KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
Please read through this manual completely before operating the actuators
SECTION 1 - SAFETY PRECAUTIONS
Precautions for using AW, AWN type actuators
safely are highlighted with the following two
warning signs to indicate the level of danger
posed. Please read the postscript carefully to
ensure safety and prevent any damage from
occurring before starting to use the product.
WARNING
A potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
A potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
ACTUATOR USE
AW, AWN Type Actuators are suitable for
operating ball valves and V-port valves.
Please use the actuators according to warnings
and cautions described in this document.
Failure to do so could result in an accident
(due to wrong storage, installing, operation,
maintenance and disassembling) and/or
serious damage.
Please keep this manual in a handy place for
immediate reference; be sure to provide it to
purchaser, contractor, piping designer, user,
operator or maintenance technician.
KTM reserves the right to discontinue the
manufacture of, change or modify design and/
or construction of any KTM product during the
manufacturing procedure, without incurring
any obligation to accept for credit, to replace or
furnish or install such changes or modifications
on products previously or subsequently sold.
This document is subject to change without
notice.
SECTION 2 - SPECIFICATION
The performance and safety of AW, AWN type
actuators and conformity with your equipment
or system should be checked by the design
engineer or the person specifying your system
based on our catalog or specification data.
Upon arrival, the applicable conditions (double
acting, direct acting, reverse acting, operating
pressure, etc.) should be first checked to make
sure they are correct.
SECTION 3 - STORAGE
CAUTION
The following items should be strictly followed in
order for the actuators to be installed
and operated properly.
1. Do not unpack the actuator from shipping
package until just prior to installing it.
2. Store the package in dry and non-corrosive
atmosphere.
3. When unpacked, plug or cap inlet and outlet
port and direct these ports in horizontal and
downward position to protecting from entering
rain and dust.
Emerson.com/FinalControl © 2017 Emerson. All rights reserved. VCIOM-02905-EN 19/04
KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 4 - MODEL IDENTIFICATION
Example: AW 17 S Q HW
Actuator type
AW (AWN only applicable for size 13)
Actuator size
13 20
17 28
Operation type Description (Supply pressure)
Blank Double acting type (0.3 to 0.7 MPa)
S Spring return type - Standard (0.4 to 0.7 MPa)
L Spring return type - Low pressure type (0.3 to 0.4 MPa)
Special (Option) Description
Blank No specials
A Direct-acting spring return
(Counter-clockwise rotation under supply pressure loss)
B Stainless steel external bolts and nuts
K For high temperature (0ºC to 120ºC)
T For low temperature (-45ºC to 60ºC)
Q High speed / frequency (500,000 cycles): Available for double acting type
High speed: Available for spring return type
S High torque type (spring return)
Accessories (Option) Description
Blank Without any accessories
CO ESDV of CO
H For double acting type with manual override handle lever:
Available for AWN13 only
HG For double acting type with manual gear operator:
Available for AW17 through AW28
HW For spring return type with manual override handle:
Available for AWN13S through AW28S
L With lift-limiting unit
PS Partial stroke test
gas type
2
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 5 - RANGE OF APPLICATION
Operating mechanism Operation Model no. Pressure (MPa)
Double acting AWN13 0.3 - 0.7
AW17
AW20
AW28
Single acting AWN13S 0.4 - 0.7
Scotch York
(Para-arm piston rod pin)
(Spring return) AW17S
AW20S
AW28S
Single acting AWN13L 0.3 - 0.4
for low pressure range AW17L 0.2 - 0.4
AW20L 0.3 - 0.5
AW28L 0.2 - 0.4
CAUTION
Use Torque Cylinders within operating pressure
ranges only.
Operation outside the specified range may cause
damage to the cylinder or malfunction.
SECTION 6 - CONSTRUCTION
Spring return
Spring return
Double acting
Double acting
FIGURE 1
NOTE
Only AWN13 has an oval-shaped upper stem and a
square-shaped lower stem.
PARTS LIST
No. Parts Nme
1 Body
2 Stem
3 Para-arm
4 Key
5 Set screw
6 O-ring
7 O-ring
8 Thrust bearing
9 Thrust bearing
10 Snap ring
11 Snap ring
12 Piston rod
13 Pin
14 Roller
15 Bearing
16 Snap ring
17 Adapter
18 Gasket
19 Bearing
20 O-ring
21 O-ring
22 Piston
23 O-ring
24 O-ring
25 Nut
26 Cylinder
27 Cap screw
28 Stopper bolt
29 Gasket
30 Cap Nut
31 Spring retainer
32 Cylinder
33 Spring case
34 Spring (Outer)
35 Spring (Inner)
36 Spring cover
37 Long bolt
38 Nut
39 Stopper bolt
40 Nut
41 Pipe
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 7 - MOUNTING OF ACTUATOR TO VALVE
Ensure the following items before mounting the
actuator to the ball valve.
1. Cleanse flanges of actuator and valve of
dust and foreign substances.
2. When mounting, make sure that the valve
opening (fully open or fully closed) coincides
with the indicator position of the actuator.
Caution
Mismatching between indication of actuator and
valve opening may result in operation trouble,
which will cause accidents. Check the indication
matching once more.
3. Use the following bolts for connection,
which should be fastened in “criss-cross”
pattern.
Stainless steel: JIS: SUS304 (AISI 304) with
strength class more than 70
Carbon steel: JIS: S45C (AISI 1045) with
strength class more than 8.8
SECTION 8 - ADJUSTMENT OF VALVE OPENING
After mounting the actuator to the valve, adjust
fully open and fully closed position according to
the following manner.
CAUTION
Since the adjusting procedure is performed
during supplying compressed air, do not touch the
moving parts of the actuator. Doing so may cause
injury.
8.2 Procedure for Single Acting Actuator
(including the model with manual operator “HW”)
1. Supply compressed air to the inlet port to
the valve open and check fully open position
of the valve.
2. If the position is not correct, exhaust the
compressed air letting the valve to close the
valve. Then perform the following steps 3
and 4.
3. Loosen hexagon nut for locking open
side stopper bolt, turn the stopper bolt
in respective direction by using hexagon
bar wrench. Clockwise turning of the bolt
reduces travel angle of the actuator, and
counterclockwise turning widen the range of
the travel angle.
4. After ensuring correct position of the valve
by supplying compressed air to the actuator,
tighten the locking nut of the stopper bolt.
5. With no compressed air in the actuator,
check the fully closed position of the valve.
6. If the position is not correct, loosen the
hexagon nut for locking stopper bolt on
closed side, then perform the following
procedures 7 and 8.
7. Turn the stopper bolt in the respective
direction by using hexagon bar wrench.
Clockwise turning of the bolt reduces travel
angle of the actuator, and counterclockwise
turning widen the range of the angle.
8. After ensuring the correct position of the
valve, tighten the locking nut of the stopper
bolt.
SECTION 9 - PIPING AND INSTALLATION
CAUTION
In piping work, care should be taken for
fragments of the sealing tape not to enter in
the pipe. Foreign matters in the tube will cause
malfunctions of accessories.
WARNING
Never climb on the actuator or accessories in field
working, which will cause failure in adjustment or
human injury.
For supplying the compressed air, refer to
Section 9 “Piping and Installation”.
The procedure explained below applies to
the combination of actuator and valve, when
turning the stem clockwise operates the valve
to closed position.
8.1 Procedure for Double Acting Actuator
1. Supply compressed air to inlet port to open
the valve and check fully open position of the
valve.
2. If the position is not correct, exhaust the
compressed air and perform steps 4 and 5.
3. Loosen hexagon nut for locking stopper
bolt on open side, turn the stopper bolt
in respective direction by using hexagon
bar wrench. Clockwise turning of the bolt
reduces travel angle of the actuator, and
counterclockwise turning widens the range
of the travel angle.
4. After ensuring correct position of the valve
by supplying compressed air to the actuator,
tighten the locking nut of the stopper bolt.
5. Supply compressed air to inlet port to close
the valve and check the fully closed position.
6. If the position is not correct, perform the
above described procedure for closed side
stopper bolt.
When operating actuator in piping work, please
pay attention to the following points.
1. Avoid installing the actuators in a place
where they are exposed to seawater,
chemicals, and high- and/or lowtemperature (above 80ºC, under -20ºC).
If it is inevitable, protect the actuators by
appropriate covering, or protect sufficiently
with anticorrosive painting.
2. Usually, copper tubes are used for
connecting attachments. When the joints
loosen by intensive vibrations, air leakage
may occur. Additional tightening will be
necessary accordingly. In vibrational
environments, use Nylon tubing.
3. Since accessories have been adjusted
already in the factory, further adjustments
are not necessary.
4. For air piping of accessories, use Φ8 xΦ6
tube or larger for AWN13~AW20, and
Φ10 xΦ8 tube or larger for AW28. If quick
operation is required, use large size tube
according to the desired speed.
5. For air piping from compressor or air tank
to supply port of actuator (or inlet port of
attachment device, if equipped), use steel
pipe of size not smaller than the air supply
port of the actuator.
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
6. When using the actuators outdoor in cold
or snowy areas moving parts of accessories
(positioner, limit switches, etc.) may be
frozen. Protect the devices by proper
covering in such cases.
7. When installation orientation of actuator is
changed for convenience of positioning, the
following caution should be taken.
1. Exhaust port of the actuator and
accessories (solenoid valve, air operate
valve, quick exhaust valve, etc.) should be
directed downward by attaching elbows.
If doing so is difficult due to surrounding
area environment, use elbow for
exhausting downward.
2. Since attaching orientation of filter
regulator or lubricator is limited, drains
should be directed downward.
CAUTION
Do not position single acting torque cylinders in
such orientation that springs are facing upward.
By doing since, the inside of the cylinder may be
corroded by entering of water, which may cause
malfunctions.
8. In piping for operating actuator work, care
should be taken as follows.
1. Clean joint and tubing sufficiently by using
compressed air before piping.
2. When sealing tape is used, apply tape to
thread starting two threads back from
end of fitting in order for the fragments of
the tape not to enter inside of the pipe.
3. Since copper tubes are regularly used for
connecting accessories, avoid vibrational
place for installing. In severe vibrational
environments, use Nylon tubing.
(The copper tube loosen by vibration may
cause leakage.)
4. Do not tighten the joint excessively to the
supply port of the actuator.
9. Pneumatic diagram for actuator and
accessories Schematic diagrams of piping
for solenoid valve to actuator are shown
below. Select appropriate mode according
to the operating purpose.
NORMALLY CLOSE (ENERGIZED TO OPEN) NORMALLY OPEN (ENERGIZED TO CLOSE)
• Double Acting type
AWN13
AW17
AW20
AW28
(4-Way
solenoid
valve)
(Filter Regulator)
FIGURE 3
Actuator
(Equalizing Valve)
Supply air
0.4 MPa
• Double Acting type
AWN13
AW17
AW20
AW28
(Equalizing Valve)
(4-Way
solenoid
valve)
(Filter Regulator)
FIGURE 5
Actuator
Supply air
0.4 MPa
CAUTION
Excessive fastening of joint may cause cracking of
supply port leading air leakage.
ca. two
threads
Wind tape in this area
FIGURE 2
• Single Acting type
AWN13S
AW17S
AW20S
AW28S
Actuator
(Pluged) (Pluged)
(Filter Regulator)
Supply air
0.4 MPa
• Single Acting type
AWN13S
AW17S
AW20S
AW28S
FIGURE 4 FIGURE 6
Actuator
(Filter Regulator)
Supply air
0.4 MPa
(Filter Regulator)(Filter Regulator)
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 10 - AIR SUPPLY FLOW RATE
The volume of air necessary for cylinder
operation is determined to obtain the following
two types of flow rates:
1. Momentary Flow Rate QD, QS
Calculation of the momentary flow rate
is necessary to determine operating
time. The shorter the operating time
with the same cylinder size, the larger
the momentary flow rate. In order to
obtain the desired operating time, the
supply source capacity, piping diameter,
pressure reducing valve capacity, solenoid
valve orifice diameter (C
value), etc. are
v
necessary. This enables the momentary
flow rate to be determined by the following
formulas (1) and (1’). If multiple cylinders
are operated simultaneously, then the
capacity of each devices used, multiplied
by the number of cylinders will provide the
momentary flow rate.
Momentary flow rate of Double Acting cylinder:
( )
Momentary flow rate of Spring Return type
Cylinder: ( )
2. Air consumption VD, VS
This shows the volume of air consumed
in a period of time. For the same size
cylinder, air consumption increases in
direct proportion to the operating time.
The consumption is determined by the
following formula. Incidentally, the total
air consumption is identical to a sum value
obtained for the total units.
Remarks
Q
D = Momentary flow rate in Double Acting
cylinder ( )
Q
S = Momentary flow rate in Spring Return
type cylinder ( )
V
D = Air Consumption of the Double Acting
cylinder ( )
V
S = Air Consumption of the Spring Return
A, B = Cylinder capacity ( )
P = Operating pressure (MPa)
T = Operating time (Sec)
n = Operating cycles in a time period
(One cycle means one reciprocating
action)
type cylinder ( )
Cylinder
model
AWN13 3.10 3.10 6.20
AW17 6.70 6.70 13.40
AW20 14.80 14.80 29.60
AW28 34.60 34.60 69.20
A B A + B
SECTION 11 - CAUTIONS PRIOR TO OPERATION
1. Check air leakage in pipeline from
compressor or tank to supply port by using
soap liquid or leak check liquid.
2. Be sure that supplying compressed air
pressure is within the range specified in
Section 5 “Range of Application”.
3. Check electric power supply voltage of
solenoid valve.
4. Check air pressure of filter regulator outlet
Cylinder capacity (ℓ)
SECTION 12 - CAUTIONS DURING OPERATION
1. Use clean and dry compressed air through
dryer and filter. (Dew point below -15ºC).
Drain sufficiently to prevent freezing
especially in cold areas.
2. Periodical draining of filter or filter regulator
should be performed.
3. Supply lubricating oil (turbine oil JIS K2213,
ISO VG32 with additives) periodically to
lubricator.
port if attached.
5. Check speed of speed controller or quick
exhaust valve if attached.
6. Ensure that the actuator and valve travel
CAUTION
Do not use machine oils and spindle oils, which
may cause troubles.
smoothly by operating accessories (solenoid
valve, air operate valve, positioner, etc.).
7. Ensure that electric wiring of solenoid valve
4. Manual operation is inhibited while
automatic operation.
or limit switches are shielded by cable
gland, cable protection tube, etc. Wiring
port should be directed in horizontal and
downward position.
WARNING
Never place or leave lever handles, spanners and
wrenches at the upper portion of the
stem. They are driven while operation and cause
human injury and equipment damages.
Air Consumption of Double Acting cylinder:
( )
Air Consumption of Spring Return type cylinder:
( )
a1 a2
A
b1 b2
B
FIGURE 7
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KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 13 - MANUAL OPERATION
WARNING
Manual operation must only be done after
stopping the air supply for both double and single
acting actuators. Manual operation while air
supply will cause injury. In operating single acting
actuator, use manual operating device “HW” for
single acting actuator. Never use spanners or
wrenches. Doing so may cause injury.
1. Manual operation of double acting actuators
(lever handle) AWN13
1. Stop compressed air supply.
2. Open equalizing valve if attached.
Otherwise, loosen the joint of supply
port of the actuator to purge air in the
actuator.
3. Apply lever handle at the upper portion of
stem to turn it. The turning range should
be within 90 degrees.
4. After manual operation, recover air supply
by closing equalizing valve or retighten
the joint at supply ports.
2. Double Acting (Manual Gear HG) AW17 to
AW28
3. Single acting actuator (Manual operator HW)
AWN13S to AW28S
The HW Type Side Handle can be used as
manual valve operation device when loss of
air supply occurs in single acting actuator.
The procedure of manual operation with HW
Type Side Handle is as follows.
1. Equalize pressure between inside of
cylinder and atmosphere by respective
methods according to the piping
configurations around the actuator.
For example: Switch the power off of
solenoid valve used for operating the
actuator. Manipulate pressure-exhausting
valve.
WARNING
1. After manual operation, be sure to remove
the lever handle. Pneumatic operation while
leaving the tools will cause injury.
2. Operate the valve with stable posture from
a set direction. Make sure that the handle
is reliably inserted into the stem’s end.
Insufficient insertion and forced operation of
the handle may result in damage or injury if
the handle slips out.
3. Excessive handle operation may break the
lever and injure the operator.
CAUTION
1. When valve is open or closed, indicator nut ➃
moves toward “OPEN” side or “SHUT” side.
Return the nut to “AUTO” position correctly by
turning Handle . Incorrect positioning of nut ➃
deviating from “AUTO” position will cause
insufficient opening or closing in automatic
operation or operation malfunctions.
2. After resetting the nut ➃ to correct “AUTO”
position, lock the Handle ➁ by chain and lock
to prevent misoperation.
CAUTION
Manual operation with side handle without
equalizing pressure between inside of cylinder
and atmosphere will bring extreme increase
in required operating force, which may cause
disabling operation or failure of actuator.
2. Operate valve by turning the side handle
manually
Reverse Acting type: Turning the handle
counterclockwise opens the valve.
Direct Acting type: Turning the handle
counterclockwise closes the valve.
CAUTION
Over winding by applying excessive force after
the valve is fully opened will cause failure of
the actuator. Never use pipe or such things to
lengthening the handle arm.
3. Be sure to turn the handle clockwise until
it stops to reset manual operation mode
before returning to pneumatic operation.
CAUTION
Leaving the handle halfway will cause trouble in
automatic operation, and the valve does not open
or close completely.
Padlock
Chain
Gear Case
Indicator
SHUT AUTO OPEN
Nut
Handle
FIGURE 8
a. Unlock Padlock ➅ of Manual operator and remove chain ➄.
b. Turning Handle ➁ enables operation of valve to open or close.
Turning the handle ➁ clockwise operates to valve closing, and counter clockwise operates valve opening.
7
KTM PNEUMATIC ACTUATORS - AW, AWN SERIES
INSTALLATION AND OPERATION MANUAL
SECTION 14 - TROUBLESHOOTING
Trouble examples Causes Measures
Valve does not operate Failure in electric power source or control signal. Check and repair of electric power source and/or control devices.
No or insufficient supply air. Check and repair of air source and attachments
(compressor, filter, reducing valve, etc.)
Failure of attachments
(solenoid valve, air actuated control valve, positioner, etc.)
Failure in actuator. After operating actuator separately, disassemble and repair.
Failure of valve. Check and disassemble valve, and repair or replace it.
Unstable operation of valve Fluctuation or low supply air pressure
(insufficient supply or fluctuation).
Failure of attachments (solenoid valve, air actuated valve, positioner, etc.)
Leakage at or failure of piston. Replace piston O-ring.
Wear or damage of piston bearing. Replace piston bearing.
Seal leakage in stem. Replace sealing O-ring.
Insufficient power of actuator. Replace actuator with larger one.
Unstable valve operating torque or increase of valve operating torque. Disassembling and checking valve.
After checking each attachment separately, repair or replace it.
Increase capacity of compressed air supply.
Install accumulator.
Increase pipe diameter.
After trying each attachment separately, repair or replace it.
Increase supply pressure.
Repair or replace valve parts.
Replace actuator with larger one.
Increase supply pressure.
CAUTION
SECTION 16 - WARRANTY
If there are any troubles in valve, read the
Installation and Maintenance Instructions of
the valve thoroughly and disassemble the valve
carefully.
The warranty period is one year from the date
of installation by the first use of the goods, or
eighteen (18) months from the date of shipment
to the first user, whichever occurs first.
SECTION 15 - MAINTENANCE
Regular maintenance period depends on
the operating environment and conditions.
Generally maintenance after 100,000 operations
or after 24 months from initial operation,
(whichever comes earlier), is recommended.
Replacing of spring units of single acting
actuator after 200,000 operations or 60 months
from first operation, (whichever comes earlier),
is recommended.
Consumption supplies should be replaced with
new ones at the same time regardless the
degree of wear and deterioration.
For purchasing spare parts, please consult a
Service Company affiliated with Emerson or a
branch office of Emerson.
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
KTM is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions,
Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed
as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and
conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
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