2. DeZURIK® COMPAK™ ACTUATOR
Use of Instructions
USE OF These instructions provide installation, operation, and maintenance information for
INSTRUCTIONS DeZURIK Compak™ Actuator. They include procedures which, when carefully fol-
lowed, help to assure satisfactory performance of this product. All warnings and cau-
tions included in these instructions must be followed to avoid personal injury and
equipment damage. These instructions are intended for use by personnel who are
responsible for the installation, operation or maintenance of a DeZURIK Compak™
Actuator.
Refer to the Data Plate attached to the valve, and also to the Product Bulletin for infor-
mation regarding materials of construction and product limitations.
SAFETY MESSAGES Safety messages in these instructions and on the label(s) on the valve are flagged with
one of the words Caution, Warning or Danger. The messages must be carefully read and
followed to avoid personal injury and/or equipment damage.
After installation, if a safety label on the actuator becomes difficult to see or read, or if a
label has been removed, please contact DeZURIK for replacement label(s). Include the
7-digit part number from the data plate on the actuator, the quantity of actuator, and an
appropriate name and mailing address.
INSPECTION This unit has been packaged to provide ample protection during shipment. However, if
the unit is mishandled in transit, it could sustain damage. Upon arrival at its final desti-
nation, the unit should be carefully inspected for damage.
If damage exists, a damage claim should be filed immediately with the carrier.
STORAGE Units should be stored in a clean, cool and dry location, and should be protected from
dirt, paper stock, dust, and other contaminants. If outdoor storage is necessary, the unit
should be wrapped in plastic and stored high enough so that it will not be immersed in
water or buried in snow.
REPLACEMENT Recommended spare parts are listed on the ACTUATOR ASSEMBLY DRAWING. These
PARTS parts should be stocked to minimize downtime. If four or more actuators are in use, it is
advisable to stock one complete actuator as a spare.
Replacement parts may be ordered from the local DeZURIK sales representative, or
directly from DeZURIK, as listed on the back cover.
DeZURIK SERVICE DeZURIK service personnel are available for start-up and repair of DeZURIK products.
DeZURIK also offers customized training programs and consultation services for cus-
tomers.
Contact a DeZURIK sales representative or visit our website at www.dezurik.com for
more information.
July 1998 D–10371
4. DeZURIK® COMPAK™ ACTUATOR
Description
DESCRIPTION The DeZURIK Compak™ Actuator is an enclosed rack and pinion cylinder actuator that
provides on-off or modulating control on quarter-turn valves. Several actuator sizes are
offered. The Compak™ is available as a double-acting actuator or as a spring-return
actuator, either spring-to-open or spring-to-close. The double-acting model is convert-
ible to spring-return, and vice versa. The spring action is reversible.
OPERATION The Compak™ Actuator is powered pneumatically, and rotates 90 degrees between the
open and closed positions, in the direction as described below. Actuators are sized for
either 60 or 80 psi. (415 or 550 kPa). All actuators are limited to a maximum pressure of
150 psi (1000 kPa).
INSTALLATION Pneumatic connections are required as described below. Connections are 1/8" NPT on
actuator sizes through M103, and are 1/4" NPT on sizes M148 and larger.
Model CMD Spring–Return Actuator
The spring-return actuator requires one pneumatic connection to the open (left-side) on
the side of the actuator. A breather is in the other (right-side) port. As the spring-return
actuator is cycled, air is alternately drawn in and exhausted through the breathers. The
breather must be protected from water because water inside of the actuator will cause
sticking and premature wear of the internal components.
With a SPRING-TO-OPEN actuator, air to the connection drives the actuator clockwise,
towards the CLOSED position of the valve. See Figure 1.
Figure 1—Model CMD Air Connection
Spring-to-Open
With a SPRING-TO-CLOSE actuator, air to the connection drives the actuator counterclock-
wise, towards the OPEN position of the valve. See Figure 2.
Figure 2—Model CMD Air Connections
Spring-to-Close
July 1998 Page 1 of 15 D–10371
5. DeZURIK® Compak™ Actuator
Lubrication
INSTALLATION Model CMD Double–Acting Actuator
(CONTINUED) The model CMD double–acting actuator requires two pneumatic connections—one to
each of the two ports on the side of the actuator.
Air to the left-side port drives the actuator counterclockwise, towards the OPEN position
of the valve.
Air to the right-side port drives the actuator clockwise, towards the CLOSED position of
the valve. See Figure 3.
Figure 3—Model CMD Air Connections
Double–Acting Actuator
Model CM Double–Acting Actuator
The model CM double–acting actuator requires two pneumatic connections—one to
each of the two ports on the side of the actuator.
Air to the left-side port drives the actuator clockwise, towards the CLOSED position of
the valve.
Air to the right-side port drives the actuator counterclockwise, towards the OPEN posi-
tion of the valve. See Figure 4.
Figure 4—Model CM Air Connections
LUBRICATION The actuator is lubricated at the factory, and does not require routine maintenance lubri-
cation. If the actuator is disassembled, lubrication is required—See “Actuator Reassem-
bly” on page 8.
OPEN AND CLOSED The open and closed position stops prevent the actuator from rotating beyond the open
POSITION STOPS and closed positions of the valve. If the actuator is factory–mounted on the valve, the
stops are preset, and do not require further adjustment.
If the actuator is not factory-mounted on the valve, or if the actuator is removed and/or
disassembled, the stops will require adjustment as described below. Refer to the VALVE
INSTRUCTIONS for closed-position information, and adjust the stops after the actuator is
mounted on the valve. The location of the stops on various actuator configurations is
shown in the accompanying figures.
July 1998 Page 2 of 15 D–10371
6. DeZURIK® COMPAK™ ACTUATOR
Open and Closed Position Stops
OPEN AND CLOSED Model CM Stops
POSITION STOPS The closed position stop on a CM double–acting actuator is adjusted by following the
(CONTINUED) steps below.
Note: The OPEN POSITION STOP is not adjustable.
1. Loosen the two sealing nuts (B13). One
nut is located on each end of the actuator.
2. Disconnect air pressure from the actua-
tor, thus allowing the actuator to move
against the closed position stops.
3. Adjust the two travel stops (B14) so that
the actuator positions the valve in the
fully closed position.
Note: Turn the stops clockwise to
decrease the stroke, or counter-
clockwise to increase the stroke.
Adjust the stops so that the
torque feels approximately the Figure 5—CM Stop Adjustment
same on both travel stops.
4. While holding either one of the travel stops from turning, tighten its sealing nut as
shown in Table A. (See pg. 5)
5. Repeat for the other travel stop and sealing nut.
Model CMD Stops—Left–Hand Side
Both the open and the closed position stops on a CMD actuator are adjustable.
The stop on the LEFT END of the CMD actuators (as shown in figure 8, pg. 8) is adjusted
by following the steps below.
1. Loosen the sealing nut (B13) on the left
end of the actuator.
2. Apply or relieve air pressure to the actua-
tor so that the actuator moves to the posi-
tion indicated by the stop on the left end
of the actuator.
3. Adjust the travel stop (B14) so that the
actuator positions the valve in the appro-
priate fully open or closed position.
Note: Turn the stop clockwise to
decrease the stroke, or counter-
clockwise to increase the stroke.
Figure 6—CMD Stop Adjustment
4. While holding the travel stop from turn- Left–Hand Side
ing, tighten its sealing nut to the torque in
Table A. (See pg. 5)
(Continued)
July 1998 Page 3 of 15 D–10371
7. DeZURIK® Compak™ Actuator
Open and Closed Position Stops
OPEN AND CLOSED Model CMD Stops—Right–Hand Side
POSITION STOPS The stop on the RIGHT END of the CMD actuators (as viewed in figure 8, pg. 8) is
(CONTINUED) adjusted by following the steps below.
1. Remove the knurled cap (B22) from
the right end of the actuator.
2. Remove the jam nut (B23) from the
adjustment shaft (B24).
3. Apply or relieve air pressure to the
actuator so that the actuator moves
to the position indicated by the stop
on the right end of the actuator.
4. Turn the adjustment nut (B23) so
that the actuator positions the valve
in the appropriate fully open or
closed position.
Note: Turn the nut clockwise to Figure 7—CMD Stop Adjustment
Right–Hand Side
decrease the stroke, or
counterclockwise to
increase the stroke.
5. Stroke the actuator to the opposite position so that the adjustment nut is accessible;
hold the adjustment nut in position, and turn the jam nut against the adjustment
nut.
6. Tighten the jam nut to correct torque. See Table A, “Fastener Torques,” on page 5.
7. Replace the knurled cap on the right end of the actuator.
8. Hand tighten the cap firmly to prevent air from leaking through the seal on the
cap.
July 1998 Page 4 of 15 D–10371
9. DeZURIK® Compak™ Actuator
Removing Acuator from Valve
REMOVING For component identification, see Figure 8—pg. 9.
ACUATOR FROM
VALVE
Flow in the pipeline with the actuator removed can allow the valve
to slam closed and cause personal injury and/or damage to the flow
system. Shut down the flow in the pipeline before removing the
actuator from the valve.
1. Shut down the flow in the pipeline.
Moving parts from unexpected operation of a powered actuator can
cause personal injury or equipment damage. Disconnect and lock
out power to the actuator before servicing.
2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental
operation of the actuator.
3. Remove the four mounting screws that fasten the actuator to the valve or bracket.
4. Remove the actuator from the valve by lifting the actuator from the valve shaft.
July 1998 Page 6 of 15 D–10371
10. DeZURIK® COMPAK™ ACTUATOR
Actuator Disassembly
ACTUATOR Follow the steps below to disassemble the actuator for replacing repair kit parts. To
DISASSEMBLY identify components, Figure 8 on page 8. Repair kit parts are marked * in Figure 8.
Loaded springs are retained under each end cap on spring-return
actuators. To prevent personal injury and equipment damage,
loosen the end cap screws slowly and evenly so that the springs
are fully relaxed before removing the screws.
1. Remove the actuator from the valve. See “Removing Acuator from Valve” on
page 6.
2. WITH A DOUBLE-ACTING ACTUATOR:
a. Remove the four screws (B16) on each of the two end caps (B4) and remove
the end caps.
b. Note the location and position of each end cap so that the end caps can be later
reassembled in the same configuration.
WITH A SPRING-RETURN ACTUATOR:
a. To prevent personal injury and equipment damage, loosen the four screws
(B16) slowly and evenly on each of the two end caps (B4) so that the springs
inside are fully relaxed before removing the screws and end caps.
b. Note the location and position of the end caps and springs (B5) so that the end
caps and springs can be later reassembled in the same configuration.
3. Rotate the pinion (B3) as required to move the two pistons (B2) apart as far as
possible. Pull and remove each piston from the body. Use pliers if necessary, but
do not damage the sealing surfaces. Note the location and position of each piston
so that the pistons can be later reassembled in the same configuration.
4. Remove the snap ring (B9) and washer (B10) from the top of the pinion (B3).
5. With the actuator located on two blocks of wood, tap the top of the pinion lightly
with a rubber mallet to loosen the pinion; then remove the pinion through the bot-
tom of the actuator.
6. Remove the following parts (marked * in Figure 8) to be replaced by repair kit
parts:
✦ Upper (B7) and lower (B8) pinion guides
✦ Piston guide skate (B11), one each
✦ Guide ring (B12), two each
✦ Piston O-ring (B17) and end cap O-ring, two each
✦ Upper (B19) and lower (B20) pinion O-rings, one each
July 1998 Page 7 of 15 D–10371
11. DeZURIK® Compak™ Actuator
Actuator Reassembly
Figure 8—Component Identification
ACTUATOR Follow the steps below to reassemble the actuator. Clean and inspect all parts before
REASSEMBLY reassembly. Lubricate all seals, bearing surfaces, cylinder walls, and gear teeth with
Dow Corning Molykote 44 grease or equivalent.
Note: Repair kit parts are marked * in Figure 8 and also below, and should be
replaced during reassembly.
1. Place the upper (B7*) and lower (B8*) guides and the upper (B19*) and lower
(B20*) O-rings on the pinion (B3) and insert the pinion into position through the
bottom of the body (B1).
2. Place the washer (B10*) and snap ring (B9*) on the top end of the pinion.
3. Place a piston guide skate (B11*), a piston guide ring (B12*), and an O-ring
(B17*) in position on each of the two pistons (B2).
4. Rotate the pinion (B3) so that the flat on top of the pinion is approximately 30 to
40 degrees beyond the open position (closed position for spring-to-open actua-
tors). Refer to Figure 10 on page 10 for pinion flat positions at the open and closed
positions.
July 1998 Page 8 of 15 D–10371
12. DeZURIK® COMPAK™ ACTUATOR
Actuator Reassembly
ACTUATOR 5. Position the two pistons (B2) as noted during disassembly, and insert the pistons
REASSEMBLY equally into the ends of the body (B1) until both pistons begin to mesh with the
(CONTINUED) pinion. Apply equal force on each position to rotate the pinion to the closed posi-
tion (open position for spring-to-open actuators).
6. Ensure that the pinion flat is perpendicular with the actuator at the closed position
as shown in Figure 10 on page 10; if not, remove the pistons and repeat steps 3
and 4, using an appropriate angle in step 3.
7. Place an O-ring (B18*) in the groove in each of the two end caps (B4).
8. WITH A SPRING-RETURN ACTUATOR:
a. Place the springs (B5) in each of the two end caps (B4)
in the configuration noted during disassembly, and
also shown in Table B and Figure 9.
b. Align the springs and end caps with the mating spring
locations in the pistons.
c. Ensure that the straight section of the end cap O-ring
is toward the top of the actuator.
d. Mount each end cap to the actuator with four screws
(B16). Figure 9—End
Cap Spring
e. Tighten the screws alternately and evenly as shown in Locations
Table A. (See pg. 5) *As viewed from
inside actuator
WITH A DOUBLE-ACTING ACTUATOR:
a. Align the end caps with the ends of the actuator.
b. Ensure that the straight section of the end cap O-ring is toward the top of the
actuator.
c. Mount each end cap to the actuator with four screws (B16).
d. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5)
Table B: Spring Quantities and Locations
Quantity of
Springs, Each
Spring Locations
End Cap
2 1 and 4
3 1, 3, and 5
4 2, 3, 5, and 6
1, 3, 4, 5, and 6—LEFT* END CAP
5
1, 2, 3, 4, and 6—RIGHT* END CAP
6 All 6
* As viewed from actuator port side
July 1998 Page 9 of 15 D–10371
13. DeZURIK® Compak™ Actuator
Piston and Pinion Configuration
PISTON AND PINION
CONFIGURATION
Figure 10—Piston and Pinion Configurations
for CMD Double–Acting and Spring–Return Actuators
Figure 11—Piston and Pinion Configurations
for CM Double–Acting Actuators
Note: In All Configurations, the air port on the LEFT SIDE (As viewed in Figure 8
on page 8) is common to the center pinion chamber; the air connection
port on the RIGHT SIDE is commmon to the two end cap chambers.
July 1998 Page 10 of 15 D–10371
14. DeZURIK® COMPAK™ ACTUATOR
Mounting Actuator on Valve
MOUNTING Follow the steps below to mount the actuator on the valve.
ACTUATOR ON
1. Place the actuator in the same position as the valve-either open or closed.
VALVE
2. Select one of the four mounting positions shown on the INSTALLATION DRAWING.
Note: The standard position is with the actuator parallel with the pipeline.
3. Fasten the actuator to the mounting plate or bracket with four screws and washers
as shown on the INSTALLATION DRAWING.
4. Tighten the screws as shown in Table A. (See pg. 5)
5. Align the actuator shaft coupling with the valve shaft and slide the actuator into
position.
6. Fasten the actuator mounting plate to the valve with four screws and washers as
shown on the INSTALLATION DRAWING.
7. Tighten the screws as shown in Table A. (See pg. 5)
8. Adjust the actuator stops, if necessary. See “Open and Closed Position Stops” on
page 2.
9. Operate the actuator and valve three full cycles to demonstrate that the unit oper-
ates smoothly in both directions with the appropriate 60 or 80 psi (415 or 550kPa)
air pressure.
10. Re-connect the pneumatic connections.
Pipeline flow may be resumed.
July 1998 Page 11 of 15 D–10371
15. DeZURIK® Compak™ Actuator
Changing Actuator From Double–Acting to Spring–to–Close
CHANGING Follow the steps below to change a double-acting actuator to a spring-to-close spring-
ACTUATOR FROM return actuator. Before proceeding, obtain one breather and also the required size and
DOUBLE–ACTING TO quantity of actuator springs. See “Component Identification” on page 8.
SPRING–TO–CLOSE
Flow in the pipeline with the actuator disconnected can allow the
valve to move unexpectedly, and can cause personal injury and/or
damage to the flow system. Shut down the flow in the pipeline
before servicing the actuator.
1. If the actuator is on a valve, shut down the flow in the pipeline, and close the
valve.
Moving parts from unexpected operation of a powered actuator can
cause personal injury or equipment damage. Disconnect and lock
out power to the actuator before servicing.
2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental
operation of the actuator.
3. Remove the four screws (B16) on each of the two end caps (B4) and remove the
end caps. Note the location and position of each end cap so that the end caps can
be later reassembled in the same configuration.
4. Place the springs (B5) in each of the two end caps (B4) in the configuration shown
in Table B on page 9, and Figure 9 on page 9.
5. Align the springs and end caps with the mating spring locations in the pistons.
6. Ensure that the straight section of the end cap O-ring is toward the top of the actu-
ator.
7. Mount each end cap to the actuator with four screws (B16).
8. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5)
9. Mount the new breather (B21) in the right-side port.
10. Re-connect the pneumatic connections.
Pipeline flow may be resumed.
July 1998 Page 12 of 15 D–10371
16. DeZURIK® COMPAK™ ACTUATOR
Changing Actuator From Double–Acting to Spring–to–Open
CHANGING Follow the steps below to change a double–acting actuator to a spring–to–open actuator.
ACTUATOR FROM Before proceeding, obtain one breather and also the required size and quantity of actua-
DOUBLE–ACTING TO tor springs. See “Component Identification” on page 8.
SPRING–TO–OPEN
1. Remove the actuator from the valve. See “Removing Acuator from Valve” on
page 6.
2. Remove the four screws (B16) on each of the two end caps (B4) and remove the
end caps. Note the location and position of each end cap so that the end caps can
be later reassembled in the same configuration.
3. Rotate the pinion (B3) as required to move the two pistons (B2) apart as far as
possible. Pull and remove each piston from the body. Use pliers if necessary, but
do not damage the sealing surfaces. Note the location and position of each piston
so that the pistons can be later reassembled in the same configuration.
4. Rotate the pinion (B3) so that the flat on top of the pinion is approximately 30 to
40 degrees beyond the closed. See Figure 8 on page 8, and Figure 10 on page 10.
5. Position the two pistons (B2) as noted during disassembly, and insert the pistons
equally into the ends of the body (B1) until both pistons begin to mesh with the
pinion. Apply equal force on each position to rotate the pinion to the open posi-
tion.
6. Ensure that the pinion flat is perpendicular with the actuator at the closed position
as shown in Figure 10; if not, remove the pistons and repeat steps 4 and 5, using
an appropriate angle in step 4.
7. Place an O-ring (B18*) in the groove in each of the two end caps (B4).
8. Place the springs (B5) in each of the two end caps (B4) in the configuration shown
in Table B on page 9 and Figure 9 on page 9.
a. Align the springs and end caps with the mating spring locations in the pistons.
Ensure that the straight section of the end cap O-ring is toward the top of the
actuator.
b. Mount each end cap to the actuator with four screws (B16).
c. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5)
9. Mount the new breather (B21) in the right-side port.
10. Mount the actuator on the valve as shown in the Mounting Actuator on Valve
section.
July 1998 Page 13 of 15 D–10371
17. DeZURIK® Compak™ Actuator
Changing Actuator From Spring–to–Close To Double–Acting
CHANGING Follow the steps below to change a spring-to-close spring-return actuator to a double-
ACTUATOR FROM acting actuator. For Component Identification, see Figure 8 on page 8.
SPRING–TO–CLOSE
TO
DOUBLE–ACTING
Flow in the pipeline with the actuator disconnected can allow the
valve to move unexpectedly, and can cause personal injury and/or
damage to the flow system. Shut down the flow in the pipeline
before servicing the actuator.
1. If the actuator is on a valve, shut down the flow in the pipeline, and close the
valve.
Moving parts from unexpected operation of a powered actuator can
cause personal injury or equipment damage. Disconnect and lock
out power to the actuator before servicing.
2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental
operation of the actuator.
3. Remove the four screws (B16) on each of the two end caps (B4) and remove the
end caps. Note the location and position of each end cap so that the end caps can
be later reassembled in the same configuration.
4. Remove all of the springs (B5) from both end caps (B4) and both pistons (B2) of
the actuator.
5. Align the end caps with the ends of the actuator.
a. Ensure that the straight section of the end cap O-ring goes toward the top of
the actuator.
b. Mount each end cap to the actuator with four screws (B16).
c. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5)
6. Remove the breather (B21) from the actuator.
7. Re-connect the pneumatic connections.
Pipeline flow may be resumed.
July 1998 Page 14 of 15 D–10371
18. DeZURIK® COMPAK™ ACTUATOR
Changing Actuator From Spring–to–Open To Double–Acting
CHANGING Follow the steps below to change a spring-to-open spring-return actuator to a double-
ACTUATOR FROM acting actuator.
SPRING–TO–OPEN
TO 1. Remove the actuator from the valve. See “Removing Acuator from Valve” on
DOUBLE–ACTING page 6.
2. Disassemble the actuator. See “Actuator Disassembly” on page 7.
3. Follow steps 1 through 6 in the Actuator Reassembly section except:
In step 4, insert the pistons as shown in Figure 10 on page 10 for a double-acting
actuator.
See “Actuator Reassembly” on page 8.
4. Align the end caps with the ends of the actuator.
a. Ensure that the straight section of the end cap O-ring is toward the top of the
actuator.
b. Mount each end cap to the actuator with four screws (B16).
c. Tighten the screws alternately and evenly as shown in Table A. (See pg. 5)
5. Remove the breather (B21) from the actuator.
6. Mount the actuator on the valve. See “Mounting Actuator on Valve” on page 11.
CHANGING The actuator may be mounted in any of four positions on the valve.
MOUNTING POSITION
To change the mounting position:
OF ACTUATOR ON
VALVE 1. Remove the actuator from the valve. See “Removing Acuator from Valve” on
page 6.
2. Replace the actuator on the valve. See “Mounting Actuator on Valve” on page 11.
TROUBLESHOOTING
Table C: Troubleshooting
Condition Possible Cause Corrective Action
Actuator closes or Set stops. See OPEN
Position stops are set
opens to wrong posi- AND CLOSED POSI-
incorrectly.
tion. TION STOPS section.
Increase cylinder pres-
Cylinder pressure is low. sure. See “Operation” on
page 1.
Actuator is sized
Use larger actuator.
incorrectly.
Install Repair Kit.
Seals are leaking.
Actuator will not fully (See pg. 7)
operate valve.
Pipeline obstruction in
valve is preventing Remove obstruction.
closure.
Double-acting actuator Air connections to cylinder Reverse air connections
rotates wrong direction. are incorrect. to cylinder.
July 1998 Page 15 of 15 D–10371
