Emerson EL-O-Matic F-Series Installation, Operation And Maintenance Manual

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Page 1

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 7

September 2017

EL-O-Matic F-Series

Rack and Pinion Pneumatic Actuators

EL Matic

Page 2

Page 3

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 7

Table of Contents

September 2017

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 Identication ................................................................................................. 3

2.2 Intended Use .................................................................................................5

2.3 Specications ................................................................................................ 5

Section 3: Configuration Code

Section 4: Installation

4.1 Before You Start ............................................................................................ 9

4.2 Actuator Rotation Direction .......................................................................... 9

4.2.1 Valve Rotation .................................................................................... 9

4.2.2 Position After Failure ........................................................................ 10

4.3 Principles of Operation ................................................................................ 10

4.3.1 Solenoid Valve .................................................................................. 10

4.3.2 Ingress Protection (IP) rating ............................................................ 11

4.3.3 Double-Acting Actuators .................................................................. 12

4.3.4 Spring-Return Actuators ................................................................... 13

4.4 Actuator Assembly Codes ........................................................................... 14

4.5 Actuator to Valve Installation ...................................................................... 15

4.6 Mounting of control and feedback accessories ............................................ 18

4.7 Recommended Tubing Sizes ........................................................................ 18

Section 5: Mechanical Stroke Adjustment

5.1 Travel Stop Adjustment ............................................................................... 20

5.1.1 Double-Acting Actuators .................................................................. 20

5.1.2 Spring-Return Actuators ................................................................... 20

5.1.3 Angular Displacement ...................................................................... 21

Section 6: Maintenance

6.1 Normal Maintenance ................................................................................... 22

6.2 Inspection and Repair .................................................................................. 23

6.2.1 Service Kits ....................................................................................... 23

6.2.2 Spring-Return Actuator .................................................................... 23

Section 7: Decommission (Out of Service)

7.1 Before You Start .......................................................................................... 24

7.2 Removing the actuator from the valve ........................................................ 25

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Table of Contents

September 2017

Installation, Operation and Maintenance Manual

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Table of Contents

Section 8: Disassembly

8.1 Removing End Caps (Sizes 25 to 600) .......................................................... 27

8.2 Removing End Caps (Sizes 950 to 4000) ...................................................... 29

8.3 Removing Spring Cartridges or Springs ....................................................... 30

8.4 Removing of Limit Stop screws .................................................................... 31

8.5 Removing Pistons ........................................................................................31

8.6 Removing pinion ......................................................................................... 32

8.7 Cleaning the Components .......................................................................... 33

Section 9: Reassembly

9.1 Grease Instructions ..................................................................................... 35

9.2 Reassembly of the pinion ............................................................................ 36

9.3 Reassembly of the pistons ........................................................................... 37

9.4 Reassembly and settings of the limit stops ..................................................39

9.5 Reassembly of the end caps ......................................................................... 40

9.5.1 Double-Acting actuators .................................................................. 40

9.5.2 Spring-Return actuators (Size 25 to 600) .......................................... 41

9.5.3 Spring-Return actuators - Size 950 to 4000....................................... 43

9.6 Basic function and Air Leak Test ................................................................... 45

Section 10: Troubleshooting

10.1 Mechanical Problems .................................................................................. 46

10.2 Pneumatic Problems ................................................................................... 46

10.3 Electrical Problems ...................................................................................... 48

Section 11: Parts List and Spare Parts Recommendations

11.1 Actuator size F12.........................................................................................49

11.2 Actuator sizes F25 to F600 ..........................................................................50

11.3 Actuator sizes F950 to F2500 ......................................................................51

11.4 Actuator sizes F4000 ................................................................................... 52

Appendix A: Spring load removal

A.1 Spring load relief ......................................................................................... 53

Appendix B: Tool & Torque Table

Appendix C: Full Stroke Adjustment Option

C.1 Full Stroke Adjustment Option .................................................................... 57

C.2 Convert a standard actuator into a Full Stroke Adjustment version .............. 58

C.2.1 Procedure ........................................................................................ 59

C.3 Full Stroke Adjustment Setting .................................................................... 60

C.3.1 Factory Setting Procedure ................................................................ 60

C.3.2 Setting the Full Stroke Adjustment screw to the required angle. ....... 61

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Before You Start

Section: 1 Before You Start

This section explains:

• Base safety procedures.

• Where to nd detailed information relating safety.

• Storage guidelines.

Installation, adjustment, putting into service, use, assembly, disassembly and maintenance

of the pneumatic actuator must be performed by qualied personnel.

NOTICE

Failure to follow the above guidelines will void warranty.

WARNING

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).

For Safety Instrumented Systems application, read the following document:

• SIL Safety Manual EL-O-Matic F-Series (Document No. DOC.SILM.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

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

tion and rapid temperature changes.

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

racks/shelves or use a pallet.

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 7

September 2017

Section 1: Before You Start

Page 6

Before You Start

September 2017

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 7

Section 1: Before You Start

1.3 On-Site Storage

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

tion and rapid temperature changes.

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

tion ports.

NOTICE

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

Page 7

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 7

September 2017

Section 2: Introduction

Section: 2 Introduction

This section explains:

• How to identify the received product.

• The intended use of the product.

• Construction details.

• Actuator specications.

2.1 Identification

The EL-O-Matic F-Series Rack and Pinion actuators are available as double-acting or springreturn 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.

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 at end caps to reduce actuator length

and internal air volume.

Page 8

Introduction

25 100

150 -

600

4000

Size End cap design

Spring design

Pinion bottom / Insert design

950 -

2500

Maximum 2

loose springs

Maximum 12

spring cartridges

Maximum 6

loose springs

Left

Right

Left Right

SR DA

Maximum 12

spring cartridges

Maximum 6

loose springs

Left Right

Notes

1. Top auxilliaries and Solenoid interface (VDI/VDE 3845; NAMUR) for size 25 to 4000. Size 12 has propriatary interface for top auxilliaries and solenoid mounting.

2. Valve interface availalable according ISO5211 or DIN 3337. Actuator size 12 is fitted with a parallel or diagonal square. Actuator sizes 25 to 2500 can be fitted with drive inserts with various inner shapes. Actuator size 4000 is fitted with a double square; parallel and diagonal.

3. Spring-Return actuators: - with springs

4. Double-Acting actuators: - no springs

5. Actuator sizes 25 to 100 have high end caps for double -acting and spring-return models. Actuator sizes 12 and 150 to 4000 have low end caps for double-acting models and high end caps for spring-return models.

6. Actuator size 12 is fitted with a maximum of 2 loose springs. Actuator sizes 25 to 600 are fitted with a maximum of 12 spring cartridges. Actuator sizes 950 to 4000 are fitted with a maximum of 6 loose

springs.

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DOC.IOM.EF.EN Rev. 7

Section 2: Introduction

Figure 1 Identification

Page 9

Introduction

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 Buttery, 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

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

Double-Acting and Single-Acting

Air, dry or lubricated and inert gases Dew point at least 10K below ambient temperature For sub-zero applications, take appropriate measures Mentioned pressure levels are "gauge pressures".

Gauge pressure is equal to absolute pressure minus atmospheric pressure.

1. Recommended air quality according ISO 8573-1 for normal operation: 7-5-4.

NOTE:

Use of lters, pressure regulators, lubricator and an oil/water separator mounted in the air

supply line, will allow a smooth and durable operation of the actuator.

For lubricated supply air, it is recommended to use a non-detergent oil without aggressive additives, VG32, group 2 (ISO 3448).

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 -10°C to +120°C (14°F to +248°F)

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Section 2: Introduction

Page 10

Introduction

Table 4. Air Volumes and Consumption

Actuator volumes:

Consumption per stoke

(in liters, pressure in barg)

Actuator

size

Maximum volume (in liters) Outward Stroke Inward Stroke

Central

chamber

End cap

chamber

Displaced

volume

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

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 7.8 7.0 5.2 21 37 68 19 33 62 2500

10.4 11.1 8.2 29 50 92 30 53 97

4000 18.4 18.9 14.0 51 88 161 52 89 165

Actuator volumes:

Consumption per stoke

(in Cu.in., pressure in psig)

Actuator

size

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

Central

chamber

End cap

chamber

Displaced

volume

Double-Acting

and Spring-Return

Double-Acting only

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

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

Central air chamber volume

Double-Acting and Spring-Return

End cap air chamber volume

Double-Acting only

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Section 2: Introduction

Page 11

Configuration Code

Section: 3 Conguration Code

This section explains:

• How to create or read the conguration code for a actuator.

Typ e

FD Double Acting

FS Spring Return

Size

0012 Size 0012 0350 Size 0350 0025 Size 0025 0600 Size 0600 0040 Size 0040 0950 Size 0950 0065 Size 0065 1600 Size 1600 0100 Size 0100 2500 Size 2500 0150 Size 0150 4000 Size 4000 0200 Size 0200

Rotation angle

N 90° rotation angle

Threads

M Metric ISO 5211

U UNC/NPT/Imperial

Spring Set

00 Double Acting (no springs) 10 Spring Set 10 40 Spring Set 40 20 Spring Set 20 50 Spring Set 50 30 Spring Set 30 60 Spring Set 60

Rotation direction

CW Spring to Close/Clock Wise

CC Spring to Open/Counter Clock Wise

Pinion Material

AL High Grade Aluminium, Hard anodized SS Stainless steel ASI 316 (+ A4-70 SS fasteners)

Valve Interface

TN Standard ISO 5211 interface SY Small interface with center plate (DIN3337)

LY Large interface with center plate (DIN3337)

Valve Stem Connection

Actuator

size

Square

Aluminum

Stainless

Steel

Parallel drive

Diagonal

drive

Star drive

No insert 000 Not applicable

0012 (39mm / 0.354" L09 D09 Q09

0025 11mm / 0.433" L11 D11 Q11

0040 &

0065

14mm / 0.551" L17 D14 Q14

0100

17mm / 0.669" D17 Q19 19mm / 0.748" L19

0150

17mm / 0.669" D17 Q22 19mm / 0.748" L19

0200 22mm / 0.866" L22 D22 Q22

0350

22mm / 0.866" D22 Q27

27mm / 1.063" L27 0600 27mm / 1.063" L27 D27 Q27 0950 36mm / 1.417" L36 D36 Q36

1600 &

2500

46mm / 1.811" L46 D46 Q46

4000 (355mm / 2.165" Q55 Q55 Q55

Temperature Range

S Standard: -20°C to +80°C (-4°F to +176°F)

H High: -10°C to +120°C (14°F to +248°F)

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

G (6Standard: -20°C to +80°C (-4°F to +176°F) PED Group 1 Label

Visual Indication Code

K Standard (Knob) N No Visual Indication

Finish

A Standard coating (EL-O-Matic Yellow) G CSR Coating

Internal code 1

00 Standard

Miscellaneous options

XX Standard H1 1/2" High Flow plate

P1 1/2" Porting according EN 15714-3 (only sizes 950-4000) FS Full stroke adjustement

Notes: See next page.

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September 2017

Section 3: Configuration Code

FS 0150 - N U 40 CW AL TN - NL19 S K A - 00 XX

Typ e

Size

Rotation angle

Threads

Spring set

Rotation

Pinion material

Valve interface

Miscellaneous options Internal code 1

Color / nish

Visual indicator Temperature Valve stem connection

Page 12

Configuration Code

Notes:

1. The options, listed here, are all options available. Not all options apply to all con-

gurations.

2. Valve Interface: Size 0012 has no center plate option. Option "S"; Small Interface with Center Plate (DIN3337) is not available for size 0025.

3. Size 0012 does not have inserts but has the inner square directly in the bottom of the pinion. Size 4000 does not have inserts but has two inner squares (diagonally and parallel oriented) directly in the bottom of the pinion.

4. Actuators with stainless steel pinions do not have inserts but have two inner squares (diagonally and parallel oriented aka "Star Drive") directly in the bottom of the pinion.

5. Contact you local EL-O-Matic representative for additional insert options.

6. PED Group 1 Label only available up to size 950.

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Section 3: Configuration Code

Page 13

Installation

The valve is closed after

a clockwise rotation.

The valve is open after

a counterclockwise rotation.

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

SAFETY

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 gure 3.

Figure 3 Normal valve rotation

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Section 4: Installation

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Installation

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

Principle of

Operation

Assembly Code Kind of Failure Position

Double-Acting

Actuator

Pressure Not dened

Signal Closed

Supply Voltage Closed

Pressure Not dened

Signal Open

Supply Voltage Open

Single-Acting

(Spring-Return)

Actuator

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 exible 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

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Section 4: Installation

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Installation

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

Table 6. Operating Speed

Cycle time in seconds

Actuator

size

Spring-Return Double-Acting

A-port

pressurized

Spring stroke

A-port

pressurized

B-port

pressurized

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 6.6 2.2 2.4 2.0

F 1600 10.6 3.5 3.6 3.3 F 2500

16.9 5.7 5.8 5.2

F 4000 29.1 9.2 9.2 9.0

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

Test conditions:

1. Solenoid with ow 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.

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Section 4: Installation

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Installation

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" posi-

tion of the valve.

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

Figure 5 Double-Acting Operation

Outward Stroke

Inward Stroke

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Section 4: Installation

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Installation

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

Inward Stroke

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Section 4: Installation

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Installation

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 and cam position

Dot in pinion slot

Default

pistons position

Reversed pistons position

Pinion 90° rotated

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 and cam position

Dot in pinion slot

Default

pistons position

Reversed pistons position

Springs

Pinion 90° rotated

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Section 4: Installation

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Installation

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.

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 Too l

Wrench – All types and sizes.

Metric and Imperial

Allen key

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

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Section 4: Installation

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Installation

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

Figure 10 Insert drive Installation

90°

45°

90°

Parallel

square

Diagonal

square

Flat head

Round with

key way

4. Install the bracket to the valve ange. Tighten all bolts and nuts and apply the cor- rect torque.

Figure 11 Bracket Installation

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Installation

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

Actuator Size ISO Pattern

Torque (Nm) Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

12 F04 M6 4.5 5 10-24UNC 3.3 3.7

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

40, 65, 100

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

150, 200, 350

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

600

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

950

F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1 F14 outer pattern M16 90.0 104.0 5/8"-11 66.4 76.7

1600, 2500

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5

F25* outer pattern 4x M16 90.0 104.0 4x 5/8"-11 66.4 76.7

4000

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5 F25 outer pattern 8x M16 90.0 104.0 8x 5/8"-11 66.4 76.7

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

Figure 12 Indicator mounting

Indicator mounting “In-line”

Indicator mounting “Across Line”

Size 12 - 350 Size 600 - 4000

90°

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Section 4: Installation

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Installation

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.

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 sufcient ow of air supply to the actuator, the following tubing sizes are

recommended.

Table 9. Tubing Sizes

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

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

950, 1600, 2500,

4000

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

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Section 4: Installation

Page 23

Mechanical Stroke Adjustment

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

Closed

-3°10°

Open

80°

93°

Size 950 - 4000Size 25 - 600

90°

Limit Stop 2Limit Stop 1

Closed

-5°10°

Open

80°

95°

90°

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Section 5: Mechanical Stroke Adjustment

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Mechanical Stroke Adjustment

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

Stop 1

Stop 2

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 dene 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

Stop 1

Stop 2

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Section 5: Mechanical Stroke Adjustment

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Mechanical Stroke Adjustment

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 dene 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

Bolt Wrench Nut wrench

size (mm) size (mm)

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 M 22 12 32

1600 M 24 14 36 2500 M 27 17 41 4000 M 22 12 32

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

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

5.1.3 Angular Displacement

Below table identies, 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 limit stops

Actuator size

Turns for 5° adjustment of the pinion: 360° revolution of limit stop screw will adjust

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 1.1 4.7°

F 1600 1.3 4.1° F 2500 1.5 3.4° F 4000 3.2 1.6°

NOTICE

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

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Section 5: Mechanical Stroke Adjustment

Page 26

Maintenance

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.

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* for sizes up to F1600 and 250,000 for sizes F2500 and F4000.

For actuators with the optional low temperature silicon seals, we advise to replace these seals after 250.000 cycles*.

NOTE:

*Cycles = one open stroke and one close stroke.

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 nal 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 ttings as required.

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

• Check if pneumatic lter cartridge (where foreseen) is sound and lter bowl

(where foreseen) has been cleaned properly.

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

• Verify that the power uid supply pressure value is within the required range.

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

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Section 6: Maintenance

Page 27

Maintenance

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

Touch-up as required in accordance with the applicable paint specication.

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

plete 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).

All actuators are supplied with sufcient 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.

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 – Actuation Technologies distributors.

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 – Actuation Technologies distributors.

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Section 6: Maintenance

Page 28

Decommission (Out of Service)

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.

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Section 7: Decommission (Out of Service)

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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 ange.

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

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Section 7: Decommission (Out of Service)

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Disassembly

Section: 8 Disassembly

This section explains:

• How to disassemble an actuator safely.

Tip

The instructions of this section can be used for maintenance or reconguration 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.

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.

The end caps of spring-return actuators sizes 25 to 600 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.

Spring return actuator size 950 to 4000 have long end cap screws to release the spring load safely.

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.

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Section 8: Disassembly

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Disassembly

8.1 Removing End Caps (Sizes 25 to 600)

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

a. Remove the screws (8) and washers (10) of the end caps (6).

b. Remove the o-ring (11) and "B" port seal (2). Discard these parts.

Figure 17 Double-Acting End Caps Removal

Double acting end caps (6) are fitted with a white warning sticker. Spring return end caps (5) are fitted with a black warning sticker.

The above end caps (5) are for actuator sizes 25, 40, 65 and 100.

End caps (6) for double acting actuator sizes 150 and larger will have flat end caps.

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Section 8: Disassembly

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Disassembly

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

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

stop screw (30) 2 full turns. For actuators with assembly code CC, turn back the left hand limit stop screw (30) 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. Uniformly loosen the screws (9) of the end caps (5) 1/4-1/2 turns at a

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

c. Remove the o-rings (11) and "B" port seals (2). Discard these parts.

Figure 18 Spring-Return End Caps Removal

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Disassembly

8.2 Removing End Caps (Sizes 950 to 4000)

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

a. Remove the screws (8) and washers (10) of the end caps (6).

b. Remove the o-ring (11) and "B" port seal (2). Discard these parts.

Figure 19 Double-Acting End Caps Removal sizes 950 to 4000

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

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

b. Uniformly loosen the screws (9) of the end caps (5) 1/4-1/2 turns at a

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

c. Remove the o-rings (11) and "B" port seals (2). Discard these parts.

Figure 20 Spring-Return End Caps Removal sizes 950 to 4000

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Section 8: Disassembly

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Disassembly

8.3 Removing Spring Cartridges or Springs

1. Remove the spring cartridges or springs (7).

Figure 21 Removing Spring Cartridges size 25 to 600

Figure 22 Removing Springs size 950 to 4000

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Disassembly

8.4 Removing of Limit Stop screws

1. Remove the limit stop screws (30), limit stop nuts (31), limit stop washers (32) and limit stop o-rings (33). Discard the o-rings.

Figure 23 Limit Stop Removal

33 30

8.5 Removing Pistons

1. Use a wrench and turn the pinion counterclockwise until the pistons (14) come out of the body.

2. Remove the piston bearings (15), piston rack bearing strips (17) and piston o-ring seals (16). Discard these parts.

Figure 24 Removing Pistons

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Section 8: Disassembly

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Disassembly

8.6 Removing pinion

1. Remove the circlip (27) and thrust bearing (23) on top of the pinion assembly. For sizes 950 to 4000 remove also the top pinion bearing (19).

2. Remove the pinion (18) by pushing it downwards. For Size 4000, remove the backup ring (29), O-ring pinion top (21) the cam (24) and cam thrust washer (25) through the main bore of the housing.

3. Remove the pinion O-ring seals (21/22) and the pinion bearings (19/20). For Size 950 to 2500, remove also the backup ring (29).

4. Discard all of these parts.

Figure 25 Pinion Removal

Sizes 950, 1600, and 2500

Sizes 25 to 600

Size 4000

29 19

29 25

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

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

12 16 mm 0.630" A1 950 65 mm 2.559 A3

25 - 100 22 mm 0.866" A2 1600 75 mm 2.953 A3

150 - 350 36 mm 1.417" A3 2500 95 mm 3.74 A4

600 55 mm 2.165" A3 4000 96 mm 3.78 A4

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Disassembly

8.7 Cleaning the Components

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.

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Section 8: Disassembly

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Reassembly

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 reconguration 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 reconguration replace the parts as supplied in the conversion kit (see also chapter 6).

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.

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Reassembly

9.1 Grease Instructions

Check the product coding on the product labels and chapter 3 of this manual, to dene

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 (-10°C to +120°C / 14°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 lm

Housing Parts:

B Piston bore Light lm C Top pinion bore Light lm D Bottom pinion bore Light lm

Piston Parts:

E O-ring & bearing groove Light lm

F Rack teeth Half the teeth depth full with grease G Piston bearing Light lm on outside H Piston rack bearing strip Light lm

Piston Parts:

J Pinion bottom & O-ring groove Light lm

K Pinion top & O-ring groove Light lm

L Gear teeth Half the teeth depth M Pinion top bearing Light lm (inside and out) N Pinion bottom bearing Light lm (inside and out)

Figure 26 Grease Instructions

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Reassembly

9.2 Reassembly of the pinion

1. Grease the pinion parts according to chapter 9.1.

2. Install the pinion bearings (19/20) and the O-ring seals (21/22) on the pinion (18). For Size 950 to 2500, install also the the backup ring (29).

3. Insert the pinion (18) in the housing. For size 4000: mount rst the cam (24), cam thrust washer (25), pinion top O-ring (21) and backup ring (29) through the mainbore onto the pinion (18).

4. For sizes 950 to 4000 install rst the top pinion bearing (19). For all sizes, install the thrust washer (23) and mount the circlip (27) on the pinion top.

— 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 27 Reassemble the pinion

Sizes 950, 1600, and 2500

Sizes 25 to 600

Size 4000

29 19

2221

29 25

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

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

12 16 mm 0.630" A1 950 65 mm 2.559 A3

25 - 100 22 mm 0.866" A2 1600 75 mm 2.953 A3

150 - 350 36 mm 1.417" A3 2500 95 mm 3.74 A4

600 55 mm 2.165" A3 4000 96 mm 3.78 A4

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Reassembly

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 rack bearing strips (17) and piston O-ring seals (16) on the pistons (14). Ensure all these parts are kept in place during assembly.

Figure 28 Reassemble the pistons

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. 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 with-

out 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 gure 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.

7. Move the pistons outward so that just the bearing groove sticks out of the housing. Fold the piston bearings (15) around the piston and hold the bearing ends in place while moving the pistons inwards.

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

inward to engage with the pinion.

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Section 9: Reassembly

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Reassembly

Figure 29 Position of the slot and the cam on the pinion top

90°

Assembly code CW Assembly code CC

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

A = Position of cam

B = Position of slot and 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.

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Reassembly

9.4 Reassembly and settings of the limit stops

1. Install the limit stop screws (30), limit stop nuts (31), limit stop washers (32) and limit stop O-rings (33).

Figure 30 Install Limit Stop Bolts

33 30

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 cor-

rect position (see gure 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.

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Reassembly

9.5 Reassembly of the end caps

9.5.1 Double-Acting actuators

1. Grease the O-ring seals (11) and B port seals (2) according to step 9.1.

2. Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

3. Install the end caps (6) and tighten the end cap screws (8). Refer to Table 15 for the correct torque.

Figure 31 Double-acting end cap assembly

Double acting end caps (6) are fitted with a white warning sticker. Spring return end caps (5) are fitted with a black warning sticker.

The above end caps (5) are for actuator sizes 25, 40, 65 and 100.

End caps (6) for double acting actuator sizes 150 and larger will have flat end caps.

Table 15. End cap Screw Torque

Actuator

size

Thread To ol Size

Torque (Nm) Torque (lbf.ft)

Target Min. Max. Target Min. Max.

12 M4

Allen key

SW 3 1.1 0.8 1.3 0.8 0.6 1.0 25 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2 40 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2 65 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2

100 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2 150 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8 200 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8 350 M8 SW 6 8.4 6.7 12.2 6.2 4.9 9.0 600 M10 SW 8 15.3 12.2 24.8 11.3 9.0 18.3

950 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7 1600 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7 2500 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7 4000 M14 SW12 43.5 34.8 66.4 32.1 25.7 49.0

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Reassembly

9.5.2 Spring-Return actuators (Size 25 to 600)

Important

EL-O-Matic F-Series Spring return actuators are supplied with springs on each side of the actuator. Throughout the F-Series size range, there are three different spring designs:

— Size F12 has only 1 spring on each side.

— Sizes F25 to F600 have 6 springs on each side (see gure below).

— Sizes F950 to F4000 have 3 springs on each side (see chapter 9.5.3 ).

Check below gures to see where to place the spring cartridges in case of spring set

conversion.

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

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

Figure 32 Spring placement size 25 to 600

2 3

N = 10 N = 20

N = 30

2 3456

N = 40

N = 50

N = 60

A = Piston top view B = Position of gear rack

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Reassembly

1. Grease the O-ring seals (11) and B port seals (2) according to step 9.1.

2. Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

3. Place the spring cartridges in actuator as per required spring set (see Figure 32).

4. Put the end cap screw washer (10) on the end cap screw (9) and tighten each end cap screw in small equal turns and in the sequence as per Figure 33. Refer to Table 15 for the correct torque. We recommend to use some grease on the screws for easier fastening.

Figure 33 Spring Return End cap assembly size 25 to 600

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Reassembly

9.5.3 Spring-Return actuators - Size 950 to 4000

Important

EL-O-Matic F-Series Spring return actuators are supplied with springs on each side of the actuator. Throughout the F-Series size range, there are three different spring designs:

— Size F12 has only 1 spring on each side.

— Sizes F25 to F600 have 6 springs on each side (Chapter 9.5.2).

— Sizes F950 to F4000 have 3 springs on each side (see gure below).

Check below gures to see where to place the springs in case of spring set conversion.

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

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

Figure 34 Spring cartridge placement

1 spring 0 spring 1 spring 1 spring 2 springs1 spring

2 springs

2 springs 3 springs2 springs3 springs3 springs

Left RightLeftRight Left Right

Left

Right Left RightLeft Right

N = 10 N = 20 N = 30

N = 40 N = 50 N = 60

A = Piston top view B = Position of gear rack

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Reassembly

1. Grease the O-ring seals (11) and B port seals (2) according to step 9.1.

2. Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

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

4. Put the end cap screw washer (10) on the end cap screw (9) and tighten each end cap screw in small equal turns and in the sequence as per Figure 35. Refer to Table 15 for the correct torque. We recommend to use some grease on the screws for easier fastening.

Figure 35 Spring Return end cap assembly size 950 to 4000

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Section 9: Reassembly

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Reassembly

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/120 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: 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.

Figure 36 Basic function and air leak test

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Section 9: Reassembly

Page 50

Troubleshooting

Section: 10 Troubleshooting

10.1 Mechanical Problems

Problem Possible error Solution Where to find

Feedback position and actual position are not the same.

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

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

Section 4

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

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

Limit stop screws are not set correctly.

Readjust the limit stop screws.

Section 5

Insert is not mounted properly.

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

Section 4.5

Pressure to low. Apply pressure as per sizing.

Sizing is wrong.

Check valve torque data with actuator torque data.

Pinion is mounted in the wrong position.

Re assemble actuator. Section 9

Actuator rotates, valve does not.

No coupling between actuator shaft and valve spindle.

Install a coupling between actuator shaft and valve spindle.

Section 4.5

Actuator does not rotate or does not rotate smoothly.

Broken gearing on pistons or pinion.

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

Spring or Spring cartridge is broken.

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

Appendix A.

Limit stop screws cannot be turned out anymore.

Limit stop screws is bend.

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

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Section 10: Troubleshooting

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Troubleshooting

10.2 Pneumatic Problems

Problem Possible error Solution Where to find

Actuator does not react to electrical control signal.

There is no supply pressure at the actuator.

Supply the right pressure to the actuator.

Section 2.3 Check that the actual supply pressure is higher than the sizing pressure.

Actuator does not react good to electrical control signal.

There is sufcient

supply air pressure but

insufcient supply air

capacity.

Take care the supply air tubing has the right dimensions.

Section 4.6

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

Check that supply pressure at the actuator and solenoid

is sufcient to operate

the actuator.

Section 2.3 Check that the actual supply pressure is higher than the sizing pressure.

Solenoid valve is not mounted properly.

Check the solenoid valve mounting.

Instructions shipped with the solenoid valve.

Speed control throttle (if present) blocks air

ow.

Turn the speed control more open.

Instructions shipped with the speed control valve.

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

Unlock manual override on the solenoid valve.

Instructions shipped with the manual override.

Air leakage between actuator and solenoid valve.

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

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

Instructions shipped with the solenoid valve.

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

Actuator has wrong solenoid valve

conguration.

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

Instructions shipped with the solenoid valve.

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

Instructions shipped with the solenoid valve.

Leakage notice on the actuator.

Seals on the limit stops screws are not air tight.

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

Section 9.6

Seals on the end caps are not air tight.

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

Section 9.6 or Section 6

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

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

Section 9.6 or Section 6

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Section 10: Troubleshooting

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Troubleshooting

10.3 Electrical Problems

Problem Possible error Solution Where to find

Actuator does not react to control signals.

Control wiring. Power supply wiring or feedback wiring are not right connected.

Connect all wiring in the right way.

Instructions of the control or feedback accessories.

The power supply voltage is not is not the same as the voltage of the applicable solenoid valve.

Connect the right power supply voltage.

Instructions of the solenoid valve.

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

The wiring of the feedback signals may be switched.

Connect the feedback wiring in the right way.

Instructions of the feedback device.

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Page 53

Parts List and Spare Parts

Section: 11 Parts List and Spare Parts

Recommendations

11.1 Actuator size F12

711

Table 16. Parts List

Pos. Qty Notes Description Material

1 1 House Extruded aluminium alloy 2 2 1 B-port ball Steel 5 2 End cap SR (DA) Cast Aluminium alloy 6 2 End cap DA Cast Aluminium alloy 7 Max. 2 Springs Spring steel 8 8 End cap screw DA Stainless Steel

9 8 End cap screw SR Stainless Steel 11 2 1 O-ring end cap Nitrile rubber 12 2 Warning sticker DA Polyester 13 2 Warning sticker SR Polyester 14 2 Piston Cast Aluminium alloy 15 2 1 Bearing piston PTFE 25% carbon-lled 16 2 1 O-ring piston Nitrile rubber 17 1 1 Guide band Nylatron 18 2 Pinion High grade aluminium 19 1 1 Bearing pinion top POM 20 1 1 Bearing pinion bottom POM 21 1 1 O-ring pinion top Nitrile rubber 22 1 1 O-ring pinion bottom Nitrile rubber 23 1 1 Thrust bearing pinion POM, black UV stabilized 26 1 Indicator assembly ABS + stainless steel screw 27 1 1 Circlip Spring steel

Notes:

1 Included in Service Kit.

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Section 11: Parts List and Spare Parts

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Parts List and Spare Parts

11.2 Actuator sizes F25 to F600

2118

Table 17. Parts List

Pos. Qty Notes Description Material

1 1 House Cast Aluminium alloy 2 2 1 B-port seal Silicon rubber 3 1 Center plate (option) Nylon PA6, Black 5 2 2 End cap SR (DA) Cast Aluminium alloy 6 2 2 End cap DA Cast Aluminium alloy 7 Max. 12 Spring cartridge Spring steel 8 8 End cap screw DA Stainless Steel

9 8 End cap screw SR Stainless Steel 10 8 End cap screw washer Stainless Steel 11 2 1 O -ring end cap Nitrile rubber 12 2 Warning sticker DA Polyester 13 2 Warning sticker SR Polyester 14 2 Piston Cast Aluminium alloy 15 2 1 Bearing piston PTFE 25% carbon-lled 16 2 1 O -ring piston Nitrile rubber 17 2 1 Bearing strip piston rack POM 18 2 Pinion High grade aluminium 19 2 1 Bearing pinion POM 21 2 1 O -ring pinion Nitrile rubber 23 1 1 Thrust bearing pinion POM, black UV stabilized 26 1 Indicator assembly ABS + stainless steel screw 27 1 1 Circlip Spring steel 28 1 Drive insert Aluminium 30 2 Limit stop screw Stainless steel 31 2 Limit stop nut Stainless steel 32 2 1 Limit stop washer PA66 33 2 1 O -ring limit stop Nitrile rubber

Notes:

1 Included in Service Kit.

2 Actuator sizes 25 to 100 have high end caps for double-acting and spring-return models. Actuator sizes

150 to 4000 have low end caps for double-acting models and high end caps for spring-return models.

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Section 11: Parts List and Spare Parts

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Parts List and Spare Parts

11.3 Actuator sizes F950 to F2500

Table 18. Parts List

Pos. Qty. Description Material

1 1 House Cast Aluminium alloy 2 2 1 B-port seal Silicon rubber 3 1 Center plate (option) Nylon PA6, Black 4 12 Thread insert Steel 5 2 End cap SR Cast Aluminium alloy 6 2 End cap DA Cast Aluminium alloy 7 Max. 6 Springs Spring steel 8 12 End cap screw DA Stainless Steel

9 12 End cap screw SR Stainless Steel 10 12 End cap screw washer Stainless Steel 11 2 1 O-ring end cap Nitrile rubber 12 2 Warning sticker DA Polyester 13 2 Warning sticker SR Polyester 14 2 Piston Cast Aluminium alloy 15 2 1 Bearing piston PTFE 25% carbon-lled 16 2 1 O-ring piston Nitrile rubber 17 2 1 Bearing strip piston rack POM 18 1 Pinion High grade aluminium 19 2 1 Bearing pinion top POM 20 1 1 Bearing pinion bottom POM 21 1 1 O-ring pinion top Nitrile rubber 22 1 1 O-ring pinion bottom Nitrile rubber 23 1 1 Thrust bearing pinion POM, black UV stabilized 26 1 Indicator assembly ABS + stainless steel screw 27 1 1 Circlip Spring steel 28 1 Drive insert Aluminium 29 1 1 Backup ring POM 30 2 Limit stop screw Stainless steel 31 2 Limit stop nut Stainless steel 32 2 1 Limit stop washer PA66 33 2 1 O-ring limit stop Nitrile rubber

Notes:

1 Included in Service Kit.

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Section 11: Parts List and Spare Parts

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Parts List and Spare Parts

11.4 Actuator sizes F4000

133

Table 19. Parts List

Pos. Qt y. Notes Description Material

1 1 House Cast Aluminium alloy

2 2 1 B-port seal Silicon rubber

3 1 Center ring Stainless Steel AISI 304

4 12 Thread insert Steel

5 2 End cap SR Cast Aluminium alloy

6 2 End cap DA Cast Aluminium alloy

7 Max. 6 Springs Spring steel

8 12 End cap screw DA Stainless Steel

9 12 End cap screw SR Stainless Steel 10 12 End cap screw washer Stainless Steel 11 2 1 O-ring end cap Nitrile rubber 12 2 Warning sticker DA Polyester 13 2 Warning sticker SR Polyester 14 2 Piston assembly Cast Aluminium alloy 15 2 1 Bearing piston PTFE 25% carbon-lled 16 2 1 O-ring piston Nitrile rubber 17 2 1 Bearing strip piston rack POM 18 1 Pinion High grade aluminium 19 2 1 Bearing pinion top POM 20 1 1 Bearing pinion bottom POM 21 1 1 O-ring pinion top Nitrile rubber 22 1 1 O-ring pinion bottom Nitrile rubber 23 1 1 Thrust washer pinion POM, black UV stabilized 24 1 Cam stroke adjustment Steel 25 1 1 Cam thrust washer POM, black UV stabilized 26 1 Indicator assembly ABS + stainless steel screw 27 1 1 Circlip Spring steel 29 1 1 Backup ring POM 30 2 Limit stop screw Stainless steel 31 2 Limit stop nut Stainless steel 32 2 1 Limit stop washer PA66 33 2 1 O-ring limit stop Nitrile rubber

Notes:

1 Included in Service Kit.

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Section 11: Parts List and Spare Parts

Page 57

Appendix

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.

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

Crush / Amputaion Hazard

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

WARNING

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Appendix

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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 actua-

tor as shown in gure 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.

Table A-1. Threaded rod dimensions in mm

Actuator Size Thread

Threaded rod length

(mm) (inch)

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 M12 498 19.6

1600 M12 498 19.6 2500 M12 498 19.6 4000 M14 600 23.6

Figure A-1 Spring load removal rod dimensions

Threaded Rod

Washer

Adjusting nut

Holding nuts

Length

Thread

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Appendix

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

Thread To ol Size

Torque (Nm) Torque (lbf.ft)

Target Min. Max. Target Min. Max.

12 M4

Allen key

SW 3 1.1 0.8 1.3 0.8 0.6 1.0 25 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2 40 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2 65 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2

100 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2 150 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8 200 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8 350 M8 SW 6 8.4 6.7 12.2 6.2 4.9 9.0 600 M10 SW 8 15.3 12.2 24.8 11.3 9.0 18.3

950 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7 1600 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7 2500 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7 4000 M14 SW12 43.5 34.8 66.4 32.1 25.7 49.0

Table B-2. Bottom flange, Metric units

Actuator

size

ISO Pattern

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

Thread Min. Max. Thread Min. Max.

12 F04 M6 4.5 5.0 10-24UNC 3.3 3.7

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

40, 65, 100

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

150, 200, 350

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

600

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

950

F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1 F14 outer pattern M16 90.0 104.0 5/8"-11 66.4 76.7

1600, 2500

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5 F25* outer pattern 4x M16 90.0 104.0 4x 5/8"-11 66.4 76.7

4000

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5 F25 outer pattern 8x M16 90.0 104.0 8x 5/8"-11 66.4 76.7

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

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Appendix

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Appendix

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

Flange

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

Thread Min. Max. Thread Min. Max.

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

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

Table B-4. Limit stop screws

Actuator size Thread

Bolt Wrench Nut wrench

size (mm) size (mm)

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 M 22 12 32 1600 M 24 14 36 2500 M 27 17 41 4000 M 22 12 32

1. Default dimension according DIN933 standard

2. Dimensions in brackets according ISO4017 standard

3. Actuator size 12 is not available with limit stops

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

Actuator

size

Pinion top

diameter

Pliers

according DIN

Actuator

size

Pinion top

diameter

Pliers

according DIN

F12 16 mm 0.630" A1

950 65 mm 2.559" A3

F25 - F100 22 mm 0.866" A2

1600 75 mm 2.953" A3

F150 - F350 36 mm 1.417" A3

2500 95 mm 3.74" A4

F600 55 mm 2.165" A3

4000 96 mm 3.78" A4

Table B-6. Angular Displacement Limit Stops

Actuator size

Turns for 5°

adjustment of the pinion:

360° revolution of

limit stop screw will adjust

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 5.0° F 350 0.8 6.3° F 600 0.8 6.3° F 950 1.1 4.7°

F 1600 1.3 4.1° F 2500 1.5 3.4° F 4000 3.2 1.6°

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Appendix

Appendix: C Full Stroke Adjustment Option

This section explains:

• How to mount the Full Stroke Adjustment option to an actuator

• How to adjust the Full Stroke Adjustment option to a required rotation angle.

C.1 Full Stroke Adjustment Option

The Full Stroke Adjustment option is available as a complete actuator or as an end cap conversion kit in order to upgrade a standard actuator into a Full Stroke Ajdustment version.

The option is available for sizes 25 to 600 and both the double acting kit and spring return kit use the spring return end cap.

Figure C-1 Availability formats of the full Stroke Adjustment option

Spring Return Full Stroke Adjustment kit

Double Acting Full Stroke Adjustment Kit

Complete Spring Return or Double Acting actuator

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Appendix

C.2 Convert a standard actuator into a Full Stroke

Adjustment version

Before starting to assemble the Full Stroke adjustment kit, please check the kit for com-

pleteness. See gure C-2.

Figure C-2 Full Stroke adjustment kit content

41 42 43 44

45 46 11

40 9 10

Table C-1 Content Full Stroke Adjustment kit

Pos. Description Material Qty. Notes

40 End cap - Full stroke adjustment Cast Aluminium alloy 2 1 41 Full Stroke adjustment screw Stainless steel 2 42 Full Stroke adjustment Nut Stainless steel 2 43 Full Stroke adjustment washer PA66 2 44 O-Ring - Full Stroke adjustment screw Nitrile rubber 2 45 O-Ring - Thread bush Nitrile rubber 2 46 Thread bush Aluminium 2

9 End cap screw Stainless steel 8 10 Washer end cap screw Stainless steel 8 11 O-ring end cap Nitrile rubber 2 12 Warning sticker DA Full Stroke adjustment Polyester 2 13 Warning sticker SR Full Stroke adjustment Polyester 2

2. The same Full Stroke adjustment end cap is used for both double acting and spring return actuators

(at double acting actuator end caps with Full Stroke Adjustoment options are not available).

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Appendix

C.2.1 Procedure

1. Remove the existing end caps of a standard actuator.

— Follow the instructions of Section 8 to remove both the end caps of the

actuator.

— For spring return actuators; note the original positions of the spring car-

tridges.

2. Mount the Full Stroke Adjustment End cap kit to the actuator.

— The stroke adjustment screw (41) is factory set at the 90° position.

3. Grease the O-ring seals (11) and B port seals (2) according to section 9.1.

4. Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

5. For spring return actuators; place the spring cartridges (7) back in their original positions.

6. Install the Full Stroke end cap kits and tighten the end cap screws (9,10). For spring return units; tighten each endap screw (9,10) in small equal turns and in the sequence as per Figure C-3. Refer to Appendix B, Table B-1 for the correct torque.

7. For Spring Return units, place the black warning sticker (13) on the end cap. For Double Acting units, place the white warning sticker (12) on the end cap.

Figure C-3 Assembly of Full Stroke adjustment end cap kit

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Appendix

C.3 Full Stroke Adjustment Setting

Note:

Standard actuators or actuators with the Full Stroke Adjustment option are shipped by default with a rotation setting of 90° +/-0.5°.

The stroke adjustment setting procedure can be two steps:

1. Setting the Full Stroke Adjustment screw to the 90° (factory) poisiton.

— This step can be applicable if a standard actuator needs to be converted

with a Full Stroke Adjustment end cap kit or if the position of the Full Stroke Adjustment screw is somehow lost.

2. Setting the Full Stroke Adjustment screw to the required angle.

C.3.1 Factory Setting Procedure

1. In order to set the Full Stroke Adjustment Screws accurately to the outward position:

— Do not change the setting of the DSA limit stop screws (A and B) located

above the air connection interface.

— Move the pistons of the actuator outwards by applying pressure to the

A-port.

2. Screw in both the Full Stroke Adjustment Screws (41) until the screws touch the pistons. You will feel an obstruction.

Important: Do not overtighten the screws.

Figure C-4 DSA limit stop screw setting

A-port

You have now set the adjustment screw to the factory setting

Notes:

1. Only the outward stroke can be adjusted with the Full Stroke Adjustment screws.

— In case of assembly code CW, the left side limit stop (A) is redundant.

— In case of assembly code CC, the right side limit stop (B) is redundant.

2. For the inward stroke the standard limit stops can be used:

— The right side limit stop (B) for assembly code CW

— The left side limit stop (A) for assembly code CC

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Appendix

C.3.2 Setting the Full Stroke Adjustment screw to the required

angle.

1. Move the pistons of the actuator inwards.

— For Spring Return actuators this happens automatically when the actuator

is vented.

— For double acting actuators vent the A-port and apply pressure to the

B-port.

2. In order to set the actuator to the required angle, use next table to dene the number of revolutions which you have to turn in the Full Stroke Adjustment Screws.

3. Turn in both the adjustment screws (41) as dened in step 2. Both the adjustment screws should be turned in with the same length or number of revolutions.

CAUTION: DO NOT SET SCREWS UN-EQUAL

Screwing in only one adjustment screw or un-equal setting of both the screws will lead to high point loads on the pistons and can cause premature failure of the actuator.

4. Test cycle the actuator to check if the correct rotation angle is set. If required, repeat steps 1 to 3 to adjust the rotation angle to the required angle.

Table C-2 Actuator angle rotation per full revolution of Full Stroke adjustment screw

Actuator

size

Stroke

Flathead

screw driver

Screw

Actuator angle rotation per

full revolution of screw

mm inch Thread Pitch (mm)

25 15.7 0.62 1.0 x 5.5 M6 1 5.7° 40 18.8 0.74 1.2 x 6.5 M8 1.25 6.0°

65 22.0 0.87 1.2 x 6.5 M8 1.25 5.1°

100 25.1 0.99 1.2 x 6.5 M10 1.5 5.4° 150 31.4 1.24 1.2 x 6.5 M10 1.5 4.3° 200 37.7 1.48 1.2 x 6.5 M10 1.5 3.6° 350 37.7 1.48 1.2 x 6.5 M12 1.75 4.2° 600 44.0 1.73 1.2 x 6.5 M16 2 4.1°

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Appendix

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Page 67

For complete list of sales and manufacturing sites, please visit

www.emerson.com/actuationtechnologieslocations or contact us at info.actuationtechnologies@emerson.com

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 USA 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 6777 8211 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

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

Berenyi u. 72- 100 Videoton Industry Park Building #230 Székesfehérvár 8000 Hungary T +36 22 53 0950 F +36 22 54 3700

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is a mark of one of the Emerson family of companies.

All other marks are property of their respective owners.

The contents of this publication are presented for information 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 on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.

EL Matic

Emerson EL-O-Matic F-Series Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual