Emerson Damcos KC 125 Quick Installation Manual Download Page 1

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Quick Installation Guide

Version: QIG 8000-81-003 Ed 01

Release: February, 2020

Damcos

™

Actuators

KC 65, KC 125, KC 250, KC 325, KC 400

Quick Installation Guide

Summary of Contents for Damcos KC 125

Page 1: ...Quick Installation Guide Version QIG 8000 81 003 Ed 01 Release February 2020 Damcos Actuators KC 65 KC 125 KC 250 KC 325 KC 400 Quick Installation Guide ...

Page 2: ...or DPI C and DPI E Position Indicators SD 3000 0E06 Product Data Sheet for Damcos Block System SD 6601 2E04 Product Data Sheet for Damcos PHP 25 05 Portable Hand Pump SI 0001 5E05 Instruction for Flushing Remote Valve Control System SD 2001 2E01 Product Data Sheet for Damcos DDPI E E C and C Double Position Indicators Copyright Damcos A S 2020 Installation Guide for KC 65 KC 125 KC 250 and KC 400 ...

Page 3: ...lation Procedure 9 Calculation of Preload 9 Mounting the Actuator to the Valve 11 Test of the DPI 15 Test of DPI E On Off signals 15 Test of DPI C analog signals 17 Adjustment of the DPI 19 Determine the Configured Stroke 23 Trouble Shooting 25 Additional Instructions for Modification Repair Only Dismounting and Disassembling 29 Preparations before Dismounting 29 Disassembling the Actuator 31 Asse...

Page 4: ...Quick Installation Guide Table of Contents RM 8000 100 01 Ed 01 February 2020 2 ...

Page 5: ...s with or without DPI The environment must be clean and without the risk of getting dirt into the unit when taken apart Make sure you have access to an indoor workshop for the actual repair Any damage caused by incorrect handling of the equipment is not covered by the manufac turer s warranty Warning Cautions and Notes In order to avoid any personal injuries damage of equipment or loss of producti...

Page 6: ...Quick Installation Guide General Information QIG 8000 81 003 Ed 01 February 2020 4 ...

Page 7: ...Quick Installation Guide February 2020 QIG 8000 81 003 Ed 01 5 Normal Installation ...

Page 8: ...Quick Installation Guide QIG 8000 81 003 Ed 01 February 2020 6 ...

Page 9: ... H Actuator spindle I Indicator bushing J DPI socket K Yoke L Screw Parts Delivered Actuator with without electrical indicator A Build in indicator bushing I Mounting instruction this document 1 Some actuators are equipped with visual indicator only E and no electrical indicator A This instruction covers actuators equipped with an electrical indicator A Most steps and illustrations will however be...

Page 10: ...t maintenance is ongoing Make sure that relevant operation systems are set to maintenance mode and alternative means of operation is ensured if required Read this instruction carefully before you start the actual repair or installation Follow all steps carefully and do not skip any steps unless specified how and when Tools Required Fork wrenches Different sizes depending on actuator model Unbrako ...

Page 11: ... the bottom of the actuator The label shows the factory configured stroke Add the value from the label b to the table in step 3 Caution If a label with configured stroke doesnot appear as shownin the illustration please follow description on page 23 3 Calculate the preload value Example For the KC 125 the configured stroke is measured to 25 mm Calculation will thus be 34 25 mm total fixed stroke 2...

Page 12: ...es KC 65 19 25 mm 16 25 mm 3 mm 12 50 mm 7 mm 10 mm 9 mm 8 mm 11 mm KC 125 34 25 mm 31 25 mm 3 mm 25 mm 9 mm 20 mm 14 mm 16 25 mm 18 mm KC 250 65 5 mm 62 5 mm 3 mm 50 mm 15 mm 37 5 mm 28 mm 25 mm 40 mm KC 325 84 25 mm 81 25 mm 3 mm 75 mm 9 mm 62 5 mm 22 mm 50 mm 34 mm 37 5 mm 47 mm KC 400 103 mm 100 mm 3 mm 87 5 mm 15 mm 75 mm 28 mm 62 5 mm 40 mm 50 mm 53 mm ...

Page 13: ...ng the Actuator to the Valve 1 Ensure that the visual indicator c is closed 2 Dismount the caps d from the two hydraulic connection fittings 3 Connect the hydraulic hand pump to connection fittings A and B 4 Operate the hand pump to until the actuator spindle e is in position Closed max out 5 Add a mark on the valve stem according to the illustration below Caution The engagement between actuator s...

Page 14: ...top flange before mounting the actuator 6 Insert the actuator unit through the hole in the valve top flange or through the hole of the packing bushing in the valve top flange depending on model 7 Connect the spindle a to the stem thread b Use of a fork wrench to turn the spindle a few turns Leave a gap c between the valve top flange d and the actuator mount ing flange e 8 Measure the distance c be...

Page 15: ...rding to the table below 12 Use the hydraulic hand pump to fully open and fully close the actuator and check that the spindle moves the distance according to the specified stroke for the valve and actuator 13 Use a fork wrench to hold the spindle in place while at the same time using a fork wrench to tighten the stem counter nut against the actuator spindle end Quality Size Stainless 70 Stainless ...

Page 16: ... the DPI according to Test of the DPI on page 15 DPI E or page 17 DPI C depending on model 16 Vessel installations only Connect the wires from the DPI connector housing to the DPI socket according to the corre sponding DPI Data Sheet ref page 2 in this instruction or the Project Specifica tion Wiring Diagrams 17 Mount the DPI connector housing and tighten the four screws a 18 Vessel installations ...

Page 17: ...stem as well as when dismounted Test of DPI E On Off signals Test of DPI E On Off signals 1 Connect a hydraulic hand pump if not connected already by dismounting the caps d from the two hydraulic connection fit tings and connect the pump hoses to fittings A and B 2 Make sure the visual indi cator c shows closed 3 Operate the hand pump and observe that the spin dle e moves in 1 actu ator is open an...

Page 18: ... Operate the hand pump until the actuator is fully Open spindlemovesin The sound signal should turn off 8 Test of Open signal The multimeter should give a sound signal when connecting the multime ter to terminal 7 8 Caution If any of the sound signals described above fail to appear please consult the description for adjustment of the DPI on page 19 9 Disconnect the multimeter 10 Leave the actuator...

Page 19: ...connection fit tings and connect the pump hoses to fittings A and B 2 Make sure the visual indi cator c is closed 3 Operate the hand pump and observe that the spin dle e moves in 1 actu ator is open and out 2 actuator is closed 4 Ensure that the actuator is in position 2 closed the spindle is in max out position before con tinuing with step 5 5 Set the multimeter to Ω signals Note Adjust DPI C in ...

Page 20: ...the hand pump until the actuator is fully Open spindlemovesin 7 Test of Open signal The multimeter should 1400 7000 Ω when con nectingthemultimeterto terminal 7 9 All values are 50 Ω Caution If any of the sound signals described above fail to appear please consult the description for adjustment of the DPI on page 19 8 Disconnect the multimeter 9 Leave the actuator in position closed actuator spind...

Page 21: ...em as well as dismounted Adjustment of the DPI 1 Connect a hydraulic hand pump if not connected already by dismounting the caps d from the two hydraulic connection fit tings and connect the pump hoses to fittings A and B 2 Make sure the visual indi cator c is closed 3 Operate the hand pump and observe that the spin dle c moves in 1 actu ator is open and out 2 actuator is closed 4 Leave the actuato...

Page 22: ...re is a gap of 3 4 mm between the con trol block and the DPI flange 9 Check the Closed signal There should be no sound or Ω display should show more than 300 1500 10 Now use the fork wrench to slowly tighten the DPI socket until the multime ter makes a sound signal or Ω display shows 300 1500 11 After Closed sound sig nal or Ω display 300 1500 tighten the DPI socket another 45 90 degrees ...

Page 23: ...ow correctly adjusted with regard to the Open and Closed signals Note For DPI E the multimeter should thus send a sound signal on terminal 7 8 when the actuator is in position open and on 9 10 when in position closed Between the two positions the sound signal must be off For DPI C the value should be Ω 300 1500 for Closed and Ω 1400 7000 for Open 14 Disconnect the multimeter 15 Fasten the locking ...

Page 24: ...Quick Installation Guide Damcos KC Actuators Adjustment of the DPI QIG 8000 81 003 Ed 01 February 2020 22 ...

Page 25: ...rwise follow description on page 9 in stead Determine the Configured Stroke 1 When in position Open spindle is max in use the caliper to measure the distance a Make a note of the value for a in the table below 2 Use the hand pump to slowly close the actuator while monitoring the closed signal Stop pumping when reaching the signal for Closed 3 Use the caliper to measure the distance b Make a note o...

Page 26: ...Quick Installation Guide Determine the Configured Stroke QIG 8000 81 003 Ed 01 February 2020 24 ...

Page 27: ...cator Adjust the indicator See DPI data sheet SD 2000 0E07 page 2 No closed signal from actuator Stroke is reduced by incorrect mounting Ensure that stroke is according to valve requirements See also Determine the Configured Stroke on page 23 in this instruction Incorrect adjustment of the indicator Adjust the indicator See DPI data sheet SD 2000 0E07 page 2 The actuator stroke does not match the ...

Page 28: ...Quick Installation Guide Trouble Shooting QIG 8000 81 003 Ed 01 February 2020 26 ...

Page 29: ...Quick Installation Guide February 2020 QIG 8000 81 003 Ed 01 27 Additional Instructions for Modification Repair Only ...

Page 30: ...Quick Installation Guide QIG 8000 81 003 Ed 01 February 2020 28 ...

Page 31: ...ion systems are set to maintenance mode and alterna tive means of operation is ensured if required Warning IKeep clear of moving valve parts due to risk of personal injury Empty from Oil Before disassembling the actuator has to be emptied from the oil Please refer to system procedures and documentation Ref documents listed on page 2 in this instruction Open the Valve and Actuator The valve must be...

Page 32: ...s 4 DPI models only Dismount the DPI connector housing Loosen the four screws a to dis mount the DPI connector hous ing from the DPI socket Make a note of the wiring Wire colors and terminal numbers b Disconnect the wires Seal the DPI connector housing from dirt and moist and leave it hanging on the cable 5 Loosen the counter nut on the stem 6 Unscrew the actuator spindle from the valve stem a 7 R...

Page 33: ... round surface of the actuator spindle In general only use tools on wrench grip surfaces and holes prepared for tools Disassembling the Actuator 1 Place the actuator unit on a clean worktable Caution Models without DPI Keep the actuator placed on the side with the visual indicator pointing upwards in order to avoid the yoke in the control block from dropping into the piston tube 2 Loosen and remov...

Page 34: ...actuator spindle a Caution Only use fork wrench or pliers on the wrench grip surfaces a Locate the screw inside the actuator by use of a long hex key Still holding the actu ator with the fork wrench now turn the hex key to loosen the screw inside the actu ator When the screw is loosened still hold ing the hex key unscrew and remove the actuator spindle ...

Page 35: ...e the indicator bushing Use the hex key to push the indicator bushing as far out as possible Then use a pair of lock ring pliers to pull the indicator bushing out of the actuator Do not use pliers on the outside surface of the indicator bushing 7 Remove the long screw from the inside of the actuator ...

Page 36: ...00 81 003 Ed 01 February 2020 34 8 DPI models only Use a long pair of tweezers to remove the yoke 9 Dismantled parts should now be as shown below D Bleed valve E Visual indicator F Screw 4 pcs H Actuator spindle I Indicator bushing J DPI socket K Yoke L Screw ...

Page 37: ... hole 3 and at the same time lead the bolt through the indicator bushing until the bolt is visible at the narrow end of the indicator bushing Caution Models without DPI If assembling a model without DPI you must ensure by visual check that the yoke is positioned correctly not visible when looking into the actuator from the bottom before mounting the indi cator bushing and make sure the actuator is...

Page 38: ...th round surface of the actuator spindle Only use tools on the wrench grip surfaces 6 DPI models only Insert the yoke into the DPI hole Use a pair of long tweezers to position the yoke cor rectly in the small hole in the bottom of the DPI hole 7 DPI models only Insert the DPI socket into the hole and make 4 5 turns by hand for loose tightening 8 Mount the bleed valve and tighten using a fork wrenc...

Page 39: ...01 37 9 Mount the visual indicator Tighten to 15 20 Nm General torque Nm below refer to pos nos on page 34 Actuator Item 65 125 250 325 400 Bleed valve D 15 20 15 20 15 20 15 20 15 20 Visual indicator E 15 20 15 20 15 20 15 20 15 20 Screw L 17 40 136 649 1120 ...

Page 40: ...Quick Installation Guide QIG 8000 81 003 Ed 01 February 2020 38 ...

Page 41: ...Quick Installation Guide February 2020 QIG 8000 81 003 Ed 01 39 Appendix A ...

Page 42: ...Quick Installation Guide QIG 8000 81 003 Ed 01 February 2020 40 ...

Page 43: ...20 17 Long Unbrako hex key sizes Actuator size Screw Hex size Max Ø c Min length a 65 M6 5 12 100 mm 125 M8 6 14 100 mm 250 M12 10 19 180 mm 325 M20 17 31 250 mm 400 M24 19 37 270 mm Spanner keys All KC models refer to pos nos on page 7 Size mm For use with Note 10 Block lock indicator page 20 step 7 19 Bleed valve D 22 Visual indicator E 24 Visual indicator E 27 DPI A Max height 4 ...

Page 44: ...Quick Installation Guide Tools QIG 8000 81 003 Ed 01 February 2020 42 Spindle key sizes Actuator size with collar without collar 65 27 16 125 30 19 250 50 38 or 41 325 N A 50 400 N A 50 ...

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Page 46: ...ation purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guaran tees expressed or implied regarding the products or services described herein or their use or applicability Standard Terms and Conditions of Sale can be issued by contacting Damcos A S We reserve the right to modify or improve the designs and specifications of our produc...

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