Emerson EL-O-Matic F-Series Bedienungsanleitung

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN, Rev. 6

September 2015

EL-O-Matic F-Series

Rack and Pinion Pneumatic Actuators

EL MaticTM

EL-O-Matic F

DOC.IOM.EF.EN Rev. 6

Contents

September 2015

ITable of Contents

Table of Contents

Section 1: Before You Start

1.1 Installation, Operation and Maintenance Reference Documents ................ 1

1.2 Warehouse Storage.................................................................................... 1

1.3 On-Site Storage ......................................................................................... 2

Section 2: Introduction

2.1 Identification ............................................................................................. 3

2.2 Intended Use ............................................................................................. 4

2.3 Specifications ............................................................................................ 4

Section 3: Product Code

3.1 Configuration code for a default actuator................................................... 6

Section 4: Installation

4.1 Before You Start......................................................................................... 7

4.2 Failure Modes............................................................................................. 7

4.2.1 Valve Rotation .............................................................................. 7

4.2.2 Position After Failure..................................................................... 8

4.3 Principles of Operation............................................................................... 8

4.3.1 Solenoid Valve .............................................................................. 8

4.3.2 Ingress Protection (IP) rating ........................................................ 9

4.3.3 Double-Acting Actuators............................................................ 10

4.3.4 Spring-Return Actuators ............................................................. 11

4.4 Actuator Assembly Codes ........................................................................ 12

4.5 Actuator to Valve Installation ................................................................... 13

4.6 Mounting of control and feedback accessories......................................... 15

4.7 Recommended Tubing Sizes .................................................................... 16

Section 5: Mechanical Stroke Adjustment

5.1 Travel Stop Adjustment............................................................................ 18

5.1.1 Double-Acting Actuators............................................................ 18

5.1.2 Spring-Return Actuators ............................................................. 18

5.1.3 Angular Displacement ................................................................ 19

Section 6: Maintenance

6.1 General .................................................................................................... 20

6.2 Repair ...................................................................................................... 20

6.2.1 Spring-Return actuator............................................................... 20

6.2.2 Recommended Spare Parts......................................................... 20

EL-O-Matic F

DOC.IOM.EF.EN Rev. 6

Contents

September 2015

Table of Contents

Section 7: Decommission (Out of Service)

7.1 Before You Start....................................................................................... 22

7.2 Removing the actuator from the valve ..................................................... 23

Section 8: Disassembly

8.1 Removing End Caps ................................................................................. 25

8.2 Removing Spring Cartridges (Spring-Return) ........................................... 26

8.3 Removing of Limit Stop ........................................................................... 27

8.4 Removing Pistons .................................................................................... 27

8.5 Removing Pinion...................................................................................... 28

8.6 Cleaning the Body.................................................................................... 28

Section 9: Reassembly

9.1 Grease Instructions.................................................................................. 30

9.2 Reassembly of the pinion ......................................................................... 31

9.3 Reassembly of the pistons........................................................................ 32

9.4 Reassembly and settings of the limit stops ............................................... 34

9.5 Reassembly of the end caps ..................................................................... 34

9.5.1 Double-Acting actuators ............................................................ 34

9.5.2 Spring-Return actuators ............................................................. 36

9.6 Basic function and Air Leak Test ............................................................... 38

Section 10: Troubleshooting

10.1 Mechanical Problems............................................................................... 39

10.2 Pneumatic Problems................................................................................ 40

10.3 Electrical Problems .................................................................................. 41

Section 11: Parts List and Spare Parts Recommendations

11.1 Exploded View and Parts List.................................................................... 42

Appendix A: Spring load removal

A.1 Spring load relief................................................................................. 43

Appendix B: Tool & Torque Table

»Table B-1 End cap bolts....................................................................... 45

»Table B-2 Bottom Flange .................................................................... 45

»Table B-3 NAMUR (VDE/VDI 3845) flanges ......................................... 46

»Table B-4 Limit stop dimensions ......................................................... 46

»Table B-5 Recommended circlip pliers................................................. 46

Before You Start

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.

NOTICE

Failure to follow the above guidelines will void warranty.

WARNING

Actuator must be isolated both pneumatically and electrically before any (dis)assembly

starts. Before mounting or (dis)assembly, the actuator consult the relevant sections of this

manual.

1.1 Installation, Operation and Maintenance

Reference Documents

Before you start, read the following documents:

• All chapters in this manual.

• Safety Guide (Document No. DOC.SG.EF.EN).

NOTICE

Failure to read the Safety Guide will void the warranty.

Not following the instructions of the Safety Guide can lead to failure of the product and

harm to personnel or equipment.

1.2 Warehouse Storage

• All actuators should be stored in a clean, dry warehouse, free from excessive

vibration and rapid temperature changes.

• All actuators should not be stored directly to the floor surface - it must be placed in

racks/shelves or use a pallet.

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6 September 2015

Section 1: Before You Start

Before You Start

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 1: Before You Start

1.3 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.

NOTICE

Failure to follow the above guidelines (Warehouse and On Site Storages) will void warranty.

Introduction

Installation, Operation and Maintenance Manual

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

2.1 Identification

The EL-O-Matic F Rack and Pinion actuators are available as double-acting or spring-return

versions. 13 models are available, ranging from 12 Nm to 4000 Nm (106 to 35000 lbf.in)

nominal torque output.

The EL-O-Matic F-Series uses standardized interfaces for solenoid, switchbox or positioner

mounting (VDI/VDE3845; NAMUR). The valve interface is equipped with an insert in the

pinion bottom that allows both ISO5211 or DIN3337 mounting.

The springs in the spring-return version allow a fail action in case of loss of air supply

pressure (Fail-to-Close or Fail-to-Open).

As from size FD150 double-acting versions have flat end caps to reduce actuator length

and internal air volume.

Figure 1 Identification

1. Top auxilliaries interface (VDI/VDE 3845; NAMUR)

2. Solenoid interface (VDI/VDE 3845; NAMUR)

3. Valve interface with ISO5211, DIN 3337 patterns and insert drive

4. Spring-return actuators: - with springs

5. Double-acting actuators: - no springs

6. High end caps for double-acting and spring-return models up to size 100

7. Low end caps for double-acting models as from size 150 and larger

Introduction

2.2 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.

2.3 Specifications

Table 1. Pressure Range

Actuator Type Pressure

Double-Acting 0.2 to 8.3 barg (2.9 to 120 psig)

Spring-Return 6 to 8.3 barg (87 to 120 psig), with maximum spring set

3 to 8.3 barg (43.5 to 120 psig), reduced spring quantity

Table 2. Operating Media

Actuator Type Operating Media

Double-Acting and Single-Acting

Air, dry or lubricated and inert gases

Dew point at least 10K below ambient temperature

For sub-zero applications, take appropriate measures

Mentioned pressure levels are "gauge pressures".

Gauge pressure is equal to absolute pressure minus

atmospheric pressure.

Table 3. Temperature Range

Actuator Type Temperature

Standard -20°C to +80°C (-4°F to +176°F)

Option: Low Temperature -40°C to +80°C (-40°F to +176°F)

Option: High Temperature -20°C to +120°C (-4°F to +248°F)

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 2: Introduction

Introduction

Table 4. Air Volumes and Consumption

Actuator volumes: Consumption per stoke

(in liters, pressure in barg)

Actuator

size

Maximum volume (in liters) Outward Stroke Inward Stroke

Central1

chamber

End cap2

chamber

Displaced3

volume

Double-Acting

and Spring-Return Double-Acting only

2.0 barg 4.0 barg 8.0 barg 2.0 barg 4.0 barg 8.0 barg

12 0.05 0.06 0.04 0.14 0.24 0.44 0.16 0.28 0.52

25 0.11 0.19 0.08 0.36 0.64 1.2 0.48 0.88 1.7

40 0.16 0.36 0.15 0.67 1.2 2.2 0.89 1.6 3.1

65 0.36 0.55 0.22 1.02 1.8 3.4 1.3 2.4 4.7

100 0.4 0.8 0.3 1.5 2.7 5.0 2.0 3.8 7.2

150 0.8 0.7 0.5 2.4 4.3 8.1 2.1 3.6 6.7

200 0.8 1.0 0.7 3.2 5.7 11 2.8 4.9 9.1

350 1.9 1.7 1.2 5.5 9.8 18 5.0 8.8 16

600 3.6 3.3 2.1 9.4 17 31 8.7 15 28

950 5.1 4.3 3.2 13 24 44 12 20 37

1600 7.8 7.0 5.2 21 37 68 19 33 62

2500 10.4 11.1 8.2 29 50 92 30 53 97

4000 18.4 18.9 14.0 51 88 161 52 89 165

Actuator volumes: Consumption per stoke

(in Cu.in., pressure in psig)

Actuator

size

Maximum volume (Cu.in.) Outward Stroke Inward Stroke

Central1

chamber

End cap2

cham-

ber

Displaced3

volume

Double-Acting

and Spring-Return Double-Acting only

40 psig 80 psig 120 psig 40 psig 80 psig 120 psig

12 3.1 3.7 2.5 11 19 28 13 23 33

25 6.4 11.8 4.7 28 52 75 38 72 106

40 10.0 22 8.9 53 96 140 71 133 196

65 22 34 13.5 81 148 215 107 200 294

100 22 50 19.9 118 216 314 165 310 455

150 48 43 32 192 352 512 163 293 424

200 50 59 44 255 466 676 220 397 573

350 118 103 76 436 796 1157 392 709 1025

600 222 201 129 742 1354 1967 683 1237 1790

950 310 260 193 1049 1905 2760 910 1628 2346

1600 477 430 319 1635 2951 4267 1505 2691 3877

2500 638 676 501 2259 4018 5776 2367 4232 6097

4000 1122 1151 853 3946 7040 10134 4027 7202 10377

1. For Double-Acting and Spring-Return. Pistons at 90° outward position

2. Only for Double-Acting. Pistons at 0° inward position

3. Stroke is 90°

Figure 2 Actuator air volumes

Central air chamber volume

Double-Acting and Spring-Return

End cap air chamber volume

Double-Acting only

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6 September 2015

Section 2: Introduction

Product Code

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.

Type

FD Double-Acting

FS Spring-Return

Size

0012 Size 0012

0025 Size 0025

0040 Size 0040

0065 Size 0065

0100 Size 0100

0150 Size 0150

0200 Size 0200

0350 Size 0350

0600 Size 0600

•

Rotation Angle

N90° Rotation

Threads

MMetric ISO 5211

UUNC/NPT/Imperial

Spring Set

00 Double-Acting (No Springs)

10 Spring Set 10

20 Spring Set 20

30 Spring Set 30

40 Spring Set 40

50 Spring Set 50

60 Spring Set 60

Rotation Direction

CW Spring to Close/Clockwise

CC Spring to Open/Counterclockwise

Pinion Material

AL High-Grade Aluminium, Hard Anodized

Valve Interface

TStandard ISO 5211 Interface

SSmall Interface with Center Plate (DIN3337)

LLarge Interface with Center Plate (DIN3337)

•

Valve Stem Connection (Insert Sizes)

Parallel

Drive

Diagonal

Drive Square Actuator

Size(s)

0000 No Insert

NL09 ND09 9mm / 0.354" 0012

NL11 YD11 11mm / 0.433" 0025

NL14 YD14 14mm / 0.551" 0040 & 0065

NL19 YD17 17 mm / 0.669"

19 mm / 0.748" 0100 & 0150

NL22 YD22 22 mm / 0.866" 0200

NL27 YD22 22 mm / 0.866"

27 mm / 1.063" 0350

NL27 YD72 27mm / 1.063" 0600

See Insert Supplement for Additional Insert Options.

Temperature Ranges

SStandard: -20°C to +80°C (-4°F to +176°F)

HHigh: -20°C to +120°C (-4°F to +248°F)

LLow: -40°C to +80°C (-40°F to +176°F)

Visual Indicator Code

KStandard (Knob)

NNo Visual Indicator

Finish

AStandard Coating

•

Internal Code 1

00 Standard

Cycle Speed Options

XX Standard

H1 1/2" High Flow plate

Notes

These options are all options available. Not all options apply to

all configurations.

Valve Interface: Option "S"; Small Interface with Center Plate

(DIN3337) is not available for size 0025.

FS 0150 .N U 40 CW AL T .NL17 S K A .00 XX Cycle Speed Option

Internal Code 1

Color/Finish

Visual Indicator

Temperature

Valve Stem Connection

Valve Interface

Pinion Material

Rotation Direction

Spring Set

Threads

Rotation Angle

Size

Type

September 2015

Installation, Operation and Maintenance Manual

DOC.IOM.EF.EN Rev. 6

Section 3: Product Code

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