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

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

4.5 Actuator to Valve Installation

WARNING - MOVING PARTS

Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.

Stay away from moving parts to prevent serious injuries. When test cycling the actuator and valve assembly by applying pressure to the A or B port, be aware that there are moving parts like pinion top, actuator to valve coupling and the valve- blade, ball, plug, etc.

NOTICE

The actuator is designed to be installed, commissioned and maintained using generic tools like wrenches, Allen keys and screwdrivers. For the removal of inserts, a special extractor tool can be supplied on request.

During assembly to the valve, do not hit with hammer on pinion top. This can damage the pinion top washer and cause premature failure.

Section 4: Installation

September 2015

Before mounting the actuator on the valve or valve bracket, be sure that both the actuator and the valve are in the same closed or open position.

Refer to appendix B, Tool and Torque tables, for using the right size tool

Table 7. Tool Table

Symbol Tool Symbol Tool

Wrench – All types and sizes. Metric and Imperial

Circlip Pliers

1. Remove handle nut, handle, lock washer, and etc. from the valve if required.

2. Visually check to make sure the valve is CLOSED.

Figure 9 Valve handle removal

Allen key

Installation

Section 4: Installation

September 2015

3. When required, check if the insert drive (23) is mounted. If not, use a plastic mallet

Figure 10 Insert drive Installation

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

and tap slightly until the reducer square is in the required position. Be sure that the insert is mounted at 90° or 45°. It is possible to mount the insert turned 22.5°. This way the valve will not open or close the right way.

90°

Parallel

square

45°

Diagonal

square

Flat head

90°

Round with

key way

4. Install the bracket to the valve flange. Tighten all bolts and nuts and apply the correct torque.

Figure 11 Bracket Installation

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

5. Install the actuator to the bracket. Tighten all bolts and apply the correct torque (refer to Table 8).

Table 8. Bottom flange torque values

Section 4: Installation

September 2015

Actuator Size ISO Pattern

12 F04 M6 4.5 5 10-24UNC 3.3 3.7

40, 65, 100

150, 200, 350

600

950, 1600, 2500, 4000

F03 inner pattern M5 2.0 3.0 10-24UNC 1.5 2.2 F05 outer pattern M6 4.5 5.0 1/4"-20 3.3 3.7 F05 inner pattern M6 4.5 5.0 1/4"-20 3.3 3.7 F07 outer pattern M8 10.5 12.5 5/16"-18 7.7 9.2 F07 inner pattern M8 10.5 12.5 5/16"-18 7.7 9.2 F10 outer pattern M10 21.0 24.5 3/8"-16 15.5 18.1 F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1 F12 outer pattern M12 34.5 43.0 1/2"-13 25.4 31.7

Torque (Nm) Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

6. When required, mount or adjust the visual indicator (22).

Figure 12 Indicator mounting

"In Line mounting" "Across Line mounting"

4.6 Mounting of control and feedback accessories

Solenoid valve and or switch boxes can now be mounted to the actuator. Check the instructions as shipped with these components for installation, operating and maintenance instructions.

We recommend to test-cycle the complete assembly to check correct operation.

Installation

Section 4: Installation

September 2015

Installation, Operation and Maintenance Manual

4.7 Recommended Tubing Sizes

In case the solenoid valve is mounted remotely (i.e. in a central solenoid cabinet) and in order to supply sufficient flow of air supply to the actuator, the following tubing sizes are recommended.

Table 9. Tubing Sizes

DOC.IOM.EF.EN Rev. 6

Actuator size

Runs up to Runs over to

1.2 meters 4 feet 1.2 meters 4 feet

25, 40, 65 6 mm 1/4 inch 6 mm 1/4 inch 100, 150, 200,

350, 600 950, 1600, 2500,

4000

6 mm 1/4 inch 8 mm 5/16 inch

6 mm 1/4 inch 10 mm 3/8 inch

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 4: Installation

September 2015

Section 5: Mechanical Stroke Adjustment

This section explains:

• What mechanical stroke adjustment is.

• What the factory settings are.

• How to adjust the travel stops.

EL-O-Matic F actuator sizes 25 to 4000 have two stroke adjustment stops for adjusting accurately the stroke of the actuator/valve assembly in open and closed position.

The smallest actuator, size F12, does not have limit stops.

The factory setting of the stroke is 90°. Most quarter-turn valve applications will not require readjustment of these settings.

If required the stroke can be adjusted by means of two-stroke adjustment bolts.

Figure 13 Factory Setting

Size 25 - 600 Size 950 - 4000

10° -5°

80°

95°

80°

93°

Limit Stop 2

-3°10°

90°90°

Limit Stop 1

Installation

Stop 1

Stop 2

Stop 1

Stop 2

Section 5: Mechanical Stroke

September 2015

Installation, Operation and Maintenance Manual

5.1 Travel Stop Adjustment

CAUTION - PRESSURIZED ACTUATOR

Do not turn out the travel stops completely when the actuator is pressurized.

When adjusting the travel stops and the actuator is still pressurized, the travel stops can be “shot” away when completely turned out.

5.1.1 Double-Acting Actuators

1. Operate valve/actuator assembly to the required "Closed" position.

2. Remove air supply.

3. Slacken locknut on the “closed” stop (2).

Figure 14

DOC.IOM.EF.EN Rev. 6

4. Turn the “closed” stop clockwise to reduce or counterclockwise to increase the travel. Consult chapter 5.1.3 (angular displacement of the pinion), to define how far the limit stop must be turned in or out.

5. Tighten the lock nut.

6. Connect air and cycle the actuator to check that the position is correct. If not repeat from 2.

7. Remove air supply.

8. For adjusting the open position repeat steps 1 to 7, but now for the open position and “open” stop (1).

5.1.2 Spring-Return Actuators

1. Connect air supply to the A port. Actuator will move to the open position.

2. Slacken locknut (24) on the “closed” stop (2).

Figure 15

Mechanical Stroke

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

3. Turn the “closed” stop clockwise to reduce or counterclockwise to increase the travel. Consult chapter 5.1.3 (angular displacement of the pinion), to define how far the limit stop must be turned in or out.

4. Remove air supply. Actuator will move to the closed position.

5. Check whether the actuator valve assembly is in the required position. If not repeat steps 1 to 5.

6. Remove air supply.

7. For adjusting the open position repeat steps 1 to 6, but now for the open position and "open" stop (1).

Table 10. Limit stop dimensions

Actuator size Thread

25 M 6 10 10 40 M 8 13 13

65 M 10 17 (16)* 17 (16)* 100 M 10 17 (16)* 17 (16)* 150 M 10 17 (16)* 17 (16)* 200 M 12 19 (18)* 19 (18)* 350 M 16 24 24 600 M 20 30 30 950

1600 2500 4000

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

3. Actuator size 12 is not available with limit stops.

Section 5: Mechanical Stroke

September 2015

Bolt Wrench Nut wrench

size (mm) size (mm)

5.1.3 Angular Displacement

Below table identifies, per actuator size, what the angular displacement of the pinions is, when using the limit stop screws.

— Turn the limit stop clockwise reduces the stroke

— Turn the limit stop counterclockwise to increase the stroke

Table 11. Angular Displacement

Actuator size

F 12 Actuator size 12 is not available with limit stops F 25 0.7 7.1° F 40 0.8 6.3°

F 65 0.6 8.3° F 100 0.7 7.1° F 150 1.2 4.2° F 200 1.0 5.0° F 350 0.8 6.3° F 600 0.8 6.3° F 950

F 1600 F 2500 F 4000

Turns for 5° adjustment of

the pinion:

360° revolution of limit

stop screw will adjust

Mechanical Stroke

NOTICE

In case of air leakage over the limit stop bolts, turn the lock nut of the limit stop bolts tighter, until leakage stops.

Section 6: Maintenance

September 2015

Section 6: Maintenance

This section explains:

• When and how to do maintenance.

— Normal maintenance

— Extraordinary maintenance

• What to do when replacing springs.

• What the availability is of spare parts, action conversion kits and temperature

conversion kits.

WARNING

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

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

6.1 Normal Maintenance

EL-O-Matic F actuators are designed to operate without maintenance for their normal working life. Normal working life is 500,000 cycles.*

We recommend regular inspections to make certain that the actuator / valve assembly operates smoothly and to check that there are no visible or audible defects. We advise to perform the following checks upon each proof test interval complying with the rules and regulations of the country of final installation:

• Visually check the entire actuator as well as the control system (where foreseen).

• Ensure there are no leaks on the actuator parts under pressure.

• Check pneumatic connections for leaks. Tighten tube fittings as required.

• Check if manual override (where foreseen) is regular.

• Check if pneumatic filter cartridge (where foreseen) is sound and filter bowl

(where foreseen) has been cleaned properly.

• Check the setting of the relief valves (where foreseen).

• Verify that the power fluid supply pressure value is within the required range.

• Remove built-up dust and dirt from all actuator surfaces.

• Inspect actuator paint work for damages to ensure continued corrosion protection.

Touch-up as required in accordance with the applicable paint specification.

• Operate the Actuator/Valve assembly for 2 complete open/close cycles with

complete closing of the valve.

• Verify the correct performing of open – close operations (e.g. check locally,

or automatically via Logic solver, the correct movement of the actuator).

Maintenance

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

All actuators are supplied with sufficient lubrication for their normal working life. If required, see Section 9.1 (Grease instructions) for the recommended grease.

For mounting the parts of the repair kit follow the instruction of the Decommission, Disassembly and Reassembly chapters of this manual.

Note:

*Cycles = one open stroke and one close stroke.

6.2 Inspection and Repair

Replacement of internal seals and bearings allows to you extend the normal working life. Service kits, containing all necessary spare parts (like seals, bearings, grease and instructions) can be obtained through authorized Emerson Process Management – Valve Automation distributors.

Section 6: Maintenance

September 2015

6.2.1 Service Kits

All soft seals, bearings, and nonreusable parts are included in the recommended service kit. The service kit is identical for both the double-acting and the spring-return models.

6.2.2 Spring-Return Actuator

For the spring-return models, we recommend a set of spare springs for each different model in addition to the recommended spare parts kit.

On spring-return actuators, the spring cartridges can be replaced. SPRING CARTRIDGES SHOULD ALWAYS BE REPLACED IN COMPLETE SETS. Spring kits are available through authorized Emerson Process Management – Valve Automation distributors.

Maintenance

Section 7: Decommission (Out of Service)

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 7: Decommission (Out of Service)

This section explains:

• How to decommission an actuator in a safe way.

7.1 Before You Start

WARNING - MOVING PARTS

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

Actuator can move when removing supply pressure and/or electrical control signal of actuators. If not already there, a spring-return actuator will cycle to its fail position.

When removing any ball valve or plug valve assemblies from a pipe system, isolate the piping system on which the Actuator is installed and relieve any media pressure that may be trapped in the valve cavities before removing the actuator for maintenance.

A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a high spring load which will cause a sudden rotation of the actuator versus the valve or valve bracket during disassembly. This can cause serious injury to personnel or damage to property.

Refer to Appendix A for instructions to safely remove the spring load before disassembling the spring-return actuator from valve or bracket.

Important

Refer to the Safety Guide for Lifting Instructions.

Decommission

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 7: Decommission (Out of Service)

7.2 Removing the actuator from the valve

1. Disconnect all air supply hoses (Ports A and B or solenoid).

2. Disconnect all electrical wirings of the switch box.

3. Disconnect the electrical wiring of the solenoid valve.

4. Remove the bolts and nuts from the valve flange.

5. Remove the bracket from the actuator.

6. Remove the switch box and solenoid valve. Refer to the documentation of the switch box and solenoid valve for safe disassembly.

Figure 16 Removing actuator from valve

September 2015

Decommission

Section 8: Disassembly

September 2015

Section 8: Disassembly

This section explains:

• How to disassemble an actuator safely.

Tip

The instructions of this section can be used for maintenance or reconfiguration like spring set change or maintenance.

Reference numbers for components refer to the exploded view in section 11.

In case of maintenance, discard all the used soft parts like O-ring seals, guide bands, wear strips and circlip.

WARNING

Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Before mounting or (dis)assembling the actuator consult the relevant sections of this manual.

CAUTION - SPRING FORCE

Spring-return actuators contain springs in a compressed state. Follow these instructions to release the spring force safely.

Normally the end caps of spring-return actuators should be free of the spring load after 10 full turns (crosswise relaxing) of the end cap screws. If there is still spring load on the end cap, this might indicate a broken spring cartridge. Stop this disassembly procedure immediately. Continuing might cause the end cap to be “shot” away causing serious injury.

Refer to Appendix A for instructions to safely remove the spring load before disassembling the end cap of a spring-return actuator with a broken spring cartridge.

NOTICE

The actuator is designed to be installed, commissioned and maintained using generic tools like wrenches, Allen keys and screwdrivers.

Refer to the tables in this section or refer to appendix B Tool and Torque tables.

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

8.1 Removing End Caps

1. For Double-acting actuators, do the following:

a. Loosen the screws (10) of the end caps (2).

b. Remove the o-ring (14) and "B" port seal (16). Discard these parts.

Figure 17 Double-Acting End Caps Removal

Section 8: Disassembly

September 2015

The above end caps (2) are for Actuator sizes 25, 40, 65 and 100.

End caps (2) for Actuator sizes 150 and larger will have flat end caps (see below).

Disassembly

Section 8: Disassembly

September 2015

2. For Spring-return actuators, do the following:

Figure 18 Spring-Return End Caps Removal

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

a. Tip: For actuators with assembly code CW, turn back the right hand limit

stop screw (17) 2 full turns. For actuators with assembly code CC, turn back the left hand limit stop screw (17) 2 full turns. This will lower the spring force on the end cap and reduces the screw out length of the end cap screws.

b. Important: Apply a strong, sudden rotational and downward force to

loosen all the end cap screws (10) for maximum 1/4 turn.

c. Uniformly loosen the screws (10) of the end caps (2) 1/4-1/2 turns at a

time, in sequence, as per figure 18, to relieve the pre-load of the springs.

d. Remove the o-rings (14) and "B" port seals (16). Discard these parts.

8.2 Removing Spring Cartridges (Spring-Return)

1. Remove the spring cartridges (5).

Figure 19

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

8.3 Removing of Limit Stop

1. Remove the limit stop screws (17), limit stop nuts (18), limit stop washers (19) and limit stop o-rings (15). Discard the o-rings.

Figure 20 Limit Stop Removal

Section 8: Disassembly

September 2015

8.4 Removing Pistons

1. Use a wrench and turn the pinion counterclockwise (180°) until the pistons (3) comes out of the body.

2. Remove the piston bearings (7), piston rack bearing strips (6) and piston o-ring seals (13). Discard these parts.

Figure 21 Piston Removal

Disassembly

Section 8: Disassembly

September 2015

8.5 Removing pinion

1. Remove the circlip (11) and thrust washer (9) on top of the pinion assembly. Discard if necessary the circlip (11) and thrust washer (9).

2. Remove the pinion (4) by pushing it downwards.

3. Remove the pinion o-ring seals (12) and the pinion bearings (8). Discard all of these parts.

Figure 22 Pinion Removal

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Table 12. Recommended circlip pliers according DIN 5254 (or equal) for shaft circlips.

Actuator size Pinion top diameter Pliers according DIN 5254

12 16 mm 0.630" A1 25 - 100 22 mm 0.866" A2 150 - 350 36 mm 1.417" A3 600 55 mm 2.165" A3

8.6 Cleaning the Body

In case of maintenance, use a clean dry cloth and thoroughly wipe clean and remove old grease from:

• The inside and outside of the body including thread holes and crevices/grooves

• The pinion gears

• The pistons

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 9: Reassembly

This section explains:

• Which parts and how to grease them.

• How to reassemble a complete actuator.

• How to set the stroke adjustment bolts after reassembly.

• How to do a basic function and air leak test.

Tip

The instructions of this section can be used for maintenance or reconfiguration like spring set change or maintenance.

Reference numbers for components refer to the exploded view in section 11.

In case of maintenance, discard all used soft parts like O-ring seals, guide bands and wear strips and circlip and replace them with the parts as supplied in the repair kit.

In case of reconfiguration replace the parts as supplied in the conversion kit (see also chapter 6).

Section 9: Reassembly

September 2015

Refer to the Safety Guide for Lifting Instructions.

NOTICE

The actuator is designed to be installed, commissioned and maintained using generic tools like wrenches, Allen keys and screwdrivers.

Refer to the tables in this section or refer to appendix B Tool and Torque tables.

Reassembly

Section 9: Reassembly

September 2015

9.1 Grease Instructions

Check the product coding on the product labels and chapter 3 of this manual, to define which type of grease to use.

- For standard actuators (-20°C to +80°C / -4°F to +176°F):

Castrol High Temperature grease (or equivalent).

- For low temperature operation (-40°C to +80°C / -40°F to +176°F):

Castrol Optitemp TT1 or LG2 grease (or equivalent).

- For high temperature operation (-20°C to +120°C / -4°F to +248°F):

Castrol High Temperature grease (or equivalent).

We recommend using a suitable sized paint brush to apply the required amount of grease on the parts as per Table 12 and Figure 23.

Table 13. Grease Instructions

Part Section of part Amount of grease

O-rings: A Completely Light film

B Piston bore Light film

Housing Parts:

Piston Parts:

C Top pinion bore Light film D Bottom pinion bore Light film E O-ring & bearing groove Light film F Rack teeth Half the teeth depth full with grease G Piston bearing Light film on outside H Piston rack bearing strip Light film J Pinion bottom & O-ring groove Light film K Pinion top & O-ring groove Light film L Gear teeth Half the teeth depth M Pinion top bearing Light film (inside and out) N Pinion bottom bearing Light film (inside and out)

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Figure 23 Grease Instructions

Reassembly

1 2

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

9.2 Reassembly of the pinion

1. Grease the pinion parts according to chapter 9.1.

2. Install the pinion bearings (8) and the O-ring seals (12) on the pinion (4).

3. Insert the pinion (4) on the housing.

4. Install the thrust washer (9) and mount the circlip (11) on the pinion top using circlip pliers.

— Install the new circlip onto its mating groove on the top shaft extension

and with the non-sharp edge (2) towards the housing and the sharp edge (1) towards the top of the shaft.

Figure 24 Reassemble the pinion

Section 9: Reassembly

September 2015

Table 14. Recommended circlip pliers according DIN 5254 (or equal) for shaft circlips.

Actuator size Pinion top diameter Pliers according DIN 5254

12 16 mm 0.630" A1 25 - 100 22 mm 0.866" A2 150 - 350 36 mm 1.417" A3 600 55 mm 2.165" A3

Reassembly

Section 9: Reassembly

September 2015

Installation, Operation and Maintenance Manual

9.3 Reassembly of the pistons

NOTICE

Before reassembling the pistons, check the required assembly code (see section 4.2).

1. Grease the piston parts according to step 9.1.

2. Install the piston bearings (7), piston rack bearing strips (6) and piston o-ring seals

(13) on the pistons. Ensure all these parts are kept in place during assembly.

Figure 25 Reassemble the pistons

DOC.IOM.EF.EN Rev. 6

3. Align the pinion (see Figure 26) so that the teeth on the pinion will pick up the

pistons rack teeth when turning the pinion. Note the position of the pinion top slot and the cam on the pinion top:

— For standard or Spring-to-Close: Assembly Code CW

— For reverse or Spring-to-Open: Assembly Code CC

4. Slightly push the pinion inward to engage with the pinion.

— Ensure that smooth movement and 90-degree operation can occur

without moving the pistons out of the actuator body.

— For larger pistons, use a rubber mallet and slightly hitting the pistons

inward to engage with the pinion.

5. When the pistons are moved 90° inwards (see figure 26), check that the pinion slot

on the pinion top is:

— Perpendicular to the length centre line of the house for assembly code CW.

— In line to the length centre line of the house for assembly code CC.

6. If not, turn pinion to move the pistons outward until they disengage from the

pinion. Shift one tooth of the pinion, reassemble and check again.

Reassembly

90°

Assembly code CW Assembly code CC

(Standard; Spring-to-Close) (Reverse; Spring-to-Open)

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Figure 26 Position of the slot and the cam on the pinion top

Section 9: Reassembly

September 2015

A = Position of cam

B = Position of slot and in dot in pinion

C = Final position of pinion dot

Note:

When the pistons are completely moved inwards, the pinion top will show a 5° over travel.

Reassembly

Section 9: Reassembly

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

9.4 Reassembly and settings of the limit stops

1. Install the limit stop screws (17), limit stop nuts (18), limit stop washers (19) and

limit stop o-rings (15).

Figure 27 Install Limit Stop Bolts

2. Move the pistons inward until the slot in the top of the pinion is perpendicular to

centerline of the housing.

3. Double check if the position of the slot and the cam on the pinion top is in the

correct position (see figure 26). Screw in the right hand travel stop until it comes into contact with the pinion stop face.

4. Move the pistons outward until the slot in the top of the pinion is in line with the

centerline of the housing.

5. Screw in the left hand travel stop until it comes into contact with the pinion stop

face.

— For accurate travel stop adjustment of the actuator on the valve, see

section 5.

9.5 Reassembly of the end caps

9.5.1 Double-Acting actuators

1. Grease the O-ring seals (14) and B port seals (16) according to step 9.1.

2. Ensure that O-ring seals (14) and B port seals (16) are kept in place during

assembly.

3. Install the end caps (2) and tighten the end cap screws (10). Refer to Table 14 for

the correct torque.

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Figure 28 Double-acting end cap assembly

The above end caps (2) are for Actuator sizes 25, 40, 65 and 100.

Section 9: Reassembly

September 2015

End caps (2) for Actuator sizes 150 and larger will have flat end caps (see below).

Table 15. End cap Screw Torque

Actuator

size

12 M4 25 M5 40 M5

65 M5 100 M5 150 M6 200 M6 350 M8 600 M10 950

1600 2500 4000

Thread Tool Size

SW 3 1.1 0.8 1.3 0.8 0.6 1.0 SW 4 SW 4 SW 4

Allen key

SW 4 SW 5 SW 5 SW 6 SW 8

Torque (Nm) Torque (lbf.ft)

Target Min. Max. Target Min. Max.

2.0 1.6 3.0 1.5 1.2 2.2

3.3 2.6 5.1 2.4 1.9 3.8

8.4 6.7 12.2 6.2 4.9 9.0

15.3 12.2 24.8 11.3 9.0 18.3

Reassembly

2 3

5 6

2 3

5 6

2 3

5 6

2 3

5 6

2 3

5 6

2 3

5 6

Section 9: Reassembly

September 2015

9.5.2 Spring-Return actuators

Important

When replacing spring cartridges in a spring-return actuator, ensure that the cartridges are replaced in their identical position from where they were removed.

Check below figure to see where to place the spring cartridges in case of spring set conversion.

Before assembling the spring cartridges and end caps, make sure that the pistons are completely inwards.

Figure 29 Spring cartridge placement

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

N=10 N=20 N=30

N=40 N=50 N=60

A = Piston top view B = Position of gear rack

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

1. Grease the O-ring seals (14) and B port seals (16) according to step 9.1.

2. Ensure that O-ring seals (14) and B port seals are kept in place during assembly.

3. Place the spring cartridges in actuator as per required spring set (see Figure 29).

4. Tighten each end cap screw in small equal turns and in the sequence as per Figure

28. Refer to Table 13 for the correct torque. We recommend to use some grease on the screws for easier fastening.

Figure 30 Spring-return end cap assembly

Section 9: Reassembly

September 2015

Reassembly

Section 9: Reassembly

September 2015

Installation, Operation and Maintenance Manual

9.6 Basic function and Air Leak Test

CAUTION - MOVING PARTS

Applying pressure to the actuator will cause the actuator/valve assembly to operate.

1. Apply pressure (max. 8 bar/116 psi) to ports A and B. Use some soap suds at the indicated points: around pinion top (1), pinion bottom (2), the end caps (3) and limit stops (4).

2. In case of leakage around:

a. The limit stop bolts (and/or the spring-package bolt at spring-return

models). Turn the lock nut of the bolts tighter; until the leakage stops.

b. The end caps: Disassemble the end caps, replace o-rings and reassemble.

c. The pinion top or bottom and A- or B- port: Disassemble the complete

actuator, replace o-rings and reassemble.

DOC.IOM.EF.EN Rev. 6

Figure 31 Basic function and air leak test

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 10: Troubleshooting

10.1 Mechanical Problems

Problem Possible error Solution Where to find

Feedback position and actual position are not the same.

Valve is in “Closed” position, actuator is in “Open” position and will not move anymore.

Actuator and valve are mounted 90° rotated in relation to each other.

Limit stop screws are not set correctly.

Remove actuator from valve. Check assembly code of actuator. Put both valve and actuator in “Closed” position. Mount actuator on valve.

Readjust the limit stop screws.

Section 10: Troubleshooting

September 2015

Section 4

Section 5

Valve does not reach the completely “Closed” or “Open” position.

Actuator rotates, valve does not.

Actuator does not rotate or does not rotate smoothly.

Limit stop screws cannot be turned out anymore.

Insert is not mounted properly.

Pressure to low. Apply pressure as per sizing.

Sizing is wrong.

Pinion is mounted in the wrong position.

No coupling between actuator shaft and valve spindle.

Broken gearing on pistons or pinion.

Spring or Spring cartridge is broken.

Limit stop screws is bend.

Mount the insert in the right position. Remark: Rotate insert to one cam = 22.5°.

Check valve torque data with actuator torque data.

Re assemble actuator. Section 9

Install a coupling between actuator shaft and valve spindle.

Contact nearest EL-O-Matic representative to replace actuator.

Section 4.5

Appendix A.

Troubleshooting

Section 10: Troubleshooting

September 2015

10.2 Pneumatic Problems

Problem Possible error Solution Where to find

Actuator does not react to electrical control signal.

Actuator does not react good to electrical control signal.

Air leakage between actuator and solenoid valve.

There is no supply pressure at the actuator.

There is sufficient supply air pressure but insufficient supply air capacity.

Supply pressure too low, causing pilot operated solenoid valve to fail.

Solenoid valve is not mounted properly.

Speed control throttle (if present) blocks air flow.

Manual override (if present) on the Solenoid Valve is locked.

Sealing between solenoid valve and actuator is not mounted air tight.

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 2.3 Supply the right pressure to the actuator.

Take care the supply air tubing has the right dimensions.

Check that supply pressure at the actuator and solenoid is sufficient to operate the actuator.

Check the solenoid valve mounting.

Turn the speed control more open.

Unlock manual override on the solenoid valve.

Reassemble solenoid valve taking care, that all seals are in place.

Check that the actual

supply pressure is

higher than the sizing

pressure.

Section 4.6

Section 2.3

Check that the actual

supply pressure is

higher than the sizing

pressure.

Instructions shipped

with the solenoid valve.

Instructions shipped

with the speed control

valve.

Instructions shipped

with the manual

override.

Instructions shipped

with the solenoid valve.

Double-acting actuator will only move to “open” position.

Leakage notice on the actuator.

Actuator has wrong solenoid valve configuration.

Seals on the limit stops screws are not air tight.

Seals on the end caps are not air tight.

Seals on the pinion top and bottom are not air tight.

Mount a solenoid valve suitable for doubleacting actuators (4/2 or 5/2 function).

Check that conversion plate on solenoids, that have both 3/2 and 5/2 functions, is in the right position.

Turn the lock nut of the bolts tighter; until the leakage stops.

Disassemble the end caps, replace O-rings and reassemble. Consider to replace all O-ring seals and bearings.

Disassemble the complete actuator, replace O-rings and reassemble. Consider to replace all O-ring seals and bearings.

Instructions shipped

with the solenoid valve.

Instructions shipped

with the solenoid valve.

Section 9.6

Section 9.6 or Section 6

Troubleshooting

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

10.3 Electrical Problems

Problem Possible error Solution Where to find

Control wiring. Power supply wiring or feedback wiring are not

Actuator does not react to control signals.

There are problems with position feedback after sending the actuator to either the “Open” or “Closed” position.

right connected. The power supply

voltage is not is not the same as the voltage of the applicable solenoid valve.

The wiring of the feedback signals may be switched.

Section 10: Troubleshooting

Connect all wiring in the right way.

Connect the right power supply voltage.

Connect the feedback wiring in the right way.

September 2015

Instructions of the

control or feedback

accessories.

Instructions of the

solenoid valve.

Instructions of the

feedback device.

Troubleshooting

Section 11: Parts List and Spare Parts

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 11: Parts List and Spare Parts

Recommendations

11.1 Exploded View and Parts List

Table 16. Parts List

Pos. Qty Description Material

1 1 House Cast Aluminium alloy 2 2 End cap Cast Aluminium alloy 3 2 Piston Cast Aluminium alloy 4 2 Pinion High grade aluminium 5 Max. 12 Spring cartridge Spring steel 6 2 * Bearing strip piston rack POM 7 2 * Bearing piston PTFE 25% carbon-filled 8 2 * Bearing pinion POM

9 1 * Thrust washer POM, black UV stabilized 10 8 End cap screw Stainless Steel 11 1 * Circlip Spring steel 12 2 * O-ring seal pinion Nitrile rubber 13 2 * O-ring seal piston Nitrile rubber 14 2 * O-ring seal end cap Nitrile rubber 15 2 * O-ring seal limit stop Nitrile rubber 16 2 * B-port seal Silicon rubber 17 2 Limit stop screw Stainless steel 18 2 Limit stop nut Stainless steel 19 2 Limit stop washer PA66 20 2 Warning sticker Polyester 21 1 Indicator assembly ABS + stainless steel screw 22 1 Center plate (option) Nylon PA6, Black 23 1 Insert drive Aluminium

* = Included in Service Kit.

Parts List and Spare Parts

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Appendix A: Spring load removal

This section explains:

• How to remove the spring load safely of spring-return actuators in case:

— The valve gets “stuck” in mid position.

— One of the spring cartridges is broken.

WARNING - MOVING PARTS

A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a high spring load which will cause a sudden rotation of the actuator versus the valve during disassembly. This can cause serious injury to personnel or damage to material.

On spring-return actuators with a broken spring cartridge, the end cap can be “shot” away during disassembly of the actuator. This can cause serious injury to personnel or damage to material.

Appendix

September 2015

A.1 Spring load relief

CAUTION - ROTATING ACTUATOR

In case of an actuator/valve assembly “stuck” in mid position, leave the actuator on the valve and/or mounting bracket during this procedure.

Figure A-1 Spring load removal

WARNING

Crush / Amputaion Hazard

Failure to follow instructions for removal of spring loaded actuator may result in surious personal injury

Appendix

1. Depressurize the actuator completely.

2. Based on the actuator size, choose the correct threaded rod kit from Table A-1.

3. Replace one by one each end cap screw for the threaded rod kit and turn down the adjusting nut until it touches the end cap.

4. Once all for end cap screws have been replaced, gradually turn the adjustment nuts on threaded rod in CCW direction by turning the nuts half turn at a time. Make sure the rod itself does not turn. Continue this until the load of springs are relieved.

5. Repeat the same procedure for the end cap screws on the other size of the actuator as shown in figure A-1.

6. In case of an actuator/valve assembly “stuck” in mid position: The actuator now can be disassembled from Valve, by removing the mounting studs/bolts.

Appendix

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Table A-1. Threaded rod dimensions in mm

Actuator Size Thread

12 M4 132 5.2 25 M5 140 5.5 40 M5 140 5.5 65 M5 140 5.5 100 M5 140 5.5 150 M6 145 5.7 200 M6 145 5.7 350 M8 185 7.3 600 M10 185 7.3 950 1600 2500 4000

Threaded rod length

(mm) (inch)

Figure A-2 Spring load removal rod dimensions

Length

Thread

Washer

Holding nuts

Threaded Rod

Adjusting nut

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Appendix B: Tool & Torque Table

This section explains:

• Which tools to use for the indicated fasteners

• The recommended amount of torque to apply on the indicated fasteners.

Table B-1. End cap bolts

Actuator

size

12 M4 25 M5 40 M5

65 M5 100 M5 150 M6 200 M6 350 M8 600 M10 950

1600 2500 4000

Thread Tool Size

SW 3 1.1 0.8 1.3 0.8 0.6 1.0 SW 4 SW 4 SW 4

Allen key

SW 4 SW 5 SW 5 SW 6 SW 8

Torque (Nm) Torque (lbf.ft)

Target Min. Max. Target Min. Max.

2.0 1.6 3.0 1.5 1.2 2.2

3.3 2.6 5.1 2.4 1.9 3.8

8.4 6.7 12.2 6.2 4.9 9.0

15.3 12.2 24.8 11.3 9.0 18.3

Appendix

September 2015

Table B-2. Bottom flange

Actuator size

40, 65, 100

150, 200, 350

600

950

1600

2500

4000

1. For actuator sizes 1600 and 2500 only 4 holes of the ISO5211 F25 drilling pattern are available.

ISO Pattern

F04 F03 inner pattern F05 outer pattern F05 inner pattern F07 outer pattern F07 inner pattern F10 outer pattern M10 21.0 24.5 3/8"-16 15.5 18.1 F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1 F12 outer pattern M12 34.5 43.0 1/2"-13 25.4 31.7 F10 inner pattern M10 3/8"-16 F14 outer pattern M16 5/8"-11 F16 inner pattern M20 3/4"-10 F251 outer pattern M16 5/8"-11 F16 inner pattern M20 3/4"-10 F251 outer pattern M16 5/8"-11 F16 inner pattern M20 3/4"-10 F25 outer pattern M16 5/8"-11

Metric Torque (Nm) Imperial Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

M6 4.5 5.0 10-24UNC 3.3 3.7 M5 2.0 3.0 10-24UNC 1.5 2.2 M6 4.5 5.0 1/4"-20 3.3 3.7 M6 4.5 5.0 1/4"-20 3.3 3.7 M8 10.5 12.5 5/16"-18 7.7 9.2 M8 10.5 12.5 5/16"-18 7.7 9.2

Appendix

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

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

Flange

Metric Torque (Nm) Imperial Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

Solenoid flange screw threads M5 2.0 3.0 10-24UNC 1.5 2.2

Top flange screw threads M5 2.0 3.0 10-24UNC 1.5 2.2

Table B-4. Limit stop screws and nuts

Actuator size Thread

25 M 6 10 10 40 M 8 13 13

65 M 10 17 (16) 100 M 10 17 (16) 150 M 10 17 (16) 200 M 12 19 (18) 350 M 16 24 24 600 M 20 30 30 950

1600 2500 4000

Default dimension according DIN933 standard Dimensions in brackets according ISO4017 standard Actuator size 12 is not available with limit stops

Bolt Wrench Nut wrench

size (mm) size (mm)

17 (16) 17 (16) 17 (16) 19 (18)

Table B-5. Recommended circlip pliers according DIN 5254 (or equal) for shaft circlips

Actuator size Pinion top diameter Pliers according DIN 5254

F12 16 mm 0.630" A1

F25 - F100 22 mm 0.866" A2

F150 - F350 36 mm 1.417" A3

F600 55 mm 2.165" A3

Appendix

EL Matic

World Area Configuration Centers (WACC) offer sales support, service, inventory and commissioning to our global customers. Choose the WACC or sales office nearest you:

NORTH & SOUTH AMERICA

19200 Northwest Freeway Houston, TX 77065 T +1 281 477 4100 F +1 281 477 2809 Av. Hollingsworth, 325, Iporanga Sorocaba, SP 18087-105 Brazil T +55 15 3238 3788 F +55 15 3228 3300

ASIA PACIFIC

No. 9 Gul Road #01-02 Singapore 629361 T +65 6501 4600 F +65 6268 0028

No.1 Lai Yuan Road Wuqing Development Area Tianjin 301700 P.R.China T +86 22 8212 3300 F +86 22 8212 3308

For complete list of sales and manufacturing sites, please visit

www.emersonprocess.com/valveautomationlocations

Or contact us at info.valveautomation@emerson.com

MIDDLE EAST & AFRICA

P. O. Box 17033 Dubai United Arab Emirates T +971 4 811 8100 F +971 4 886 5465

P. O. Box 10305 Jubail 31961 Saudi Arabia T +966 3 340 8650 F +966 3 340 8790

24 Angus Crescent Longmeadow Business Estate East P.O. Box 6908; Greenstone; 1616 Modderfontein, Extension 5 South Africa T +27 11 451 3700 F +27 11 451 3800

EUROPE

Asveldweg 11 7556 BR Hengelo (O) The Netherlands T +31 74 256 1010 F +31 74 291 0938

www.emersonprocess.com/elomatic

All Rights Reserved. We reserve the right to modify or improve the designs or specifications of the products mentioned in this manual at any time without notice. Emerson Process Management does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management product remains solely with the purchaser. ©2015 Emerson Electric Co.

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