Emerson Damcos KC 65 User manual

Quick Installation Guide
Version: QIG 8000-81-003 Ed 01
Release: February, 2020
Damcos™Actuators
KC 65, KC 125, KC 250, KC 325, KC 400
Quick Installation Guide

This instruction is for trained personnel only
For additional technical information please refer to:
SD 1100-3E07 Product Data Sheet for Damcos KC Hydraulic linear double-acting actuator
SD 2000-0E07 Product Data Sheet for DPI-C and DPI-E Position Indicators
SD 3000-0E06 Product Data Sheet for Damcos Block System
SD 6601-2E04 Product Data Sheet for Damcos PHP 25-05 Portable Hand Pump
SI 0001-5E05 Instruction for Flushing, Remote Valve Control System
SD 2001-2E01 Product Data Sheet for Damcos DDPI-E, E/C and -C Double Position Indicators
Copyright ©Damcos A/S, 2020
Installation Guide for KC 65, KC 125, KC 250 and KC 400 Actuators in English

Table of Contents Quick Installation Guide
February 2020 RM 8000-100-01 Ed 01
1
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Normal Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Parts Delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Before You Start the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Calculation of Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mounting the Actuator to the Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Test of the DPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Test of DPI-E, On/Off signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Test of DPI-C, analog signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustment of the DPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Determine the Configured Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Additional Instructions for Modification/Repair Only
Dismounting and Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Preparations before Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembling the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembling the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix A
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Quick Installation Guide Table of Contents
RM 8000-100-01 Ed 01 February 2020
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General Information Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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General Information
Introduction
This instruction covers dismounting, disassembling and installation of the Actuator KC 65, KC 125,
KC 250, KC 325, KC 400 when mounted to a valve with extended stem/bonnet.
Reservations
•Installation or repair must be performed by trained personnel only.
•Tools and equipment used for installation and repair must in good condition and calibrations up
to date.
•Illustrations shown in this instruction reflect actuators with control block and electrical DPI.
However, the instruction will be applicable for actuators without DPI too. Pay attention to notes
for models ‘with’ or ‘without’ DPI.
•The environment must be clean and without the risk of getting dirt into the unit when taken
apart. Make sure you have access to an indoor workshop for the actual repair.
•Any damage caused by incorrect handling of the equipment is not covered by the manufac-
turer’s warranty.
Warning, Cautions and Notes
In order to avoid any personal injuries, damage of equipment or loss of production time, please
observe and obey Warning, Cautions, and Notes made throughout this document.
The following warning levels are used in the documentation of Damcos A/S for the safety of people
and equipment.
Warning! Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Caution! Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Note! Indicates important information regarding the product.

Quick Installation Guide General Information
QIG 8000-81-003 Ed 01 February 2020
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Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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Normal Installation

Quick Installation Guide
QIG 8000-81-003 Ed 01 February 2020
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Overview Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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Overview
ADPI - Direct Position Indicator 1 (referred to as ‘DPI’ in this document)
BControl block 2
CFittings for hydraulic hand pump connection
DBleed valve
EVisual indicator
FScrews (4 pcs)
GValve bonnet/stem top flange
HActuator spindle
IIndicator bushing
JDPI socket
KYoke
LScrew
Parts Delivered
•Actuator with/without electrical indicator (A)
•Build-in indicator bushing (I)
•Mounting instruction (this document)
1. Some actuators are equipped with visual indicator only (E) and no electrical indicator (A). This
instruction covers actuators equipped with an electrical indicator (A). Most steps and illustrations
will however be applicable for installation of actuators without the electrical indicator (A).
2. Some models only!

Quick Installation Guide Preparations
QIG 8000-81-003 Ed 01 February 2020
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Preparations
Before You Start the Installation
•Locate the valve bonnet/stem on which the
actuator is to be installed/repaired.
•If exchange/repair of existing actuator:
–Locate the name plate and identify the 'Type'
name.
–Compare the type name listed on the name
plate with the type name on the part(s) to be
replaced.
•Make sure that tools required (see below) are
available, before you start.
•If repair of existing actuator:
–Before dismounting the actuator make sure
to identify the actual cause of the error, pref-
erably by consulting ‘Trouble Shooting’ sec-
tion in this instruction.
•Advise the system operators and other relevant persons that maintenance is ongoing.
•Make sure that relevant operation systems are set to maintenance mode, and alternative means
of operation is ensured (if required).
•Read this instruction carefully before you start the actual repair or installation.
•Follow all steps carefully, and do not skip any steps unless specified how and when.
Tools Required
•Fork wrenches. Different sizes depending on actuator model
•Unbrako hex keys (according to table on page 41)
•Long T-hex keys (according to table on page 41)
•Torque wrench (according to table on page 13)
•Long pair of tweezers
•Needle nose pliers
•Hydraulic hand pump
•Multimeter
•Vernier caliper
•Loctite 542 adhesive (or similar)
Other Tools Required
Inspect the valve bonnet/stem prior to the installation/repair in order to identify if any tools, other
than those listed above, are required.
Indoor Facility
Make sure you have access to a workshop (indoor facility) for the actual repair.

Calculation of Preload Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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Installation Procedure
Calculation of Preload
Caution! Before mounting the actuator to the valve, it is very important to determine the actua-
tors preload in order to get correct ‘open’ and ‘closed’ signals from the actuator when
in operation.
Follow the procedure below to determine the preload.
Calculation of Preload
1. Look up the value of the total fixed stroke (a) (= actuator size/model) in the table on the next
page, and add it to the calculation form in step 3 below.
–Example: For the KC 125 the total fixed stroke (a) = 34.25
2. Locate the label (b) in the bottom of the
actuator. The label shows the factory
configured stroke,
Add the value from the label (b) to the
table in step 3.
Caution! If a label with configured stroke
does not appear as shown in the
illustration, please follow
description on page 23.
3. Calculate the preload value:
–Example: For the KC 125 the configured stroke is measured to 25 mm. Calculation will
thus be 34.25 mm (total fixed stroke) - 25 mm (configured stroke) = 9.25 mm (preload
value).
4. Compare the calculated preload value with the values in the table on page 10. The value
should be equal to the preload value listed for the configured stroke (within +/- 1 mm)
Note! Note the table does not reflect all possible configurations. In case the configured stroke
is between values in the examples below, the preload should likewise be between the
two corresponding preload values.

Quick Installation Guide Calculation of Preload
QIG 8000-81-003 Ed 01 February 2020
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Actuator Total fixed stroke
(a)
Configured stroke
(examples)
Preload
(examples)
KC 65 19.25 mm
16.25 mm 3 mm
12.50 mm 7 mm
10 mm 9 mm
8 mm 11 mm
- -
KC 125 34.25 mm
31.25 mm 3 mm
25 mm 9 mm
20 mm 14 mm
16.25 mm 18 mm
- -
KC 250 65.5 mm
62.5 mm 3 mm
50 mm 15 mm
37.5 mm 28 mm
25 mm 40 mm
- -
KC 325 84.25 mm
81.25 mm 3 mm
75 mm 9 mm
62.5 mm 22 mm
50 mm 34 mm
37.5 mm 47 mm
KC 400 103 mm
100 mm 3 mm
87.5 mm 15 mm
75 mm 28 mm
62.5 mm 40 mm
50 mm 53 mm

Mounting the Actuator to the Valve Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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Mounting the Actuator to the Valve
Caution! Before mounting, ensure that the actuator is fully closed, by connecting a hydraulic
hand pump and operate the actuator to ‘closed’.
Mounting the Actuator to the Valve
1. Ensure that the visual indicator (c) is closed.
2. Dismount the caps (d) from the two hydraulic connection fittings.
3. Connect the hydraulic hand pump to connection fittings A and B.
4. Operate the hand pump to until the actuator spindle (e) is in position ‘Closed’ (= max. out).
5. Add a mark on the valve stem according to the illustration below.
Caution! The engagement between actuator spindle (e) and the valve stem must be min. 1.5
times the spindles thread diameter

Quick Installation Guide Mounting the Actuator to the Valve
QIG 8000-81-003 Ed 01 February 2020
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Note! On some models the packing bushing is
an integrated part of the actuator (a).
On other models the packing bushing is a
separate part placed into the top flange of
the valve bonnet (b).
In case the actuator is without the
integrated bushing (a), make sure the
separate packing bushing (b) is mounted,
and correctly placed into the groove of
the valve bonnet’s top flange, before
mounting the actuator.
6. Insert the actuator unit through the hole in the valve top flange (or through the hole of the
packing bushing in the valve top flange, depending on model).
7. Connect the spindle (a) to
the stem thread (b). Use
of a fork wrench to turn
the spindle a few turns.
Leave a gap (c) between
the valve top flange (d)
and the actuator mount-
ing flange (e).
8. Measure the distance (c)
between the valve top
flange (d) and the actuator
mounting flange (e) and
adjust the spindle (a) until
the distance between the
two flanges match the cal-
culated distance for pre-
load (ref. ’Calculation of
Preload’ on page 9).
Do not tighten the
counter nut (f) yet!
cont...

Mounting the Actuator to the Valve Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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9. Mount the four screws (a).
Do not tighten yet.
10. Slowly operate the hand
pump (b) to press the
actuator and the valve
bonnet together (c) until
there is a tight fit between
the actuator flange and
the valve top flange. This
operation presses the pis-
ton into the actuator and
establish the preload.
11. Tighten the four screws (a) to torque (Newton meters) according to the table below.
12. Use the hydraulic hand pump to fully open and fully close the actuator, and check that the
spindle moves the distance according to the specified stroke for the valve and actuator.
13. Use a fork wrench to hold the spindle in place, while at the same time, using a fork wrench to
tighten the stem counter-nut against the actuator spindle end.
Quality
Size
Stainless
70
Stainless
80
Steel
8.8
Steel
10.9
Steel
12.9
M 4 2.9 4 4.9
M 5 4.1 5.4 5.7 8.1 9.7
M 6 7 9.3 9.8 14 17
M 8 17 22 24 33 40
M 10 33 44 47 65 79
M 12 57 76 81 114 136
M 16 140 187 197 277 333
M 20 273 364 385 541 649
M 24 472 630 665 935 1120
M 30 1310 1840 2210

Quick Installation Guide Mounting the Actuator to the Valve
QIG 8000-81-003 Ed 01 February 2020
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DPI models only!
Mounting the Actuator to the Valve - DPI models only
14. Dismount the DPI connector housing
from the DPI socket by loosening the
four screws (a).
15. Check signals from the DPI according to
‘Test of the DPI’ on page 15 (DPI-E) or
page 17 (DPI-C) depending on model.
16. Vessel installations only! Connect the
wires from the DPI connector housing
to the DPI socket according to the corre-
sponding DPI Data Sheet (ref. page 2 in
this instruction) or the Project Specifica-
tion Wiring Diagrams.
17. Mount the DPI connector housing and
tighten the four screws (a).
18. Vessel installations only!
–Mount the hydraulic pipes to the control block.
–De-air the hydraulic pipes.

Test of DPI-E, On/Off signals Quick Installation Guide
February 2020 IG 8000-81-003 Ed 01
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Test of the DPI
DPI models only
Some actuators are equipped with a DPI (Direct Position Indicator). The DPI on KC Actuators will be
either DPI-E or DPI-C.
The tests described in the following can be made on the actuator when mounted on the valve bon-
net/stem as well as when dismounted.
Test of DPI-E, On/Off signals
Test of DPI-E, On/Off signals
1. Connect a hydraulic hand
pump (if not connected
already) by dismounting
the caps (d) from the two
hydraulic connection fit-
tings and connect the
pump hoses to fittings A
and B.
2. Make sure the visual indi-
cator (c) shows closed.
3. Operate the hand pump
and observe that the spin-
dle (e) moves in (1 = actu-
ator is open) and out (2 =
actuator is closed).
4. Ensure that the actuator
is in position 2 = closed
(the spindle is in max.
‘out’ position) before con-
tinuing with step 5.

Quick Installation Guide Test of DPI-E, On/Off signals
IG 8000-81-003 Ed 01 February 2020
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5. Set the multimeter to
sound signals.
6. Test of ‘Closed’ signal:
The multimeter should
give a sound signal when
connecting the multime-
ter to terminal 9 + 10.
7. Operate the hand pump
until the actuator is fully
‘Open’ (spindle moves in).
The sound signal should
turn off.
8. Test of ‘Open’ signal:
The multimeter should
give a sound signal when
connecting the multime-
ter to terminal 7 + 8.
Caution! If any of the sound signals described above fail to appear, please consult the description for
adjustment of the DPI on page 19.
9. Disconnect the multimeter.
10. Leave the actuator in position 'Closed' = actuator spindle is max. out.

Test of DPI-C, analog signals Quick Installation Guide
February 2020 QIG 8000-81-003 Ed 01
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Test of DPI-C, analog signals
Test of DPI-C, analog signals
1. Connect a hydraulic hand
pump (if not connected
already) by dismounting
the caps (d) from the two
hydraulic connection fit-
tings and connect the
pump hoses to fittings A
and B.
2. Make sure the visual indi-
cator (c) is closed.
3. Operate the hand pump
and observe that the spin-
dle (e) moves in (1 = actu-
ator is open) and out (2 =
actuator is closed).
4. Ensure that the actuator
is in position 2 = closed
(the spindle is in max.
‘out’ position) before con-
tinuing with step 5.
5. Set the multimeter to Ω
signals.
Note! Adjust DPI-C in
position ‘Closed’.
Check the value for
‘Open’ but do NOT
adjust.

Quick Installation Guide Test of DPI-C, analog signals
QIG 8000-81-003 Ed 01 February 2020
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6. Test of ‘Closed’ signal:
The multimeter should
show 300/1500 Ωwhen
connecting the multime-
ter to terminal 7 + 9.
Operate the hand pump
until the actuator is fully
‘Open’ (spindle moves in).
7. Test of ‘Open’ signal:
The multimeter should
1400/7000 Ωwhen con-
necting the multimeter to
terminal 7 + 9. All values
are +/- 50 Ω.
Caution! If any of the sound signals described above fail to appear, please consult the description for
adjustment of the DPI on page 19.
8. Disconnect the multimeter.
9. Leave the actuator in position 'closed' = actuator spindle is max. out.