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1. El o matic Pneumatic Actuators are pneumatic quarter turn 90 actuators Special versions are available for half turn 180 applications The design utilizes a double rack and single pinion A unique patented features of the actuator is the application of a 3 point support for pistons Three carbon filled Teflon guide bands are a balanced piston and the cylinder walls which eliminates wear and increases the actuator life The unit has an extended top shaft and a complete modular design which allows simple attachment to a variety of control accessories 2 SPECIFICATIONS P SERIES PD 0 2to 10 bar PE 6to 10 bar standard springs PE 3 to 10 bar reduced springs 1 Pressure range 2 Torque 23 to 4955 Nm at 6 bar working pressure 3 Media Air dry or lubricated non corrosive gas or light hydraulic oil Suitable for indoor or outdoor Installation Actuator size PD or PE 60 4 Construction The bottom mounting pad of the actuator is as per ISO 5211 Thus it can be directly mounted on any valve which conforms to ISO 5211 flange configuration Details relating to dimensions assemblies part list and materials are given in the drawings data sheets in sections 13 14 15 and 16 180 actuators are available only in the P series Type PD and PE Dimensions of 180 actuators correspond to those of 90 actuators Torque ratings of 180 actuators are different 5 Temperature 20 Cto 80 C 6 Ro2. INDIA I PVT LTD IN COLLABORATION WITH EL O MATI B V ii HOLAND ENGINEERING MANUAL al User Manual VALVE ACTUATOR SYSTEM EL O MATIC CONTENTS SECTION 1 PRELIMINARY INFORMATION 1 1 How to use this manual l 2 How to order spares SECTION 2 ORDER SUPPLY amp SYSTEM DETAILS 2al Order details 2 2 Scope of supplv 2 3 Svstem drawings SECTION 3 COMPONENT MANUALS Manuals for only those system components actually ordered marked are included in this manual set 3 1 ACTUATOR 3 2 PROCESS VALVE vw 3 3 SOLENOID VALVE sov 3 4 LIMIT SWITCH UNIT LSB 3 5 POSITION TRANSMITTER amp INDICATORS 3 6 I P CONVERTOR IPC 3 7 POSITIONER 3 8 AIR TANK 3 9 MANUAL OVER RIDE UNIT gt z gt 2 5l IS dii 3 10 OTHER PNEUMATIC ACCESSORIES AFR QEV FCV ALV NRV PNEU LOCK EQV es E B 3 11 ELECTRONIC CONTROLS PAGE User Manual PRECAUTION VALVE ACTUATOR SYSTEM EL O MATIC READ THIS MANUAL THOROUGHLY BEFORE ATTEMPTING TO INSTALL OR SERVICE THIS EQUIPMENT PAY CAREFUL ATTENTION TO THE PRECAUTIONARY INSTRUCTIONS GIVEN AT VARIOUS PLACES IN THE USER MANUALS IN OUTLINE BOXES SECTION 1 PRELIMINARY INFORMATION 1 1 How to use this manual Section 1 of this manual contains instructions relating to how to use this manual ordering spares Contact your nearest branch of our headquarters if you require Service Assistance Spare parts Actuator
3. Change adaptor Align correctly and tighten bolts Check and reset limit stop screws to achieve required stroke Check limit stop settings on MO and readjust if required to achieve full rotation Check for mechanical obstructions if any and remove Check air supply pressure and ensure specified supply pressure Check spring selection PAGE User Manual PNEUMATIC ACTUATOR EL O MATIC FAULT PROBABLE CAUSE REMEDIAL ACTION Noise inside actuator ACTUATORS CONTROLLED WITH POSITIONERS Additional checks Actuator not functioning on increasing signal pressure Incorrect positioning Improper clearance between rack and pinion Broken or loosened rack bolts Insufficient lubrication due to prolonged use at high ambient temperatures Metal to metal contact due to worn out sealing guiding elements Leakage in signal line signal not reaching Positioner Insufficient supply air pressure Faulty Positioner seized spool valve Feed back mechanism not functioning broken Excessive play in feed back mechanism Wrong span and zero adjustment Wrong selection of feed back cam profile Open actuator and check tightness of rack bolts Ifloose tighten properly If worn out replace racks shaft Open actuator clean and lubricate with specified lubricant grease Replace guide bands sealing elements Check signal line fittings and tighten properly Check for blockag
4. This may lead to corrosion to springs or excessive wear and early failure to piston sealing ring To avoid such problems customers are advised to use BREATHER BLOCK Breather block avoids suction of atmospheric air into spring chamber Port B During spring stroke it allows air from centre chamber Port A to fill the spring chamber and then exhaust to atmosphere User Manual 12 TROUBLE SHOOTING ACTUATOR For identification of all numbered parts refer to drawing numbers in sections 14 and 16 i AN ACTUATOR SHOULD NEVER BE REMOVED e FROM THE SERVICE PROCESSVALVE UNDER PRESSURE Make sure that all internal port passages are clear and free of any obstructions Make sure that the actuator is lubricated and that there is no solidified grease between the pinion and the piston racks 1 Ifthe actuator has no lubrication apply generous amounts of grease If the actuator is for high or low temperature operation consult El o matic for proper lubricant SECTION 3 1 PNEUMATIC ACTUATOR ACT EL O MATIC If solidified grease between the pinion and the piston racks is present clean dry regrease and reassemble Verify that the actuator pinion shaft and or pistons are bound If bound reassemble following the rebuilding Instructions If the actuator exhibits excessive amounts of backlash check teeth in piston racks for wear If worn replace piston gear rack assembly In spring return
5. KIT All soft seals bearings and non reusable parts are included in the recommended spare part kit Each kit includes Guide band piston 2 nos Guide band housing 1 2 nos O rings piston 2 nos O rings endcap 2 nos O rings shaft 2 nos Guide bush shaft l no Bearing band shaft l no Washer shaft l no Circlip shaft l no Passage O rings 2 4 nos The spare parts kit 1s identical for both the double acting and the spring return models For the spring return models it is safe to have a set of spare springs for each different model in addition to the recommended spare parts kit Keep in mind that when necessary springs are to be replaced in complete set Racks are not recommended for replacement instead piston rack assemblies should be replaced if required User Manual 10 DISASSEMBLY Before disassembling any actuator be sure that the complete repair kit is available and that the kit has been checked for all parts 1 Disconnect the air supply and electrical service to the actuator 2 Remove the actuator from its mounting bracket DISASSEMBLY AND REASSEMBLY OF THE ACTUATOR MUST BE DONE IN CLEAN DUST FREE ENVIRONMENTS BALL VALVES AND PLUG VALVES CAN TRAP PRESSURIZED MEDIA IN THE CAVITY ISOLATE THE PIPING SYSTEM IN WHICH THE ACTUATOR VALVE ASSEMBLY IS MOUNTED AND RELIEVE ANY PRESSURE ON THE VALVE 3 Remove solenoid valve by unscrewing the mounting screws Take care to retai
6. EW circlip into its mating groove on the top shaft extension The removed shaft clip is not to be re used When properly installed the shaft clip should rotate freely within the groove User Manual SPRING RETURN ACTUATOR P SERIES Model SR 11 When replacing spring return actuator ensure that the springs are replaced in their identical position in the end cap from where they were removed When less than the standard number of seven springs are used in each end cap these springs should be positioned in balanced configuration refer FIG 2 below 10 SPRINGS CD SPRING FIG 2 PE SERIES ACTUATOR 12 SPRINGS 14 SPRINGS 12 Ifa spring return actuator is being repaired due to a failed spring replace ALL the springs in this actuator as well as any other parts which may have been damaged 13 When replacing the springs place the actuator body on a clean flat surface Position it so that it stands on one end Ensure that the pistons are stroked fully inward toward the center of the actuator This may be done by rotating the actuator shaft with a wrench 14 Place the springs on the piston face engaging them with the bosses cast into the piston 15 Place the endcap over the springs Align them with the corresponding bosses on the endcap 16 Place the endcap bolts through the retention holes of the endcaps IF CONVERTING A DOUBLE ACTING UNIT TO SPRING RETURN BE SURE TO USE NEW END CAPS 17
7. Engage the bolts with the tapped holes in the actuator body by forcing down slightly on the cap Tighten each bolt in SMALL and EQUAL turns SECTION 3 1 PNEUMATIC ACTUATOR EL O MATIC E SERIES Model ES 18 When replacing ES springs in a spring return actuator ensure that the springs are replaced in their identical positions in the spring pack from where they were removed 19 Ifa spring return actuator is being repaired due to a failed spring replace ALL springs in this actuator as well as any other parts which may have been damaged 20 To change springs open the endcaps remove nut cover locknut washer and O ring 21 Remove the spring retaining socket bolt using a hexagon wrench 22 Remove and if necessary replace springs as indicated by the spring return torque chart Be sure that all springs are located correctly in the end cap and the spring pack retainer FIG 3 SPRING SET 2 SPRING SET 3 MIDDLE INNER MIDDLE SPRING SET 4 SPRING SET 5 SPRING SET 6 INNER OUTER MIDDLE OUTER INNER MIDDLE OUTER FIG 3 Q SPRING ES SERIES ACTUATOR 23 Repeat steps 20 to 22 for the other spring pack 24 Re assemble in reverse order FIG 1 CAUTION When spring return actuators are used in a highly corrosive atmosphere or when installed in the open there are chances of corrosive media or water entering during suction through the silencer breather provided on the spring chamber port Port B
8. PLY WHILE MANUAL OPERATION IS BEING PERFORMED Air must be allowed to exhaust from the actuator for manual operation This may call for disconnecting air lines or providing three way vent valves at inlet ports depending on the pneumatic circuits 7 AIR CONSUMPTION The charts showing the amount of air consumed per 90 of stroke in litres stroke are given in specifications above 8 MAINTENANCE THE ACTUATOR MUST BE ISOLATED BOTH PNEUMATICALLY AND ELECTRICALLY BEFORE ANY MAINTENANCE IS CARRIED OUT Periodic checks should be performed to make sure that all fasteners remain tight SECTION 3 1 PNEUMATIC ACTUATOR EL O MATIC All actuators are supplied with sufficient lubrication for their normal working life If required recommended lubricant for all standard actuators is GREASE SERVOGEM 2 Consult El o matic for lubricants used for high or low temperature applications Depending upon the conditions under which the actuator must work such as extended duty non compatible operating media or abnormal operating conditions periodic replacement of internal seals is recommended Repair kits containing all necessary seals can be ordered from El o matic On spring return actuators the springs may need replacement after extended duty since springs may be subject to fatigue SPRINGS SHOULD ALWAYS BE REPLACED IN COMPLETE SETS ONLY Spring kits are available from El o matic 9 RECOMMENDED SPARES REPAIR
9. actuators check for misplaced or broken springs If springs are broken check the body bore for Scoring User Manual ACTUATOR SYSTEM PNEUMATIC ACTUATOR EL O MATIC IMPORTANT READ THESE GUIDELINES BEFORE ATTEMPTING ANY REPAIRS o FAULT PROBABLE CAUSE REMEDIAL ACTION FOR SOLENOID OPERATED ACTUATORS 1 Actuator does not function SECTION 3 1 Valve jammed seized Excessive friction in valve gland Solenoid valve not operating Functioning Air supply not reaching actuator Insufficient air supply pressure Manual Override engaged in manual mode where MO is mounted Equalizing valve open if provided only for system with MO Speed control valve regulating valve fully closed for system with speed control valve Actuator undersize for the given application Check valve operation through Wrench Manual Override MO if provided otherwise remove actuator and check valve for smooth operation Check gland packing loosen gland ifrequired Check solenoid coil and ensure that specified supply voltage is applied to coil Check solenoid valve operation listen for click sound Replace coil valve ifnot functioning Check pneumatic line and connections Check air after regulator setting use local pressure gauge for checking supply pressure Check air supply pressure and ensure specified air supply pressure Declutch manual override and diseng
10. age handwheel Check equalizing valve and close valve fully before giving air supply Check position of speed control valve Ensure that valve is kept partially opened Cross check valve torque requirements Select correct size of actuator User Manual PNEUMATIC ACTUATOR EL O MATIC a FAULT PROBABLE CAUSE REMEDIAL ACTION Actuator functions but exhibits lack of power 3 Full stroke of actuator not achieved Leakage in pneumatic line Leakage across pistons or between ports A amp B can happen only due to prolonged operation over a period of time Low air supply pressure Severe misalignment between actuator and valve Excessive friction in gland packing Excessive clearance play in adaptor linkage Mounting bolts loose or wrongly Oriented Limit stops on actuator if provided not set correctly Limit stops on MO incase of systems with MO not set properly Obstruction in valve or linkage Excessive spring torque in case of spring return actuators Low air supply pressure Check all pneumatic connections and tighten properly Use Teflon tape thread sealants on threads Pressurise port A B and check for leakage from the others Change sealing parts if required Check supply pressure and ensure correct air supply pressure Check linkage loosen mounting bolts and align actuator correctly for friction free rotation Check gland and loosen if required
11. e in signal line Check and ensure specified air supply pressure Check and repair See Positioner instruction manual or replace Positioner Check Positioner feed back linkage ensure positive feed back Check linkage and connect properly Tighten grub screws provided on adaptor Check span and readjust to obtain specified span Correct zero Adjustment Check selected cam profile and ensure that the required profile only selected PAGE
12. ilicone or graphite base grease 11 REASSEMBLY DOUBLE ACTING ACTUATOR Replace the top and bottom shaft bearings Replace the shaft in the body through the bottom of each actuator body The bottom hole in the actuator body is larger inside diameter than the top hole in the body Very carefully align the shaft square to the body Align the pinion gear so that the teeth on the center gear will pick up the piston assembly s rack teeth when turning the top extension of the center gear clockwise CW To ensure proper meshing of the teeth rotate the center gear 45 or two teeth counter clockwise CCW from its normal position with the piston assemblies located at the body ends Normal positions 1s that position which provides the proper output shaft orientation required With the piston assemblies in the body gently push each piston into the body Turn the top shaft extension clockwise CW At the proper point of engagement between the center gear and piston assemblies both piston assemblies will move toward the center of the body when turning top shaft extension of the actuator clockwise CW Once the pinion gear and pistons are properly engaged ensure that smooth movement and 90 operation can occur without moving the pistons out of the actuator body This is important Take care of seal O rings while replacing the actuator endcaps Replace the washer over the top shaft extension 10 Install the N
13. le on special order Rotation is accomplished by feeding supply air into the center chamber through port A forcing the two opposing pistons outward resulting in counter clockwise rotation of the drive shaft to the Open position ACTUATOR ASSY MODE D SPRING TO OPEN CCW User Manual For double acting actuators closure is obtained by feeding supply air into the end cap chambers through port B which forces the pistons inward resulting in clock wise rotation of the drive shaft For spring return actuators closure is accomplished by means of springs contained in the end cap chambers which force the pistons inward when the supply air to the center chamber port A is allowed to exhaust To reverse the stroke direction of the actuator remove both the pistons rotate them by 180 and re install This will reverse the direction of rotation of the output shaft see FIG 1 6 MANUAL OPERATION In the event of air failure the actuator can be cycled manually This is accomplished by applying a wrench to the exposed top shaft of the actuator and turning it in the desired direction This is not recommended on Model PD 500 and larger size of actuators For these El o matic offers optional Manual Override gear units with declutchable hand wheels Manual wrench is not recommended for spring return actuators CARE MUST BE TAKEN TO ENSURE THAT THE ACTUATOR IS NOT OPERATED AUTOMATICALLY THROUGH AIR SUP
14. n the solenoid valve O rings 4 Each endcap is fitted into the body with a set of end cap bolts Remove all endcap bolts from both endcaps by loosening them evenly and a little at a time After the screws are removed gently pry off each endcap being careful not to damage the endcap O rings IF THE ACTUATOR ISA SPRING RETURN MODE UNIFORMLY LOOSEN ALL END CAPS SCREWS ON EACH END CAP TWO TO THREE TURNS AT A TIME IN SEQUENCE TO RELIEVE PRE LOAD OF THE SPRINGS ON ALL ACTUATORS WITH SPRINGS USE CAUTION WHEN REMOVING ENDCAPS l The two pistons can now be removed by rotating the actuator shaft driving the piston assembly outward until the gear rack and pinion have disengaged Remove and discard circlip and the washer from the shaft Remove the shaft through the bottom of the body All repair kit O rings guide bands and bearings may now be installed if all the actuator surfaces are clean and free of grit and scratches If the inside wall of the body is scored the actuator will leak after Rebuilding New unscored parts should be obtained from the factory Light tracing barely detectable to touch is acceptable Lubricate the standard actuator thoroughly with grease Servogem 2 Apply a light film of grease to all O rings SECTION 3 1 PNEUMATIC ACTUATOR ACT EL O MATIC 10 If converting over to a high temperature actuator or rebuilding an existing one consult El o matic for proper high temperature s
15. s or valve actuator systems Section 2 gives details which are specific to this order Customer s order reference our works reference and scope of supply Drawings of the valve actuator systems supplied are also given in this section 1 2 Section 3 contains separate manuals for each major component of the valve actuator systems supplied under this order Each user manual is complete with respect of the system component it covers It includes detailed specifications standard drawings and instruction disassembly re assembly and trouble shooting How to order spares Spares for El o matic Actuators and valve actuator systems can be ordered through the El o matic Branch office nearest to you PLEASE FOLLOW PART NUMBERS AND PART NAMES ACCURATELY AS GIVEN IN THE USER MANUALS OTHERWISE IT CAN LEAD TO ERRORS AND OR DELAYS IN EXECUTING ORDERS SECTION 1 INFO User Manual PNEUMATIC ACTUATOR EL O MATIC IMPORTANT READ THIS MANUAL THOROUGHLY BEFORE INSTALLATION OR SERVICING CONTENTS 1 DESCRIPTION 7 AIR CONSUMPTION 2 SPECIFICATIONS 8 MAINTENANCE 3 ORIENTATION 9 RECOMMENDED 4 AIR SUPPLY SPARES REPAIR KIT 5 OPERATION 10 DISASSEMBLY 6 MANUAL OPERATION 11 REASSEMBLY 13 P SERIES ACTUATOR DIMENSIONS 14 P SERIES CONSTRUCTION PARTS AND MATERIALS 15 E SERIES ACTUATOR DIMENSIONS 16 E SERIES CONSTRUCTION PARTS AND MATERIALS 12 TROUBLE SHOOTING 1 DESCRIPTION
16. tation Counter clockwise to open with port A pressurized Spring return actuators air fail to close clockwise 91 5 from 0 5 CW to 91 CCW 7 Movement Factory lubricated for the normal life of the actuator soo 750 1100 2500 4000 Units 8 Lubrication Bore 80 EE Ea 164 200 210 300 325 mm Stroke 18 8 25 1 31 4 37 6 37 6 50 3 56 8 81 7 mm Weight PD 2 6 5 3 92 140 22 4 30 8 647 97 8 kg PE 3 0 cm ae ee EE Bar km es a Operating time standard Eg 12 120 Air Consumption Port A 0 27 CE ECE 13 50 actual volume at 1 atmosphere Port B 0 38 0 80 1 60 2 50 4 20 5 40 9 30 17 50 Litres PAGE EL O MATIC User Manual PNEUMATIC ACTUATOR E SERIES l Pressurerange ED 0 2to 10 bar 5 Temperature 20 C to 80 C ES 6 to 10 bar standard springs ES 3to10 bar reduced springs 6 Rotation Counter clockwise to open with port A pressurized 2 Torque 9 to 251 Nm at 6 bar working pressure l Spring return actuators air fail to close 3 Media Air dry or lubricated clockwise non corrosive gas or light hydraulic oil Suitable for indoor or outdoor Installation 4 Construction 7 Movement 8 Lubrication 91 5 from 0 5 CW to 91 CCW Factory lubricated for the normal life of the actuator Actuator size ED or ES 12 25 140 1100 200 350 600 950 1600 Bore 46 56 70 91 110 145 175 200 1230 Jmm S
17. troke 12 6 15 7 18 8 25 1 37 7 37 7 44 0 50 3 62 8 IMM ED 1061 13 2 0 3 7 68 10 4 19 4 26 4 42 7 IKg Weight ES 067117 126 5 0 10 3 16 9 27 6 38 6 65 8 Kg Operating time Standard 704 os o7 12 23 36 13 6 54 69 Sec Air Consumption Port A 0 05 0 10 0 16 0 35 0 80 1 80 2 90 4 70 7 30 Litres Actual volume at 1 atmosphere Port BI 0 06 0 11 0 22 0 49 1 00 1 90 3 10 4 90 8 00 Litres 3 ORIENTATION The actuator is normally installed with its major axis parallel to the pipeline The actuator can be oriented above beside or beneath the valve without affecting its operation The unique full machined shaft and square drive mounting pattern allows reorientation of the actuator to accommodate installations where physical obstructions might otherwise be prohibitive All El o matic actuators feature a blow out proof shaft design This means that the pistons must be removed before the shaft can be reoriented ACTUATOR ASSY MODE A SPRING TO CLOSE CW PAGE 4 AIR SUPPLY El o matic actuators are factory lubricated For optimum operation the use of clean dry air gas is recommended Lubricated air is not necessary Standard double acting actuators require to 8 bar air supply pressure and spring return actuators 3 to 8 bar 5 OPERATION The El o matic actuator drive shaft rotates through a full 90 180 actuators are availab
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