Kitz ESR Series User manual

Document No：KE-4032-02
Operation Manual
KITZESRSeriesSpringReturnTypeElectricActuators
for KITZ Compact Ball Valves
Thank you for having chosen KITZ products.
For safe and trouble-free use of the product, ensure to carefully
read every instruction provided in this manual beforehand. Keep
this manual in a convenient place for easy access of all valve
operating personnel.

Document No：KE-4032-02
SAFETY CAUTIONS
This manual calls users careful attention to the dangers and hazards that may be caused to
personnel or properties during handling, storage, installation, operation or maintenance of the
product. Such dangers and hazards are specifically highlighted in the operation manual with either
one of the following marks.
A warning indicates a potentially hazardous condition that may result in
serious injury or death of personnel, if such a warning is ignored.
A caution indicates a potentially hazardous condition that may result in
minor injury to personnel or damage to properties, if such a caution is
ignored.
＊ Refer to the following for the classification of severity of damages.
Serious injury: Loss of sight, injury, burn (high and low temperature), electric shock, fracture
of bones, intoxication, etc. that have aftereffects.
And those requiring hospitalization and/or long-term hospital visit for
treatment
Minor injury: Injuries not requiring hospitalization and/or long-term hospital visit
Physical damage: Enlargement loss, etc. related to houses, household articles, live stocks, and
pets Moreover, the types of precautions we ask you to observe are classified
and explained by the following graphics.
(The followings show examples of graphic.)
This type of graphic indicates cautions to call users attention to be careful.
This type of graphic indicates prohibition of actions.
This type of graphic indicates compulsory actions that must be performed.
This type of graphic indicates risk of electric shock that may involve minor/serious
injuries.
This type of graphic indicates prohibition of disassembly that may damage product
functions.
This type of graphic indicates risk of explosion that may involve minor/serious
injuries.

Document No：KE-4032-02
NOTES TO USERS
◆ This manual provides users with the instructions on correct use of KITZ ESR Series electric
actuators. Ensure to carefully read all the items of this manual before handling, storage,
installation, operation and maintenance of the product.
◆ This manual covers the normal use of the product as a general guide to users, but does not
necessarily cover all possible conditions or situations that may be caused to users while using
the product. If technical assistance beyond the scope of this manual is required, users are
recommended to contact KITZ Corporation or the distributors in their locations.
◆ Numerical limits and procedures of operation, maintenance and inspection provided in this
manual are specified in consideration of safe and trouble-free operation of the product. It is
forbidden to use the product in any condition that may exceed such numerical limits or conflict
with such procedures.
◆ Drawings, tables, photographs and illustrations of the product in this manual provide users with
only the basic information. Ask KITZ Corporation or the distributors for detailed assembly
drawings of the products, if needed.
◆ Any information provided in this manual is subject to from-time-to-time change without notice
for error rectification, product discontinuation, design modification, or any other causes that
KITZ Corporation considers necessary.

Document No：KE-4032-02
Contents
Page
1. Design and Functions･･････････････････････････････････････ 1
1-1. Technical Features ･･･････････････････････････････････ 1
1-2. Product Coding ･･････････････････････････････････････ 1
1-3. Appearance Diagrams and Dimensions ･････････････････ 2
1-4. Actuator-valve Assembly ･････････････････････････････ 2
1-5. Design Specifications ･････････････････････････････････ 4
2. Handling and Storage ･････････････････････････････････････ 6
2-1. Cautions for Handling and Storage ････････････････････ 6
3. Piping Installation ･････････････････････････････････････ 7
3-1. Recommended Service Environments ･･････････････････ 7
3-2. Cautions for Piping Installation ････････････････････････ 8
3-3. Cautions for Electric Wiring ･･･････････････････････････ 10
4. Operation ･････････････････････････････････････ 12
4-1. Manual Operation ････････････････････････････････････ 12
4-2. Electric Operation ････････････････････････････････････ 13
4-3. Operational Precautions ･･････････････････････････････ 14
5. Maintenance/Inspection ･･････････････････････････････････ 16
5-1. Dismantling and Reinstallation･･････････････････････････ 16
5-2. Trouble Shooting ･････････････････････････････････････ 18
6. Others ･････････････････････････････････････ 19
6-1. Product Warranty ････････････････････････････････････ 19

Document No：KE-4032-02 Page：1/19
1. Design and Functions
1-1. Technical Features
① Turn the main power supply ON/OFF to open/close the valve.
• Unlike conventional electric valve actuators, only two wirings are required for the
ON-OFF operation.
② There are no problems of water hammers.
• Since the operation speed is not too fast unlike solenoid valves, there are no
problems of water hammers even if the fluid is liquid.
③ Manual operation
• It is easy to operate manually.
④ Manual lock mechanism
• Since it is equipped with the manual lock mechanism, it is possible to hold the valve
in the open status even if the power supply is turned off.
1-2. Product Coding
Application ON-OFF control for cold and hot water
Product
coding
ESR 100 TKLBE △△
Valvesize
Valvetype
100: Power supply: AC100V
200: Power supply: AC200V
Actuatortype:KITZESRSeries

Document No：KE-4032-02 Page：2/19
1-3. Appearance Diagrams and Dimensions
[ESR100-1, ESR200-1]
Fig. 1
1-4. Actuator-valve Assembly
Fig. 2
Actuator (ESR)
Cord
Name plate
Gasket
Insulator
Valve body
Hexagon bolt with
spring washer
Motor
Cover
Gear Box
Gear
Base plate
Housing
Shaft
Coil spring
Manual lever
Cord
Rubber bush

Document No：KE-4032-02 Page：3/19
 The product is not designed for explosion-proof. Do not install it in
any explosive environment to prevent accidental mishaps. Also do not
install it in any corrosive environment which will affect the service life.
 Do not carry out wiring works on actuators being energized, and do not
remove covers of their housings during wiring, to eliminate the danger of
an electric shock.
 Do not disassemble energized actuators from valves. It will damage
valves or actuators and cause problems.
 Do not put your fingers or foreign objects such as tools into ports of
valves being fully opened or closed. It may cause injuries or equipment
damages.
 Before dismantling actuated valves from piping, ensure to equalize the
piping pressure with the ambient pressure and thoroughly release line
fluid from the piping. Otherwise, residual pressure and line fluid will
dangerously extrude from valve bores.
 Factory-assembled actuated valves are adequately adjusted for
satisfactory function and performance. Do not disassemble them for any
reason, unless approved in advance by KITZ Corporation, as it may cause
valve malfunction, valve seat leakage and other technical problems.
 This manual covers the procedures to properly handle KITZ compact ball
valves driven by KITZ ESR Series actuators. For the product
specifications of ball valves and so on that mount this product, refer to
individual specifications.
 Ensure to follow all instructions given in this manual on piping
installation, electric wiring, maintenance and inspection of actuated
valves, to eliminate concerns of accidental mishaps and product failures.
 Mounting actuated metal valves on plastic piping may cause an excessive
load during manual operation, and damage the piping. Care must be
taken to eliminate such a concern

Document No：KE-4032-02 Page：4/19
1-5. Design Specifications
1-5-1. Design Specifications
Type-size
Specifications ESR100-1 ESR200-1
Power supply (single phase)
50/60 Hz * AC100V AC200V
Rated current 200mA 100mA
(50/60Hz) 10 sec.
Approx. 90°
operation time Spring return 20 sec.
Duty factor Continuous
Insulation class Class E
Insulation strength 1 min./AC1500V or 1 sec./AC1800V
Insulation resistance Minimum 100MΩ (DC 500V)
Service environment Indoor type *
Ambient temperature -10℃ 〜 +50℃
Mounting orientation Vertical to horizontal (no downwards)
Power cable / cable connection Vinyl cabtyre cord 0.75 mm2, length 3000 mm
Lubrication Grease
Painting color Black housing with light blue cover
※Maximum voltage variation: ±10%
* It cannot be used outdoor, in locations subject to water splash, or high humidity locations.
1-5-2. Electric Wiring Diagrams
[ESR100-1, ESR200-1]
Fig. 3
Product provision range
Motor
Close
Open Toggle switch
100/200 V
50/60Hz

Document No：KE-4032-02 Page：5/19
1-5-3. Actuator Operation Principle of ESR
● Opening operation (fully closed → fully open)
① If you turn on the motor power supply, the motor rotates and the motor force
is transmitted to the output shaft via the reduction gear and the valve rotates
in the opening direction.
② It opens the valve while lifting the spring attached to the output shaft.
③ When the Actuator shaft opens in the direction by 90°, it gets into contact
with the stopper inside the actuator and stops at the full-open position. At
this point, the motor stops and maintains the springs reaction force.
Fig.4
● Closing operation (fully open → fully closed)
① If you turn off the motor power supply the output shaft rotates to the closing
direction by the reaction force of the spring.
② When the Actuator shaft rotates to the closing direction by 90°, it comes
into contact with the stopper inside the actuator and stops at the fully closed
position.
Fig. 5
Product provision range
Motor
Close
O
p
en Toggle switch
100/200 V
50/60Hz
Product provision range
Motor
Close
O
p
en Toggle switch
100/200 V
50/60Hz

Document No：KE-4032-02 Page：6/19
2. Handling and Storage
2-1. Cautions for Handling and Storage
 Handle actuated valves by holding valve bodies. Holding instrumentation cables
will cause electric wiring failures and other troubles (Fig.6).
 Do not fall the product on the ground.
Protect the product from excessive impact
shock or vibration to eliminate concerns of
malfunction (Fig.7).
 Overloading the product must be
prevented. Do not place any heavy object
on the product. Do not step on the product.
 Do not store the product in the place subject to rain or high humidity. Poor
storage environment will cause product malfunction, such as corrosion inside the
product.
 Do not disassemble the product to avoid malfunction or damage of the product.
 The product is carefully packed to protect actuators and valves from intrusion of
dusts and other foreign objects. Do not unpack the product until you are ready
for installation on piping.
Fig. 6 Fig. 7

Document No：KE-4032-02 Page：7/19
3. Piping Installation
3-1. Recommended Service Environments
 The product is not designed for explosion-proof. Do not install it in any
explosive environment to prevent accidental mishaps. Also do not install it in
any corrosive environment which will affect the service life.
 This product is indoor type. Do not install the product outdoor, in location
subject to water splash or high humidity.
 Do not install the product where rainwater may gather high enough to submerge
the product installed on piping.
 Do not install the product where the vibration generated by nearby facilities
might affect the function of the product. Otherwise, take appropriate
protective measures to insulate the vibration
 Do not install the product where it is directly exposed to the sunlight.
Otherwise, take appropriate protective measures such as installation of a cover
or a shelter. Raising the temperature of the product may cause malfunction and
affect service life of the product
 Protect the product appropriately in environments where salty water, snow or
freeze may affect functions of the product.
 Keep a sufficient room around the installed product to ease dismantling,
disassembly, manual operation, maintenance and re-installation of the product.
 Where the product is exposed to radiant heat, take appropriate protective
measures such as installation of a cover or a shelter.
 Where access of passersby to the product is concerned about, such as where
the piping directly faces to a road, take appropriate protective measures like
installation of a fence or an enclosure.

Document No：KE-4032-02 Page：8/19
3-2. Cautions for Piping Installation
 Do not apply too much sealing materials for piping. An excessive application may
cause intrusion of sealing materials into the valve interior and cause malfunction
or internal leakage of line fluid. The first one or two threads of piping ends are
better to be left free from sealing materials
 Do not apply an excessive load by hand to
adjust mounting orientation of an actuated
valve, or do not tighten a valve with a wrench, to
eliminate a risk of damaging the valve (Fig.8).
 Do not excessively thread a valve into a pipe. It
will damage or distort the valve interior and
cause malfunction of the valve or external fluid
leakage.（Fig. 9, Table 1 in Page 13）.
 Do not hold a valve with a vice to eliminate a
concern of deformation or damage of the valve,
which may cause valve malfunction or external
fluid leakage (Fig.10).
 Do not apply an external force to a valve
counterclockwise during mounting on piping. It
may loosen the body-cap joint of the valve and
cause external fluid leakage.
 Do not mount an actuated valve facing
downward to the ground to prevent possible
water intrusion into the actuator interior. Mount
it on piping horizontally, vertically or at any
intermediate angle, depending on piping or
operating convenience (Fig.11)
 Do not overload an actuator, or step on it during
mounting of an actuated valve on piping, to
eliminate concerns of fluid leakage and product
malfunction (Fig.12).
 Do not open or close a valve for any reason, while being flushed after piping installation.
It will damage valve seats with foreign residues left inside the valve bore, and result in
internal fluid leakage.
 Do not construct heat-retention materials and other structures that hinder the
operations within the operation range of the manual operation lever of the actuator. If
there are any obstacles within the operation range, the valve may not operate properly.
Fig. 8
Fig. 9
No bumping of a pipe end against the
valve interior：No scratching
Fig. 10
Fig. 11
Fig. 12

Document No：KE-4032-02 Page：9/19
 Mount an actuated valve with a wrench
firmly held around the valve end, which
is jointed with a pipe. Holding the
wrench around another valve end,
which is open to the atmosphere, may
cause a too excessive load to the
valve body (Fig.13).
 Do not apply any excessive bending moment to an actuated valve, to avoid valve
body deformation and valve functional failure.
 Provide an appropriate support to an actuated valve, if the weight of the valve
and operation cycles may cause an excessive load to the piping. Where metal
valves are mounted on plastic piping, care must be particularly taken to securely
support the both ends of the valve.
 If sands, metallic particles and other foreign objects are contained in the line
fluid, ensure to mount a filtering device such as a strainer on the upstream side
piping. These foreign objects may get stuck around valve seats and affect valve
function or cause internal fluid leakage.
① Prior to piping installation, check that the design specifications of an actuated valve
all satisfy service conditions.
② Also remove dusts, scales and other foreign residues from valve end threads and
piping internals
③ Check the kind and the standard of valve threads with a gauge and confirm that the
required number of effective threads are provided.
④ For threading a valve into piping, use a wrench held around the valve end, which is
jointed with a pipe.
⑤ Thread a valve with a tightening torque recommended in Table 1.
⑥ To threaded ends, apply the sealing material which is suitable to the service fluid and
temperature.
⑦ After piping installation, fully open valves and flush the piping to remove all internal
residues.
Table 1 Thread Tightening Torque
（The table below shows figures in cases of bronze/brass valves.）
Valve size 1/2 3/4 1 11/4 11/2 2
Tightening torque
N-m
(kgf-m)
20〜29
(2〜3) 39〜49 (4〜5) 49〜59 (5〜6) 59〜69 (6〜7) 69〜78 (7〜8) 78〜88 (8〜9)
Fig. 13

Document No：KE-4032-02 Page：10/19
3-3. Cautions for Electric Wiring
 Ensure to switch off an actuator before electric wiring, to eliminate the danger of
an electric shock
 Do not work for electric wiring in rainwater, to avoid the danger of an electric
shock.
 Do not unnecessarily pull
out connecting cables
and wires, as they may
get disconnected and
cause an electric shock.
Cabling an actuator to
the power source with
some slack is recommended (Fig.14). Fig.14
 Do not modify an actuator for any reason, to avoid concerns of functional
failures.
 Do not separate an actuator-valve assembly or disassemble an actuator, to
avoid damage of the actuator.
 An actuator is designed for either AC100V or AC200V. Check that the power
source voltage on site matches to the design specification of an actuator.
 Ensure to make correct wiring to eliminate the danger of an earth leakage or a
short circuit.
 Work for electric wiring according to the indication attached to an actuator.
Incorrect wiring may damage instrumentation devices.

Document No：KE-4032-02 Page：11/19
 There is a small gap between an electric cable and inner wires. If waterproofing
of cable connections and exposed cable ends is not adequately done, capillary
phenomenon may cause water intrusion into the interior of an actuator, resulting
in corrosion of parts and components. To prevent malfunction of an actuator,
ensure to adequately waterproof all cable connections and exposed cable ends
(Fig.15).
Fig.15
 Ensure to isolate open ends of unused cables and wires to eliminate concerns of
a short circuit and actuator malfunction.
① Electric wiring must be worked by the personnel who are officially qualified according
to relevant national standards, rules and/or regulations.
② Refer to the wiring diagram shown on a housing cover of an actuator for correct wiring.
③ Tightly bundle cables in a cable sheath and
firmly cover them cable ends with a plastic
tape, after having applied some gap filler.
Gap filler
Closed end
connector Tightly filled with no gap
Actuator cable
Gap filler
to the
control
panel
Plastic tape
Cable
sheath
Cable
sheath
① Waterproofing for edges of unused
electric cables, and for joint of
cable wires with relay cables.
② Waterproofing clearance between
cables and cable sheath.

Document No：KE-4032-02 Page：12/19
4. Operation
4-1. Manual Operation
 Do not disassemble energized actuators from valves. It will damage valves or
actuators and cause problems.
 Ensure to turn off an actuator for manual operation not to damage the actuator.
 Manual operation must be done slowly to prevent an actuator from damage or
malfunction.
[ESR100-1, ESR200-1]
① The valve operation range is 100% (fully open) at manual operation.
② Since it is equipped with the lock groove, it is possible to hold the valve in the fully
opened status by the manual operation.
③ When shifting from manual to electric operation, make sure to check that the manual
lever is released from the lock groove.
Fig. 16
Manual lever
Lock groove
Closed position Opened position
Open to Close
Close to Open

Document No：KE-4032-02 Page：13/19
4-2. Electric Operation
Perform the electric operation with the following procedure.
① Checking power supply voltage
Check that the power source voltage conforms with the design specification of an
actuator.
② Checking wiring connection
Check that control circuits of an actuator are correctly wired, according to the wiring
diagram indicated on an actuator housing and the color codes of wires
③ Turning on the power supply
Turn on an actuator to detect if anything abnormal might happen. If anything abnormal
such as smoke emission or failure of control circuit fuse happens, immediately turn off
the actuator, detect the cause and take an appropriate corrective measure to solve
the problem.
④ Electric operation
Turn on the power supply and confirm that valve opens. Similarly, turn off the power
supply in the fully open status and confirm that the valve closes.
⑤ Others
●In case of motor overheating, smoke emission or fuse failure, turn off an actuator,
detect the cause of failure and apply an appropriate corrective measure to solve the
problem.
●In the electric operation, the manual lever is released free and moves in the opening
direction; this is not malfunction.

Document No：KE-4032-02 Page：14/19
4-3. Operational Precautions
 Do not drive an actuator to continually open and close a valve. Pause for at least
ten second between opening and closing operations (Fig. 17).
Fig. 17
 Do not control an actuator with a Solid-State Relay (SSR). When the actuator is
turned off, a leakage current may affect its function or affect its service life. If
SSR must be used for any particular reason, ensure to test the actuator to check
its proper activation prior to operation.
 Do not drive an actuator directly by contact output of a sequence controller. If
such an activation is inevitable for any particular reason, drive the actuator by
means of a switching element like a relay provided with an adequate contact
capacity.
 Do not perform the closing (opening) operation while the valve is in the middle of
opening (closing). It will shorten the life significantly.
 This series of actuators is designed for technically non-critical applications, and
electromagnetic waves and noises may affect its operation. For connection of
this series of actuators with other equipment, which may cause electromagnetic
waves and noises, ensure to check its proper operation before application.
Pause for 10 seconds or longer
open close

Document No：KE-4032-02 Page：15/19

Ensure to provide a fuse or a short circuit breaker on the control panel to
prepare for accidental short circuits.
 Protective measures for extraordinary pressure rises
When a floating-ball type ball valve is used for highly volatile liquid service,
rise of line temperature or ambient temperature may often cause an
extraordinary rise of the pressure of the fluid left within a body cavity and
result in seat damage or valve malfunction. This problem may be solved by
the following preventive measures:
 For fully closed valves: Optional provision of a pressure equalization hole
through the upstream side of the ball, or a pressure equalization groove on the
upstream ball seat is recommended (Fig.18). This provision will make the fluid
flow uni-directional, so that care must be taken to decide mounting direction of
the valve on piping.
 For fully open valves： Standard provision of a pressure equalization hole on the
top of the ball where it contacts with the valve stem is provided (Fig.19). Valve
mounting orientation remains bi-directional.
 Countermeasures in piping loop
Extraordinary pressure rises also could be a problem for a valve mounted at the
end of the piping loop for liquid service. No effective solution could be
recommended for such a valve itself. The entire piping system needs an
appropriate design reconsideration in advance so that a pressure relief valve
may be installed or the piping loop may not be ended with a valve.
Fig. 18 Fig. 19
Pressure
equalization groove Pressure
equalization hole
Pressure
equalization hole Fullyclosed Fullyopen
Fluid flow direction
Body
cavity

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5. Maintenance/Inspection
 Unusual noise may be generated if foreign objects are caught in the valve seat.
Promptly remove foreign objects in the seat. If such objects are left as is, the
seat may be damaged or malfunction.
 Leaving unusual piping vibration as is causes malfunction. If unusual vibration is
detected, fix the piping with support or similar to prevent vibration.
① Ball valves and actuators introduced in this manual are all designed
lubrication-free.
② Inspections of all actuated valves must be carried out periodically, and as
frequently as possible to prevent accidental mishaps. Here are the items of
inspections required as a minimum:
１） Check trouble-free opening and closing of valves.
２） Detect any external fluid leakage from valves and piping connections.
３） Check vibration of valves and piping during operation.
４） Inspect loosened bolts and nuts
5-1. Dismantling and Reinstallation
 Do not disassemble an energized actuator from a valve, to eliminate concerns of
valve damages and accidental mishaps.
 Do not put your fingers or foreign objects such as tools into ports of valves being
fully opened or closed. It may cause injuries or equipment damages.
 Before dismantling an actuated valve, ensure to equalize the pressure of the
piping and the valve interior with the ambient pressure. Otherwise, residual
pressure and line fluid may dangerously extrude from the valve bore and cause
accidental mishaps.