®

CAMERON LEDEEN
Quarter Turn Actuator
SY Series – IP67 Pneumatic
Installation, Operation and Maintenance Manual

10/05/2019 Initial release Tartara A. Negrini D.

DATE ISSUE PREPARED BY APPROVED BY

Schlumberger-Private
All the information contained in this manual is the exclusive property of Cameron. Any reproduction or use of
the calculations, drawings, photographs, procedures or instructions, either expressed or implied, is forbidden
without the written permission of Cameron or its authorized agent.

Release – May 2019

© 2019 Cameron, a Schlumberger Company

1
 PREFACE
The procedures included in this book are to be performed in conjunction with the requirements and
recommendations outlined in API Specifications. Any repairs to the equipment covered by this book should be
done by an authorized Cameron service representative. Cameron will not be responsible for loss or expense
resulting from any failure of equipment or any damage to any property or death or injury to any person resulting
in whole or in part from repairs performed by anyone other than authorized Cameron personnel. Such
unauthorized repairs shall also serve to terminate any contractual or other warranty, if any, on the equipment
and may also result in equipment no longer meeting applicable requirements.

File copies of this manual are maintained. Revisions and/or additions will be made as deemed necessary by
Cameron. The drawings in this book are not drawn to scale, but the dimensions shown are accurate.

This book covers Cameron products.

Cameron, a Schlumberger Company

Ledeen Facility
Via L. Gandini 4
27058 Voghera (PV) – Italy
cameron.slb.com

2
NOTES:

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CONTENTS
I. GENERAL .......................................................................................................................................................................................5
A. Legend for Safety Symbols .......................................................................................................................................................5
B. Original Spare Parts ..................................................................................................................................................................6
C. Operative Staff ..........................................................................................................................................................................6
D. Damages Derived From Use .....................................................................................................................................................6
E. Interruptions and suspending ....................................................................................................................................................6
F. Modification of The Actuator .....................................................................................................................................................6
G. Actuator Disposal ......................................................................................................................................................................6
H. Safety of the Power Supply Connection (If Applicable) .............................................................................................................7
I. Safety Recommendations .........................................................................................................................................................7
J. Electrostatic Discharges Prevention .........................................................................................................................................7
K. Actuator Marking (According to 2014/34/EU Directive) .............................................................................................................8
L. Actuator Name plate description ...............................................................................................................................................9

II. RECEIVING,STORAGE AND HANDLING ..............................................................................................................................10

A. Preliminary Verification Upon Receipt of Material ...................................................................................................................10
B. Storage and Preservation .......................................................................................................................................................10
C. Handling ..................................................................................................................................................................................12

III. OPERATION ...........................................................................................................................................................................18

IV. COMMISSIONING ..................................................................................................................................................................18

A. Mounting to Valve (With Adaptor Piece) .................................................................................................................................18
B. Adjustment ..............................................................................................................................................................................20
C. Actuator Start up .....................................................................................................................................................................25

V. MAINTENANCE ......................................................................................................................................................................27
A. Routine Maintenance ..............................................................................................................................................................27
B. Extraordinary Maintenance .....................................................................................................................................................28
C. Instruction for replacement of Dynamic seals .........................................................................................................................28

VI. TROUBLE SHOOTING & REMEDIES ....................................................................................................................................31

VII. DISASSEMBLY AND REASSEMBLY .....................................................................................................................................32

A. Disassembly: ...........................................................................................................................................................................39
B. Reassembly: ...........................................................................................................................................................................48
C. Adjustment after assembly: .....................................................................................................................................................51

VIII. SPARE PARTS .......................................................................................................................................................................52

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I. GENERAL
• Keep this manual for future reference.
• Please keep this manual near the actuator so that it is available for consultation.
• For questions or clarifications please contact cameron.slb.com
• To get / request new copies of the manual please contact cameron.slb.com
• The manufacturer reserves the right to modify , without prior notice, the characteristics of the equipment
described in this publication and is not obligated to update any products and manuals previously issued.
• This manual shall be read in conjunction with applicable technical documentation shipped with
actuator

A. Legend for Safety Symbols

Explanation of Warning Symbols (Where Applicable)

Before carrying out any operation on the actuator, the electric power
supply (if present) must be shut-off.

Risk of explosion: before carrying out any operation on the actuator, the
actuator must be isolated from the pneumatic supply source.

Before carrying out any operation on the actuator, the control group (if
present) must be discharged from the pressure therein trapped, particular
care shall be taken on storage tanks and pressure filters.

Every operation on the actuator must be performed by qualified personnel,

equipped with safety clothes and devices (gloves, helmet, glasses, etc.).

During the operation on the actuator, the operator must pay attention to
the presence of liquids potentially noxious for the health and the
environment.

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B. Original Spare Parts

The use of any non-genuine Cameron spare parts by customer exempts Cameron from any responsibility
for indemnity on claims.

C. Operative Staff

The maintenance-staff assigned to Cameron's Ledeen products must have the qualified technical
preparation to perform the function. The lack of the above-mentioned preparation, included therein the
unavailability to attend adequate training courses by specialized Cameron technicians at its workshop,
cannot be charged to the company Cameron, who will be considered exempt from any responsibility on
claims. Also the lack of knowledge, by the operative personnel, of the manuals and instruction books
supplied by Cameron in the languages indicated in the supply contract, cannot be imputed to Cameron.

D. Damages Derived From Use

Any damage derived from corrosion, fouling, pollution, oxidation, wear, or gradual deterioration of the
materials, for which the customer did not specify the adaptability limits, will be at the Customer’s own loss.

E. Interruptions and suspending

Damages derived from a period of instrument use failure, during which the instrument wasn’t in
maintenance condition to assure a perfect preservation, will be at the customer’s own loss.

F. Modification of The Actuator

Damages derived from any modification made by the customer without prior authorization from Cameron,
especially if not in accordance to the initial conditions established in the buying order, will be at the
customer’s own loss.

G. Actuator Disposal

To finally dispose the actuator at the end of its operating life, please carry out the following operations:
• Open the frame enclosure.
• Remove the lubricants taking care not to pollute the environment.
• Clean the frame internally using a mixture of water and degreasing soap.
• Dispose of the cleaning fluid and lubricants extracted from the actuator according to
the local laws regarding the disposal of waste material.
• After the actuator’s disposal, all casings must be sent to the scrapping service.
• In case of replacement of any part, it must be handled and disposed of as listed in
the owner's manual.

6
 • If the actuator is provided with spring container:

Warning:

DO NOT OPEN AND/OR FORCE THE SPRING CONTAINER

The spring container contains one or more compressed springs.

A forced or non-controlled opening of the container can cause the non-controlled and violent ejection of
material potentially harmful to people and/or capable of causing damage to property.
The opening and disposal of the spring container must be carried out only by authorized personnel.
Please contact Cameron in case of any doubt or for further information.

H. Safety of the Power Supply Connection (If Applicable)

Before carrying out any operation on the actuator, check that the power supply is off.

Before connecting the actuator:

• Verify the absence of the power supply and always connect the ground cable to the actuator first.
• Check that the power supply line characteristics are in accordance with the nameplate and
installation manual data.

I. Safety Recommendations

Check that the ground resistance complies with the limits allowed by the National Laws relevant to the
country where the actuator is installed.
If the actuator is stored/installed in a hazardous area, do not use open flames and/or devices that could
cause sparks.
At the end of any intervention on the actuator please check that all the boxes and covers are properly
closed.
The operators assigned to the actuator's maintenance must be authorized personnel or otherwise must
have attended a training course dedicated to the use and maintenance of the actuator.

J. Electrostatic Discharges Prevention

The actuator handling must be carried out using the handling ring supplied with the actuator. In order to
prevent the electro-static charges storage, attention must be paid during the cleaning of any external
component made from plastic material.
The plastic material must be cleaned only with a damp cloth or with antistatic products.

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 K. Actuator Marking (According to 2014/34/EU Directive)

Please refer to the following example of actuator marking:

εX II 2 G c Tx

Where:

= symbol of conformity to the EU applicable directives

εX = ATEX symbol

II = group II (surface)
2 = apparatus of category 2
G = explosive atmosphere with presence of gas, vapours, fogs
c = type of protection
Tx = temperature class

Hazardous area Installation category according to ATEX Directive No. 2014/34/EU

Gas, fog or vapours Zone 1 2G
Gas, fog or vapours Zone 2 3G

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 L. Actuator Name plate description

The actuator nameplate shows the following data:

1. Contract No.
2. Order No.
3. Item No.
4. Actuator model
5. Valve size
6. Year of manufacturing
7. Actuator Serial No.
8. Actuator Tag No.
9. Name and complete address of the manufacturer

(*) where applicable

See for reference the nameplate drawing below.

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II. RECEIVING,STORAGE AND HANDLING
A. Preliminary Verification Upon Receipt of Material

Warning:

At receipt of the material:

1. Check the completeness of the supply, by referring to the packing list;

2. Check the tag number, serial number and technical information in the nameplate with reference to the
order acknowledgement.
3. The actuators are delivered with plugged connections. Which must remain plugged if not utilized or must
be re-plugged with the relevant plug or reconnected after any testing operation.
4. Carry out a preliminary verification in order to ensure:

• The integrity of the material and the absence of damages;

• The integrity of the painting. If necessary, carry out the paint touch up, by following the instructions
of the painting specification (please refer to the technical documentation);
• The presence of the plugs on all the pneumatic and (where present) electric connections.

B. Storage and Preservation

Warning:

If the storage of the actuator is necessary, please follow these instructions.

Storage conditions
The actuator must be stored in a warehouse adequately protected against harmful environment.
The recommended ambient temperature is : Minimum - 20°C / Maximum 70°C
Relative Humidity : Maximum + 90%

Indoor storage
• Restore the paintwork of the components that have been damaged during transport
• Place the actuators on a wood surface pallet so as to prevent direct contact with the
ground.
• Keep the electric components (where present) perfectly dry.

Outdoor storage
• Restore the paintwork of the components that have been damaged during transport
• Place the actuators above the ground level.

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 • To store the actuator at temperatures below of –30°C and up to +70°C, it is necessary to carry out
additional checks and tests from time to time, depending on the ambient conditions.

Preservation conditions
The procedures that must be performed to the equipment during storage to assure proper operation of
the equipment after installation are the following:
• Place the actuators on a wood surface pallet so as to prevent direct contact with the ground.
• Protect all unpainted parts with grease.

Note : Before installing the actuator, perform one complete operation (opening and closing) to
verify it strokes properly.

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 C. Handling

Proper Lifting, Weights and Dimensions, Fastener Torque Chart

Warning:

Important: These instructions refer to the lifting of the actuator only, not assembled on the valve.
Do not attempt to lift the actuator-valve assembly by using the lifting points of the actuator:

The lifting equipment consists on commercial chains and slings of adequate dimensions, according to the weight
of the actuator.

Refer to the following sheets for standard commercial equipment.

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LIFTING DEVICES MAXIMUM WORKLOAD

Chains

13
LIFTING DEVICES MAXIMUM WORKLOAD

Slings

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15
16
17
III. OPERATION

This series pneumatic actuator is designed for on-off and control service and is applicable over a wide range of
pressure, temperature and environments.
The scotch yoke mechanism converts the linear motion of pneumatic piston into valve rotation by the actuator
shaft. The symmetric scotch yoke mechanism generates high torque at start (0° degree) and the end (90°
degree) of the valve stroke. The canted scotch yoke mechanism generates very high torque when valve is
closed.

Pressure is applied via supply ports in either end of the cylinder assembly onto pistons running within the
cylinder liner. This enables the scotch yoke mechanism of the actuator to drive in both directions.

IV. COMMISSIONING

A. Mounting to Valve (With Adaptor Piece)

The actuator can be assembled on top of the valve flange either by using the actuator-housing flange with
threaded holes, or by the interposition of a proper mounting hardware.

Warning:

Note: No special tools are required for these operations, but only some Allen wrenches and hexagonal
wrenches of the required sizes.

Before the installation, please check that the actuator was not damaged during the transportation.

The actuator along with the adapter assembly is shipped to mount on the valve. In case it is necessary to
assemble the actuator onto the valve, proceed as follows:

The actuator drive sleeve is generally connected to the valve stem by an insert bush or a stem extension.
The assembly position of the actuator, with reference to the valve, must comply with the plant requirements
(cylinder axis parallel or perpendicular to the pipeline axis).

a. Check that the coupling dimensions of the valve flange and those of the valve stem meet the coupling
dimensions of the actuator.

b. Clean the flange of the valve and remove anything that may prevent a perfect adherence to the actuator.

c. Lubricate the shaft of the valve with oil or grease.

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d. Set the actuator position same as that of the valve position, either open or close.

e. Lift the actuator by means of adequate slings as per the weight of the actuator to render the perfect
horizontal (this is very important for easy coupling) utilizing the existing lifting point on the actuator. (refer
to page no. 12-16)

f. Clean the adapter piece flange and remove anything that may prevent a perfect adherence to the valve.

g. Lower the actuator onto the valve in such a way that the adapter, assembled on the valve stem, enters
the actuator drive sleeve. This coupling must take place without forcing and only with the weight of the
actuator.

Note: Ensure that the adapter is fixed to the valve stem by means of the screw provided along with the
adapter. (Refer the below picture)

Note: Caution should be taken while connecting the adapter piece on to the valve stem.

h. Check if the holes of the valve flange and adapter flange meets as well as any dowel pins (if provided).
If yes secure the actuator to the valve using correctly sized fasteners.

i. Uniformly tighten the fasteners of the adapter flange. (refer to page no. 17 for tightening torque of
fasteners).

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 B. Adjustment

Warning:

Note: No special tools are required for these operations, but only some hexagonal wrenches of the required
sizes.
Important: The actuator is shipped with a preliminary adjustment and not on the real valve stroke. If it is
necessary to change the adjustment, proceed as follows:

a) Adjustment of mechanical stops

After having removed relevant cap nut (item 23 for opening side & item 42 for closing side) & loosening
locking nut (item 24 for opening side & item 39 for closing side) rotate the mechanical stops (item 22 for
opening side & item 52 for closing side) clockwise or counter-clockwise for adjusting the angular stroke.

By rotating the mechanical stops (item 22 for opening side & item 52 for closing side) clockwise, the
angular stroke is reduced. Rotating counter-clockwise, the angular stroke is increased.

Double acting actuator

Note: For Spring return actuators, before adjusting the mechanical stops on the pneumatic cylinder, it is
necessary to pressurize the same with required pressure in order to reduce the pressure provided by the spring
thrust against the mechanical stop to be adjusted.
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Spring return actuator

21
When the end cap seals need to be replaced (DA & SR) follow the instructions below:

1. Place the actuator in fail safe position.

2. Remove any electric power and pressure supply.
3. Remove the cap nut and clean the surface in contact with the lock nut and the internal thread.
4. Remove the locking nut paying attention that the mechanical stop does not move from the original position.
5. Remove the existing O-rings and clean both surfaces and the thread.
6. Clean the surface of the end flange of the cylinder.
7. Install the new o-rings and apply a grease film.
(suggested grease: Parker super-o-lube or equivalent)
8. Install the locking nut , applying 45-50Nm torque.
9. Install the cap nut, applying 45-50Nm torque.
10. Restore the normal working condition and pressurize the actuator, checking for leakages throug the parts.
11. Restore, if necessary, the paint layer as per the original paint specification.

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b). Verification of Position Indicator

Warning:

Note: No special tools are required for these operations, but only some Allen wrenches and hexagonal
wrenches of the required sizes.

Position indicator alignment

Verify the correct indication of the actuator position by the local position indicator:

• OPEN when the actuator is in open position. Pointer will be parallel to the axis of the actuator.

• CLOSED when the actuator is in closed position. Pointer will be indicating perpendicular to the axis of
the actuator.

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For frame equipped with Namur interface, refer to STC1780 for dimensional drawing.

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C. Actuator Start up

a. Arrangement for start-up

Warning:

Note: No special tools are required for these operations, but only some Allen wrenches and hexagonal
wrenches of the required sizes.
Pneumatic connections:

a. Before connecting the actuator to the pneumatic supply line, check that pipes and fittings are according
to the applicable plant specifications, in order to guarantee the required air flow for the operation of the
actuator and to avoid that the supply pressure drops below the minimum allowable value.
b. Clean the inside of the pipes used for connection by washing them with suitable detergent and by
blowing air into them. Take every precaution to remove any solid or liquid foreign matter from the pipe
work to the actuator, so as to avoid possible damages to the actuator itself or loss of performance.
c. Fasten the piping in a right way, in order not to cause loosening of threaded connections, in the event
that the system may be subject to strong vibrations.
d. After the completion of the pneumatic connections, operate the actuator in order to
ensure that it works correctly. Also check that its operating times are in accordance with those specified
in the test certificate and that there are not leakages in the pneumatic connections .

Electric connections:

a. Introduce connection cables.

b. Make the connections in compliance with applicable wiring diagrams on the documentation supplied.
c. Tighten the cable gland.
d. Replace the plastic plugs of unused entries with metal plugs.

b. Start-up

Warning:

Note: No special tools are required for these operations, but only some Allen wrenches and hexagonal
wrenches of the required sizes.

a) Carry out the electrical in accordance with the electrical wiring diagram.

b) Check that the pressure of the process supply, as well as its quality (filtering degree, dehydration) are
as prescribed.

25
c) Check that the feed voltage values of the electric components (solenoid valves coils, micro switches,
pressure switches etc., if applicable) are as prescribed.

d) Check that the actuator controls, such as remote control, local control, emergency control etc. (if
applicable), are properly working in accordance with the schematic diagram.

e) Check that the required remote signals (valve position, air pressure, etc.) are correct.

f) The setting of the components of the actuator control unit is according to the requirements of the plant.

g) Check that there are no leaks in the pneumatic connections. If necessary tighten the fittings.

h) Check the correct working of the actuator with the pneumatic supply in open and closed direction.

i) Restore the paintwork of the components which may have been damaged during transportation or
commissioning after having removed the rust.

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V. MAINTENANCE
Every maintenance operation on the actuator must be carried out only after having closed the pressure taps
in order to prevent undesired operation and enable the operating personnel to work in safe conditions.
If present, shut-off the electric power supply and check the absence of hazardous atmosphere near the
actuator.

A. Routine Maintenance

Warning:

Every 6 months:

a) Check the correct valve position signalling on the control panel.

b) Check the correct working of the actuator with pneumatic supply by manually stroking the same for a
small percentage not to affect the flow in the main line. The actuator shall be operated back to its initial
position just after the partial stroke end line is reached. This operation can be automatically performed
by means of the partial stroke test facility, if any.
c) If provided with a manual override (hand wheel or hand pump) check the correct working by operating
the actuator for a small percentage not to affect the flow in the main line. The actuator shall be operated
back to its initial position just after the partial stroke end line is reached.

Every year:

a) Check the lubrication of the scotch yoke and if necessary lubricate with SHELL GADUS S5 or equivalent
grease.
b) Check that there is no leakage from the piston rod of the cylinder.
c) Remove, if any, the condensation in the housing, by actuating the pressure relief valve placed on the
bottom of the housing.

Every 3 year:

a) If provided with a hand pump override check that the oil is in good condition and that it is always clear.
b) Ensure the oil is changed as per the oil manufacturer’s Material Safety Data Sheet.

Important: In case of oil change, the replaced oil must be disposed of as special waste, in accordance to
the laws applicable in the country where the actuator is installed.

c) A replacement of all the soft seals in the control panel (where applicable) is suggested.

27
B. Extraordinary Maintenance

Warning:

a) In case of leakage from the pneumatic cylinder, disassemble, clean the O-ring grooves and substitute
the O-ring if damaged.
b) If there is a leakage from the pneumatic piping, tighten the fittings, or if necessary, change them if
damaged.
c) In case of malfunction or leakage from the actuator, disassemble referring to the disassembly section
(from page no. 32). Clean with care and replace damaged components.

Important: In case that the actuator or any of its part must be replaced, please follow the instructions of the
“ Actuator Disposal” .

C. Instruction for replacement of Dynamic seals

Warning:

If there are leaks in the pneumatic cylinder or a malfunction in the mechanical components, or in case of
scheduled preventative maintenance, the actuator must be disassembled and seals must be replaced
with reference to the disassembly section (from page no. 32) and adopting the following procedure.

Note: When the seals need to be replaced, it is necessary to check before assembly, that their seats are
clean and lubricated.

a) Replacement of Piston seal: ( See Figure 1 )

For replacing piston seal proceed as described here below:

• Remove the hex nuts (item 40) and washer (item 41) from the tie rods.
• Remove the end flange (item 32) from liner (item 28).
• Gradually remove the liner from head flange (item 31).
• Remove the O-ring (item 35), and the guide slider (item 37) from piston (item 29). Carefully clean the
relative piston grooves.
• Replace the seals and lubricate them with a grease film.

Taking care not to damage the seals, proceed with the reassembling as follows:

• Reassemble the liner and the end flange.

• Uniformly tighten the hex nuts on the tie rod after installing the washers.
Carry out a few operations with the actuator, in order to check that the movement is regular and that
there are no leakages through the seals.

28
Figure 1

Figure 2

29
b) Replacement Piston rod seal in head flange: (See Figure 1 & 2)
For replacing piston rod seal in head flange proceed as described below:

• Remove the hex nuts (item 40) and washer (item 41) from the tie rods.
• Remove the end flange (item 32) from liner (item 28).
• Gradually remove the liner from head flange (item 31).
• Remove the piston (item 29) from piston rod (item 30) by unthreading it.
• Remove the position indicator assembly from the top of the frame by unscrewing the four socket head
screws.
• Remove the frame cover (item 2) with gasket by gasket (item 8) by unscrewing the bolts (item 10).
• Remove the 4 bolts (item 44) which holds the head flange to the frame.
• Pull the head flange (item 31) out of the frame (item 1) (housing) and from the piston rod (item 30).
• Remove the O-ring (item 34), Clean the groove and brush with grease.
• Replace the O-ring and to reassemble the actuator, follow the procedure in reverse order.

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 VI. TROUBLE SHOOTING & REMEDIES

Problems Possible cause Remedy

Lack of pneumatic supply Check supply line.
Consult valve manufacturer
Defective main valve
Actuator doesn't work documentation.
properly Failure of the control group Consult Cameron Ledeen.
Actuator is incorrectly sized for torque Check the sizing criteria for both the Actuator
output against the Valve torque. and the Valve.
1.Check air supply
1.Low air supply
2.Loosen adapter piece bolts and retry.
2.Valve coupling binding
If OK tighten bolts evenly.
Undersized tubing or components on
Consult Cameron Ledeen.
pneumatic circuit
Jerky Movement
Remove cylinder. Check piston o-ring for wear,
Piston binding in cylinder change if necessary. Grease, Reassembly and
test.
Consult valve manufacturer
Faulty Valve
documentation
Low supply pressure Adjust supply pressure
Incorrect speed control settings Adjust speed controls to increase flow
Actuator too slow Remove and clean the exhaust port silencers
Exhaust port blocked
and replace
The valve is jammed Consult valve manufacturer documentation.
High supply pressure Reset.
Actuator too fast
Incorrect speed control settings Adjust speed controls to decrease flow
Deterioration and/or damage to gaskets Tighten loose fittings
Leakages on pneumatic
and or loosed fittings Consult Cameron Ledeen.
circuits
Damage to fittings Consult Cameron Ledeen
Leakages on pneumatic
Damage to seals Replace cylinder seals.
cylinder

Wrong adjustment of mechanical stops Re-adjust setting.

Incorrect position of the
valve
Wrong electric limit switches indication. Re-adjust setting.

31
VII. DISASSEMBLY AND REASSEMBLY

Warning:

Note: No special tools are required for these operations, but only some Allen wrenches, hexagonal
wrenches of the required sizes, Ratchet wrench with extension and Swivel wrench, Torque wrench
and Circlip plier.

Note: If the RFID tag has been provided on the actuator that identifies each actuator with a unique number and
when any disassembly process is undertaken, all components removed from within the actuator
assembly must be reinstalled within that specific actuator during the reassembly process. DO NOT
mix components from one actuator assembly with those of a different actuator assembly.

32
Refer to the Double acting actuator assembly drawing below.

ITEM DESCRIPTION QTY

10 FRAME SUB ASSEMBLY 1

20 PNEUMATIC CYLINDER SUB ASSEMBLY 1

33
Refer to the Spring return actuator assembly drawing below.

ITEM DESCRIPTION QTY

10 FRAME SUB ASSEMBLY 1

20 PNEUMATIC CYLINDER SUB ASSEMBLY 1
60 SPRING CONTAINER 1

34
Refer to the Double acting actuator sectional assembly drawing below:

35
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
1 FRAME 19 PLATE FOR END STROKE 37 GUIDE SLIDER
2 COVER 20 MICRO SWITCH PLATE 38 TIE ROD
3 SCOTCH YOKE 21 PIN 39 LOCK NUT
4 BUSHING 22 END STOP 40 HEX.NUT
5 SLIDING BLOCK 23 CAP NUT 41 WASHER
6 SLIDING PIN 24 O-RING 42 CAP NUT
7 GUIDE BLOCK 25 LOCK NUT 43 DU-BEARING
8 FRAME SEAL 26 BUSHING 44 SOCKET HEAD CAP SCREW
9 GUIDE BAR 27 SOCKET HEAD CAP SCREW 45 PLUG
10 HEX.HEADED BOLT 28 CYLINDER LINER 46 BUSH
11 DOWEL PIN 29 PISTON 47 LIFTING FLANGE
12 CIRCLIP 30 ROD 48 SCREW
13 DU-BEARING 31 HEAD FLANGE 49 HEX.NUT
14 PLUG 32 END FLANGE 50 WASHER
15 FLANGE 33 O-RING 51 BUSH
16 GASKET 34 O-RING 52 MECHANICAL STOP
17 SCREW 35 O-RING
18 O-RING 36 O-RING

36
Refer to the Spring return actuator sectional assembly drawing below:

37
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
1 FRAME 16 GASKET 38 TIE ROD 53 SPRING CONTAINER
2 COVER 17 SCREW 39 LOCK NUT 54 END STOP
3 SCOTCH YOKE 18 O-RING 40 HEX.NUT 55 CAP NUT
4 BUSHING 20 MICRO SWITCH PLATE 41 WASHER 56 LOCK NUT
5 SLIDING BLOCK 21 PIN 42 CAP NUT 57 O-RING
6 SLIDING PIN 28 CYLINDER LINER 43 DU-BEARING 58 SPRING PUSHER
SOCKET HEAD CAP
7 GUIDE BLOCK 29 PISTON 44 SCREW 59 DU-BEARING
8 FRAME SEAL 30 ROD 45 PLUG 60 SOCKET HEAD CAP SCREW
9 GUIDE BAR 31 HEAD FLANGE 46 BUSH 61 BUSHING
HEX.HEADED
10 BOLT 32 END FLANGE 47 LIFTING FLANGE 62 BUSH SPRING CONTAINER
11 DOWEL PIN 33 O-RING 48 SCREW 63 HEAD FLANGE
12 CIRCLIP 34 O-RING 49 HEX.NUT 64 END FLANGE
13 DU-BEARING 35 O-RING 50 WASHER 65 SPRING
14 PLUG 36 O-RING 51 BUSH 66 PUSHER DISC
15 FLANGE 37 GUIDE SLIDER 52 END STOP

38
 A. Disassembly:
Note: Before removing the actuator from the process piping for inspection by disassembly, check that the
operating pressure is at atmospheric pressure. Also check that the pressure within the valve main unit is at
atmospheric pressure to assure safety.

Note: If the control valve is intended for the control of fluid containing drastic chemicals that are harmful to
human body, be sure to check that the inside of the control valve is washed completely before starting the work.

Note: Before starting disassembly, ensure spare parts seal kit is available as indicated on page 52.

Note: If bearing replacement is expected, contact Cameron for additional instructions.

• Detach the actuator from the valve assembly as the first step before starting to disassemble the actuator
and the next step is to remove all the accessories.
1. Ensure that the actuator is in the failed position (i.e., at the end of spring stroke) to disassemble the
actuator from the valve assembly. Then lift the actuator (Refer to page no. 12-16) in horizontal
orientation and place the actuator assembly on a suitable work bench resting on its base.
2. Remove the air piping and electric wiring of the accessories carefully and then remove the accessory
devices from the actuator.
a. Removing Position Indicator assembly from Frame:
(Refer to page: 35-38 for sectional assembly drawing)
• Remove the screw (item 54) placed in the bottom of position indicator shaft (inside the scotch yoke)
• Remove the position indicator shaft on the top of actuator frame

39
40
b. Removal of Spring Container from Frame: (See the Exploded view below)
(Refer to page 37 for sectional assembly drawing, page 42 and 46 for exploded view)

Note: Before commencing any disassembly of the actuator, ensure that the actuator is isolated from the
supply pressure and mechanical end stops are released.

• Remove frame cover fasteners (item 10).

• Remove the frame cover (item 2) with gasket (item 8) and place it on table away from the actuator.

• If desired, remove the inspection hole flange (item 15) with the gasket (item 16) from frame cover by
unscrewing the fasteners (item 17) and place the parts on table away from actuator.

• If desired, remove the dowel pin (item 11) from frame.

• Support the spring container with proper lifting devices (Refer to pages 12-16) for removing the spring
container assembly from frame. Now, remove the four socket head screws (item 60), which holds the
spring container to the frame (item 1).

• Remove the spring container assembly out of the frame with the lifting devices.

Note: Spring pusher is neither connected to guide block nor to the spring container. Care should be take while
pulling out the spring container.

• Place the spring container assembly on table away from the frame.

• Remove spring pusher (item 58) from bush of guide block and place it away from the actuator.

• Remove bush from guide block by unthreading it.

• Remove cap nut (item 55) followed by lock nut (item 56) and mechanical stop (item 54) from the spring
container flange and place it away from the table.

• If desired remove seal (item 57) from the lock nut.

41
Spring container exploded view

ITEM DESCRIPTION QTY

53 SPRING CONTAINER 1

54 MECHANICAL STOP 1

55 CAP NUT 1

56 LOCK NUT 1

57 O-RING 2

58 SPRING PUSHER 1

59 DU BEARING 1

60 SOCKET HEAD SCREW 4

61 BUSHING FOR CYL. CENTERING 1

62 BUSH SPRING CONTAINER SIDE 1

42
c. Removal of Cylinder sub assembly from Frame & disassembly:
(Refer to page: 35-38 for sectional assembly drawing)

• Remove frame cover fasteners (item 10).

• Remove the frame cover (item 2) with gasket (item 8) and place it on table away from the actuator.
• If desired, remove the inspection hole flange (item 15) with the gasket (item 16) from frame cover by
unscrewing the fasteners (item 17) and place the parts on table away from actuator.
• If desired, remove the dowel pin (item 11) from frame.
• Rotate the scotch yoke (item 3) until the hexagonal flats on piston rod (Item 30) besides the guide block
(item 7) is accessible.

Note: While using the Wrench, care should be taken that the surface of the Piston Rod is not damaged.

• Unthread the piston rod from the bush of the guide block using a wrench. Place the wrench on the tool
kit away from actuator.
• Unthread the bush from the guide block by using wrench. Place the wrench on the tool kit away from
actuator.
• Support the cylinder with proper lifting devices (Refer to page 14 & 15) for removing the cylinder
assembly from frame. Now, unscrew the four hexagonal head bolts (item 44) which holds the cylinder
to the frame (item 1).
• Remove the cylinder assembly out of the frame with the lifting devices.
• Place the cylinder sub assembly on table away from the frame.

43
d. Cylinder sub assembly:
(See the Exploded view below)

44
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
CYLINDER
28 LINER 1 37 GUIDE SLIDER 1 46 BUSH 1
29 PISTON 1 38 TIE ROD 10 47 LIFTING FLANGE 1
30 ROD 1 39 LOCK NUT 1 48 SCREW 2
31 HEAD FLANGE 1 40 HEX.NUT 20 49 HEX.NUT 2
32 END FLANGE 1 41 WASHER 20 50 WASHER 2
33 O-RING 2 42 CAP NUT 1 51 BUSH 1
34 O-RING 1 43 DU-BEARING 1 52 END STOP 1
35 O-RING 1 44 SOCKET HEAD CAP SCREW 4
36 O-RING 2 45 PLUG 4

1. Place cylinder on a suitable work bench in a vertical orientation by resting head flange (item 31) at
the bottom to disassemble the cylinder assembly,.
2. Remove the end flange fasteners (item 40 & 41) from the end flange (item 32) and place the parts
on table away from cylinder assembly.

Note: If Hammering is desired on to the machined parts, use nylon hammer.

3. Remove the end flange (item 32) from liner (item 28) by using the nylon hammer to tap uniformly
around the end flange. Place the end flange on table away from cylinder assembly.
4. If desired, remove the seal (item 33) from end flange.
5. Remove the piston and rod subassembly from cylinder liner and place the parts on table away from
work bench.
6. Place the piston (item 29) resting on its bottom on a suitable work bench for removing the piston
from piston rod (item 30). Holds the hexagonal slot end of the piston rod and unscrew it from piston.
7. Remove the piston from piston rod and carefully place the parts on table away from the work bench
without damaging the surfaces of the piston.
8. If desired, remove the seal (item 35) and the guide slider (item 37) from piston.
9. Gradually remove the cylinder liner (item 28) from head flange (item 31) and place it carefully without
damaging the inside surface, away from the work bench.
10. Remove the tie-rods (item 38) one by one from the head flange (item 31) by unthreading it.
11. If desired, remove the external seal (item 33) and internal seal (item 34) from head flange.

45
e. Frame sub assembly: (See the Exploded view below)

46
 ITEM DESCRIPTION Qty ITEM DESCRIPTION Qty
1 FRAME 1 18 O-RING 4
2 COVER 1 20 POSITION INDICATOR DRIVE BAR 1
3 SCOTCH YOKE 1 21 ROLL PIN 2
4 BUSHING 2 22 WASHER FOR INSPECTION FLANGE 8
5 GUIDE BLOCK 1 23 SCREW 1
6 SLIDING PIN 1 24 O-RING 2
7 SLIDING BLOCK 2 25 LOCK SCREW 1
8 FRAME SEAL 1 26 O-RING 1
9 GUIDE BAR 1 27 SOCKET HEAD CAP SCREW 4
10 HEX.HEADED BOLT 26 28 WASHER FOR FRAME COVER 26
11 DOWEL PIN 6 30 POSITION INDICATOR SHAFT 1
12 CIRCLIP 2 31 POSITION INDICATO ARROW 1
13 DU-BEARING 2 32 CLOSING FLANGE 2
14 PLUG 1 33 SCREW FOR CLOSING FLANGE 8
15 FLANGE 1 34 BOLT FOR CLOSING FLANGE 8
16 FLANGE SEAL 1 63 O-RING 2
17 FLANGE SCREW 8 64 SEAL WASHER 16
148* SOCKET HEAD CAP SCREW 4
149* END STROKE PLATE 1
150* BUSHING 1
151* END STOP 1
152* O-RING 2
153* CAP NUT 1
154* LOCK NUT 1
* DA models only

Disassembly of Frame sub assembly:

Note: Point 1 – 3 is for Double acting models. For Spring return skip these points 1 – 3.

1. In order to remove the end stroke assembly from the frame which is at the opposite side of the pneumatic
cylinder, remove the fasteners (item 148) of plate for end stroke (item 149) and remove.
2. Now loosen and remove the cap nut (item 153), locking nut (item 154) and mechanical stop (item 151)
from plate. Place the parts on table away from the frame.
3. If desired, remove the seal (item 152) from locking nut.
4. Remove the screw (item 27) into the scotch yoke, in order to disassemble the position indicator (item
30).
5. Now loosen and remove the hex headed bolts (item 10) and the cover (item 2).
6. Place the hex bolts (item 10), the frame seal (item 8) and the washers (item 28) on table, away from
frame.
47
 7. Loosen and remove bolts (item 33) and nuts (item 34) and remove the closing flange (item 32), if
provided.
8. Place the o-rings (item 63) and the seal washers away (item 64).
9. Partially remove the guide bar (item 9), remove the o-rings (item 24) and place them on table, away
from frame.
10. Remove the guide bar (item 9).
11. Remove the scotch yoke (item 3) from lower bushing (item 4) and place it on the table, paying attention
to the o-ring (item 18).
12. Disassemble the circlip (item 12) and remove the sliding pin (item 6) and the sliding block (item 7), in
order to remove the guide block (item 5).

B. Reassembly:
a. Frame sub assembly (Refer the page 46 for frame exploded view)

Note : With the actuator fully disassembled into its component parts, each part should be thoroughly cleaned
and inspected. Any parts damaged or worn out should be replaced. It is recommended as a minimum to
replace all sealing components, and to replace the internal components if any damage or erosion is
present.

Note: Ensure that all parts and all necessary tools are available and are clean. Ensure the cleanliness of the
work bench.

Note: During seal assembling, remove dust from the groove and apply grease.

1. Place the actuator frame (item 1) on a suitable work bench in horizontal orienta¬tion resting on its base.
2. Check that the bushing (item 4) and the o-rings (item 18) are properly placed, with a thin film of grease.
3. On a separate work bench, place the scotch yoke (item 3), and put the guide block between the cams.
4. Install the sliding pin (item 6) in the guide block (item 5).
5. Insert the sliding block (item 7) into both ends on sliding pin (item 6) and anchor them using the circlips
(item 12).
6. Lift the scotch yoke assembly and insert it into the bushing (item 4), previously positioned into the bottom
of the frame.
7. Lubricate the du-bearings (item 13) into the guide block (item 5) and insert the guide bar (item 9).
8. Before completely inserting the guide bar (item 9), install and lubricate the o-rings (item 24) in their
grooves.
Note :For double acting actuator follow the below steps before mounting the pneumatic cylinder, otherwise skip
these steps.
9. Locate the mechanical stop (item 22), cap nut (item 23), plate for end stroke (item 19) and lock nut with
seals (item 24).
10. Lightly grease the threads on the plate where mechanical stop is going to be assembled.

48
 11. Install the mechanical stop in position of actuator frame and set the stroke required by the actuator.
Rotating the mechanical stop clockwise reduces the angular stroke and rotating it counter-clockwise
increases the angular stroke.

12. Install the lock nut seal in its grooves and apply grease film. (Suggested grease: Parker super-o-lube or
equivalent) Install the lock nut by screwing into the mechanical stops by applying 45-50 Nm torque.
13. Finally install the cap nut by screwing in to the mechanical stop.

Note : Frame shall not be closed with frame cover at this stage, Once the cylinder sub assembly & spring
container (If available) is assembled, the frame shall be closed.

b. Cylinder sub assembly (Refer page 44 for pneumatic cylinder exploded view)

Note: Ensure that all parts and all necessary tools are available and are clean. Ensure the cleanliness of the
work bench.

Note: During seal assembling, remove dust from the groove and brush with grease.

1. Place the cylinder head flange (item 31) on a suitable work bench in horizontal orientation (if cylinder
must be mounted on spring return actuator arrange the head flange directly on frame side). Make sure
that seal groove side face is visible.
2. Locate the head flange external (item 33) and internal seals (item 34) and carefully place it in its grooves.
3. Locate piston (item 29). Install the piston seal (item 35) and guide slider (item 37) to the piston and
gradually screw the piston assembly into the piston rod.

Note: While threading the piston rod in the piston apply Loctite 243 for thread fixing.

4. Install the piston and rod assembly in a vertical position in such a way that the piston rod projects out of
the head flange. Care should be taken not to damage the cylinder liner as well as the piston seals. (if
cylinder must be mounted on double acting actuator go to point “3 in c” to assemble piston rod into the
guide block of the frame)
5. Locate the liner (item 28). Slide the liner over the piston seal and the head flange seal without damaging
the seals.
6. Locate the tie rods (item 38) and thread them into head flange.
7. Locate the end flange seal and install the seal in the end flange groove.
8. Locate the end flange (item 32) and slowly lower it into the cylinder liner and in the tie rods. Ensure the
air supply ports are properly oriented with the air supply ports on the head flange.
9. Locate the tie rod nuts, Install and tighten to secure the end flange.

49
 10. Locate the mechanical stop (item 52), lock nut (item 39) with seals (item 36)
11. Lightly grease the threads on the end flange where mechanical stop is going to be assembled.
12. Install the mechanical stop in position of end flange and set the stroke required by the actuator.
Rotating the mechanical stop clockwise reduces the angular stroke and rotating it counter-clockwise
increases the angular stroke.
13. Install the lock nut seal in its grooves and apply grease film. (Suggested grease: Parker super-o-lube or
equivalent) Install the lock nut by threading onto the mechanical stops (applying 45-50 Nm torque)
followed by cap nut.

c. Assembling Cylinder sub assembly in to the Frame sub assembly:

(Refer page 35-38 for sectional assembly drawing)

1. Place the actuator frame assembly in a vertical position to admit the cylinder assembly into the frame
bore.
2. Gradually lower the cylinder assembly into the frame bore.
3. Thread the bush (item 51) into the guide block by using a wrench.

Note: While threading the bush into the guide block apply Loctite 243 for thread fixing.
While using the wrench, care should be taken that the surface of the Piston Rod is not damaged.

4. Thread the piston rod into the bush of the guide block by using a wrench.
5. Locate the hexagonal socket head screws (item 44).
6. Secure the cylinder sub assembly in position by means of fasteners (item 44).

Note: If it is a Spring return Actuator proceed directly to point d.”Assembling Spring container assembly in to the
Frame assembly”.
If it is a Double acting actuator continue with the below steps.

7. Place the actuator assembly on a suitable work bench in a horizontal orientation with the actuator frame
resting on its base.
8. Locate the frame gasket (item 8) and frame cover (item 2) assembly
9. Check the bushing in frame cover and apply grease film.
10. Slowly lower the frame cover and place in position by means of locating pins and fasteners.
11. Locate the position indicator assembly and install it in position of frame cover in the same axis as that of
the scotch yoke.
12. Ensure that the position indicator shaft is correctly located into the position indicator drive bar.
13. Reassembly of the double acting actuator is now complete.

50
 d. Assembling Spring container assembly in to the Frame assembly:
(Refer page 35-38 for sectional assembly drawing)

1. Lift and turn the actuator in a vertical orientation, Place it on the pneumatic cylinder flange on a wooden
or rubber support.
2. Thread the bushing (item 62) into the guide block by using a wrench.

Note: While threading the bushing into the guide block apply Loctite 243 for thread fixing.

3. Guide the spring pusher (item 58) through frame side bore and assemble it into the bushing of the guide
block in a vertical position.
4. Gradually lower the spring container assembly guiding the pusher rod into the bushing of the spring
container bore.
5. Locate the hexagonal socket head screws (item 60).
6. Secure the spring container assembly in position by means of fasteners (item 60).
7. Place the actuator assembly on a suitable work bench in a horizontal orientation with the actuator frame
resting on its base.
8. Locate the frame gasket (item 8) and frame cover (item 2) assembly.
9. Check the bushing in frame cover and apply grease film.
10. Slowly lower the frame cover and place in position by means of locating pins and fasteners.
11. Locate the position indicator assembly and install it in position of frame cover in the same axis as that of
the scotch yoke.
12. Ensure that the position indicator shaft is correctly located into the position indicator drive bar.
13. Reassembly of the spring return actuator is now complete.

C. Adjustment after assembly:

Check the following when assembly is completed. If satisfactory result is not obtained, disassemble the actuator
again, find the cause, and assemble it back together.
1.Check valve opening and closing positions
2.Performance Check and Adjustment
• Check that the actuator operates smoothly when specified air pressure is applied to it.
• Check for leakages through the cylinder and frame seals.

51
VIII. SPARE PARTS

1. Frame sub Assembly

(Refer to frame assembly exploded view on page 46) :

• Item 8, qty. 1
• Item 16, qty. 1
• Item 18, qty. 4
• Item 24, qty. 2
• Item 26, qty. 1
• Item 63, qty. 2
• Item 64, qty. 16

2. End stroke Assembly (For double acting actuator)

(Refer to frame assembly exploded view on page 46) :

• Item 152, qty. 2

2. Cylinder sub Assembly

(Refer to pneumatic cylinder assembly exploded view on page 44) :

• Item 33, qty. 2

• Item 37, qty. 1
• Item 35, qty. 1
• Item 34, qty. 1
• Item 36, qty. 2

3. Spring container Assembly

(Refer to spring container assembly exploded view on page 42) :

• Item 57, qty. 2

52