Morin EHP, EHPX Electro-Hydraulic Actuator Operation And Maintenance Instructions

Bulletin EHPOM0712

110 COMMERCE DRIVE

VALLEY COMMERCIAL CENTER

PELHAM, AL 35124

PHONE (205) 663-0533

FAX (205) 663-0703

Operation And

Maintenance Instructions

For

Models EHP and EHPX Electro-Hydraulic Actuators

General Application

Morin Electro-Hydraulic Actuators are designed for “on-off” control of any quarter-turn ball, butterfly, rotary plug or damper style valve application.

Technical Data

Supply Voltage: 115 or 230 VAC Single Phase, 15 Amp max or as specified by nameplate.

Duty Cycle: One minute on, and three minutes off.

Temperature rating: Standard Range: -20



F to 130



F

Optional Range: -65



F to 130



F

Service Conditions: All components are suitable for indoor or outdoor installation and are weather resistant. Model EHP is a

Angular rotation:

Mounting: weather resistant unit (IP54). Model EHPX is weather resistant (IP54) and suitable for explosive atmospheres: NEC Class 1, Division 2, Group D

90 degrees



8 degrees

Horizontal, beacon up or vertical, motor up.

Page 1 of 13

1. Description

The Morin electro-hydraulic actuator is a self-contained unit consisting of an electric hydraulic power unit with integral oil reservoir, control limit switches, terminal block, open/closed position beacon and a hydraulic actuator. The standard product is offered as spring fail closed (clockwise rotation) and electric motor powered open (counterclockwise rotation). Optional spring return, fail open or double acting are available. (Closing and opening rotation as viewed from the beacon side of the actuator.)

This manual covers primarily the installation and operation of the electro-hydraulic actuator.

Overview of Operation:

The hydraulic power unit (HPU) operates on Single Phase 115 or 230 VAC depending on customer order. Power is applied to the actuator closing the solenoid valve and starting the HPU motor. The fail closed actuator begins to open. The motor shuts off when the actuator reaches the fully open position but the hydraulic control solenoid remains energized with its solenoid valve closed. The actuator closes by spring energy when the electricity is shut off (either by remote control or by a power failure). The rotating beacon shows valve position. (See Figure 1)

If over a long period of time the actuator drifts a few degrees closed, the motor will automatically switch on and reestablish the fully open position. If electric power is lost, spring return actuators automatically move to the fail position. Double acting units fail in last position.

Figure 1 Figure 2

2. Installation

The actuator can be mounted parallel or perpendicular to pipeline provided the fill port of the reservoir is oriented up. The following instructions are for a spring return fail closed actuator. For a fail open actuator the method is similar.

A. Bolt a mounting bracket to the actuator.

B. Install a coupling on the valve. The rotary stops on valve must be removed or adjusted to allow actuator stops to do the stopping.

C. Install the actuator and bracket assembly to the valve and tighten all fasteners.

D. Remove the switch box cover and conduit plug. Install the hot, neutral, and ground wires from the power conduit at terminals 1 and 3 or 1,3 and 24 on the terminal strip depending on supply voltage. (See figures 2 and 3).

E. Follow the appropriate NEC and local codes for your electrical wiring. If the explosion-proof NEC class 1 Division 2 actuator is being installed, be sure to install a conduit seal at the conduit inlet of the switch box. See NEC section 501 for proper procedure. A conduit seal is required at the inlet and outlet conduit connections because the switch box is actually rated NEC class 1 division 1 and both conduit seals are required to isolate the internal switch contacts.

F. Apply power keeping hands clear of wires and the terminal strip. Allow the valve to open fully and verify that the motor shuts off just before the actuator reaches its position stop.

G. Remove power and verify the actuator closes.

Page 2 of 13

H. If the actuator did not open or close fully, adjust the actuator stops and repeat step “F”. (See Figure 1).

I. If the motor does not shut off just before the actuator reaches fully open, turn off the power, wait for the valve to close, and adjust the motor limit switch cam by pressing the cam down slightly and turning it in the appropriate direction. The uppermost cam controls the closed limit switch. Repeat step “F” and verify the motor shuts off. (See figure 2).

J. Reinstall switch cover.

Figure 3 Figure 4

The models EHP15 and EHPX15 actuators use a square male output shaft drive. After the actuator is set up in steps A-H above, the actuator should be centered precisely in its coupling on the valve. Reposition the motor limit switch cam to stop the motor with the actuator in the half open position. Then loosen all the mounting bracket bolts. Grasp the actuator and shift it back and forth to center the actuator, coupling, and valve shafts along a common centerline. Then tighten all the mounting bracket bolts, turn the power off to close the actuator, and then reposition the motor stop cam to shut the motor off slightly before the actuator contacts the open position stop.

Open and Closed position switches:

The switch box has 4 adjustable limit switches (see figure 2). The Two upper switches control the HPU motor. (Only one of the two switches is used for spring return actuators). The two lower switches can be used by the customer to provide actuator position feedback for control panel lights or other instruments. Refer to the schematic in Figure 3 for wiring information.

3. Operation

The actuator has been set up by the factory for correct operation and is ready to install and use. The reservoir is filled half full with hydraulic oil. The HPU has integral speed controls, an overpressure bypass control preset to 2250 psi, and a thermal relief valve to provide for fluid expansion with temperature changes. (See Figure 4) The speed controls are adjustable by the customer. They are set by the factory for maximum opening and closing speed. The opening speed is limited by how quickly the hydraulic pump can transfer fluid into the actuator cylinder, and this is relatively slow. The closing speed is controlled by the actuator spring and this speed is relatively fast. The factory sets the closing speed to 4 seconds and this is the maximum recommended closing speed. The hydraulic reservoir should be filled to half full.

Page 3 of 13

4. Maintenance

The actuator is factory lubricated and does not normally require periodic lubrication while in service. Check the HPU reservoir periodically and maintain the fluid level half full with the actuator in the spring closed position. Use Chevron

Hydraulic Oil AW or equal high quality petroleum based hydraulic fluid, ISO 22 viscosity. Do not over fill.

Figure 5

5. Removal of Actuator from Valve

CAUTION:

Do not attempt to remove mounting bolts between actuator and valve until supply voltage has been disconnected. If spring return, be sure that valve is completely in failed position. Caution: If valve is frozen in a position causing the spring to be compressed, removal of bracket bolts would allow spring to stroke, resulting in the actuator rotating over bracket causing possible injury or damage.

A. Loosen bracket to actuator bolts to hand tight position.

B. Physically shift actuator back and forth to be sure there is no strain (or shear stress) on the bracket bolts. Once it has been determined that there is no pressure or spring load remaining on the actuator, remove bolts and actuator from valve.

C. In the event the valve is frozen or locked in place, resulting in spring energy remaining in the actuator, replace EHP adjustment screw (37a) on end of actuator opposite spring end with length of “all thread” rod of sufficient length and turn clockwise until it contacts the piston. Caution: Make sure the hydraulic pressure is vented before removing the travel stop. This procedure will safely secure the piston and spring assembly and allow actuator removal. Be sure to carefully remove “all thread” rod prior to actuator disassembly.

6. Operating instructions:

Operate the actuator in accordance with the pressure and temperature limits specified on the nameplate. See the appropriate

Morin Catalog for technical information.

Page 4 of 13

7. Troubleshooting:

The electrohydraulic actuator is shipped ready to install and use. If the unit does not operate correctly check the following: a. Motor won’t start.



Check for power at terminals 1 and 3.



Check to see if the valve is already open



Check top microswitch cam adjustment. b. Motor won’t stop.



Check to see if top microswitch cam is correctly adjusted.



Check to see that sufficient fluid is in the reservoir.



Check actuator stop bolt adjustment. The motor should power the actuator until the switch shuts it off. It should not hit the stop bolt first.



Check to see that all wires are seated correctly in terminal block c. Motor starts, actuator will not move.



Check to see if the reservoir has enough fluid. Fill reservoir half full.



The motor fan should rotate clockwise. Reverse motor leads to change direction.

For other questions contact the factory.

IMPORTANT

SAFEGUARDS

Caution: To reduce the risk of injury:



Read the entire Operation and Maintenance Instruction manual before installing, operating, or servicing this actuator. Review the actuator specific operation, maintenance and installation manual for safety information.



Warning: Danger of Electrical Shock. This unit operates on high voltage electricity; refer service and installation to a trained electrician.



Inspect the actuator regularly for signs of corrosion and repair immediately.



Always remove pressure and disconnect power supply before servicing the actuator.



Keep hands and feet clear of an actuator that is in service.



Do not disassemble the actuator without reviewing the disassembly procedure in this manual first. This is particularly important that the proper procedure be followed to avoid injury from internal spring power.



Before attempting to remove an actuator from the equipment it is assembled to, always be sure that spring is in the

“failed” or extended position. Remove any accessory equipment that may cause the spring to remain compressed. If there is any doubt that the actuator is in the “failed” position, remove the hydraulic pressure from the actuator and install a long threaded bolt (a bolt that exceeds the length of the cylinder) in place of both travel stops. Once the actuator has been removed from the equipment the long bolts must be removed first before the actuator can be disassembled.



Repair or replace a damaged actuator immediately.



Operate the actuators within the pressure and temperature ranges specified on the nameplate. Otherwise the actuator life may be reduced or serious safety hazards may develop.

Page 5 of 13

OPERATION

And

MAINTENANCE INSTRUCTIONS

For

HP Model High Pressure Actuators

1. Installation

The actuator is factory lubricated and does not normally require periodic lubrication while in service. The actuator can be mounted parallel or perpendicular to pipeline

Bolt mounting bracket to actuator hand tight. DO NOT tighten yet.

A. Install coupling on valve. Be sure rotary stops on valve are removed or adjusted to allow actuator stops to do the stopping.

B. Install actuator and bracket to valve being sure to leave all fastener connections hand tight. If possible, stroke valve and actuator to a half open position 45



and physically shift actuator back and forth until coupling and all fasteners are relaxed then tighten all bolts and nuts. This procedure will accurately align valve stem to actuator output shaft and prolong valve stem seal life.

C. Cycle valve / actuator assembly and observe for smooth operation.

D. Adjust travel stops and motor switch cam stop as noted above.

Page 6 of 13

Page 7 of 13

44a

45

46

47

48

49

50

51

38

38a

39

41

41a

42

43

44

52

53

54

55

56

57

58

36

36a

37

37a

32

33

34

35

26

26b

27

28

29

29a

30

31

22

23

24

25

18

19

20

21

14

15

16

17

13

13a

13b

13c

11

12

I2a

12b

7

8

9

10

1

2

3

4

5

6a

6b

ITEM

Housing

Yoke

Output shaft

Piston rod

Bushing - Output Shaft

Yoke Pin

Key - Yoke

Bushing - Piston Rod

Retaining Ring - Output Shaft

Thrust Pin

Roller Bearing

Retaining Ring - Pin

Seal, Thrust Plate

Set Screw

Retaining Ring - Lower Bearing

Pointer Adaptor

Position Indicator

Thrust Plate

Gasket, Thrust Plate

Hex Head Bolt

Lock Washer

Pointer

Round Head Screw

Cover- Housing

Hex Head Bolt

Lock Washer

Pointer washer

Thrust Washer

Gasket - Cover

Cylinder

Piston

Adaptor

HP Adaptor

End cap

Rod Cover

Seal -Piston Rod

U cup Seal - Piston Rod

Seal -Piston Bolt

Seal- Piston

Gasket - Housing

Piston Bolt

Lock Washer

Bearing - Piston

Thread Seal

Cap Nut Seal

Travel Stop Bolt

HP Adjustment Screw

Jam Nut

Cap Nut

Socket Head Cap Screw

Tie Rod

Nut - Tie Rod

Seal - Output Shaft

Lock Washer

Hex Head Bolt

Socket Head Cap Screw

Stato-seal

Cylinder Gasket or O-ring

Label - Nameplate

Seal - Output Shaft Bushing

Cylinder - Spring Side

Tie Rod - Spring Side

Hex Head Bolt

Travel Stop Bolt

Flat Washer

End cap - Spring Side

Spring - Outer

Spring - Inner

Breather

Label - Spring

HP 15

18-8 SS

316 SS

18-8 SS

18-8 SS

18-8 SS

-

18-8 SS

18-8 SS

18-8 SS

BUNA-N

BUNA-N

MYLAR

-

316 SS

316 SS

18-8 SS

316 SS

316 SS

316 SS

316 SS

BUNA-N

URETHANE

BUNA-N

BUNA-N

FIBER

18-8 SS

18-8 SS

TEFLON

SS/EPDM

BUNA-N

18-8 SS

304 SS

18-8 SS

18-8 SS

316 SS

STEEL

STEEL

18-8 SS

LEXAN

-

304 SS

-

-

18-8 SS

18-8 SS

SOFT PVC

18-8 SS

316 SS

18-8 SS

18-8 SS

18-8 SS

-

FIBER

316 SS

316 SS

316 SS

17-4 PH

17-4 SS

316 SS

TEFLON

18-8 SS

-

TEFLON

15-7 MO

440C SS

440C SS

15-7 MO

-

18-8 SS

-

HP 25 & HP 30

18-8 SS

316 SS

18-8 SS

18-8 SS

18-8 SS

-

18-8 SS

18-8 SS

18-8 SS

BUNA-N

BUNA-N

MYLAR

-

316 SS

316 SS

18-8 SS

316 SS

316 SS

316 SS

316 SS

BUNA-N

URETHANE

BUNA-N

BUNA-N

FIBER

18-8 SS

18-8 SS

TEFLON

SS/EPDM

BUNA-N

18-8 SS

304 SS

18-8 SS

18-8 SS

316 SS

STEEL

STEEL

18-8 SS

LEXAN

316 SS

17-4 PH

17-4 SS

316 SS

TEFLON COMPOSITE

-

17-4 PH

TEFLON

15-7 MO

440C SS

440C SS

15-7 MO

BUNA-N

-

18-8 SS

NYLON

-

316 SS

FIBER

18-8 SS

18-8 SS

SOFT PVC

18-8 SS

316 SS

18-8 SS

18-8 SS

18-8 SS

18-8 SS

FIBER

316 SS

316 SS

Materials of Construction

S MATERIAL

HP 15

18-8 SS

DUCTILE IRON

18-8 SS

18-8 SS

18-8 SS

BUNA-N

18-8 SS

18-8 SS

18-8 SS

BUNA-N

BUNA-N

MYLAR

BUNA-N

316SS

316 SS

18-8 SS

DUCTILE IRON

DUCTILE IRON

DUCTILE IRON

DUCTILE IRON

BUNA-N

URETHANE

BUNA-N

BUNA-N

FIBER

18-8 SS

18-8 SS

TEFLON

STEEL/EPDM

BUNA-N

18-8 SS

DUCTILE IRON

18-8 SS

18-8 SS

DUCTILE IRON

STEEL

STEEL

STEEL

LEXAN

DUCTILE IRON

17-4 PH

4140

CPO

BRONZE

STEEL

-

BRONZE

STEEL

440C SS

440C SS

STEEL

-

18-8 SS

-

-

DUCTILE IRON

-

-

18-8 SS

18-8 SS

SOFT PVC

18-8 SS

STEEL

18-8 SS

18-8 SS

18-8 SS

-

FIBER

316 SS

DUCTILE IRON

B MATERIAL

HP 25 & HP 30

STEEL

DUCTILE IRON

STEEL

STEEL

STEEL

-

STEEL

STEEL

STEEL

BUNA-N

BUNA-N

MYLAR

-

316 SS

STEEL

STEEL

DUCTILE IRON

DUCTILE IRON

DUCTILE IRON

DUCTILE IRON

BUNA-N

URETHANE

BUNA-N

BUNA-N

FIBER

STEEL

STEEL

TEFLON

STEEL/EPDM

BUNA-N

STEEL

DUCTILE IRON

STEEL

STEEL

DUCTILE IRON

STEEL

STEEL

STEEL

LEXAN

DUCTILE IRON

17-4 PH

4140

CPO

TEFLON COMPOSITE

-

STEEL

BRONZE

STEEL

440C SS

440C SS

STEEL

BUNA-N

-

STEEL

NYLON

-

DUCTILE IRON

FIBER

STEEL

STEEL

SOFT PVC

STEEL

STEEL

STEEL

STEEL

STEEL

STEEL

FIBER

316 SS

DUCTILE IRON

C MATERIAL

HP 25 & HP 30

STEEL

DUCTILE IRON

STEEL

STEEL

STEEL

-

STEEL

STEEL

STEEL

BUNA-N

BUNA-N

MYLAR

-

STEEL /XYLAN

STEEL

STEEL

DUCTILE IRON

DUCTILE IRON

DUCTILE IRON

DUCTILE IRON

BUNA-N

URETHANE

BUNA-N

BUNA-N

FIBER

STEEL

STEEL

TEFLON

STEEL/EPDM

BUNA-N

STEEL

DUCTILE IRON

STEEL

STEEL

DUCTILE IRON

STEEL

STEEL

STEEL

LEXAN

DUCTILE IRON

17-4 PH

4140

CPO

TEFLON COMPOSITE

-

STEEL

BRONZE

STEEL

440C SS

440C SS

STEEL

BUNA-N

-

STEEL

NYLON

-

DUCTILE IRON

FIBER

STEEL

STEEL

SOFT PVC

STEEL

STEEL

STEEL

STEEL

STEEL

STEEL

FIBER

STEEL /XYLAN

DUCTILE IRON

Page 8 of 13

2. Spring Conversion

Consult factory for spring conversion. Some spring conversions can be done in the field and others will require a new spring cylinder.

3. Failure Mode Change

(Model HP15)

Conversion from “fail close” to “fail open” is accomplished by flipping the actuator over. The top and bottom of the center housing have identical mounting flanges and output shaft dimensions. Remove the vinyl pointer and indicator plate and mount them on opposite side of actuator.

(Models HP25, HP30, HP65, HP80)

Fail open and fail closed must be specified at time of order.

4.

Removal of Actuator from Valve

CAUTION

Do not attempt to remove mounting bolts between actuator and valve until supply pressure has been disconnected and vented.

If spring return, be sure that valve is completely in failed position. If valve is frozen in a position causing the spring to be compressed, removal of bracket bolts would allow spring to stroke, resulting in the actuator rotating over bracket causing possible injury or damage.

D. Loosen bracket to actuator bolts to hand tight position.

E. Physically shift actuator back and forth to be sure there is no strain (or shear stress) on the bracket bolts. Once it has been determined that there is no pressure or spring load remaining on the actuator, remove bolts and actuator from valve.

F. In the event the valve is frozen or locked in place, resulting in spring energy remaining in the actuator, replace HP adjustment screw (37a) on end of actuator opposite spring end with length of “all thread” rod of sufficient length and turn clockwise until it contacts the piston. This procedure will safely secure the piston and spring assembly and allow

FIGURE 5 FIGURE 6 FIGURE 7

actuator removal. Be sure to carefully remove “all thread” rod prior to actuator disassembly.

5. Disassembly-Symmetric Yoke Actuators

A. Remove endcap(s) (27 & 54); tie rods (41 & 50) and cylinder (24 & 49). Remove rod cover (28) if applicable.

B. Remove piston bolts (33) and pistons (25) and springs if applicable (55 and 56).

C. Remove adaptor (26) and piston rod seals (29).

D. Remove housing cover (18), pointer (16) and position indicator (13) (where applicable).

(Model HP15)

E. Disengage yoke (2) from roller bearing assembly by pulling piston rod to extreme right, as in FIGURE 5, and swing yoke mechanism clear of roller bearing as in FIGURE 6.

F. Rotate piston rod 90



to allow access to retaining ring (11) as shown in FIGURE 7.

G. Remove retaining ring (11) and bearing (10). Then rotate piston rod (4) 180



and remove the bearing (10) and thrust pin

(9) assembly.

H. Remove piston rod (4) and piston rod bushings (7).

I. Remove plug (12a) from back of housing.

J. Using a punch or suitable dowel pin, insert through clearance hole and press yoke pin (6a) out.

K. Remove retaining ring (8) from output shaft (3). Remove output shaft (3) and yoke (2).

L. Remove bushings (5) from housing.

Page 9 of 13

(Models HP25 & HP30)

E. Disengage yoke (2) from roller bearing assembly by pulling piston rod (4) to extreme right, as in FIGURE 5, and swing yoke (2) clear of roller bearing (10) assembly. See FIGURE 6.

B. Rotate piston rod (4) 90



to allow access to retaining ring (11) as shown in FIGURE 7.

C. Remove retaining ring (11) and bearing (10). Then rotate piston rod (4) 180



and remove the bearing and thrust pin assembly.

D. Remove piston rod (4) and piston rod bushings (7).

I. Remove retaining rings (8) and (12b) on both ends of output shaft.

J. Remove thrust plate (13b) and thrust washers (22) from the output shaft (3).

K. Position the yoke (2) in the fully clockwise position (viewed from the thrust plate (13b) side).

L. Using a soft hammer, drive output shaft (3) out through top of housing (1).

M. Withdraw yoke (2) from housing (1).

N. Remove the output shaft bushings (5) from the housing (1).

Disassembly – Canted Yoke Actuators

Canted yoke actuators are disassembled the same way as the symmetric yoke actuators except for the following additional instructions for specific models:

(Models HP15)

These actuators are disassembled using the same procedure as the symmetric actuators. However, the thrust pin (9) is removed from the housing (1) via access plugs on the upper and lower housing mounting flanges.

(Models HP25 & HP30)

G. Remove the pointer (16), pointer adaptor (13) and pry out the thrust plate seal (12) (if fitted).

H. Remove the thrust plate (13b) and thrust washers (22) from the output shaft (3).

I. Position the yoke (2) in the fully clockwise position (viewed from the thrust plate (13b) side).

J. Using a soft hammer, drive output shaft (3) out through the thrust plate side of the housing (1). This will drive out the upper output shaft bushing (5) and yoke key (6b).

K. Remove the piston rod bushings (7) from the housing (1).

L. Shift the yoke (2) around in the housing (1) so that the thrust pin (9) and roller bearing (10) assembly can be moved out of the yoke slot. Remove the thrust pin retaining rings (11) and withdraw the roller bearings (10), thrust pin (9), piston rod (4) and yoke (2).

M. Remove the lower output shaft bushing retaining ring (12b) and lower output shaft bushing (5).

6. Assembly-Symmetric Yoke Actuators

(Model HP15)

A. Insert piston rod bushings (7) and output shaft bushings (5) in housing. Lube output shaft bushings o-rings (48) with

"Dow Corning #55" lubricant. Push one o-ring halfway on each bushing and install bushings in housing.

B. Place yoke (2) in position in housing. Lubricate with "WD40" or similar lubricant and install output shaft (3). Lube output shaft o-rings (42) with "Dow Corning #55" lubricant. Install one o-ring on one end of output shaft and insert through housing and yoke. Install second o-ring on opposite end of output shaft and push output shaft back into housing.) Secure output shaft with retaining rings (8).

C. Lubricate and press yoke pin (6) into yoke and output shaft assembly from open side of housing. Be sure pin is pressed flush in yoke to prevent interference with piston rod (4).

Page 10 of 13

(Models HP25 & HP30)

A. Insert yoke key (6b) into output shaft (3).

B. Install yoke (2) in housing (1). Slide output shaft (3) through top of housing (1) into the yoke (2). Install lubricated upper and lower bearings (5a).

C. Install lower thrust washer (22), thrust plate (13), upper thrust washer (22) retaining ring (8) and thrust plate seal (12) (if fitted). Install lower bearing retaining ring (12b).

(Models HP15, HP25, HP30)

D. Lubricate with "WD40" and install piston rod (4) being careful not to scratch sealing surfaces when sliding through yoke assembly.

E. Swing yoke clear toward left side of housing as shown in FIGURE 7.

F. Sub-assemble thrust pin (9) with one roller bearing (10) and one retaining ring (11). Pre-lubricate sub-assembly with high temperature grease such as "Whitmore’s Omnitemp II".

G. Install roller bearing sub-assembly per FIGURE 7. Rotate piston rod 180



and assemble second roller bearing and retaining ring. Place ample amount of high temperature grease on roller bearing and inside wear area of yoke.

H. Engage roller bearing in yoke assembly as shown in FIGURE 7, 6, & 5.

I. Install plug (12a) in back of housing if applicable. Use "Loctite 222 Thread Locker".

(Cylinder and Rod Cover Assembly-All Models)

J. Assemble bolt (33) on end of piston rod before installing rod cover when rod cover is required.

K. Install rod cover (28) if applicable. Actuators utilizing one piston only require a rod cover. Bolt rod cover and gasket in place with socket head screws (39). Use “Locktite 222 Thread Locker.”

L. Install piston rod lip seal (29a), by lubricate o-ring with "Dow Corning #55" lubricant, and then inserting cup end into deeper recess of HP adaptor (26b). The open lips of the cup must face the cylinder so that the lip seal expands

under operating pressure (shown in Figure 8). If spring return lubricate piston rod o-ring (29) with "Dow Corning

#55" lubricant and install on piston rod (4, 4a).

Page 11 of 13

Install U-Cup into adaptor with the O-ring side facing the pressure.

FIGURE 8

M. Lubricate piston bolt o-ring (30) with “Dow Corning #55” lubricate and put on piston rod (4).

N. Assemble adaptor (26, 26b) to housing. The seal must slide over the lubricated piston o-ring (30) on the piston rod (4) to avoid damage to the seal lips. A gasket (32) must be used between adaptor and housing. If actuator is spring return model be sure to insert long tie rod bolts (51) with washer into adaptor prior to bolting adaptor to housing. Insert socket head cap screws (44) from housing into HP adaptor (26b) using Loctite. If spring return, insert hex head bolts (44) with stato-seals (45) through spring side adaptor (26) into housing (1). Use “Locktite 262 Permanent Thread Locker”.

Uniformly tighten bolts. Refer to Assembly Torque Requirement (FIGURE 10) for proper bolt torque.

O. Assemble piston (25) to piston rod with bolt (33) and lock washer (34). Use "Loctite 262 Permanent Thread Locker" on bolt threads. Rotate piston before tightening piston bolt to ensure proper seating of o-ring. Refer to Assembly Torque

Requirement (FIGURE 10) for proper bolt torque.

P. Install lubricated o-ring (46) in HP adaptor (26b) groove.

Q. Lubricate piston o-ring (31) with "Dow Corning #55" lubricant and install on piston (25).

R. Lubricate piston bearing (35) with "Dow Corning #55" lubricant and install on piston (25). Assemble bottom two tie rods

(41) on HP adaptor (26b). Lubricate cylinder (24) with "Dow Corning #55" lubricant and slide cylinder over piston (25) until cylinder is in contact with o-ring (46) in HP adaptor (26b) groove. Assemble top two tie rods (41) on HP adaptor

(26b).

S. Insert cylinder o-ring (46) in endcap (27) groove and place endcap over tie rods (41) and on cylinder (24).

T. Assemble lock washers (43) and nuts (#?) on tie rods (41) and uniformly tighten. Do not exceed torque values shown in

Assembly Torque Requirement Table (FIGURE 10).

U. Install position indicator (13) and pointer (16), where applicable. Assemble HP adjusting screws (37a), cap nuts (38), and cap nut seals (36a). For rod cover assemble adjusting screw (37) with jam nut (38) and install on rod cover (28).

V. Stroke actuator with rated supply air and check for leaks.

TIE ROD TIGHTENING SEQUENCE

1

4

3

2

5

3

1

2

4

6

ASSEMBLY TORQUE REQUIREMENTS (FT./LBS.)

Model No.

HP15-2

HP15-3

HP25-3

HP25-4

HP30-4

HP30-6, HP60-6

HP30-8, HP60-8

HP65-6, HP80-6

HP65-8, HP80-8

Adaptor

Bolt (44)

30

30

150

150

150

250

250

250

250

Piston

Bolt (33)

40

150

150

150

150

250

250

250

250

Tie Rod

(41)

30

150

150

250

250

250

250

250

250

Tie Rod Bolt

Spring side (51)

25

25

100

250

250

250

250

250

250

FIGURE 9 FIGURE 10

SPRING RETURN ONLY

All Models

W. Lubricate piston bolt o-ring (30) with "Dow Corning #55" lubricant and put on piston rod. Assemble piston (25) to piston rod with bolt (33) and lock washer (34). Use "Loctite 262 Permanent Thread Locker” on bolt threads. Rotate piston before tightening piston bolt to ensure proper seating of o-ring. Refer to Assembly Torque Requirement

(FIGURE 10) for proper bolt torque.

X. Install lubricated cylinder o-ring (46) in adaptor (26) groove.

Y. Lubricate piston seal (31) with "Dow Corning #55" lubricant and install on piston (25).

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Z. Lubricate piston bearing (35) and cylinder (24) with "Dow Corning #55" lubricant. Hold piston bearing (35) in place on piston (25) and slide cylinder (49) over piston and bearing until cylinder is in contact with o-ring (46) in adaptor (26) groove

.

AA. Place cylinder o-ring (46) in endcap (54). Insert long bolts (51) with flat washer (53) in endcap (54).

AB. Place springs against piston, being sure to nest in contours.

AC. Mount endcap over extended spring(s) and fasten to hollow tie rods (50) with bolts (51). To prevent galling, lubricate bolts (51) with "Whitmore’s Omnitemp II" grease or equal. Alternately and uniformly tighten bolts (51) in hollow tie rods. Tighten each bolt approximately ¼” – ½” following the sequence shown in Tie Rod Tightening Sequence

(FIGURE 9) until spring is completely compressed. Be sure that each hollow tie rod slides into the counterbore in the endcap. Do not over tighten bolts. Refer to Assembly Torque Requirements Table (FIGURE 10).

AD. Install position indicator (13) and pointer (16), where applicable. Assemble adjusting screws (52), thread seals (36) and jam nuts (38).

AE. Stoke actuator with rated supply air and check for leaks.

Assembly – Canted Yoke Actuators

Canted yoke actuators are assembled the same way as the symmetric yoke actuators except for the following additional instructions for specific models.

Canted yoke actuators have a non-symmetrical piston rod as well as a non-symmetrical yoke. It is important to

orient the piston rod with the longer dimension in relation to the yoke as shown in Figure 7c. Note that the finished housing assembly is used for both fail open and fail closed actuators.

(Models HP25 & HP30)

A. Insert the yoke (2) into the housing (1) and position the yoke in the fully clockwise position (viewed from the thrust plate

(13b) side).

B. Insert the piston rod (4) correctly oriented with the longer dimension as shown in figure 7c.

C. Install the thrust pin (9) and roller bearings (10) using generous amounts of Whitmore Omnitemp grease and install both pin retaining rings (11).

D. Shift the yoke (2) and piston rod (4) so that the thrust pin (11) and roller bearing (10) assembly can be inserted into the yoke slot. The absence of the piston rod bushings (7) and output shaft bushings (5) allows just enough room for this process.

E. Insert the lower output shaft bushing (5) and retaining ring (12b). This bushing must have a press fit. The integral seal o-ring must be oriented toward the yoke.

F. Insert the yoke key (6b) into the output shaft (3), then insert the output shaft into the housing (1) and yoke (2) and lower output shaft bushing (5).

G. Install the upper output shaft bushing (5) over the output shaft and into the housing (5). The bearing must have a press fit. The integral seal o-ring must be oriented toward the yoke.

H. Install output shaft thrust washer (22), thrust plate gasket (13b) thrust plate (13b), thrust washer (22) and retaining ring

(8).

I. Install Pointer adaptor (13) using two socket head cap screws.

J. Install the thrust plate seal (12), pointer (16) and pointer washer (21).

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