting from this hazard. It is the responsibility of the
wall to unacceptably high operator to ensure that the operating medium remains within
temperature permissible limits of the environment that contains -
hazards.
All outside parts of the valve are made of metal and are
Charging of individual valve
conductive connected with each other.
components from the function
It is necessary to ensure that the TRI-CON valve is properly
(OPEN-CLOSE)
grounded and remains this way.

Warning for the electro-/hydraulic-/pneumatic actuator and/or the accessories:


The actuator/the (electric) accessories of the valve has its own source of ignition.
No additional ignition danger results from the combination of the TRI-CON valve and the
actuator/the (electric) accessories in an environment with -hazards if the warnings of the table
in Section 8.1 above are adhered to.

Source of hazard Measure


The supplied documentation of the actuator's manufacturer
(see the declarations by manufacturer ZWICK that were
Actuator delivered as part of the shipping) must be strictly and
completely adhered to and must considered in the risk
analysis of the pipe section.

9 Further Information
You will receive these instructions, the named ZWICK brochures and further information and
advice also in other languages from:

Zwick Armaturen GmbH, Egerstrae 1


D-58526 Ennepetal,
Tel: +49 (0) 2333 98565
E-Mail: info@zwick-gmbh.de
www.zwick-armaturen.de

Zwick Armaturen GmbH, D-58256 Ennepetal 12


Instructions No. Zw-TriCon-2014 / Rev.07
Operating instruction Butterfly valve TRI-CON with gear or actuator

10 EU directives

Declaration of conformity according to: Directive 97/23 EC


Manufacturer's declaration according to: Directive 06/42 EC
Manufacturer's declaration according to: Directive 94/9 EC

The Manufacturer Zwick Armaturen GmbH, D-58256 Ennepetal


Butterfly valve Series TRI-CON

explains that the valve with pneumatic-/ electro-/ hydraulic actuator


with free shaft extension for later actuator mounting

EC Directives
Directive 97/23 EC Directive 06/42 EC Directive 94/9 EC
1. is a pressurized equipment within 3. is a partly completed machinery (applies (without actuator/accessories)
the meaning of the EC pressure only to model that has an actuator) within 7. has been submitted to a hazard
equipment directive 97/23 EC and the meaning of art. 2 g of the directive analysis according to directive 94/9
complies with the requirements of 06/42 EC (machine directive) and is only EC
this directive intended to be installed in a completed
8. has no own source of ignition and
2. may be only operated under machinery
can therefore be used in an
consideration of the supplied 4. must not be put into service unless it is explosive atmosphere
operating instruction no. Zw- incorporated in a completed machinery
9. cannot comply with the directive
TriCon-2014. which has been declared in conformity with
94/9/EC
this directive
10. may be only operated under
5. fulfills the declared requirements of this
consideration of the supplied
directive
operating instruction no. Zw-TriCon-
6. may be only operated under consideration 2014, especially chap. 8
of the supplied operating instruction no.
Note:
Zw-TriCon-2014.
Electrical/pneumatic/hydraulic
actuators and accessories have to
be submitted to a separate
assessment of conformity according
to directive 94/9 EC.
The activation of this valve is only allowed if the valve is attached on both sides to the pipe, which excludes danger of injury.

Applied EU directives and standards:


97/23 EC EC Pressure Equipment Directive
EN 593 Industrial valves Metallic butterfly valves
EN 12516 Industrial valves Shell design strength
94/9 EC European explosion-protection directive
EN 1127-1 Explosive Atmospheres Explosion prevention and protection
EN 13463-1 Non-electrical equipment for potentially explosive atmospheres
06/42 EC EC Machine Directive
Type description and technical characteristics:
ZWICK Catalog <Butterfly valves Series TRI-CON>

Authorized person to compile technical documentation:


Daniel Zwick, D-58256 Ennepetal

Applied conformity assessment procedure:


for Directive 97/23 EC on pressure equipment, category III, module H
Name of the notified body: Identification no. of the notified body:
LRQA GmbH Hamburg 0525

Modifications to valves and/or assemblies will render these declarations invalid if these changes have an impact on the technical data of
the valve and the <Appropriate use> pursuant to Section 1 of the operating instructions and when they substantially alter the valve
and/or a supplied assembly.

Ennepetal, 01st October 2014

Daniel Zwick, CEO

Zwick Armaturen GmbH, D-58256 Ennepetal 13


Instructions No. Zw-TriCon-2014 / Rev.07
ROTOR4003 FO Series AB 1104 23-11-2004 12:07 Pagina 1

Handwheel Selection Chart


 Input Torque 
Type M.A. 10%
A B A B
AB 150 9.6
AB 210 11.6
AB 215 11.6 EN
SH
UT
OP OPE
AB 550 12.0
N

S
AB 880 13.2

H
U
T
AB 1250 19.0

PE N

SHU
AB 1950 19.0 O T

AB 1950 HR 28.3

T
AB 1950/SP4 54.4

U
EN

H
OP

S
AB 6800 27.5
N
880
AB 6800 LT/SP4 93.6 DEL
AB
No
MO IAL
AB 6800/SP4
AB 6800/SP9
93.6
185.0
BR SG SER

A 250 LT/SP9 225.0


A 250/SP9 225.0

 Type A B
BR100 100 38 RIM Effort in N 200 300 360 400
BR125 125 42 1000
BR160 160 48 900
BR200 200 53
800
BR250 250 66
BR315 315 68 700
BR400 400 92
600
Handwheel Diameter in mm

 Type A B
500

400 Example how to use this Chart:


SG200 200 80
1 Get the input torque required
SG250 250 110 300
Output Required
SG300 300 115 250 Input Torque =
200 M.A.
SG400 400 130 2 Define Maximum allowable RIM effort
SG500 500 150 (Standard is 360 N)
SG600 600 150 3 Select Handwheel diameter
SG700 700 150 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Input Torque in Nm
SG800 800 150
SG900 900 160
SG1000 1000 160


Rotork Gears BV Rotork Gears UK / Exeeco Rotork Valvekits
Nijverheidstraat 25 Regina House Brookside Way
7581 PV Losser Ring Road Nunn Park
P.O. Box 98 Bramley Huthwaite

Series AB
7580 AB Losser Leeds Nottinghamshire
The Netherlands West Yorkshire LS13 4ET NG17 2NL
Phone: +31 (0)53 - 5388677 England England
Fax: +31 (0)53 - 5383939 Phone: +44 (0) 113 - 205 7276 Phone: +44 (0) 1623 - 440211
E-mail: info@rotorkgears.nl Fax: +44 (0) 113 - 256 3556 Fax: +44 (0) 1623 - 440214
E-mail: sales@rotorkgears.co.uk E-mail: sales@rotorkvalvekits.co.uk www.rotork.com
AB02 ISSUE 11/04

www.rotork.com
ROTOR4003 FO Series AB 1104 23-11-2004 12:07 Pagina 3

 

Gearbox AB Series
Series AB
www.rotork.com

 
Description Applications
The Rotork Gears Series AB quarter-turn gear operators are rugged, industrial Rotork Gears series AB operators are quarter-turn
grade products manufactured with cast iron housing components. devices intended for the operation of ball, plug and
All models in this series feature a polyurethane coating and high performance butterfly valves as well as power and process dampers.
axial bearings. These gear operators are well suited for applications in The handwheels are available in a variety of sizes for
chemical, power, waterworks, HVAC and most general industrial applications. smooth and easy operation.


Materials Features
Housing: Cast iron Cast iron housing (ductile iron optional)
Input shaft: Steel Steel input shaft (Stainless Steel optional) option: Rotork Gears series AB-LX
Gear segment: Ductile iron 15 models up to 32.000 Nm (283.224 lbf.in.) output mountingflange with 1 or 2, V3 Limitswitches
Stroke Adjusters: Steel Rugged construction for buried acc. UL/VDS/APSAD/FM
Indicator: PP Axial needle bearings service in specifications.
Coating: Polyurethane Polyurethane coating combination Available in the sizes
Stroke: 0 - 900 ( 50 adjustable) with an 150 LX, 210 LX, 550 LX
OP
EN extension/bevel and 880 LX.
S
H
U
T

 Nr. Description Material Specification/Notes


1 Set-screw Carbon Steel 8.8 / DIN 916
2 Worm Carbon Steel C45 / AISI 1045
T
U

3 Gasket NBR 70 Shore


EN
H

OP
S

4 Needle-Bearing AXK-AS HardenedSteel


N
AB
880 5 Bushing Sintered Steel FP15
DEL No
SPURGEAR
MO
S E R IAL 6 Oil-seal Nitrile -
7 Shaft Carbon Steel C45 / AISI 1045
8 Grease Lithium-Calcium Multipurpose EP-2
9 Position indicator Polypropylene -
10 Coverplate Cast Iron GG25 / ASTM A48-40
11 Quadrant Ductile Iron GGG40 / ASTM D60-40-18
11A Quadrant 215 Ductile Iron GGG50 / ASTM D70-50-05
12 Body Cast Iron GG25 / ASTM A48-40
13 Gear Carbon Steel C45 / AISI 1045

 Torque Nm (lbf. inch) M.A Weight  Type A B C D E F G k Valve Connection Bore


Type Ratio Output Input 10% Kg. (Lb.) BC acc. ISO 5211 Max.
AB 150 40:1 150 (1328) 16 (138) 9.6 2.2 (4.8) AB 150 80 (3.15) 124 (4.88) 58 (2.28) 42.5 (1.67) 95 (3.74) 47.5 (1.87) - 12 (0.47) F05-F07 20 (0.78)
Environmental specification AB 210
AB 215
37:1
37:1
330
500
(2921) 28.5 (252) 11.6
(4425) 43 (381) 11.6
3.5
3.5
(7.7)
(7.7)
AB 210
AB 215
125 (4.92)
125 (4.92)
125 (4.92)
125 (4.92)
51 (2.01)
51 (2.01)
45 (1.77)
45 (1.77)
160 (6.30)
160 (6.30)
60 (2.36)
60 (2.36)
139 (5.47)
139 (5.47)
15 (0.59)
15 (0.59)
F05-F07-F10
F05-F07-F10
30 (1.18)
30 (1.18)
AB 550 34:1 1000 (8851) 83 (738) 12.0 8.5 (18.7) AB 550 138 (5.43) 174 (6.85) 69 (2.72) 71 (2.80) 201 (7.91) 87 (3.43) 172 (6.77) 20 (0.79) F07-F10-F12-F14 45 (1.77)
Enclosure: N type sealed to IP67 for standard environment AB 880 38:1 2000 (17701) 152 (1341) 13.2 14 (30.9) AB 880 200 (7.87) 226 (8.90) 100 (3.94) 86 (3.39) 189 (7.44) 90 (3.54) 182 (7.17) 20 (0.79) F10-F12-F14-F16 60 (2.36)
W type sealed to IP68 for prolonged submerged applications AB 1250 55:1 3250 (28765) 171 (1514) 19.0 22 (48.5) AB 1250 220 (8.66) 258 (10.16) 110 (4.33) 105 (4.13) 230 (9.06) 100 (3.94) 200 (7.87) 20 (0.79) F10-F12-F14-F16 65 (2.56)
G type sealed to IP68 for burried service applications AB 1950 52:1 5500 (48679) 289 (2562) 19.0 32 (70.5) AB 1950 285 (11.22) 322 (12.68) 142 (5.60) 130 (5.12) 275 (10.83) 125 (4.92) 204 (8.03) 25 (0.98) F12-F14-F16-F25 80 (3.15)
Temperature: -20 to +1200 C (-4 to +2500 F) AB 1950 HR 84:1 4500 (39828) 159 (1407) 28.3 32 (70.5) AB 1950 HR 285 (11.22) 323 (12.70) 143 (5.61) 130 (5.12) 275 (10.83) 111 (4.37) 204 (8.03) 25 (0.98) F12-F14-F16-F25 80 (3.15)
AB 1950 / SP4 208:1 6800 (60185) 125 (1106) 54.4 45 (99.2) AB 1950 /SP4 285 (11.22) 322 (12.68) 142 (5.60) 211 (8.31) 335 (13.19) 125 (4.92) 334(13.15) 25 (0.98) F12-F14-F16-F25 80 (3.15)
AB 6800 78:1 8400 (74346) 305 (2704) 27.5 56 (123.5) AB 6800 370 (14.57) 402 (15.83) 170 (6.69) 182 (7.17) 300 (11.81) 160 (6.30) 257(10.12) 25 (0.98) F16-F25-F30 100 (3.94)
AB 6800 LT/SP4 312:1 9000 (79657) 96 (851) 93.6 70 (154.3) AB 6800 LT/ SP4 370 (14.57) 402 (15.83) 170 (6.69) 263 (10.35) 388 (15.28) 160 (6.30) 385(15.16) 25 (0.98) F16-F25-F30 100 (3.94)
AB 6800 / SP4 312:1 12500 (110634) 134 (1182) 93.6 70 (154.3) AB 6800 /SP4 370 (14.57) 402 (15.83) 170 (6.69) 263 (10.35) 388 (15.28) 160 (6.30) 385(15.16) 25 (0.98) F16-F25-F30 100 (3.94)
AB 6800 / SP9 702:1 17000 (150463) 92 (813) 185.0 100 (220.0) AB 6800 /SP9 370 (14.57) 584 (22.99) 170 (6.69) 182 (7.17) 466 (18.35) 160 (6.30) 504(19.84) 30 (1.18) F16-F25-F30 100 (3.94)
A 250 LT/ SP9 705:1 26000 (230119) 116 (1023) 225.0 225 (496.0) A 250 LT/SP9 510 (20.08) 585 (23.03) 235 (9.25) 431 (16.97) 499 (19.65) 187 (7.36) 500(19.69) 30 (1.18) F25-F30-F35-F40 150 (5.91)
A 250 /SP9 705:1 32000 (283224) 142 (1259) 225.0 225 (496.0) A 250 /SP9 510 (20.08) 585 (23.03) 235 (9.25) 431 (16.97) 499 (19.65) 187 (7.36) 500(19.69) 30 (1.18) F25-F30-F35-F40 150 (5.91)
Contents subject to change without notice.
MANUAL
FOR
INSTALLATION
AND
OPERATING

for gearbox model AB, 242, 232 and 300

PUB033-005-00_1214
model AB, 232, 242, 300 manual
Table of contents
1 PREFACE .................................................................................................................................................... 3
1.1 Introduction 3
2 TECHNICAL DATA SPECIFICATIONS .................................................................................................. 3
2.1 Maximum allowable input- and output torque 3
3 HANDLING AND SAFETY PRECAUTIONS .......................................................................................... 4
3.1 Qualification of staff 4
3.2 Commissioning 4
3.3 Operation 4
3.4 Protective measures 4
3.5 Maintenance 4
3.6 Storage 5
3.7 Long-term storage 5
3.8 Packing 5
3.9 Handling 5
3.10 IP rating and environmental conditions 5
3.11 Stem shaft water ingress 5
3.12 Paint 6
3.13 Primer 6
3.14 Seals 6
3.15 Grease 6
3.16 Gearboxes for 60C operation 6
3.17 Correct use 6
3.18 Installation and operating 6
3.19 Disposal 6
3.20 Identification 7
3.21 Orientation options of gearboxes. 7
3.22 Keyway and drive positions 7
4 INSTALLATION: MOUNTING TO THE VALVE ................................................................................... 8
4.1 Mounting instructions chainwheel 9
4.2 Adjustment of set screws 11
4.3 Operating instruction 13
4.4 Number of turns opening or closing 14
4.5 Handwheel type 15
STANDARD CONDITIONS .............................................................................................................................. 16
5 IP RATING................................................................................................................................................ 18
5.1 Solid Particle protection 18
5.2 Liquid ingress protection 18
6 CERTIFICATES ....................................................................................................................................... 19
6.1 Atex 19
6.2 Certificates of conformity 19
6.3 Other certificates 19
6.4 Reach 20

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: +31 (0)53 5388677 - Fax: +31 (0)535383939 2
Mail: info@rotorkgears.nl - Web: www.rotork.com

PUB033-005-00_1214
model AB, 232, 242, 300 manual

1 PREFACE
1.1 Introduction
The gearbox of the AB, 232, 242 and 300 series is a quarter turn gearbox designed to use for the manual
operation of valves (e.g. butterfly/ball valves) in pipelines.

NB. This manual is valid only for the standard AB, 232, 242 and 300-series gearboxes of Rotork Gears BV.
For special versions, specifications and model can differ. Rotork Gears BV is not responsible for any damage
caused by incorrect use of the gearbox.

2 TECHNICAL DATA SPECIFICATIONS


2.1 Maximum allowable input- and output torque
Max. Manual operating
Gearbox Connection Valve Torque in [Nm]
type ISO 5211/1 Input Output
AB 150 F05-F07 16 150
AB 210(LB) F05-F07-F10(-F12) 28.5 330
AB 215 (LB) F05-F07-F10(-F12) 43 500
AB 550 (LB) F07-F10-F12-F14(-F16) 83 1000
AB 880 (LB) F10-F12-F14-F16 152 2000
AB 1250 (LB) F10-F12-F14-F16(-F25) 171 3250
AB 1950(LB) F12-F14-F16-F25(-F30) 289 5500
AB 1950(LB) HR F12-F14-F16-F25(-F30) 159 4500
AB 1950(LB)/SP4 F12-F14-F16-F25(-F30) 125 6800
AB 1950(LB/PR4) F12-F14-F16-F25(-F30) 106 7000
AB2000 (LB) F12-F14-F16-(F25) 136 4500
AB 3000(LB) F16-F25(-F30) 305 7000
AB 3000(LB/PR4) F16-F25(-F30) 111 9000
AB 3000(LB/PR6) F16-F25(-F30) 104 11000
AB 6800(LB) F16-F25-F30(-F35) 305 8400
AB 6800(LB)LT/SP4 F16-F25-F30(-F35) 96 9000
AB 6800(LB)/SP4 F16-F25-F30(-F35) 134 12500
AB 6800(LB)/PR4 F16-F25-F30(-F35) 130 12500
AB 6800(LB)/SP6 F16-F25-F30(-F35) 121 17000
AB 6800(LB)/PR6 F16-F25-F30(-F35) 121 17000
AB 6800(LB)/SP9 F16-F25-F30(-F35) 92 17000
A 200/SP9 F25-F30-F35 166 26000
A 200/PR10 F25-F30-F35 124 26000
A 250LT/SP9 F25-F30-F35-F40 116 26000
A 250/SP9 F25-F30-F35-F40 142 32000
A 250/PR10 F25-F30-F35-F40 142 32000

242-10 F05-F07 15 150


242-20 F07-F10-F12 30 300
242-30 F07-F10-F12-F14 65 650
242-40 F10-F12-F14-F16 120 1200
242-50LT F14-F16-F25 120 1800
242-50 F14-F16-F25 140 2100

232-05O F05-F07 13 125


232-05N F05-F07 12,5 125

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: +31 (0)53 5388677 - Fax: +31 (0)535383939 3
Mail: info@rotorkgears.nl - Web: www.rotork.com

PUB033-005-00_1214
model AB, 232, 242, 300 manual
232-06 F05-F07 25 250
232-07 F05-F07 21 250
232-08 F07-F10 41,7 500
232-10 F07-F10-F12 39 500
232-11 F10-F12 75 900
232-12 F10-F12-F14 100 1000
232-13 F10-F12-F14 83 1000
232-14 F10-F12-F14 125 1500
232-15 *per application 125 1500

307 F07 21 250


310 F10 39 500
312 F12 100 1000
Table 1 : Connection data of the gearbox
For more specified information, you can contact our sales department.

3 HANDLING AND SAFETY PRECAUTIONS


Be sure to read and understand this manual before installation and use of our gearboxes. All personnel working
with this gearbox must be familiar with the instructions in this manual and observe the instructions given.
Safety instructions must be observed to avoid personal injury or property damage.

3.1 Qualification of staff


Assembly, commissioning, operation, and maintenance must be carried out exclusively by suitably qualified
personnel authorised by the end user or contractor. Prior to working on this product, the staff must have
thoroughly read and understood these instructions and, furthermore, know and observe officially recognised
rules regarding occupational health and safety. Work performed in explosive atmospheres is subject to special
regulations which have to be observed. The end user or contractor is responsible for respect and control of
these regulations, standards, and laws.

3.2 Commissioning
Prior to commissioning, it is important to check that all settings are in compliance with the requirements of the
application. Incorrect settings might present a danger to the application, e.g. cause damage to the valve or the
installation. The manufacturer will not be held liable for any consequential damage. Such risk lies entirely with
the user.

3.3 Operation
Prerequisites for safe and smooth operation:
Correct transport, proper storage, mounting and installation, as well as careful commissioning.
Only operate the gearbox if it is in perfect condition while observing these instructions.
Immediately notify Rotork Gears BV about any faults and damage and allow for corrective measures.
Observe recognised rules for occupational health and safety. Observe the national regulations.

3.4 Protective measures


The end user or the contractor is responsible for implementing the required protective measures on site, such as
enclosures, barriers or personal safety equipment for the staff.

3.5 Maintenance
To ensure reliable gearbox operation, the maintenance instructions included in this manual must be observed.
Any gearbox modification requires the consent of the manufacturer. A Rotork Gears BV gearbox requires only
little maintenance. To ensure that the gearbox is always ready to operate, we recommend for gearboxes the
following measures. Three (3) months after commissioning and each year:

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: +31 (0)53 5388677 - Fax: +31 (0)535383939 4
Mail: info@rotorkgears.nl - Web: www.rotork.com

PUB033-005-00_1214
model AB, 232, 242, 300 manual
- Check the bolts on top of the gearbox;
- Check the bolts on the valve flange;
- Perform a test run every six months;
- Check the gearbox for leakage of grease;
- For gearboxes with permanently vibration and exposure above 60C, checks should be performed at
shorter intervals.

3.6 Storage
The gearboxes need to be stored inside 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. Protect against
floor dampness by storage on a shelf or on a wooden pallet. Apply suitable corrosion protection agent to bare
surfaces.

3.7 Long-term storage


If the Gearbox must be stored for a long period (more than 6 months) the following points must be observed.
Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting surface, with long-term
corrosion protection agent.
At an interval of approximately 6 months:
Check for corrosion. If first signs of corrosion show, apply new corrosion protection.

3.8 Packing
Our products are protected and packed by special packaging for the transport ex works. The packaging consists
of environmentally friendly materials which can easily be separated and recycled. We use the following
packaging material: wood, cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.

3.9 Handling
Never drop the gearbox or otherwise subject it to strong impact. Standard gearboxes are delivered without
eyebolts. On request assembled eyebolts are available for the AB gearboxes these need to be ordered in the
preliminary stages of the order. Eyebolts should only be used to lift the gearbox horizontal on the valve. The
input shaft or hand wheel cannot be used for lifting the gearbox. Do not lift the gearbox when it is assembled to
the valve with eyebolts, input shaft or handwheel.

3.10 IP rating and environmental conditions


The enclosure protection IP65, 67 and 68 only refers to the interior of the gearboxes and not to the stem shaft
coupling compartment. (See table. 6 - IP rating)
Suitability for any specific application is not claimed. IP rating is done in accordance to a standard test
protocol. It is recommended that users carry out tailor made tests to prove the product is fit for purpose for the
specific environmental conditions. For example marine environment, tropical conditions, cold or very hot
conditions, chemical sites with acids or salty conditions requires the end user to assess the fit for purpose.
When the product is used in areas with high temperature fluctuations it is recommended to use pressure
compensators to prevent pressure differences between the outside environment and the interior of the gearbox.

3.11 Stem shaft water ingress


Water can enter into the coupling compartment along the valve shaft, this would lead to corrosion. Therefore a
suitable anticorrosive (or sticky grease) must be applied on the inside bore hole of the gearbox and coupling
before mounting. When water ingress protection towards the stem shaft and rotating quadrant in the coverplate
is required, aluminium position indicators with NBR O-ring is needed, which should be mentioned during
order process. Our G and W gearbox type are suitable. A condition that can occur in some areas is snow on top
of the gearbox with melting water on top of the gearbox, in that case the position indicator with O-ring is
recommended. For horizontal outdoor installation also a sealed aluminium position indicator is recommended.
For gas applications with sealed position indicators an air vent in the indicator could be required. In case of
permanent submersion of the gearboxes or for buried service, a protection cover must be fitted instead of a
position indicator and should be mentioned in the order. Exchange of the position indicator for the protection
cover is possible.

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: +31 (0)53 5388677 - Fax: +31 (0)535383939 5
Mail: info@rotorkgears.nl - Web: www.rotork.com

PUB033-005-00_1214
model AB, 232, 242, 300 manual
3.12 Paint
We deliver our gearboxes in different RAL colours, our standard average paint thickness is 60 microns for AB
and 242 gearboxes and 40 microns for the 232 gearboxes, suitable for installation in a clean and dry industrial
indoor environment. Our process consists of a phosphating pre-treatment followed by our standard DTM
(direct to metal) paint system (Polyaspartic) or primer paint. Other paint systems are on customer request. For
submersed, marine conditions, use for buried service or exposed to corrosive outside environment and other
non-standard environments, paint system are to be advised by the customer including IP rating. On request we
can deliver paint systems and thicknesses (see table 4 standard conditions and options)

3.13 Primer
On request we deliver gearboxes in primer. Standard primer is a 1K industry primer which has a maximal
lifetime of 1, 5 month and must be stored only in indoor, clean and dry conditions. On request zinc primer can
be supplied which has a maximal lifetime of 3 months when free from zinc salts and free from contamination
and stored in a clean exterior. In industrial or marine conditions this should be reduced to the practical
minimum.

3.14 Seals
Rotork Gears BV is using a silicone low volatile liquid seal between cover lid and body. Loosening the top
bolts of the cover plate from the gearbox can break the seal resulting to leakage. Rotork Gears BV will not be
held liable when the top bolts are opened without notification. Once opened a new liquid sealing must be
applied. Liquid seals kits may be obtained from Rotork Gears BV. During the order process it should be
mentioned when gearboxes are exposed to high- or low temperatures. Seals made of elastomeric materials are
subject to ageing. All NBR seals subject to rotating parts are lubricated with MI-setral 9-M. Gearboxes up to
minus 60 degrees Celsius are built with special O-rings and an aluminium indicator will be used to prevent
water increase into the bore of the gearbox.

3.15 Grease
Rotork Gears BV is applying grease that is non-self-igniting and do not present an explosion hazard.
Dependent on the environmental conditions different greases can be used such as high temperature grease,
silicone free grease, foodgrade grease or oxygen free grease. Gearboxes for minus 60 degrees Celsius are built
with 75% filling level of grease. Gearboxes are filled for life but on customer request grease nipples are an
option to be mentioned during order process.

3.16 Gearboxes for 60C operation


Gearboxes for 60C have special O-rings and seals. The AB range has a position indicator with O-ring and
have special closed stainless nuts on the stud bolts with a copper ring and an additional O-ring around the input
shaft. Gearboxes are filled for life with 75% grease. Up to AB1250 the housing is made of cast iron and tested
up to minus 60 degrees Celsius. On request ductile iron is available. For the AB1950 up to the A250 we supply
ductile iron housing for 60C as standard. On request the gearboxes will be supplied with stainless steel
name plate.

3.17 Correct use


Prior to installation, be sure the gearbox will NOT be overloaded during normal use. For this, verify that valve
size and required opening torque do not exceed the values given for the gearbox. For the maximum allowable
torque on the gearbox, (see table 1). AB, 232, 242 and 300 gearboxes can only be used for manual operation.

3.18 Installation and operating


Not observing the rules as stated in this manual, can lead to damage and/or personal injuries. Qualified
personnel must be fully aware of the instructions as described in this manual. Only when the instructions are
observed, correct operation of the gearboxes can be guaranteed.

3.19 Disposal
Never dispose a gearbox at a general disposal site/depot. 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.

Rotork Gears BV - Nijverheidstraat 25 - 7581 PV Losser The Netherlands - Tel: +31 (0)53 5388677 - Fax: +31 (0)535383939 6
Mail: info@rotorkgears.nl - Web: www.rotork.com

PUB033-005-00_1214
model AB, 232, 242, 300 manual
3.20 Identification
Each gearbox has a nameplate. On this nameplate you find the following standard information:
Model type Rotork Gears BV order.no with line.no Production date and other customer information,
when required.
N.B. Information on the name plate is important and is required in case of non-conformities or requests. In case
of non-conformity, please send a description of the complaint, details from the nameplate with clear
photograph(s) to sales.gearsbv@rotork.com.

3.21 Orientation options of gearboxes.


To determine whether a gearbox is left or right handed, the gearbox is observed from above (top view) with set
screws pointing downwards. The shaft is than at the top either pointing to the left (left handed gearbox) or to
the right (right handed gearbox).
Standard we deliver our gearboxes in A2 orientation. Other options are available (see Figure 1).

A1 = LH input shaft anticlockwise in, clockwise out. A2 = LH input shaft clockwise in, clockwise
out.
B1 = RH input shaft clockwise in, clockwise out. B2 = RH input shaft Anticlockwise in,
Clockwise out.
Figure 1: Orientation of gearboxes

3.22 Keyway and drive positions


Figure 2 shows the different options of key positions. Figure 3 is the top view of our standard left handed
gearbox in closed position. Figure 4 shows the different drive options. Special drive requirements on request.

Figure 2: keyway in closed position Figure 3: AB left handed gearbox Figure 4: drive options
Top view top view with setscrews bottom side

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model AB, 232, 242, 300 manual

4 INSTALLATION: MOUNTING TO THE VALVE


Following description applies to standard type gearbox.
1. The gearbox is standard delivered in the closed position, setscrews are loosely tightened.
2. It is recommended to mount a hand wheel on the input shaft before assembling the gearbox to the
valve (see figure 5).

Figure 5: mounting handwheel

3. Check if the bolt circle of the flanges (of gearbox and valve) coincide. Also check if the valve stem
and the bore of the gearbox match.
4. Make sure the valve is in the closed position. If not, close the valve before continuing.
5. Check if the gearbox is in fully closed position by turning the handwheel clockwise.
6. When stud bolts are used for fixing the gearbox to the valve, it is recommended to screw them into the
bottom flange of the gearbox before mounting the gearbox on top of the valve.
7. The use of a gasket or liquid seal between the flange of the valve and gearbox is recommended to
prevent water ingress.
8. Mount the gearbox perpendicular to the valve (see figure 6)
9. Fix the gearbox to the valve appropriate studs and nuts with washers or bolts. Take into account Table
2 for maximum screw dept. For tightening, refer to standard VDI 2230.
10. The assembly is now ready for adjustment.

Figure 6: left handed gearbox perpendicular to the valve

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PUB033-005-00_1214
model AB, 232, 242, 300 manual
4.1 Mounting instructions chainwheel

Following instructions need to be followed for mounting the chainwheel on the shaft. It is advised to use a
suitable anticorrosive (or sticky grease) on the inside bore hole of the chainwheel and guide sleeve. When used
outside or in a wet or humid environment then we recommended the use of a stainless steel shaft for which we
have different classifications to suit several environmental specifications and not a protected or painted C45
steel shaft. Corrosion between the shaft and the chain guide can cause the combination of the chainwheel and
the guide to fail. When ordering chain please order 2x the necessary operation distance + full diameter of
chainwheel. The chainwheel needs to be sized on the maximum rimpull of 700N. The use of chainwheel is not
applicable to the aluminium 232 & 300 range. It is not advised to apply more force than the 700N downward
force towards the chainwheel as this gives the risk of damaging the input shaft of the gearbox. For the AB
range the smallest gearbox with chainwheel is AB210 and for the 242 range is this 242-30. For the AB150 and
242-10 and 20 chainwheel is not applicable.

1. The gearbox is standard delivered in the closed position, setscrews are loosely tightened.
2. It is recommended to mount the chainwheel on the input shaft before assembling the gearbox to the
valve (see figure 7).
3. Mount item 1, 2, 3, 4 and 5 on the input shaft (see figure 7)
4. Locate the holes of the chainwheel and shaft opposite each other, insert item 6 (slotted springtype
straightpin) by hammering.
5. Mount item 7b (set screw with cone point) in front of the chainwheel. Optional item 7a (hexagon
head bolt) can be mounted, this for additional locking of the chain wheel. This extra option need to be
ordered in the preliminary stages of the order.
6. Slide item 4, 3, 2 and 1 together and mount item 8 (hexagon head bolt) in tapped hole of item 1 (Axial
disc)
7. Mount the chain after you have fixed the gearbox to the valve. Connect the loose ends of the chain
with the supplied splitlink (see figure 8)

Figure 7: Mounting chainwheel kit

Figure 8: Chain splitlink

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

PCD F05 F07 F10 F12 F14 F16 F25 F30 F35 F40
Max. screw depth 8 11 13 14 16 18 18 18 30 36
Maximum screw depth per pitch circle diameter (PCD) for the AB range

PCD F05 F07 F10 F12 F14 F16 F25


Max. screw depth 6 8 10 12 16 20 16
Maximum screw depth per pitch circle diameter (PCD) for the 242 range

PCD F05 F07 F10 F12 F14 F16 F25


Max. screw depth 8 11 13 14 16 18 18
Maximum screw depth per pitch circle diameter (PCD) for the 232 range

Table 2. Maximum screw depth

Figure 9: Standard delivery off-center. On request we can deliver on-center with reduced tapping depths
and dowel pin holes

Figure 10: left handed gearbox setscrew adjustment

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PUB033-005-00_1214
model AB, 232, 242, 300 manual
4.2 Adjustment of set screws
The gearbox is now mounted on top of valve (see installation chapter 4).
1. Close the valve completely, by turning the handwheel clockwise (standard gearbox).
2. The valve position is indicated by the arrow on the position indicator.
3. Remove carefully the plastic caps from the setscrews.
4. When the fully closed position cannot be achieved, loosen the setscrew-close (see figure 10) by turning
them counterclockwise. Continue turning the hand wheel until valve is totally closed.
5. Screw the set-screw back into the gearbox (by turning clockwise) until tight (blocked). Secure the
setscrewclose with the nut.
6. Open the valve by turning the handwheel counterclockwise.
7. When opening the valve completely (90) is not possible, loosen the setscrew-open (see figure 3) by
turning it counter clockwise. Continue turning the handwheel until the valve is completely opened.
8. Screw the set-screw back into the gearbox (by turning clockwise) until tight (blocked). Secure the
setscrewopen with the nut.
9. Close the valve with the handwheel.
10. Put the plastic caps back on the setscrews.
11. Adjustment completed

For the AB, 242 and 232, the set screws contain bonded seals. This is to prevent oil leakage from inside the
gearbox when the gearboxes are mounted on the valve with the studbolts pointing downwards. When adjusting
the set screws more than once it may result in a loss of the bonded seal and it is advised to apply Loctite
Threadlock 242. It is also important to lock the screws properly with a torque according to the table below.

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

TORQUE
TYPE SCREW SIZE TORQUE TIGHTNESS Nm
TIGHTNESS lbs ft
M4 2 - 3 3 - 4
M5 4 - 6 5 - 8
M6 7 - 10 9 - 13
M8 16 - 24 21 - 32
SOCKET HEAD M10 32 - 47 42 - 63
M12 55 - 82 74 - 110
M16 136 - 204 182 - 247
M20 266 - 400 357 - 535
M24 460 - 690 616 - 924
M6 4 - 6 5 - 8
M8 10 - 15 13 - 20
M10 19 - 29 26 - 39
HEXAGON M12 34 - 51 46 - 68
HEAD
M16 84 - 126 113 - 169
M20 170 -255 231-364
M24 294 - 441 399 - 598
M8 30 - 45 40 - 60
M10 57 - 86 77 - 115
DURLOK M12 101 - 151 135 - 203
M16 246 - 370 330 - 496
M20 476 - 713 638 - 956
M8 18 - 27 24 36
M10 35 - 52 47 71
SOCKET CAP M12 60 - 91 82 124
w / NORDLOCK
WASHER M16 148 - 221 200 300
M20 289 - 434 392 588
M24 502 - 752 680 1020
Table 3: Tighten force in Nm

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

4.3 Operating instruction


The AB and 242 models are manually operated quarter turn gearboxes made of cast iron. The 232 models are
made of aluminium and the 300 range is made of stainless steel. All mentioned gearboxes can only be used for
manual operating.

The maximum allowable input- and output torques are listed in (table 1).
1. The gearbox is manually operated by handwheel.
2. For opening the valve, the handwheel is turned counterclockwise. For closing turn the handwheel
clockwise1.
3. Stop turning when the required valve position is achieved. The number of turns needed to completely
open or close the valve is stated in table 3. (Changed to table 3)
4. The valve position is indicated by the position indicator on top of the gearbox. In case of buried
service remote position indicators can be used.
5. When the valve cannot be completely opened (or closed), first detect and solve the cause of
malfunction.
6. In case of malfunction of the gearbox ask directly assistance from Rotork Gears and explain the
malfunction of the complaint with details from the nameplate with clear photograph(s). Send your
mail to sales.gearsbv@rotork.com.
7. When it is decided to do the repair in house, all replacement parts must be obtained from Rotork
Gears to assure proper operation of the gearbox.
8. The gearbox is self-braking. Therefore no fixation needs to be installed to retain the valve position2.
9. Turn the handwheel until blocked to open or closed position.
10. The system is ready for us.

1
As special we can deliver clockwise = opening, counter clockwise=closing.
2
Option is the possibility to fix the inputshaft to prevent (not allowed) turning.

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PUB033-005-00_1214
model AB, 232, 242, 300 manual
4.4 Number of turns opening or closing
Model Number of turns
AB Range
AB 150 10
AB 210/215 9,25
AB 550 8,5
AB 880 9,5
AB 1250 13,75
AB 1950(LB) 13
AB 1950(LB) HR 21
AB 1950(LB)/SP4 52
AB 1950(LB)/PR4 54,25
AB2000 (LB) 27,25
AB3000 (LB) 14,5
AB3000 PR4 (LB) 60,75
AB3000 PR6 87
AB 6800(LB) 19,5
AB 6800(LB)LT/SP4 79
AB 6800(LB)/PR4 81,5
AB 6800(LB)/SP6 117
AB 6800(LB)/PR6 162,56
AB 6800(LB)/SP9 160,25
A 200/SP9 148
A200/PR10 182,25
AB 250LT/SP9 176
AB 250LT/PR10 182,25
AB 250/SP9 176
AB 250/PR10 182,25

242 Range
242-10 10
242-20 10
242-30 10
242-40 10
242-50LT 15
242-50 15

300 Range
307 9,25
310 11,25
312 10
232 Range
232-05 10
232-06 10
232-07 9,25
232-08 9,25
232-10 11,25
232-11 11,25
232-12 10
232-13 10
232-14 10
232-15 10

Table 4 . Number of turns for complete opening /closing

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

4.5 Hand
wheel type
Handwheel Type - weight Kgs (lbs)
CD PS SG S F
Size in mm
(casted) (pressed steel) (Steel welded) (Stainless steel) (Steel welded)
50 0.11 (0.24) - - - -
75 0.21 (0.46) - - - -
100 0.32 (0.71) 0.15 (0.33) - - -
125 0.54 (1.19) 0.2 (0.44) - - -
150 - - 1 (2.20) 0.4 (0.88) -
160 - 0.35 (0.77) - - -
200 1 (2.20) 0.75 (1.65) 1.35 (2.98) 1 (2.20) 1 (2.20)
250 - 1.5 (3.31) 1.4 (3.09) - -
300 - - 1.8 (3.97) - 1.5 (3.31)
315 - 2 (4.41) - - -
350 - - 2.3 (5.07) 1.5 (3.31) -
400 - 3.5 (7.72) 2.8 (6.17) - 2.2 (4.85)
450 - - 3 (6.61) - -
500 - - 3.5 (7.72) - 3 (6.61)
600 - - 4.5 (9.92) - 3.2 (7.05)
700 - - 5 (11.02) - 5.5 (12.13)
800 - - 5.5 (12.13) - 6.6 (14.55)
900 - - 6 (13.23) - 7.2 (15.87)
Table 5. Handwheel type weight Kgs (lbs)

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

STANDARD CONDITIONS
Conditions
Enclosure protection Standard: 300 and 232 range IP65
(See table 4: IP Standard: 242 range IP67
rating)
Option: AB range N type IP67
Option: AB range G type IP68
Option: AB range W type IP68-1 (tested 1mtr under water, 72 hours)
Option: AB range CS type IP68-10 (tested 10 meter under clean water continuously)
Option: Special requirements on request
Paint protection Standard:
AB range 60 microns. Suitable for installation in clean and dry industrial indoor
units.
232 range 40 microns. Suitable for installation in clean and dry industrial indoor
units.
242 range 60 microns. Suitable for installation in clean and dry industrial indoor
units
Options:
120 microns. Suitable for installation in industrial outdoor units water, gas or power
plants with a low pollutant concentration
Higher thickness on request. Suitable for installation in occasionally or permanently
outdoor atmosphere with a moderate pollutant concentration (e.g. in waste water
treatment plants, chemical/oil/gas industry)
Other paint systems on request
Pre treatment Standard: Chemical treatment (phosphating)
Option: Sandblasting SA 2.5
Option: Other pre-treatments on request
Paint Standard: QD polyaspartic direct to metal paint
Paint Options: Epoxy coat, other paint systems on request
Primer Standard: 1K industry primer (maximum lifetime 1,5 month stored only in indoor,
clean and dry conditions)
Zinc primer Options: Zinc primer (maximum lifetime 3 months when free from zinc salts and free
from contamination and stored in clean exterior conditions. In industrial or
marine conditions this interval should be reduced to the practical minimum.
Colour Standard: different RAL colours on request
Paint thickness Standard: 40 microns 232 serie (Gloss paint)
Paint thickness Standard: 60 microns AB and 242 serie (QD polyaspartic)
Paint thickness Options: 120 microns higher thickness on request (Epoxy coat or QD polyaspartic)
Paint thickness Standard: 40 microns (1K industry primer)
Options: 40 60 microns (zinc primer)
Grease Standard: Renolit CLX 2 grease
Ambient temperature Standard: 20C to + 120C
Options: 40C to + 120C
Options: 60C to + 120C
Options: Other types of grease (low temperature, food, silicone free or high
temperature) on request

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model AB, 232, 242, 300 manual
Set screws cover Standard: Plastic nutcaps with dubo ring (N type)
Option: W-nuts with dubo ring (W gearbox type)
Option: W-nuts with washer for 60C specification
Option: W-nuts with cupper ring (G and CS gearbox type)

Position indicator Standard: Plastic indicator with zinc plated bolt screws (N type)
Option: Aluminium indicators without NBR O-rings (N gearbox type)
Option: Aluminium indicators with NBR O-rings (protected for water ingress at
stem shaft) (G, W, gearbox type)
Option: Aluminium or GG25 indicators with Special O-rings for 60C
specification.
Option: Buried surface and special requirements on request

Shafts Standard: Carbon steel shafts (N type gearbox)


Option: Stainless steel shaft different classifications (G, W and CS type gearbox)
Option: Shaft extensions on request

Handwheels Standard: Pressed steel RAL9005


Standard: Steel welded RAL9005
Standard: For 242 gearboxes Casted handwheel RAL9005
Option: For 242 Pressed steel or steel welded RAL9005
Option: Stainless steel handwheels
Option: Chainwheel (kit) with zinc plated-, steel zinc plated- or stainless steel chain.
Note: When ordering chain please order 2x the necessary operation distance + full
diameter of chainwheel.
Padlock system Option: Stainless steel chainwheel on request.

Option: To prevent unauthorized people to operate the gearbox (padlock material


Table 6: Standard conditions and options cast iron) other material types on request.
GG25

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

5 IP RATING
5.1 Solid Particle protection
The first digit indicates the level of protection that the enclosure provides against access to hazardous parts
(e.g., electrical conductors, moving parts) and the ingress of solid foreign objects.
Level Object size protected against Effective against
6 Dust tight No ingress of dust; complete protection against contact

5.2 Liquid ingress protection


The second digit indicates the level of protection that the enclosure provides against harmful ingress of water.
Level Protected against Testing for Details
Water projected by a nozzle (6.3 mm) Test duration: at least 3 minutes
5 Water jets against enclosure from any direction shall Water volume: 12.5 litres per minute
have no harmful effects. Pressure: 30 kPa at distance of 3 m
Water projected in powerful jets (12.5
Test duration: at least 3 minutes.
mm nozzle) against the enclosure from
6 Powerful water jets Water volume: 100 litres per minute.
any direction shall have no harmful
Pressure: 100 kPa at distance of 3m.
effects.
Ingress of water in harmful quantity shall Test duration: 30 minutes
not be possible when the enclosure is
7 Immersion up to 1 m immersed in water under defined Immersion at depth of at least 1 m
conditions of pressure and time (up to 1 measured at bottom of device, and at least
m of submersion). 15 cm measured at top of device
The equipment is suitable for continuous
immersion in water under conditions
which shall be specified by the Test duration: continuous immersion in
manufacturer. Normally, this will mean water
8 Immersion beyond 1 m that the equipment is hermetically sealed.
However, with certain types of
equipment, it can mean that water can Depth specified
enter but only in such a manner that it
produces no harmful effects.

Table 7. IP rating

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

6 CERTIFICATES
6.1 Atex
Directive EC 94/9/EG states the directive only applies to equipment which is capable of causing an explosion
through its own potential sources of ignition. The gearboxes from type AB, 242, 232, 300, ILG/S and ILG/D
dont have their own potential source of ignition, so directive EC 94/9/EG doesnt apply. Therefore we state
that:

Operation of gearboxes type series AB, 232 and 300 with the marking:

II 2 G D c 120 C

in areas with explosive gas atmospheres Zone I and II Category 2 (and 3)


and explosive dust atmospheres Zone 21 and 22 Categories 2 (and 3)

: this product meets the requirements for explosion prevention


II : in a potential explosive surrounding, other than in mines,
2 : with a high level of safety, based on normal operation and anticipated risks
GD : suitable for a possible explosive atmosphere caused by gases, vapours, mists of air/dust
mixtures
c : safety obtained by constructive solutions.
120C : indicating the maximum surface temperature in C

6.2 Certificates of conformity


Rotork Gears BV certify that the Gearbox models AB, 242, 232 and 300 supplied conforms in all respects to
our specifications and have been subject to our Quality System conforming to BS EN IS09001:2008

6.3 Other certificates


For other certificates please contact our sales department, these are on request an need to be ordered in the
preliminary stages. The following certificates we can provide:

- EUR 1 certificate
- Certificate of origin
- GOST certificate
- Certificate of Conformity
- 2.2 certificate
- Long term supplier declaration

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PUB033-005-00_1214
model AB, 232, 242, 300 manual

6.4 Reach

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