I-TORK PDS PNEUMATIC ACTUATOR

Installation & Operation Manual

(I-TORK PDS Series Pneumatic Actuator)

PDS-M0108/1010

74-6, Chun Ui-Dong, Won Mi-Gu, Bucheon, Kyoung Ki-Do, Korea

Tel : 82-2-855-1365, 66 Fax : 82-2-855-1367 E-mail : roy75@i-tork.com

Website: www.i-tork.com

I-Tork PDS Pneumatic Actuator

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Table of Contents

1. GENERAL
2. SCOTCH-YOKE PRINCIPLE & ADJUSTMENT

3. IMPORTANT SAFETY PROCEDURES

4. OPERATION

5. LUBRICATION REQUIREMENTS

6. APPLICATION
7. INSTALLATION & PIPING

8. DISMANTLE & ASSEMBLY

9. PDS50~200 PART LIST

10. TROUBLE SHOOTING

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Many thanks for purchasing our I-Tork PDS Pneumatic Actuator!

For safe and proper operation, please read this manual carefully before using it and save it for reference.

Important Notice: The contents in this manual are subject to change

without notice due to quality improvement.

1. General
I-Tork PDS series actuators are designed for rotary quarter turn valves and there are
PD (Double Acting) and PS (Single Acting-with Spring Pack).

I-Tork PDS series actuators can be used with a 4~8Kg/㎠ range of air supply pressure.
Standard air pressure is 5.5Kg/㎠.
PD : Pmax 8 bar (116 psi)
PS : Pmax 7 bar (110 psi)

ISO Mounting Design:

ISO 5211 for valve flange or mounting bracket.
VDE 3845 (Namur) for solenoid valve.

Operating Medium:
Filtered inert gas or air must be used, and exhaust air must be passed through silencer
before being vented into the atmosphere. The dew point shall be equal to -20 °C or at
least, 10 °C below the ambient temperature (ISO8573 Part1, Class 3). The maximum
particle size shall not exceed 40 μm (ISO8573 Part1, Class 5). Max Pressure shall be
0.8 Mpa (8 bar) and the minimum design pressure for pressurized parts shall be 1.5
times the maximum operating pressure.

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2. Scotch Yoke Principle & Adjustment;

I-Tork Actuators uses a Scotch Yoke assembly with angled slots.

This allows for a more compact design when compared to Rack & Pinion actuators.
Scotch-Yoke technology is known as the most suitable actuator mechanism for valve
and damper applications, as it produces higher torque at both ends (open and close)
positions compare to Rack and Pinion, which has a constant output torque. The
standard operation ambient temperature range is -20 ~ + 80 ℃.

Single Acting actuators have the pistons rotated 180° for a fail close position; this
means any adjustment will take place in the open position. If the SR actuator is set to
the ‘Fail Open’ position, then the adjustment will take place in the closed position. The
adjustment angle for both is ±3° by Adjusting Screws.

The adjustment is done by loosening the Adjusting Screws, and I-Tork PDS have 2
Adjusting Screws for open and close positions.

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3. Important Safety Procedures

Caution: Always disconnect the Air and Electrical supplies before carrying out
any form of maintenance on an Actuator.

Caution: When removing any ball valve or plug valve assemblies from a pipe
system, isolate the piping system on which the Actuator is installed and relieve
any media pressure that may be trapped in the valve cavities before removing
the Actuator for maintenance.

Never use ‘Blow Out’ the Pistons or the End Caps from the Actuator Body.

Never turn the adjusting screws completely out when the actuator is under
pressure.

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4. Operation

Figure 1 : PD (Double Acting)

Close Open
When air is supplied to the left port, the actuator will move to the Close position.
When air is supplied to the right port, the actuator will move to the Open Position.

Figure 2 : PS (Single Acting) Fail Close Position

Open Close (fail Position)

When air is supplied to the left port, the actuator will move to the Open Position.
When the air supply fails, the actuator will move to the fail position (Close).

Figure 2 : PS (Single Acting) Fail Open Position

Close Open (fail position)

When air is supplied to the left port, the actuator will move to the Close position.
When the air supply fails, the actuator will move to the fail position (Open).

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5. Lubrication Requirements:

I-Tork PDS generally do not require lubrication, however, oil mist lubrication is
recommended for actuator which has performed more than 100,000 operation cycles.

Recommended Lubrication Grease:

Parts Actuator Version Grease

Cylinder Bore, Shaft Standard & High Dark Brown Grease
Sealings Temperature ALVANIA RL2/DC111
Cylinder Bore, Shaft Low Temperature White Grease DC 111
Sealings (DOWCORNING)

6. Application

All quarter turn type valves and equipment as follows

1) Ball Valve(2 way, 3 way, 4 way), Screw end and flanged
2) Butterfly Valve
3) Plug Valve
4) Damper
5) etc

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7. Installation and Piping

1) Selection of actuator
Determine the appropriate torques and strokes taking into consideration the
following parameters and questions.

- Valve Question
- Valve: type, size, function and operation characteristics
Operating Conditions: Media, Temperature, Pressure, Flow rate, Frequency of
operation and required stroking time.
Valve Torque Characteristics (seating/unseating, dynamic torque <when
applicable>)
Maximum Allowable Stem Torque Limitation

- Actuator Question
Air Supply Pressure : Minimum and Maximum
Operation: On/off or Control
Acting: Double or Single (Fail Position open or close)
Frequency of operation

- Ancillary Question
Limit Switches: Type, Voltage, etc.
Positioners: Pneumatic or Electro-Pneumatic
Position Transmitters: Local Electrical Regulations
Solenoid Valve: Type, Voltage, etc.

- Environmental Conditions
Indoor, outdoor, saline, corrosive chemicals, etc.
Enclosure Protection type
Hazardous or non-Hazardous areas
Ambient Temperature

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2) Installation and Mounting on the Valve

I-Tork PDS can be mounted in any position, ie: Vertical or Horizontal.

It is very important that the actuator shaft and the valve stem are centered and
must have a 0.5 ~ 1 mm gap between the actuator shaft and the valve shaft (or
driving bush) depending on the actuator size. If the valve stem is too high, it may
force the actuator shaft upward thus displacing the shaft seal. This would cause air
leakage at the shaft seal.
Please note that the actuator has a hexagonal drive shaft.
Do not mount the actuator at a 45˚ angle.

All the mounting dimensions of PDS series follows international standard and as
follows.
Top mounting hole : VDI/VDE3845
Top end of shaft : NAMUR for installation of Limit Switch Box or Positioner.
Bottom Mounting Hole: ISO5211
Bottom End of Shaft: Double Square for Easy Mounting (ISO5211)

3) Piping (Air Tubing)

All I-Tork PDS actuators can be piped with solid or flexible tubing with the solenoid
valve mounted remotely from the actuator or by mounting a NAMUR designed solenoid
valve directly onto the NAMUR mounting pad on the side of the actuator.

- Precaution
Please check the environmental conditions (Temperature, Pressure,
Characteristics of fluid, Piping standard) before piping.
If air tubing connection is not properly fitted, it may cause lower torque,
shorten the life cycle of actuator. Connection of actuator is PT 1/4” for PDS
40~200.

- Solenoid valve
Be sure that the solenoid valve’s connection type is compatible to the
actuator’s.

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- Operating
To operate the actuator, supply a clean and dry air through a filter regulator
(this is strongly recommended)
Power up the solenoid valve.
The actuator should operate.

4) Storage

I-Tork PDS actuator’s body is made of Hard-Anodized aluminum both inside and
outside for protection against corrosion.
Store in a dry area and care to be taken when stacking the actuators.
Do not remove the air holes plugs until the actuator is ready for installation.

5) Manual Operation:

When operating the actuator manually, be sure that all compressed air is fully
vented before carrying out the manual operation.

6) Adjusting Screw Adjustment

For Open Position

1. Operate Valve/Actuator assembly to the open position.
2. Remove Air supply
3. Loosen the lock nut on the adjusting screw
4. Turn the “Close” adjusting screw clockwise to reduce or counter clockwise to
increase the travel.
5. Tighten the lock nut.
6. Connect air and check if the position is correct. (If not, repeat from 2)
For Close Position
7. Operate Valve/Actuator assembly to the close position.
8. Remove Air supply
9. Loosen the lock nut on the adjusting screw
10. Turn the “Open” adjusting screw clockwise to reduce or counter clockwise to
increase the travel.
11. Tighten the lock nut.
12. Connect air supply and check if the position is correct. (If not, repeat from 8)

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8. Dismantle and Assembly

(For Replacing O-ring and other parts.)

PD series (Double Acting)

Dismantling

Caution: Vent all compressed air from the actuator and disconnect all electric
power before dismantling.

1) Loosen the adjusting screws (23).

2) Loosen both end cover bolts (26) using Hexagonal Wrench and dismantle.
3) Using the spanner, rotate the stem more than 90° until pistons are released
automatically and pull out the pistons (3).
4) Loosen the Set Screw (27) of Scotch - Yoke (5).
5) Take the Snap Ring (21)/Washer (12)/Thrust Washer (11) out from the top of
shaft.
6) Separate the shaft (4) from the body.
7) Replace the part.
8) For Assembly: Do the Reverse.

PS series (Single Acting)

Dismantling

Caution: Vent all compressed air from the actuator and disconnect all electric
power before dismantling.

1) Loosen the adjusting screws (23).

2) Using hexagonal wrench, loosen 2 bolts (26) in a diagonal position on both end
covers.
Then loosen the other 2 bolts in a diagonal position on both end covers slowly.
(Ensure spring pack pressure is released before removing bolts fully, if unsure,
then remove 2 diagonal bolts only and insert longer bolts until spring pressure is
released)
3) Take out the cover (28) and spring pack (22/29/30/31/32/33).
4) Using the spanner, rotate the stem more than 90° until pistons are released

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automatically and pull out the pistons (3).

5) Loosen the Set Screw (27) of Scotch - Yoke (5).
6) Take the Snap Ring (21)/Washer (12)/Thrust Washer (11) out from the top of
shaft.
7) Separate the shaft (4) from the body.
8) Replace the part.
9) For Assembly: Do the Reverse.

Converting PD to PS Actuators:

All I-Tork PD (Double Acting) actuators can be converted to PS (Single Acting)

actuators by adding a spring pack as follows.
Caution: Vent all compressed air from the actuator and disconnect all
electrical power before dismantling.

If ‘Fail Open’ position is required:

All parts are the same except for the addition of the spring pack; just the PD cover
needs to be replaced with the appropriate PS spring pack.

If ‘Fail Closed’ position is required:

1. Loosen the Adjusting Screws (23) from the body.

2. Disassemble the End Covers (2).
3. Disassemble the Pistons (3) according to PD disassembly.
4. Rotate the Pistons (3) and Yoke (5) 180°; then assemble the pistons to the body.
5. Mount Spring Pack to the body when the pistons (3) are in their inner most
position.

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Disassembling of Spring Pack:

For safe disassembling of the spring packs, the following procedure must be carried
out.

1. Disconnect all air and electrical supplies.

2. Springs must not be in the compress position (that is, the springs must be at
fully extended position).
3. Loosen the bolts (26) of the end cover separate Spring Pack from the body.

Spring Packs
 Pretension Bolt(33)/Spring Washer(32)/Plain Washer(31)/Spring Retainer(30)
Spring(29)/O-Ring(22)/Spring Cover(28)/Bolt(26)

From PS 40 to PS100 (Single Spring per pack)

There are 2 Spring Options:

One is for 4.2 bar pressure;
The other is for 5.5 bar pressure.

From PS 125 to PS200 (Double Springs per pack)

There are 2 Spring Options:

One is for 4.2 bar pressure.
The other is for 5.5 bar pressure.

<Remark> When placing order PS Single Acting type Pneumatic Actuator,

please specify the Spring Option (4.2 bar or 5.5 bar).

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9. PDS50~200 PART LIST

Part List No Material Part List No Material Part List No Material
1. Cylinder Aluminum 12.Washer-Shaft Steel 23. Adjust screw Steel
2. Cover Aluminum 13. Roller Pin Steel 24. NUT Stainless Steel
3. Piston Aluminum 14. Roller Steel 25. Washer-Stopper Stainless Steel
4. Shaft Steel 15. Piston Guide – POM 26. HEX. Head Stainless Steel
Shaft Pad Socket Bolt
5. Scotch yoke Steel 16. Support Band PTFE 27. Set Screw Stainless Steel
6. Stopper Steel 17. O-Ring - NBR 28. Spring Aluminum
Piston Return Cover
7. Shaft Wearing POM 18. O-Ring – NBR 29. Spring Spring Steel
Shaft, lower
8. Support Ring POM 19. O-Ring – NBR 30. Spring Steel
- Lower Shaft - upper Retainer
9. Support Ring POM 20. O-Ring - NBR 31. Plane Steel
- Middle Stopper Washer
10. Support Ring POM 21. Snap Ring Stainless Steel 32. Spring Steel
- Upper Washer
11. Thrust Washer POM 22. O-Ring- Cover Stainless Steel 33. Pretension bolt Steel

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10. TROUBLE SHOOTING

Status Possible Reason Recommended action

Check the incoming voltage
Electric power line fails
or power line
Check voltage of solenoid Coil
Actuator doesn’t If coil is OK, check operation
Trouble in solenoid valve
work at all of spool valve by using
manual button
Blockage or leak in air
Check air supply line
supply line
Air pressure is too low Increase supply air pressure

Blockage in air inlet/outlet Take out foreign material in

lines by foreign material the line

Speed controller is locked Open speed controller

Actuator is working,
but not smoothly Air leakage through piston
Replace the piston ring
ring
1) Increase air supply
Actual valve torque is too pressure
high 2) Replace with a larger
actuator
Stopper setting is wrong Set stopper again

Valve doesn’t open Actual valve torque is too

Replace with a larger actuator
or close fully higher than specification.

Piston or cover bushing o-

Air leakage Replace O-rings
ring worn out

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