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.