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.
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Section 1: Before You Start

Before You Start
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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
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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
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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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Section 3: Product Code

Installation
Section 4: Installation
This section explains:
• The actuator rotation direction.
• In which position the actuator will end after a failure.
• Principles of operation:
— Solenoid operation
— Double acting and Spring return operation
• Assembly codes.
• Actuator to valve assembly.
4.1 Before You Start
SAFETY FIRST
In case of an air or electrical failure, it is important to know the behavior of the actuator.
Before mounting the actuator on a valve, consult the following sections below.
4.2 Actuator Rotation Direction
4.2.1 Valve Rotation
For the following paragraphs we assume that valves rotate as indicated in figure 3.
Figure 3 Normal valve rotation
The valve is closed after
a clockwise rotation.
The valve is open after
a counterclockwise rotation.
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Installation
4.2.2 Position After Failure
The position of the actuator after a failure depends on the:
1. Principle of operation (see paragraph 4.3)
2. Assembly codes (see paragraph 4.4)
3. Kind of failure. Refer to the table below.
Table 5. Position After Failure
Principle of
Operation Assembly Code Kind of Failure Position
Double-Acting
Actuator
Pressure Not defined
Signal Closed
Supply Voltage Closed
Pressure Not defined
Signal Open
Supply Voltage Open
Single-Acting
(Spring-Return)
Actuator
Pressure Closed
Signal Closed
Supply Voltage Closed
Pressure Open
Signal Open
Supply Voltage Open
4.3 Principles of Operation
4.3.1 Solenoid Valve
All actuators can be either piped with solid or flexible tubing with the solenoid valve
mounted remotely from the actuator or by mounting a VDI/VDE 3845 (NAMUR) designed
solenoid valve DIRECTLY onto the NAMUR mounting pad on the side of the actuator
Figure 4 Typical solenoid operation
ABA
CW
CW
Spring-Return Operation Double-Acting Operation
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Section 4: Installation

Installation
The table below represents the cycle time (operating time) per different Actuator sizes:
Table 6. Operating Speed
Cycle time in seconds
Actuator
size
Spring-Return Double-Acting
A-port
pressurized
Spring
stroke
A-port
pressurized
B-port
pressurized
F 12 0.4 0.4 0.4 0.4
F 25 0.5 0.4 0.5 0.4
F 40 0.6 0.5 0.6 0.5
F 65 0.7 0.5 0.6 0.6
F 100 0.8 0.6 0.8 0.7
F 150 1.0 0.8 0.9 0.8
F 200 1.3 0.9 1.0 1.0
F 350 1.9 1.3 1.4 1.5
F 600 3.2 1.9 2.2 2.2
F 950 4.6 3.2 3.9 3.6
F 1600 6.9 4.8 5.9 4.8
F 2500 9.0 6.3 7.8 7.9
F 4000 15.4 10.8 13.3 13.0
Operating time is average with actuator under load and solenoid valve fitted.
Test conditions:
1. Solenoid with flow capacity: 0.6 m3/hr
2. Pipe diameter: 6mm
3. Medium: clean air
4. Supply pressure: 5.5 bar (80psi)
5. Load: with average load
6. Stroke: 90°
7. Temperature: Room temperature
4.3.2 Ingress Protection (IP) rating
EL-O-Matic F actuators are IP66/IP67 rated. In case of IP66 or IP67 requirements, take
precautions that comply with the IP66/IP67 requirements to prevent moisture or dust from
entering the actuator through the open air exhaust port(s), either directly on the actuator
or at the exhaust ports of the connected solenoid valve.
We recommend to connect tubing to the exhaust(s) and lead this into a dry and dust free
area, or to use check valves in the exhaust.
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Section 4: Installation

Installation
4.3.3 Double-Acting Actuators
The operating principle, as explained here, is applicable for actuators with assembly code
CW (direct acting).
• Applying supply pressure to port A will move the pistons outward to the "Open"
position of the valve.
• Applying supply pressure to port B will move the pistons inward to the "Close"
position of the valve.
• For assembly codes CC, the operating principle is reversed (reverse acting).
Figure 5 Double-Acting Operation
Outward Stroke
A
BA
Inward Stroke
AB
B
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Installation
4.3.4 Spring-Return Actuators
The operating principle, as explained here, is applicable for actuators with assembly code
CW (direct acting).
• Applying supply pressure to port A will move the pistons outwards to the "Open"
position of the valve.
• Venting the supply pressure from port A will cause the springs to move the pistons
inwards to the "Close" position of the valve.
• For assembly codes CC, the operating principle is reversed (reverse acting).
Figure 6 Stroke Movements
Outward Stoke
A
A
A
A
AB
Inward Stroke
B
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Installation
4.4 Actuator Assembly Codes
Figure 7 Assembly Code - Double-Acting
Assembly code: CW Assembly code: CC
= Standard, Clockwise-to-Close rotation = Reverse, Counterclockwise-to-Open
= Fail-to-Close = Fail-to-Open
AB
AB
A
B
A
B
A = Rotation when central air chamber is pressurized.
B = Rotation when end cap air chambers are pressurized.
All views are from above. Pistons are shown in inward position.
Figure 8 Assembly Code - Spring-Return
Assembly code: CW Assembly code: CC
= Standard, Clockwise-to-Close rotation = Reverse, Counterclockwise-to-Open
= Fail-to-Close = Fail-to-Open
AB AB
A
BA
B
Pinion
Pinion
Pistons
Pistons
Pistons
Pistons Spring
Cartridge
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Section 4: Installation

Installation
4.5 Actuator to Valve Installation
WARNING - MOVING PARTS
Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.
Stay away from moving parts to prevent serious injuries. When test cycling the actuator
and valve assembly by applying pressure to the A or B port, be aware that there are moving
parts like pinion top, actuator to valve coupling and the valve- blade, ball, plug, etc.
NOTICE
The actuator is designed to be installed, commissioned and maintained using generic tools
like wrenches, Allen keys and screwdrivers. For the removal of inserts, a special extractor
tool can be supplied on request.
During assembly to the valve, do not hit with hammer on pinion top. This can damage the
pinion top washer and cause premature failure.
Before mounting the actuator on the valve or valve bracket, be sure that both the
actuator and the valve are in the same closed or open position.
Refer to appendix B, Tool and Torque tables, for using the right size tool
Table 7. Tool Table
Symbol Tool Symbol Tool
Wrench – All types and sizes.
Metric and Imperial Allen key
Circlip Pliers
1. Remove handle nut, handle, lock washer, and etc. from the valve if required.
2. Visually check to make sure the valve is CLOSED.
Figure 9 Valve handle removal
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Installation
3. When required, check if the insert drive (23) is mounted. If not, use a plastic mallet
and tap slightly until the reducer square is in the required position.
Be sure that the insert is mounted at 90° or 45°. It is possible to mount the insert
turned 22.5°. This way the valve will not open or close the right way.
Figure 10 Insert drive Installation
23
4. Install the bracket to the valve flange. Tighten all bolts and nuts and apply the
correct torque.
Figure 11 Bracket Installation
90°
45°
90°
90°
Parallel
square
Diagonal
square
Flat head
Round with
key way
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Installation
5. Install the actuator to the bracket. Tighten all bolts and apply the correct torque
(refer to Table 8).
Table 8. Bottom flange torque values
Actuator Size ISO Pattern Torque (Nm) Torque (lbf.ft)
Thread Min. Max. Thread Min. Max.
12 F04 M6 4.5 5 10-24UNC 3.3 3.7
25 F03 inner pattern M5 2.0 3.0 10-24UNC 1.5 2.2
F05 outer pattern M6 4.5 5.0 1/4"-20 3.3 3.7
40, 65, 100 F05 inner pattern M6 4.5 5.0 1/4"-20 3.3 3.7
F07 outer pattern M8 10.5 12.5 5/16"-18 7.7 9.2
150, 200, 350 F07 inner pattern M8 10.5 12.5 5/16"-18 7.7 9.2
F10 outer pattern M10 21.0 24.5 3/8"-16 15.5 18.1
600 F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1
F12 outer pattern M12 34.5 43.0 1/2"-13 25.4 31.7
950, 1600, 2500,
4000
6. When required, mount or adjust the visual indicator (22).
Figure 12 Indicator mounting
"In Line mounting" "Across Line mounting"
22 22
4.6 Mounting of control and feedback accessories
Solenoid valve and or switch boxes can now be mounted to the actuator. Check
the instructions as shipped with these components for installation, operating and
maintenance instructions.
We recommend to test-cycle the complete assembly to check correct operation.
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Installation
4.7 Recommended Tubing Sizes
In case the solenoid valve is mounted remotely (i.e. in a central solenoid cabinet) and in
order to supply sufficient flow of air supply to the actuator, the following tubing sizes are
recommended.
Table 9. Tubing Sizes
Actuator size Runs up to Runs over to
1.2 meters 4 feet 1.2 meters 4 feet
25, 40, 65 6 mm 1/4 inch 6 mm 1/4 inch
100, 150, 200,
350, 600 6 mm 1/4 inch 8 mm 5/16 inch
950, 1600, 2500,
4000 6 mm 1/4 inch 10 mm 3/8 inch
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