Valves & Controls
ZH-000 Series Linear Pneumatic Actuator
(Control System) Operation Manual
Valves & Controls
Preface
This manual is for the use of linear pneumatic actuators including control
systems. For other types and models of pneumatic actuators, please use the manual
of the corresponding product.
This manual is very important and necessary for users who are using the linear
pneumatic actuator for the first time and is also an indispensable reference for
experienced users. Please read this manual carefully and practice it after fully
understanding it.
This manual explains the structure of each part of the linear pneumatic actuator,
working principle, technical parameters of the whole machine, installation,
commissioning, maintenance steps and precautions, etc., and strives to provide users
with comprehensive knowledge of this product.
With the continuous application of new technologies and processes, the content
of this manual may be slightly different from the product you purchased. If you have
any questions about the product you purchased or this manual, please contact us.
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Valves & Controls
Safety Warning
In order to use our products correctly and safely, please read this User Manual
carefully before use！
If you do not follow the precautions in the manual, casualties may occur at any
time.！
Failure to follow the precautions in the manual may cause damage to the
equipment or the equipment may not be used properly at any time.
If the operation is not carried out according to the usage or operation methods
in this manual, the user shall be responsible for the resulting safety responsibility
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Valves & Controls
Contents
Foreword ................................................................................................................................... 1
Contents ................................................................................................................................................. 2
Product Description .............................................................................................................................. 3
General assembly drawing of the whole control system ................................................................ 4
Storage and transportation.................................................................................................................. 5
Preparation before installation ............................................................................................................ 6
Hoisting ................................................................................................................................................... 7
Actuator and valve installation .............................................................................................................8
Control system overview ....................................................................................................................... 9
Control systems - electrical ................................................................................................................... 10
Control systems - mechanical switching and operation .................................................................. 11
Control system——remote/local air control and switching ............................................................ 13
Maintain ................................................................................................................................................... 14
Typical linear pneumatic actuator assembly drawing ...................................................................... 15
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 Product Description
General assembly drawing of the whole control system
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Valves & Controls
Storage and transportation
► This product must be strictly packaged during transportation
► This product must be handled with care.
► Place the product carefully in the box, secure it, and handle with care. Do not stack boxes on top of each
other.
► During storage and transportation, it is strictly forbidden to hit or throw the product and its
accessories.
► Before installation and use, this product must be stored in its packaging state, placed in a low and
flat place, and placed stably. Do not store it in the following places:
⧫
Where it rains
⧫
Places with high temperature exceeding 60℃
⧫
Dusty places
⧫
Locations with high humidity
► When the actuator cannot be put into service immediately, the actuator needs to be properly stored.
⧫
Clean all dirt, dust, grease and contaminants from the exposed drive rod. Wet the surface with a
soft cloth and appropriate oil-based solvent. Avoid using abrasives when cleaning the drive rod
surface.
⧫
Introduce clean and dry air/nitrogen into the lower air inlet of the pneumatic actuator, retract
the drive rod into the actuator, and apply a proper amount of grease to the exposed part of the
drive rod
⧫
Lubricate all exposed threads
► If the actuator is moved and stored again, the storage notes listed above must be repeated to ensure
correct storage conditions.
► Indoor environment is the ideal place for actuator storage.
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Valves & Controls
Preparation before installation
► Tool preparation
Lists the recommended tools and materials that may be required for actuator installation, additional
tools and materials may be required depending on the specific actuator/valve.
⧫
Vernier/Ruler
⧫
One set of SAE combination wrenches and sockets
⧫
One set of SAE hexagon wrenches
⧫
Small and medium pipe wrenches
⧫
Large size box wrench
The crane is equipped with a sling, a pair of shackles
⧫ Clean and dry air/nitrogen source, not less than the minimum operating pressure
⧫
and flow of the actuator
⧫
Pipe thread sealants (such as PTFE tape, pipe dope)
⧫
Grease cleaner
► Pre-installation verification Note:
The stroke of a linear actuator mounted on a valve is properly adjusted at the factory. Before it is first
installed on a valve, several important measurements and markings need to be made. These measurements
and markings cannot be made after the actuator is installed and are helpful in checking or
Adjust your itinerary.
NOTE: Marking should be done with a marker, chalk, or other tool that will not damage the actuator sealing
surface.
⧫
Measure and mark the height of the valve stem when the valve is tightly closed
⧫
Measure and mark the height of the valve stem when the valve is fully open
⧫
Verify the maximum travel of the valve
⧫
Measure and mark the length of the drive rod when the actuator is closed
⧫
Measure and mark the length of the drive rod when the actuator is fully open
⧫
Verify the maximum travel of the actuator
Confirm that the above measurements are correct and proceed to the next step.
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Valves & Controls
Hoisting
CAUTION: Use proper lifting equipment
The lifting lugs on the top of the actuator are designed to lift the actuator and the
connecting bracket
Do not lift with valve. Vertical lifting:
Before lifting the actuator, make sure the valve is disconnected from the actuator.
Be careful when transporting and installing the actuator, especially
When operating and lifting the actuator, the actuator can only be lifted from the lifting
ring located on the upper end cover. See Figure 2 Lifting method
Figure 2 Lifting method
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Valves & Controls
Actuator and valve installation
1.
Pay attention to the connection flange surface to prevent hands and fingers from
entering
2.
If the air source is introduced, the valve may open or close unexpectedly. It is
recommended to install the valve when there is no pressure in the actuator pipeline.
⧫
The stroke of the ZH-000 linear pneumatic actuator installed on the valve is
properly adjusted by the manufacturer and further adjustment is required to install
the valve with the ZH-000 linear pneumatic actuator directly in the pipeline.
⧫
If the valve was not shipped with an actuator, the valve may need to be prepared
for installation. Anything that restricts free movement of the stem or prevents the
actuator from being installed (such as handwheels or stem nuts) must be removed,
consult the valve manufacturer for instructions.
⧫
When connecting to the air supply, always use internally clean pipes or tubing and
ensure the actuator has the proper pressure and flow. A clean, dry air supply will
help ensure trouble-free operation.
⧫
Before starting installation, check the compatibility of the valve and actuator,
confirm that the connector threads match the valve stem, verify that the actuator
mounting flange is consistent with the valve flange size (including the locating
boss), and verify that the number, length and size of mounting bolts, nuts, spring
washers, etc. are correct.
Ensure threads and mating flange face surfaces are free of dust and debris.
⧫ Open or close the valve according to its working condition and adjust it to the
⧫
corresponding position.
3.
Lubricate the drive rod and valve stem connecting threads. Synchronous rotation may
occur during the assembly process. A caliper is needed to clamp the valve stem to
prevent synchronous rotation. A large wrench is needed to rotate the drive rod
according to the direction of the thread.
4.
To close the valve tightly, leave a gap of 2~5mm between the actuator connection flange
and the valve connection flange. Use the fastening bolts to eliminate the gap and tighten
the connection. Ensure that the valve closed, or open mark position is accurate. When
the valve is fully closed, the actuator mark point cannot be seen.
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Figure 3 Installation diagram
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Control System Overview
1.
The control system of the pneumatic actuator is very important for pneumatic valves. It
can achieve different working states of the valve under different working conditions, and
requires reliable design, reasonable component layout, and convenient operation. The
design of the pneumatic actuator control system and the selection of components are
based on the requirements and working conditions of the valve, so the pneumatic
actuator control systems of different products are very different. If it is different from this
manual, please contact the pneumatic actuator manufacturer.
2.
Figure 4 The main drive panel of the pneumatic actuator integrates components such as
the filter pressure reducing valve, solenoid valve, position-holding valve, and air control
valve. The overall design is compact and reasonable and is easy to install and maintain.
The drive panel can be removed from the actuator for inspection and maintenance in a
place with conditions.
3.
Figure 5 Pneumatic actuator operator control panel, also modular in design, easy to
install and maintain, with a mechanical handwheel with a safety buckle to prevent
accidental opening or closing of the pneumatic actuator. The manual/automatic switch
and the pneumatic operation switch are covered with a shield to prevent accidental
objects from falling and opening or closing the pneumatic actuator.
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Valves & Controls
⧫
Figure 4 Main drive panel of pneumatic actuator (Left)
⧫
Figure 5 Pneumatic actuator operator control panel (Right)
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Control systems - electrical
Figure 6 Solenoid valve, the electrical interface of the solenoid valve is 1/2“NPT. Open the
upper cover of the solenoid valve to connect the control power supply. Select the
appropriate wire size or add a relay according to the control distance. After completing the
wiring, confirm that the 4 screws on the upper cover are tightened, the upper cover and the
body are completely closed, and the threads at the electrical interface should be wrapped
with polytetrafluoroethylene tape or coated with pipe sealant.
Figure 6 Solenoid valve
Figure 7 Proximity switch. After installing the actuator and adjusting the stroke, you can
confirm the position of the proximity switch and make sure that the distance between the
proximity switch and the valve position indicator is within the rated distance of the proximity
switch and cannot contact the valve position indicator.
Figure 7 Proximity switch
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Valves & Controls
Control systems - mechanical switching and operation
Note: Do not operate without training.
The pneumatic actuator can only be opened or closed mechanically when the air
source fails. When the air source is normal, the pneumatic actuator can be opened or closed
using on-site air control.
Figure 8 Mechanical operation part
(Right picture)
⧫ The dark part shown in Figure 8A is the pressure relief valve.
Although the air source fails,
there is still a certain amount of
pressure stored inside the
actuator. To be able to close the
valve tightly when the air source
fails, if mechanical manual
operation is required, the
pressure relief valve needs to be
rotated 90 ° to the exhaust
position.
⧫
The dark part in Figure 8-B is
the hand wheel operated
safety buckle. The safety
buckle needs to be unlocked
during mechanical operation.
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Valves & Controls
⧫
Figure 8-C The dark part is the connection pin
Insert the connecting pin into the hole during mechanical operation.
⧫ According to Figure 8-D, turn the hand wheel until the connecting pin holes.
⧫
between the connecting rod and the piston rod are aligned before inserting.
⧫
Connecting pin.
Figure 8-E, When the mechanical operation is switched to automatic or on-site pneumatic
operation, it is necessary to unplug the pin and turn the handwheel counterclockwise to move
the connecting rod to the uppermost position, which is the limit position.
Finally, buckle the safety buckle onto the handwheel.
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Valves & Controls
Control system - remote/local gas control and switching
Note: Do not switch to ground operation mode when the solenoid valve is
powered on
Note: All components related to mechanical operation are configured in
automatic mode
Figure 9 There are two manual air-operated valves in the control panel, namely the
local/remote transfer switch and the local operation switch.
► Remote operation
The solenoid valve loses power (the valve is in the closed state), the local operating switch
turns to the closed position and the switching switch turns to the remote position.
► On-site operation
The solenoid valve loses power (the valve is in the closed state), and the switch is turned to
the local position. Turn the local operation switch to the closed position and the valve will be
closed.
Turn the local operating switch to the open position and the valve will open.
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Figure 9 Control Panel
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Maintenance
Regular maintenance
1.
If possible, remove line pressure before performing any maintenance. Under normal
operating conditions, only seals and gaskets need to be replaced.
2.
In addition to the recommended tools and materials, the following tools and materials
are recommended for maintenance
⧫
Grease or equivalent
⧫
A tube of sealant
⧫
Leak detection fluid (such as soapy water)
⧫
Seals, gaskets and other applicable parts are available as repair kits.
Test
System operation should be tested regularly, and performance noted to detect any problems early.
Troubleshooting
This section focuses on the most common symptoms and their possible solutions. It is for actuator use
only. Failures of control components must be eliminated according to the instructions provided by
their manufacturers. However, if a control component fails,
You can also contact us for more information.
► The actuator does not move, is too slow, creeps, or cannot move
——Check whether there is sufficient gas source pressure and flow, that is, check the accessories, such
as the filter pressure reducing valve, to ensure that the filter element is not blocked.
- Check to make sure the speed regulating valve or stop valve is not completely closed.
——Check whether the operating conditions have changed, that is, the pipeline pressure is too high,
the fluid is different, and the valve packing is too tight.
——Check whether the mechanical operating part is fully in automatic state
——Switch to mechanical operation, open or close the valve, and use automatic operation to see if
the actuator can be started.
► If the problem persists, continue to the next section.
—— Check for external leaks (use leak detector)
If there is a leak, check the torque of the corresponding nut and tighten the nut if necessary to see if
the leak stops.
► If there is leakage around the drive rod, cycle the actuator a few times to see if the leakage stops. If
the leakage continues, the seal may be damaged and needs to be replaced.
► There are many pipes on the control system, which are prone to leakage from the ferrule joints. If
leakage occurs at the joints, tighten the nuts to see if the leakage stops.
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Valves & Controls
► If leakage persists, the corresponding seal needs to be replaced.
► Valve leaks or does not close completely.
If the leakage is through the pipeline valve itself (the valve cannot be completely closed), check the
maximum stroke of the actuator and the maximum stroke of the valve, refer to the installation of the
valve and actuator, and increase the connection gap.
If the problem persists, please contact the manufacturer VESON.
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Valves & Controls
Typical linear pneumatic actuator assembly diagram
Number
Description
Number
Description
1
Piston rod (drive rod)
11
Bracket for connecting with
valve
2
Adjusting bolt
12
Support ring
protection cover
3
Stroke adjustment bolt
13
Cylinder seal
4
Upper cover
14
Piston seal
5
Piston fastening nut
15
Piston support ring
6
Piston fastening nut
16
Cylinder seal
7
Piston
17
Buffer device
8
Lower end cover
18
Eye bolt
9
Piston rod seal
19
End cover seal
10
End cover seal
20
Support ring
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Valves & Controls
Our company reserves the right to modify this instruction manual
Veson valve ltd
Address: No. 78 Fengjin Road, Xidu Industrial Park, Fengxian District, Shanghai
Tel: 0086-021-61629172
Fax: 0086-021-61625929
Email: sales@veson-valve.com
Http://www.veson-valve.com
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