Curtiss-Wright EL30 Manual

Curtiss-Wright | EL30 Rev. H PN23942 6/14/16
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EL30 Explosion-Proof Linear Actuator
Installation and Service Manual
Class 1, Division 1, Groups B, C and D Hazardous
Environment Rating
Information furnished by Exlar Corporation is believed to be accurate and reliable.
However, no responsibility is assumed by Exlar Corporation for its use. Exlar reserves
the right to change the design and operation of the equipment described herein and any
associated motion products that may appear in this document. Information in this
document pertaining to equipment not furnished by Exlar should be confirmed by that
equipment manufacturer. Exlar assumes no responsibility for changes to information by
other manufacturers or errors in that information or the description of that information.
Information in this document is subject to change without notice.
This document does not contain any export controlled technical data.

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TABLE OF CONTENTS
1.0 Introduction
1.1 Warranty and Limitations of Liability
1.2 Safety Considerations
1.3 Explosion-Proof Ratings
2.0 System Configuration
2.1 Typical System Configuration
2.2 Typical System Wiring
2.3 Standard Actuator Pin-outs and Connections
2.4 Feedback Information
3.0 Installation and Operation
3.1 Lubrication Requirements
3.2 Grease Lubrication
3.5 Mounting Configurations
3.6 Mounting Considerations
3.7 General Operation
4.0 Maintenance Procedures
4.1 Disassembly
4.2 Lubrication Maintenance
4.3 Reassembly
4.4 Seal Maintenance
5.0 System Installation
5.1 Exlar SV Series Digital Positioner with Exlar EL30
6.0 Troubleshooting
6.1 Returning Product for Repair
7.0 Certifications

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1.0 INTRODUCTION
1.1 Warranty and Limitation of Liability
Products are warranted for two years from date of manufacture as determined by the
serial number on the product label. Labels are generated and applied to the product at the
time of shipment. The first and second digits are the year and the third and fourth digits
represent the manufacturing week. Product repairs are warranted for 90 days from the date
of the repair. The date of repair is recorded within Exlar’s database tracked by individual
product serial number.
Exlar Corporation warrants its product(s) to the original purchaser and in the case of
original equipment manufacturers, to their original customer to be free from defects in
material and workmanship and to be made only in accordance with Exlar's standard
published catalog specifications for the product(s) as published at the time of purchase.
Warranty or performance to any other specifications is not covered by this warranty unless
otherwise agreed to in writing by Exlar and documented as part of any and all contracts,
including but not limited to purchase orders, sales orders, order confirmations, purchase
contracts and purchase agreements. In no event shall Exlar be liable or have any
responsibility under such warranty if the product(s) has been improperly stored, installed,
used or maintained, or if Buyer has permitted any unauthorized modifications, adjustments
and/or repairs to such product(s). Seller's obligation hereunder is limited solely to repairing
or replacing (at its opinion), at the factory any product(s), or parts thereof, which prove to
Seller's satisfaction to be defective as a result of defective materials, or workmanship and
within the period of time, in accordance with the Seller's stated product warranty (see Terms
and Conditions above), provided, however, that written notice of claimed defects shall have
been given to Exlar within thirty (30) days from the date of any such defect is first
discovered. The product(s) claimed to be defective must be returned to Exlar, transportation
prepaid by Buyer, with written specification of the claimed defect. Evidence acceptable to
Exlar must be furnished that the claimed defects were not caused by misuse, abuse, or
neglect by anyone other than Exlar.
Components such as seals, wipers, bearings, brakes, bushings, gears, splines, and
roller screw parts are considered wear parts and must be inspected and serviced on a
regular basis. Any damage caused by failure to properly lubricate Exlar products and/or to
replace wear parts at appropriate times, is not covered by this warranty. Any damage due to
excessive loading is not covered by this warranty.
The use of products or components under load such that they reach the end of their
expected life is a normal characteristic of the application of mechanical products. Reaching
the end of a product’s expected life does not indicate any defect in material or workmanship
and is not covered by this warranty.
Costs for shipment of units returned to the factory for warranty repairs are the
responsibility of the owner of the product. Exlar will return ship all warranty repairs or
replacements via UPS Ground at no cost to the customer.
For international customers, Exlar will return ship warranty repairs or replacements via
UPS Expedited Service and cover the associated shipping costs. Any VAT or local country
taxes are the responsibility of the owner of the product.
The foregoing warranty is in lieu of all other warranties (except as Title), whether
expressed or implied, including without limitation, any warranty of merchantability, or of
fitness for any particular purpose, other than as expressly set forth and to the extent
specified herein, and is in lieu of all other obligations or liabilities on the part of Exlar.
Seller's maximum liability with respect to these terms and conditions and any resulting
sale, arising from any cause whatsoever, including without limitation, breach of contract or
negligence, shall not exceed the price specified herein of the product(s) giving rise to the
claim, and in no event shall Exlar be liable under this warranty otherwise for special,
incidental or consequential damages, whether similar or dissimilar, of any nature arising or
resulting from the purchase, installation, removal, repair, operation, use or breakdown of the
product(s) or any other cause whatsoever, including negligence.
The foregoing warranty shall also apply to products or parts which have been repaired or
replaced pursuant to such warranty, and within the period of time, in accordance with
Seller's stated warranty.
NO PERSON INCLUDING ANY AGENT OR REPRESENTATIVE OF EXLAR IS
AUTHORIZED TO MAKE ANY REPRESENTATION OR WARRANTY ON BEHALF OF
EXLAR CONCERNING ANY PRODUCTS MANUFACTURED BY EXLAR, EXCEPT TO
REFER PURCHASERS TO THIS WARRANTY.

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1.2 Safety Considerations
As with any electro-mechanical device, safety should be considered
during the installation and operation of your EL Series actuator.
Throughout this manual you will see paragraphs marked with CAUTION
and WARNING signs as shown below.
CAUTION WARNING
Pay particular attention to these paragraphs. They are intended to
provide you with helpful information to ensure safe and trouble-free
installation.
1.3 Explosion-Proof Ratings
EL Series actuators are rated for Class 1, div 1, Groups B, C and D.
The classification of "Class 1" means that flammable gases or vapors
may be present in the air in quantities sufficient to produce explosive or
ignitable mixtures. "Division 1" means that hazardous concentrations in
the air may exist continuously, intermittently, or periodically under normal
operating conditions. "Group B" allows for atmospheres containing
hydrogen, or gases (or vapors) of equivalent hazard, such as
manufactured gas. "Group C" allows for atmospheres containing ethyl-
ether vapors, ethylene or cyclo propane. "Group D" allows for
atmospheres containing gasoline, hexane, naptha, benzene, butane,
alcohol, acetone, benzol, lacquer solvent vapors, or natural gas.
EL Series actuators are not rated for operation in atmospheres
containing acetylene.
It is the responsibility of the user to provide for properly rated
conduit connections to the EL Series actuator. Exlar takes no
system responsibility beyond the actuator ratings.

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2.0 SYSTEM CONFIGURATION
2.1 EL Series Actuator System Configurations
EL Series actuators incorporate an integral brushless servo motor.
The design of this motor and selection of the proper feedback
configuration allows EL Series actuators to be powered by nearly
every brand of brushless motor amplifier on the market that powers
brushless motors with resolver feedback.
The schematic below shows the typical connections for a single
axis system with an EL actuator and servo amplifier.
Each brand of brushless motor amplifiers may have unique wiring
requirements, parameter settings and operational principles that
affect how the actuator operates. Details on connections can be
obtained from Exlar applications engineering.
Never attempt to connect or disconnect the actuator
with power applied. Dangerous voltages are present.
Damage to equipment and injury to personnel can result. Many
amplifiers have voltage present for a considerable time period
after incoming power is removed. Take care to insure that the
amplifier has discharged all power.
Typical System Connections

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2.2 Typical System Wiring
Please refer to Section 7.0 for specific wiring information.
2.3 Standard Actuator Connections
Please refer to Section 7.0 for connection information.
2.4 Feedback Information
EL Series actuators use resolvers as their primary feedback
device. Depending on the amplifier that will e used to operate the
actuator, the hookup of the actuator can vary. Always consult
Section 7.0 for proper wiring, or contact Exlar for the correct wiring
details.
The EL Series actuators incorporate a 2 pole resolver as the
primary rotary feedback device. The selection of this feedback
device is dictated by the amplifier that the end user will use to
operate the actuator. This amplifier is indicated in the model number
of the EL Series actuator as a 3 digit code consisting of 2 letters and
1 number.
Each amplifier has specific requirements for the feedback on the
motor. Not all resolver-based amplifiers can use the same resolver,
resolver alignment, or relative direction of resolver rotation.
Many amplifiers offer software that allows the entering of
parameters or the downloading of "motor data files" that dictate how
the feedback must be set up on the motor. Exlar can provide many of
these "data files" or the proper parameters to enter. Entering motor
parameter data to some amplifiers may require assistance from the
amplifier manufacturer.
Feedback Alignment
When Exlar manufactures an EL Series actuator, the feedback is
mounted, aligned and test run on the amplifier that the customer
plans to use, or one that is known to be equivalent for confirming
proper feedback alignment and operation. In any case where it is
determined that the feedback has become misaligned, or an amplifier
change is made requiring the feedback to be aligned differently, it is
recommended that Exlar be contacted and arrangements made to
have that procedure performed
Feedback Wiring
The wiring of the feedback device is critical to the operation of the
actuator with the selected amplifier. Mis-wiring the feedback cable
can cause unstable operation, incorrect operation or no operation at
all. In some cases, if the proper current limits are not set in the
amplifier, mis-wiring of the feedback cable can lead to damage of the
motor.

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Resolvers
A resolver is a non-electronic device that works like a small
transformer. When rotated, it generates two sine waves that are out
of phase with one another. By decoding these two sine waves, the
amplifier can monitor the direction; revolutions traveled and speed of
rotation of the motor. Each sine wave typically represents one
revolution of the motor, so the amplifier can also use these signals to
know where the motor is within that revolution. By knowing the
motor's position, the amplifier can properly time the supply of current
and voltage to the motor for it to rotate. This process is
commutation. For the amplifier to properly commutate the motor, it
must have a reference, or zero, point from which to track the motor's
rotation. This reference point is critical, and is provided to the
amplifier through the proper alignment of the resolver to the phases
of the motor during the actuator assembly.
3.0 INSTALLATION AND OPERATION
3.1 Lubrication Requirements
The actuator is shipped from the factory fully greased and ready
for installation. Exlar recommends using Mobilith SHC 220, a high
performance, extreme-pressure grease. The unique physical
properties of the synthetic base oil provide outstanding protection
against wear, rust, corrosion and high or low-temperature
degradation. Mobilith SHC allows for very low starting and running
torque values. Its operating range is minus 40 degrees C to plus
177 degrees C (-40 degrees F to +350 degrees F).
3.2 Mounting Configurations
The EL Series actuators come with a choice of mounting
configurations. The standard configurations available are Rear
Clevis, Front Flange or Threaded Face. Certified drawings are
available from Exlar. General drawings are shown in the Exlar
catalog.
Excessive side load on the output rod of the actuator
will dramatically reduce the life of the actuator and
should be avoided completely. Side load can be caused from
misalignment or loading that is not in line with the actuator
output rod.

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3.3 Mounting Considerations
As with any linear actuator product, misalignment of the EL Series
actuator with respect to whatever load the actuator is being used to
move is of great concern. Any misalignment will decrease the life of the
components within the actuator and also may create problems within
the application associated with misalignment. Therefore every effort
should be made to minimize misalignment as much as is possible.
3.4 General Operation
The EL Series linear actuators function in the same manner as a
brushless servomotor. The servo amplifier is used to rotate the motor at
controlled speed and torque, and for controlled numbers of revolutions
and move times. This rotary motion is translated into linear motion by
the internal planetary roller screw mechanism of the EL Series linear
actuator.
The relationship between the rotary motion of the motor and the linear
motion of the actuator corresponds to the following relationships:
Linear Distance Traveled (in) = (Motor Revolutions)*(Roller Screw
Lead)
Linear Speed (in/sec) = ((Motor RPM) / 60)*(Roller Screw Lead)
Linear Force (lbf) = ((Motor Torque (in-lbf))*(2)*(efficiency)) / (Roller
Screw Lead (in))
All of the above relationships require proper anti-rotation of the EL
Series actuator rod.
For more information on sizing and selection of EL Series actuators
and servo amplifiers to power them, consult the sizing and selection
section of the Exlar catalog.
Motor RMS current must be maintained at a level below the
continuous current rating of the EL Series actuator or damage
to the motor stator will result.
The peak current setting must be maintained at a level below the
peak current rating of the EL Series actuator or damage to the stator will
result.
Care should be taken not to exceed the physical travel limits of
EL Series Actuators. Doing so will cause the actuator to end-
crash internally. End crashes can physically damage the roller screw
and the internal components of the actuator.

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4.0 MAINTENANCE PROCEDURES
4.1 Disassembly
Refer to the exploded view on the following page.
1. Remove the actuator assembly from the machine by
disconnecting the cables, main rod coupling and actuator
mounting bolts or fasteners.
2. If your unit does not have an external anti rotate assembly, skip
this step. Loosen the two machine screws that clamp the anti-
rotate cross member to the actuator output rod. Slide the anti-
rotate mechanism forward and off the actuator.
3. Remove the rear tie rod nuts from the back of the actuator.
Extreme care should be taken when removing the tie rod
nuts or tie rods so as not to twist or pull on the end cap
of the actuator. The end cap houses the feedback device.
Alignment of this feedback device to the phases of the motor
is critical to the operation of the system. Some feedback devices
are sensitive to movement of their mounting surface once
installed and can be damaged if care is not taken.
4. If your actuator does not have a front flange, skip this step. Slide
the front flange forward and off the actuator. The tie rods will
remain attached to the front flange.
4.2 Lubrication Maintenance
Grease lubricated units will require periodic inspection and renewal
of the bearing and roller screw grease. The table below shows the
recommended grease renewal period.
RMS
Rotational
speed (RPM)
Recommended Grease Renewal Period hours)
CASE TEMP
65ºC (149ºF)
CASE TEMP
80ºC (176ºF)
CASE TEMP
95ºC (203ºF)
250
10,000
5,000
2,500
500
8,500
4,250
2,125
1000
6,000
3,000
1,500
1500+
3,500
1,750
875

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Grease Renewal
The angular contact thrust bearings located in the front of the
actuator, the roller screw cylinder, and the roller screw assembly are
the components that require grease. They require a coating of
grease. They do not need to be packed with grease. Excess grease
only requires more torque from the motor when returned to operation,
and does not improve the lubrication of the unit.
1. Use a brush to work approximately 0.5 in3of grease for every 3
inches of stroke length into the roller screw cylinder. Be sure to
cover all of the threaded areas of the cylinder.
2. Use a brush to work grease in to the roller screw assembly. Be
sure to cover all the threaded surfaces of the screw assembly. This
can be accomplished by applying grease to a few places on the
roller screw assembly and rotating the components repeatedly in
both directions to work the grease into the assembly.
3. Force grease into the front of the thrust bearing assembly. Make a
concerted effort to insure that the grease is well worked in. Grease
must reach the bearing just behind the bearing that is visible as
well. Use the following amounts of grease for each size roller screw
and bearing: Use EL30: 0.75 in3
4.3 Reassembly
1. Rethread the roller screw into the internally threaded cylinder
(ITC). It is a multiple start screw, and this is not always easy.
DO NOT FORCE THE ROLLER SCREW INTO THE
CYLINDER. It is best to have the actuator vertical with the
open end of the roller screw cylinder facing up. Position the
roller screw above the cylinder so that it is aligned axially with
the ITC. Slowly turn the roller screw 1/4 to 1/2 a turn
counterclockwise with it in contact with the ITC. This will help
to align the threads on the roller screw with the threads in the
ITC. Rotate the roller screw clockwise and it should begin to
thread into the cylinder. If it does not turn freely, remove it
and begin again. When threading the screw into the cylinder,
it will roll freely into the actuator. When it reaches the portion
of the cylinder that contains the motor magnets, the roller
screw will be more difficult to turn because of the magnetic
field of the magnets. THIS IS NORMAL. Continue to thread
the roller screw into the cylinder. When it reaches the bottom,
it will become difficult to turn and the motor and bearings will
begin to rotate with it. The roller screw is now fully inserted
into the cylinder.

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2. Place a small amount of seal lubricant on the inside surface
of the seal/bushing assembly.
3. Replace the faceplate and case extension. Remount front
flange by sliding tie rods through the holes in the faceplate
and through the holes in the rear end cap. Place the flange
on the pilot diameter located on the front of the faceplate.
4. Replace the rear tie rod washers and nuts and tighten to the
proper torque. Tighten the nuts simultaneously by partially
tightening each in an opposing corner pattern until each is
torqued to the rated value shown below.
EL30: 90 lbf-in (7.5 lbf-ft, 10.16 N-m)
4.4 Seal Maintenance
It is recommended that at the suggested time of lubrication the
main rod seal and bushing assembly (FSB) be replaced. The main
rod seal can be removed by threading it out of the face plate using a
standard rod seal gland wrench or spanner wrench. A new main rod
seal can be slid over the main rod, taking care not to touch the seal
material to the threaded rod end. To have this service performed for
you, contact Exlar Engineering or arrange with Exlar Returns
Department to send your unit in for service.
Standard FSB Part Numbers
Install Torque
EL30
11617
200 lb-in (22.58 N-m)
Main Rod Seal FSB and Bushing
Note: Some actuators are
provided with special FSBs due
to chemical exposure or other
special requirements. Contact
Exlar if there is a question about
your particular actuator having a
standard material FSB.

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FSB Installation/Replacement:
1. Using proper sized gland or spanner wrench, remove existing FSB
from actuator face plate, and slide off the actuator rod. This will
require the removal of any rod attachments. One source for gland
wrenches is Martin Fluid Power.
http://www.mfpseals.com/seal_repair_kits/parker-2.shtml
Exlar Actuator
Model
Martin Fluid
Power Part No.
Size
(in)
Description
EL30
PH-0695900000
1/2, 5/8
Rod Gland
Wrench
2. Remove the o-ring from the 0-ring grove located inside the opening
from which the FSB was just removed.
3. Replace the o-ring with the o-ring
supplied with the new FSB.
4. Taking care not to touch the seal
material to any sharp rod features
such as threads, slide the FSB on to
the actuator rod and to the face
plate.
5. Using the appropriate gland and
spanner wrench, tighten the FSB to
the proper torque level indicated in
the previoustable.
5.0 SYSTEM INSTALLATION
This section provides you with cable and wiring information for
operation of your EL Series actuator with Exlar’s SV Series Digital
Positioner. (NOTE: If you use a different amplifier, contact Exlar for
assistance.)
EL Series
Actuator
Inertia
lb-in-s2
EL30-03xx
0.00319
EL30-06xx
0.00361
EL30-10xx
0.00416
EL30-14xx
0.00473
EL30-18xx
0.00533

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For detailed set up instructions see the SV Series installation
and configuration manual.
5.1 Exlar SV Series Digital Positioner with Exlar EL30

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6.0 TROUBLESHOOTING PROCEDURES
Symptom /
Trouble
Possible Cause / Troubleshooting Procedure
No response from
actuator.
1.Check amplifier for faults that may indicate problem.
2.Check to insure that amplifier is enabled.
3.Check for proper wiring.
Actuator seems to
be enabled
(receiving current)
but is not
operating or is
operating
erratically.
1.Amplifier may be improperly tuned. Check all gain settings.
If a motor file or parameters specific to your amplifier/actuator
combination have been supplied by Exlar, be sure that they are
entered or downloaded properly.
2.Amplifier may be set up improperly for the particular motor being
used. Check amplifier settings for number of poles, voltage,
current, resistance, inductance, inertia, etc.
3.Feedback wiring may be incorrect.
4.Feedback conductors are touching, or feedback cable may be
damaged.
5.Motor phases are wired incorrectly or in incorrect order. (R,S,T).
6.Feedback (resolver or encoder) is improperly aligned. Contact
Exlar.
Actuator cannot
move load.
1.Load is too large for the capacity of the actuator or too much
friction is present.
2.Excessive side load.
3.Misalignment of output rod to load.
4.Amplifier has too low of current capacity or is limited to too low of
current capacity.
Actuator housing
moves or vibrates
when shaft is in
motion.
1.Check actuator mounting. Insure that the actuator is securely
mounted.
2.Amplifier is improperly tuned (wrong gain settings.) Tune amplifier.
Output rod rotates
during motion and
thus does not
provide proper
linear motion.
1.Install Exlar anti-rotation assembly or incorporate anti-rotation
into the application.
Limit switches not
functioning.
1.Limit switches wired improperly. Refer to manual.
2.The device being driven by the limit switches is not compatible
with the electrical output of the limit switch. Check device
requirements.
3.Switches have been damaged by improper wiring or improper
voltage applied. Replace switches.
Brake does not
hold load in place.
1.Load is larger than the capacity of the brake.
-check load level against actuator rating
-oil lubricated units reduce holding capacity of the brake
2.Brake is not engaged. (Power is not removed, or only partially
removed from brake).
3. Brake is being used as other than a power loss holding brake.
Actuator is
overheating.
1. Insufficient cooling for application requirements. See oil cooling
section of this manual or main catalog or contact Exlar engineering.
2.Actuator is being operated outside of continuous ratings.
3.Amplifier is poorly tuned causing excessive unnecessary current
to be applied to motor. Check Gain settings.

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6.1 Returning Product for Repair
STANDARD EVALUATION AND REPAIR LEADTIME:
Leadtime is dependent upon production capacity and level
of demand. Please contact the factory for current leadtime.
EXPEDITED EVALUATION LEADTIME:
An additional charge per unit can be quoted to expedite an
evaluation.
Ability to expedite is dependent upon production capacity
and level of demand. Please contact the factory for current
expedited evaluation lead time.
PROCEDURE:
Please discuss the return with Exlar Technical Support prior
to requesting an RGA number to see if it is possible to
resolve the issue prior to return.
If it is determined that an RGA number is required, please
do so by completing an online RGA request form located at
http://exlar.com/return-authorization-request/
–International Repairs: Closely follow instructions
provided by the Exlar Returned Goods Administrator.
Failure to comply with issued instructions may result in
delays for repair and return.
Exlar requires a purchase order at the time of RGA; $750 on
warranty returns (refunded if warranty status is confirmed by
the factory), or for the desired service package charge per
unit on all non-warranty units.

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7.0 CERTIFICATIONS

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