Emerson EL-O-Matic F-Series User manual

Installation, Operation and Maintenance Manual
DOC.IOM.EF.EN Rev. 7
September 2017
EL-O-Matic F-Series
Rack and Pinion Pneumatic Actuators
EL MaticTM
EL MaticTM

Installation, Operation and Maintenance Manual
DOC.IOM.EF.EN Rev. 7
Table of Contents
September 2017
I
Table 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 Identication................................................................................................. 3
2.2 Intended Use................................................................................................. 5
2.3 Specications................................................................................................ 5
Section 3: Configuration Code
Section 4: Installation
4.1 Before You Start ............................................................................................ 9
4.2 Actuator Rotation Direction .......................................................................... 9
4.2.1 Valve Rotation .................................................................................... 9
4.2.2 Position After Failure ........................................................................ 10
4.3 Principles of Operation................................................................................ 10
4.3.1 Solenoid Valve.................................................................................. 10
4.3.2 Ingress Protection (IP) rating ............................................................ 11
4.3.3 Double-Acting Actuators.................................................................. 12
4.3.4 Spring-Return Actuators................................................................... 13
4.4 Actuator Assembly Codes ........................................................................... 14
4.5 Actuator to Valve Installation ...................................................................... 15
4.6 Mounting of control and feedback accessories............................................ 18
4.7 Recommended Tubing Sizes........................................................................ 18
Section 5: Mechanical Stroke Adjustment
5.1 Travel Stop Adjustment ............................................................................... 20
5.1.1 Double-Acting Actuators.................................................................. 20
5.1.2 Spring-Return Actuators................................................................... 20
5.1.3 Angular Displacement ...................................................................... 21
Section 6: Maintenance
6.1 Normal Maintenance................................................................................... 22
6.2 Inspection and Repair.................................................................................. 23
6.2.1 Service Kits....................................................................................... 23
6.2.2 Spring-Return Actuator .................................................................... 23
Section 7: Decommission (Out of Service)
7.1 Before You Start .......................................................................................... 24
7.2 Removing the actuator from the valve ........................................................ 25

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Table of Contents
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Table of Contents
Section 8: Disassembly
8.1 Removing End Caps (Sizes 25 to 600) .......................................................... 27
8.2 Removing End Caps (Sizes 950 to 4000)...................................................... 29
8.3 Removing Spring Cartridges or Springs ....................................................... 30
8.4 Removing of Limit Stop screws.................................................................... 31
8.5 Removing Pistons........................................................................................ 31
8.6 Removing pinion......................................................................................... 32
8.7 Cleaning the Components .......................................................................... 33
Section 9: Reassembly
9.1 Grease Instructions ..................................................................................... 35
9.2 Reassembly of the pinion ............................................................................ 36
9.3 Reassembly of the pistons ........................................................................... 37
9.4 Reassembly and settings of the limit stops .................................................. 39
9.5 Reassembly of the end caps......................................................................... 40
9.5.1 Double-Acting actuators .................................................................. 40
9.5.2 Spring-Return actuators (Size 25 to 600) .......................................... 41
9.5.3 Spring-Return actuators - Size 950 to 4000....................................... 43
9.6 Basic function and Air Leak Test................................................................... 45
Section 10: Troubleshooting
10.1 Mechanical Problems .................................................................................. 46
10.2 Pneumatic Problems ................................................................................... 46
10.3 Electrical Problems...................................................................................... 48
Section 11: Parts List and Spare Parts Recommendations
11.1 Actuator size F12......................................................................................... 49
11.2 Actuator sizes F25 to F600 .......................................................................... 50
11.3 Actuator sizes F950 to F2500 ...................................................................... 51
11.4 Actuator sizes F4000................................................................................... 52
Appendix A: Spring load removal
A.1 Spring load relief ......................................................................................... 53
Appendix B: Tool & Torque Table
Appendix C: Full Stroke Adjustment Option
C.1 Full Stroke Adjustment Option .................................................................... 57
C.2 Convert a standard actuator into a Full Stroke Adjustment version .............. 58
C.2.1 Procedure ........................................................................................ 59
C.3 Full Stroke Adjustment Setting.................................................................... 60
C.3.1 Factory Setting Procedure ................................................................ 60
C.3.2 Setting the Full Stroke Adjustment screw to the required angle. ....... 61

Before You Start
Section: 1 Before You Start
This section explains:
• Base safety procedures.
• Where to nd detailed information relating safety.
• Storage guidelines.
Installation, adjustment, putting into service, use, assembly, disassembly and maintenance
of the pneumatic actuator must be performed by qualied 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).
For Safety Instrumented Systems application, read the following document:
• SIL Safety Manual EL-O-Matic F-Series (Document No. DOC.SILM.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 vibra-
tion and rapid temperature changes.
• All actuators should not be stored directly to the oor 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 vibra-
tion and rapid temperature changes.
• Prevent moisture or dirt from entering the actuator. Plug or seal both air connec-
tion 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 specications.
2.1 Identification
The EL-O-Matic F-Series 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 at end caps to reduce actuator length
and internal air volume.

Introduction
12
25 -
100
150 -
600
4000
Size End cap design 5Spring design 6Pinion bottom /
Insert design 2
950 -
2500
SR
Maximum 2
loose springs
Maximum 12
spring cartridges
Maximum 6
loose springs
Left Right
Left Right
Left Right
Left Right
DA
SR DA
SR DA
SR DA
SR DA
Maximum 12
spring cartridges
Maximum 6
loose springs
or
Left Right
Notes
1. Top auxilliaries and Solenoid interface (VDI/VDE 3845; NAMUR) for size 25 to 4000.
Size 12 has propriatary interface for top auxilliaries and solenoid mounting.
2. Valve interface availalable according ISO5211 or DIN 3337. Actuator size 12 is fitted with a parallel or
diagonal square. Actuator sizes 25 to 2500 can be fitted with drive inserts with various inner shapes.
Actuator size 4000 is fitted with a double square; parallel and diagonal.
3. Spring-Return actuators: - with springs
4. Double-Acting actuators: - no springs
5. Actuator sizes 25 to 100 have high end caps for double-acting and spring-return models. Actuator sizes
12 and 150 to 4000 have low end caps for double-acting models and high end caps for spring-return
models.
6. Actuator size 12 is fitted with a maximum of 2 loose springs. Actuator sizes 25 to 600 are fitted with a
maximum of 12 spring cartridges. Actuator sizes 950 to 4000 are fitted with a maximum of 6 loose
springs.
2
1
3
4
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Section 2: Introduction
Figure 1 Identification

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 Buttery, 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.
1. Recommended air quality according ISO 8573-1 for normal operation: 7-5-4.
NOTE:
Use of lters, pressure regulators, lubricator and an oil/water separator mounted in the air
supply line, will allow a smooth and durable operation of the actuator.
For lubricated supply air, it is recommended to use a non-detergent oil without aggressive
additives, VG32, group 2 (ISO 3448).
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 -10°C to +120°C (14°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
chamber
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

Configuration Code
Section: 3 Conguration Code
This section explains:
• How to create or read the conguration code for a actuator.
Type
FD Double Acting
FS Spring Return
Size
0012 Size 0012 0350 Size 0350
0025 Size 0025 0600 Size 0600
0040 Size 0040 0950 Size 0950
0065 Size 0065 1600 Size 1600
0100 Size 0100 2500 Size 2500
0150 Size 0150 4000 Size 4000
0200 Size 0200
Rotation angle
N90° rotation angle
Threads
MMetric ISO 5211
UUNC/NPT/Imperial
Spring Set
00 Double Acting (no springs)
10 Spring Set 10 40 Spring Set 40
20 Spring Set 20 50 Spring Set 50
30 Spring Set 30 60 Spring Set 60
Rotation direction
CW Spring to Close/Clock Wise
CC Spring to Open/Counter Clock Wise
Pinion Material
AL High Grade Aluminium, Hard anodized
SS Stainless steel ASI 316 (+ A4-70 SS fasteners)
Valve Interface (2
TN Standard ISO 5211 interface
SY Small interface with center plate (DIN3337)
LY Large interface with center plate (DIN3337)
Valve Stem Connection
Actuator
size Square
Aluminum Stainless
Steel (4
Parallel
drive
Diagonal
drive Star drive
No insert 000 Not applicable
0012 (3 9mm / 0.354" L09 D09 Q09
0025 11mm / 0.433" L11 D11 Q11
0040 &
0065 14mm / 0.551" L17 D14 Q14
0100 17mm / 0.669" D17 Q19
19mm / 0.748" L19
0150 17mm / 0.669" D17 Q22
19mm / 0.748" L19
0200 22mm / 0.866" L22 D22 Q22
0350 22mm / 0.866" D22 Q27
27mm / 1.063" L27
0600 27mm / 1.063" L27 D27 Q27
0950 36mm / 1.417" L36 D36 Q36
1600 &
2500 46mm / 1.811" L46 D46 Q46
4000 (3 55mm / 2.165" Q55 Q55 Q55
Temperature Range
SStandard: -20°C to +80°C (-4°F to +176°F)
HHigh: -10°C to +120°C (14°F to +248°F)
LLow: -40°C to +80°C (-40°F to +176°F)
G (6 Standard: -20°C to +80°C (-4°F to +176°F) PED Group 1 Label
Visual Indication Code
KStandard (Knob)
NNo Visual Indication
Finish
AStandard coating (EL-O-Matic Yellow)
GCSR Coating
Internal code 1
00 Standard
Miscellaneous options
XX Standard
H1 1/2" High Flow plate
P1 1/2" Porting according EN 15714-3 (only sizes 950-4000)
FS Full stroke adjustement
Notes:
See next page.
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Section 3: Configuration Code
FS 0150 - N U 40 CW AL TN - NL19 S K A - 00 XX
Type
Size
Rotation angle
Threads
Spring set
Rotation
Pinion material
Valve interface
Miscellaneous options
Internal code 1
Color / nish
Visual indicator
Temperature
Valve stem connection

Configuration Code
Notes:
1. The options, listed here, are all options available. Not all options apply to all con-
gurations.
2. Valve Interface: Size 0012 has no center plate option. Option "S"; Small Interface
with Center Plate (DIN3337) is not available for size 0025.
3. Size 0012 does not have inserts but has the inner square directly in the bottom of
the pinion.
Size 4000 does not have inserts but has two inner squares (diagonally and parallel
oriented) directly in the bottom of the pinion.
4. Actuators with stainless steel pinions do not have inserts but have two inner
squares (diagonally and parallel oriented aka "Star Drive") directly in the bottom of
the pinion.
5. Contact you local EL-O-Matic representative for additional insert options.
6. PED Group 1 Label only available up to size 950.
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Section 3: Configuration Code

Installation
The valve is closed after
a clockwise rotation.
The valve is open after
a counterclockwise rotation.
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
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 gure 3.
Figure 3 Normal valve rotation
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Section 4: Installation

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 dened
Signal Closed
Supply Voltage Closed
Pressure Not dened
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 exible 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
Spring-Return Operation Double-Acting Operation
CW
CW
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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 6.6 2.2 2.4 2.0
F 1600 10.6 3.5 3.6 3.3
F 2500 16.9 5.7 5.8 5.2
F 4000 29.1 9.2 9.2 9.0
Operating time is average with actuator under load and solenoid valve tted.
Test conditions:
1. Solenoid with ow 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" posi-
tion 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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Section 4: Installation

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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Section 4: Installation

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
Pinion and
cam position
Dot in
pinion slot
Default
pistons position
Reversed
pistons position
Pinion 90°
rotated
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 and
cam position
Dot in
pinion slot
Default
pistons position
Reversed
pistons position
Springs
Pinion 90°
rotated
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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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Section 4: Installation

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
90°
45°
90°
90°
Parallel
square
Diagonal
square
Flat head
Round with
key way
15
4. Install the bracket to the valve ange. Tighten all bolts and nuts and apply the cor-
rect torque.
Figure 11 Bracket Installation
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Section 4: Installation