Kitz FBS User manual

Document No.:KE-4011-03
Operation Manual
For
KITZ FBS Pneumatic Actuators
Thank you for choosing KITZ products.
For safe and trouble-free function and performance of the product,
ensure to read and understand all items of this manual before valve
mounting and operation.
Keep this manual in a convenient place for your valve operators’ easy
access.

Document No.:KE-4011-03
NOTES TO USERS
This manual applies to the KITZ FBS Series Pneumatic Valve Actuators.
For actuators of automatically operated value, refer to the operation manual of relevant actuators
prepared by the manufacturers.
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.
Indicate to call attention of an action.
Indicates prohibition of an action.
Indicates mandatory implementation of an action.
◆ This manual provides users with the instructions on correct use of KITZ FBS pneumatic valve
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 every condition or situation 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 given in this manual such as operating pressures and service temperatures are
specified in consideration of safe and trouble-free operation of the products. It is forbidden to use
the product in any condition that may exceed such numerical limits.
◆ Drawings 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.
If any item of this manual is not strictly followed by users, KITZ Corporation shall have no responsibility
for any resulting accident or failure of the product.

Document No.:KE-4011-03
C O N T E N T S
Page
1 Attention for user’s system ······················································································ 1
2 Product Features ··········································································································· 1
3 Product Codes ·············································································································· 1
4 Mounting of Actuators on Valves ·········································································· 2
5 Dimensions and Mass ································································································· 2
6 Design Specifications ································································································· 3
7 Product Identification Plates ··················································································· 3
8 Actuator Driving Mechanism ···················································································· 4
9 Output Torques ············································································································ 4
10 Supply of Air Operation Pressure ·········································································· 5
11 Air Consumption ··········································································································· 6
12 Handling and Storage of Actuators and Actuated Valves ···························· 7
13 Valve Opening Positions Set for Shipment ························································ 7
14 Adjusting Valve Opening Range ·············································································· 8
15 Mounting KITZ Optional Accessories on Actuators ······································· 9
16 Automatic Operation of Actuators············································································· 11
17 Manual Operation of Actuators ··················································································· 13
18 Inspection and Maintenance of Actuators and Actuated Valves ·············· 13
19 Disassembly and Reassembly of Actuators ······················································· 15
20 KITZ Standard Spare Parts ······················································································ 25
21 Trouble Shooting ·········································································································· 26
22 Notes to Users ·············································································································· 27
23 Product Warranty ········································································································· 27
24 Emergency Call for Technical Assistance ·························································· 27

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1. Attention for user’s system
2. Product Features
2-1. KITZ FBS pneumatic valve actuator is provided with output torque characteristics suitable for
operation of KITZ smaller size ball valves.
2-2. KITZ FBS pneumatic valve actuator is designed for direct modular mounting of KITZ optional
accessories on the actuator housing.
3. Product Codes
F B S – 1
① ② ③
①Type of valves to operate ②Type of operation ③Actuator size
B…Smaller size ball valves S…………Spring return 1…Size 1
① Holding valve position
KITZ pneumatic actuators Do not assure no leakage. Actuators do not hold
valve positions long time without continuous air supply. If you need to hold
valve position long time without continuous air supply, contact KITZ
Corporation or its distributors.
② Internal air residue of spring return type actuators
Out put torques of spring return type actuators indicate values without
internal air residue remains inside their cylinders. Please design your systems
to be able to exhaust internal air residue at spring return action. If internal air
residue remains in the cylinders, out put torque will be small and valves do not
open or close by spring return action.
① Do not pressurize spring return type actuator’s breathing port.
② Prevent entering dust, rainwater or waste into actuators through the breathing
port.

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4. Mounting of Actuators on Valves
KITZ FBS pneumatic valve actuator is mounted on KITZ smaller size ball valves directly with male
shape driving shaft.
5. Dimensions and Mass
Mass
FBS-1 2.1kg
Unit: mm
Air supply port
Screw size of
breathing port elbow

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6. Design Specifications
FBS-1
Shaft rotating range 90°±7°
Cylinder volume (Ｌ) 0.15
Standard operation pressure 0.4 MPa
Operation pressure range *1 0.3～0.7 MPa
Housing shell test pressure 0.97 MPa
Valve opening position indicator 90°with 7 division marks including [O] and[S]
Service temperature range *2 －20℃～＋80℃
Bottom pad for mounting on valves ISO5211
*1. Contact KITZ for technical advice, if the operating pressure is lower than 0.39MPa.
*2. The air supply must not be frozen.
7. Product Identification Plate
For the identification of the product code and service conditions, a metal plate is attached to the
actuator housing.
ID plate for FA-1 actuator
ID plate location

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8. Actuator Driving Mechanism
Type FBS spring return actuator
(1) The Air pressure supplied into the chamber A through the inlet ① pushes the piston-gear
rack assembly toward the left, compresses the spring and discharges the air residue left in
the chamber B through the outlet ② (Fig 1).
(2) At the same time the gear rack rotates the pinion gear and the shaft counter-clockwise, to
drive the valve.
(3) At the moment the air in A is discharged through the solenoid valve, the spring force
pushes the piston and the gear rack to the reverse direction, and the gear rack activates
rotation of the shaft clockwise to reversely operate the valve.
Fig1
9. Output Torques
Type FBS spring-return actuator Unit: N-m
Actuator
type-size
Spring
rating
Operating pressure (air) Operating force
(spring)
0.3 MPa 0.4 MPa 0.5 MPa
0°* 1 90°* 2 0°* 1 90°* 2 0°* 1 90°* 2 0°* 3 90°* 4
FBS-1
3 8.8 6.0 13.7 10.9 18.6 15.8 5.9 8.7
4 － － 12.1 8.0 17.0 12.9 7.6 11.7
5 － － － － 15.1 10.0 9.4 14.5
*1. For starting an actuator travel to open a fully closed valve:
*2. For ending an actuator travel to open a fully closed valve.
*3. For ending an actuator travel to close a fully open valve.
*4. For starting an actuator travel to close a fully open valve.
Spring
Drive shaft
Gear rack
Piston
Pinion gear

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10. Supply of Air Operation Pressure
10.1 For the actuator factory-assembled with a solenoid valve, provide the air tubing between the air
compressor and the solenoid valve. Air inlets are Rc 1/4.
10.2 Use copper, coated copper or plastic tubes of an adequate diameter and wall thickness. Clean
tube bores to remove all foreign residues and tightly seal all connections to avoid leakage of air
during a travel from the compressor.
10.3 If you want to mount your own solenoid valves other than those factory-assembled, select the
following type. For FBS actuators, 3-way or 4-way solenoid valves with plug up just one port are
used.
10.4 Air inlets are Rc1/4. Use hexagonal fittings of 19mm and smaller width of flat . Contact KITZ
Corporation for technical advice, if you want to use larger tubes for faster operation of actuators.
10.5 Keep the air always free from dust and moisture ( -15℃ or lower dew point under the atmospheric
pressure ), using air-filters and air-dryers.
10.6 Choose the capacities of your own accessories and the sizes of auxiliary air tubing, in consideration
of possible loss of air pressure during a travel from the compressor.
10.7 The exact volume (Q) of air supply required per minute for actuators must be known before the air
tubing installation so that the provided operation pressure may be sufficient to properly drive
actuators and valves. Calculate your air supply requirement with the following equation.
10.8 The required air pressure must be kept constant at the air inlet of an actuator. Insufficient air
supply causes intermittent piston drive and results in malfunction of actuators.
Q = V(P + 0.1013) / 0.1013 x 60/t [L /min.(ANR)]
V: Volume of actuator housing [L] ( V1 or V2 in Section 10 )
P: Air operation pressure [MPaG]
t: Time required per stroke [second] under 0.39MPa operation pressure,
where no valve nor accessory is provided. ( Refer to Table 1 )
ANR: Air supply volume under the standard condition of 20℃ ( 68°F ),
760mmHg absolute pressure and 65% relative humidity
Fig2. Design of solenoid valve mounting pad( air inlet/outlet ports )
Actuator type Time[sec]
FBS-1 0.2
Open port
Table 1.
Time [t] required per
stroke under 0.4
MPa

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11. Air Consumption
Air consumption means the volume (Q) of the air released to the atmosphere from an actuator operating
[n] times forward and backward per hour as converted to the average volume per minute. Decide the
capacity of an air compressor using the result of the following calculation. We recommend to use an air
reservoir of an adequate size to constantly operate an actuator at the preset time.
◆ Air consumption of FBS actuator:
Q = V (P + 0.1013) / 0.1013 x n/60 [L/min.(ANR)]
V: Volume of actuator housing [L]
Refer to Table 2 and the illustration shown below.
P: Air operation pressure [MPaG]
n: Number of operation cycles per hour
Table 2 Volume of actuator housing
Fig3

The required capacity of an air compressor depends on the availability and the
volume of an air reservoir, the number of hourly operations, the time required for
valve stroke and whether the air compressor is used exclusively or otherwise for
the actuator.

To decide the practical capacity of air compressors and reservoirs, adding some
extra 30% to the calculated air consumption volume is recommended to absorb
possible loss of air caused during a travel through air tubing and accessories.
 Use an air-filter to continually supply clean, dry air to an actuator.
 Use plastic tapes for tightly sealing piping connection, ensuring that tape ends do
not enter into the tube bore and block the port.
 Also ensure that there is no leakage of air through all tubing connections.
Insufficient supply of air pressure causes malfunction or failure of an actuator.
 Appropriately design the total length of air tubing. Too long air tubing causes
pressure loss or insufficient flow rate of the air, and results in malfunction or
failure of an actuator.
Actuator type V [L]
FBS－1 0.15

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12. Handling and Storage of Actuators and Actuated Valves
12.1 Store actuators and valves in cool, dry, corrosion-free environment to keep them rust-free and
prevent their malfunction, although surfaces are appropriately finished for primary protection.
12.2 Actuators and actuated valves are provided with dust protectors and packed individually for damage
prevention. Don’t unpack them and don’t remove protectors until you are ready to install them on pipes.
12.3 Overloading actuators and valves must be prevented. Don’t fall them on the ground. Don’t place
any other objects on them. Don‘t step on them.

Actuators or actuated valves are individually packed and all openings and
connections are sealed for dust prevention. Don’t unpack them and don’t
remove protectors until you are ready to install them on pipes.
 Modification of actuators or actuated valves is forbidden, unless accepted by
KITZ Corporation or the authorized modification shops in advance.

Carefully handle actuators packed particularly in cardboard cases, since the
cases might have become very fragile due to moisture and other causes.
 Care must be taken to handle actuators equipped with solenoid valves and other
accessories during storage or transportation.
 Store actuators or actuated valves in cool, dry, corrosion-free environment to
keep them rust-free and prevent their malfunction or failure.
13. Valve Opening Positions Set for Shipment
KITZ ball valves equipped with FBS actuators are all shipped in the de-energized condition.

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14. Adjusting Valve Opening Range
Fig 4
14.1 Release the compressed air from the actuator housing. Loosen a hexagon nut and adjust the
position of either one of two stopper bolts illustrated above for your desired valve opening position.
The dimensional requirements of ball valve balls ([L] in Table 3) must be satisfied. Refer to Table 4
on the sizes of stopper bolts.
14.2 Clockwise rotation of the stopper bolt makes the valve operation range smaller, and counter-
clockwise rotation makes it larger.
14.3 After having tightened the nuts, supply the compressed air to the port and check the valve opening
range. Repeat this work until you have a satisfactory result
Table 3: Adjustment for KITZ Class 150/300 full-bored floating ball valves (*5)
(*5) In the case of 3-way ball valves, adjust the center of the ball bore so that it may align with the
center of the valve end flange bore. During adjustment, you can monitor the work through either side
opening of the valve end flanges.
Table 4: Size of stopper bolts (Hexagon socket set screws)
Actuator type Bolt size
FBS－1 Ｍ6
Valve size (full-bore) L[mm]
NPS DN
3/8～ 3/4
1～11/2
2
10～ 20
25～40
50
5.0
5.5
6.0
Open side stopper bolt Closed side stopper bolt
Nut Nut
Fully closed
Half open from the
fully closed position
L L

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15. Mounting KITZ Optional Accessories on Actuators
KITZ FBS pneumatic valve actuator employs NAMUR dimensions for an accessory mounting pad on the
top. Any NAMUR dimensioned solenoid valve can be directly mounted on the actuator without tubing.
For detailed information on mounting KITZ optional accessories on FBS actuator, refer to the operating
instructions provided for each optional accessory.
◆ Mounting diagram of KITZ optional accessories
Positioner
Switch box Explosion-proof
limit switch
Potentio-meter box
Angle adjuster
Ball valve
Speed controller
FBS actuator
By-pass valve
By-pass valve Solenoid valve Filter regulator
Air exhaust reducing silencer Silencer
◆ Mounting view of KITZ optional accessories
Proximity Switch
Mechanical Limit Switch
By-pass Valve
Air-filter Regulator
Solenoid Valves
Speed Controller
Switch Box

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◆ Design specifications of KITZ optional accessories
Accessories Specification
NAMUR solenoid valves
Explosion proof
Weather proof indoor use
Weather proof outdoor use
Power supply
：AC100V／110V 50／60Hz
：AC200V／220V 50／60Hz
：DC24V
Air inlets：Rc1/4
Maximum working pressure：0.7MPa
Switch boxes
With built-in sensitive switches
With built-in proximity switches
Switch boxes with built-in sensitive switches
Resistive load ：11A AC125V／250V
：0.5A DC125V
：0.25A DC250V
Inductive load ：7A AC125/250V
Switch boxes with built-in proximity switches
Power supply ：DC10～36V
Maximum output current
（instantaneous and continuous）：200mA
Limit switches
Weather proof
Explosion proof
Weather proof ：10A－125V／250V／480V AC
：0.8A－125V／0.4A－250V DC
Explosion proof ：5A－125V／250V／480V AC
：0.8A－125V／0.4A－250V DC
Proximity switch Power supply ：20-250V AC／DC
Switching current：AC350mA／DC100mA
Air filter-regulator Working pressure：Inlet Max0.97MPa
：Outlet Max0.4～0.7MPa
Connection：Rc1/4
Speed controller Connection：Rc1/4
Maximum working pressure ：0.97MPa
Silencer Connection：Rc1/4
Maximum working pressure ：0.90MPa
Positioner Connection：Rc1/4（Pressure gauge：Rc1/8）
Supply pressure：0.3～0.7MPa
Signal pressure：0.02～0.10MPa
Signal current：4～20mA
Air consumption：20NL/min.(Max.)
[Supply pressure： 0.5MPa]
By-pass valve Connection ：Rc1/4 Maximum working pressure ：
0.7MPa

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16. Automated Operation of Actuators
16.1 KITZ FBS pneumatic valve actuator is operated with the standard air pressure of 0.4MPa , however,
can be set for operation with minimum 0.3MPa and maximum 0.7MPa air pressure. Actuators
equipped with air filter-regulators are set for operation with 0.4MPa.
16.2 Compressed instrumentation air ( or nitrogen gas ) is the standard operation medium. Use of air
filters and air dryers are recommended to keep the air in the housing dry and clean for trouble-free
operation of actuators.
16.3 Check the following points during pilot operation of your actuators.
(1) Check trouble-free function of an actuator by manually or automatically operating it a few cycles.
(2) Check air leakage from the air tubing through a travel from a compressor to the actuator. If the
operation mode of the equipped solenoid valve is changed from AIR-TO-OPEN to AIR-TO-CLOSE
or vice versa, the gasket connection between the solenoid valve and its adaptor must be also
checked for air leakage.
(3) Check if a solenoid valve is provided with your required specifications.
(4) Check if the operating pressure has been set with your required specification.
(5) Check if an equipped air regulator has been set for your required operation pressure.
(6) If a speed controller is equipped, adjust the flow rate of the exhaust air to match your required
operation speed.

Use either compressed instrumentation air or nitrogen gas for operation of
actuators. Use of any other operating medium may affect the function of
actuators.
 Use of operation pressure exceeding 0.7MPa may damage actuators or
accessories.
 Keep the operation medium completely dry. High humidity causes rust and may
result in malfunction or failure of actuators or accessories.
 A part to avoid entering water into a spring case (“Mizukiller”) is installed on
spring return type actuator’s breathing port. And The Mizukiller is sealed with a
sticker. Remove the sticker before running automated operation.
(For products shipped before December 2009, a cap is installed on spring return
type actuator’s breathing port instead of the Mizukiller. Remove the cap before
running automated operation. If the cap remains, actuator speed may become
slow.)

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When Type FBS spring return actuator is used outside or wet condition, water may enter into a
spring unit in some actuator orientation. Rotate a part avoiding entering water (“Mizukiller”)
clockwise and set it adequate position that open side tip of Mizukiller shall be upword.
(1) Actuator supply port faces upward.
(2) Actuator supply port faces ground.
(3) Actuator supply port feces side and spring case is upward.
(4) Actuator supply port faces side and spring case is downward.
Mizukiller
Open side tip shall be upward.
Open side tip shall be upward.
Open side tip shall be upward.
Open side tip shall be upward.
Nomal position of Mizukiller
Open side tip

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17. Manual Operation of Actuators
All KITZ optional solenoid valves are provided with a manual switch. Choose any one of the
following solenoid valves for manual operation of the actuators being energized.
① KOGANEI Model A180
Keep pressing a switch with the tip of a screwdriver for manual operation. Removal of the
screwdriver returns the actuator to the original automated operation mode.
② CKD Model 4F310
Rotate a knob for manual operation.
③ KANEKO Model MK15G
Pull out a switch for manual operation.
④ ASCO SCXD551
Set the position of a manual operation thread, with a screwdriver, to Position [O] of the indicator
for manual operation. Set it to Position [1] to energize the actuator for automated operation
mode.
18. Inspection and Maintenance of Actuators and Actuated Valves
18.1 Both actuators and actuated valves are designed for lubrication-free operation, and maintenance or
replacement of parts and components is not usually needed, except consumable sealing materials.
18.2 If aging or highly frequent use has caused malfunction or failure of actuators or actuated valves,
use KITZ genuine parts for replacement.
18.3 If actuators are equipped with air filter-regulators, periodically clean the bore of drain cocks to
remove all internal residues.
18.4 Replace sealing materials such as O-rings and gaskets, if any leakage is detected through sealed
connections of actuators and accessories.
18.5 If a lubricator is used, the quality of the lubricant must be appropriately controlled. We recommend
use of Turbine Oil Class 1 ISO VG32, or the equivalent for refill.
18.6 Seal washers are used for cylinder’s stopper bolts. Leakage may occur from the seal washers after
long-term use. Then retighten nuts or replace seal washers.

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18.7 Ensure to carry out the following inspections periodically. Do it as frequently as possible for safe
and trouble-free operation of actuators and actuated valves.
◇ Check the fully open or closed position of a valve.
◇ Ensure that the valve opening or closing range is correctly maintained in accurate response to a
signal currency or a signal pressure of actuators and accessories.
◇ Check the air leakage through all air tubing connections and valves.
◇ Check an abnormal noise generated from the air tubing or valves.
◇ Check vibration of actuators and valves.
◇ Ensure that all bolts and nuts are securely tightened.

Don
’
t use any spindle oil or gear oil for lubrication of actuators and accessories

An abnormal noise may be generated due to valve seat galling ( valve seats
getting stuck with foreign objects ) or blockage of actuator air tubing caused by
internal residues. Take corrective measures immediately, since damage of valve
seats and malfunction of actuators and valves may be caused by negligence of
such problems.
 Ensure to replace terminals of electric devices, if needed, with those designed
with the same specifications. Different design specifications could be a cause
of technical troubles.
 Leaving an abnormal vibration of actuators and valves also causes equipment
failure. Support the piping system securely.

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19. Disassembly and Reassembly of Actuators
19.1 When you disassemble or reassemble these actuators for inspection or maintenance, the utmost
care must be taken to respect the warnings and cautions mentioned here.

Before disassembly of spring cartridges from FBS actuator, evenly loosen all of 4
spring cover bolts ( but don’t completely remove them from the cover ) and check
if the spring has been released from the compression force and bolts can be
rotated by hand.
 If the spring cover bolts are found too tight to be rotated by hand, the spring still
remains energized, possibly due to damage of the spring cartridge or the housing
pressure remaining higher than the atmospheric level. In such a case,
disassembly work must be immediately discontinued to prevent the spring
cartridge from jumping out.
 If you have a concern of damage of a spring cartridge, securely retighten spring
cover bolts, and replace the actuator itself without removal of the spring cartridge.
 Before disassembling, loosen the hexagon headed bolt under air port to
depressurize the housing.
 A compressed heavy-duty spring is packed in a spring cartridge of FBS spring
return actuator. Careless disassembly of the cartridge may cause the spring to
jump out and result in damage of properties or injury of personnel. Don’t loosen a
retainer guide from the spring retainer.
 Don’t fall or step on a spring cartridge. Careless or rude handling may cause an
unintended separation of the highly energized spring from the cartridge.
 Don’t remove an end cover from a pressurized actuator housing. Disassembly of
any energized actuator is forbidden.
 Don’t use compressed air as the measure of disassembly of an actuator. A
piston may hazardously jump out.
Retainer guide
Spring retainer
Spring
Spring cover
Hexagon headed bolt

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19.2 Disassembly of KITZ FBS pneumatic valve actuator
(1) Make the air pressure the same as the atmospheric level.
(2) Gradually loosen all air tubing fittings and ensure that the housing pressure has been
equalized with the atmospheric level. Dismantle an actuated valve from the pipeline and
disassemble an actuator from the valve.
(3) Unthread a hexagon headed bolt and a seal washer near the solenoid valve mounting pad.
It is possible that piston O-rings are worn and cause air leakage and pressurize the interior
of the housing. Therefore, before working on disassembly of an actuator, gradually loosen
the hexagon headed bolt and check that the housing pressure has been equalized with the
atmospheric level ( Fig.5 ).
Fig.5
(4) Remove a snap ring (with snap ring pliers), a position indicator, headed screws and an
indicator plate (Fig.6).
Fig.6
Bolt <13B>
Seal washer <155B>
Snap ring <48B>
Indicator <97>
Bolt <39>
Indicator plate <98>

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(5) Remove the cover from the housing (Fig.7).
Fig.7
(6) Loosen bolts and remove the end cover and the spring unit. O-rings are placed inside
the end cover and the spring unit (Fig.8).
Fig.8
(7) Loosen a hexagon headed bolt and remove a piston from the housing, by picking an
outside rib with pliers (Fig.9).
Fig.9
Bolt <35B>
Cover <2C>
Piston bearing <67C>
Bolt <13A>
O
-
ring <45D>
Piston <117>
Housing <1>
Gear rack <103>
O
-
ring <45A>
End cover <2A>
O-ring <45F>
Bolt <35>
End cover <2A>
Spring unit