Compact Compact4 II User manual

The Four Piston
Pneumatic Actuator
Sizes Included:
C15, C20, C25, C30, C35,C45, C60, C75
Installation, Operating & Maintenance
www: Compact4.com
Compact Inc.

WARNINGS & SAFETY INSTRUCTIONS
Compact cannot anticipate all of the situations a user may
encounter while installing and using the Compact II actuators.
The user must know and follow all applicable industry
specifications on the safe installation and use of these
actuators. Misapplication of the product may result in injuries
or property damage. Refer to Compact catalogue for
additional product safety information or contact Compact.
1. Make sure the actuator is isolated from air supply or electrical
ancillaries before attempting to do any maintenance.
2.Before removing the actuator from a valve always make
sure the line has been depressurized and drained. Cycle the
valveafewtimestorelieveanypressurethatcouldbetrapped
in the body cavity.
3. Utmost caution must be taken when handling the
actuator. Only qualified personal are who are trained for
maintenance work and have read the instructions are
to assemble or disassemble the actuator.
4. Before operating an actuator which is connected to a valve
in the pipeline make sure you know the valve function.
5. Use only Compact II components and spare parts
supplied in the Repair Kits.
6. Do not attempt to remove the actuator pistons by use
of air pressure when the covers have been removed.
7. Do not leave any grip key or shaft connection attached
to the actuator, or try to manually operate the actuator
while it is still connected to the air pressure.
8. Use the actuator within the pressure and temperature
limits indicated on the nameplate or as given in our
GENERAL
This Installation, Operating & Maintenance manual covers the
instructions required for safe use of the Compact II pneumatic
actuator. Before using the actuator, read the entire IOM and
make sure you understand everything.
Installation, Operating & Maintenance instructions
PAGE 2
Supply Pressure
The supply pressure for the Compact II actuators are as
follows:
Double-acting: 2-8 barg (30-120 psig).
Spring-return: 3-8 barg (40-120 psig).
Spring-return actuators can also operate with air pressure
of 2 barg (30 psig) by using the appropriate spring
configuration as shown in the Compact catalogue. When
sizing an actuator to available air supply, make sure you
have adequate power in the actuator to allow the valve to
complete its operation and leave enough power for safety
margin.
STORAGE
The Compact actuator has been packaged to provide
protection during shipment, however, it can be damaged in
transport. Prior to storage, inspect the actuator for shipping
damage. Keep the actuators in their original packing box
during storage. It is recommended to keep the actuators in
a clean and dry environment until ready for use. The actuator
has two air ports, which should be plugged during storage
to prevent liquids or other materials from entering the actuator
during storage. If the actuators are to be stored for a long
period of time before installation, it is recommended to
stroke them periodically to prevent setting of the seals. Store
the actuators indoors to protect them from humidity and
dust.
Air Supply
Use clean dry air. Other inert gases may be used such as
nitrogen, argon and natural gas. Thin hydraulic oil can also
be used. Do not use water as supply media. Oxygen or
hydrogen must NOT BE USED.
The operating medium is to be filtered to 30 micron particle
size or less. Always consult with a representative of Compact
for suitability and recommended practice.
Piping connected to the actuator or accessories should be
fitted according to recommended instrumentation piping
practice. Prior to connection make sure all lines have no
loops and are free of water, oil or other contaminants that
may be trapped in the pipes. Pipes must be flushed with air
to clean the passages. Where sealants are been used for
threaded connections, care must be taken to avoid excess
material been forced into the actuator ports.
OPERATING CONDITIONS
Lubricants
The actuators come lubricated from the factory and under
normal operating conditions do not require re-lubrication. In
the event of actuator maintenance it is recommended to use
the following lubricants:
For NBR O-rings use EP1.
The lubricant is suitable for use from -20°C (-4°F) to +80°C
(+176°F).
For Viton O-rings use Molykote 111 or OKS 1110.
The lubricants are suitable for use from -40°C (-40°F) to
+140°C (+284°F).
For EPDM O-rings use only Silicone grease (i.e. Molykote
111 or OKS 110).
The lubricants are suitable for use from -40°C (-40°F) to
+140°C (+284°F).
Explosive Environment
The Compact II can be installed in any appropriate potentially
explosive hazardous area as listed on the identification
nameplate on the actuator. The Compact II is certified to
category II according to the ATEX Directive 94/9/EC
(Equipment intended for use in Potentially Explosive
Atmospheres).
For applications requiring category I protection please consult
with Compact representative .

PRINCIPLE OF OPERATION
The Compact II actuator is a pneumatic quarter-turn Rack
& Pinion actuator. Air pressure applied to the piston surface
area generates thrust which transforms linear motion to
rotary motion of the pinion. The Compact II has four pistons
centrally located around one pinion. This means that the
actuator can generate twice the torque of dual l piston
actuators, is lightweight, occupies minimum space and has
minimal air consumption.
Installation, Operating & Maintenance instructions
PAGE 3
Supply Pressure
The supply pressure for the Compact II actuators are as
follows:
Double-acting: 2-8 barg (30-120 psig).
Spring-return: 3-8 barg (40-120 psig).
Spring-return actuators can also operate with air pressure
of 2 barg (30 psig) by using the appropriate spring
configuration as shown in the Compact catalogue. When
sizing an actuator to available air supply, make sure you
have adequate power in the actuator to allow the valve to
complete its operation and leave enough power for safety
margin.
Temperature
The standard temperature limits for the Compact II actuators
are -20°C (-4°F) to +80°C (+176°F). For temperatures below
or above these figures special preparation and materials are
required such as grease, O-rings, pinion bearings and pads.
The Compact II maximum working temperature is 130°C
(266°F) when used with Viton O-rings and HT grease.
The Compact II minimum working temperature is -40°C (-
40°F) when used with EPDM O-rings and LT grease.
For temperatures below -40°C (-40°F) please consult with
Compact.
When used in sub-zero temperatures it is essential to use
an air dryer for the supply to avoid any moisture.
Always consult with a representative of Compact II for
suitability and recommended practice.
AIR CONNECTIONS
The actuator air connections are marked A and B.
Port B connects to a chain of holes to all the four pistons. The air
passes into the Namur cover (or insert) and through holes which are
connented to the two neibouring pistons. Each piston recieves the
air flow from two directions which ensures a quick response.
In sizes C15 to C45 port A is to
the right and port B to the left.
A
B
Pressure entering port A into the
center chamber pushes the
pistons outward and rotates the
pinion CCW
A
B
Pressure entering port B into the
outer chambers pushes the
pistons inward and rotates the
pinion CCW
In sizes C60 and C75 the air
connections are vertical where
port A is above port B.
A
BB
A
Double Acting (DA)
Pressure entering Port A to open:
Center chamber pressurized. Pistons move outward and the pinion
rotates counter clockwise (CCW).
Spring Return (SR)
Pressure entering Port A to open:
Center chamber pressurized. Pistons move outward and
the pinion rotates counter clockwise (CCW).
Springs are compressed.
Pressure entering Port B to close:
Outside chambers pressurized. Pistons move inward and
the pinion rotates clockwise (CW).
drawing 1.

ISO 5211 or DIN 3337
The actuator bottom flange is in accordance with ISO 5211
(or DIN 3337) international standard and incorporates a star
shaped female drive for flexibility to fit various valve output
shafts. The valve can be attached by a bracket or mounted
directly onto the actuator, using one of the various ISO hole
patterns.
TRAVEL ADJUSTMENT
The actuator comes factory adjusted to produce 90°rotation.
The rotation is restricted by the stop (13) and four adjustment
screws (19) which provide fine tuning or a limiting stroke.
Installation, Operating & Maintenance instructions
PAGE 4
Pressure exiting Port A to close:
Air released from center chamber. Springs drive pistons
inward. Pinion rotates clockwise (CW).
NAMUR Solenoid Mounting
Air supply connection is done by mounting a solenoid directly
onto the Namur cover which has a mounting pad conforming
to the Namur standards. (Only Solenoids made to the
NAMUR standard can be mounted in this way.) The Compact
II actuator can also be piped with solid or flexible tubing
from remote
solenoid valves.
The screws are threaded into the actuator body and are
diametrically opposed to create simultaneous and equal
forces on opposite sides of the stop to eliminate off-center
forces.
The standard stop screws
allow adjustment of +/-5°in
the travel limits.
Other Intermediate positions
can be achieved with a longer
set of stop screws which will
enable travel from 0°to 20°
and from 90°to 70°rotation.
0 °
90°
+5°
-5°
95°85°70°
20°
INDICATOR & PUCK
All actuators are assembled with a highly visible indicator
or puck. The indicator and puck have interchangeable ”snap-
on” flow direction arrows for identification of valve position.
The arrows provide any type of pattern
according to the valve ports.
Use a screw driver or sharp
object at the arrow head to
push it out.
TWO WAY T - PORT L - PORT
The puck has three position signaling
inserts screws to allow
signaling of any position. The puck is
screwed to the
pinion Namur thread.

Before the screws leave the threads the springs
become free of tension.
If in the initial rotation the screws are jammed, hit them
lightly on the head with a flat pin to make them loose.
When there are 4 screws in the cover (sizes C60,
C75), work on two opposing screws first and then on
the second set as described before.
3.3 Remove the covers making sure not to damage the
cover seals.
3.4 Remove the springs (4,5,6) from the cylinder and lay
them together in their covers for the assembly stage.
The indicator snaps to the pinion with its
Namur interface projecting above it and
enabling any ancillary to connect to the
pinion.
Installation, Operating & Maintenance instructions
PAGE 5
IDENTIFICATION
Compact II actuators are supplied with a nameplate which
is located on the side of the body. The information includes
actuator size, model, type, spring set, threads, indicator,
additional options, date of manufacture, protection rating,
pressure limits and company logo.
Actuator
description Date of
manufacture
H20 SR-2A2B-R M/45
QUATER TURN ACTUATOR
MODEL
SERIES
MAX PRESSURE: 120 PSI, 8 BAR
********** * **
COMPACTII, 12305, IL
II 2 GD cg T4
Baseefa04ATEX0042X
ATEX marking of
explosion protection “GD” for
Gas & Dust
CE mark
Limiting
Pressure
DISASSEMBLY
General
Before performing any disassembly operations make sure
you read all the warnings and safety instructions in this
leaflet.
1
Do not attempt to disassemble the actuator while it is still
connected to the valve or to any ancillary.
Verify that the actuator is not pressurized. Check that the air
ports are vented and spring return actuators are in the fail
close position.
Work in a clean area, free of dust, debris, grease, corrosives
and moisture. For security and comfort do the repairs on a
table with a vice and available air supply. Clamp an adaptor
to the vice and place the actuator drive on it. Use only Metric
hex head wrenches and make sure they are not blunt on the
edges
2.1 Before disassembly, mark the covers (8, 8A, 9) with
the body. This is recommended to identify each cover
to its original position when you re-assemble the
actuator.
2.2 Remove the cover screws (10). If in the initial rotation
the screws are jammed, hit them lightly on the head
with a flat pin to make them loose.
2.3 Remove the covers making sure not to damage the
O-ring seals (7, 7A, 10).
When removing the Namur cover (8A) make sure the
O-ring connecting to the inner chamber is secure in
its slot.
To convert to SR actuator, go to Section 6 for assembly.
Disassembly of Double
Acting Covers
2
Caution: Springs in the actuator are under tension.
3.1 Before disassembly, mark each of the covers (8,8A,9)
with the body. This is recommended to identify each
cover to its original position when you re-assemble
the actuator.
3.2 Remove the cover screws in sequence by turning
each opposing screw two rotations at a time. When
removing the Namur cover (8A) make sure the
O-ring connecting to the inner chamber is secure in
its slot.
Disassembly of Spring
Return Covers
3

Installation, Operating & Maintenance instructions
PAGE 6
+30 ¡
After another 30¡ rotation the
pistons are ejected from the body
Pistons Disassembly
4
4.1 Looking at the actuator as shown to the left, withdraw
the left of each pair of stroke adjustment screws (19)
approximately 6-10 mm outward. This will enable the
stop to rotate beyond its 90°limit so the pistons can
come out. It may require a little force to release the
adjustment screws as they are assembled with a thin
layer of Loctite® 221.
4.2 Grip the actuator body with both hands and rotate it
in the CW direction to eject the 4 pistons out of their
cylinders. The 4 pistons will
eject out of the actuator
body as demonstrated to
the right.
4.3 Remove the piston O-rings (3) by pressing them slightly
from both sides of the
piston, creating a loop and
pull them out of their groove.
Do not use a sharp object
to pry them out.
4.4 Push the four pads (18) in towards the pinion with a
tool and remove them from body.
Note: Usually it is not required
to remove the pads.
3.5 Follow the same routine on all four cylinders.
To replace the spring configuration or to convert to
DA actuator, go to Section 6 for assembly.
Pinion Disassembly
5
Pinion Disassembly
For C45 to C75 go to section 7.0
5.1 Remove the indicator (21). Use a two screwdrivers to
pry it off the pinion. Do not apply force on the indicator.
5.2 Remove the circlip (17).
5.3 Push the pinion (12) down and remove it from the
body.
5.4 The stop plate (13), bottom bearing (14) and pinion
Pinion Disassembly
5
O-ring (15) will drop out with the pinion. There is no need
to separate the stop from the pinion. Make sure the
stop and pinion stay together in the same orientation
they came out.
5.4 Remove the disc bearing (16), upper bearing (14) and
O-ring (15) from the body.
Namur Cover
Side
Top View Side View
Left
screw
Left
screw
0 ¡
As the body is rotated CW, the
pistons moveout of the cylinders
+90 ¡
After 90¡ rotation the pistons are
alinged with the body
Left
screw

Installation, Operating & Maintenance instructions
PAGE 7
Assembly
6
General
Before performing assembly, clean the grease in the cylinders
and all the actuator parts. Check the cylinder for any scratches.
The surface should be smooth and without any damage,
debris, rust or other contaminants.
Apply grease to all the parts prior to assembly.
6.1 If you have removed the pads, push them back into
their holes as shown in section 4.4.
6.2 If the stop (13) has been removed from the pinion
(12), insert it back making sure the orientation of the
two stop protrusions are at 45°to the Namur slot as
shown in the drawing to the right. Use the two grooves
which are cast on the stop bottom plane to identify
the stop orientation.
6.3 Fit the thrust washer (14) and pinion O-ring (15) to the
pinion (12) and stop (13).
For C45 to C75 go to section 8.0
6.4 Insert the pinion assembly into the body. Make sure
that the thrust washer tongue engages to the opposing
groove in the body.
Thrust washer
tongue
6.5 When inserting the pinion to the body, bring the
grooves of the stop perpendicular to the adjustment
screws to ensure correct angle of rotation. Rotate the
pinion CCW until the protrusion flats hit the adjustment
screws and the grooves line up with the threaded
holes as shown below.
Step 1
Grooves perpendicular to
adjustment screws
Step 2
Grooves aligned to
adjustment screws
Bottom View Bottom View
6.6 Fit the pinion O-ring (15), thrust washer (14) and disc
bearing (16) to the pinion. Make sure that the thrust
washer tongue engages to the opposing groove in
the body.
6.7 Always use a new circlip (17). Insert it on the pinion.
If the pinion does not protrude high enough, make
sure that the bottom thrust bearing tongue has properly
engaged into the body groove and the stop is recessed
in the body. Clip the indicator (21) back on the pinion.
6.8 Place the assembled body with the pinion on the rig
with the adaptor for inserting the pistons back in the
Position the Namur slot horizontaly and the stop protrusions
at 45°as shown. The stop has a groove that indicates the
orentation of the protrusions for ease of assembly.
Bottom View
Top View
45°45°
Namur Slot
Stop
Protrusions
Grooves
Top View Bottom View
Actuator bottom
plane
Trust washer
tongue engages
to groove in body

Installation, Operating & Maintenance instructions
PAGE 8
6.12 Insert the four pistons in the cylinders, keeping the
orientation of the racks so the teeth engage with the
pinion teeth.
6.13 Holding all 4 pistons with both hands as shown, rotate
the body CCW until it stops against the adjustment
screws and all 4 pistons are pulled inside. Make sure
all the 4 pistons have reached the same position in
the cylinder.
6.14 Rotate the body back 90°CW to the open position
so the pistons are now almost flush with the actuator
body.
6.15 Rotate the body back and forth to get the pistons
running smoothly in the cylinders.
6.16 Bring the pistons in to the close position and once
again apply grease in the cylinders behind the pistons.
6.17 Apply grease to all the spring sets.
6.18 Push the cover O-rings (7) in the groove of the covers
(8, 9). If needed, replace them with a new set. Notice
that the Namur cover (8A) has an additional small O-
ring (10) that should be in place.
6.19 Lubricate the cover screws (11).
6.20 Assemble the Namur cover first (8A). If this is a SR
actuator, place the spring set in the cover and then
screw the spring cover (8).
6.21 Always tighten the screws in sequence.
6.22 Assemble the DA covers (9). Make sure the covers
are put back according to your marking during
disassembly.
6.23 Assemble the SR covers with the spring set. The
screws are long enough to engage to the thread
before the springs start to compress. Tighten the
screws in sequence and only two turns at a time.
6.24 Finally torque the screws to the set figures in the table
below.
Actuator Screws Torque Figures
Actuator
Size
C15 - C20
C25 - C30
C35
C45 - C75
Screw Lb-ftNM Lb-in
M5
M8
M10
M12/M16
3.5
9.0
18.0
40.0
2.5
6.5
13.0
30.0
30
80
160
360
cylinders.
6.9 Looking from the top of the actuator, rotate the body
90°CW and another 40°to bring it to the position
for inserting the pistons.
6.10 Fit the O-rings on the pistons.
6.11 Apply grease in the body cylinders, to the pistons
groove and rack and to the piston O-rings.
6.12 Insert the four pistons in the cylinders, keeping the
orientation of the racks so the teeth engage with the
pinion teeth.
Apply a drop of Loctite® 221 to the two adjustment
screws that were pulled away and screw them back
until they both touch the stop. Adjust them until you
visually see that the pinion flats are paralel with the
body plane.
Bottom View
Angle of rotation
+90¡ +40¡
0¡

Installation, Operating & Maintenance instructions
PAGE 9
CW
CCW
Sizes C45-C75
Sizes C45, C60 and C75 have a slightly different pinion
assembly than the smaller sizes. The top bearing, O-ring
disc bearing and circlip are smaller in diameter than the
bottom items. The top bearing and O-ring are assembled
from the bottom and not the top as with the smaller sizes.
The instruction below highlights the assembly differences.
Pinion Disassembly
7.1 Remove the circlip (17) and the disc bearing (16).
7.2 Push the pinion (12) down very carefully and remove
it from the body.
7.3 The top bearing (14b) is inserted in the body and the
top O-ring (15b) is fitted to the pinion. They should
both come out with the pinion from the bottom.
7.4 The stop plate (13), bottom bearing (14) and bottom
O-ring (15) will drop out with the pinion. There is no
need to separate the stop from the pinion. Make sure
the stop and pinion stay together in the same
orientation they came out. The C75 has an integral
stop and will not seperate.
Sizes C45-C75
7
Return to section 6.0
Pinion Assembly
8
8.1 Assemble the stop (13), bottom bearing (14) and O-
ring (15) as described in section 6.2.
8.2 Assemble the top bearing (14b) on the pinion (12)
shoulder.
8.2 Fit the top O-ring (15b) on the pinion in its groove.
Apply grease.
8.3 Insert the pinion assembly into the body. Make sure
that the thrust washer tongue engages to the opposing
groove in the body. Be careful not to harm the top O-
ring.
8.4 When inserting the pinion to the body, bring the grooves
of the stop perpendicular to the adjustment screws to
ensure correct angle of rotation. Rotate the pinion

Installation, Operating & Maintenance instructions
PAGE 10
CCW until the protrusion flats hit the adjustment
screwsand the grooves line up with the threaded holes
as shown below.
See illustrations in section 6.3.
8.5 Fit the disc bearing (16) to the pinion.
8.6 Always use a new circlip (17). Insert it on the pinion.
If the pinion does not protrude high enough, make sure
that the bottom thrust bearing tongue has properly
engaged into the body groove and the stop is recessed
in the body.
8.7 Place the assembled body with the pinion on the rig
with the adaptor for inserting the pistons back in the
cylinders.
Return to section 6.9
ACTUATOR TESTING
After completion of actuator assembly it is required to follow
these testing procedures to ensure the actuator has been
assembled correct and to minimize the risk of personal.
Pneumatic Leak Test
The pneumatic test checks there is no leakage across the
pistons or to environment.
Use commercial leak testing solution to check leakage to
atmosphere. It is acceptable to allow a small amount of
leakage to atmosphere. A bubble which breaks every 10
seconds is considered acceptable.
The leak testing pressure will be 80 psig (5.5 barg). Use a
calibrated pressure regulator to apply pressure to the actuator.
WARNING: Do not exceed the maximum operating pressure
rating listed on the nameplate.
Cycle the actuator at least 5 times to allow the seals to find
their position before commencing with the leak test.
Piston leakage
Any leakage across the piston is not acceptable.
1.0 Apply the pressure to port A and leave port B open.
2.0 Apply a leak testing soap solution to port B and check
for leakage.
3.0. For DA actuators repeat this applying pressure to port
B and check port A for leakage.
4.0 If leakage is observed, disassemble the actuator again
and check the seals, surface finish and cleanliness of
the internal parts to find the cause of leakage.
After doing the repair work, the leakage test must be
performed again.
External leakage
For SR actuators apply the pressure to port A and leave
port B open.
For DA actuators apply the pressure to port A and B.
After applying pressure, wait a few seconds to let the pistons
stabilize and then check for leakage. Apply the leak testing
solution to the pinion output. For DA actuators apply the
leak testing solution to the covers.
TM-36-01C-01/05-HA
(Loctite is a registered trademark of Loctite Corp.)

Installation, Operating & Maintenance instructions
PAGE 11
PARTS LIST
ST.ST 316
Delrin, NRG, UHMWPE
Buna N, Viton, EPDM
ST.ST / Delrin
ST.ST
Delrin, NRG, UHMWPE
ST. ST.
Delrin, (Brass)
Plastic (ABS), Red & White
Plastic (ABS), Red & White
ST.ST
ST.ST
AL 380
ST.ST
AL 356-T6
AL 356/380
Buna N, Viton, EPDM
Spring steel, Painted
Spring steel, Painted
Spring steel, Painted
Buna N, Viton, EPDM
Buna N, Viton, EPDM
AL 356/380
AL 356/380
AL 356/380
Buna N, Viton, EPDM
ST. ST.
Steel E.N.Coated
1
4
4
4
4
4
3
1
3
1
3
1
8-16
1
1
2
2
1
1
4
4
1
1
1
1
4
1
2
Description Qty Material
1
2
3
4
5
6
7
7a
8
8a
9
10
11
12
Body
Piston
Piston O-Ring
Inner Spring
Middle Spring
Outer Spring
Cover O-Ring
Namur Cover O-Ring
Spring Return Cover
Namur Cover
Double Acting Cover
Air Supply O-Ring
Cover Screw
Pinion
Description Qty Material
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Stop
Thrust Washer
Pinion O-Ring
Disc Bearing
Circlip
Pad
Stroke Adjustment Screw
Exhaust Plug (Silencer)
Indicator
Puck
Indicator Screw
Tag (not shown)
Namur insert
Insert screw

Compact Inc.
Compact, Inc. PO Box 1444, Paramus, NJ 07652
Phone: [phone], Fax: [phone]
[email protected]