Emerson EL-O-Matic F-Series User manual

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 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

II
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
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Section 1: Before You Start

Before You Start
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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
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Section 2: Introduction
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
7
6
4
5
1
2
3
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)
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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
AB
Central air chamber volume
Double-Acting and Spring-Return
End cap air chamber volume
Double-Acting only
Installation, Operation and Maintenance Manual
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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
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Installation, Operation and Maintenance Manual
DOC.IOM.EF.EN Rev. 6
Section 3: Product Code