DESCRIPTION BULLETIN NO. Pneumatic Actuators & Accessories PA-100R1

Design Features PA-101R1

Actuator Dimensions PA-102R1

Torque Charts, Double Acting & Spring Return PA-103R1

Actuator Weights, Air Volumes & Actuator Cycle Time PA-104R1

Installation & Operating Maintenance Manual IOM-100-104

Series 6519 High CV Solenoid SV-100A

Series 6519 Technical Data SV-100B

Valve Position Transmitters Design Features SB-100

Dimension & Ordering Information SB-101

Watchman V.P.T. NEMA 4, 4X SB-102

Sentinel V.P.T. NEMA 4, 4X, 7, 9 SB-103

Position Sensing SB-104

Two Stage Package SB-105ASB-105B

V. P. T. Wiring Diagrams SB-106ASB-106B

Series 40/41 Rotary Postitioner RP-100ARP-100BRP-100CRP-100D

Series 50 Smart Postition SP-100ASP-100B

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Section 4Index

Bullentin No.PA-100R1

SERIES “P” DIRECTMOUNT ACTUATOR

ELECTRIC-PNEUMATIC POSITIONER V.P.T. & SOLENOID PRE-WIRED

UNIVERSAL DRIVE SYSTEM

PNEUMATIC ACTUATORS& ACCESSORIES

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DESIGN FEATURES 2. BearingsTop quality bearings and seals forlow friction and high cycle life toensure trouble free operation.Same bearings are used for both high andlow temperature operations.

3. Spring CartridgesModular pre-loaded spring cartridgeswith metal spring guides for use in bothhigh and low temperature applications.

4. Extruded Aluminum BodyHard anodized extruded aluminum bodywith honed internal surface for strength, highcycle life, and low frictionalresistance.

5. Shaft InsertUnique output shaft insert can be selectedfrom a variety of standard sizes, includingdouble D, ISO square, and round and keyed,or can be custom designed to fit any outputshaft configuration.

6. Blow-Out Proof ShaftGuide bar in pistons provides aninherent blow-out proof shaftdesign.

7. Wide Base DesignWide actuator base design optioncan be adapted to mount valvedesigns requiring wider than ENISO 5211 drilling.

8. Dual Rack and Pinion DesignDual rack and pinion design offersdouble acting and fail safeoperations in the same body.Reverse rotation can beaccomplished by simply invertingthe pistons.

9. FastenersInternal and external stainless steel fastenersand specially coated springs providecorrosion resistance in a variety ofenvironments.

10. Position IndicatorUnique position indicator can be indexed toshow alternate positions. Top of actuator hasa NAMUR slot to engage with all popularsensors and positioners.

11. End CapsStandard end caps are rounded with nocrevices to accumulate contamination.Optional end caps are available to provide100% stroke adjustment in one direction.

12. Actuator MountingManufactured in full compliance with the latest requirements ofEN ISO 5211, with provisions for mounting solenioid valves andaccessories, comply with NAMUR VDI/VDE 3845.

13. Alloy Steel ShaftHigh strength alloy steel shaft with electroless nickel platingprotection for maximum wear and corrosion resistance.

14. Compact Modular DesignCompact modular design with same body and end caps for dou-ble acting and spring return designs combined with a shaft in-sert design to offer the most efficient use of inventory.

1. Travel StopsTwo external travel stops permiteasy adjustment of the open andclosed stroke + or - 5 degree. Thedesign of the stop adjustment campermits the actuator to be lockedout in the full open or full closedposition.

Bullentin No.PA-101R1

hallengeralve ACTUATOR DIMENSIONS

SIZE ØA ØA1 ØA2 ØB ØB1 ØB1 C D E F ØG H J ØK L ØM N P Sq. Q S(NPT)

055 2.76 1.97 1.42 5/16"-18x0.47 1/4"-20X0.35 10-24UNCX0.32

6.61 2.87 2.97 0.79 0.59 0.47 0.55 0.92 3.15 0.55 0.39 1.28 0.43 0.47 1/8

065 2.76 1.97 - 5/16"-18x0.47 1/4"-20X0.35 - 8.37 3.33 3.46 0.79 0.70 0.55 0.55 1.18 3.15 0.55 0.39 1.28 0.55 0.63 1/4

075 2.76 1.97 - 5/16"-18x0.47 1/4"-20X0.35 - 9.25 3.68 3.86 0.79 0.70 0.55 0.55 1.18 3.15 0.75 0.51 1.28 0.67 0.75 1/4

085 2.76 1.97 - 5/16"-18x0.47 1/4"-20X0.35 - 10.80 4.15 4.28 0.79 0.83 0.67 0.55 1.34 3.15 0.75 0.51 1.28 0.67 0.75 1/4

100 4.01 2.76 - 3/8"-16X0.59 5/16"-18x0.47 - 11.58 4.80 4.95 0.79 0.91 0.67 0.55 1.50 3.15 0.87 0.63 1.28 0.87 0.94 1/4

115 4.92 4.01 2.76 1/2"-13X0.71 3/8"-16X0.59 5/16"-18x0.47 13.80 5.49 5.53 1.18 1.18 0.79 0.79 1.85 5.12 0.87 0.63 1.28 0.87 0.94 1/4

125 4.92 4.01 2.76 1/2"-13X0.71 3/8"-16X0.59 5/16"-18x0.47 15.95 5.87 6.00 1.18 1.18 0.79 0.79 1.85 5.12 1.18 0.87 2.13 0.87 0.94 1/4

150 4.92 4.01 - 1/2"-13X0.71 3/8"-16X0.59 - 18.80 7.18 7.34 1.18 1.50 1.18 0.79 2.16 5.12 1.18 0.87 2.13 1.06 1.14 1/4

175 4.92 4.01 - 1/2"-13X0.71 3/8"-16X0.59 - 20.83 8.27 8.46 1.18 1.69 1.26 0.71 2.44 5.12 1.18 0.87 2.13 1.06 1.14 1/4

200 6.50 4.92 - 3/4"-10X1.18 1/2"-13X0.71 - 25.27 9.19 9.76 1.18 1.97 1.42 0.71 2.83 5.12 1.38 - 2.52 1.42 1.50 1/4

Bulletin No.PA-102R1

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Spring Return Actuator Torque Data ( LB.-INCH ) AIR SUPPLY PRESSURE PSISE=SPRING END TORQUE, SB=SPRING BREAK TORQUE, PE=PNEUMATIC END TORQUE, PB=PNEUMATIC BREAKTORQUE

Size Spring/Piston

40 60 80 90 100 Spring Stoke

PB PE PB PE PB PE PB PE PB PE SB SE

055 3 88 53 133 97 203 168 71 44

4 115 71 186 142 203 168 248 212 97 62

5 168 115 186 142 239 186 124 71

6 150 88 177 115 221 159 142 88

065 3 142 97 221 168 327 283 115 71

4 195 124 301 239 336 274 416 345 150 97

5 274 195 310 230 389 310 186 115

6 248 150 292 195 363 266 230 142

075 3 195 115 310 230 478 398 195 133

4 257 159 425 327 487 381 593 496 266 177

5 381 248 424 310 549 416 327 212

6 327 177 389 230 496 345 398 257

085 3 292 186 451 345 699 593 274 177

4 389 239 637 487 717 566 876 735 363 239

5 566 389 646 469 814 628 460 292

6 504 283 584 363 743 531 549 354

100 3 451 274 699 522 1080 903 434 266

4 602 363 982 743 1106 867 1354 1115 575 354

5 885 584 1009 708 1257 956 717 443

6 779 425 903 549 1159 797 858 531

115 3 761 487 1177 894 1797 1522 681 434

4 1018 646 1637 1266 1841 1469 2257 1885 912 575

5 1478 1018 1682 1221 2098 1637 1133 717

6 1319 761 1522 965 1938 1381 1363 858

125 3 1000 646 1540 1186 2345 1991 867 549

4 1336 867 2142 1673 2407 1938 2947 2478 1159 735

5 1938 1354 2204 1620 2744 2160 1443 920

6 1735 1027 2000 1301 2540 1832 1735 1106

150 3 1575 1000 2505 1929 3903 3319 1611 1089

4 2106 1336 3496 2726 3965 3195 4894 4116 2142 1451

5 3098 2133 3558 2593 4487 3523 2682 1814

6 2691 1531 3160 2000 4089 2930 3222 2177

175 3 2443 1602 3823 2983 5894 5054 2283 1522

4 3266 2142 5328 4213 6018 4903 7399 6275 3036 2027

5 4770 3363 5461 4054 6833 5434 3797 2540

6 4204 2522 4894 3213 6275 4594 4558 3045

200 3 3717 2514 5824 4620 8975 7771 3416 2328

4 4956 3354 8116 6505 9160 7558 11267 9656 4549 3107

5 7249 5240 8302 6293 10400 8399 5691 3877

6 6390 3974 7435 5027 9541 7134 6824 4655

Actuator Air Supply in PSI

Model 40 60 80 90 100

055 133 177 248 274 319

065 221 292 407 443 522

075 336 451 620 673 788

085 487 655 894 974 1142

100 752 1000 1381 1505 1752

Actuator Air Supply in PSI

Model 40 60 80 90 100

115 1239 1655 2274 2478 2894

125 1611 2151 2956 3221 3761

150 2788 3717 5106 5576 6505

175 4142 5514 7584 8275 9655

200 6310 8408 11558 12611 14718

Double Acting Torque Ratings (LB_IN.)

Bulletin No.PA-103R1

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ACTUATOR WEIGHTS (LB.S)

SIZE 055 065 075 085 100 115 125 150 175 200

DOUBLE ACTING 3.1 4.8 6.2 8.8 12.8 19.2 24.5 42.3 62.8 99.2

SPRING RETURN 3.5 5.7 7.3 10.8 15.2 22.9 30.0 51.4 75.8 122.3

Bulletin No.PA-104R1

ACTUATOR VOLUMES (CUBIC INCHES)

SIZE 055 065 075 085 100 115 125 150 175 200

OPENING 9.2 15.9 23.2 34.2 51.3 88.8 113.8 196.2 289.3 433.3

CLOSING 12.2 24.4 34.2 52.5 74.4 119.3 162.3 272.5 408.9 648.1

ACTUATOR SPEEDS IN SECONDS ARE AT 80 PSI AIR SUPPLY WITH A ORIFICE DIAMETER OF 0.16INCHES.

SIZE 055 065 075 085 100 115 125 150 175 200

OPEN/CLOSE STROKE 0.3 0.35 0.45 0.6 0.8 1.0 1.3 1.5 2.0 3.5

ACTUATOR VOLUMES (CUBIC M.M.)

SIZE 055 065 075 085 100 115 125 150 175 200

OPENING 151 261 380 560 841 1455 1865 3215 4741 7100

CLOSING 200 400 560 860 1219 1955 2660 4465 6701 10620

ACTUATOR WEIGHTS (KG.S)

SIZE 055 065 075 085 100 115 125 150 175 200

DOUBLE ACTING 1.41 2.18 2.81 3.99 5.81 8.71 11.11 19.19 28.49 45.00

SPRING RETURN 1.59 2.59 3.31 4.90 6.89 10.39 13.61 23.32 34.38 55.48

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

ENGINEERING DATA SHEETE.D.S. NO – EDS119ISSUE DATE - -- 24/04/2007

(Please read the entire instructions carefully before installation or servicing.)

Guarantee :

“Our liability, with respect of any defect or failure of the goods supplied or forany loss, injury or damage attributable onward is limited to replacement or re-pair of the defects which under proper use appear therein and arise solely fromfaulty materials and workmanship. This guarantee is for a period of 18 calendarmonths after the original goods were first shipped or within 12 calendar monthsfrom the date of installation, whichever is earlier, provided that such defectiveparts are returned without charge to our factory for examination.No other warranty is either expressed or implied.”

TABLE OF CONTENTS

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DESCRIPTION:

GeneralDisassembly & Assembly Instruction

Extended Travel Stop/StorageExploded View

BULLETIN NO.:

IOM-101IOM-102IOM-102AIOM-102BIOM-102CIOM-103IOM-104

Bulletin No.IOM-100

1. General :This manual contains the important information regarding the installation, operationand troubleshooting of the ‘Challenger’ pneumatic actuators. Please read theseinstructions carefully before operating the actuator.Warning:• It is important that the actuator should only be used within the pressure limits

indicated in our technical specifications.• Operating the actuator over pressure limits will damage internal parts as well

as cause damage to the housing.• Operating the actuator over temperature limits will damage internal and exter-

nal components (disassembly of spring return actuator may become danger-ous).

• Operating the actuator in corrosive environments with incorrect protectionmay damage the internal and external parts.

• Do not disassemble the individual spring cartridges. Disassembly may result inpersonal injury.

• Isolate all airlines and make sure that actuator air connection is vented beforeinstallation or servicing of the actuator.

• Do not remove end caps or disassemble the actuator while the actuator ispressurized.

• Before installing onto a valve, make sure that the rotation of the valve and theactuator are the same and that the position indicator orientation is also correct.

• If the actuator is in a system or used within safety devices or circuits, thecustomer shall ensure that the national and local safety laws and

• regulations are observed.2. Technical Data :

Operating Media: Dry or lubricated air, non-corrosive and inert gas, or lighthydraulic oil.Air Supply: 8 bar (116 PSI) Maximum.Temperature:Standard: -4 °F to 175°F (-20°C to 80°C)Viton ‘O’ Rings: -4 °F to 300°F (-20°C to 150°C)Silicon ‘O’ Rings: -40 °F to 175°F (-40°C to 80°C)Lubrication: Factory lubricated for the life of the actuator under normal conditions.Construction: Suitable for indoor and outdoor use.External Travel Stops: ±5° adjustments on 90° strokes. 3. Installation :1. Ensure that the desired failure mode is correct (Refer to figure no. 1,2 & 3).

The ‘Challenger’ actuator typically operates counter clockwise to open andclockwise to close, it is possible to change this style of operation. If the springreturn actuator is not set up in the configuration desired, follow thedisassembly procedure section 5.2. Reverse the orientation of the pistons,and then reassemble following the assembly procedure, section 5.3.

2. Mount the actuator to the valve as per the desired orientation (parallel orperpendicular to the pipeline).

3. Connect a regulated air supply to the NPT fitting on the actuator housing.Caution: The maximum operating pressure is 116 psi (8 bar).

4. Adjust the stroke adjustment bolts following assembly section 5.3.4. Strokeadjustment bolts can be adjusted by up to ±5°.

4. Operation :

The ‘Challenger’ actuators have simple operational characteristics. Port ‘A’ (facingthe ports and reading right to left) is connected to the interior cavity between thepistons directing the airflow into/out of the interior cavity. Port ‘B’ is connected tothe end cap cavities directing airflow into/out of the end cap area.1 Double Acting (Figure 1): Air supplied through port ‘A’ forces the piston awayfrom each other causing the pinion to rotate counter clockwise (with exhaust airexiting through port ‘B’). Air introduced through port ‘B’ forces the piston towardseach otherCausing the pinion to rotate clockwise (with exhaust air exiting through port ‘A’).

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2 Spring Return:

2.1 Fail Clockwise (FCW) (Standard Scope of Supply)(Figure 2): Air introduced through port ‘A’ forces the pistonaway from each other, compressing springs and causing thepinion to rotate counter clockwise (with exhaust air exitingthrough port ‘B’). Upon loss /release of air pressure, springsforces the piston towards center position causing pinion torotate clockwise (FCW) (with exhaust air exiting through port‘A’).

2.2 Fail Counter Clockwise (FCCW) (Figure 3): Air intro-duced through port ‘A’ forces the piston away from eachother, compressing springs and causing the pinion to rotateclockwise (with exhaust air exiting through port ‘B’). Uponloss /release of air pressure, springs forces the piston to-wards center position causing pinion to rotate counter clock-wise (FCCW) (with exhaust air exiting through port ‘A’).

5 Maintenance :

5.1 General:‘Challenger’ actuator can be supplied with Metric / UNC fasten-ers. Under normal operating conditions, the actuator requiresonly periodic observation to ensure proper adjustment. Servicekits are available to replace seals and bearings (soft parts). Theseparts are identified in Figure 24 and listed in Table 4. Table 1lists kit numbers.

Table 1

Actuator Service Kit055 20.SK.055.XX.0065 20.SK.065.XX.0075 20.SK.075.XX.0085 20.SK.085.XX.0100 20.SK.100.XX.0115 20.SK.115.XX.0125 20.SK.125.XX.0150 20.SK.150.XX.0175 20.SK.175.XX.0200 20.SK.200.XX.0

Bulletin No.IOM-101

5.2 Disassembly:

When disassembly of the actuator isrequired for maintenance, remove theactuator from the valve. Ensure properlifting procedures are followed whenmoving or carrying actuators. Caution:Do not use M5 VDI/VDE mountingholes for lifting the actuator.When disassembling the ‘Challenger’ actu-ators, use caution and be certain that theactuator is free from accessories and theair supply is disconnected. When the actu-ator is a spring-return unit, make sure thatthe actuator is in the failed position be-fore disassembling.

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Bulletin No.IOM-102

a) Remove both the Stroke Adjustment Bolts (14) togetherwith nut (16) washer (15) and ‘O’ Ring (24). Replace theStroke Adjustment Bolts (14) in case of excessive wearobserved on the bolt surface.

1. Removal of Local Position indicator (27) (Figure

2. Removal of Stroke adjustment Bolts (14) (Figure

a. Remove the counter sunk screw (29), if fitted.b. Remove the Local position indicator (27) from the pinion(05). It may be necessary to pry gently with a screwdriver.

3. End Cap (02, 03) Disassembly (Figure 6):

a) Remove the end cap bolts (17) in the sequence shown in the (figure6).

Caution: When disassembling a spring return actuator, the endcap (02, 03) should be loose after unscrewing end cap bolts (17)4-5 turns. If there is still force on the end cap bolt (17), this mayindicate a damaged spring cartridge and any further disassem-bly should be discontinued. Further disassembly of the end capsmay result in serious personal injury. Return the actuator toChallenger for further maintenance.

b) For spring return actuators, remove spring cartridges (08).

4.Piston (04) Disassembly (Figure 7):

a) Hold the body (01) in a vice or similar device. Rotate the pinion(05) until the pistons (04) reach the end positions (i.e. the pistonrack teeth disengages with pinion teeth). Caution : Air pres-sure should not be used to remove the pistons from thebody. Clean and inspect the piston teeth for signs of wear.Replace pistons, if wear seems excessive.

b) Remove piston ‘O’ rings (22), piston guide band (10). Discard the “O” rings and guide band, if replacing the soft parts.

5. Removal of Pinion (05), Cam (06) and bearings(11, 12) (Figure 8):

a) Remove the circlip (19) using a circlip plier.b) Remove the shim (25).c) Remove the top thrust bush (07).d) Apply a downward force to top of the pinion (05)

so that the pinion will move out of the center ofthe body (01) and remove the cam (06), it may benecessary to pry gently to cam with a screw-driver. Observed the cam surface for excessivewear, where the stroke adjustment bolts areresting and the cam ID (Square c/s) replace thecam, if excessive wear is observed.

e) Apply a downward force to top of the pinion (05)so that the pinion will move completely out of thebottom of the body (01). If the Pinion (05) doesnot move freely, gently tap with a plastic mallet.

f) Remove the top and bottom bearings (11, 12) andtop and bottom ‘O’ rings (20, 21). Discard ifreplacing all soft parts.

6 Cleaning and inspection:

When all components are disassembled, those notbeing replaced should be properly cleaned and in-spected for wear prior to re-assembly.5.3 Assembly:

Prior to assembly, ensure that all components areclean and undamaged.It is recommended to use the lubricants as mentionedin Table 2.

Table 2: Recommended Lubri-cantsGeneral Use CASTROL GREASE -

AP3Low Temperature MOSIL - SN 64

1 Pinion (05) Assembly (Figure 09):

a) Install the top and bottom bearings (11, 12)and ‘O’ rings (20, 21) on to the pinion (05).

b Apply grease to the pinion bearings (11, 12),shaft ‘O’ rings (20, 21) using general-purposegrease listed in table 2.

c) Insert the pinion (05) in to body (01) from the bottomside up to body center.

d Insert the cam (06) & bottom thrust bush (07) on thepinion (05).

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Bulletin No.IOM-102A

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e) Insert the pinion (05) into the body (01) from the bottom side. Ensure thatbottom surface of the pinion should be around 0.5mm inside the bodybottom face and the pinion top slot orientation is as shown in figure 11.

f) Insert the top thrust bush (07) & shim (25) & circlip (19) (using the Cir- clip Plier) on the pinion (05).

2. Piston (04) Assembly (Figure 12 & 13):

a) Fit piston pad (09), piston guide band (10), and piston o-rings (22) onthe pistons (04).

b) Apply grease to the internal bore of the body (01) & to the pistonrack teeth using recommended general - purpose grease listed intable 2.

c) Press the two pistons simultaneously in the body bore until thepinion racks are engaged and rotate the pinion until the strokeis completed. Take care that the pistons are oriented correctlyas per the fail position of the actuator (The standard fail actionof actuator is fail clockwise). Refer Fig 12 & Fig 13.

d) To ensure that the piston (04) teeth are evenly engaged,fully compress both the pistons inward and measure thedistance from the edge of the body to the piston (04)face on each side, shown as dimension ‘A’ in figure 13. Ifa different value is obtained on each side, remove thepistons and repeat from step 2c.

e) Temporarily install the local position indicator (27)onto the pinion (05) to determine whether thecorrect stroke is obtained. Ensure that the arrowin the local position indicator (27) will rotate aminimum of 5° beyond the 90° vertical centerlineof the actuator body (01) and a minimum of 5°beyond the 0° horizontal centerline of the actua-tor body as shown in figure 14. If the properstroke is not obtained, remove the pistons andrepeat from step 2c. Once proper stroke is ob-tained, remove the local position indicator (27).

Bulletin No.IOM-102B

Spring Pattern

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SPRING RETURN ACTUATORS.

For spring return actuator, insert the proper quantity of the springcartridges (08) according to the pattern shown in Fig 15 (referringto the total number of springs). Insert the spring cartridges (08) asshown in Fig 16.

Apply grease to the end cap ‘O’ rings (23). Fit the ‘O’ rings (23) intothe groove in each end cap (02, 03). Fit the Plug Transfer port (13)inside the body (01) on each side. Fit the end caps. Insert all the end capbolts (17) (Apply grease to the end cap bolts refer table no-3) and handtighten.Complete tightening by following the sequence indicated in Fig 17.

Table 3 : Recommended Lubricants

ANTI SEIZE GREASE MOSIL - 2200

DOUBLE ACTING ACTUATORS

Apply grease to (refer table no-2) the end cap ‘O’ rings (23).Fit the ‘O’ rings (23) into the groove in each end cap (02, 03).Fit the Plug Transfer port (13) inside the body (01) on eachside.

Fit the end caps (02, 03) onto the body (01), verifying that the ‘O’ rings (23) remain in the groove.Insert all the end cap bolts (17) (Apply grease to theend cap bolts refer table no.3) and hand tighten. Com-plete tightening by following the sequence indicated inFig 17.

3. Assembly of Stroke Adjustment Bolts (14):(Figure 18)

a) Insert the nut (16), washer (15) onto thestroke adjustment bolt.

b) Insert the “O” Rings (24) in the body (01) “O”Ring groove.

c) (Apply grease to the stroke adjustment bolt(14) Refer table No. 3) Screw in the bolts (14)into the body (01).

4. External Travel Stop Adjustment (Figure18):

The stroke adjustment bolt to the right controlsthe clockwise end of travel, while to the leftcontrols the counter-clockwise end of travel.

a) Cycle the actuator to the clockwise end oftravel and determine if the pinion top slot is inthe proper position (In most of the applica-tions this will be perpendicular to the actuatorbody i.e. at 900)

b) If the pinion top slot is not in the correctposition, turn the right stop adjustment bolt(14) IN to reduce actuator travel, or OUT toincrease actuator travel.

c) When the correct clockwise position is ob-tained, hold the adjusting bolt (14) stationarywhile tightening the nut (16).

d) Cycle the actuator to the counter-clockwiseend of travel and measure to determine if thepinion top slot is in the proper Position. (In mostof the applications, this will be parallel to theactuator body i.e. at 00 ).

e) If the pinion top slot is not in the correctcounter-clockwise position, turn the left stopadjustment bolt (14) IN to reduce actuatortravel, or OUT to increase actuator travel.

f) When the correct counter-clockwise positionis obtained, hold the adjusting bolt (14) station-ary while tightening the nut (16).

Bulletin No.IOM-102C

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Fig-18a

gg) Special machined slot provided on the

stroke adjustment bolt to release the pres-surized air after extra Opening of the boltshence to avoid blow out of the stroke ad-justment bolts. (As shown in fig. 18a)

5 Local Position indicator Assembly (Figure19):

• Fit local position indicator (27) assembly on to thepinion (05). Ensure that it indicates the correctActuator position.

• Tighten the counter sunk screw (29) to securethe local position indicator

6. 100% TRAVEL STOP ARRANGEMENT. (FIG No, 20 & 21)

This arrangement is used to restrict opening of the actuator to any position between full close (-5º) to full open(100º) position. This is achieved by rotating the stop bolt (31) in clock wise / counter clockwise direction as perthe desired stroke.

Note: - 100% travel stop arrangement is possible in only one direction i.e. during opening of the actuator.

7: Storage:All the Challenger actuators are factory lubricated for one million cycles under normal operating conditions.a) Store in a dry enviromentb) It is recommended that the actuator be stored in its original box.Do not remove the plastic plugs on the air supply ports.

Bulletin No.IOM-103

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8. Exploded View : (Figure-24)

Bulletin No.IOM-104

9. Parts List :No. PART DESCRIPTION MATERIAL SPEC QTY01 BODY ASTM B2221,6063-T3 01

02 LEFT END CAP LM-24 PDC 01

03 RIGHT END CAP LM-24 PDC 01

04 PISTON LM-24 02

05 PINION EN19-ENP 01

06 CAM IC 4140-ARCOR 01

07*

PINION TOP/BOTTOMTHRUST BUSH

STAYNL T W 371 02

08**

SPRING CARTRIDGEASSEMBLY

- - 12MAX

09*

PISTON PAD STAYNL T W 371 02

10*

PISTON BAND STAYNL T W 371 02

11*

TOP BUSH STAYNL T W 371 01

12*

BOTTOM BUSH STAYNL T W 371 01

13*

PLUG TRANFERPORT NITRILE 02

14 STROKE ADJUSTABLEBOLT

SS304 02

15 WASHER SS304 02

16 HEX NUT SS304 02

17 HEX HEAD SCREW SS304 08

18 M/C WASHER SS304 08

No. PART DESCRIPTION MATERIAL SPEC QTY19*

CIRCLIP SPRING STEEL 01

20*

O-RING NITRILE RUBBER 01

21*

O-RING NITRILE RUBBER 01

22*

O-RING NITRILE RUBBER 02

23*

O-RING NITRILE RUBBER 02

24*

O-RING NITRILE RUBBER 02

25*

SHIM SS304 01

26 1/4” PLUG PLASTIC 02

27 LOCAL POSITION IN-DICATOR IDOMEI

ABS PLASTIC 01

28 DISC ABS PLASTIC 01

29 COUNTER SUNKSCREW

SS304 01

30 ACTUATOR MAINSTICKER

PVC 01

2A *** LEFT END CAP 100%TRAVEL STOP ARRG.

LM-24 PDC 01

3A *** RIGHT END CAP 100%TRAVEL STOP ARRG.

LM-24 PDC 01

31***

STOP BOLT SS304 02

32***

NUT SS304 02

33***

WASHER SS304 02

34***

O-RING NITRILE RUBBER 02

* Suggested spare parts for maintenance** Valid for Spring Return Actuator only*** Optional Only for 100% travel stop Arrangement

SERIES 6519 NAMUR SOLENOID

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Bulletin No.SV-100A

TECHNICAL DATA, SERIES 6519

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Bulletin No.SV-100B

VALVE POSITION TRANSMITTERS DESIGN FEATURES

Why Switch To Our VPTs?

See for Yourself! Place a Moniteur Valve Position Transmitter next to a competitor and notethe improvements that make it the finest on the market:

Indicator• Indicator cover is free from decals or paint, which fade in the sun or during plant

washdowns.• Indicator is O-ring sealed from the environment.• 100% change of indication with 360 degree visibility.• Indicator cover has no flanges which could crack during installation or hard use.

Enclosure• All housings are sealed with a compressed O-ring. On the thermoplastic enclosure, a

raised lip on the enclosure cover assures optimum sealing.• All inserts are cast into the enclosure during the molding process, assuring better

resistance to tearout. Other designs have welded or glued-in inserts.• All enclosure threads are “blind-tapped” to protect the threads from the environment.• Shaft bushing is 20% longer for more secure and accurate shaft operation.• Shaft is held into the bushing with an internal stainless steel lock ring, protected from

the environment with an O-ring. Other designs use an external snap ring unprotectedfrom dirt or corrosive air.

• Two conduit entries are standard.

Internal• Switches and terminal strip are labeled for easier wiring.• Mechanical switches are enclosed in a protective housing that safeguards against

electric shock during cam setting. Other designs have exposed contacts.• Terminal strip is angled 15 degrees for easier installation.

Electrical• Mechanical switches are specified with higher operating forces offering better

resistance to freeze up from cold or dirty environments.• Moniteur offers a broad array or Non-Contact (proximity-type) switches better suited

to today’s sophisticated process control systems. Choose Tungsten TTL switches forhigh current applications, or Rhodium and Bifurcated TTL for low voltage/low currentDC applications.

• A wide variety of inductive sensors is available (NAMUR, PNP, NPN) to match nearlyevery control interface found in today’s modern process plants.

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Bulletin No.SB-100

DIMENSIONS & ORDERING INFORMATION

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Bulletin No.SB-101

WATCHMAN - NEMA 4, 4X

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Bulletin No.SB-102

SENTINEL - NEMA 4, 4X, 7, 9

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Bulletin No.SB-103

OPTIONAL VALVE POSITION SENSING

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Bulletin No.SB-104

TWO STAGE PACKAGE

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Bulletin No.SB-105A

TWO STAGE PACKAGE

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Bulletin No.SB-105B

WIRING DIAGRAMS

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Bulletin No.SB-106A

WIRING DIAGRAMS CONTINUED

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Bulletin No.SB-106B

SERIES 40 ROTARY POSITIONER

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Bulletin No.RP-100A

SERIES 40 SPECIFICATIONS

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Bulletin No.RP-100B

SERIES 40 PIPING CONFIGURATIONS

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Bulletin No.RP-100C

SERIES 40 DIMENSIONS & ORDERING INFORMATION

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Bulletin No.RP-100D

SERIES 50 SMART POSITIONER

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Bulletin No.SP-100A

SERIES 50 DIMENSIONS & ORDERING INFORMATION

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Bulletin No.SP-100B