Installation, Operation & Maintenance Manual

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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 Installation, Operation & Maintenance Manual

DelVal Flow Controls Private limited

(A DIVISION OF DelTech CONTROLS LLC, USA)

DelTorq Series –21

ACTUATOR
INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
Year of Mfg:

(Please read the entire instructions carefully before installation or servicing.)

Guarantee:
“Our liability, with respect of any defect or failure of the goods supplied or for any
loss, injury or damage attributable onward is limited to replacement or repair of the
defects which under proper use appear therein and arise solely from faulty materials
and workmanship. This guarantee is for a period of 18 calendar months after the
original goods were first shipped or within 12 calendar months from the date of
installation, whichever is earlier, provided that such defective parts are returned
without charge to our factory for examination. No other warranty is either expressed
or implied.”
TABLE OF CONTENT
Item Description Page no.
1. General 3
2. Technical Data 3
3. Unpacking & Storage Instructions 3
4. Lifting Instructions 4
Putting into Service 4
5.
4.1 Before putting into service 4
4.2 Installation 4
4.3 Things to be observed after putting into service 4
6. Operation 4
Maintenance 5
7.1 General 5
7
7.2 Disassembly 5
7.3 Assembly 6
7.4 Tightening torques for bolts 9
8. 100% Travel Stop Arrangement 9
9. Size 045 Actuator 9
10. Things that are to be observed after maintenance 10
11 Troubleshooting 10
12. Important 10
13. Atex Instructions 10
14. Other instructions 10
15. Engineering 11
16. Exploded View 13
17. Part List 13
18. Ordering code for actuators 14
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 Installation, Operation & Maintenance Manual

1. General:
0 0
Extra travel stop arrangement: ±5 Adjustment on 90 Stroke
This manual contains the important information regarding the
Maximum Noise level: 82.2 dB (A) maximum, measured on
installation, operation and troubleshooting of the ‘DelTorq’
pressure level scale for size 200 actuator (intermittent)
pneumatic actuators. Please read these instructions carefully
Maximum Surface Temperature in extreme conditions of
before operating the actuator. 0
pressure 8-bar: 49 C
Actuator base standard: ISO – 5211
Intended Use:
Solenoid valve mounting standards: VDI/VDE 3845
Deltorq series21 actuator comes under group II category 2
equipment intended for use in areas in which explosive
Material of Construction:
atmospheres caused by mixtures of air & gases, vapours or mists
or by air/dusts are likely to occur.
ASTM B221 6063 – T6 – Hard
Body
Anodised
i Warning against foreseeable misuse of actuator: Piston LM24 – (BS-1460)

• It is important that the actuator should only be used within the End Caps LM24 – (BS-1460)
pressure limits indicated in our technical specifications.
• Operating the actuator beyond its designated pressure may EN8/EN 19 – Electroless
result in either actuator malfunctioning or explosion of Pinion
Nickel Plated
• actuator which may result in hazard to operating or
maintenance personnel. ‘O’ Ring Nitrile / Silicon / Viton
• Operating the actuator over temperature limits will damage Piston pad Stanyl TW-371.
internal and external components which may result in hazard
to operating or maintenance personnel. Piston band Stanyl TW-371
• Disassembly of spring return actuator to be carried out by Piston Bearings Stanyl TW-371
following all the necessary precautions mentioned in section
7.3. Hardware SS304
• Do not operate the actuator in highly corrosive environment
(eg. Offshore applications) without necessary protective
measures such as ENP on external & internal surfaces of 3. Unpacking & storage instructions:
components or SS bodies. Consult factory before use.
• Do not disassemble the individual spring cartridges.
Disassembly may result in personal injury. 1. Box contains material as per packing slip.
2. Do not lift box/heavy products manually.
• Isolate all airlines and make sure that actuator air connection
3. Keep the box on flat/plain surface with arrow side marked at
is vented before installation or servicing of the actuator.
top.
• Do not remove end caps or disassemble the actuator while
the actuator is pressurised.
• Before installing onto a valve, make sure that the rotation of
4. Open up the box from arrow side (Top side) only.
the valve and the actuator are the same and that the position
indicator orientation is also correct. 5. For heavy actuators, follow the lifting procedure given in
Instruction Operation & Maintenance manual.
2. Technical Data: 6. Manual lifting of heavy actuators may cause serious injury.
7. Handle the product with care.
Product Specifications:
All the ‘DelTorq’ actuators are factory lubricated for one million
cycles under normal operating conditions. The ports are plugged
General Features:
to prevent material from entering the actuator during the
Actuator Type: Pneumatic Rack & Pinion type Actuator
shipment. If the actuators are not for immediate use, the following
Actuator Series: Series 21
precautions must be taken during storage.
Size Range: 045 to 200
Actuator Variants:
1. Store the boxes in dry place.
1. Double Acting (DA) actuator
2. Protect the product from rain & heat.
2. Spring Return (SR) actuator
3. Do not remove the plastic plugs on the air supply ports.
Operating medium: Dry Compressed Air
4. Store the actuator with its bottom resting on flat base.
Operating Pressure Range: 2.5bar(36PSI) to 8 bar (116 PSI)
(See Fig A for actuator top & Bottom)
Temperature Range:
5. Duration of storage: 2 years Max from date of mfg.
Standard Actuator: -4 F to 176 F (- 20 C to 80 C)
0 0 0 0

– Nitrile‘O’ ring ACTUATOR TOP

High Temperature Actuator: -4 F to 302 F (- 20 C to 150 C)
0 0 0 0

– Viton ‘O’ ring

0 0 0 0
Low Temperature Actuator: -40 F to 302 F (- 40 C to 150 C)
– Silicon ‘O’ ring
Actuator weights range:
D.A. Actuator: 0.8 Kg. To 45 Kg.
S.R. Actuator: 1 Kg. To 55.5 Kg.
Actuator volume range:
3 3
Opening: 75 cm to 7100 cm
3 3
Closing: 78 cm to 10620 cm
Actuator Opening/Closing time at 5.5bar & orifice dia approx.
4mm: 0.2 S to 3.5 S
Torque range: 2 N-m to 1900 N-m
Lubricants Used: ACTUATOR BOTTOM
General Use: Castrol AP-3 Grease & Mosil 2200
Low Temperature: Mosil SN-64
Fig. A.

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4. Lifting Instructions:
For lifting 175 & 200 actuators, polyester sling is to be used. This
sling is having following specifications:
Length of the sling: 2 m
Width of the sling: 1 “
Material: Polyester
Maximum working load that sling can lift: 800 Kg.
Factor of safety considered: 7
Lifting Arrangement:
1.Hook both the ends of the sling to both ends of the actuator
through left & right end caps as shown in the photograph B.
2. Put the sling into hook of the crane.
3. Ensure that both the ends of the sling are properly being
hooked around the end caps.
4. Lift the actuator slowly with the help of crane at approximate
height of one feet.
5. Ensure proper balancing of the actuator. If the actuator is not
properly balanced adjust the sling with actuator such that proper
balancing of actuator will be done.
6. Now lift the actuator to required height. Rest it at the required
surface. Release the tension in the
sling & remove the sling.
A. Lifting of Size150 SR actuator by Normal Person
B. Lifting of Size 200 SR Actuator with the help of
Sling
5. Putting into Service:
5.1 Before putting into service:
1. Inspect the actuator for any damage during transportation.
2. See all the connections have been made proper.
3. Ensure specified air pressure in the line.
4. Ensure proper quality of air i.e. air should not contain
moisture in it.
5. Adjust the stroke adjustment bolts as per requirement.
5.2 Installation:
1. Ensure that the desired failure mode is correct (Refer to
figure no. 1,2 & 3). The ‘DelTorq’ actuator typically operates
counter clockwise to open and clockwise to close, it is
possible to change this style of operation. If the spring return
actuator is not set up in the configuration desired, follow the
disassembly procedure section 5.2. Reverse the orientation
of the pistons, and then reassemble following the assembly
procedure, section 5.3.
2. Mount the actuator to the valve as per the desired
orientation (parallel or perpendicular to the pipeline).
Mounting with bracket: Place coupling on valve stem and
actuator on mounting bracket. Align valve & actuator in order
to eliminate unbalanced forces on the system; tighten all the
assembly fasteners.
Direct Mounting: Firstly position the actuator on valve.
Insert the valve stem into the insert of pinion into the
actuator. Align valve & actuator in order to eliminate
Installation, Operation & Maintenance Manual
unbalanced forces on the system; tighten all the assembly
fasteners.
3. In case of DA Actuators connect the regulated air supply to
center port ‘A’ (Shown in Fig.1) to open the actuator & side
port ‘B’ to close the actuator.
Note: Use ¼” NPT fittings for connection purpose
except for all the actuators other than 045 & 055 size.
For size 045 & 055 use 1/8” NPT fittings.
Connections to be made should be rigid or flexible
according to requirement of user.
Caution: Make sure that connections made (either
flexible or rigid) must be intended for their use in
potentially explosive environment.
Caution: The maximum operating pressure is 116 psi
(8 bar)
4. In case of SR Actuators, connect the regulated air supply to
center port ‘A’ to open the actuator & exhaust air through
port ‘B’. Silencer may be connected to port ‘B’ to reduce the
exhaust air noise.
5. Adjust the stroke adjustment bolts following assembly
section 5.3.4. Stroke adjustment bolts can be adjusted by up
to ±5°.
5.3 Observe the following things after putting actuator in
service:
1. Actuator is doing its intended function properly.
2. Actuator enable valve opening/closing smoothly and no jerk
& uneven motion is being observed.
3. There is no leakage of air from actuator.
4. There is no any abnormal noise from actuator.
5. If you find any discrepancy in functioning of actuator, please
refer trouble shooting section. After troubleshooting still the
discrepancy observed then contact our authorised
representative on given address.
6. Operation:
The ‘DelTorq’ actuators have simple operational characteristics.
Port ‘A’ (facing the ports and reading right to left) is connected to
the interior cavity between the pistons directing the airflow
into/out of the interior cavity. Port ‘B’ is connected to the end cap
cavities directing airflow into/out of the end cap area.
1 Double Acting (Figure 1):
Air supplied through port ‘A’ forces the piston away from each
other causing the pinion to rotate counter clockwise (with exhaust
air exiting through port ‘B’). Air introduced through port ‘B’ forces
the piston towards each other
Causing the pinion to rotate clockwise (with exhaust air exiting
through port ‘A’).
2 Spring Return:
2.1 Fail Clockwise (FCW) (Standard Scope of Supply) (Figure
2): Air introduced through port ‘A’ forces the piston away from
each other, compressing springs and causing the pinion to rotate
counter clockwise (with exhaust air exiting through port ‘B’). Upon
loss /release of air pressure, springs forces the piston towards
center position causing pinion to rotate clockwise (FCW) (with
exhaust air exiting through port ‘A’).
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 Installation, Operation & Maintenance Manual

2. Removal of Stroke adjustment Bolts (14) (Figure 5):

2.2 Fail Counter Clockwise (FCCW) (Figure 3): Air introduced
through port ‘A’ forces the piston away from each other,
compressing springs and causing the pinion to rotate clockwise
(with exhaust air exiting through port ‘B’). Upon loss /release of
air pressure, springs forces the piston towards center position
causing pinion to rotate counter clockwise (FCCW) (with exhaust
air exiting through port ‘A’).
7. Maintenance:
7.1 General:
‘DelTorq’ actuator can be supplied with Metric / UNC fasteners.
Under normal operating conditions, the actuator requires only
periodic observation to ensure proper adjustment. Service kits
are available to replace seals and bearings (soft parts). These
parts are identified in Figure 24 and listed in Table 4. Table 1 lists
kit numbers.

7.2 Disassembly:
When disassembly of the actuator is required for maintenance,
remove the actuator from the valve. Ensure proper lifting
procedures are followed when moving or carrying actuators.
Caution: Do not use M5 VDI/VDE mounting holes for lifting
the actuator.
When disassembling the ‘‘DelTorq’’ actuators, use caution and be
certain that the actuator is free from accessories and the air
supply is disconnected. When the actuator is a spring-return unit, a) Remove both the Stroke Adjustment Bolts (14) together with
make sure that the actuator is in the failed (closed) position nut (16) washer (15) and ‘O’ Ring (24). Replace the Stroke
before disassembling. Adjustment Bolts (14) in case of excessive wear observed
on the bolt surface.
1. Removal of Local Position indicator (27) (Figure 4):
3. End Cap (02, 03) Disassembly (Figure 6):

a) Remove the end cap bolts (17) in the sequence shown in

a) Remove the counter sunk screw (29), if fitted.
b) Remove the Local position indicator (27) from the pinion
(05). It may be necessary to pry gently with a screwdriver.
the (figure 6).
Caution: When disassembling a spring return actuator, the
end cap (02, 03) should be loosen till spring tension get
released. If there is still force on the end cap bolt (17), this
may indicate a damaged spring cartridge and any further
disassembly should be discontinued. Further disassembly of
the end caps may result in serious personal injury. Return
the actuator to DelTech for further maintenance.
b) For spring return actuators, remove spring cartridges (08)

c) Remove end cap ‘O’ rings (23) and discard if replacing all
soft parts.

4. Piston (04) Disassembly (Figure 7):

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 Installation, Operation & Maintenance Manual

Table 2: Recommended Lubricants

General Use CASTROL GREASE - AP3
Low Temperature MOSIL - SN 64

1. Pinion (05) Assembly (Figure 09):

a) Hold the body (01) in a vice or similar device. Rotate the

pinion (05) until the pistons (04) reach the end positions (i.e.
the piston rack teeth disengages with pinion teeth).
Caution: Air pressure should not be used to remove the
pistons from the body. Clean and inspect the piston teeth
for signs of wear. Replace pistons, if wear seems excessive.
b) Remove piston ‘O’ rings (22), piston guide band (10). a) Install the top and bottom bearings (11, 12) and ‘O’ rings
Discard the ‘O’ rings and guide band, if replacing the soft (20, 21) on to the pinion (05).
parts.
b) Apply grease to the pinion bearings (11, 12), shaft ‘O’ rings
(20, 21) using general-purpose grease listed in table 2.
5. Removal of Pinion (05), Cam (06) and bearings (11, 12)
(Figure 8):

a) Remove the circlip (19) using a circlip plier.

b) Remove the shim (25).
c) Remove the top thrust bush (07).
d) Apply a downward force to top of the pinion (05) so that the
pinion will move out of the center of the body (01) and
remove the cam (06), it may be necessary to pry gently to c) Insert the pinion (05) in to body (01) from the bottom side up
cam with a screwdriver. Observed the cam surface for to body center.
excessive wear, where the stroke adjustment bolts are d) Insert the cam (06) & bottom thrust bush (07) on the pinion
resting and the cam ID (Square c/s) replace the cam, if (05).
excessive wear is observed.
e) Apply a downward force to top of the pinion (05) so that the
pinion will move completely out of the bottom of the body
(01). If the Pinion (05) does not move freely, gently tap with
a plastic mallet.
f) Remove the top and bottom bearings (11, 12) and top and
bottom ‘O’ rings (20, 21). Discard if replacing all soft parts.
6 Things to do during maintenance:
1. Clean all the parts of an actuator with the help of damp cloth.
2. Inspect all the parts of the actuator thoroughly.
3. Observe for any scratch on inner diameter of the actuator
body.
4. Observe for any crack or wear of casting components.
5. Observe for any wear & tear of soft components.
6. If any wear found , replace that component with new one.

7.3 Assembly:

Prior to assembly, ensure that all components are clean and

undamaged.
It is recommended to use the lubricants as mentioned in Table 2.

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e) Insert the pinion (05) into the body (01) from the bottom
side. Ensure that bottom surface of the pinion should be
around 0.5mm inside the body bottom face and the pinion
top slot orientation is as shown in figure 11.
f) Insert the top thrust bush (07) & shim (25) & circlip (19)
(using the Circlip Plier) on the pinion (05).
2. Piston (04) Assembly (Figure 12 & 13):
a) Fit piston pad (09), piston guide band (10), and piston o-
rings (22) on the pistons (04).
b) Apply grease to the internal bore of the body (01) & to the
piston rack teeth using recommended general - purpose
grease listed in table 2.
c) Press the two pistons simultaneously in the body bore until
the pinion racks are engaged and rotate the pinion until the
stroke is completed. Take care that the pistons are oriented
correctly as per the fail position of the actuator (The
standard fail action of actuator is fail clockwise). Refer Fig
12 & Fig 13.
d) To ensure that the piston (04) teeth are evenly engaged,
fully compress both the pistons inward and measure the
distance from the edge of the body to the piston (04) face on
each side, shown as dimension ‘A’ in figure 13. If a different
value is obtained on each side, remove the pistons and
repeat from step 2c.
Installation, Operation & Maintenance Manual
e) Temporarily install the local position indicator (27) onto the
pinion (05) to determine whether the correct stroke is
obtained. Ensure that the arrow in the local position indicator
(27) will rotate a minimum of 5° beyond the 90° vertical
centerline of the actuator body (01) and a minimum of 5°
beyond the 0° horizontal centerline of the actuator body as
shown in figure 14. If the proper stroke is not obtained,
remove the pistons and repeat from step 2c. Once proper
stroke is obtained, remove the local position indicator (27).
SPRING RETURN ACTUATORS.
• For spring return actuator, insert the proper quantity of the
spring cartridges (08) according to the pattern shown in
Fig 16 (referring to the total number of springs). Insert the
spring cartridges (08) as shown in Fig 16.
• Ensure proper alignment of spring cartridge during assembly
of end cap.
• Apply grease to the end cap ‘O’ rings (23). Fit the ‘O’ rings
(23) into the groove in each end cap (02, 03). Fit the Plug
Transfer port (13) inside the body (01) on each side. Fit the
end caps. Insert all the end cap bolts (17) (Apply grease to
the end cap bolts refer table no-3) and hand ghten.Complete
tightening by following the sequence indicated in Fig 15.
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 Installation, Operation & Maintenance Manual

Position. (In most of the applications, this will be parallel to

0
the actuator body i.e. at 0 ).
e) If the pinion top slot is not in the correct counter-clockwise
position, turn the left stop adjustment bolt (14) IN to reduce
actuator travel, or OUT to increase actuator travel.
f) When the correct counter-clockwise position is obtained,
hold the adjusting bolt (14) stationary while tightening the
nut (16).
g) Special machined slot provided on the stroke adjustment
bolt to release the pressurized air after extra Opening of the
bolts hence to avoid blow out of the stroke adjustment bolts.
(As shown in fig. 18a)

DOUBLE ACTING ACTUATORS

Table 3: Recommended Lubricants

ANTI SEIZE GREASE MOSIL - 2200
• Apply grease to (refer table no-2) the end cap ‘O’ rings (23).
Fit the ‘O’ rings (23) into the groove in each end cap (02,
03). Fit the Plug Transfer port (13) inside the body (01) on
each side.
• Fit the end caps (02, 03) onto the body (01), verifying that 5. Local Position indicator Assembly (Figure 19):
the ‘O’ rings (23) remain in the groove. Insert all the end cap • Fit local position indicator (27) assembly on to the pinion
bolts (17) (Apply grease to the end cap bolts refer table (05). Ensure that it indicates the correct Actuator position.
no.3) and tighten the bolts as per torque given in torque • Tighten the counter sunk screw (29) to secure the local
table. Complete tightening by following the sequence position indicator
indicated in Fig 17.

For valve Fail safe to close condition

Local position indicator to be fitted on actuator as shown in fig. A
For valve Fail safe to open condition
Local position indicator to be fitted on actuator as shown in fig. B
3. Assembly of Stroke Adjustment Bolts (14): (Figure 18) Convention for Local Position Indicator:
a) Insert the nut (16), washer (15) onto the stroke adjustment
bolt.
b) Insert the “O” Rings (24) in the body (01) “O” Ring groove.
c) (Apply grease to the stroke adjustment bolt (14) Refer table
No. 3) Screw in the bolts (14) into the body (01).
4. External Travel Stop Adjustment (Figure 18):
The stroke adjustment bolt to the right controls the clockwise Local Position Indicator Local Position Indicator
end of travel, while to the left controls the counter-clockwise showing VALVE in ‘OPEN’ condition
end of travel. VALVE in ‘CLOSE’ condition
a) Cycle the actuator to the clockwise end of travel and FIG.B
determine if the pinion top slot is in the proper position (In FIG.A
most of the applications this will be perpendicular to the
0
actuator body i.e. at 90 ) NOTE:
b) If the pinion top slot is not in the correct position, turn the
right stop adjustment bolt (14) IN to reduce actuator travel, 1.Actuator considered being parallel to the pipeline
or OUT to increase actuator travel. 2. Valve considered being perpendicular to the pipeline
c) When the correct clockwise position is obtained, hold the
adjusting bolt (14) stationary while tightening the nut (16).
d) Cycle the actuator to the counter-clockwise end of travel and
measure to determine if the pinion top slot is in the proper

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 Installation, Operation & Maintenance Manual

7.4 Tightning torques for actuator end cap bolts & valve with actuator mounting bolts:

Endcap bolts tightning torques Actuator mounting bolts

Size
(N-m) tightning torques (N-m)

M4 5 3
M5 / 10-24 UNC 10 6
M6 / 1/4”- 20 UNC 16 10
M8 / 5/16”-18 UNC 40 25
M10 / 3/8”- 16 UNC 80 48
M12 / 1/2” - 13 UNC 135 83
M16 / 5/8” - 11 UNC 360 218

8. 100% TRAVEL STOP ARRANGEMENT. (FIG No, 20 & 21)

(OPTIONAL)

This arrangement is used to restrict opening of the actuator to any position between full close (-5º) to full open (100º) position. This is
achieved by rotating the stop bolt (31) in clock wise / counter clockwise direction as per the desired stroke.

Note: - 100% travel stop arrangement is possible in only one direction i.e. during opening of the actuator.

9. SIZE 045 ACTUATOR

9.1 Pinion design permits pinion to be inserted from top or bottom of the actuator to use all three bolts circles (F03, F04 & F05).

9.2 To use F03 & F05 Bolt Circle, Actuator to be assembled as shown in fig –22
Note: - For Double acting actuator air to flow in right inlet port to open the actuator, to close the actuator air to flow in the left inlet port. In
spring return actuator air to flow in right inlet port to compress the springs and open the actuator, Springs to close the actuator.

9.3 To use F04 Bolt Circle, Actuator to be assembled as shown in fig –23
Note: - For Double acting actuator air to flow in left inlet port to open the actuator, to close the actuator air to flow in the right inlet port. In
spring return actuator air to flow in left inlet port to compress the springs and open the actuator, Springs to close the actuator.

9.4 External travel stop arrangement given for opening the actuator at 0 to 90º or 0º to 95º position.

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 Installation, Operation & Maintenance Manual

10.Things that are to be observed after maintenance:

1. Ensure that all internal ports are clear and free from foreign
particles.
2. Ensure all the soft parts are cleaned & free from dust.
3. Ensure all the components are being assembled correctly.
4. Ensure cleanliness of inside grease before assembly.
5. All the parts are properly fitted.
6. End cap bolts are tightened to required tightening torques
given in this IOM.
7. Adjust the stroke adjustment bolt as per instructions.
8. When putting into service after maintenance, observe the
same things mentioned in section 5.3
11.Troubleshooting:
1. Check that air supply is at required pressure.
2. Ensure that the air supply is not restricted in any way.
3. Check for air leakage on supply lines to the actuator.
4. Check leakage at top & bottom of the pinion shaft.
5. Check for leakage across the piston seal by applying
pressure to port B and looking for leakage from port A
If required torque is not achieved, see for problem in the valve
itself.
12. IMPORTANT:
i any kind of injury.
1. Periodic maintenance of the actuator to be carried out after
every 2,00,000 cycles.
2. Soft parts of an actuator like Piston pad, piston band, ‘O’ ring,
bearings are to be replaced after every 5,00,000 cycles.
(Refer spares list mentioned in section 17)
3. Surface temperature of actuator may get rise up to Maximum
0
49 C under extreme working conditions (tested under lack of
lubrication for internal moving parts & maximum working
pressure.)
4. Always remove the air & electric supplies before carrying out
any form of maintenance on an actuator.
5. Remove all the accessories like solenoid valve, AFR unit
before carrying out maintenance.
5. This manual refers only for Deltorq series 21 actuator.
Controls & accessories are referred to End user’s scope. Delval
flow controls recommends ‘CE (ATEX)’ marked controls &
accessories for its use in potentially explosive environment.
6. Control system should be designed such that starting of
actuator should be possible only after voluntary actuation of
control.
7. Actuator START/STOP function depends only upon supply of
air. Control of air is scope of user.
8. Air to be supplied for actuator must be clean & dry and should
not contain any hazardous gas.
9. In case of accidental blockage do not open actuator. Return
the actuator to Deltorq for further maintenance.
10. Do not size the actuator for higher torques than
recommended to avoid overloading.
11.Silencer should be used to reduce the noise from actuator.
It should be connected to exhaust port (B) of actuator.
Potential Ignition sources that can cause ignition:
1. Electrostatic phenomenon caused by non-metallic
components.
2. Dust Deposits in gap
• Connection pieces to valves must be designed for
optimal dust protection
• Dust deposited on the exterior parts of the actuator
must be removed regularly. Dust deposition layer
should not be more than 5mm on connection pieces
to the valve.
3. Mechanical Impact on actuator body
• Take preventative measure to avoid mechanical
impact on actuator body.
14. Other instructions:
14.1 Necessary personal protection equipment:
Although, pneumatic rack & pinion actuator does not need
operator to operate & it operates on pneumatic energy, no
special protection measures are needed while it is operating.
But while handling the actuator operator must wear personal
safety equipments such as hand gloves & safety shoes to avoid
Also operator must follow the instructions given for lifting heavy
actuators.
14.2 Scrapping of soft parts: Soft parts are to be scraped,
after use of them for predescribed operating cycles, according to
the norms of countries in which they are being used.
14.3 Caution:
Material used for local position indicator is Plastic, which may
produce electrostatic charges due to rubbing action. So it must
be cleaned with damp cloth to avoid any kind of electrostatic
discharge.
14.4 Emergency Situations:
In emergency situatuations it is always advisable to stop the
operation of actuator. As the actuator operates on pneumatic
energy, the only way to stop the actuator by cut- off air supply.
In case of emergency contact the Authorized Representative of
Delval Flow Controls Pvt. Ltd. in the respective country.
14.5 Legal Bindings: Strictly adhere to instructions given in
this IOM for intended use of the product. Delval Flow Control will
not be responsible for misuse of equipment at customer end.
CE Nameplate:

13.Atex Instructions for use in potentially explosive

environment.
DelVal Flow Controls Private Limited
Safety Instructions: DelTech

• Prevent any kind of ignition during installation,

adjustment, putting into service & use.
• Assembly, disassembly & maintenance must be done
outside potentially explosive areas.
• Installation, adjustment, putting into service, use,
assembly, disassembly, and maintenance of
pneumatic actuator is strictly reserved to qualified
persons.
• Rubbing of shim & circlip and rubbing of shim &
washer may produce electrostatic discharge. But as
the actuator gets mounted on the valve directly or
indirectly, there is always metal-to-metal contact
between valve stem & actuator insert. So any
electrostatic discharge may ground through valve.
User must ensure earthing of valve before installation.

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15.Engineering:

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16. Exploded View: (Figure-24)

17. Part List:

NOTE: For ordering of individual component refer above table. Order the individual component by giving number &
part description for particular size of actuator.

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 Installation, Operation & Maintenance Manual

18. Ordering Code for Actuators:

BOLT CIRCLE
SHAFT SHAFT SPECIAL
SERIES ACTUATOR SIZE NO. OF SPRING DIAMETER &
ROTATION CONNECTION OPTION
UNC TAPPING

DIGIT-1 DIGIT-2 DIGIT-3 DIGIT-4 DIGIT-5 DIGIT-6 DIGIT-7 DIGIT-8 DIGIT-9 DIGIT-10 DIGIT-11 DIGIT-12
21 = standard 045 00 = Double acting C = fail P= 00 = Serrated 0 = Standard
actuator 055 clockwise 1.97/1.42/1.65, actuator
065 12 = spring return, direction (STD) 1/4”-20 01= 0.55x0.39 (No Special
2L = for low 075 6&6 10-24UNC (055 / 065) requirements.)
temperature 085 F = Fail counter T=
actuator 100 clockwise 2.76/1.97/1.42 03 = 0.75 x 0.51 Note:- for
115 direction 5/16”-18 (075 / 085) special
125 1/4”-20 requirement as
150 S = Stayput (for 10-24UNC 04 = 0.87 x 0.63 specified by
175 double acting) A= (100 / 115) customer.
200 counter 2.76/1.97
clockwise. 5/16”-18 05 = 1.18x 0.87
1/4”-20 (125 to 175)
Y = Stay put (for 7 =
double acting) 4.01/2.76 22 = Ø1.38 R & K
clockwise 3/8” -16
opening 5/16”-18
B=
4.92/4.01/2.76
1/2”-13
3/8” -16
5/16”-18
Y=
4.92/4.01
1/2”-13
3/8” -16
D=
6.5/4.92
3/4” -10
1/2”-13

Ordering Code for Repair Kit/ Seal Kit :

COMPONENT
SERIES ACTUATOR SIZE MATERIAL CODE TEMPERATURE REVISION
CODE

DIGIT-1 DIGIT-2 DIGIT-3 DIGIT-4 DIGIT-5 DIGIT-6 DIGIT-7 DIGIT-8 DIGIT-9 DIGIT-10
21 = standard 045 RK = Repair Kit 3 = Nitrile (Normal temperature) L = Low temperature
actuator 055 SK = Seal Kit 4 = Viton (High temperature) N = Normal temperature
2L = for low 065 S = Silicon (Low temperature) H = High temperature
temperature 075
actuator 085
100
115
125
150
175
200

DelVal Flow Controls Private Limited Address of Authorised

Gat No. 625/1/2,Kuruli, Pune- Nasik Highway, Representative
Pune-410501
Phone: 02135 –661700 Fax: 02135- 662727
Email: sales@deltechcontrols.com
Website: www.deltechcontrols.com

Note: If you have any technical questions that have not been taken into account in this manual, then
please contact the Athorised representative of Delval Flow Controls.

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