I-Tork PDS Series User manual

I-Tork PDS Pneumatic Actuator
Installation and operating manual (PDS-M0108/1010)
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Installation Operation Manual
(I-TORK PDS Series Pneumatic Actuator)
PDS-M0108/1010
74-6, Chun Ui-Dong, Won Mi-Gu, Bucheon, Kyoung Ki-Do, Korea
Tel : [phone], 66 Fax : [phone] E-mail : [email protected]
Website: www.i-tork.com

I-Tork PDS Pneumatic Actuator
Installation and operating manual (PDS-M0108/1010)
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Table of Contents
1. GENERAL
2. SCOTCH-YOKE PRINCIPLE ADJUSTMENT
3. IMPORTANT SAFETY PROCEDURES
4. OPERATION
5. LUBRICATION REQUIREMENTS
6. APPLICATION
7. INSTALLATION PIPING
8. DISMANTLE ASSEMBLY
9. PDS50~200 PART LIST
10. TROUBLE SHOOTING

I-Tork PDS Pneumatic Actuator
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Many thanks for purchasing our I-Tork PDS Pneumatic Actuator!
For safe and proper operation, please read this manual carefully before using it and sa e it for reference.
1. General
I-Tork PDS series actuators are designed for rotary quarter turn al es and there are
PD (Double Acting) and PS (Single Acting-with Spring Pack).
I-Tork PDS series actuators can be used with a 4~8Kg/㎠ range of air supply pressure.
Standard air pressure is 5.5Kg/㎠.
PD : Pmax 8 bar (116 psi)
PS : Pmax 7 bar (110 psi)
ISO Mounting Design:
ISO 5211 for al e flange or mounting bracket.
VDE 3845 (Namur) for solenoid al e.
Operating Medium:
Filtered inert gas or air must be used, and exhaust air must be passed through silencer
before being ented into the atmosphere. The dew point shall be equal to -20 °C or at
least, 10 °C below the ambient temperature (ISO8573 Part1, Class 3). The maximum
particle size shall not exceed 40 μm (ISO8573 Part1, Class 5). Max Pressure shall be
0.8 Mpa (8 bar) and the minimum design pressure for pressurized parts shall be 1.5
times the maximum operating pressure.
Important Notice: The contents in this manual are subject to change
without notice due to quality improvement.

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2. Scotch Yoke Principle Adjustment;
I-Tork Actuators uses a Scotch Yoke assembly with angled slots.
This allows for a more compact design when compared to Rack & Pinion actuators.
Scotch-Yoke technology is known as the most suitable actuator mechanism for al e
and damper applications, as it produces higher torque at both ends (open and close)
positions compare to Rack and Pinion, which has a constant output torque. The
standard operation ambient temperature range is -20 ~ + 80 ℃.
Single Acting actuators ha e the pistons rotated 180° for a fail close position; this
means any adjustment will take place in the open position. If the SR actuator is set to
the ‘Fail Open’ position, then the adjustment will take place in the closed position. The
adjustment angle for both is ±3° by Adjusting Screws.
The adjustment is done by loosening the Adjusting Screws, and I-Tork PDS ha e 2
Adjusting Screws for open and close positions.

I-Tork PDS Pneumatic Actuator
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3. Important Safety Procedures
 Caution: Always disconnect the Air and Electrical supplies before carrying out
any form of maintenance on an Actuator.
 Caution: When remo ing any ball al e or plug al e assemblies from a pipe
system, isolate the piping system on which the Actuator is installed and relie e
any media pressure that may be trapped in the al e ca ities before remo ing
the Actuator for maintenance.
 Never use ‘Blow Out’ the Pistons or the End Caps from the Actuator Body.
 Never turn the adjusting screws completely out when the actuator is under
pressure.

I-Tork PDS Pneumatic Actuator
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4. Operation
Figure 1 : PD (Double Acting)
Close Open
When air is supplied to the left port, the actuator will mo e to the Close position.
When air is supplied to the right port, the actuator will mo e to the Open Position.
Figure 2 : PS (Single Acting) Fail Close Position
Open Close (fail Position)
When air is supplied to the left port, the actuator will mo e to the Open Position.
When the air supply fails, the actuator will mo e to the fail position (Close).
Figure 2 : PS (Single Acting) Fail Open Position
Close Open (fail position)
When air is supplied to the left port, the actuator will mo e to the Close position.
When the air supply fails, the actuator will mo e to the fail position (Open).

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5. Lubrication Requirements:
I-Tork PDS generally do not require lubrication, howe er, oil mist lubrication is
recommended for actuator which has performed more than 100,000 operation cycles.
Recommended Lubrication Grease:
Parts Actuator Version Grease
Cylinder Bore, Shaft
Sealings
Standard & High
Temperature
Dark Brown Grease
ALVANIA RL2/DC111
Cylinder Bore, Shaft
Sealings
Low Temperature White Grease DC 111
(DOWCORNING)
6. Application
All quarter turn type al es and equipment as follows
1) Ball Val e(2 way, 3 way, 4 way), Screw end and flanged
2) Butterfly Val e
3) Plug Val e
4) Damper
5) etc

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7. Installation and Piping
1) Selection of actuator
Determine the appropriate torques and strokes taking into consideration the
following parameters and questions.
- Valve Question
- Val e: type, size, function and operation characteristics
Operating Conditions: Media, Temperature, Pressure, Flow rate, Frequency of
operation and required stroking time.
Val e Torque Characteristics (seating/unseating, dynamic torque <when
applicable>)
Maximum Allowable Stem Torque Limitation
- Actuator Question
Air Supply Pressure : Minimum and Maximum
Operation: On/off or Control
Acting: Double or Single (Fail Position open or close)
Frequency of operation
- Ancillary Question
Limit Switches: Type, Voltage, etc.
Positioners: Pneumatic or Electro-Pneumatic
Position Transmitters: Local Electrical Regulations
Solenoid Val e: Type, Voltage, etc.
- Environmental Conditions
Indoor, outdoor, saline, corrosi e chemicals, etc.
Enclosure Protection type
Hazardous or non-Hazardous areas
Ambient Temperature

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2) Installation and Mounting on the Valve
I-Tork PDS can be mounted in any position, ie: Vertical or Horizontal.
It is ery important that the actuator shaft and the al e stem are centered and
must ha e a 0.5 ~ 1 mm gap between the actuator shaft and the al e shaft (or
dri ing bush) depending on the actuator size. If the al e stem is too high, it may
force the actuator shaft upward thus displacing the shaft seal. This would cause air
leakage at the shaft seal.
Please note that the actuator has a hexagonal dri e shaft.
Do not mount the actuator at a 45˚ angle.
All the mounting dimensions of PDS series follows international standard and as
follows.
Top mounting hole : VDI/VDE3845
Top end of shaft : NAMUR for installation of Limit Switch Box or Positioner.
Bottom Mounting Hole: ISO5211
Bottom End of Shaft: Double Square for Easy Mounting (ISO5211)
3) Piping (Air Tubing)
All I-Tork PDS actuators can be piped with solid or flexible tubing with the solenoid
al e mounted remotely from the actuator or by mounting a NAMUR designed solenoid
al e directly onto the NAMUR mounting pad on the side of the actuator.
- Precaution
Please check the en ironmental conditions (Temperature, Pressure,
Characteristics of fluid, Piping standard) before piping.
If air tubing connection is not properly fitted, it may cause lower torque,
shorten the life cycle of actuator. Connection of actuator is PT 1/4” for PDS
40~200.
- Solenoid valve
Be sure that the solenoid al e’s connection type is compatible to the
actuator’s.

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- Operating
To operate the actuator, supply a clean and dry air through a filter regulator
(this is strongly recommended)
Power up the solenoid al e.
The actuator should operate.
4) Storage
I-Tork PDS actuator’s body is made of Hard-Anodized aluminum both inside and
outside for protection against corrosion.
Store in a dry area and care to be taken when stacking the actuators.
Do not remo e the air holes plugs until the actuator is ready for installation.
5) Manual Operation:
When operating the actuator manually, be sure that all compressed air is fully
ented before carrying out the manual operation.
6) Adjusting Screw Adjustment
For Open Position
1. Operate Val e/Actuator assembly to the open position.
2. Remo e Air supply
3. Loosen the lock nut on the adjusting screw
4. Turn the “Close” adjusting screw clockwise to reduce or counter clockwise to
increase the tra el.
5. Tighten the lock nut.
6. Connect air and check if the position is correct. (If not, repeat from 2)
For Close Position
7. Operate Val e/Actuator assembly to the close position.
8. Remo e Air supply
9. Loosen the lock nut on the adjusting screw
10. Turn the “Open” adjusting screw clockwise to reduce or counter clockwise to
increase the tra el.
11. Tighten the lock nut.
12. Connect air supply and check if the position is correct. (If not, repeat from 8)

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8. Dismantle and Assembly
(For Replacing O-ring and other parts.)
PD series (Double Acting)
Dismantling
Caution: Vent all compressed air from the actuator and disconnect all electric
power before dismantling.
1) Loosen the adjusting screws (23).
2) Loosen both end co er bolts (26) using Hexagonal Wrench and dismantle.
3) Using the spanner, rotate the stem more than 90° until pistons are released
automatically and pull out the pistons (3).
4) Loosen the Set Screw (27) of Scotch - Yoke (5).
5) Take the Snap Ring (21)/Washer (12)/Thrust Washer (11) out from the top of
shaft.
6) Separate the shaft (4) from the body.
7) Replace the part.
8) For Assembly: Do the Re erse.
PS series (Single Acting)
Dismantling
Caution: Vent all compressed air from the actuator and disconnect all electric
power before dismantling.
1) Loosen the adjusting screws (23).
2) Using hexagonal wrench, loosen 2 bolts (26) in a diagonal position on both end
co ers.
Then loosen the other 2 bolts in a diagonal position on both end co ers slowly.
(Ensure spring pack pressure is released before remo ing bolts fully, if unsure,
then remo e 2 diagonal bolts only and insert longer bolts until spring pressure is
released)
3) Take out the co er (28) and spring pack (22/29/30/31/32/33).
4) Using the spanner, rotate the stem more than 90° until pistons are released

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automatically and pull out the pistons (3).
5) Loosen the Set Screw (27) of Scotch - Yoke (5).
6) Take the Snap Ring (21)/Washer (12)/Thrust Washer (11) out from the top of
shaft.
7) Separate the shaft (4) from the body.
8) Replace the part.
9) For Assembly: Do the Re erse.
Converting PD to PS Actuators:
All I-Tork PD (Double Acting) actuators can be con erted to PS (Single Acting)
actuators by adding a spring pack as follows.
Caution: Vent all compressed air from the actuator and disconnect all
electrical power before dismantling.
If ‘Fail Open’ position is required:
All parts are the same except for the addition of the spring pack; just the PD co er
needs to be replaced with the appropriate PS spring pack.
If ‘Fail Closed’ position is required:
1. Loosen the Adjusting Screws (23) from the body.
2. Disassemble the nd Covers (2).
3. Disassemble the Pistons (3) according to PD disassembly.
4. Rotate the Pistons (3) and Yoke (5) 180°; then assemble the pistons to the body.
5. Mount Spring Pack to the body when the pistons (3) are in their inner most
position.

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Disassembling of Spring Pack:
For safe disassembling of the spring packs, the following procedure must be carried
out.
1. Disconnect all air and electrical supplies.
2. Springs must not be in the compress position (that is, the springs must be at
fully extended position).
3. Loosen the bolts (26) of the end co er separate Spring Pack from the body.
Spring Packs
 Pretension Bolt(33)/Spring Washer(32)/Plain Washer(31)/Spring Retainer(30)
Spring(29)/O-Ring(22)/Spring Co er(28)/Bolt(26)
From PS 40 to PS100 (Single Spring per pack)
There are 2 Spring Options:
One is for 4.2 bar pressure;
The other is for 5.5 bar pressure.
From PS 125 to PS200 (Double Springs per pack)
There are 2 Spring Options:
One is for 4.2 bar pressure.
The other is for 5.5 bar pressure.
<Remark> When placing order PS Single Acting type Pneumatic Actuator,
please specify the Spring Option (4.2 bar or 5.5 bar).

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9. PDS50~200 PART LIST
Part List No Material Part List No Material Part List No Material
1. Cylinder Aluminum 12.Washer-Shaft Steel 23. Adjust screw Steel
2. Co er Aluminum 13. Roller Pin Steel 24. NUT Stainless Steel
3. Piston Aluminum 14. Roller Steel 25. Washer-Stopper Stainless Steel
4. Shaft Steel 15. Piston Guide –
Shaft Pad
POM 26. HEX. Head
Socket Bolt
Stainless Steel
5. Scotch yoke Steel 16. Support Band PTFE 27. Set Screw Stainless Steel
6. Stopper Steel 17. O-Ring -
Piston
NBR 28. Spring
Return Co er
Aluminum
7. Shaft Wearing POM 18. O-Ring –
Shaft, lower
NBR 29. Spring Spring Steel
8. Support Ring
- Lower
POM 19. O-Ring –
Shaft - upper
NBR 30. Spring
Retainer
Steel
9. Support Ring
- Middle
POM 20. O-Ring -
Stopper
NBR 31.
Plane
Washer
Steel
10. Support Ring
- Upper
POM 21. Snap Ring Stainless Steel 32. Spring
Washer
Steel
11. Thrust Washer POM 22. O-Ring- Co er Stainless Steel 33. Pretension bolt Steel

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10. TROUBLE SHOOTING
Status Possible Reason Recommended action
Actuator doesn’t
work at all
Electric power line fails Check the incoming oltage
or power line
Trouble in solenoid al e
Check oltage of solenoid Coil
If coil is OK, check operation
of spool al e by using
manual button
Blockage or leak in air
supply line Check air supply line
Actuator is working,
but not smoothly
Air pressure is too low Increase supply air pressure
Blockage in air inlet/outlet
lines by foreign material
Take out foreign material in
the line
Speed controller is locked Open speed controller
Air leakage through piston
ring Replace the piston ring
Actual al e torque is too
high
1) Increase air supply
pressure
2) Replace with a larger
actuator
Val e doesn’t open
or close fully
Stopper setting is wrong Set stopper again
Actual al e torque is too
higher than specification. Replace with a larger actuator
Air leakage Piston or co er bushing o-
ring worn out Replace O-rings