Fisher D500243X012 User Manual

Instruction Manual

D500243X012

Fisherr POSI-SEAL™ 1035/El-O-Matic Rack-and-Pinion Rotary Actuator

1035/El-O-Matic Actuator

August 2012

Contents

Introduction 1.................................

Scope of Manual 1.............................

Description 2.................................

Specifications 2...............................

Installation 4..................................

Operation 6...................................

Adjustment 12................................

Troubleshooting 12.............................

Maintenance 13................................

Actuator Disassembly 13.......................

Actuator Assembly 16..........................

Changing Rotation Direction 18..............

Spring Return E Series Actuators 20...........

Spring Return P Series Actuators 20...........

Installing the Bypass Valve 20................

Parts Ordering 21...............................

Parts Kits 22...................................

Parts List 23...................................

Figure 1. Fisher POSI-SEAL 1035/El-O-Matic Actuator with A41 Valve

W9255

Introduction

Scope of Manual

This instruction manual includes installation, maintenance, and parts ordering information for Fisher POSI-SEAL 1035/El-O-Matic rack-and-pinion rotary actuators (figure 1). These actuators are available in both double-acting and spring-return (figure 2) configurations. Spring return units provide fail action in response to spring compression. The actuator is field reversible. Instructions for the valve and for any accessories used with the actuator are found in separate manuals.

Do not install, operate, or maintain a 1035 actuator without being fully trained and qualified in valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is important to carefully read, understand, and follow all the contents of this manual, including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson Process Management sales office before proceeding.

www.Fisher.com

1035/El-O-Matic Actuator

August 2012

Table 1. Specifications

Instruction Manual

D500243X012

1035 Actuator:

Double Acting Spring Return. EDA 25 ESA 25 EDA 40 ESA 40 EDA 65 ESA 65 EDA 100 ESA 100 EDA 200 ESA 200 EDA 350 ESA 350 EDA 600 ESA 600 EDA 950 ESA 950 EDA 1600 ESA 1600 PDA 2500 PSA 2505 PDA 4000 PSA 4005

Output Shaft:

J Optional ISO 5211 square insert, J Recessed ISO

J Double D insert for A41 valves

5211 square drive for P Series actuators

Dual Stop Adjustment:

J ESeriesactuatorsare

furnishedwithdualstopadjustments(DSA)asa standard feature.

J P Series actuators provide dual

stops with the use of the “Limit Stop Plate” (LSP) option. The LSP is mounted between the actuator and yoke.

Supply Pressure

(1)

(Operating Pressure)

Temperature: -40 to 79_C(-40to175_F) with EPDM and special lubricant (an “LT” in model number)

Performance Characteristics

See tables 2 and 3

Rotation for Code A Construction

Rotation is counterclockwise with port “A” pressurized with standard code A construction. Spring return actuators fail clockwise with standard construction for standard code A actuators (see figure 3 for optional constructions)

Maximum Output Torque

See Catalog 14

Lubrication

Factory lubricated for the normal life of the actuator (see temperature range shown above)

Coating

All units feature a two component polyurethane coating system as standard

2.8 to 8.3 bar (40 to 120 psig) for both double acting andspringreturnactuators

Temperature Range

(1)

Standard: -20 to 79_C (-4 to 175_F) with Nitrile O-rings Optional: High Temperature: -20 to 121_C (-4 to 250_F) with fluorocarbon O-rings (a “V” in model number), or Low

1. The pressure-temperaturelimits in this manual and any applicable code or standard installationshould not be exceeded.

2. For more information, contact your Emerson Process Management sales office.

Actuator Tubing Size

3/8 inch O.D. standard for all sizes

Options

J Parts kits: O-ring kits provides O-rings only, and

repair kits provide O-rings, guide bushings and soft parts. Kits are available for standard and high temperature or for low temperature applications

J Unit is field reversible

Description

The 1035 actuator is a rack-and-pinion, pneumatic quarter-turn actuator. The actuator utilizes a double rack and single pinion design (see figure 2). The actuator uses three carbon filled PTFE guide bands, with a balanced piston which prevents metal-to-metal contact between the pistons and cylinder wall.

The E Series actuator uses a recessed bushing inserted into the end of the actuator drive shaft. Standard recessed double-D bushings match the A41 valve drive shaft. In most applications, the valve shaft is inserted directly into the recessed actuator shaft bushing. The P Series actuators provide a recessed s quare output shaft for coupling the actuator to the valve shaft. The A41 valve uses a square-to-double-D drive coupler construction. Optional couplings are available for other applications.

Instruction Manual

D500243X012

1035/El-O-Matic Actuator

August 2012

Table 2. Performance Characteristics

ESERIES

ACTUATOR

SIZE

E25 56 2.2 15.7 0.62 0.5 0.1 6.1 0.11 6.7

E40 70 2.8 18.8 0.74 0.7 0.16 9.8 0.22 13.4

E85 80 3.1 22.0 0.87 1.1 0.33 20.1 0.36 22.0

E100 91 3.6 25.1 0.99 1.2 0.35 21.4 0.49 29.9

E200 110 4.3 37.7 1.48 2.2 0.8 48.8 1.0 61.0

E350 145 5.7 37.7 1.48 3.7 1.8 110 1.9 116

E600 175 6.9 44.0 1.73 3.3 2.9 177 3.1 189

E950 200 7.9 50.3 1.98 5.4 4.7 287 4.9 299

E1600 230 9.1 62.8 2.47 5.8 7.3 445 8.0 488

P2500/P2505 300 11.8 56.5 2.22 6.7 8.0 488 9.3 567

P4000/P4005 325 12.8 81.7 3.22 12.4 13.5 824 17.5 1068

1. These times assume smaller solenoids for smalleractuators and larger solenoidsfor larger actuators with varying Cvs, but a constant air supplypressure of 80 psi (5.51 bar). E25 to E350 assume a 0.09 Cv (0.08Kv); E600 & E9500 a 0.26 Cv (0.22 Kv); E1600, P2505 & P4005 a0.51 Cv (0.44 Kv).

2. To calculate air consumption per stroke multiply free air volume X air supply pressure (absolute).

BORE STROKE

mm Inch mm Inch

AVERAGE

STROKE

TIME

(1)

(SEC)

Port

“A”(liter)

FREE AIRVOLUME

Port

“A”(in

(2)

)

Port

“B”(liter)

FREE AIR

VOLUME

Port

“B”(in

Figure 2. Typical Actuator Assembly

(2)

)

COUPLER

STANDARD SQUARE END

DOUBLE ACTING

ACTUATOR

SPRING

W6954

END CAP SPRING RETURN

STANDARD SQUAREDOUBLED CONNECTION

E SERIES INSERT

1035/El-O-Matic Actuator

August 2012

Instruction Manual

Table 3. Approximate Weights

ACTUATOR SIZE

E25 1.2 1.7 2.7 3.7

E40 1.8 2.4 4.0 5.3

E65 2.4 3.6 5.3 7.9

E100 2.8 4.6 6.1 10.1

E200 5.8 9.1 12.8 20.1

E350 10.4 16.9 22.9 37.3

E600 19.4 27.6 42.8 60.8

E900 26.4 38.6 58.2 85.0

E1600 42.7 65.8 94.1 145

P2500/P2505 56.7 88.0 125 194

P4000/P4005 86.2 132.0 190 291

EDA ESA EDA ESA

kg lbs

Table 4. Bolting Torques between 1035 and Yoke

ACTUATOR SIZE Bolt Diameter, Inches Torque, NSm Torque, lbfSft

E25 1/4 11 8.3

E40 E65

E100 E200

E350 E600 1/2 91 67

E950 5/8 163 120

E1600 3/4 258 190

P2500/P2505 P4000/P4005

5/16 22 16.5

3/8 39 29

3/4 203 150

D500243X012

Installation

When an actuator and a valve are shipped together, the actuator is normally mounted on the valve. Follow the valve body instructions when installing the control valve in the pipeline. If the actuator is shipped separately from the valve or if it is necessary to mount the actuator on the valve, perform the procedures in the Actuator Mounting section.

WARNING

Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal injury.

To avoid personal injury or property damage caused by bursting of pressure-retaining parts, be certain the service conditions do not exceed the limits given in table 1. Use pressure-limiting devices or pressure-relieving devices to prevent the cylinder pressure from exceeding these limits.

If hoisting the valve and actuator assembly or the actuator by itself, take precautions to prevent people from being injured in case the hoist or sling slips unexpectedly. Refer to table 3 for actuator weights. Carefully position the sling to prevent damage to tubing or any accessories.

Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this instruction manual.

Instruction Manual

D500243X012

1035/El-O-Matic Actuator

August 2012

Actuator Mounting

Use the following steps to connect a valve and actuator that has been ordered separately.

The 1035 E Series is offered with a Double D insert as standard to allow direct coupling to the A41 valve drive shaft. A few actuator/valve combinations will require the use of an external coupler: E100 with a 1-inch drive shaft, E200 and E350 with a 1-1/2-inch drive shaft.

P Series applications, the actuators feature an ISO 5211 recessed square drive shaft and requires an external coupler to engage the valve drive shaft. P Series actuators also require the use of a Limit Stop Plate (LSP) if a Fisher 1080 Declutchable Manual actuator is not being used.

Assemble the bracket, actuator, LSP (if necessary) and valve assembly as follows:

1. Rotate the valve drive shaft to the position necessary to match the valve/actuator operation. See figure 3 for

mounting style codes and positions.

2. Attach the yoke/mounting bracket to the actuator or the LSP (if necessary). Do not fully tighten cap screws at this

time. You will need to align the valve and actuator, or valve, coupler, LSP and actuator before tightening the mounting screws to the required torque. The 5/8-inch screws should not be used to mount the actuator to the yoke/mounting bracket. These screws are only to be used for mounting the LSP. Only the 3/4-inch screws are to be used to mount the actuator to the yoke/mounting actuator.

WARNING

Exceeding any torque requirement may impair the safe operation of this actuator by causing broken or damaged parts. Refer to table 4 for bolting torque requirements.

The LSP, if used, will also have to be attached to the 1035. Use 4 screws for size P2500/P2505 and 8 screws for size P4000/P4005. The bolting torque for these 5/8-inch screws will be 10.2 NSm(90inSlb).

3. The P Series and a few E Series actuator combinations require a coupler. Insert the square end of the coupler into

the drive shaft recess in the actuator, making sure the coupler engages properly.

4. Lower the actuator, and coupling assembly onto the valve, making sure that the male valve stem engages into the

coupler or insert.

a. Secure the mounting bracket to the valve using cap screws and lock washers provided in the mounting kit.

b. At this time, make sure that the actuator is in the operation mode desired, and that the valve is in the correct

position required foryourapplication.

5. For E Series actuators with A41 valves, insert the valve drive shaft end (double-D) into the recessed insert.

6. Align the valve shaft with the actuator drive shaft by changing the positioning on the mounting bracket between

them.

1035/El-O-Matic Actuator

August 2012

Instruction Manual

D500243X012

Operation

Units supplied from the factory as an assembly are adjusted per specifications supplied to the factory on the original order.

Unless the valve/actuator assembly has been damaged during shipment, or the actuator removed for maintenance, the assembly should be factory adjusted and ready for service.

Actuator Orientation: The 1035 actuator is normally installed with its major axis parallel to the pipeline (see code A, figure 3). However, the actuator can also be oriented 90 degrees to thepipeline.Seefigure3forstandardandoptional orientations. (Note: Code B is not available in the E Series.)

The P or E Series actuator drive shaft turns a full 90 degrees and the stroke is adjustable for the valve closed position. When necessary, refer to the actuator adjustment steps in this manual.

Note

The A41 High Performance Butterfly valve should not be turned by the power actuator more than 90 degrees of rotation. Pre-adjust actuator stops to limit travel to 90 degrees or less until adjustment steps are completed.

Adoubleactingactuatorcanbechangedinthefieldtoaspringreturn unit, or vice-versa (requires different end caps). Code A actuators can be converted to a code D unit by turning the pistons 180 degrees from the position shown for code A (See figure 3 for piston and shaft orientation).

Adjustments

ESeriesactuatorsprovide end cap adjustment screws to limit outward travel of the piston. The inward movement of the piston is limited by the housing stop (see figure 4).

PSeriesactuatorshave a Limit Stop Plate option (LSP) which is used with standard actuator constructions. The LSP is not used when a Fisher 1080 is used. T he LSP, or the 1080, limits travel in either direction for any construction. Refer to figure 4.

To adjust the travel stops, refer to the valve instruction manual for open and closed positions of the valve. Upon assembly, ensure that the power actuator does not drive the valve past 90 degrees of rotation. Valve component parts can be damaged if high actuator air pressure is applied past 90 degrees. Travel limits must be set in the actuator, not in the valve. It is recommended that the valve be out of the pipeline when adjusting travel limits.

Instruction Manual

)

D500243X012

Figure 3. Mounting Style Codes and Positions (Section 1)

DOUBLE-D POSITION

ACTUATOR DRIVE SHAFT AND PINION GEAR

PISTON

PORT A CHAMBER

PORT B CHAMBER (BOTH E NDS)

1035/El-O-Matic Actuator

THIS CONSTRUCTION CANNOT BE USED BECAUSE THE HOUSING TRAVEL STOP CAN NOT BE USED TO ADJUST THE CLOSED POSITION OF THE DISC, AND THE SLOT IN THE TOP OF THE ACTUATOR SHAFT WILL NOT INDICATE DISCPOSITION.

August 2012

END CAP TRAVEL STOP ADJUSTS OPEN POSITION

HOUSING TRAVEL STOP ADJUSTS CLOSED POSITION

CODE A STANDARD CONSTRUCTION

• CODE A VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).

• AIRATPORTAROTATESPINIONGEARCCW,AND AIRATPORTBROTATES PINION CW.

• HOUSING TRAVEL STOP ADJUSTS VALVE CLOSED

POSITION, AND END CAP TRAVEL STOP ADJUSTS VALVE OPEN POSITION.

PIPELINE

END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)

PISTONS INSTALLED 180_ FROM STANDARD CODE A

ADJUSTMENT SCREW REMOVED

CODE C OPTIONAL CONSTRUCTION

• CODE C VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PERPENDICULAR WITH PIPELINE.

• AIRATPORTAROTATESPINIONGEARCW,AND AIRATPORTBROTATESPINIONCCW.

75B0451 A7043

NOTES:

THE SHAFT WITH RESPECT TO THE SLOT IN THE TOP OF THE DRIVE SHAFT.

2 3

AND REPLACE IT WITH A CAP SCREW FOR CODE C AND D.

• END CAP TRAVEL STOPADJUSTS VALVE CLOSED POSITION, AND HOUSING STOP IS NOT AVAILABLE.

DRAWING SHOWS THE ORIENTATION OF THE DOUBLE-D VALVE CONNECTION ON

ADJUST THE TRAVEL STOP SCREWS EQUALLY ON BOTHENDS OF THE ACTUATOR. FROM A STANDARD CONSTRUCTION CODE A, REMOVE HOUSINGADJUSTMENT SCREW AND LOCKNUT,

ESERIESDOUBLEACTINGACTUATORCODES

PORT A CHAMBER

PORT B CHAMBER (BOTH ENDS)

• CODE B VALVE-ACTUATOR POSITION IS SHOWN.

• NOT AVAILABLE.

ACTUATOR DRIVE

SHAFT ROTATED 90_ FROM STANDARD

END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)

• CODE DVALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).

• AIR AT PORT A ROTATES PINION GEAR CW, AND AIRATPORTBROTATESPINIONCCW.

• END CAP TRAVEL STOP ADJUSTS VALVE CLOSED POSITION, AND HOUSINGSTOP IS NOT AVAILABLE.

NOT AVAILABLE

CODE B CONSTRUCTION

PISTONS INSTALLED 180_ FROM STANDARD CODE A

ADJUSTMENT SCREW REMOVED

CODE D OPTIONAL CONSTRUCTION

PORT A CHAMBER

PORT B CHAMBER (BOTH ENDS

1035/El-O-Matic Actuator

August 2012

Figure 3. Mounting Style Codes and Positions (Section 2)

DOUBLE-D POSITION

CODE A STANDARD CONSTRUCTION

• CODE A VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).

• AIRATPORTAROTATESPINIONGEARCCW,AND SPRING COMPRESSION ROTATES PINION CW.

• SPRING FAILS DISC TO CLOSED POSITION.

• HOUSING TRAVEL STOP ADJUSTS VALVE CLOSED

POSITION, AND END CAP TRAVEL STOP ADJUSTS

VALVE OPEN POSITION.

ACTUATOR DRIVE SHAFT AND PINION GEAR

PISTON

PORT A CHAMBER

HOUSING TRAVEL STOP

ADJUSTS CLOSED POSITION

Instruction Manual

CODE B CONSTRUCTION

• CODE B VALVE-ACTUATOR POSITION IS SHOWN.

• NOT AVAILABLE.

D500243X012

NOT AVAILABLE

PISTONS INSTALLED 180_

PIPELINE

END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)

FROM STANDARD CODE A

ADJUSTMENT SCREW REMOVED

CODE C OPTIONAL CONSTRUCTION

• CODE C VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PERPENDICULAR WITH PIPELINE.

• AIRATPORTAROTATESPINIONGEARCW,AND

75B0442 A7044

SPRING COMPRESSION ROTATES PINION CCW.

• SPRING FAILS DISC TO OPEN POSITION.

• END CAP TRAVEL STOPADJUSTS VALVE CLOSED POSITION, AND HOUSING STOP IS NOT AVAILABLE.

NOTES:

THE SHAFT WITH RESPECT TO THE SLOT IN THE TOP OF THE DRIVE SHAFT.

2 3

AND REPLACE IT WITH A CAP SCREW FOR CODE CAND D.

DRAWING SHOWS THEORIENTATION OF THE DOUBLE-D VALVE CONNECTION ON

ADJUST THE TRAVEL STOP SCREWS EQUALLY ON BOTH ENDS OF THE ACTUATOR. FROM A STANDARD CONSTRUCTION CODE A, REMOVE HOUSINGADJUSTMENT SCREW AND LOCKNUT,

E SERIES SPRING RETURN ACTUATOR CODES

PORT A CHAMBER

ACTUATOR DRIVE

SHAFT ROTATED 90_ FROM STANDARD

END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)

PISTONS INSTALLED 180_ FROM STANDARDCODE A

ADJUSTMENT SCREW REMOVED

CODE D OPTIONAL CONSTRUCTION

• CODE D VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).

• AIRATPORTAROTATESPINIONGEARCW,AND SPRING COMPRESSION ROTATES PINION CCW.

• SPRING FAILS DISC TO OPEN POSITION.

• END CAP TRAVEL STOPADJUSTS VALVE CLOSED POSITION, AND HOUSING STOP IS NOT AVAILABLE.

PORT A CHAMBER

Instruction Manual

D500243X012

Figure 3. Mounting Style Codes and Positions (Section 3)

SQUARE INSERT

ACTUATOR DRIVE SHAFT AND PINION GEAR

PISTON

1035/El-O-Matic Actuator

August 2012

ACTUATOR DRIVE SHAFT ROTATED 90_ FROM STANDARD

CODE A STANDARD CONSTRUCTION

• CODE A VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).

• AIR AT PORT A ROTATES PINION GEAR CCW, AND AIRATPORTBROTATESPINIONCW.

• LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS.

LSP IS MOUNTEDBETWEEN ACTUATOR AND MOUNTING BRACKET. SEE FIGURE 4 FOR DETAILS.

PISTONS INSTALLED 180_

PIPELINE

FROM STANDARD CODE A

PORT A CHAMBER

PORT B CHAMBER

PORT A CHAMBER

PORT B CHAMBER

CODE B OPTIONAL CONSTRUCTION

• CODE B VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PERPENDICULAR WITH PIPELINE.

• AIR AT PORT A ROTATES PINION GEAR CCW, AND AIRATPORTBROTATESPINIONCW.

• LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSEPOSITIONS. LSP

IS MOUNTED BETWEEN ACTUATOR AND MOUNTING BRACKET. SEE FIGURE 4 FOR DETAILS.

ACTUATOR DRIVE SHAFT ROTATED 90_ FROM STANDARD

PISTONS INSTALLED 180_ FROM STANDARDCODE A

PORT A CHAMBER

PORT B CHAMBER

PORT A CHAMBER

PORT B CHAMBER

CODE C OPTIONAL CONSTRUCTION

• CODE C VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR IS PERPENDICULAR WITH PIPELINE.

• AIR AT PORT A ROTATES PINION GEARCW, AND AIR AT PORT B ROTATES PINION GEAR CCW.

• LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS.

LSP IS MOUNTEDBETWEEN ACTUATORAND MOUNTING BRACKET. SEEFIGURE4FORDETAILS.

75B0452 A7045

NOTES:

ON THE SHAFT WITH RESPECT TO THE SLOT IN THE TOP OF THE DRIVE SHAFT.

DRAWING SHOWS THE ORIENTATION OF THE SQUARE INSERT VALVE CONNECTION

P SERIES DOUBLE ACTING ACTUATOR CODES

CODE D OPTIONAL CONSTRUCTION

• CODE D VALVE-ACTUATOR POSITION IS SHOWN.

• ACTUATOR ISPARALLEL WITH PIPELINE(TOP VIEW).

• AIR AT PORT A ROTATES PINION GEAR CW, AND AIR AT PORT B ROTATESPINION CCW.

• LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS.

LSP IS MOUNTED BETWEEN ACTUATOR AND MOUNTING BRACKET. SEEFIGURE4FORDETAILS.

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