Emerson EL-O-Matic F Series Installation, Operation And Maintenance Manual
Rack and pinion pneumatic actuators
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Summary of Contents for Emerson EL-O-Matic F Series
- Page 1 Installation, Operation and Maintenance Manual DOC.IOM.EF.EN, Rev. 6 September 2015 EL-O-Matic F-Series Rack and Pinion Pneumatic Actuators EL Matic EL Matic...
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Page 3: Table Of Contents
EL-O-Matic F Contents DOC.IOM.EF.EN Rev. 6 September 2015 Table of Contents Section 1: Before You Start Installation, Operation and Maintenance Reference Documents ....1 Warehouse Storage..................1 On-Site Storage ..................2 Section 2: Introduction Identification ..................... 3 Intended Use ..................... 4 Specifications .................... - Page 4 EL-O-Matic F Contents DOC.IOM.EF.EN Rev. 6 September 2015 Section 7: Decommission (Out of Service) Before You Start ..................22 Removing the actuator from the valve ............. 23 Section 8: Disassembly Removing End Caps ................. 25 Removing Spring Cartridges (Spring-Return) ........... 26 Removing of Limit Stop ................
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Page 5: Section 1: Before You Start
Installation, Operation and Maintenance Manual Section 1: Before You Start DOC.IOM.EF.EN Rev. 6 September 2015 Section 1: Before You Start This section explains: • Base safety procedures • Where to find detailed information relating safety. • Storage guidelines. Installation, adjustment, putting into service, use, assembly, disassembly and maintenance of the pneumatic actuator must be performed by qualified personnel. -
Page 6: On-Site Storage
Section 1: Before You Start Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 On-Site Storage • All actuators should be stored in a clean, dry warehouse, free from excessive vibration and rapid temperature changes. • Prevent moisture or dirt from entering the actuator. Plug or seal both air connection ports. -
Page 7: Section 2: Introduction
Installation, Operation and Maintenance Manual Section 2: Introduction DOC.IOM.EF.EN Rev. 6 September 2015 Section 2: Introduction This section explains: • How to identify the received product, • The intended use of the product • Construction details • Actuator specifications Identification The EL-O-Matic F Rack and Pinion actuators are available as double-acting or spring-return versions. -
Page 8: Intended Use
Section 2: Introduction Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 Intended Use The EL-O-Matic F Rack and Pinion actuators are intended for the automation and operation of quarter-turn valves like Butterfly, Ball and Plug valves. Rack and Pinion actuators can also be used to operate dampers or any other quarter-turn applications. - Page 9 Installation, Operation and Maintenance Manual Section 2: Introduction DOC.IOM.EF.EN Rev. 6 September 2015 Table 4. Air Volumes and Consumption Consumption per stoke Actuator volumes: (in liters, pressure in barg) Maximum volume (in liters) Outward Stroke Inward Stroke Actuator Double-Acting Central End cap Displaced Double-Acting only...
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Page 10: Section 3: Product Code
Section 3: Product Code Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 Section 3: Product Code This section explains: • How to create the configuration code for a default actuator. • How to create the configuration code for an actuator with added integral options. FS 0150 . -
Page 11: Section 4: Installation
Installation, Operation and Maintenance Manual Section 4: Installation DOC.IOM.EF.EN Rev. 6 September 2015 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 —... -
Page 12: Position After Failure
Section 4: Installation Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 4.2.2 Position After Failure The position of the actuator after a failure depends on the: Principle of operation (see paragraph 4.3) Assembly codes (see paragraph 4.4) Kind of failure. Refer to the table below. Table 5. -
Page 13: Ingress Protection (Ip) Rating
Installation, Operation and Maintenance Manual Section 4: Installation DOC.IOM.EF.EN Rev. 6 September 2015 The table below represents the cycle time (operating time) per different Actuator sizes: Table 6. Operating Speed Cycle time in seconds Spring-Return Double-Acting Actuator A-port Spring A-port B-port size pressurized... -
Page 14: Double-Acting Actuators
Section 4: Installation Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 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. -
Page 15: Spring-Return Actuators
Installation, Operation and Maintenance Manual Section 4: Installation DOC.IOM.EF.EN Rev. 6 September 2015 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. -
Page 16: Actuator Assembly Codes
Section 4: Installation Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 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 Pistons Pistons A = Rotation when central air chamber is pressurized. -
Page 17: Actuator To Valve Installation
Installation, Operation and Maintenance Manual Section 4: Installation DOC.IOM.EF.EN Rev. 6 September 2015 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. - Page 18 Section 4: Installation Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 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°...
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Page 19: Mounting Of Control And Feedback Accessories
Installation, Operation and Maintenance Manual Section 4: Installation DOC.IOM.EF.EN Rev. 6 September 2015 Install the actuator to the bracket. Tighten all bolts and apply the correct torque (refer to Table 8). Table 8. Bottom flange torque values Torque (Nm) Torque (lbf.ft) Actuator Size ISO Pattern Thread... -
Page 20: Recommended Tubing Sizes
Section 4: Installation Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 Recommended Tubing Sizes In case the solenoid valve is mounted remotely (i.e. in a central solenoid cabinet) and in order to supply sufficient flow of air supply to the actuator, the following tubing sizes are recommended. -
Page 21: Section 5: Mechanical Stroke Adjustment
Installation, Operation and Maintenance Manual Section 4: Installation DOC.IOM.EF.EN Rev. 6 September 2015 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. -
Page 22: Travel Stop Adjustment
Section 5: Mechanical Stroke Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 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”... -
Page 23: Angular Displacement
Installation, Operation and Maintenance Manual Section 5: Mechanical Stroke DOC.IOM.EF.EN Rev. 6 September 2015 Turn the “closed” stop clockwise to reduce or counterclockwise to increase the travel. Consult chapter 5.1.3 (angular displacement of the pinion), to define how far the limit stop must be turned in or out. Remove air supply. -
Page 24: Section 6: Maintenance
Section 6: Maintenance Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 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. -
Page 25: 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 Process Management – Valve Automation distributors. 6.2.1... -
Page 26: Section 7: Decommission (Out Of Service)
Installation, Operation and Maintenance Manual Section 7: Decommission (Out of Service) September 2015 DOC.IOM.EF.EN Rev. 6 Section 7: Decommission (Out of Service) This section explains: • How to decommission an actuator in a safe way. Before You Start WARNING - MOVING PARTS Actuator must be isolated pneumatically and electrically before any (dis)assembly starts. -
Page 27: Removing The Actuator From The Valve
Section 7: Decommission (Out of Service) Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 Removing the actuator from the valve Disconnect all air supply hoses (Ports A and B or solenoid). Disconnect all electrical wirings of the switch box. Disconnect the electrical wiring of the solenoid valve. -
Page 28: Section 8: Disassembly
Installation, Operation and Maintenance Manual Section 8: Disassembly September 2015 DOC.IOM.EF.EN Rev. 6 Section 8: Disassembly This section explains: • How to disassemble an actuator safely. The instructions of this section can be used for maintenance or reconfiguration like spring set change or maintenance. -
Page 29: Removing End Caps
Installation, Operation and Maintenance Manual Section 8: Disassembly DOC.IOM.EF.EN Rev. 6 September 2015 Removing End Caps For Double-acting actuators, do the following: Loosen the screws (10) of the end caps (2). Remove the o-ring (14) and "B" port seal (16). Discard these parts. Figure 17 Double-Acting End Caps Removal The above end caps (2) are for Actuator sizes 25, 40, 65 and 100. -
Page 30: Removing Spring Cartridges (Spring-Return)
Installation, Operation and Maintenance Manual Section 8: Disassembly September 2015 DOC.IOM.EF.EN Rev. 6 For Spring-return actuators, do the following: Tip: For actuators with assembly code CW, turn back the right hand limit stop screw (17) 2 full turns. For actuators with assembly code CC, turn back the left hand limit stop screw (17) 2 full turns. -
Page 31: Removing Of Limit Stop
Installation, Operation and Maintenance Manual Section 8: Disassembly DOC.IOM.EF.EN Rev. 6 September 2015 Removing of Limit Stop Remove the limit stop screws (17), limit stop nuts (18), limit stop washers (19) and limit stop o-rings (15). Discard the o-rings. Figure 20 Limit Stop Removal Removing Pistons Use a wrench and turn the pinion counterclockwise (180°) until the pistons (3) -
Page 32: Removing Pinion
Installation, Operation and Maintenance Manual Section 8: Disassembly September 2015 DOC.IOM.EF.EN Rev. 6 Removing pinion Remove the circlip (11) and thrust washer (9) on top of the pinion assembly. Discard if necessary the circlip (11) and thrust washer (9). Remove the pinion (4) by pushing it downwards. Remove the pinion o-ring seals (12) and the pinion bearings (8). -
Page 33: Section 9: Reassembly
Section 9: Reassembly Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 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. •... -
Page 34: Grease Instructions
Installation, Operation and Maintenance Manual Section 9: Reassembly September 2015 DOC.IOM.EF.EN Rev. 6 Grease Instructions Check the product coding on the product labels and chapter 3 of this manual, to define 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). -
Page 35: Reassembly Of The Pinion
Section 9: Reassembly Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 Reassembly of the pinion Grease the pinion parts according to chapter 9.1. Install the pinion bearings (8) and the O-ring seals (12) on the pinion (4). Insert the pinion (4) on the housing. Install the thrust washer (9) and mount the circlip (11) on the pinion top using circlip pliers. -
Page 36: Reassembly Of The Pistons
Installation, Operation and Maintenance Manual Section 9: Reassembly September 2015 DOC.IOM.EF.EN Rev. 6 Reassembly of the pistons NOTICE Before reassembling the pistons, check the required assembly code (see section 4.2). Grease the piston parts according to step 9.1. Install the piston bearings (7), piston rack bearing strips (6) and piston o-ring seals (13) on the pistons. - Page 37 Section 9: Reassembly Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 Figure 26 Position of the slot and the cam on the pinion top Assembly code CW Assembly code CC (Standard; Spring-to-Close) (Reverse; Spring-to-Open) 90° 90° A = Position of cam B = Position of slot and in dot in pinion C = Final position of pinion dot Note:...
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Page 38: Reassembly And Settings Of The Limit Stops
Installation, Operation and Maintenance Manual Section 9: Reassembly September 2015 DOC.IOM.EF.EN Rev. 6 Reassembly and settings of the limit stops Install the limit stop screws (17), limit stop nuts (18), limit stop washers (19) and limit stop o-rings (15). Figure 27 Install Limit Stop Bolts Move the pistons inward until the slot in the top of the pinion is perpendicular to centerline of the housing. - Page 39 Section 9: Reassembly Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 Figure 28 Double-acting end cap assembly The above end caps (2) are for Actuator sizes 25, 40, 65 and 100. End caps (2) for Actuator sizes 150 and larger will have flat end caps (see below). Table 15.
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Page 40: Spring-Return Actuators
Installation, Operation and Maintenance Manual Section 9: Reassembly September 2015 DOC.IOM.EF.EN Rev. 6 9.5.2 Spring-Return actuators Important When replacing spring cartridges in a spring-return actuator, ensure that the cartridges are replaced in their identical position from where they were removed. Check below figure to see where to place the spring cartridges in case of spring set conversion. - Page 41 Section 9: Reassembly Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 Grease the O-ring seals (14) and B port seals (16) according to step 9.1. Ensure that O-ring seals (14) and B port seals are kept in place during assembly. Place the spring cartridges in actuator as per required spring set (see Figure 29).
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Page 42: Basic Function And Air Leak Test
Installation, Operation and Maintenance Manual Section 9: Reassembly September 2015 DOC.IOM.EF.EN Rev. 6 Basic function and Air Leak Test CAUTION - MOVING PARTS Applying pressure to the actuator will cause the actuator/valve assembly to operate. Apply pressure (max. 8 bar/116 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). -
Page 43: Section 10: Troubleshooting
Section 10: Troubleshooting Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 Section 10: Troubleshooting 10.1 Mechanical Problems Problem Possible error Solution Where to find Feedback position and Remove actuator from actual position are not valve. Check assembly code the same. -
Page 44: Pneumatic Problems
Section 10: Troubleshooting Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 10.2 Pneumatic Problems Problem Possible error Solution Where to find Section 2.3 Actuator does not react There is no supply Supply the right Check that the actual to electrical control pressure at the pressure to the... -
Page 45: Electrical Problems
Section 10: Troubleshooting Installation, Operation and Maintenance Manual DOC.IOM.EF.EN Rev. 6 September 2015 10.3 Electrical Problems Problem Possible error Solution Where to find Control wiring. Power Instructions of the supply wiring or Connect all wiring in control or feedback feedback wiring are not the right way. -
Page 46: Section 11: Parts List And Spare Parts Recommendations
Section 11: Parts List and Spare Parts Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 Section 11: Parts List and Spare Parts Recommendations 11.1 Exploded View and Parts List Table 16. Parts List Pos. Description Material House Cast Aluminium alloy End cap Cast Aluminium alloy Piston... -
Page 47: Appendix A: Spring Load Removal
Installation, Operation and Maintenance Manual Appendix DOC.IOM.EF.EN Rev. 6 September 2015 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. —... - Page 48 Appendix Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 Table A-1. Threaded rod dimensions in mm Threaded rod length Actuator Size Thread (mm) (inch) 1600 2500 4000 Figure A-2 Spring load removal rod dimensions Length Thread Washer Holding nuts Threaded Rod Adjusting nut Appendix...
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Page 49: Appendix B: Tool & Torque Table
Installation, Operation and Maintenance Manual Appendix DOC.IOM.EF.EN Rev. 6 September 2015 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. - Page 50 Appendix Installation, Operation and Maintenance Manual September 2015 DOC.IOM.EF.EN Rev. 6 Table B-3. NAMUR (VDE/VDI 3845) flanges Metric Torque (Nm) Imperial Torque (lbf.ft) Flange Thread Min. Max. Thread Min. Max. Solenoid flange screw threads 10-24UNC Top flange screw threads 10-24UNC Table B-4.
- Page 51 F +31 74 291 0938 Emerson Process Management does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper For complete list of sales and manufacturing sites, please visit selection, use and maintenance of any Emerson Process Management www.emersonprocess.com/valveautomationlocations...