Linear Pneumatic Actuators - eDART · Linear Actuator Pneumatic Manual L-MAN-02-10 ∙ Issue 01 ∙ 23 AUG 2016 Page 2 of 35 NOTE Please read through this entire document before work

Linear Pneumatic Actuators

© Copyright 2016 LargeActuators.Com (PTY) LTD This document is subject to copyright. The content of this document may not be

copied or reproduced in part or full without the prior written consent of the owner.

ESA EDA EDT

Document No.: L-MAN-02-10

Document Title: Linear Actuator Pneumatic Manual

Document

Synopsis:

Linear Pneumatic Actuator Manual:

Product description,

Installation,

Operation,

Maintenance, and

Routine/periodic checks

Issue No.: 01 Date of Issue: 23 AUG 2016

Manufacturer

and Contact

Details:

Large Actuators.Com (Pty) Ltd

Unit 11, 25 Middle Road,

Anderbolt, Gauteng, South Africa.

www.LargeActuators.com

Tel. +27.11.894.4276email:

[email protected]

WARNING

This procedure has been developed for competent and trained

personnel to maintain the product.

This procedure should be reviewed by the customer before any

work is executed.

Should there be any conflict between the customer’s safe

working practices and other applicable procedures, and this

procedure, a resolution in writing shall be made before work

commences.

Linear Actuator Pneumatic Manual

L-MAN-02-10 ∙ Issue 01 ∙ 23 AUG 2016 Page 2 of 35

NOTE

Please read through this entire document

before work commences.

Table of Contents

1. Introduction ......................................................................................................... 3

2. Safety ................................................................................................................. 4

3. Product Details ..................................................................................................... 7

4. Required Equipment and Tools .............................................................................. 16

6. Removal of the Actuator ....................................................................................... 17

7. Disassembly of the Actuator .................................................................................. 18

8. Disassembly of the Fail Action Actuator (Spring) ...................................................... 20

9. Inspection .......................................................................................................... 22

10. Reassembly of the Actuator ................................................................................. 23

11. Pressure Test .................................................................................................... 26

12. Reassembly of a Standard Double Acting Actuator ................................................. 27

13. Reassembly of Spring Actuator Part One ............................................................... 27

14. Reassembly of an Internal Feedback Actuator ........................................................ 28

15. Reassembly of Spring Actuator Part Two ............................................................... 29

16. Internal Feedback Actuator Troubleshooting .......................................................... 30

17. Spare Parts ....................................................................................................... 31

18. Problems .......................................................................................................... 31

19. Document Revision Table .................................................................................... 31

Appendix 1. Capscrew Swap Out Procedure ................................................................ 32

Appendix 2. Retightening Band Clamps ...................................................................... 34

WARNING

Under no circumstances should the valve be lifted by the actuator.

This may cause damage to the actuator.

WARNING

Do not exceed 8 (eight) bar(g) working pressure



1. Introduction

This manual for actuator range provides the technical details of the product range.

Guidelines for the installation and operation aspects of the actuator plus detailed

instructions for the disassembly, maintenance and re-assembly the various actuator types

are given. Recommended checks are provided and a maintenance schedule is

recommended.

Two icons are used in this document to draw the reader’s attention to pertinent

information.

A warning sign to indicate where the reader should pay particular

attention for safety critical items,

And note symbol for additional information.

NOTE

Exchange units are available from the factory with full pressure test

certificate. These units are assembled by trained and certified technicians.

Please contact your sales representative or the factory.



2. Safety

2.1. Introduction

The purpose of this chapter is to assist in the related HAZOP studies and is not meant to be

a complete and final analysis.

It is very important to remember that actuators, when pressurised, contain a large amount

of energy since the working fluid is compressible.

Only suitably qualified persons to work on or maintain LargeActuators.Com actuators.

2.2. Installation Safety Issues

2.2.1. Initial Actions

All actuators have been pressure tested before leaving the factory to 9 bar – ~10% above

the maximum working pressure. If there is concern that any damage has occurred in

transit or in installation, then special care should be taken to pressurise the actuator to test

confirmation pressure under the strictest of supervision.

All site Health and Safety procedures shall apply and a risk analysis undertaken before any

actuator is pressurised for the first time. Please contact your sales representative if there

is any doubt.

2.2.2. Rigging Operations

Rigging equipment and lifting procedures are to be followed

It is important to ensure that the actuator is not used to lift the valve; the valve must have

its own rigging points. The smaller actuators (smaller than and including the 250) may be

lifted by hand, but larger actuators should be rigged using the lifting points provided.

Ensure that the unit is not damaged in any way before commissioning.



2.2.3. Fitting operations

All fasteners used to mount the actuator must be inspected for any defects and once

tightened; they must be inspected regularly to ensure it is still tight as it might vibrate

loose if there is any excessive vibration during operation.

Special attention needs to be paid to the length of the bolts mounting the actuator. There

must be sufficient engagement without bottoming out.

2.3. Commissioning Safety Issues

Before pressurising the actuator, all visual checks for defaults must be made. All personnel

must be warned and made to stand back before switching on.

Safety procedures for the use of compressed air are to be followed.

Ensure that first aid kit and fire equipment with trained personal is on site to ensure

prompt medical attention in case of an emergency.

2.4. Operation Safety Issues

2.4.1. Actuator operates unexpectedly

Visually inspect the units regularly to ensure the actuator is operating normally. If any

abnormalities are detected then the unit must be isolated and removed for through

inspection or replacement in the workshop.

Always disconnect air, signal and power before any work commences. Ensure actuator is

depressurised.

2.4.2. Pinch points

Although there are no pinch points in the actuator itself, the unit provides the locomotive

force for pinch points to occur.

Fingers and loose clothing need to be kept away from any moving parts. With the

equipment being under pressure it will cause serious injuries, broken bones and even

amputation should a body part or clothing get in contact with the moving parts.



2.4.3. Routine stroking

It is important to operate the actuator on a regular basis. If the normal duties do not

require the actuator to operate regularly it is recommended that a procedure is introduced

to stroke the actuator on a monthly basis.

The advantage of this is that cylinder lubrication is achieved and any possible problems

that may occur are identified before consequential damage can result.

2.5. Maintenance Safety Issues

Due consideration is to be given to the weight of the components before dismantling. The

unit from 250 and down can be handled by hand; those above 300 are to be lifted using

the lifting eye located on the body of the valve.

Any actuator that has been reassembled should be repressurised to an

appropriate/operational pressure before being brought back into operation.

All local safety rules and regulations with respect to safety clothes applicable, tools and

equipment used and methods of operation are to be adhered to.

2.6. Routine Checks

The following information is recommended to incorporate into the site routing maintenance

schedule:

Version Check Frequency Severity

All General corrosion/discolouration Biannually1 Mild

Loose mounting fasteners Biannually Mild

ESA Missing/broken radial capscrews2 Quarterly Severe

EDA Missing/broken band clamps3 Quarterly Severe

EDT Missing tie bar nuts Quarterly Moderate

1 Twice a year 2 Refer Appendix 1 – Capscrew Swap Out Procedure, page 32 3 Refer Appendix 2 – Retightening Band Clamps, page 34



3. Product Details

3.1. Naming Convention

The actuators are given a unique alphanumeric part number in the form:

TypeSize-Cylinder Length-Spring Option-Stem Thread Type

[-Internal Feedback]-Stroke[-B[Bottom Stroke Limit]][-Material][-Special]

3.1.1. Type

The first part of the code designates the type of actuator.

Version Visual Image Distinguishing Feature

ESA This was the first version and was manufactured from 2008 until approximately mid-2011.

This actuator is characterised by radial

capscrews. These attach the structural pressure retaining element of the design to the end plates

and thus should any of these capscrews be missing or corroded, then maintenance should be scheduled as soon as possible.

EDA This was the second version of the linear pneumatic actuator and was manufactured from approximately mid-2011 to early 2015.

This actuator is characterised by band clamps

and two outer covers. These attach the

structural pressure retaining element of the

design to the end plates and thus should any of

these bandclamps be missing or corroded, then

maintenance should be scheduled as soon as

possible.



Version Visual Image Distinguishing Feature

EDT This is the third version of the linear pneumatic actuator and has been manufactured from approximately late 2014.

This actuator is characterised by visible tie bars.

These attach the structural pressure retaining element of the design to the end plates and thus

should any of these tie bars/tie rods be missing or corroded, then maintenance should be scheduled as soon as possible

3.1.2. Size

LargeActuators.Com names the actuators according to the Internal Diameter of the

pneumatic cylinder:

Code Description Thread Size on stem Notes

160 Pneumatic Diameter: 160 mm M16 Standard Size





550 Pneumatic Diameter: 551 mm M36 Special



3.1.3. Cylinder Length

Each size of cylinder has a standard nominal length corresponding to the maximum stroke

possible:

Size Code (maximum stroke [mm]) Notes

160 105; 165 Spring Pack is only available

in 105mm stroke

200 175; 250 Spring Pack is only available

in 175mm stroke

250 280 Spring Pack is only available

in 280mm stroke

300 350; 450 There are only two standard strokes

on this model

400 490; 510; 585; 620; 700

550 680

The cylinder stroke may be changed, which effects the overall size of the actuator, or the

stroke may be limited using hard stops within the cylinder (see §3.1.7)

3.1.4. Spring Option

The following options for springs are offered:

Code Description Notes

DA Double Acting Air from the positioner is piped to both sides of

the piston.

BE Bias Fail Extended The actuator is still piped double acting for

superior control but the spring is used to

create a fail action normally assisted by the

flow direction over the plug. BR Bias Fail Retracted

HE Heavy Duty Fail Extended The Actuator is piped double acting but the

spring generates more force than in the bias

cases HR Heavy Duty Fail Retracted



3.1.5. Stem Thread Type

The Actuator stem may be configured with either a male or female thread:

Code Description Notes

M Male eDART valves with anti-rotation stem clamp

F Female Mainly used on standard industrial valves.

3.1.6. Internal Feedback

The internal feedback option uses a linear pot that runs down the centre of the actuator

shaft.

3.1.7. Stroke

The stroke may be limited by any amount by placing hard stops within the actuator. The

number stated here is the actual stroke of the actuator and it is assumed that the stop is

on the top of the piston. This means that the actuator stem all extend to the same

distance but retract to different distances according to the stroke limiter. These limiters

are called Top Stroke Limiters and all actuators have one. Even if the stroke is not limited

then the stroke limiter prevents the shaft from engaging the top plate and is long enough

to account for the Nylok Nut holding the piston together.

3.1.8. -B Bottom Stroke Limit

A bottom stroke limiter may also be added and is designated with a "-B". This number

corresponds directly with the amount by which the stem in the extended position is

reduced. If there is only a B and no number associated with it then it means that the

stroke is entirely limited by the bottom stroke limiter only. Actuators may have both Top

and Bottom Stroke Limiters.



3.1.9. Material

Should the material not be stated then the Standard (STD) is assumed. Most options have

Buna-N O-Rings and PTFE wear strips although Viton O-Rings may be employed.

Code STD 316

Pneumatic Barrel Glass Reinforced Plastic

End Plates S355JR Steel and

Electrogalvanised + E-Coated

StSt 316

Tie Bars and

fasteners

Galvanised Gr4.6 Mild Steel

Threaded Bar

StSt 316

Actuator Stem StSt 304 StSt 316

Wear Strip PTFE

O-Rings Buna-N / Viton

Piston ≤ 300: Anodised Aluminium

≥ 400: S355JR Steel + Galvanised

Cover StSt 304 StSt 316

Transducer Magnetic Linear Potentiometer

(for internal feedback versions).



3.2. Actuator Thrusts

The thrusts developed by the actuators are tabulated below.

Force

[tonnes]

Actuator Size

160 200 250 300 400 550

Pressu

re [

bar(g

)]

1 0.20 0.32 0.5 0.72 1.3 2.4

2 0.41 0.64 1.0 1.4 2.6 4.8

3 0.61 0.96 1.5 2.2 3.8 7.3

4 0.82 1.3 2.0 2.9 5.1 9.7

4.5 0.92 1.4 2.3 3.2 5.8 11

5 1.0 1.6 2.5 3.6 6.4 12

6 1.2 1.9 3.0 4.3 7.7 15

7 1.4 2.2 3.5 5.0 9.0 17

8 1.6 2.6 4.0 5.8 10 19

3.3. Free Air Volumes

The free air volumes required by the actuators are tabulated below.

Free Air

[litres]

Actuator Working Pressure [bar(g)]

stroke 1.0 bar 2.0 bar 4.0 bar 4.5 bar 5.0 bar 8.0 bar

Actu

ato

r S

ize

160 105 mm 4.2 l 6.3 l 10 l 11 l 13 l 19 l

165 mm 6.6 l 9.9 l 16 l 18 l 20 l 30 l

200 175 mm 11 l 16 l 27 l 30 l 33 l 49 l

250 mm 16 l 23 l 39 l 43 l 47 l 70 l

250 280 mm 27 l 41 l 68 l 75 l 82 l 120 l

300 350 mm 49 l 74 l 120 l 130 l 150 l 220 l

450 mm 63 l 95 l 160 l 170 l 190 l 280 l

400 490 mm 120 l 180 l 300 l 340 l 370 l 550 l

700 mm 170 l 260 l 440 l 480 l 520 l 780 l

550 680 mm 320 l 480 l 800 l 880 l 960 l 1400 l



3.4. Internal Construction

The general internal construction is shown below:

Please note the arrangement of bushes and wipers at the bottom.



3.5. Piston Construction

The piston construction for the two types is shown below. For 400 and above, the piston is

engineered and fabricated to reduce mass.

Size: ≤ 300 ≥ 400

Please note the use of the double O-Ring and the Wear Ring.



3.6. Nomenclature (illustrated with Internal Feedback)

CCG Housing

Linear Pot

Top Air Port

Top Plate

Top Ring

Cursor

Special Nut

Top stroke Limiter

Top Piston Plate

O-Ring

Wear Strip

O-Ring

Bottom Piston Plate

Actuator Model Number

indicating max stroke

Cover Tube

Front Plate

Serial Number

Bottom Ring

Bottom Air Port

Actuator Stem



4. Required Equipment and Tools

The following tools are required for the EDT actuator type.

Qty Tool Main Purpose

1 1 set of metric spanners

(13 mm – 21 mm)

Air Fittings require a variety of spanner sizes

depending on size, manufacturer and style.

1 4 mm Allen key Remove cover plate

1 Vice grip Hold the M12 threaded bar

1 13 mm spanner Remove the spring pack (if applicable)

1 19 mm spanner Remove nuts on M12 threaded bar

1 19 mm socket Tighten nuts on M12 threaded bar

1 32 mm spanner To tighten the linear pot.

1 Torque wrench To achieve correct tightening torque

~ Compressed Air To Repressurise the actuator for pressure test

~ Loctite (<10) For standard actuator versions

~ Copper compound For stainless steel actuator versions



6. Removal of the Actuator

Please read through this whole procedure before starting the disassembly.

1. Isolate air supply and de-energise actuator.

WARNING

Please pay particular attention to this – ensure that there is no air pressure

remaining in the actuator.

2. Disconnect air connections (and linkages of the positioner if appropriate, remove

positioner).

3. Remove stem clamp or unscrew actuator from connecting stem as appropriate.

4. Unscrew the bolts (or sometimes nuts if studs were used) holding the actuator to the

valve pedestal.



7. Disassembly of the Actuator

Please read through this whole procedure before starting the disassembly.

WARNING

Please ensure that there is no air pressure remaining in the actuator.

1. Remove air fitting from bottom port.

2. If spring pack is used, remove M8 nuts holding the self-contained spring unit onto

the top plate and lift the spring pack off. See section 8 below for complete

information regarding the addition steps when maintaining an actuator with a spring

pack.

WARNING

Ensure the spring is in the lowest energy state before loosening any

nuts, that is, make sure that nothing is preventing the actuator from

properly stroking under spring action.

WARNING

Do not attempt to open the spring unit as this could result in serious

injury or death. The spring is energised.

3. Remove the front plate by unscrewing the two M5 capscrews holding it in position.

4. Carefully remove the cover tube.

NOTE

If there is any damage please contact your sales representative for a

replacement.



5. Remove the M12 nuts at the top of each tie bar. Use vice-grips to prevent the

threaded bar from rotating.

6. Lift the top plate off the barrel. For the internal feedback actuator, be very

careful to slide the linear pot out of the hole down the centre of the actuator

stem.

7. Slide cylinder tube up off the bottom plate and piston.

8. Push out the piston sub-assembly from the bottom plate.

9. For the internal feedback actuator, undo the two capscrews holding the

cursor (this is necessary so the curser may be reset later).

10.If there is cause to suspect that the small O-Ring at the stem-piston interface is

faulty then remove nut from actuator stem and remove piston. However, this

normally causes more trouble than not, so it is advisable to skip this point and keep

the piston/stem intact.



8. Disassembly of the Fail Action Actuator (Spring)

Follow the steps given in §7 above to disassemble the actuator body. Read through this

whole procedure before starting the disassembly.

WARNING

The spring unit is self-contained. Do not attempt to open the spring

unit, failure to ignore this warning may result in serious injury or

death

Make sure that the BR or HR actuators are in the retracted position and BE or HE actuators

are in extended position before attempting to remove spring pack. This will indicated

whether the spring is in the low energy state. The different spring packs may be identified

from the model number on the tag plate and/or by taking off the polyurethane spring cap

and look for the nut on the buttons on the retracted versions (Red Circles on diagram

below).

Bias Retracted

(low energy)

Bias Extended

(energised)

HD Retracted

(low energy)

HD Extended

(energised)

(Blue circles show the M8 mounting bolts attaching the spring pack to the actuator)



1. The spring unit can be removed from the top plate by removing the M8 Nuts.

WARNING

Ensure the spring is in the lowest energy state before loosening any

nuts, i.e. make sure that nothing is preventing the actuator from

properly stroking under spring action

2. For the extended models, lift the push rod out from the actuator. For the Fail

Retracted models, the nut inside the top of the spring pack securing the tension rod

to the “Movable” spring button must be unscrewed.

3. The top plate contains a push rod O-Ring and a guide bush. These can be removed

by loosening the M8 set screws and removing the Guide Retainer Plate. Please

replace these bolts and use an adhesive (e.g. loctite) to provide the seal again.



9. Inspection

WARNING

Visually inspect the actuator for any damage. If any of the barrel,

end plates or tie bars (that is: the pressure containing components)

are in any way deformed or damaged,

DO NOT REUSE

Please scrap and contact your sales representative.

All parts must be inspected for wear and corrosion. Thoroughly investigate all worn parts

to determine the cause of the damage. The particular areas of these components that

need to be inspected include the following:

Component Criteria

Corrosion Wear Scoring

O-Rings

Bushes

Cylinder bore

Actuator Stem

End Plates

Tie Bars and Nuts

Any significant area of damage should be reported to your sales representative directly.

Clean all metal components with a suitable solvent (isopropanol or rubbing alcohol).



10. Reassembly of the Actuator

When servicing, the following parts should be replaced:

Piston O-Rings (use pneumatic grease to lubricate)

Cylinder end O-Rings

And if damaged:

Guide bushes

Actuator stem O-Rings

To replace these parts (skip steps if the piston hasn’t been disassembled):

1. Replace the small O-Ring and Bottom Guide Bush into the recess of the bottom plate.

2. Place the thin Guide Retainer plate into place.

3. Gently press the Wiper Bush into the Wiper Retainer and bolt to the bottom plate so as

to retain the Guide Retainer with its Guide Bush and Actuator Stem O-Ring

4. Hold the actuator stem on the flats at the bottom end in a soft jaw vice.

5. Fit the bottom piston plate (the one with the O-Ring recess) onto the actuator stem.

For the larger sizes, only one piston plate is required.

6. Insert piston stem O-Ring. Ensure the O-Ring is properly located.

7. Place the PTFE Wear Ring onto the bottom piston plate.

8. Replace top piston plate and the thin stroke limiter bracket. Tighten with the nut in

accordance with the torque table below. For the Heavy duty fail retracted version

the Tension Rod serves this purpose and the internal feedback actuator has a

special nut for the cursor.



Actuator Size Stem Torque

EDT 160 60 N∙m

EDT 200 140 N∙m

EDT 250 250 N∙m

EDT 300 420 N∙m

EDT 400 420 N∙m

EDT 550 790 N∙m

9. Insert the piston assembly into the bottom end plate - barrel assembly. Ensure the

bottom O-Ring does not get damaged. There are two bottom O-Rings on the larger

sizes.

10. Put light smear of silicon grease on the piston O-Rings and fit to the piston.

11. Replace the cylinder end O-Ring into groove on the bottom plate and apply a light

coating of silicon grease.

12. Apply liberal coating of grease to the bore of the cylinder with a soft blade. Please do

not score the bore.

13. Slide the cylinder tube over the piston and piston O-Ring. Do not damage the O-Ring.

14. Once the piston is located in the cylinder tube, straighten the tube and slide it onto the

lower end plate and over the O-Ring. Do not damage the O-Ring.

15. Replace the top stroke limiter pipe.

If a standard Double Acting Actuator is being assembled then proceed

to Section 11 point 1 after completing instructions given in point 15

here. You will return to point 16 below.

If a Spring is being assembled then proceed to Section 13 point 1

after completing instructions given in point 15 here. You will return

to point 16 below.

If an Internal Feedback Actuator is being assembled then proceed to

Section 14 point 1 after completing instructions given in point 15

here. You will return to point 16 below.



16. If applicable, fit the top ring over the top plate ensuring that the inclined surfaces mate

properly. Otherwise there will be a single end plate.

17. All the threaded bars should protrude through the holes in the plate.

18. Place a nut on each threaded bar and torque to:

Actuator Size

Tie Bar Torque

Standard

Use loctite

Stainless Steel

Use copper compound

EDT 160 25 N∙m 25 N∙m

EDT 200 25 N∙m 25 N∙m

EDT 250 25 N∙m 25 N∙m

EDT 300 30 N∙m 30 N∙m

EDT 400 30 N∙m 30 N∙m

EDT 550 30 N∙m 30 N∙m

First hand tighten each nut and then use the standard cross shaped bolt tightening

procedure to ensure an even and uniform tension on the ring. See

tinyurl.com/BoltTighteningProcedure for an in depth explanation.

19. Repeat tightening sequence to the correct torques with the second lock nut.

20. Position and fasten in place the cover tube and the cover plate.

If a Spring is being assembled then proceed to Section 14 point 1

after completing instructions given in point 20. You will return to

point 21 directly below.

21. Stroke the actuator to ensure smooth operation of the actuator. Should the piston not

operate smoothly please repeat procedure from step 13 or call sales representative for

further assistance.

WARNING

Do not exceed 8 (eight) bar(g) when pressurizing the cylinder except

when pressure testing

NOTE

Please visually inspect the actuator for any defects or damage

http://tinyurl.com/BoltTighteningProcedure



11. Pressure Test

At this point it is necessary to pressure

test the actuator.

It is required that the unit is, at least

cordoned off, but preferably caged, and

pressurised to 9 bar with air (10%

greater than maximum working

pressure).

Please be very careful that people in the

vicinity are fully aware that this step is

being executed.

Please do a full HAZOP as per your

standard operation procedures.

Once an independent witness has verified

the pressure, please mark the unit that

it been tested for a maximum of

8 bar

Please contact LargeActuators.Com for any queries regarding this step

Tel. +27.11.894.4276

email: [email protected]



12. Reassembly of a Standard Double Acting Actuator

Follow the steps to reassemble an actuator given in Section 10 until

point 15.

1. Fit the top plate O-Ring into the groove of the top plate and apply a light smear of

grease. Fit plate onto the cylinder tube, ensure that the top and bottom air fittings

are aligned. Slide the recessed part of the top plate into the cylinder tube until the

lip of the top plate rests on the cylinder tube. Make sure not to damage the O-Ring.

Now return to Section 10 point 16 after completing instructions given

in point 1.

13. Reassembly of Spring Actuator Part One


point 15.

1. When reassembling the top plate, insert the O-Ring and top guide into the recess.

Hold in place using the retaining plate and the M8 set screws. Use loctite on the

setscrews to create the pneumatic seal. Tighten evenly.

2. Ensure that there is a Top Stoke Limiter on piston nut. All spring units have this – it

will be a minimum of 35mm long.

3. Depending on the model, insert the bias spring push rod for the fail extended version

or for the retracted versions screw the tension rod on top of the actuator stem.

4. Fit the top plate O-Ring and apply a light smear of grease. Fit plate onto the

cylinder tube ensuring the push, or tension, rod is still located. Please ensure that

the air fittings, top and bottom, line up.


in point 4.



14. Reassembly of an Internal Feedback Actuator


point 15.

1. Fit the top plate O-Ring into the groove of the top plate and apply a light smear of

grease.

2. Insert the cap screws into the cursor.

3. Slide the magnet over the internal pot stem

4. Slide the magnet all the way to the top of the pot stem and into the retainer. This

resets the pot.

5. Slide the magnet down to about 5cm from the bottom of the pot stem and let it go.

Ensure that this is done while resting the pot on a solid surface to prevent the

magnet from accidently sliding off the pot stem.

6. The magnet should slide until ± 2cm from the bottom of the pot stem and stop. If it

does not it has not be re-set properly.

7. If it has not been reset properly go back to step 3.

8. Fit plate onto the cylinder tube, ensure that the top and bottom air fittings are

aligned. Slide the recessed part of the top plate into the cylinder tube until the lip of

the top plate rests on the cylinder tube. Make sure not to damage the O-Ring.


in point 8.



15. Reassembly of Spring Actuator Part Two


point 20 (including Section 11)

1. Replace the spring pack.

a. For the Retracted version, ensure the push rod is located in the hole on the

spring pack bottom, then fasten the nut on the stud in the top of the tension

rod so that the "movable" spring button is held in place.

b. For the extended version the piston will need to be pushed down into the

extended position

2. Replace and tighten the M8 nuts. This will add pre-compression to the spring pack.

3. For the retracted versions, put the Spring Pack PU cap back into place.


in point 3.



16. Internal Feedback Actuator Troubleshooting

The following steps should be taken to assist in the troubleshooting process.

1. Unplug the field cable from the CCG box.

2. Apply air to the bottom of the actuator so that the actuator moves into the fully

retracted position. Remove the air.

3. With no air on the actuator, loosen the CCG box mounting screws and carefully

lift the CCG box from the actuator.

4. Loosen the screws on the internal pot retaining plates and remove the retaining

plates. Gently pull the internal pot out of the actuator.

5. Now insert the pot back into the actuator and push it down until the bottom O-

ring is inside the top of the actuator.

6. Install the pot retaining plates and tighten the screws.

7. Connect a multi-meter selected on the 20K scale between the blue and yellow

wires. The reading should be between zero and a few ohms.

8. Connect a multi-meter selected on the 20K scale between the blue and brown

wires. The reading should be approximately five kilo ohms.

9. Apply air to the top of the actuator so that the actuator fully extends.

10. Connect a multi-meter selected on the 20K scale between the blue and yellow

wires. The approximate reading depends on pot length.

Pot Length mm 50 – 300 350 – 600 650 – 1,000

Resistance kΩ 5 10 20

11. Connect a multi-meter selected on the 20K scale between the blue and brown

wires. The reading should be between zero and a few ohms.

If the above checks out then the internal pot is correct. Fit the CCG box, connect through

to the positioner, connect air lines and test. All should work. If not, check the continuity

of all cables between the CCG box and the positioner.



17. Spare Parts

The actuator has been designed to withstand high pressures, fit only original equipment

manufacturers spare parts. Failure to do so could result in the actuator failing.

18. Problems

For any problems please contact LargeActuators.com directly on –

Tel. +27 (0)11 894 4276, or

email: [email protected]

19. Document Revision Table

Iss Date Edited Changes Approved Date

01 2016-08-23 NS Combined documents

L-MAN-02-01/04/07/09



Appendix 1. Capscrew Swap Out Procedure

Appendix 1.1. Introduction

This procedure is only applicable to the ESA style of actuator; below is a representation of

what the ESA’s look like:

Appendix 1.2. Problem

Missing Capscrews for any reason

Corrosion on capscrews due to slurry spillage or general exposure to atmosphere

Appendix 1.3. Notes

Urgently replace all missing capscrews.

If a capscrew shears or breaks off in the plate and a new capscrew cannot be

inserted, remove actuator and send back to LargeActuators.Com to overhaul.

Remove one capscrew at time and replace so that there is only one

capscrew missing at any point.

Cover ends

flush with top

Visible radial

capscrew

heads



Appendix 1.4. Procedure

Clean the actuator with a damp cloth and wipe off all build-up around existing

capscrews.

Blow out all debris in the tapped holes with compressed air.

Insert new stainless steel Capscrews in tapped holes in currently missing screw

holes. Use loctite to ensure the capscrews will not loosen with vibration. Tighten

properly by hand.

Starting with the capscrews around the top of the actuator, take a single old

capscrew out. Blow the hole with compressed air to clear all debris. Replace with a

stainless steel capscrew using loctite to ensure tightness.

Repeat procedure of exchanging capscrew on opposite side.

Repeat by working around the top of the actuator (alternating sides) and then the

bottom screws of the actuator.

Appendix 1.5. Additional tool and equipment requirements

Qty Description

1 Size 4mm Allen Key

1 Size 5mm Allen Key

Actuator Size Capscrew Qty Capscrew Size

160 16 M5 x 12

200 16 M6 x 16

250 20 M6 x 16

300 44 M6 x 16

400 52 M6 x 16

WARNING

If anything is uncertain, please contact LargeActuators.Com

immediately on +27.11.894.4276



Appendix 2. Retightening Band Clamps

Appendix 2.1. Introduction

This procedure is only applicable to the EDA style of actuator; below is a representation of

what the EDA’s look like:

The following table gives the required torque and tools required (the size should be

correlated with the actuator size on the following page):

Bolt Size

(Metric)

Specified

Torque

Allen

Key

Spanner

Jaw size

Spanner

Length

Mass-force applied

at end of spanner

M8 20 Nm 6 13 125 mm 16 kg

M10 20 Nm 8 17 145 mm 14 kg

M12 36 Nm 10 19 165 mm 22 kg

M16 60 Nm 14 24 205 mm 30 kg

A video procedure may be found at: http://tinyurl.com/bandclamps



Appendix 2.2. Procedure

1. Obtain lockout / permission to work

2. Ensure air supply is removed/isolated

3. Depressurise actuator

4. Record actuator serial number and size of actuator

5. Band clamp:

a. Tighten band clamp nylok nut to specified torque

b. Tap the strap around perimeter five times with a rubber mallet

c. Repeat until nylok nut does not tighten further

6. Measure the gap between band clamps – record value

7. Confirm that the gap is in the allowable range (if not, isolate actuator, carry on

checking other actuators, and inform LargeActuators.Com)

8. Put on second nut and tighten to specified torque

9. Apply dab of paint (e.g. Loctite Torque Marque) to the torqued nuts to indicate that

the check has been carried out.

10.Reconnect air



Actuator Size Band Clamp Bolt Maximum Gap Size Specified Torque

EDA160 M8 ≤ 12 mm 20 Nm

EDA200 M8 ≤ 12 mm 20 Nm

EDA250 M10 ≤ 15 mm 20 Nm

EDA300 M10 ≤ 14 mm 20 Nm

EDA400 M16 ≤ 15 mm 60 Nm

Appendix 2.3. Additional tool and equipment requirements

Qty Description

1 ea Size 6 mm, 8 mm, 10 mm, 14 mm Allen Key

1 ea Size 13 mm, 17 mm, 19 mm, 24 mm Spanner/Wrench

! Loctite Torque Marque

If the gaps exceed the maximum, please isolate the actuator

and advise LargeActuators.Com immediately on

+27.11.894.4276

Band Clamp gap Second Nut on Band Clamp

Linear Pneumatic Actuators - eDART · Linear Actuator Pneumatic Manual L-MAN-02-10 ∙ Issue 01 ∙ 23 AUG 2016 Page 2 of 35 NOTE Please read through this entire document before work

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