Fisher D500243X012 User Manual

Instruction Manual
Form 5417 February 2007
1035/El-O-Matic Actuator
Type 1035/El-O-Matic Rack-and-Pinion Rotary Actuator
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .
Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Disassembly 12. . . . . . . . . . . . . . . . . . . .
Actuator Assembly 14. . . . . . . . . . . . . . . . . . . . . . .
Changing Rotation Direction 15. . . . . . . . . . . . .
Spring Return E Series Actuators 16. . . . . . . . .
Spring Return P Series Actuators 17. . . . . . . . .
Installing the Bypass Valve 18. . . . . . . . . . . . . .
Parts Ordering 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Scope of Manual
This instruction manual includes installation, maintenance, and parts ordering information for Type 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 Type 1035 actuator without first D being fully trained and qualified in valve, actuator, and accessory installation, operation, and maintenance, and D carefully reading and understanding the contents of
W9255
Figure 1. Type 1035/El-O-Matic Actuator
with Type A41 Valve
this manual. If you have any questions about these instructions, contact your Emerson Process Managementt sales office before proceeding.
Note
Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and end-user.
www.Fisher.com
D500243X012
1035/El-O-Matic Actuator
Instruction Manual
Form 5417
February 2007
Table 1. Specifications
Type 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: valves
J Recessed ISO 5211 square drive for P Series
J Optional ISO 5211 square insert,
J Double D insert for Type A41
actuators
Dual Stop Adjustment:
J E Series actuators are
furnished with dual stop adjustments (DSA) as a 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.
(1)
Supply Pressure
(Operating Pressure)
to 175_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 and spring return actuators
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 Temperature: –40 to 79_C (–40
1. The pressure-temperature limits in this manual and any applicable code or standard installation should not be exceeded.
2. For more information, contact your Emerson Process Management sales office.
Description
The Type 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
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
inserted into the end of the actuator drive shaft. Standard recessed double-D bushings match the Type 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 square output shaft for coupling the actuator to the valve shaft. The Type A41 valve uses a square-to-double-D drive coupler construction. Optional couplings are available for other applications.
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Instruction Manual
STROKE
Form 5417 February 2007
Table 2. Performance Characteristics
E SERIES
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 smaller actuators and larger solenoids for larger actuators with varying Cvs, but a constant air supply pressure of 80 psi (5.51 bar). E25 to E350 assume a 0.09 Cv (0.08 Kv); E600 & E9500 a 0.26 Cv (0.22 Kv); E1600, P2505 & P4005 a 0.51 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
STANDARD SQUARE END
AVERAGE
STROKE
(SEC)
1035/El-O-Matic Actuator
(2)
3
)
Port
‘‘B’’(liter)
TIME
FREE AIR VOLUME
(1)
Port
‘‘A’’(liter)
Port
‘‘A’’(in
FREE AIR
VOLUME
Port
‘‘B’’(in
(2)
3
)
COUPLER
END CAP SPRING RETURN
W6954 / IL
DOUBLE ACTING
ACTUATOR
SPRING
STANDARD SQUAREDOUBLE D CONNECTION
E SERIES INSERT
Figure 2. Typical Actuator Assembly
3
1035/El-O-Matic Actuator
ACTUATOR
Instruction Manual
Form 5417
February 2007
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
Table 4. Bolting Torques between 1035 and Yoke
ACTUATOR
SIZE
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
kg lbs
EDA ESA EDA ESA
Bolt Diameter,
Inches
5/16 22 16.5
3/8 39 29
3/4 203 150
Torque, NSm Torque, lbfSft
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.
Actuator Mounting
Use the following steps to connect a valve and actuator that has been ordered separately.
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
The Type 1035 E Series is offered with a Double D
insert as standard to allow direct coupling to the Type 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 Type 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
4
Instruction Manual
Form 5417 February 2007
1035/El-O-Matic Actuator
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 Type 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 (90 inSlb).
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.
Actuator Orientation: The Type 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 the pipeline. See figure 3 for standard and optional 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 Type 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.
A double acting actuator can be changed in the field to a spring return 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).
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 for your application.
5. For E Series actuators with Type 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.
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.
Adjustments
E Series actuators provide 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).
P Series actuators have a Limit Stop Plate option (LSP) which is used with standard actuator constructions. The LSP is not used when a Type 1080 is used. The LSP, or the Type 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.
5
1035/El-O-Matic Actuator
Instruction Manual
Form 5417
February 2007
DOUBLE-D POSITION
END CAP TRAVEL STOP ADJUSTS OPEN POSITION
1
ACTUATOR DRIVE SHAFT AND PINION GEAR
HOUSING TRAVEL STOP ADJUSTS CLOSED POSITION
CODE A STANDARD CONSTRUCTION
S CODE A VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW). S AIR AT PORT A ROTATES PINION GEAR CCW, AND
AIR AT PORT B ROTATES PINION CW. S HOUSING TRAVEL STOP ADJUSTS VALVE CLOSED POSITION, AND END CAP TRAVEL STOP ADJUSTS VALVE OPEN POSITION.
PISTONS INSTALLED 180_
PIPELINE
FROM STANDARD CODE A
PISTON
PORT A CHAMBER
PORT B CHAMBER (BOTH ENDS)
ACTUATOR DRIVE
1
SHAFT ROTATED 90_ FROM STANDARD
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 DISC POSITION.
NOT AVAILABLE
CODE B CONSTRUCTION
S CODE B VALVEĆACTUATOR POSITION IS SHOWN. S NOT AVAILABLE.
PISTONS INSTALLED 180_ FROM STANDARD CODE A
PORT A CHAMBER
PORT B CHAMBER (BOTH ENDS)
END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)
2
ADJUSTMENT SCREW REMOVED
3
CODE C OPTIONAL CONSTRUCTION
S CODE C VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PERPENDICULAR WITH PIPELINE. S AIR AT PORT A ROTATES PINION GEAR CW, AND
AIR AT PORT B ROTATES PINION CCW. S END CAP TRAVEL STOP ADJUSTS VALVE CLOSED POSITION, AND HOUSING STOP IS NOT AVAILABLE.
NOTES:
DRAWING SHOWS THE ORIENTATION OF THE DOUBLE-D VALVE CONNECTION ON
1
THE SHAFT WITH RESPECT TO THE SLOT IN THE TOP OF THE DRIVE SHAFT.
ADJUST THE TRAVEL STOP SCREWS EQUALLY ON BOTH ENDS OF THE ACTUATOR.
2
FROM A STANDARD CONSTRUCTION CODE A, REMOVE HOUSING ADJUSTMENT SCREW AND LOCKNUT,
3
AND REPLACE IT WITH A CAP SCREW FOR CODE C AND D.
75B0451 A7043 / IL
E SERIES DOUBLE ACTING ACTUATOR CODES
Figure 3. Mounting Style Codes and Positions (Section 1)
END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)
2
ADJUSTMENT SCREW REMOVED
CODE D OPTIONAL CONSTRUCTION
S CODE D VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).
S AIR AT PORT A ROTATES PINION GEAR CW, AND
AIR AT PORT B ROTATES PINION CCW. S END CAP TRAVEL STOP ADJUSTS VALVE CLOSED POSITION, AND HOUSING STOP IS NOT AVAILABLE.
PORT A CHAMBER
PORT B CHAMBER (BOTH ENDS)
3
6
Instruction Manual
Form 5417 February 2007
1
DOUBLE-D POSITION
CODE A STANDARD CONSTRUCTION
S CODE A VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).
ACTUATOR DRIVE SHAFT AND PINION GEAR
HOUSING TRAVEL STOP ADJUSTS CLOSED POSITION
PISTON
PORT A CHAMBER
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 DISC POSITION.
NOT AVAILABLE
S AIR AT PORT A ROTATES PINION GEAR CCW, AND SPRING COMPRESSION ROTATES PINION CW.
S SPRING FAILS DISC TO CLOSED POSITION. S 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
PORT A CHAMBER
ADJUSTMENT SCREW REMOVED
2
3
ACTUATOR DRIVE
1
SHAFT ROTATED 90_ FROM STANDARD
CODE C OPTIONAL CONSTRUCTION
S CODE C VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PERPENDICULAR WITH PIPELINE. S AIR AT PORT A ROTATES PINION GEAR CW, AND
SPRING COMPRESSION ROTATES PINION CCW.
S SPRING FAILS DISC TO OPEN POSITION. S END CAP TRAVEL STOP ADJUSTS VALVE CLOSED
POSITION, AND HOUSING STOP IS NOT AVAILABLE.
NOTES:
DRAWING SHOWS THE ORIENTATION OF THE DOUBLE-D VALVE CONNECTION ON
1
THE SHAFT WITH RESPECT TO THE SLOT IN THE TOP OF THE DRIVE SHAFT.
2
ADJUST THE TRAVEL STOP SCREWS EQUALLY ON BOTH ENDS OF THE ACTUATOR. FROM A STANDARD CONSTRUCTION CODE A, REMOVE HOUSING ADJUSTMENT SCREW AND LOCKNUT,
3
AND REPLACE IT WITH A CAP SCREW FOR CODE C AND D.
75B0442 A7044 / IL
E SERIES SPRING RETURN ACTUATOR CODES
Figure 3. Mounting Style Codes and Positions (Section 2)
CODE B CONSTRUCTION
S CODE B VALVEĆACTUATOR POSITION IS SHOWN. S NOT AVAILABLE.
PISTONS INSTALLED 180_ FROM STANDARD CODE A
END CAP TRAVEL STOP ADJUSTS CLOSED POSITION (BOTH ENDS)
2
ADJUSTMENT SCREW REMOVED
CODE D OPTIONAL CONSTRUCTION
S CODE D VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW).
S AIR AT PORT A ROTATES PINION GEAR CW, AND
SPRING COMPRESSION ROTATES PINION CCW.
S SPRING FAILS DISC TO OPEN POSITION. S END CAP TRAVEL STOP ADJUSTS VALVE CLOSED
POSITION, AND HOUSING STOP IS NOT AVAILABLE.
PORT A CHAMBER
3
7
1035/El-O-Matic Actuator
Instruction Manual
Form 5417
February 2007
1
SQUARE INSERT
ACTUATOR DRIVE SHAFT AND PINION GEAR
CODE A STANDARD CONSTRUCTION
S CODE A VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW). S AIR AT PORT A ROTATES PINION GEAR CCW, AND
AIR AT PORT B ROTATES PINION CW. S LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS. LSP IS MOUNTED BETWEEN ACTUATOR AND MOUNTING BRACKET. SEE FIGURE 4 FOR DETAILS.
PISTON
PORT A CHAMBER
PORT B CHAMBER
ACTUATOR DRIVE SHAFT ROTATED 90_ FROM STANDARD
CODE B OPTIONAL CONSTRUCTION
S CODE B VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PERPENDICULAR WITH PIPELINE. S AIR AT PORT A ROTATES PINION GEAR CCW, AND
AIR AT PORT B ROTATES PINION CW. S LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS. LSP IS MOUNTED BETWEEN ACTUATOR AND MOUNTING BRACKET. SEE FIGURE 4 FOR DETAILS.
PORT A CHAMBER
PORT B CHAMBER
PISTONS INSTALLED 180_
PIPELINE
FROM STANDARD CODE A
PORT A CHAMBER
PORT B CHAMBER
CODE C OPTIONAL CONSTRUCTION
S CODE C VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PERPENDICULAR WITH PIPELINE. S AIR AT PORT A ROTATES PINION GEAR CW, AND
AIR AT PORT B ROTATES PINION GEAR CCW. S LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS. LSP IS MOUNTED BETWEEN ACTUATOR AND MOUNTING BRACKET. SEE FIGURE 4 FOR DETAILS.
NOTES:
DRAWING SHOWS THE ORIENTATION OF THE SQUARE INSERT VALVE CONNECTION
1
ON THE SHAFT WITH RESPECT TO THE SLOT IN THE TOP OF THE DRIVE SHAFT.
75B0452 A7045 / IL
P SERIES DOUBLE ACTING ACTUATOR CODES
ACTUATOR DRIVE SHAFT ROTATED 90_ FROM STANDARD
CODE D OPTIONAL CONSTRUCTION
S CODE D VALVEĆACTUATOR POSITION IS SHOWN. S ACTUATOR IS PARALLEL WITH PIPELINE (TOP VIEW). S AIR AT PORT A ROTATES PINION GEAR CW, AND
AIR AT PORT B ROTATES PINION CCW. S LIMIT STOP PLATE ADJUSTS BOTH OPEN AND CLOSE POSITIONS. LSP IS MOUNTED BETWEEN ACTUATOR AND MOUNTING BRACKET. SEE FIGURE 4 FOR DETAILS.
PISTONS INSTALLED 180_ FROM STANDARD CODE A
PORT A CHAMBER
PORT B CHAMBER
Figure 3. Mounting Style Codes and Positions (Section 3)
8
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