Leading Technologies

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Product Instruction Manual

OpTK
Spring Cylinder Linear Actuator
TABLE OF CONTENTS WARNING: Standard industry safety
INTRODUCTION practices must be followed when
working on this or any process control
Safety Information ................................ pg. 1 product. Specifically, personal
Unpacking.............................................. pg. 1 protection and lifting devices must be
INSTALLATION ................................................ pg. 1 used as warranted.
PREVENTIVE MAINTENANCE........................ pg. 2
ACTUATOR DISASSEMBY ............................ pg. 2 Unpacking
ACTUATOR REASSEMBLY ............................ pg. 3 While unpacking the actuator, check packing list
ACTUATOR ACTION REVERSAL .................. pg. 4 against materials received. Lists describing the
actuator and accessories are included in each
shipping container.
1. Position the lifting straps and hoist to avoid
INTRODUCTION damage to the tubing and mounted accessories
Scope of Manual when lifting the actuator from the shipping
container.
The following instructions are designed to assist in
installing, troubleshooting and servicing Optimux
spring cylinder actuators. Product users and WARNING: When lifting an actuator
maintenance personnel should thoroughly review with lifting straps through the yoke
this bulletin prior to installing, operating or
disassembling the actuator. legs, be aware the center of gravity
may be above the lifting point.
This publication does not contain information on Therefore, support must be given to
Optimux positioners. Refer to the appropriate prevent the actuator from rotating or
installation operation and maintenance instructions
causing serious injury to personnel or
for installing, maintaining, troubleshooting,
calibrating and operating Optimux positioners. damage to nearby equipment.

2. Contact your shipper immediately in the event

SAFETY INFORMATION of shipping damage.
WARNING: Indicates a potentially 3. Contact your Optimux representative in the
hazardous situation, which, if not case of any problems.
avoided, could result in death or
serious injury. INSTALLATION
CAUTION: Indicates a potentially Prior to installation, make sure adequate overhead
hazardous situation, which, if not clearance for the actuator is provided to allow for
avoided, could result in minor or proper removal from the valve body and for proper
moderate injury and/or property maintenance. Refer to Table 1.
damage.
NOTE: If the actuator is attached to a valve body
Note: Indicates a potential situation, assembly, see Installation, Operation,
which, if not avoided, may result in an Maintenance Instructions 1 for overhead
undesired result or state. clearances.
OpTK Spring Cylinder Linear Actuator

Actuator Size Minimum Clearance 5. Ensure all accessories, brackets and

25 6 inches associated bolting are securely fastened.
50 8 inches 6. If possible, remove air supply and observe
100,200,300 9 inches actuator for correct fail-safe action.
400,500,600
7. Check rubber bellows for wear.
Table 1: 8. Spray soap solution around the cylinder
Overhead Clearance for Disassembly retaining ring, the adjusting screw and the
lower actuator stem bushing to check for air
leaks through the O-rings and gasket.
1. Connect the air supply and instrument signal air
lines to the two appropriately marked 9. Clean any dirt or foreign material from the
connections on the positioner. Since both the actuator stem.
cylinder and positioner are suitable for 150 psi 10. If an air filter is supplied, check and replace
air supply, an air regulator should not be used cartridge as necessary.
unless the supply exceeds 150 psi.

ACTUATOR DISASSEMBLY
NOTE: In some cases, air supply must be limited Refer to Figures 1 through 5 to disassemble the
to 100 psi rather than 150 psi; this will be cylinder actuator.
indicated by a sticker found near the upper air
port on the cylinder. 1. Shut off air supply. If actuator is installed on an
Optimux valve, remove the valve per OpGL
Product Instruction Manual.
WARNING: To avoid personal injury or
equipment damage, do not exceed
recommended supply pressure. WARNING: To avoid serious injury,
depressurize the line to atmospheric
pressure and drain all fluids before
2. Installation of an air filter on the supply line is working on the actuator.
recommended.
3. Use a soap solution to make sure all air 2. Disconnect all tubing. Remove stem clamp and
connections are leak free. stem bellows from the actuator stem.
3. Relieve spring compression completely by
PREVENTIVE MAINTENANCE removing the adjusting screw. Remove
At least once every six months, check for proper adjusting screw gasket from adjusting screw.
operation by following the preventive maintenance
steps outlined below. These steps can be
CAUTION: Do not use a screwdriver or
performed while the actuator is in service and, in
some cases, without interrupting service. If an bar to turn the adjusting screw;
internal problem is suspected with the actuator, instead, use a wrench on the flats of
refer to the “Assembling/ Reassembling” sections. the screw.
1. Examine the actuator for damage caused by
corrosive fumes and process drippings. WARNING: To avoid serious personal
2. Clean the actuator and repaint any areas with injury, relieve the spring compression
severe oxidation. before further disassembly. The
3. If possible, stroke the actuator and check for cylinder could possibly fly off the yoke
smooth, full-stroke operation. when removing the cylinder retaining
ring.

WARNING: To avoid serious injury,

keep hands, hair and clothing away 4. Remove the cylinder retaining ring from the
from all moving parts while operating groove at the base of the cylinder by using two
the actuator. screw-drivers. Insert one screwdriver in slot
found in the ring and pry the ring from the
groove. Use the other screwdriver to help work
4. Make sure positioner mounting bolts, linkage the ring out of the cylinder groove.
and stem clamp are securely fastened.

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 Product Instruction Manual

5. Pull the cylinder off the yoke and piston; some 1. All O-rings should be replaced. New O-rings
O-ring resistance may be felt. should be lubricated with a silicone lubricant
(Dow Corning 55M or equivalent). Silicone O-
rings must be lubricated with Magnalube-G
WARNING: To avoid serious personal lubricant or equivalent. Do not use silicone
injury, do not use air pressure to lubricant on silicone O-rings.
remove the cylinder. The cylinder 2. Thoroughly clean all internal parts before
could possibly fly off the yoke. beginning assembly. Lubricate cylinder wall
with silicone lubricant.
6. For heavy-duty spring designs using a spring 3. Lubricate the outside of the replacement
cap (see Figure 4), remove the spring cap and bushings if the stem bushings have been
cap O-ring from the cylinder. removed. Press a new lower stem bushing into
the actuator stem bore in the yoke until it
7. For air-to-retract configurations, remove the bottoms out. Press the upper stem bushing into
spring(s) and spring button for cleaning and the bore until it is flush with the top of the yoke
inspection (see Figures 1, 3 and 5). Remove (refer to Figures 1 or 2).
the actuator stem locknut and slide the piston
and stem spacer off the actuator stem. The 4. Replace the actuator stem O-ring and yoke O-
spring guide should be removed when using ring.
heavy-duty spring designs. 5. Reassemble the piston, piston stem O-ring and
stem spacer on the actuator stem according to
the proper air-action (refer to either Figure 1 or
NOTE: The dual, heavy-duty spring configuration 2). Replace the piston O-ring. Air-to-extend
(Figure 3) has two springs, one inside the other. configurations require the spring button to be
Remove both springs during this step. stored under actuator stem locknut. Tighten the
locknut firmly.
For air-to-extend configurations, slowly loosen
and remove the actuator stem locknut. Be NOTE: When reassembling heavy-duty, spring-
certain the piston follows the stem locknut up design actuators, the spring guide must be first
the actuator stem and does not bind on the inserted under the actuator stem locknut (see
actuator stem. Remove the actuator stem Figures 3 and 4).
locknut, spring button, piston, spring and stem
spacer.
6. For air-to-extend configurations, place the spring
under the piston and insert the actuator stem
WARNING: To avoid personal injury, be through the yoke, being careful not to pinch the
actuator stem O-ring or gall the stem and stem
certain the spring force is completely
bushings. For air-to-retract configurations,
relieved before removing actuator stem insert the actuator stem through the yoke and
locknut. place the spring(s) and spring button above the
piston.
8. Remove the piston O-ring, piston stem O-ring 7. Replace the cap O-ring and install the spring
and yoke O-ring. cap in the cylinder when using heavy-duty
spring designs using spring caps (see Figure
9. Remove the actuator stem O-ring. 4).
8. Install the cylinder, making sure the yoke is
NOTE: The upper and lower stem bushings are pushed deeply enough into the cylinder to allow
pressed into the yoke. Removal of the bushings the cylinder retaining ring to be installed. Care
to replace the actuator stem O-ring is should be taken not to scar or cut the piston
unnecessary. and yoke O-rings.
9. Reinsert the cylinder retaining ring by until it
10. Use appropriately sized press to push worn or snaps in place. Use a hammer and drift punch
damaged bushings out of yoke. to lightly tap the retaining ring in the groove.

ACTUATOR REASSEMBLY WARNING: To avoid personal injury,

the cylinder retaining ring must be
To reassemble the cylinder actuator, refer to Figures
solidly in place. The cylinder could
1 through 5:
possibly fly off when pressurized. Be

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OpTK Spring Cylinder Linear Actuator

careful not to pinch or cut fingers on

the square edges of the retaining ring
during installation.

10. Reinstall the adjusting screw using a new

adjusting screw gasket.

NOTE: Be certain the hole in the spring button is

directly centered under the adjusting screw hole
in the cylinder on air-to-retract configurations.

11. Tighten the adjusting screw enough to provide

an air seal with the gasket. Do not over tighten.
12. Reinstall the stem bellows and stem clamp.

NOTE: To ensure maximum clamping strength

when installing the stem clamp, make sure the
stem clamp bolting is perpendicular to one of the
slots machined into the actuator stem.

13. Apply air over the piston. Tighten the stem clamp
bolting with the stem clamp adjusted to point at
the closed position of the stroke indicator plate.

NOTE: If the actuator is installed on an Optimux

valve, refer to OpGL Product Instruction Manual
for correct plug stem thread engagement.

14. Reconnect tubing, supply and signal lines.

ACTUATOR ACTION REVERSAL

To change the air action from air-to-retract to air-to
extend, or vice versa, refer to Figures 1, 2 or 5:

NOTE: Heavy-duty spring actuators are not

reversible.

1. Disassemble the actuator according to the

“Disassembling the Actuator” section.
2. For air-to-retract action, reassemble the
actuator with stem spacer and spring button
over the piston.
3. For air-to-extend action, reassemble with
spring and stem spacer below the piston and
with the spring button stored above the piston.
4. Reassemble the actuator according to the
“Reassembling the Actuator” section.
5. The positioner must also be reversed. See the
appropriate positioner maintenance
instructions.

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 Product Instruction Manual

Adjusting Screw
Adjusting Screw Gasket (Item No. 210)
(Item No. 248)

Cylinder
Spring Button (Item No. 202)
(Item No. 227)

Spring
Actuator Stem Locknut (Item No. 229)
(Item No. 348)

Stem Spacer
Piston Stem O-ring (Item No. 223)
(Item No. 272)

Piston O-ring
Piston (Item No. 271)
(Item No. 225)

Yoke O-ring
Upper Stem Bushing (Item No. 274)
(Item No. 253)

Cylinder Retaining
Actuator Stem O-ring
(Item No. 275)
Ring
(Item No. 256)

Lower Stem Bushing

(Item No. 254) Actuator Stem
(Item No. 211)

Stem Clamp Bolting

(Item No. 240/345)
Stem Bellows
(Item No. 247)

Stem Clamp
(Item No. 249) Stroke Plate
(Item No. 213)

Yoke
(Item No. 201)

Figure 1: Air-to-retract Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

Adjusting Screw Gasket Adjusting Screw

(Item No. 248) (Item No. 210)

Actuator Stem Locknut

Cylinder (Item No. 348)
(Item No. 202)
Piston
(Item No. 225)
Spring Button
(Item No. 227)
Stem Spacer
(Item No. 223)
Piston O-ring
(Item No. 271) Actuator Stem O-ring
(Item No. 275)

Piston Stem O-ring Yoke O-ring

(Item No. 272) (Item No. 274)

Spring Cylinder Retaining Ring

(Item No. 229)
(Item No. 256)
O
Upper Stem Bushing Actuator Stem
(Item No. 253) (Item No. 211)

Lower Stem Bushing Stem Bellows

(Item No. 254) S
(Item No. 247)

Stem Clamp Bolting Stroke Plate

(Item No. 240/345) (Item No. 213)

Stem Clamp Yoke

(Item No. 249) (Item No. 201)

Figure 2: Air-to-extend Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

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OpTK Spring Cylinder Linear Actuator

Adjusting Screw Gasket

(Item No. 248) Adjusting Screw
(Item No. 210)

Outer Spring Cylinder

(Item No. 229) (Item No. 202)

Inner Spring Spring Button

(Item No. 230) (Item No. 227)

Actuator Stem Locknut Spring Guide

(Item No. 348) (Item No. 326)

Piston Stem O-ring Piston O-ring

(Item No. 272) (Item No. 271)

Piston Yoke O-ring

(Item No. 225) (Item No. 274)

Upper Stem Bushing Cylinder Retaining Ring

(Item No. 253) O (Item No. 256)

Actuator Stem O-ring Actuator Stem

(Item No. 275) (Item No. 211)

S Stem Bellows
Lower Stem Bushing
(Item No. 254) (Item No. 247)

Stem Clamp Bolting Stroke Plate

(Item No. 240/345) (Item No. 213)

Stem Clamp Yoke

(Item No. 249) (Item No. 201)

Figure 3: Dual-Spring Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

Adjusting Screw
Adjusting Screw Gasket (Item No. 210)
(Item No. 248)

Spring Cap
Spring Button (Item No. 325)
(Item No. 227)

Spring
Cap O-ring (Item No. 229)
(Item No. 270)

Actuator Stem Locknut Cylinder

(Item No. 202)
(Item No. 348)

Piston Stem O-ring Spring Guide

(Item No. 326)
(Item No. 272)

Piston Piston O-ring

(Item No. 271)
(Item No. 225)

Yoke O-ring
Upper Stem Bushing (Item No. 274)
(Item No. 253)

Cylinder Retaining Ring

Actuator Stem O-ring (Item No. 256)
(Item No. 275)
O
Actuator Stem
Lower Stem Bushing (Item No. 211)
(Item No. 254)
S Stem Bellows
Stem Clamp Bolting (Item No. 247)
(Item No. 240/345)

Stroke Plate
Stem Clamp (Item No. 213)
(Item No. 249)
Yoke
(Item No. 201)

Figure 4: Cap-spring Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

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 Product Instruction Manual

Lifting Ring
(Item No. 209)

Adjusting Screw
(Item No. 210)

Adjusting Screw Gasket

(Item No. 248)

Cylinder
(Item No. 202)

Actuator Stem Locknut

(Item No. 348)
Spring Button
(Item No. 227)

Spring
(Item No. 229) Spring Button
(Item No. 227)
Actuator Stem Lock Nut
(Item No. 348) Piston O-ring
AIR-TO- (Item No. 271)
AIR-TO-
RETRACT Stem Spacer Piston
EXTEND
(Item No. 228)
(Item No. 225)

Piston O-ring Piston Stem O-ring

(Item No. 271) (Item No. 272)

Piston Stem Spacer

(Item No. 225)
Spring
(Item No. 229)
Piston Stem O-ring
(Item No. 272)

Actuator Stem
(Item No. 211)

Upper Stem Bushing

(Item No. 253)

Actuator Stem O-ring

(Item No. 275)

Lower Stem Bushing

(Item No. 254)

Yoke O-ring
(Item No. 274)

Yoke
(Item No. 201)
Serial Plate
(Item No. 252)

Stroke Plate
(Item No. 213)

Cylinder Retaining Ring

(Item No. 256) Stem Clamp
(Item No. 249)

Stem Bellows
(Item No. 247)
Stem Clamp Bolt
(Item No. 240)

Stem Clamp Nut

(Item No. 247)

Figure 5: Exploded View, Spring Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

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OpTK Spring Cylinder Linear Actuator

Troubleshooting OpTK Spring Cylinder Linear Actuator

Problem Probable Cause Corrective Action

High air consumption 1. Leaks in the air supply or instrument 1. Tighten connections and replace any leaking
or leakage signal system lines
2. Malfunctioning positioner 2. Refer to appropriate positioner maintenance
bulletin
3. Leaks through O-rings or adjusting 3. Replace O-rings or gasket
screw gasket

Actuator does not 1. Air pressure in cylinder not venting 1. Refer to appropriate positioner maintenance
move to fail position because of faulty positioner bulletin
upon loss of air 2. Spring failure 2. Replace spring
supply pressure 3. Internal valve problem 3. Refer to valve’s maintenance bulletin

Jerky or sticking stem 1. Insufficient air supply pressure 1. Check air supply and any filters or
travel regulators; check for leaking O-rings
2. Unlubricated cylinder wall 2. Lubricate cylinder wall with silicone lubricant
3. Check actuator stem for damage; replace
3. Worn or damaged stem bushings actuator stem, O-ring, and stem bushings, if
necessary
4. Improperly assembled spring 4. Disassemble actuator and check cylinder
and piston for damage; reassemble actuator
correctly
5. Internal valve problem 5. Refer to valve’s maintenance instructions

Optimux customers should be aware that Optimux products might be used in numerous applications under a wide variety of industrial
service conditions. Although Optimux can (and often does) provide general guidelines, it cannot provide specific data and warnings
for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection,
installation, operation and maintenance of Optimux products. The purchaser/user should read and understand the Product Instruction
Manual (PIM) included with the product, and train its employees and contractors in the safe use of Optimux products in connection
with the specific application.
While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative
purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained
herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because
Optimux is continually improving and upgrading its product design, the specifications, dimensions and information contained herein
are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact
TRIMTECK, LLC at any of its worldwide operations or offices.

For more information, contact:

For more information about Trimteck and its products,

contact www.trimteck.com or call USA (954) 753-5545

TRIMTECK LLC
12461 NW 44th Street
Coral Springs, FL 33065
Phones: (954) 753-5545
Fax: (954) 753-5561
[email protected]

FORM # PIM0910