COMPAK™ACTUATOR© 1998 DeZURIK, A unit of General Signal                                           Instruction D–10371     ...
DeZURIK® COMPAK™ ACTUATORUse of Instructions             USE OF      These instructions provide installation, operation, a...
DeZURIK® COMPAK™ ACTUATORTable of Contents             TABLE OF   Description . . . . . . . . . . . . . . . . . . . . . . ...
DeZURIK® COMPAK™ ACTUATORDescription        DESCRIPTION     The DeZURIK Compak™ Actuator is an enclosed rack and pinion cy...
DeZURIK® Compak™ Actuator                                                                                                 ...
DeZURIK® COMPAK™ ACTUATOROpen and Closed Position Stops OPEN AND CLOSED           Model CM Stops   POSITION STOPS         ...
DeZURIK® Compak™ Actuator                                                                               Open and Closed Po...
DeZURIK® COMPAK™ ACTUATORFastener Torques            FASTENER             TORQUES                       Table A: Fastener ...
DeZURIK® Compak™ Actuator                                                                          Removing Acuator from V...
DeZURIK® COMPAK™ ACTUATORActuator Disassembly          ACTUATOR     Follow the steps below to disassemble the actuator for...
DeZURIK® Compak™ Actuator                                                                                      Actuator Re...
DeZURIK® COMPAK™ ACTUATORActuator Reassembly         ACTUATOR          5. Position the two pistons (B2) as noted during di...
DeZURIK® Compak™ Actuator                                                                    Piston and Pinion Configurati...
DeZURIK® COMPAK™ ACTUATORMounting Actuator on Valve         MOUNTING            Follow the steps below to mount the actuat...
DeZURIK® Compak™ Actuator                                          Changing Actuator From Double–Acting to Spring–to–Close...
DeZURIK® COMPAK™ ACTUATORChanging Actuator From Double–Acting to Spring–to–Open       CHANGING          Follow the steps b...
DeZURIK® Compak™ Actuator                                         Changing Actuator From Spring–to–Close To Double–Acting ...
DeZURIK® COMPAK™ ACTUATORChanging Actuator From Spring–to–Open To Double–Acting         CHANGING        Follow the steps b...
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De zurik actuator molykote 44 grease

  1. 1. COMPAK™ACTUATOR© 1998 DeZURIK, A unit of General Signal Instruction D–10371 July 1998
  2. 2. DeZURIK® COMPAK™ ACTUATORUse of Instructions USE OF These instructions provide installation, operation, and maintenance information for INSTRUCTIONS DeZURIK Compak™ Actuator. They include procedures which, when carefully fol- lowed, help to assure satisfactory performance of this product. All warnings and cau- tions included in these instructions must be followed to avoid personal injury and equipment damage. These instructions are intended for use by personnel who are responsible for the installation, operation or maintenance of a DeZURIK Compak™ Actuator. Refer to the Data Plate attached to the valve, and also to the Product Bulletin for infor- mation regarding materials of construction and product limitations. SAFETY MESSAGES Safety messages in these instructions and on the label(s) on the valve are flagged with one of the words Caution, Warning or Danger. The messages must be carefully read and followed to avoid personal injury and/or equipment damage. After installation, if a safety label on the actuator becomes difficult to see or read, or if a label has been removed, please contact DeZURIK for replacement label(s). Include the 7-digit part number from the data plate on the actuator, the quantity of actuator, and an appropriate name and mailing address. INSPECTION This unit has been packaged to provide ample protection during shipment. However, if the unit is mishandled in transit, it could sustain damage. Upon arrival at its final desti- nation, the unit should be carefully inspected for damage. If damage exists, a damage claim should be filed immediately with the carrier. STORAGE Units should be stored in a clean, cool and dry location, and should be protected from dirt, paper stock, dust, and other contaminants. If outdoor storage is necessary, the unit should be wrapped in plastic and stored high enough so that it will not be immersed in water or buried in snow. REPLACEMENT Recommended spare parts are listed on the ACTUATOR ASSEMBLY DRAWING. These PARTS parts should be stocked to minimize downtime. If four or more actuators are in use, it is advisable to stock one complete actuator as a spare. Replacement parts may be ordered from the local DeZURIK sales representative, or directly from DeZURIK, as listed on the back cover. DeZURIK SERVICE DeZURIK service personnel are available for start-up and repair of DeZURIK products. DeZURIK also offers customized training programs and consultation services for cus- tomers. Contact a DeZURIK sales representative or visit our website at www.dezurik.com for more information.July 1998 D–10371
  3. 3. DeZURIK® COMPAK™ ACTUATORTable of Contents TABLE OF Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CONTENTS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installation Model CMD Spring–Return Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Model CMD Double–Acting Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model CM Double–Acting Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Open and Closed Position Stops Model CM Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Model CMD Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Model CMD Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removing Acuator from Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Actuator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Actuator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Spring Quantities and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Piston and Pinion Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Mounting Actuator on Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Changing Actuator Action From Double–Acting to Spring–to–Close . . . . . . . . . . . . . . . . . . . . . . . . 13 From Double–Acting to Spring–to–Open . . . . . . . . . . . . . . . . . . . . . . . . 14 From Spring–to–Close to Double–Acting . . . . . . . . . . . . . . . . . . . . . . . 15 From Spring–to–Open to Double–Acting . . . . . . . . . . . . . . . . . . . . . . . . 16 Changing Mounting Position of Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16July 1998 D–10371
  4. 4. DeZURIK® COMPAK™ ACTUATORDescription DESCRIPTION The DeZURIK Compak™ Actuator is an enclosed rack and pinion cylinder actuator that provides on-off or modulating control on quarter-turn valves. Several actuator sizes are offered. The Compak™ is available as a double-acting actuator or as a spring-return actuator, either spring-to-open or spring-to-close. The double-acting model is convert- ible to spring-return, and vice versa. The spring action is reversible. OPERATION The Compak™ Actuator is powered pneumatically, and rotates 90 degrees between the open and closed positions, in the direction as described below. Actuators are sized for either 60 or 80 psi. (415 or 550 kPa). All actuators are limited to a maximum pressure of 150 psi (1000 kPa). INSTALLATION Pneumatic connections are required as described below. Connections are 1/8" NPT on actuator sizes through M103, and are 1/4" NPT on sizes M148 and larger. Model CMD Spring–Return Actuator The spring-return actuator requires one pneumatic connection to the open (left-side) on the side of the actuator. A breather is in the other (right-side) port. As the spring-return actuator is cycled, air is alternately drawn in and exhausted through the breathers. The breather must be protected from water because water inside of the actuator will cause sticking and premature wear of the internal components. With a SPRING-TO-OPEN actuator, air to the connection drives the actuator clockwise, towards the CLOSED position of the valve. See Figure 1. Figure 1—Model CMD Air Connection Spring-to-Open With a SPRING-TO-CLOSE actuator, air to the connection drives the actuator counterclock- wise, towards the OPEN position of the valve. See Figure 2. Figure 2—Model CMD Air Connections Spring-to-CloseJuly 1998 Page 1 of 15 D–10371
  5. 5. DeZURIK® Compak™ Actuator Lubrication INSTALLATION Model CMD Double–Acting Actuator (CONTINUED) The model CMD double–acting actuator requires two pneumatic connections—one to each of the two ports on the side of the actuator. Air to the left-side port drives the actuator counterclockwise, towards the OPEN position of the valve. Air to the right-side port drives the actuator clockwise, towards the CLOSED position of the valve. See Figure 3. Figure 3—Model CMD Air Connections Double–Acting Actuator Model CM Double–Acting Actuator The model CM double–acting actuator requires two pneumatic connections—one to each of the two ports on the side of the actuator. Air to the left-side port drives the actuator clockwise, towards the CLOSED position of the valve. Air to the right-side port drives the actuator counterclockwise, towards the OPEN posi- tion of the valve. See Figure 4. Figure 4—Model CM Air Connections LUBRICATION The actuator is lubricated at the factory, and does not require routine maintenance lubri- cation. If the actuator is disassembled, lubrication is required—See “Actuator Reassem- bly” on page 8. OPEN AND CLOSED The open and closed position stops prevent the actuator from rotating beyond the open POSITION STOPS and closed positions of the valve. If the actuator is factory–mounted on the valve, the stops are preset, and do not require further adjustment. If the actuator is not factory-mounted on the valve, or if the actuator is removed and/or disassembled, the stops will require adjustment as described below. Refer to the VALVE INSTRUCTIONS for closed-position information, and adjust the stops after the actuator is mounted on the valve. The location of the stops on various actuator configurations is shown in the accompanying figures.July 1998 Page 2 of 15 D–10371
  6. 6. DeZURIK® COMPAK™ ACTUATOROpen and Closed Position Stops OPEN AND CLOSED Model CM Stops POSITION STOPS The closed position stop on a CM double–acting actuator is adjusted by following the (CONTINUED) steps below. Note: The OPEN POSITION STOP is not adjustable. 1. Loosen the two sealing nuts (B13). One nut is located on each end of the actuator. 2. Disconnect air pressure from the actua- tor, thus allowing the actuator to move against the closed position stops. 3. Adjust the two travel stops (B14) so that the actuator positions the valve in the fully closed position. Note: Turn the stops clockwise to decrease the stroke, or counter- clockwise to increase the stroke. Adjust the stops so that the torque feels approximately the Figure 5—CM Stop Adjustment same on both travel stops. 4. While holding either one of the travel stops from turning, tighten its sealing nut as shown in Table A. (See pg. 5) 5. Repeat for the other travel stop and sealing nut. Model CMD Stops—Left–Hand Side Both the open and the closed position stops on a CMD actuator are adjustable. The stop on the LEFT END of the CMD actuators (as shown in figure 8, pg. 8) is adjusted by following the steps below. 1. Loosen the sealing nut (B13) on the left end of the actuator. 2. Apply or relieve air pressure to the actua- tor so that the actuator moves to the posi- tion indicated by the stop on the left end of the actuator. 3. Adjust the travel stop (B14) so that the actuator positions the valve in the appro- priate fully open or closed position. Note: Turn the stop clockwise to decrease the stroke, or counter- clockwise to increase the stroke. Figure 6—CMD Stop Adjustment 4. While holding the travel stop from turn- Left–Hand Side ing, tighten its sealing nut to the torque in Table A. (See pg. 5) (Continued)July 1998 Page 3 of 15 D–10371
  7. 7. DeZURIK® Compak™ Actuator Open and Closed Position Stops OPEN AND CLOSED Model CMD Stops—Right–Hand Side POSITION STOPS The stop on the RIGHT END of the CMD actuators (as viewed in figure 8, pg. 8) is (CONTINUED) adjusted by following the steps below. 1. Remove the knurled cap (B22) from the right end of the actuator. 2. Remove the jam nut (B23) from the adjustment shaft (B24). 3. Apply or relieve air pressure to the actuator so that the actuator moves to the position indicated by the stop on the right end of the actuator. 4. Turn the adjustment nut (B23) so that the actuator positions the valve in the appropriate fully open or closed position. Note: Turn the nut clockwise to Figure 7—CMD Stop Adjustment Right–Hand Side decrease the stroke, or counterclockwise to increase the stroke. 5. Stroke the actuator to the opposite position so that the adjustment nut is accessible; hold the adjustment nut in position, and turn the jam nut against the adjustment nut. 6. Tighten the jam nut to correct torque. See Table A, “Fastener Torques,” on page 5. 7. Replace the knurled cap on the right end of the actuator. 8. Hand tighten the cap firmly to prevent air from leaking through the seal on the cap.July 1998 Page 4 of 15 D–10371
  8. 8. DeZURIK® COMPAK™ ACTUATORFastener Torques FASTENER TORQUES Table A: Fastener Torques Stainless Steel Grade 2 Carbon Steel Fastener Size Foot Newton Foot Newton Pounds Meters Pounds Meters 26 ± 4 2.9 ± 0.5 10-32 40 ± 5 4.5 ± 0.6 inch pounds inch pounds 45 ± 6 1/4-20 5.1 ± 0.7 7±1 9±1 inch pounds 5/16-18 8±1 11 ± 1 14 ± 2 19 ± 3 3/8-16 15 ± 2 20 ± 3 26 ± 3 35 ± 4 7/16-14 24 ± 4 33 ± 5 41 ± 3 56 ± 4 1/2-13 38 ± 5 52 ± 7 63 ± 8 85 ± 11 5/8-11 77 ± 10 104 ± 14 130 ± 20 176 ± 27 3/4-10 140 ± 18 190 ± 24 230 ± 30 312 ± 41 47 ± 6 M5 X 0.8 5.3 ± 0.7 inch pounds 78 ± 10 M6 X 1 8.8 ± 1.1 inch pounds M8 X 1.25 16 ± 2 22 ± 3 Not Applicable M10 X 1.5 33 ± 4 45 ± 5 M12 X 1.75 58 ± 8 79 ± 11 M14 X 2 93 ± 12 126 ± 16 M16 X 2 150 ± 20 203 ± 27July 1998 Page 5 of 15 D–10371
  9. 9. DeZURIK® Compak™ Actuator Removing Acuator from Valve REMOVING For component identification, see Figure 8—pg. 9. ACUATOR FROM VALVE Flow in the pipeline with the actuator removed can allow the valve to slam closed and cause personal injury and/or damage to the flow system. Shut down the flow in the pipeline before removing the actuator from the valve. 1. Shut down the flow in the pipeline. Moving parts from unexpected operation of a powered actuator can cause personal injury or equipment damage. Disconnect and lock out power to the actuator before servicing. 2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental operation of the actuator. 3. Remove the four mounting screws that fasten the actuator to the valve or bracket. 4. Remove the actuator from the valve by lifting the actuator from the valve shaft.July 1998 Page 6 of 15 D–10371
  10. 10. DeZURIK® COMPAK™ ACTUATORActuator Disassembly ACTUATOR Follow the steps below to disassemble the actuator for replacing repair kit parts. To DISASSEMBLY identify components, Figure 8 on page 8. Repair kit parts are marked * in Figure 8. Loaded springs are retained under each end cap on spring-return actuators. To prevent personal injury and equipment damage, loosen the end cap screws slowly and evenly so that the springs are fully relaxed before removing the screws. 1. Remove the actuator from the valve. See “Removing Acuator from Valve” on page 6. 2. WITH A DOUBLE-ACTING ACTUATOR: a. Remove the four screws (B16) on each of the two end caps (B4) and remove the end caps. b. Note the location and position of each end cap so that the end caps can be later reassembled in the same configuration. WITH A SPRING-RETURN ACTUATOR: a. To prevent personal injury and equipment damage, loosen the four screws (B16) slowly and evenly on each of the two end caps (B4) so that the springs inside are fully relaxed before removing the screws and end caps. b. Note the location and position of the end caps and springs (B5) so that the end caps and springs can be later reassembled in the same configuration. 3. Rotate the pinion (B3) as required to move the two pistons (B2) apart as far as possible. Pull and remove each piston from the body. Use pliers if necessary, but do not damage the sealing surfaces. Note the location and position of each piston so that the pistons can be later reassembled in the same configuration. 4. Remove the snap ring (B9) and washer (B10) from the top of the pinion (B3). 5. With the actuator located on two blocks of wood, tap the top of the pinion lightly with a rubber mallet to loosen the pinion; then remove the pinion through the bot- tom of the actuator. 6. Remove the following parts (marked * in Figure 8) to be replaced by repair kit parts: ✦ Upper (B7) and lower (B8) pinion guides ✦ Piston guide skate (B11), one each ✦ Guide ring (B12), two each ✦ Piston O-ring (B17) and end cap O-ring, two each ✦ Upper (B19) and lower (B20) pinion O-rings, one eachJuly 1998 Page 7 of 15 D–10371
  11. 11. DeZURIK® Compak™ Actuator Actuator Reassembly Figure 8—Component Identification ACTUATOR Follow the steps below to reassemble the actuator. Clean and inspect all parts before REASSEMBLY reassembly. Lubricate all seals, bearing surfaces, cylinder walls, and gear teeth with Dow Corning Molykote 44 grease or equivalent. Note: Repair kit parts are marked * in Figure 8 and also below, and should be replaced during reassembly. 1. Place the upper (B7*) and lower (B8*) guides and the upper (B19*) and lower (B20*) O-rings on the pinion (B3) and insert the pinion into position through the bottom of the body (B1). 2. Place the washer (B10*) and snap ring (B9*) on the top end of the pinion. 3. Place a piston guide skate (B11*), a piston guide ring (B12*), and an O-ring (B17*) in position on each of the two pistons (B2). 4. Rotate the pinion (B3) so that the flat on top of the pinion is approximately 30 to 40 degrees beyond the open position (closed position for spring-to-open actua- tors). Refer to Figure 10 on page 10 for pinion flat positions at the open and closed positions.July 1998 Page 8 of 15 D–10371
  12. 12. DeZURIK® COMPAK™ ACTUATORActuator Reassembly ACTUATOR 5. Position the two pistons (B2) as noted during disassembly, and insert the pistons REASSEMBLY equally into the ends of the body (B1) until both pistons begin to mesh with the (CONTINUED) pinion. Apply equal force on each position to rotate the pinion to the closed posi- tion (open position for spring-to-open actuators). 6. Ensure that the pinion flat is perpendicular with the actuator at the closed position as shown in Figure 10 on page 10; if not, remove the pistons and repeat steps 3 and 4, using an appropriate angle in step 3. 7. Place an O-ring (B18*) in the groove in each of the two end caps (B4). 8. WITH A SPRING-RETURN ACTUATOR: a. Place the springs (B5) in each of the two end caps (B4) in the configuration noted during disassembly, and also shown in Table B and Figure 9. b. Align the springs and end caps with the mating spring locations in the pistons. c. Ensure that the straight section of the end cap O-ring is toward the top of the actuator. d. Mount each end cap to the actuator with four screws (B16). Figure 9—End Cap Spring e. Tighten the screws alternately and evenly as shown in Locations Table A. (See pg. 5) *As viewed from inside actuator WITH A DOUBLE-ACTING ACTUATOR: a. Align the end caps with the ends of the actuator. b. Ensure that the straight section of the end cap O-ring is toward the top of the actuator. c. Mount each end cap to the actuator with four screws (B16). d. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5) Table B: Spring Quantities and Locations Quantity of Springs, Each Spring Locations End Cap 2 1 and 4 3 1, 3, and 5 4 2, 3, 5, and 6 1, 3, 4, 5, and 6—LEFT* END CAP 5 1, 2, 3, 4, and 6—RIGHT* END CAP 6 All 6 * As viewed from actuator port sideJuly 1998 Page 9 of 15 D–10371
  13. 13. DeZURIK® Compak™ Actuator Piston and Pinion Configuration PISTON AND PINION CONFIGURATION Figure 10—Piston and Pinion Configurations for CMD Double–Acting and Spring–Return Actuators Figure 11—Piston and Pinion Configurations for CM Double–Acting Actuators Note: In All Configurations, the air port on the LEFT SIDE (As viewed in Figure 8 on page 8) is common to the center pinion chamber; the air connection port on the RIGHT SIDE is commmon to the two end cap chambers.July 1998 Page 10 of 15 D–10371
  14. 14. DeZURIK® COMPAK™ ACTUATORMounting Actuator on Valve MOUNTING Follow the steps below to mount the actuator on the valve. ACTUATOR ON 1. Place the actuator in the same position as the valve-either open or closed. VALVE 2. Select one of the four mounting positions shown on the INSTALLATION DRAWING. Note: The standard position is with the actuator parallel with the pipeline. 3. Fasten the actuator to the mounting plate or bracket with four screws and washers as shown on the INSTALLATION DRAWING. 4. Tighten the screws as shown in Table A. (See pg. 5) 5. Align the actuator shaft coupling with the valve shaft and slide the actuator into position. 6. Fasten the actuator mounting plate to the valve with four screws and washers as shown on the INSTALLATION DRAWING. 7. Tighten the screws as shown in Table A. (See pg. 5) 8. Adjust the actuator stops, if necessary. See “Open and Closed Position Stops” on page 2. 9. Operate the actuator and valve three full cycles to demonstrate that the unit oper- ates smoothly in both directions with the appropriate 60 or 80 psi (415 or 550kPa) air pressure. 10. Re-connect the pneumatic connections. Pipeline flow may be resumed.July 1998 Page 11 of 15 D–10371
  15. 15. DeZURIK® Compak™ Actuator Changing Actuator From Double–Acting to Spring–to–Close CHANGING Follow the steps below to change a double-acting actuator to a spring-to-close spring- ACTUATOR FROM return actuator. Before proceeding, obtain one breather and also the required size andDOUBLE–ACTING TO quantity of actuator springs. See “Component Identification” on page 8. SPRING–TO–CLOSE Flow in the pipeline with the actuator disconnected can allow the valve to move unexpectedly, and can cause personal injury and/or damage to the flow system. Shut down the flow in the pipeline before servicing the actuator. 1. If the actuator is on a valve, shut down the flow in the pipeline, and close the valve. Moving parts from unexpected operation of a powered actuator can cause personal injury or equipment damage. Disconnect and lock out power to the actuator before servicing. 2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental operation of the actuator. 3. Remove the four screws (B16) on each of the two end caps (B4) and remove the end caps. Note the location and position of each end cap so that the end caps can be later reassembled in the same configuration. 4. Place the springs (B5) in each of the two end caps (B4) in the configuration shown in Table B on page 9, and Figure 9 on page 9. 5. Align the springs and end caps with the mating spring locations in the pistons. 6. Ensure that the straight section of the end cap O-ring is toward the top of the actu- ator. 7. Mount each end cap to the actuator with four screws (B16). 8. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5) 9. Mount the new breather (B21) in the right-side port. 10. Re-connect the pneumatic connections. Pipeline flow may be resumed.July 1998 Page 12 of 15 D–10371
  16. 16. DeZURIK® COMPAK™ ACTUATORChanging Actuator From Double–Acting to Spring–to–Open CHANGING Follow the steps below to change a double–acting actuator to a spring–to–open actuator. ACTUATOR FROM Before proceeding, obtain one breather and also the required size and quantity of actua-DOUBLE–ACTING TO tor springs. See “Component Identification” on page 8. SPRING–TO–OPEN 1. Remove the actuator from the valve. See “Removing Acuator from Valve” on page 6. 2. Remove the four screws (B16) on each of the two end caps (B4) and remove the end caps. Note the location and position of each end cap so that the end caps can be later reassembled in the same configuration. 3. Rotate the pinion (B3) as required to move the two pistons (B2) apart as far as possible. Pull and remove each piston from the body. Use pliers if necessary, but do not damage the sealing surfaces. Note the location and position of each piston so that the pistons can be later reassembled in the same configuration. 4. Rotate the pinion (B3) so that the flat on top of the pinion is approximately 30 to 40 degrees beyond the closed. See Figure 8 on page 8, and Figure 10 on page 10. 5. Position the two pistons (B2) as noted during disassembly, and insert the pistons equally into the ends of the body (B1) until both pistons begin to mesh with the pinion. Apply equal force on each position to rotate the pinion to the open posi- tion. 6. Ensure that the pinion flat is perpendicular with the actuator at the closed position as shown in Figure 10; if not, remove the pistons and repeat steps 4 and 5, using an appropriate angle in step 4. 7. Place an O-ring (B18*) in the groove in each of the two end caps (B4). 8. Place the springs (B5) in each of the two end caps (B4) in the configuration shown in Table B on page 9 and Figure 9 on page 9. a. Align the springs and end caps with the mating spring locations in the pistons. Ensure that the straight section of the end cap O-ring is toward the top of the actuator. b. Mount each end cap to the actuator with four screws (B16). c. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5) 9. Mount the new breather (B21) in the right-side port. 10. Mount the actuator on the valve as shown in the Mounting Actuator on Valve section.July 1998 Page 13 of 15 D–10371
  17. 17. DeZURIK® Compak™ Actuator Changing Actuator From Spring–to–Close To Double–Acting CHANGING Follow the steps below to change a spring-to-close spring-return actuator to a double- ACTUATOR FROM acting actuator. For Component Identification, see Figure 8 on page 8. SPRING–TO–CLOSE TO DOUBLE–ACTING Flow in the pipeline with the actuator disconnected can allow the valve to move unexpectedly, and can cause personal injury and/or damage to the flow system. Shut down the flow in the pipeline before servicing the actuator. 1. If the actuator is on a valve, shut down the flow in the pipeline, and close the valve. Moving parts from unexpected operation of a powered actuator can cause personal injury or equipment damage. Disconnect and lock out power to the actuator before servicing. 2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental operation of the actuator. 3. Remove the four screws (B16) on each of the two end caps (B4) and remove the end caps. Note the location and position of each end cap so that the end caps can be later reassembled in the same configuration. 4. Remove all of the springs (B5) from both end caps (B4) and both pistons (B2) of the actuator. 5. Align the end caps with the ends of the actuator. a. Ensure that the straight section of the end cap O-ring goes toward the top of the actuator. b. Mount each end cap to the actuator with four screws (B16). c. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5) 6. Remove the breather (B21) from the actuator. 7. Re-connect the pneumatic connections. Pipeline flow may be resumed.July 1998 Page 14 of 15 D–10371
  18. 18. DeZURIK® COMPAK™ ACTUATORChanging Actuator From Spring–to–Open To Double–Acting CHANGING Follow the steps below to change a spring-to-open spring-return actuator to a double- ACTUATOR FROM acting actuator. SPRING–TO–OPEN TO 1. Remove the actuator from the valve. See “Removing Acuator from Valve” on DOUBLE–ACTING page 6. 2. Disassemble the actuator. See “Actuator Disassembly” on page 7. 3. Follow steps 1 through 6 in the Actuator Reassembly section except: In step 4, insert the pistons as shown in Figure 10 on page 10 for a double-acting actuator. See “Actuator Reassembly” on page 8. 4. Align the end caps with the ends of the actuator. a. Ensure that the straight section of the end cap O-ring is toward the top of the actuator. b. Mount each end cap to the actuator with four screws (B16). c. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5) 5. Remove the breather (B21) from the actuator. 6. Mount the actuator on the valve. See “Mounting Actuator on Valve” on page 11. CHANGING The actuator may be mounted in any of four positions on the valve.MOUNTING POSITION To change the mounting position: OF ACTUATOR ON VALVE 1. Remove the actuator from the valve. See “Removing Acuator from Valve” on page 6. 2. Replace the actuator on the valve. See “Mounting Actuator on Valve” on page 11. TROUBLESHOOTING Table C: Troubleshooting Condition Possible Cause Corrective Action Actuator closes or Set stops. See OPEN Position stops are set opens to wrong posi- AND CLOSED POSI- incorrectly. tion. TION STOPS section. Increase cylinder pres- Cylinder pressure is low. sure. See “Operation” on page 1. Actuator is sized Use larger actuator. incorrectly. Install Repair Kit. Seals are leaking. Actuator will not fully (See pg. 7) operate valve. Pipeline obstruction in valve is preventing Remove obstruction. closure. Double-acting actuator Air connections to cylinder Reverse air connections rotates wrong direction. are incorrect. to cylinder.July 1998 Page 15 of 15 D–10371

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