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.
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.
2
Instruction Manual
STROKE
Form 5417
February 2007
Table 2. Performance Characteristics
E SERIES
ACTUATOR
SIZE
E25562.215.70.620.50.16.10.116.7
E40702.818.80.740.70.169.80.2213.4
E85803.122.00.871.10.3320.10.3622.0
E100913.625.10.991.20.3521.40.4929.9
E2001104.337.71.482.20.848.81.061.0
E3501455.737.71.483.71.81101.9116
E6001756.944.01.733.32.91773.1189
E9502007.950.31.985.44.72874.9299
E16002309.162.82.475.87.34458.0488
P2500/P250530011.856.52.226.78.04889.3567
P4000/P400532512.881.73.2212.413.582417.51068
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).
BORESTROKE
mmInchmmInch
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
E251.21.72.73.7
E401.82.44.05.3
E652.43.65.37.9
E1002.84.66.110.1
E2005.89.112.820.1
E35010.416.922.937.3
E60019.427.642.860.8
E90026.438.658.285.0
E160042.765.894.1145
P2500/P250556.788.0125194
P4000/P400586.2132.0190291
Table 4. Bolting Torques between 1035 and Yoke
ACTUATOR
SIZE
E251/4118.3
E40
E65
E100
E200
E350
E6001/29167
E9505/8163120
E16003/4258190
P2500/P2505
P4000/P4005
kglbs
EDAESAEDAESA
Bolt Diameter,
Inches
5/162216.5
3/83929
3/4203150
Torque, NSmTorque, 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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