Emerson EL-O-Matic FS 0012, EL-O-Matic FS 0150, EL-O-Matic FS 0350, EL-O-Matic FS 0200, EL-O-Matic FS 0600 Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual

EL Matic

EL-O-Matic F-Series

Rack and Pinion Pneumatic Actuators

DOC.IOM.EF.EN, Rev. 6

September 2015

EL-O-Matic F

DOC.IOM.EF.EN Rev. 6

Table of Contents

Section 1: Before You Start

1.1 Installation, Operation and Maintenance Reference Documents ................ 1

1.2 Warehouse Storage.................................................................................... 1

1.3 On-Site Storage ......................................................................................... 2

Section 2: Introduction

2.1 Identification ............................................................................................. 3

2.2 Intended Use .............................................................................................4

2.3 Specifications ............................................................................................ 4

Section 3: Product Code

3.1 Configuration code for a default actuator. .................................................. 6

Contents

September 2015

Section 4: Installation

4.1 Before You Start ......................................................................................... 7

4.2 Failure Modes............................................................................................. 7

4.2.1 Valve Rotation .............................................................................. 7

4.2.2 Position After Failure ..................................................................... 8

4.3 Principles of Operation ...............................................................................8

4.3.1 Solenoid Valve .............................................................................. 8

4.3.2 Ingress Protection (IP) rating ........................................................ 9

4.3.3 Double-Acting Actuators ............................................................ 10

4.3.4 Spring-Return Actuators ............................................................. 11

4.4 Actuator Assembly Codes ........................................................................ 12

4.5 Actuator to Valve Installation ................................................................... 13

4.6 Mounting of control and feedback accessories ......................................... 15

4.7 Recommended Tubing Sizes .................................................................... 16

Section 5: Mechanical Stroke Adjustment

5.1 Travel Stop Adjustment ............................................................................ 18

5.1.1 Double-Acting Actuators ............................................................ 18

5.1.2 Spring-Return Actuators ............................................................. 18

5.1.3 Angular Displacement ................................................................ 19

Section 6: Maintenance

6.1 General .................................................................................................... 20

6.2 Repair ...................................................................................................... 20

6.2.1 Spring-Return actuator ............................................................... 20

6.2.2 Recommended Spare Parts ......................................................... 20

ITable of Contents

EL-O-Matic F

DOC.IOM.EF.EN Rev. 6

Section 7: Decommission (Out of Service)

Section 8: Disassembly

Section 9: Reassembly

Contents

September 2015

7.1 Before You Start ....................................................................................... 22

7.2 Removing the actuator from the valve ..................................................... 23

8.1 Removing End Caps .................................................................................25

8.2 Removing Spring Cartridges (Spring-Return) ...........................................26

8.3 Removing of Limit Stop ........................................................................... 27

8.4 Removing Pistons ....................................................................................27

8.5 Removing Pinion ...................................................................................... 28

8.6 Cleaning the Body .................................................................................... 28

9.1 Grease Instructions .................................................................................. 30

9.2 Reassembly of the pinion ......................................................................... 31

9.3 Reassembly of the pistons ........................................................................ 32

9.4 Reassembly and settings of the limit stops ............................................... 34

9.5 Reassembly of the end caps ..................................................................... 34

9.5.1 Double-Acting actuators ............................................................ 34

9.5.2 Spring-Return actuators ............................................................. 36

9.6 Basic function and Air Leak Test ............................................................... 38

Section 10: Troubleshooting

10.1 Mechanical Problems ............................................................................... 39

10.2 Pneumatic Problems ................................................................................ 40

10.3 Electrical Problems .................................................................................. 41

Section 11: Parts List and Spare Parts Recommendations

11.1 Exploded View and Parts List .................................................................... 42

Appendix A: Spring load removal

A.1 Spring load relief ................................................................................. 43

Appendix B: Tool & Torque Table

» Table B-1 End cap bolts....................................................................... 45

» Table B-2 Bottom Flange .................................................................... 45

» Table B-3 NAMUR (VDE/VDI 3845) flanges ......................................... 46

» Table B-4 Limit stop dimensions ......................................................... 46

» Table B-5 Recommended circlip pliers ................................................. 46

Table of Contents

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 1: Before You Start

This section explains:

• Base safety procedures

• Where to find detailed information relating safety.

• Storage guidelines.

Installation, adjustment, putting into service, use, assembly, disassembly and maintenance of the pneumatic actuator must be performed by qualified personnel.

NOTICE

Failure to follow the above guidelines will void warranty.

WARNING

Section 1: Before You Start

September 2015

Actuator must be isolated both pneumatically and electrically before any (dis)assembly starts. Before mounting or (dis)assembly, the actuator consult the relevant sections of this manual.

1.1 Installation, Operation and Maintenance Reference Documents

Before you start, read the following documents:

• All chapters in this manual.

• Safety Guide (Document No. DOC.SG.EF.EN).

NOTICE

Failure to read the Safety Guide will void the warranty.

Not following the instructions of the Safety Guide can lead to failure of the product and harm to personnel or equipment.

1.2 Warehouse Storage

Before You Start

• All actuators should be stored in a clean, dry warehouse, free from excessive

vibration and rapid temperature changes.

• All actuators should not be stored directly to the floor surface - it must be placed in

racks/shelves or use a pallet.

Section 1: Before You Start

September 2015

1.3 On-Site Storage

• All actuators should be stored in a clean, dry warehouse, free from excessive

vibration and rapid temperature changes.

• Prevent moisture or dirt from entering the actuator. Plug or seal both air

connection ports.

NOTICE

Failure to follow the above guidelines (Warehouse and On Site Storages) will void warranty.

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Before You Start

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 2: Introduction

This section explains:

• How to identify the received product,

• The intended use of the product

• Construction details

• Actuator specifications

2.1 Identification

The EL-O-Matic F Rack and Pinion actuators are available as double-acting or spring-return versions. 13 models are available, ranging from 12 Nm to 4000 Nm (106 to 35000 lbf.in) nominal torque output.

The EL-O-Matic F-Series uses standardized interfaces for solenoid, switchbox or positioner mounting (VDI/VDE3845; NAMUR). The valve interface is equipped with an insert in the pinion bottom that allows both ISO5211 or DIN3337 mounting.

Section 2: Introduction

September 2015

The springs in the spring-return version allow a fail action in case of loss of air supply pressure (Fail-to-Close or Fail-to-Open).

As from size FD150 double-acting versions have flat end caps to reduce actuator length and internal air volume.

Figure 1 Identification

Introduction

1. Top auxilliaries interface (VDI/VDE 3845; NAMUR)

2. Solenoid interface (VDI/VDE 3845; NAMUR)

3. Valve interface with ISO5211, DIN 3337 patterns and insert drive

4. Spring-return actuators: - with springs

5. Double-acting actuators: - no springs

6. High end caps for double-acting and spring-return models up to size 100

7. Low end caps for double-acting models as from size 150 and larger

Section 2: Introduction

September 2015

2.2 Intended Use

The EL-O-Matic F Rack and Pinion actuators are intended for the automation and operation of quarter-turn valves like Butterfly, Ball and Plug valves.

Rack and Pinion actuators can also be used to operate dampers or any other quarter-turn applications.

2.3 Specifications

Table 1. Pressure Range

Actuator Type Pressure

Double-Acting 0.2 to 8.3 barg (2.9 to 120 psig)

Spring-Return

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

6 to 8.3 barg (87 to 120 psig), with maximum spring set 3 to 8.3 barg (43.5 to 120 psig), reduced spring quantity

Table 2. Operating Media

Actuator Type Operating Media

Air, dry or lubricated and inert gases Dew point at least 10K below ambient temperature

Double-Acting and Single-Acting

For sub-zero applications, take appropriate measures Mentioned pressure levels are "gauge pressures".

Gauge pressure is equal to absolute pressure minus atmospheric pressure.

Table 3. Temperature Range

Actuator Type Temperature

Standard -20°C to +80°C (-4°F to +176°F) Option: Low Temperature -40°C to +80°C (-40°F to +176°F) Option: High Temperature -20°C to +120°C (-4°F to +248°F)

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Table 4. Air Volumes and Consumption

Actuator volumes:

Actuator

size

12 0.05 0.06 0.04 0.14 0.24 0.44 0.16 0.28 0.52 25 0.11 0.19 0.08 0.36 0.64 1.2 0.48 0.88 1.7 40 0.16 0.36 0.15 0.67 1.2 2.2 0.89 1.6 3.1

65 0.36 0.55 0.22 1.02 1.8 3.4 1.3 2.4 4.7 100 0.4 0.8 0.3 1.5 2.7 5.0 2.0 3.8 7.2 150 0.8 0.7 0.5 2.4 4.3 8.1 2.1 3.6 6.7 200 0.8 1.0 0.7 3.2 5.7 11 2.8 4.9 9.1 350 1.9 1.7 1.2 5.5 9.8 18 5.0 8.8 16 600 3.6 3.3 2.1 9.4 17 31 8.7 15 28 950 5.1 4.3 3.2 13 24 44 12 20 37

1600 2500 4000 18.4 18.9 14.0 51 88 161 52 89 165

Maximum volume (in liters) Outward Stroke Inward Stroke

Central

chamber

End cap chamber

Displaced

volume

7.8 7.0 5.2 21 37 68 19 33 62

10.4 11.1 8.2 29 50 92 30 53 97

Section 2: Introduction

September 2015

Consumption per stoke

(in liters, pressure in barg)

Double-Acting

and Spring-Return

Double-Acting only

2.0 barg 4.0 barg 8.0 barg 2.0 barg 4.0 barg 8.0 barg

Actuator volumes:

Consumption per stoke

(in Cu.in., pressure in psig)

Maximum volume (Cu.in.) Outward Stroke Inward Stroke

cham-

ber

Displaced

volume

Double-Acting

and Spring-Return

Double-Acting only

40 psig 80 psig 120 psig 40 psig 80 psig 120 psig

Actuator

size

Central

chamber

End cap

12 3.1 3.7 2.5 11 19 28 13 23 33

25 6.4 11.8 4.7 28 52 75 38 72 106

40 10.0 22 8.9 53 96 140 71 133 196

65 22 34 13.5 81 148 215 107 200 294 100 22 50 19.9 118 216 314 165 310 455 150 48 43 32 192 352 512 163 293 424 200 50 59 44 255 466 676 220 397 573 350 118 103 76 436 796 1157 392 709 1025 600 222 201 129 742 1354 1967 683 1237 1790 950 310 260 193 1049 1905 2760 910 1628 2346

1600 477 430 319 1635 2951 4267 1505 2691 3877 2500 638 676 501 2259 4018 5776 2367 4232 6097 4000 1122 1151 853 3946 7040 10134 4027 7202 10377

1. For Double-Acting and Spring-Return. Pistons at 90° outward position

2. Only for Double-Acting. Pistons at 0° inward position

3. Stroke is 90°

Figure 2 Actuator air volumes

Introduction

Central air chamber volume

Double-Acting and Spring-Return

End cap air chamber volume

Double-Acting only

Section 3: Product Code

September 2015

Section 3: Product Code

This section explains:

• How to create the configuration code for a default actuator.

• How to create the configuration code for an actuator with added integral options.

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

FS 0150 . N U 40 CW AL T . NL17 S K A . 00 XX

Type

FD Double-Acting

FS Spring-Return

Size

0012 Size 0012 0025 Size 0025 0040 Size 0040 0065 Size 0065 0100 Size 0100 0150 Size 0150 0200 Size 0200 0350 Size 0350 0600 Size 0600

•

Rotation Angle

N 90° Rotation

Threads

M Metric ISO 5211

U UNC/NPT/Imperial

Spring Set

00 Double-Acting (No Springs) 10 Spring Set 10 20 Spring Set 20 30 Spring Set 30 40 Spring Set 40 50 Spring Set 50 60 Spring Set 60

Cycle Speed Option Internal Code 1 Color/Finish Visual Indicator Temperature Valve Stem Connection Valve Interface Pinion Material Rotation Direction Spring Set Threads Rotation Angle Size Type

Valve Stem Connection (Insert Sizes)

Parallel

Drive

NL09 ND09 9mm / 0.354" 0012

NL11 YD11 11mm / 0.433" 0025 NL14 YD14 14mm / 0.551" 0040 & 0065

NL19 YD17

NL22 YD22 22 mm / 0.866" 0200

NL27 YD22

NL27 YD72 27mm / 1.063" 0600

See Insert Supplement for Additional Insert Options.

Temperature Ranges

S Standard: -20°C to +80°C (-4°F to +176°F) H High: -20°C to +120°C (-4°F to +248°F)

L Low: -40°C to +80°C (-40°F to +176°F)

Visual Indicator Code

K Standard (Knob) N No Visual Indicator

Finish

A Standard Coating

•

Internal Code 1

00 Standard

Diagonal

Drive

0000 No Insert

Square

17 mm / 0.669" 19 mm / 0.748"

22 mm / 0.866" 27 mm / 1.063"

0100 & 0150

0350

Actuator

Size(s)

Rotation Direction

CW Spring to Close/Clockwise

CC Spring to Open/Counterclockwise

Pinion Material

AL High-Grade Aluminium, Hard Anodized

Valve Interface

T Standard ISO 5211 Interface S Small Interface with Center Plate (DIN3337)

L Large Interface with Center Plate (DIN3337)

•

Cycle Speed Options

XX Standard H1 1/2" High Flow plate

Notes

These options are all options available. Not all options apply to

all configurations.

Valve Interface: Option "S"; Small Interface with Center Plate

(DIN3337) is not available for size 0025.

Product Code

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 4: Installation

This section explains:

• The actuator rotation direction.

• In which position the actuator will end after a failure.

• Principles of operation:

— Solenoid operation

— Double acting and Spring return operation

• Assembly codes.

• Actuator to valve assembly.

4.1 Before You Start

Section 4: Installation

September 2015

SAFETY FIRST

In case of an air or electrical failure, it is important to know the behavior of the actuator. Before mounting the actuator on a valve, consult the following sections below.

4.2 Actuator Rotation Direction

4.2.1 Valve Rotation

For the following paragraphs we assume that valves rotate as indicated in figure 3.

Figure 3 Normal valve rotation

Installation

The valve is closed after

a clockwise rotation.

The valve is open after

a counterclockwise rotation.

Section 4: Installation

September 2015

4.2.2 Position After Failure

The position of the actuator after a failure depends on the:

1. Principle of operation (see paragraph 4.3)

2. Assembly codes (see paragraph 4.4)

3. Kind of failure. Refer to the table below.

Table 5. Position After Failure

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Principle of Operation

Double-Acting Actuator

Single-Acting (Spring-Return) Actuator

Assembly Code Kind of Failure Position

Pressure Not defined

Signal Closed Supply Voltage Closed Pressure Not defined Signal Open Supply Voltage Open Pressure Closed Signal Closed Supply Voltage Closed Pressure Open Signal Open Supply Voltage Open

4.3 Principles of Operation

4.3.1 Solenoid Valve

All actuators can be either piped with solid or flexible tubing with the solenoid valve mounted remotely from the actuator or by mounting a VDI/VDE 3845 (NAMUR) designed solenoid valve DIRECTLY onto the NAMUR mounting pad on the side of the actuator

Figure 4 Typical solenoid operation

Spring-Return Operation Double-Acting Operation

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

The table below represents the cycle time (operating time) per different Actuator sizes:

Table 6. Operating Speed

Cycle time in seconds

Actuator

size

F 12 0.4 0.4 0.4 0.4 F 25 0.5 0.4 0.5 0.4 F 40 0.6 0.5 0.6 0.5

F 65 0.7 0.5 0.6 0.6 F 100 0.8 0.6 0.8 0.7 F 150 1.0 0.8 0.9 0.8 F 200 1.3 0.9 1.0 1.0 F 350 1.9 1.3 1.4 1.5 F 600 3.2 1.9 2.2 2.2 F 950 4.6 3.2 3.9 3.6

F 1600 6.9 4.8 5.9 4.8 F 2500 F 4000 15.4 10.8 13.3 13.0

Operating time is average with actuator under load and solenoid valve fitted.

pressurized

Spring-Return Double-Acting

A-port

9.0 6.3 7.8 7.9

Spring stroke

A-port

pressurized

Section 4: Installation

September 2015

B-port

pressurized

Test conditions:

1. Solenoid with flow capacity: 0.6 m3/hr

2. Pipe diameter: 6mm

3. Medium: clean air

4. Supply pressure: 5.5 bar (80psi)

5. Load: with average load

6. Stroke: 90°

7. Temperature: Room temperature

4.3.2 Ingress Protection (IP) rating

EL-O-Matic F actuators are IP66/IP67 rated. In case of IP66 or IP67 requirements, take precautions that comply with the IP66/IP67 requirements to prevent moisture or dust from entering the actuator through the open air exhaust port(s), either directly on the actuator or at the exhaust ports of the connected solenoid valve.

We recommend to connect tubing to the exhaust(s) and lead this into a dry and dust free area, or to use check valves in the exhaust.

Installation

Section 4: Installation

September 2015

4.3.3 Double-Acting Actuators

The operating principle, as explained here, is applicable for actuators with assembly code CW (direct acting).

• Applying supply pressure to port A will move the pistons outward to the "Open"

position of the valve.

• Applying supply pressure to port B will move the pistons inward to the "Close"

position of the valve.

• For assembly codes CC, the operating principle is reversed (reverse acting).

Figure 5 Double-Acting Operation

Outward Stroke

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Inward Stroke

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

4.3.4 Spring-Return Actuators

The operating principle, as explained here, is applicable for actuators with assembly code CW (direct acting).

• Applying supply pressure to port A will move the pistons outwards to the "Open"

position of the valve.

• Venting the supply pressure from port A will cause the springs to move the pistons

inwards to the "Close" position of the valve.

• For assembly codes CC, the operating principle is reversed (reverse acting).

Figure 6 Stroke Movements

Outward Stoke

Section 4: Installation

September 2015

Installation

Inward Stroke

Section 4: Installation

September 2015

Installation, Operation and Maintenance Manual

4.4 Actuator Assembly Codes

Figure 7 Assembly Code - Double-Acting

Assembly code: CW Assembly code: CC

= Standard, Clockwise-to-Close rotation = Reverse, Counterclockwise-to-Open

= Fail-to-Close = Fail-to-Open

Pinion

DOC.IOM.EF.EN Rev. 6

Pistons

A = Rotation when central air chamber is pressurized.

B = Rotation when end cap air chambers are pressurized.

All views are from above. Pistons are shown in inward position.

Figure 8 Assembly Code - Spring-Return

Assembly code: CW Assembly code: CC

= Standard, Clockwise-to-Close rotation = Reverse, Counterclockwise-to-Open

= Fail-to-Close = Fail-to-Open

Pinion

Spring Cartridge

Pistons

Installation

+ 35 hidden pages

Emerson EL-O-Matic FS 0012, EL-O-Matic FS 0150, EL-O-Matic FS 0350, EL-O-Matic FS 0200, EL-O-Matic FS 0600 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual