Zeppelin Vacuum Scale

STANDARD
MANUAL
Clean Feed Vacuum Scale

Installation, Operation and
Maintenance Guide
Shop order:>
Manual number:>
Version number:>
Issue date:>
000000
602033
003
16 April 2003
Throughout this manual the following conventions have been adopted:
DANGER
This symbol is used to indicate that failure to comply with the attached instructions may
cause personal injury.
CAUTION
This symbol is used to indicate that failure to comply with the attached instructions may
cause damage to product of equipment.
Warning
Personal injury may result if the following safety precautions are not observed when operating or maintaining
this equipment.
DO NOT attempt to operate or maintain the equipment until you are fully conversant with its operation and have
studied the instruction manuals provided.
Be sure that the equipment has been installed correctly and connected to a recognised electrical earth.
DO NOT operate the equipment in a manner for which it was not intended.
Read and understand machine warning labels and never remove or deface them.
If unsure of the correct functionality of the equipment, please contact Zeppelin before putting it into operation.
Ensure that all access to the equipment is restricted to trained personnel for operation and maintenance.
Check thoroughly all interfaces between Zeppelin equipment and other suppliers equipment to ensure that
possible hazards are identified and removed before putting it into operation.
Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen
Contents
Clean Feed Vacuum Scale 5
Introduction ..
Filter Unit ..
Description ...
Drawings ...
Parts list .
5
5
5
6
10
Installation .. 11
Operation and setting up ... 13
Butterfly Valve Pneumatic Operation
(Tomoe) . 15
Preface .. 15
Storage .. 17
Installation. 19
Additional Recommendations . 21
Installation of a Butterfly Valve
Adjacent to a Bend .. 23
Post-Installation Procedures 25
Inspection and Maintenance 27
Removal . 29
Overhaul and Re-Assembly . 31
Overhaul Procedure for the 2M
Worm Gear Driven Valve
(For 40-300mm) ... 31
Worm Gear Driven Butterfly
Valve (for 350-600mm)........................ 34
Locked Handlever Driven Butterfly
Valve ...................................................
Proper Assembly of the Valve ............
(For 40-300mm) .................................
(For 350 600mm).................... ..........
36
37
37
40
Mounting an Actuator on a
Butterfly Valve ........................................... 43
Procedure for Mounting the Gear
Actuator............................................. 43
Procedure for Mounting the Handlever.. 44
Components ............................................... 45
1M Locked Handlever Driven
(40-200mm) .......................................
Parts List ..............................
2M Manual Worm Gear Driven
(40 300mm) ...................................
Parts List .............................
(350-600mm) ....................................
Partls List ...............................
2M Manual Worm Gear Driven
(350-600mm).....................................
Parts List.................................
45
45
46
46
47
47
Pneumatic Actuator P and E Series
49
Description . 49
Actuator Orientation 49
Actuator Mounting Instructions .. 49
Air Supply and Electrical Installation 50
Air Supply . 50
Air Supply Pressure 50
Air Supply Connections . 50
Recommended Tubing Sizes 51
Air Consumption 51
Actuator Assembly Modes .. 52
Operation .. 52
Basic Actuator .. 52
Actuator with Solenoid Valves. 53
Standard Stroke Times 55
Manual Operation ..55
Maintenance .. 55
Recommended Spare Parts . 56
Troubleshooting 57
For Solenoid controlled
actuators 57
Rebuilding Instructions 58
Actuator Dis-Assembly 58
Actuator Re-Assembly . 60
Spring Return Actuator P Series (Model SR) ............................ 60
Spring Return Actuator
E Series (Model ES) ..............................61
Construction, Parts and Materials,
Standard Actuators ............................. 62
Construction, Parts and Materails,
Series E .............................................. 64
Construction, Parts and Materials,
Steel E ................................................ 66
Actuator Assembly Modes .................. 68
Installation of Springs .......................... 69
Installation of Springs Series E Actuator ................................ 70
Maintenance and Operation Stroke Adjustment, Series E................ 71
Description .............................. 71
Spring stoke adjustmentFail close ............................... 71
Spring stroke adjustment Fail open ................................. 71
Maintenance and Operation Spring Change, Series E ..................... 72
Description ..............................
Procedure ................................
48
48
72
73
Actuator Solenoid .
Description ..
General Specification
Actuator Switch Box.
Description
Specification .
Maintenance ..............
Filter Unit
Introduction .
Pressure system Regulations..
Explosion Prevention .
Usage ..
Health & Safety .
Supply Services Required ..
Supply Services Required .
Compressed Air Supply
Installation ..
Installation ..
Handling ..
Assembly .
Supply Connection .
Cartridge Installation ..
Installation and
Commissioning ..
Duct System
Operation .
Operation
General Operating
Parameters .
Air Volumes..
Collection Bins
Start Up ..
Stopping
Adjustment of the Cleaning Cycle .
Adjustment of the Cleaning Cycle
Duration ..
Interval .
Pressure Differential .
Units Supplied without an
Adjustable Cleaning Controller..
Maintenance and Service .
Maintenance and Service .
Safety
Routine Inspection .
Maintenance Access .
Inspection of Compressed
Gas Equipment
Troubleshooting .
Troubleshooting
Spare Parts List
73
73
74
74
75
75
77
79
79
79
80
80
80
81
81
81
83
83
83
83
83
83
Operating Instructions
Standard Controller Printed
Circuit Boards
95
Index ..
99
84
84
85
85
85
85
85
86
86
87
87
87
87
87
87
89
89
89
89
89
90
91
91
93
Clean Feed Vacuum Scale
Introduction
This manual contains the technical information for the safe and efficient installation, commissioning and
operation of the vacuum scale.
Filter Unit
For instructions for the scale filter unit, see the appropriate section in this manual.
Description
The weigh scale has been designed to weigh non free flowing powdered materials in a vacuum
conveying system. The maximum design weighment is 100Kg. The parts which come into contact with
the material are sintered plastic, polished stainless steel and coated mild steel.
The scale consists of 4 parts, the top chamber, the dust filter unit, the main cone body of the scale
which is polished stainless steel and the fluidsation bottom cone to which the discharge valve is fitted.
The scale assembly is supported from a steel mounting frame, to which the 3 precision loadcells are
fitted. The scale hangs from these loadcells by means of special hanger rods.
Fitted to the side hopper is a stainless steel inlet pipe, the materials handled are drawn through this by
means of a vacuum. This pipe is connected to the scaled infeed branch pipe with a flexible section of
pipe. The bottom cone is connected to the fluidastion air supply from the air conditioning unit. The
fluidization air is controlled by a pneumatic diaphragm valve mounted on the local control panel.
The suction connection to the scale is located on one side of the filter housing.
The scale discharge valve is a butterfly valve fitted with a pneumatically operated actuator, see separate
section in this manual.
A pneumatics and control panel is supplied with the scale. Mounted on this panel is the electrical
terminal box, and fluidisation control valves, and a pneumatics filter, regulator and lubricator. This panel
should be mounted on the adjacent steelwork.
Front Elevation of Scale
Plan View of Scale
Loadcell Assembly
Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Description
Item
Weigher Support Frame

Infeed Plate Support Frame
Clean Air Pip Support Frame
IDC Filter Assembly
Weigher Upstand
Weigh Hopper Upper Cone Assembly
Hopper Lower Section (250 outlet)
Plastic Fluidisation Cone (250outlet)
Distance Ring
Rubber Seal
M10 Studding x 350 LG
250 Mucon Disc Valve
300 Spigot
300 Flexible
Clean Air Flexible
Infeed Pipe
Infeed Flexible
Loadcell Mounting Bracket
500lb Loadcell Weightronix
M8 U Bolt
U Bolt Plate
M8 Hex Nut
M8 Plain Washer
M10 Washer Spherical with seat
M10 Studding x 160 LG
Auto-Cal Weight Rack
500lb Weighbar Retaining Ring Clip
1 Neoprene Adhesive Rubber Strip
Jubilee Clip (70 -90 Dia)
Description
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Jubilee Clip (85 100 Dia)

Jubilee Clip (40 55 Dia)
Jubilee Clip (300 Dia Cut to suit)
M6 x 20LGHex. Hd. Bolt
M6 Hex. Hd. Nut
M6 Plain Washer
M6 Spring Washer
M10 x 25LGHex Hd. Bolt
M10 Hex. Hd. Nut
M10 Plain Washer
M10 Spring Washer
M12 Hex. Hd. Nut
M12 Plain Washer
M12 Spring Washer
M16 Studd x 95LG
M16 Hex. Hd. Nut
M16 Plain Washer
M16 Spring Washer
Aspiration Spigot
Aspiration Sock
3 Butterfly Valve
32 NB Heavy Duty Air Hose x 190LG
Installation
Note: The vacuum scales should be installed before any discharge chutes or mixer entry chutes have
been fitted, but dimensions checked to ensure these parts will fit in the space envelope left.
When unpacking the scale check for obvious damage to components, particularly to the loadcells and
hangers.
The main support structure for the scale should be pre-erected ready for the installation.
The scale has been pre-assembled at CR and should only require connecting up to the pneumatics and
electrics.
A scale support frame has been provided and this should be installed on the main support frame.
Fit loadcell mounting brackets and loadcell safety brackets to the scale support frame, fit loadcells in
position in brackets and place hangers over loadcell ends. Hangers are to be secured to the loadcell
using retaining clips.
CAUTION
Ensure brackets are properly secured with the correct size

bolts.
Place scale in position under the support frame. Carefully raise the scale up to the hangers on the
loadcell and fit hangers through the holes on the support brackets on the scale hopper. Fit nuts and
locking nuts to underside of brackets. Adjust scale until level on all three hangers. This is important!
Lock off nut and lock nut.
CAUTION
Do not clamp hangers to scale support brackets.
CAUTION
Lower scale gently on the loadcells. Do not bang scale hopper

into loadcells when raising into position.
The loadcell safety brackets should be fitted underneath the loadcell mounting brackets. A length of
screwed rod should not be fitted to both the safety bracket and the hopper hanger bracket. Use both
nut and locknut at both ends to secure the screwed rod. The rod should hang loose and interfere with
the weigher.
Mount panel adjacent to scale. Make electrical and pneumatic connections.
Connect the 19 mm bore rubber hose to the fluidisation air connection on the bottom cone. The air
supply to the bottom cone is to be 0.5n BarG and is to be taken from the air preparation equipment
supplied by CR. DO NOT shorten the rubber hose!
CAUTION
The hose when connected should not cause restriction to the scale movement.
Connect conveying pipe, suction pipe and discharge chutes to scales as shown on drawings.
Connect loadcells to local terminal boxes and connect terminal boxes to control panel
CAUTION
Do not cut loadcell wires short, they should be at length supplied.
Operation and Setting Up

The Operation of the scale is an integral part of the weighing mixing system and requires no manual
operation. See the functional specification and electrical manuals for details.
For setting up instructions, see the functional specification and electrical manuals.
Butterfly Valve Pneumatic Operation (Tomoe)

Preface
This manual contains details applicable to both manually and pneumatically actuated butterfly valves.
The valves assembly is common to both types.
The instructions given for installation, removal, overhaul and re-assembly of the valve include details of
worm gear and lever manual actuators.
Details for installation of manual actuators are given in the section Mounting an Actuator on a Butterfly
Valve.
Details for installation and maintenance of pneumatic actuators are given in the section Pneumatic
Actuator P and E Series.
Storage
The butterfly valves should be stored in a cool and well ventilated, preferably air conditioned,
warehouse. Do not remove the protective coverings.
During long term storage, open and shut the valves once every three months. In addition,
apply rust-prevention oil on the plated parts, such as position indicators, worm shafts, bolts and
nuts periodically, approximately once every six months.
CAUTION
After the valves are unpacked, avoid any concentration of load onto the actuator
shaft or other critical parts before use.
Installation
After aligning the pipes, put two bolts into the bottom two flange holes for temporary support of the
butterfly valve while it is being placed into position.
Note: For size 350-600mm, see below.
Put two jacking bolts between the pipe flange as shown below. By adjusting the jacking bolts and the
two flange bolts, maintain the gap between the flanges at about 3 to 5mm beyond its final position.
Drop the butterfly valve into position. During this operation, care should be taken to keep the surfaces
of the joints free from dents, scratches, etc.
Before the butterfly valve has been lowered completely onto the bottom flange bolts, place another two
bolts immediately below the upper lugs of the valve. Then ease the valve down until the lugs rest on the
bolts.
Note: for sizes 350-600mm, insert 4 bolts.
Remove the jacking bolts and install all remaining bolts. Partially tighten all bolts then align the valve.
Once valve alignment is checked, tighten all bolts until the pipe flanges touch the metal surfaces of the
valve. Take care to apply equal load to all bolts around the flange.
Additional Recommendations
Before installation, check that the material quality of the seat ring and disc meets the required
specifications.
When handling butterfly valves, pick them up by the neck (the upper stem housing) with a nylon
sling.
Caution
Install valves in a pipeline only after the flange weld zones have cooled down. Flanges
should never be welded with a butterfly valve placed between them.
When installing the valve removing it from the pipeline, keep the disc flash open to about 10.
Sharp edges, gashes, or flash on the piping flanges should be filed off, to prevent damage to
the valve seat ring. The pitch circle of flange bolt holes should be exactly concentric with the
piping bore.
The flange surfaces should be cleaned with compressed air then wiped with a solevent-soaked
cloth. The pipeline should also be cleaned by compressed air or steam blower before installing
the valve.
The valve should be aligned with the pipeline.

Before final tightening of flange bolts, make sure that the valve disc is not obstructed by the
walls of the pipes when opened and closed.
A short piece of pipe should be inserted between the butterfly valve and a check valve, bend, or
pump, to prevent interference with disc motion.
Seat rings should be kept free from solvent. No oily substances except those made of NBR or
Viton should come into contact with the seat ring.
Pipes whose walls are lined with resin should have the lining continuously extended up to the
flange surface and the lining flared to cover the surface. The inside diameter as measured on
the resin lining should be equal to or more than the rated size of the butterfly valve.
Special attention should be paid to the orientation of the butterfly valve when it is installed
downstream from a bend.
Installation of a Butterfly Valve adjacent to a Bend
Where practicable, the butterfly valve should be installed upstream from a bend.
If a downstream installation is unavailable, the valve stem should have parallel orientation with
axis of the upstream piping.
Installation of a butterfly valve downstream from a bend with the stem not parallel to the axis of
the upstream pipeline is not acceptable for the following reasons: - differences in fluid velocity
(pressure) on both sides of the disc may cause it to vibrate, and, - in some cases, may cause
erosion of the disc on the side having higher fluid velocity.
Post- Installation Procedures

Pipelines should be flushed and cleaned after installation of valves.
Note: Inspect and check for any leaks in the piping flanges, valve glands, or bottom cover by
hydrostatic or pneumatic testing.
If any leaks are found, retighten bolts carefully, making sure that the distribution of load to all
bolts is uniform.
Caution
When opening or closing the valve, operate the hand lever or worm gear hand
wheel without the help of an extension lever. Applying excessive force to the
level or hand wheel with a temporary extension lever will cause damage.
The butterfly valve should not be closed to hold testing pressure exceeding the rated pressure
of the valve. If such testing is required, the valve should be removed and temporarily replaced
by a blank flange.
During long-term shutdown of a pipeline, the butterfly valve should be operated periodically at
least once every two weeks.
The butterfly valve should not normally be operated at less than 30open. If such operation is
required, consult with our Engineering Department beforehand.
Inspection and Maintenance

Inspect the disc and seat ring for any corrosion or wear once a year. As a rule, worm gear and hand lever
actuators are maintenance free.
If any abnormality is noticed during operation, it may be that foreign matter is clogging the valve or the seat ring
is damaged. Remove the valve from the system for inspection.
Rust-prevention and lubrication procedures are outlined in the table below.
Plated parts
(indicator, bolts, nuts, & worm shaft)
Ant-rust oil
Shafts & shaft sealings
Ferrogaurd # 1009
(Ronco Labs. Inc., USA
Shaft Grease D
(Satoh Tokushu Selyu, Japan)
Grease
Gears
Disc edge
Silicon oil
Cup Grease #250

(Idemitsu Kosan, Japan)
Shin-etsu Silicon KF96H
(Shin-etsu Kagaku, Japan)
Removal
DANGER
Before removing a butterfly valve from a pipeline, first check that the system
pressure has been completely released. The system should also be completely
drained before opening up a piping joint.
Shut the valve before loosening the flange bolts. Remove the bolts, leaving the bottom two
in place. Open the flanges by means of jacking bolts, then remove the valve.
Overhaul and Re-Assembly

Overhaul and re-assemble for inspection or repair in accordance with the following procedures:
Overhaul Procedure for the 2M Worm Gear Driven Valve (For 40-300mm)
Open the butterfly valve completely.
Remove the four bolts (51) which joint the valve body and the 2M actuator.
Grip the body in a vise and extract the actuator from the valve. The upper stem (3) will remain in
position.
Remove the machine screws (8) with a screw driver.

Grip the upper stem (3) in the vise and take out the valve body (1).
Remove the two bolts (10-1), and take out the bottom cover (6) and gasket (14).
Now insert one of the bottom cover bolts (10-1) into the threaded holes at the bottom end of the lower
stem (4) and turn it a few times. Remove the lower stem (4) by pulling out the bolt (10-1).
Insert a screw driver between the seat ring (12) and the valve body (1).
Insert your fingers into the gap between the body (1) and the seat ring (12) and take it out.
Overhaul Procedure for the 2M Worm Gear Driven Valve (For 350-600mm)
Grip the body in a vise.
Remove the four bolts (51) which join the valve body to the 2M actuator and extract the actuator from
the valve.
Loosen hex, nut / washers (9) until they are flush with the end of the taper bolt (8) securing stem and
disc.
Tap the nut on the screw side of taper bolt (8) with a hammer to release it, taking special care not to
deform the screw, remove nut from screw & remove screw.
Use a chuck to lift out the tip of stem (3), and pull it upward, while turning it reciprocally to the right and
left.
Open the disc completely, hold the disc in both hands, and pull it out from the seat ring,
Take out the seat ring as instructed for 40-300mm.

Take out the body from the vise. Remove seat packing (14) and bottom cover (6) which is fixed with a
hex, bolt / spring washer (10). Take special care not to lose the ball (16).
Overhaul Procedure for the IM Locked Handlever Driven Butterfly Valve

Open the valve completely.
Remove all nuts (36) and spring washers (37) from the NOTCH (25) and the valve body (1).
Remove the C.B.T (cap bolt) (33) and spring washer (32) and set screw (39) fixing the upper stem (3)
and the adapter.
Fix the body in a vice, then remove the NOTCH (25) and the lever by pulling upward, At this time, the
upper stem (3) is left in the body, but the thrust washer is removed together with the NOTCH (25). Be
sure to keep the thrust washer for reassembly.
It is advisable that Bushing (13) is replaced with a new one, even if not worn out yet.
Proper Assembly of the Valve
Before assembly, clean each component carefully with solvent, and check for damages or defects.
Replace Bushing (13) and gaskets with new ones at each overhaul, even if they appear intact.
(For 40-300mm)
Temporarily fit the lower stem (4) to facilitate alignment if the seat ring (12)
Put the seat ring (12) into the body (1) aligning the lower hole with the temporarily fitted lower stem.
Make sure that the holes of the two components match exactly.
To position the seat ring (12) to fit into the body (1). Push the upper part of the seat ring downward so
that it curves like the letter U. Take care to keep the secondary seal ring (11) in place.
Check that the top and bottom holes of the seat ring (12) completely match those of the body (1).
Apply silicone oil to the top and bottom ends of the disc (2) and place it into the bore of the seat ring
(12).
Apply grease to the lower stem (4) and put it in place, taking care not to do damage to the bottom hole
of the seat ring (12).
After the lower stem is fitted into the disc (2), place the gasket (14) and bottom cover (6) on the bottom
end of the body (1), and tighten them with the bolts (10-1) and spring washers (10-2).
Looking down from the top of the body (1), check that the holes of the seat ring (12) and disc (2) are
properly aligned with the valve.
Apply grease to the upper stem (3) and lower it down to fit into the disc (2) at the two-flat joint. Insert
the upper stem until the bushing (13) (including O rings & plate) is flush with the flange of the body,
then fix the bushing with two machine screws (8).
(for 350-400mm)
Fit the seat ring (12) into the body as instructed for 40-300mm
Place the disc into the bore of the seat ring (12) as instructed for 40-300mm. It would be easier to pull
the disc into the body.
Apply grease to the tip of the stem (3) and insert it carefully so as not to damage the seat ring hole.
Prior to re-assembly, secure the disc (2) and stem (3) with pin (8) and new O-ring (8-1), and align them
correctly in the same position as before disassembly. Always apply grease to taper bolt (8).
Place the gasket (14) and bottom cover (6) on the bottom end of the body (1), and tighten with the bolts
(10).
Apply grease to the tip of the hollow bolt (set screw) (17). Push the ball (16) with the hollow bolt until it
touches the stem (3) and then tighten the lock nut (18).
Put to the O-ring (13) and (Osaeban) (7) on top of the valve body.
Fix the key (g41) to stem (3). After re-assembly, ensure that each part has been re-assembled correctly
and there are no errors in mounting.
Mounting an Actuator on a Butterfly Valve
Procedure for Mounting the Manual Gear Actuator

Put two joints (49) into position and mount the manual gear assembly on top of the valve body (1)
Note: No joint for 40 and 200-600mm,
Tighten the actuator flange with the bolts (51) and spring washers (52).
Operate the actuator to shut the valve and see if the indicator and disc are in the exact shut position. I
the indicator does not point to the exact position of valve, adjust the indicator with the set screw, A(32)
on your right. A clockwise turn moves the indicator in the open direction; a counter clockwise turn to
the shut direction. After adjustment, secure the set screw, A (32) with the set screw B(33).
Procedure for Mounting the Handlever

Align the NOTCH (25) and the indicator plate (26) with the hole in the body (1) and loosely fasten them
with the square shouldered bolts (29), nuts (36), and spring washers (37).
Place the thrust washer on the indicator plate (26) to fit the lever to the stem, Push the adaptor (22)
against the thrust washer, and lock it with the C.B.T (cap bolt) (33) with the spring washer (32) and set
screw (39).
Operate the lever to close the stem. Tighten up the nuts (36) after checking the disc is completely
closed.
When assembly is completed, operate the handlever and check for free movement of the valve and
proper functioning of the locking device. Also check that the indicator pointer aligns to the actual
position of the valve.
Components
I M Locked Handlever Driven (40-200mm)
Part List
A 2 pcs will be required in case of 200mm and smaller 4 pcs for 250 and 300mm.
2M Manual Worm Gear Driven (40-300mm)

Parts List
No
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Description
Casing
Cover
Worm Gear
Worm
Worm shaft
End cover
Spacer
Indicator
Indicator cap
Bushing A
Bushing B
Set screw A
Set screw B
Socket screw
Socket screw
Spring pin
O ring
O ring
O ring
Gasket
Rubber gasket
Handwheel
Collar
Bolt
Spring washer
Bolt
Spring washer
Plain washer
Joint
Bushing, C
Bolt
Spring washer
*B: 4 pcs will be required in case of 150mm and smaller 5 pcs for 200mm and over.
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
*B
1
1
2
1
1
1
1
1
1
1
2
2
2
2
1
4
4
(350-600mm)
Part List
2M Manual Worm Gear Driven (350-600mm)

Part List
Pneumatic Actuator P and E Series

El-o-matic pneumatic actuators are available in two model series (Series P and Series E).
Each series has a special prefix in its model number to identify them as double acting or spring return.
P Series
E Series
Double acting
PD
ED
Spring return
PE
ES
Description
El-o-matic actuators are pneumatic quarter turn actuators. The design utilizes a double rack and single
pinion. A unique patented feature of the El-o-matic actuator is the application of three carbon filled
Teflon* guide bands, on a patented balanced piston which prevents metal to metal contact between the
pistons and cylinder wall, eliminates wear and enhances cycle life.
Standard units at 6 bar provide from 15 to 4,945 Nm, of torque and feature an extended top shaft and a
completely modular design which allows simple attachment of a variety of control accessories. All units
feature and integral solenoid control block which properly directs supply air to the actuator. On available
with independently adjustable speed controls for both the opening and closing strokes of the actuator.
El-o-matic recommends speed controls for all actuator applications.
Actuator Orientation
The El-o-matic actuator is normally installed with its major axis parallel to the pipeline. The actuator can
be oriented above, beside and beneath the valve without affecting its operation.
Note: All El-o-matic actuators feature a blow out proof shaft design. This means that the pistons must
be removed before the shaft can be reorientated. See Disassembly / Reassembly instructions.
Step 1
Step 2
Step 3
Determine mode of operation of the valve (normally open or normally closed)

Determine desired quadrant for bracket attachment and direction of mounting of the
actuator (in line or cross line)
Attach bracket/actuator valve assembly as follows:
DANGER
Never disassemble valve that is under pressure
Actuator Mounting Instructions

a) Rotate valve stem to position necessary to achieve desired operation.
b) Remove handle nut, handle, lockwasher, etc as required by mounting hardware instructions.
c) Attach mounting bracket to actuator do not fully tighten bolts at this time
d) Insert coupling into drive sleeve of the actuator making sure that the coupling engages properly.
e) Lower mounting bracket / actuator / coupling assembly onto valve, making sure that male valve
stem engages in coupling.
f) Secure bracket valve using cap screws and lock washers provided in mounting kit. Tighten
securely.
g) At this time make sure that the actuator is in the operational mode desired and that the valve is
in the corresponding open or close position: if not:
1. Remove the fasteners at the mounting bracket/actuator end then rotate actuator 90
degrees while still engaged with valve stem or,
2. If integral solenoid valve is present on double acting model, remove the solenoid
assembly and invert it (turn it upside down) and remount.
Note: Some valves are manufactured so that they operate is only one 90 degree segment, a good rule
of thumb is to mount the actuator for counter clockwise rotation to open and clockwise to close the
valve.
Air Supply and Electrical Installation
Air Supply
El-o-matic actuators are factory lubricated. For optimum operation, the use of clean, dry air or gas is
recommended. Lubricated air is not necessary.
Air Supply Pressure
Standard double-acting actuators 1 to 10 bars supply air. Spring return actuators require 3 to 10 bar
supply air.
Air Supply Connections
No Integral Solenoid Double-Acting (Models ED &PD).
First remove dust plugs, then connect air supply lines to both ports on the air manifold in the centre of
the actuator body.
The standard unit (CodeA) operates as follows:

Air to Port A:
Air to Port B:
Counter clockwise / open

Clockwise / close
Rack and pinion arrangements as viewed from above.

To reverse actuator rotation, invert pistons.
Spring Return (Models ES & SR) Connect air supply line to NPT port (A)
The El-o-Matic actuator stroke direction can be reversed. To reverse stroke direction remove both
pistons, rotate them 180 degrees and reinstall. This will reverse the direction of rotation of the output
shaft.
With integral Solenoid Connect air supply line to pressure port on the solenoid block.
Recommended Tubing Sizes
In order to provide sufficient flow of supply air to the El-o-Matic actuator, the following tubing sizes are
recommended.
Actuator
Model No.
P-35,60
E- 12,25,40
P-150,280,500,7500
E- 100,200
P-1100,2500,4000
Runs up to
1.2m
Runs over
1.2
6mm
6mm
6mm
6mm
8mm
12mm
Air Consumption
The following chart shows the amount of air consumed per 90 degrees of stroke in ltr. / stroke.
Air consumption ltr / stroke
Air chamber
P series
A
B
E Series
A
B
Model
35
60
0.13 0.27
0.17 0.38
12
25
0.05 0.10
0.06 0.11
150
0.6
0.8
40
0.16
0.22
280
1.5
1.6
100
0.35
0.49
500
1.9
2.5
200
0.8
1.0
750
3.2
4.2
1100
4.2
5.4
2500
8.0
9.3
4000
13.5
17.5
Actuator Assembly Modes

The El-o-matic actuator may be field or factory converted to provide different directional rotations and
shaft orientations. The four configurations A,B,C,D, are shown.
Note: A standard. All are views from above
Operation
Basic Actuator
The El-o-matic actuator drive shaft rotates through a full 90 degrees (some P Series models may be
ordered with full 180 degrees of rotation). Rotation is accomplished by feeding supply air in to the
centre chamber, forcing the two opposing pistons outward, resulting in counterclockwise rotation of the
drive shaft to the open position.
For double-acting actuators closure is obtained by feeding supply air into the end cap chambers, which
forces the pistons inward, resulting in clockwise rotation of the drive shaft.
For spring return actuators, closure is accomplished by means of springs contained within the end caps,
which force the pistons inward when the supply air to the centre chamber is allowed to exhaust.
If the rotation opposite to that described above is required, refer to Actuator Orientation for the proper
procedure to reverse the rotation.
Actuator with Solenoid Valves
Double-Acting
Air is supplied to the pressure port on the solenoid block. When the solenoid is energized the spring
plunger is withdrawn, allowing the supply air to shift the spool within the block, which opens the supply
path to the centre chamber (Port A) of the actuator. Air from the end chambers (Port B) of the actuator
is allowed to pass through the block and exhaust to atmosphere.
When the solenoid is de-energised the spring loaded plunger blocks the flow of air to the centre
chamber of the actuator. The spool now shifts within the block to a position which opens the supply
path to the end chambers (Port B) of the actuator. Air from the centre chamber (Port A) of the actuator
is allowed to pass through the block and exhaust to atmosphere.
The double acting solenoid assembly is responsive to electrical failure. That is, it will return to its deenergised position upon electrical failure and cycle the actuator to the closed position provided the air
supply is not interrupted. This action may be reversed by inverting the entire solenoid valve on the air
manifold. (i.e de-energised condition will pressurize Port A).
Solenoid assemblies are available with independently adjustable speed controls which can be used to
adjust the speed of operation for the opening and/or closing stroke. If the speed controls are too tight,
air will pass and the unit will not operate.
Spring Return
Air is supplied to the pressure port on the solenoid block. When the solenoid is energised the spring
loaded plunger is withdrawn, which opens the supply path to the centre chamber (Port A) of the
actuator. Air from the end chambers of the actuator is allowed to pass directly through the block exhaust
to atmosphere.
When the solenoid is de-energised the spring loaded plunger blocks the flow of air to the centre
chamber of the actuator, at the same time the air from A is allowed to pass to exhaust. The springs in
the end cap of the actuator, which were compressed on the opening stroke, can now extend, forcing the
pistons together and providing the clockwise rotation of the output shaft.
Standard Stroke Times

Standard stroke times of the El-o-matic actuators are shown in the following table.
Time shown are in seconds and represent average times under no-load conditions with an air supply
pressure of 6 bar. Times shown are per stroke for double acting actuators. For spring return actuators,
the opening stroke times may be slightly longer, stoke times for the closing (spring) stroke are
dependent upon the number of springs used.
The figures shown below are meant as an indication of obtainable speeds only. Faster or slower
speeds are obtainable, if required, by using additional control equipment.
Stroking times (seconds)
Series
P Series
35
0.7
12
0.5
E Series
60
1.2
2.5
0.5
150
2.3
40
0.7
280
3.4
200
1.2
500
4.2
200
2.3
Model
750
1100
4.8
6
2500
7
4000
17
Manual Operation
In the event of air failure, the El-o-matic actuator can be cycled manually. This is accomplished by
applying a wrench to the exposed top shaft of the actuator and turning it in the desired direction. This is
not recommended on Model Sizes No. 15 and larger or on spring return actuators. In this case, El-omatic offers an optional declutchable manual override system (Series NO).
CAUTION
Care must be taken to ensure that the actuator is not operated automatically
while manual operation is being performed.
Note: Air must be allowed to exhaust from the actuator for manual operation. This requires
disconnecting air lines or providing three-way vent valves at inlet ports.
If a routing cycle check is to be performed on a double-acting actuator equipped with the El-o-matic
solenoid control block, the actuator can be cycled manually by operating the integral manual override
button on the solenoid body. Care must be taken to hold the button in the desired (if fitted) position until
the actuator has cycled. Provided the air supply is still on, the actuator will cycle to its original position
as soon as the manually applied pressure on the button is released.
Maintenance
DANGER
The actuator must be isolated both pneumatically and electrically before any
maintenance is begun.
Periodic checks should be performed to make certain that all fasteners remain tight.
All actuators are supplied with sufficient lubrication for their normal working life. If required,
recommended lubrication for all standard actuators is a Pensoil MP705. Consult Zeppelin for lubricants
used for high or low temperature applications.
Depending upon the conditions under which the actuator must work such as extended duty, noncompatible operating media or abnormal operating conditions, periodic replacement of internal seals is
recommended. Repair kits containing all necessary seals can be obtained through Zeppelin.
CAUTION
On spring return actuators, the springs may need replacement after extended
duty since springs may fatigue. Springs should always be replaced in complete
sets. Spring kits are available through Zeppelin.
Recommended Spare Parts

All soft seals, bearings, and non-reusable parts are included in the recommended spare parts kit.
Each kit includes

Description
Set of guide bands
Piston O rings
End cap O rings
Shaft bearings
Output shaft O rings
Nylon washer
Spring clip retainer ring
Qty
1
2
2
2
2
1
1
The spare parts kit is identical for both the double-acting and the spring return models. For the spring
return models we recommend a set of spare springs for each different model in addition to the
recommended spare parts kits. Keep in mind that, when necessary, springs are to be replaced in
complete sets.
Troubleshooting
Note: Before dis-assembling actuator for any reason, consult re-building instructions contained in the
following section.
For solenoid controlled actuators
A) If actuator does not function, check to ascertain that:
1. Valve is free to rotate. This can be done as described above in Manual Operation
2. Actuator is the correct size
3. Speed control screws are loose (if screws are tightened all the way, actuator will not
operate).
4. Correct voltage is supplied to solenoid (valve coil is tagged with correct voltage).
5. Sufficient air supply at inlet to control block. Inlet pressure to control block on a 5/2 solenoid
valve should be at least 2 bar, When checking supply pressure, place gauge in line at
control block inlet and monitor gauge for unexpected pressure drops.
B) If proper voltage and air pressure have been verified and valve is free proceed as follows:
1. Turn on signal voltage. Check solenoid for clicking sound.
2. If no sound detected.
a) Carefully unscrew solenoid and solenoid stem from block.
b) Reapply signal voltage and observe solenoid plunger. If it does not retract, replace
solenoid.
3. If solenoid functions, remove solenoid valve block and place on bench. Connect to reduced
air supply, and correct voltage. Switch signal voltage and check air flow. Air should flow
out only one output port when solenoid is energised. (slight back pressure may be required
to shift the valve spool. This may be generated by obstructing the outlet ports)
C) If the actuator functions but exhibits leakage, or power loss accompanied by leakage, proceed as
follow:
1. Check voltage. Voltage must be within 10% of the specified voltage (low voltage will cause
leakage out of the back of the solenoid and burn out the coil.)
2. Check air supply. Be certain that no sharp drops occur as unit is cycled. Loss of pressure can
cause incomplete shifting of the spool valves in the block, or at one of the piston seal will
usually leak on either cycle.
On spring return actuators, piston seal leakage will show at Port B of the air manifold flange.
The recommended procedure in the case above is to replace the spool valve O-rings first. If the
leakage persists rebuild the actuator using a factory supplied repair kit.
.For actuators without a solenoid control block or if block and solenoid are operating correctly,
remove the actuator from the valve.
DANGER
Never dis-assemble valve that is under pressure.
Apply air pressure (0.5 1 bar for double acting, 2-5 bar for spring return) to see if it will cycle under a no load
condition. If actuator works properly then the problem is in the valve. Consult the valve manufacturer for
assistance. If the actuator does not cycle then dis-assemble as per Actuator Dis-assembly Instructions below,
and check the following:
Note: Actuator should not be removed from the valve under pressure.
a) Make sure that all internal porting is free and clear of any obstructions.
b) Make certain that the actuator has lubrication, and that there is no solidified grease between the
pinion and the piston racks.
1. If the actuator has no lubrication, apply a generous amount of grease. If the actuator is
prepared for high or low temperature operation, consult Zeppelin for proper lubricant.
2. If solidified grease between the pinion and the piston racks is present, clean, dry,
regrease and re-assemble.
c) Verify that actuator pinion shaft and/or pistons are not bound. If bound, re-assemble as per
Rebuilding instructions.
d) If unit exhibits excessive amounts of backlash, check teeth on piston racks for wear. If worn,
replace piston/gear rack assembly.
e) In spring return actuators, check for misplaced or broken springs. If springs are broken, check body
bore for scoring.
Note: Springs should always be replaced in complete sets.
f)
1. If springs are broken, replace springs.

2. If body bore is scored, replace if necessary. Also replace O-rings (contained in Repair
kit).
If actuator is free, valve is free and control lock (if used) is shifting air properly, re-assemble the
actuator and retest. If unit still fails to operate, consult Zeppelin.
Rebuilding Instructions
For identification of all numbered parts discussed below, see the actuator data sheet at the end of this manual.
Actuator Dis-Assembly
Before disassembling any actuator be sure that a complete seal kit is available and that the kit has been
checked for parts.
Description
Ser of guide bands
Piston O rings
End cap O rings
Shaft Bearings
Output shaft O rings
Nylon Washer
Spring clip retainer ring
Qty
1
2
2
2
2
1
1
1. Disconnect the air supply and electrical service to the actuator.

2. Remove the actuator and its mounting bracket from the valve.
DANGER
Ball valves and plug valves can trap pressurised media in the cavity, isolate the
piping system in which the actuator valve assembly is mounted and relieve any
pressure on the valve.
3. Remove the actuator mounting bracket (and actuator switch box, positioned and other accessories
if provided) from the actuator to begin repair. (Note position of removed mounting bracket and
accessories for easy re-assembly).
4. Remove solenoid control block (if so equipped) by removing the solenoid block bolts. Use care to
retain the solenoid block seals.
5. Each end cap (P3,E4) is fitted onto the body (1) with a set of end cap bolts. Remove all end cap
bolts (P24 E36) from both end caps by loosening them evenly and a little at a time. After the screws
are removed, gently pry off each end cap being careful not to damage the end cap ) O-rings.
CAUTION
If the actuator is a Spring Return model, uniformly loosen all end caps screws
on each end cap two to three turns at a time, in sequence, to relieve pre-load of
the springs. On all actuators with springs, use caution when removing end
caps.
6. The two pistons (2) can now be removed by rotating the actuator shaft, driving the piston assembly
outward until the gear rack and pinion have disengaged
7. Remove and discard retainer ring (P20, E35) (not a reusable part) and the washer (21) from the
shaft.
8. Remove the shaft (pinion gear) through the bottom of the body.
9. All rebuilding kit O-rings (P16-19, E25-29) guide bands (P14-15, E10 -11) and bearings (P9-10,
E12-20) may now be installed, if all the actuator surfaces are clean and free of grit and scratches. If
the inside wall of the body is scored the actuator will leak after rebuilding. New unscored parts
should be obtained from the factory. Light tracing, barely detectable to touch, is acceptable.
10. Lubricate the standard actuator thoroughly with grease. Apply a light film of grease to all O-rings.
11. If converting over to a high temperature actuator, or rebuilding an existing one, consult Zeppelin
for proper high temperature silicone or graphite base grease.
CAUTION
If the actuator is Spring Return model, uniformly loosen all end cap screws on
each end cap two to three times, in a sequence, to relieve pre-load of the
springs. On larger actuators with springs, use caution when removing end
caps.
Actuator Re-assembly
1. Replace the top and bottom shaft bearings.
2. Replace the pinion gear / shaft in the body through the bottom of each actuator body. The
bottom hole in the actuator body is a larger inside diameter than the top hole in the body.
3. Very carefully align the pistons square to the body.
4. Align the pinion gear so that the teeth on the centre gear will pick up the pistons assemblys
rack teeth when turning the top extension of the centre gear clockwise (CW).
5. To ensure proper meshing of teeth, rotate the centre gear 45 degrees (or two teeth) counter
clockwise (CCW) from its normal position with the piston assemblies located at the body ends.
Normal position is that position which provides the proper output shat orientation require.
6. With the piston assemblies in the body, gently push each piston into the body. Turn the top
shaft extension clockwise (CW). At the proper point of engagement between the centre gear
and piston assemblies, both piston assemblies will move toward the centre of the body when
turning the top shaft extension of the actuator clockwise (CW).
7. Once the pinion gear and pistons are properly engaged, ensure that smooth movement of 90
degree operation can occur without moving the pistons actuator body. This is important!
8. Replace the actuator end caps taking care to properly seal O-rings.
9. Replace the washer over the top shaft extension.
10. Very important! Install the new shaft clip onto its mating groove on the top shaft extension.
(The removed shaft clip is not to be reused). When properly installed the shaft clip should
rotate freely within the groove.
Spring Return Actuator P series (Model SR)

1. When replacing spring return actuator, ensure that the springs are replaced in their identical
position in the end cap from where they were removed.
Note: Important When less than the standard number of seven springs (P Series only) are
used in each end cap, these springs should be positioned as shown below.
2. If a spring actuator is being repaired due to a failed spring, replace all the necessary springs in
this actuator, as well as any other parts which may have been damaged.
3. When replacing the springs in a P series spring return actuator place the actuator body on a
flat surface. Position it so that it stands on one end. Ensure that the pistons are stroked fully
inward toward to the centre of the actuator. This may be done by rotating the actuator shaft
with a wrench.
4. Place the springs on the piston face engaging them with the alignment nibs cast into the piston.
5. Place the end cap over the springs. Align them with the corresponding nibs on the end cap.
6. Place the end cap bolts through the retention holes of the end cap. If converting a double acting
unit to a spring return be sure to use new end cap.
7. Engage the bolts with the tapped holes in the actuator body by forcing down slightly on the cap.
Tighten each bolt in small and equal turns.
Spring Return Actuator E Series (Model ES)

For details see data sheets 4.202, 4.204.03 and 4,204.04
1. When replacing springs in a spring return actuator, ensure that the springs are replaced in their
identical position in the spring pack from where they were removed.
2. If a spring return actuator is being repaired due to a failed spring, replace all the necessary springs
in this actuator, as well as any other parts which may have been damaged.
3. To change springs remove nut cover (39), locknut, washer and O-ring (38,22,29).
4. Remove the spring retaining socked bolt (37) using hexagon wrench Nr. 3
5. Remove and / or replace springs as indicated by spring torque chart. Be sure that all springs are
located correctly in end cap (5) and the spring pack retainer (9).
6. Repeat steps 3-5 for the other spring pack.
7. Re-assemble in reverse order.
Construction, Parts and Material, Standard Actuators
Nr: 1.101
Notes:
1. Aluminium parts have a chromate pre-treatment
2. These parts are also covered with the standard coating finish.
3. The actual parts used will vary depending on the actuator model and size.
Part No.
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Description
Body
Piston
Endcover double acting
Endcover spring return
Central drive shaft
Gear rack
Spring
Bearing bush
Bearing bush
Bearing strip
Bearing strip
O ring piston
O ring cover
O ring shaft
O ring shaft
Spring clip
Washer
Bolt
Key
Endcover bolt DA
Endcover bolt SR
Ball
Qty
1
2
2
2
1
2
14max
1
1
2
2
2
2
1
1
1
1
2
2
8
8
2
Construction, Parts and Materials, Series E
Nr: 1.101.03
Notes:
1. Aluminium parts have a chromate pre-treatment
2. These parts are also covered with the standard coating finish
3. The actual parts used will vary depending on the actuator model and size.
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25
Description
Body
Piston
Drive Shaft
End cap ED
End cap ES
Spring-Inner
Spring-Mid
Spring-outer
Bearing-Body
Bearing-Piston
Bearing bush B
Bearing bush T
Thrust washer
O ring body
O ring piston
O ring shaft
O ring shaft
Spring clip
End bolt
Ball
Washer
Spring holder
Bolt
washer
Dome nut
O ring
Qty
1
2
1
2
2
2
2
2
1
2
1
1
1
2
2
1
1
1
8
2
2
2
2
2
2
2
Construction, Parts and Materials Steel E
Nr.1.101.05
Notes
1.
2.
3.
4.
5.
6.
Items 1,4,5 have phosphate finish

Item 3 has an Endurion+ oil finish
Items 9,34,38,40,41,42,43 have zinc plate + Passivate
Paint finish is as 4.204.01
Pistons, item 2, can be of SG iron as an option
Items, 23,30,38,39,40 are only included in the L1 Version of the actuator.
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
20
21
23
24
25
26
27
28
29
30
34
35
36
37
38
39
40
41
42
Description
Body
Pistons
Drive shaft
End cap DA
End cap SR
Spring - inner
Spring - mid
Spring - outer
Spring holder
Bearing - body
Bearing - piston
Bearing bush B
Bearing bush T
Thrust washer
Washer
Air filter
O ring cover
O ring piston
O ring shaft T
O ring, shaft B
O ring, spring
O ring stop
Washer
Spring clip
End bolt
Bolt
Nut
Nut cover
Screw
Nut
Nut
Qty
1
2
1
2
2
2
2
2
2
1
2
1
1
1
2
2
2
2
1
1
2
2
2
1
8
2
2
2
2
2
2
Actuator Assembly Modes

All are views from above
Installation of Springs
Nr.4.201
Installation of Springs Series E Actuator
Nr.4.202
Maintenance and Operation Stroke Adjustment, Series E
Nr.4.204.03
Description
The spring assembly uses a maximum of 6 springs, 3 per end built into each end cap.
The three, large diameter springs are rated for 5.5 bar and lower pressures may be accommodated by removing
some of the springs.
Each spring pack incorporates a stroke adjustment screw. This may be used to adjust the end of stroke position
for valve seating, either for fail open or fail closed arrangements. This works as follows.
Spring stroke adjustment Fail close
Pressure applied to port A , pressurizes the actuator centre chamber and forces the pistons outward against
the springs located in the end caps. This causes a counterclockwise rotation of the output shaft, opening the
valve.
The closing stroke occurs when air is exhausted from port A, this allows the pistons to be driven together by
the force of the springs. This inward movement of the pistons continues until the spring holder, item 9 makes
contact with the washer, item 34 under the head of the stop screw, item 37.
A (clockwise) rotation of the stop screw, item 37, provides for more (clockwise) rotation and vice visa.
Spring stroke adjustment Fail open
Should the adjustment be required at the other stroke (counterclockwise, pistons moving outwards), the
stopscrew, item 37, may be screwed right in until it takes up a position where it touches the face of the piston,
item 2.
This adjustment is best carried out with some pressure on port A. The backnut, item 38, must be backed off.
Maintenance and Operation Spring Change, Series E
Nr. 4.204.04
Table B Tool List

Tool Nr:
Wrench type:
Actuator:
25
40
100
200
1
Socket
2
Spanner
3
Socket
4mm
4mm
5mm
6mm
10mm
10mm
13mm
17mm
5mm
5mm
6mm
8mm
Description
The spring assembly uses a maximum of 6 springs, 3 per end built into each end cap.
The three, large diameter springs are rated for 5.5 bar and lower pressures may be accommodated by removing
some of the springs.
Table A Spring selection for various pressures
Air Pressure
(bar)
2.8 -3.7
3.7 4.6
4.6 5.5
5.5 +
Spring set
Nr
3
4
5
6
Springs used
Inner + mid
Inner + outer
Mid + outer
Inner + mid + outer
Reference
Pressure (bar)
2.9
3.6
4.4
5.1
Procedure
1.
Disconnect the air supply from the actuator
2.
Remove one end cap by removing the four end cap bolts, using socket wrench Nr.1.
3.
Remove the nut cover item 39.
4.
Remove the locknut, washer and O-ring, items 38, 22 and 29.
5.
Remove the spring retaining socket bolt, item 37, using socket wrench Nr. 3 this is done by inserting
the wrench into the central recess in the spring holder, item 9.
6.
Remove and / or replace the springs, with reference to table A. Be sure that the springs are
located correctly in the end cap, item 5, and the spring holder, item 9.
7.
Repeat items 2 to 6 on the other end cap.
8.
Re-assemble as in reverse order, 1 to 5.
9.
Apply the reference air pressure to port A (table A) and check that the actuator output shaft rotates
through its full movement.
Actuator Solenoid
Description
For general purpose solenoid control a Lucifer solenoid valve is fixed directly to the NAMUR interface on the
side of the actuator (E12 has an adaptorplate). The valve is a universal type. (5/2 or 3/2) and can be used on
double acting or spring return actuators by simply rotating the sealing plate.
When used in the 3/2 mode a breather function protects spring chamber from corrosion.
The single solenoid control is continuously rated, and in the event of electrical failure actuator returns to the
clockwise (normally valve closed) position: by mechanical spring in case of single; and air in case of double
acting versions.
The normally 1/8 ported valve has a high kv value, allowing fast opening times.
The assembly is waterproof to IP65. A local manual operation facility is provided as standard. Speed
controllers are available for the exhaust ports.
General Specification:
Type:
Air pressure:
Lubrication:
Temperature:
Voltage:
Power:
Air Entry:
Air flow, kv:
Code:
Part No: AC/DC:
Electrical Entry:
Enclosure:
Lucifer type 341 L95 04

1 to 10 bar
Not necessary
-10 to 65C
AC 50Hz24,48, 110/115, 220/240, 380V
DC 12, 24,48, 110 V
AC 2 OW DC 2.5W
G
0.27 (M/h)
WP
341 L9504 488980
Plug, Din 43650B
IP65
Actuator Switch Box
Description
This general purpose switch box encloses two single pole double throw change over switches for indicating the
fully open and fully closed actuator positions.
The switches are operated by two cams on an extension of the actuator drive shaft and all mechanical parts are
contained within the enclosure. All six terminals of the two switches are pre-wired to a terminal block which is
easily accessible when the top cover is removed. The cover screws are captive.
Both switches are independently adjustable and are factory set to indicate at 5 before each end position.
Switch is adjustable through the operating stoke and can be locked in any position after adjustment is complete.
The switch box is mounted on top of the actuator with an accessory bracket which incorporates a visual position
indicator. A provision for manual override is possible.
Specification
Switches: Type:
Voltage:
Current:
Contacts:
Temperature:
Mechanical, V3
250V AC or DC
11A at 250 V AC 1A at 12 V DC 0.25 A at 250 DC
Normally open and normally closed
-25C to 80C
Housing:
Base: ABS (black), cover: ABS clear)

pg 11
IP65
The NAMUR mounting kit fits all actuators except E 12. The E 12 has
its own bracket.
Material:
Main electricity entry:
Enclosure:
Mounting:
Maintenance
DANGER
Isolate machine prior to carrying out maintenance
Check all electrical connections
Check all pneumatic connections
Check function of dust filter mounted on top of weigh scale.
Check operation of pneumatic control valve for the butterfly valve using the manual override facility,
and subsequently the operation of the butterfly valve.
Check calibration of scale by adding weight to it. It is recommended that 20Kg weights are used
working through the scale range. It is not necessary to check up to full capacity of the scale, 60% is
sufficient, providing the results are linear.
Check operation of piston valves by using manual override.
Check connections and condition of flapper jacket and fluidisation hoses.
Periodically disconnect rubber hoses from scale connections and check for traces of material. If
material traces are present then it is possible that either the rubber jacket or fluidisation cone are
damaged. If this is the case then these should be changed.
It is recommended that these items are changed by a qualified Zeppelin engineer.
Filter Unit
Introduction
Please read this manual carefully before using the Dustcheck unit.
Great care should be exercised in the application of any filter unit. A competent dust extraction engineer should
be consulted before use. Certain dusts are dangerous to handle (i.e explosive, carcinogenic or statically
charged in nature). The mixing of even apparently innocuous dusts within the same extraction system should
be approached with care as this can cause a serious hazard.
Explosion relief panels, where fitted, should be vented to a safe area.
Note: It is IMPERETIVE that a risk assessment is carried out on the plant/system PRIOR to the equipment
being taken into use. All aspects of the plant and its usage, including routine operation, emptying, cleaning,
maintenance, access, control function, and activation must be assessed for Health/Safety risks and protective
measures, visible warnings and user training must have been implemented before operation is allowed.
Where combustible dusts are being handled it is extremely important that the dust collection equipment is
suitable for the application. Where equipment is to be used on applicants other than those for which it was
originally specified, the installer/ user MUST ensure the suitability of the equipment for purpose.
In all dusty environments good housekeeping is essential to creating and maintaining a safe, healthy
environment. With potentially explosive dusts it is IMPERETIVE that all areas, and in particular areas around
any explosion vents, are dust free to minimize the risk of secondary explosion in the event of primary explosion
within the equipment.
Care should be taken during the emptying of waste collection bins and final waste disposal to avoid possible
secondary dust emission or contamination,
It is recommended that respiratory protective equipment be used. For further information consult B.S
4275:1974 RECOMMENDATIONS FOR THE SELECTION AND USE OF RESPIRATORY PROTECTIVE
EQUIPMENT.
Dust collectors must be used in accordance with CoSHH regulations. For further information refer to current
Health and Safety executive guidance note EH40 Occupational exposure limits and guidance note EH44 Dust
in the workplace general principles of protection
Dust collectors must, as a minimum requirement under the CoSHH regulations, be inspected and tested at least
once every 14 months or in accordance with the specified schedules. Suitable records of examination, tests
and subsequent repairs shall be maintained and be kept available for a minimum period of 5 years.
Please refer to manufacturer or Health and Safety Executive if in any doubt before using.
Pressure System Regulations
As this type of unit is to be connected to a compressed gas supply exceeding 0.5bar, the compressed air
manifold has been designed and manufacture to comply with the requirements of the Pressure Equipment
Regulations 1999 and the EC Pressure Equipment Directive (97/23/EC). The manifold is fitted with a data
plate giving relevant information, the presence of N/A in any box indicates that this specific information either
need not or must not be given in order for manifolds in the stated category to comply with the regulations.
Where a test pressure is given this may be on the basis of a sample testing routine and does not indicate that
each individual manifold has been tested.
A reverse air dust collector, when connected to a pressure system, is regarded as a part of that system and
should be maintained and inspected as required by current guide lines and legislation.
Explosion Prevention
Any dust collector of dust collection system handling a product or products with a potential for dust explosion
should, in accordance with current guide-lines, be fitted with explosion relief, explosion suppression, or be
capable of explosion containment. It is important that when installing such equipment due consideration is
given to ensure adequate earth bonding to prevent static build up, which could create sparks that might result in
the ignition of explosive mixtures of the dust and air.
Usage
The equipment is specifically designed for the handling of dry dusts in air and must not be used for any other
purpose.
Where Dustcheck Ltd has been consulted regarding the application of the equipment and the product being
handled, this information will be stated on the datasheet in the appendix. If sufficient information has not been
imparted to Dustcheck Ltd, there will be no statement of product or application and thus the installer/user MUST
ensure that the equipment is suitable for purpose.
Health and Safety
Prior the final acceptance for use, a risk assessment should be carried out (and documented) and all
safeguards must to in place, to ensure that all aspects of usage and operation can be carried out without risk to
the user/operator.
Supply Services Required

Supply Services Required
Compressed Air Supply
Consumption (approx):
Model
Consumption
Units with 2 or 3 cartridge / valves
7.6
Units with 4 cartridge / valves
10.1
The figures are free air delivered (F.A.D.) based on a pulse interval of 15 secs with pulse duration of 100 msecs.
Quality: It is extremely important that the compressed air supply is clean, dry and oil free. Contaminated air will
cause malfunction and reduce the life-span of the filter media.
Note: We recommend the fitting of a moisture separator with line filter and regulator immediately prior to the
manifold. Such a device must be capable of ensuring that the maximum pressure specified for the manifold is
not exceeded and also of isolating the compressed air supply and draining the pressure from the cleaning
system. The supply pipe should be nominal bore as a minimum, N.B is recommended for long pipe
runs.
Operating pressure: 0.5 to 6.0 bar g
Maximum pressure: 6.5 bar g
Installation
Installation
Handling
These units are, in many instances, easily handled manually but it is imperative when doing so that the correct
technique are used and if suitable hand holds are not available that handles, straps of slings are attached.
Where lifting equipment is to be used, this can be attached directly to the bolt holes in the flanges it may be
necessary to remove individual bolts to allow attachment.
DO NOT remove more bolts than necessary and DO NOT lift with bolts missing as this may weaken the
structure.
Assembly
When assembling split units or mating collectors to other plant an appropriate sealant must be used on all joints
to ensure an airtight seal adequate for the operating pressures.
Where a collector is floor mounted it is necessary to ensure that the floor is level, otherwise function of the bin
mechanism could be adversely affected.
Supply Connection
All supply connections are to be made in accordance with the appropriate statutory requirements. Refer to
Appendix for writing diagrams.
IMPORTANT: the controller as supplied is designed to EMC standards and to meet these standard requires
electrical supply where the neutral is NOT earth bonded. Earth bonding of the neutral may result in the unit not
meeting the standards required by the electro-magnetic compatibility directive.
Where possible the cleaning controls should be independently wired of the fan sets or other equipment, thus
facilitating cleaning operation (should it be required) under no air flow conditions.
Ensure that the compressed air supply is connected in such a way that this can be isolated and the retained
pressure can be released from the cleaning system.
Cartridge Installation
Prior to opening any access point to the dirty side of a dust collector, ensure that appropriate protective
equipment is used. Minimum requirement dust mask.
For dust collectors supplied with loose filter cartridge elements, or when replacing elements, the following
installation procedure must be adhered to.
Clean side removal units:
Access to the cartridge elements is through the clean section. It is necessary to remove/open the access cover,
release and remove the jet tubes and release the cartridge clamps. The cartridges on their adaptor plates can
now be withdrawn.
Dirty side removal:

Access to the cartridges is through the dirty section access door. See removal and installation instructions for
changing the cartridges.
Removal: Grip bottom end cap and unscrew cartridge.
Installation:
Before fitting the cartridge(s) smear a small amount of grease on to the male adaptor to ensure ease of future
removal. Spin the cartridge(s) on by hand, ensuring seal compression. Check for correct seating.
Hand tighten by use of the bottom end cap.
DO NOT APPLY EXCESS PRESSURE TO THE MEDIA.
Installation and Commissioning
Check that all packaging and protection materials are removed prior to start up. i.e remote controls taped inside
unit, protection around explosion relief panel, etc. for units fitted with bins check that the mechanism is free to
operate as a locking pin may have been fitted to inhibit removal during transit.
Check that all connections have been correctly made and that the appropriate power sources are available.
Ensure correct fan rotation (where fan is fitted)
Check all control functions.
Ensure all cartridges are correctly fitted.
Ensure all access doors and bins are sealed.
Adjust the system airflow to the design duty and take a static pressure reading as a basis point for reference
and future comparison.
Reduce the airflow as described under paragraph 4.2
It is imperative that the unit is installed and adjusted to ensure that the stated airflow is not exceeded
excessive air volumes can seriously affect filtration efficiency and element life.
Note: Unless otherwise specified, the cleaning control and manifold have been tested and are fully functional on
dispatch from our works. With the exception of power supply to the controller and compressed air supply to the
manifold no other connections are required.
DO NOT plug, or make connections to, the solenoid valve vent ports as this may inhibit the operation of the
valves.
Duct System
Where a dust collector is not fitted with a main volume control damper, it is strongly recommended that such a
damper be fitted in the duct system to allow adjustment of air volume. Systems without any form of volume
control may allow the passage of excessive volumes of air which can have detrimental operational effects.
Operation
Operation
General Operating Parameters
The cleaning controls are NOT preset and works to suit any specific application, although under inspection
these will normally be left set at approximately 150 millisecond duration and 15 second interval. As no two
applications are the same, filtering process must be monitored and the controls adjusted to suit the particular
application, as outlined in section 5.
Where a unit has a collection bin, it is essential that the bin is correctly sealed at all times while the fan is in
operation, as air leaks at the peripheral seal may cause fine dust to remain in suspension. In the interest of
good housekeeping, the bin should not be allowed to overfill.
Under no circumstance should the fan be operated with the ductwork system, collection bin or access door
removed. This will dramatically reduce the extraction at the exhaust points, but, more importantly, will probably
create a fan motor overload situation, which in a relatively short time could burn-out the motor.
The compressed air manifold has been designed and manufactured to the operating limits of temperature and
pressure as stated on the manifold data plate. The limits of temperature, in particular the upper limit, are
specific to the manifold fabrication and do not imply that all other components associated with the manifold or
dust collector are capable of operating at such temperatures. If a unit is to be utilised in an operating
temperature range other than that for which it was originally intended please contact Dustcheck Ltd to ascertain
suitability.
Note: Units fitted with explosion doors unless otherwise specified these doors are not designed for positive
pressure situations, consequently the reverse jet cleaning should only be in operation when air is being
extracted. If the cleaning controls are operated without extraction there is a risk of dust leakage from around the
door seals.
Air Volumes
It is important on initial start up that the air be gradually increased to full duty over a period of hours
and the system checked to ensure that the design duty is not exceeded, as this causes increased
filtration velocity which can give premature deterioration of the media. We recommend, particularly on
fine dusts, that the equipment be dampered down to run at a maximum of 75% design duty for 8 hours
with normal levels of dust loading for the system. It is also important that the cleaning cycle cot be
activated before a filter cake has developed) i.e not before a differential pressure across the media a
100mm.w.g. has been reached.) THESE CONDITIONS ALSO APPLY WHEN NEW CARTRIDGES HAVE
BEEN FITTED.
Collection Bins
The removal and emptying of collection bins must be carried out only when the unit is de-activated. Always
ensure that the cleaning controls are non-operational. Always wear the appropriate mask and other protective
equipment.
Standard bin mechanisms are provided with a locking point, comprising mating holes in the mechanism which
allows a padlock/bolt to be inserted in the locked position. This facility must be utilised should a risk
assessment indicate that locking of the bin is necessary.
Should a collection bin be located on a discharge point from a screw conveyor, rotary valve or other piece of
moving machinery, it may not have been possible to insert adequate guards into the outlet without inhibiting
product discharge.

Note: Cleaning cycle adjustment requires access to an enclosure containing live terminals Isolate
before opening.
Duration
Duration is basically adjusted to suit the type and binding characteristics of the dust being handled,
generalised as specific gravity and stickiness.
As general indication -
heavy, free flowing dust

Light, sticky dust
= short duration
= long duration
Interval
Interval is normally related to dust load.
As a general indication -
heavy dust load

Light dust load
=short duration
=long duration
Pressure Differential
The filter cleaning system should be adjusted to give an approximate average pressure differential
across the media of 100mm w.g.
IT IS ESSENTIAL THAT THE CLEANING CYCLE IS MONITORED, IN PARTICULAR DURING THE
FIRST WEEKS OF OPERATION AND THAT ADJUSTMENT IS MADE TO ENSURE THAT THE
CLEANING CYCLE CONTINUES TO SUIT THE OPERATING CONDITIONS.
Optimum monitoring of the cleaning cycle can be affected by the installation of a Differential
Pressure Monitor.
Units Supplied without an Adjustable Cleaning Controller
Care should be taken with any unit supplied without a cleaning controller which allows duration of
the pulse of compressed air to be adjustable. Without duration control, the only way of adjusting the
intensity of the reverse jet blast is by altering the manifold pressure. It is recommended therefore
that under such circumstances a 30% lower manifold pressure is set and the cleaning cycle
monitored for efficiency before increasing pressure. Excessive quantities of air at high pressure
could cause media damage.
Maintenance and Service

Maintenance and Service
Safety
Inspection and maintenance should be carried out by adequately trained personnel.
Appropriate dust mask, respirator and other personal protective equipment MUST be worn when
accessing the dirty (contaminated) section of a dust collector.
ALWAYS ensure that ALL sources of energy are isolated and locked off and that any retained
compressed air in the cleaning system is drained PRIOR to accessing the interior of the unit.
Routine Inspection
To ensure trouble free operation and minimize the risk of unscheduled stoppages it is advised that the following
inspection be performed at least once every 6 months.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Inspection of clean air compartment

Check filter cartridges
Check filter clamps and seals
Test cleaning cycle of reverse air systems and mechanisms
Measure and record system aiflow volume
Measure and record pressure differential
Measure and record static pressure
Record controller settings
Check fans and motors
Check doors, cover, and collection bin seals and clamping
Inspect explosion panels and weather covers.
Maintenance Access
Dust collectors may not be supplied or fitted with walkways or ladders which allow any or all parts of the unit to
be safely accessed for maintenance purposes.
It is important that no effort is made to gain access to any part of a unit, or to carry out any maintenance
operation, unless correct and SAFE working conditions are established.
DO NOT, under any circumstances, attempt to work in conditions where appropriate working platforms and
access have not been erected or where personal safety equipment appropriate to the task in hand is not
available.
Inspection of Compressed Gas Equipment

The manifold assembly on a dust collector is, when connected to a compressed gas supply exceeding 0.5 bar g,
covered by the requirements of the Pressure Equipment Regulations 1999 and the EC Pressure Equipment
Directive (97/23/EC) and as such should be routinely inspected, together with all associated pressure
equipment on site, at regular intervals by a qualified person as required by the legislation in force at the time.
Inspection of the compressed air manifold itself, under normal circumstances, would be visual with an
assessment of any effects of corrosion.
Should it be decided that a manifold requires pressure testing, this must be carried out hydrostatically in
accordance with the original specification. Manifolds MUST NEVER be tested with cleaning valves and
other equipment fitted, the manifold must be stripped and blanking plates fitted prior to testing.
Troubleshooting
Troubleshooting
FAULT
POSSIBLE CAUSE
A. Filter elements not cleaning
:check compressed air supply turned on

: Pressure as specified contaminate free
: check controller is operating
: check solenoid valve operation
: check that the solenoid valve vent ports have not been
obstructed of plugged.
: check diaphragm valve operation
B. Dust deposits on clean side
:check filter media for damage

: check all seals for damage
: check filter element location
C. High differential pressure
: check cleaning cycle (as for A)

: check that design air volume is not being exceeded
D. Low differential pressure
: check filter media for damage

: check cleaning cycle, cleaning too frequently?
: check for correct fan rotation
E. Low air volume
: check all doors, bin seals and explosion panels

: check for blocked ducts
: check filter elements blinding change if necessary
: check fan for correct rotation
F. Fan stop
: check overload setting

: check overload size
: incorrect fan rotation can cause overload
: check for wiring fault
Spare Parts List

Model: SFJC12-1-06 CSR
Serial No.(s): 3688 & 3689
It is recommended that the following items be stocked to cover a 12 month service requirement.
Item
Description
Part
Number
Quantity
Per Unit
Quantity
Spares
Cartridge
VC06003
12
12
Diaphragm Valve Service Kit
DP00029
Solenoid Valve Service Kit
DP00030
Solenoid Coil (110v)
DP0007
Controller PCB
CD08001
**
** Customer choice. Item is usually ex-stock, only recommended for export orders or essential operation
system
Operating Instructions
Standard Controller Printed Circuit Boards
This instruction is to be read in conjunction with diagram CWO13 (standard 8 way and 16 way configuration) or
other similar diagrams based on the same PCB layout and functions.
Note: The board is designed using a programmable chip which consults its memory at the beginning of each
cycle. Consequently, any adjustments made will only be implemented at the beginning of the next cleaning
cycle.
IMPORTANT
The controller as supplied is designed to EMC standards and to meet this standard requires electrical supply
where the neutral is NOT earth bonded. Earth bonding of the neutral may result in the unit not meeting the
standards required by the electro-magnetic compatibility directive.
This electronic controller is NOT designed for mounting on vibrating equipment. Excessive vibration may result
in unstable and erratic performance, and can cause damage to transformer mountings and other components.
A
AC Input Voltage Selector (for AC supply boards only)
Link between the selected input voltage and the input power common, set to 24v, 48v, 110v, or 230v AC as
required. This selection does not exist on DC input boards.
B
DC Input and Output Voltage Selector (for DC supply boards only)
Set to 12v or 24v DC as required. This sets both the input and output voltage to the same selected setting.
This selection does not exist on AC input or output boards.
C
DC Output Voltage Selector (for AC boards with DC output only)
Set to 12v, 24v or 48v DC as required. This selection does not exist on AC output boards.
D
AC Output Voltage Selector (for AC input and output boards only)
Link between the selected output voltage and the output power common, set to 24v, 48v 11 Ov or 230v AC as
required. This selection does not exist on DC input or DC output boards.
E
Input Voltage Connections
Link input power source to the appropriate terminals

Note: The terminals are dual marked as the basic board is used to make both AC and DC units. When
connecting follow the convention for the supply being used.
ACLL = Live,
N = Neutral DC+ = Positive, - , = Negative
F
Outputs to Valves
Individually connect the valves to the output terminals. Unless otherwise specified by Dustcheck, in writing, only
one valve to be connected to each output position.
Overflow Connecter
This connecter allows boards to be connected together in series, thus enabling the creation of larger capacity
sequencing. The +/- terminals on this connector are for factory use only and must NOT be used.
When interconnecting boards in sequence, make a connection from the out terminal of the first boards in
terminal of the second board, and continue to interconnect out to in until the last board is reached. From the
out terminal of the last board interconnect back to the in terminal o the first board. Each board must be
supplied with power to the input voltage terminals.
H
Number of Outputs
Set the number of outputs required corresponding to the number of valves to be connected. It is important
that only one switch is selected putting more than on switch into the up position may cause
damage. If an overflow connection is to be made, set the Number of Outputs on the last board on the series
to suit the operating requirement of that board corresponding to the number of valves to be connected.
On a 16way board the output selector comprises 2 switch block, each with eight switches. To select up to 8
ways, use the left hand block, selecting the switch corresponding to the number of ways. For more than 8 ways
no selection should be make on the left hand block and the appropriate switch on the right hand block should be
selected indicating the number of ways in excess of 8 (i.e if 12 ways, set switch number 4 on right hand block)
Note: Setting switch positions on both blocks can cause confusion of the logic system.
J
Options
These are a series of operating options to improve user friendliness of the board.
1
Manual start. This allows the board to run in continuous test mode despite any pressure switch
control connections which may be made. The board will ignore external controls and run continuously as long
as power is applied, with this switch in the on position.
2
50/60Hz: This compensates for the differences made to potentiometer settings by a change in the
frequency of the power supply. A unit can thus be pre-set under 50 Hz conditions and despatched to 60Hz area
for use without the controls have to be re-set if this switch is used. 50 Hz is the off position.
3
Cycle enable: This enables a cyclic cleaning function to be initiated which is independent of any
external controls which may be connected. If no external controls are connected and this function is activated,
the unit when powered will operate for one cycle and then wait for the time lapse set on the cycle time
potentiometer (L), before continuing with a further cycle. If an external control, such as a pressure monitor, is
fitted, should the period between cleaning caused by the external control exceed the time lapse, then a single
cleaning cycle will be instigated.
4
Stop immediately/Run to end: When the cleaning is managed by an external control the option is
offered of the cleaning stopping immediately on the command to stop, or running to the end of the cycle. I an
immediate stop is set, the cleaning will start at the same point at which it stopped when the re-start command is
received. Run to end is the off position.
K
Pressure Switch Start
When the cleaning is to be managed by a differential pressure monitoring system, the board can be set to take
account of the requirement for normally open (NO) or normally closed (NC) switching. The jumper should be
inserted accordingly. If no pressure switch is fitted the jumper should be in the normally closed (NC) position
and no connections should be made to the terminals, the board will then run as soon as power is supplied.
Cycle Time
This is the potentiometer which adjusts the time lapse when J3 is set to on. Nominal range 30 secs to 2 hours.
M
Interval
This is the potentiometer which adjusts the time interval between output signals (valve pulsing). Nominal range
1 sec to 130 secs.
N
Duration
This is the potentiometer which adjusts the period during which the output signal is supplied (length of time of
the valve being open). Nominal range 50 millisecs to 4secs.
P
External Start (16 way board only)
A volt free contact to enable external starting from a PLC. Short circuit to start. If this requirement is not
specified on ordering the facility will not exist.
R
PLC Start (16 way board only)
Facility for an external start signal can be supplied. This must have been specified when ordering and any
signal voltage up to 240v can be accommodated. If this requirement is not specified on ordering the facility will
not exist.
The following standard settings will normally apply on al printed circuit boards supplied loosed and on all units
where the specification of the control system does not dictate otherwise.
A. 230v
B. either
C. any
D. 110v
H. Maximum no
J1. Off
J2. 50Hz
J3. Off
J4. Run to end

K. link + NC
L. no specific setting
M,N. see specific section in manual
Index
A
Air Failure
Air Preparation Equipment
Air Supply
Operation
Basic Actuator
With Solenoid Valve
Orientation
Overhaul & Reassembly

1M Locked Handlever
2M Worm Gear Driven
(350-600mm)
2M Worm Gear Driven
(40-300mm)
Parts List
1M Locked Handlever
(40-200mm)
2M Worm Gear (350-600mm)
2M Worm Gear (40-300mm)
Post Installation Precautions
Storage Conditions
Top Chamber
Troubleshooting
Tubing Sizes
Reassembly
Regulator
C
Check Calibration
Clean Feed Vaccum Scale
Construction, Parts and materials
D
Damage
Direction of Operation
Reversing
Disassembly
E
E series Model ES
Spring Positioning
Electrical Connections
F
Fluidisation Air
Fluidisation Control Valves
Fluidised Bottom Cone
L
Level
Loadcell
Loadcell Safety Brackets
Lubrication
TOMOE Butterfly Valve
Lubricator
P
P Series Model SR
Spring Positioning
Piston Valves
Pneumatic Actuator
Actuator Model
Air Consumption
Pneumatic Connections
Weighment
S
Scale Discharge
Scale Filter Unit
Solenoid
Description
Specifications
Spring Positioning
Model ES61
Model SR60
Stroke Adjustment
Stroke Times
Switch Box
Description
Specifications
M
Main Support Structure
Maintenance
Actuator Lubricant
Actuator Spring Changing
Periodic Seal Replacement
Spring Change Series
Manual Operation
Model Identity
T
TOMOE Butterfly valve
Handling
Inspection Periodicity
Installation
Adjacent to a Bend
Precautions
Lubrication & Rust Prevention
Mounting a Handlever
Mounting a Manual Gear
Actuator
Operational Abnormality
Customer Services
Our worldwide multi application experience and record of innovation,

established for more than a century, is reinforced by a positive
commitment to providing a comprehensive range of Customer Support
Services. Our Aftersales Division is structured to meeting the on site
requirements of all out customers.
Installation & Commissioning We offer complete installation services: mechanical, electrical,

equipment relocation, mechanical refurbishing and new controls retrofit
packages, alternatively we are pleased to supervise others to carry out
all or part of the work.
Preventative Maintenance
It is unrealistic and a false economy to expect optimum long term

equipment performance without a programme of preventative
maintenance. Minimise your production downtime by taking advantage
of the services provided by our factory trained engineers who will
advise, plan and undertake the regular servicing of your equipment.
Spare Parts
Spare parts can be compared to an insurance policy, you never know

how good the cover is until you have a problem. Our experienced team
of parts specialists ensure that you get the widest possible cover within
the constraints of your budget. We are always pleased to offer advice
to assist you with your budget preparation and identification of essential
spare parts inventory.
Training
Our purpose built Training Centre and full time instructors are available
to all users of our equipment. Training courses tailored to individual
products or your specific requirements may be conducted on site at
our Nottingham Training Centre using interactive training systems and
off line fully operational training machines.

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STANDARD

Clean Feed Vacuum Scale

Throughout this manual the following conventions have been adopted:

Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

Pneumatic Actuator P and E Series

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Clean Feed Vacuum Scale

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Front Elevation of Scale

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Plan View of Scale

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Weigher Support Frame

Jubilee Clip (85 100 Dia)

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Ensure brackets are properly secured with the correct size

Do not clamp hangers to scale support brackets.

Lower scale gently on the loadcells. Do not bang scale hopper

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Do not cut loadcell wires short, they should be at length supplied.

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Operation and Setting Up

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Butterfly Valve Pneumatic Operation (Tomoe)

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Note: For size 350-600mm, see below.

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Note: for sizes 350-600mm, insert 4 bolts.

Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

The valve should be aligned with the pipeline.

Installation of a Butterfly Valve adjacent to a Bend

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Post- Installation Procedures

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Inspection and Maintenance

Shafts & shaft sealings

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Cup Grease #250

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Overhaul and Re-Assembly

Remove the machine screws (8) with a screw driver.

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Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

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Take out the seat ring as instructed for 40-300mm.

Overhaul Procedure for the IM Locked Handlever Driven Butterfly Valve

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Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

Mounting an Actuator on a Butterfly Valve

Procedure for Mounting the Manual Gear Actuator

Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

Procedure for Mounting the Handlever

Zeppelin Materials Handling GmbH Leutholdstrae 108 D-88045 Friedrichshafen

2M Manual Worm Gear Driven (40-300mm)