Spring Cylinder Linear Actuator

Linear Actuator

Linear Actuator
General arrangement
Mascot spring cylinder linear actuator is a powerful, high-performance pneumatic actuator, which provides positive throttling or
on-off operation to pneumatic control valves. Uniquely designed positioner with multiple sized cylinders supply pressures up to
150 psi, making very high thrusts available in a relatively compact unit.
The Mascot spring cylinder linear actuator is fully field reversible for air-to-open or air-to-close action without additional parts;
a spring provides reliable fail-safe operation. Air is supplied to both the sides of the piston by the positioner providing very stiff
and precise movement alongwith very high frequency response.

Figure 1: Spring Cylinder Linear Actuator

Lifting Ring
Adjusting Screw
Spring Button

Adjusting Screw
Gasket

Spring

Cylinder

Actuator Stem
Locknut

Piston Stem O-ring

Stem Spacer

Piston

Upper Stem Bushing

Piston O-ring

Actuator Stem O-ring

Yoke O-ring

Cylinder
Retaining Ring
Yoke

Stem Bellows
O

Actuator Stem
Stem Clamp

Lower Stem Bushing

Stroke Plate

Stem Clamp Bolting

Linear Actuator
Features and Advantages

Following are the Salient features and advantages of the Mascot spring cylinder linear actuator:
Salient features
Higher thrust

Advantages

Operating pressure of 150 psi (10.3 Bar) permitting substantially higher thrust capabilities
than diaphragm actuators.
Tighter valve shutoff due to higher thrust.

High frequency

Responds quickly to signal changes because of double acting configuration.

Lightweight and
Compact

Substantially lighter and more compact than comparable linear diaphragm actuators.
Offers ease of maintenance.

Wild choice

Usual actuator sizes 25, 50 and 100 and a few more that can handle thrust requirements
for over 95 percent of valve sizes.
For special applications, larger sizes up through size 600 are available.

Least number of parts

33% less parts than diaphragm actuators Cost of wear parts is 10% then for diaphragms,
actuators allowing low inventory and maintenance.

Excellent positioning
accuracy

Powerful pneumatic stiffness allows a high pressure drop without plug slamming is
possible due to air volume between the piston and the bottom of the cylinder.
For stiff and precise actuator operation, supply pressure is sent to both sides of the piston.

Field reversible

Easily reversible failure mode without additional parts leading to reduced inventory costs.

No need of pressure
regulators

Easy handling of air supplies up to 150 psi (10.3 bar) without a pressure regulator and
can be operated with as little as 30 psi (2.1 Bar).*

Spring is fail-safe

Fail-safe operation is provided by internal spring in the event of air system failure.
Universal spring bench set is not needed.

Stiff operation

Supply pressure is sent to both sides of piston for stiff actuator operation.

Sturdy components

Minimal maintenance is needed as there is no diaphragm, therefore no rupture.

Easy maintenance

The spring cylinder actuator only needs the removal of two parts to access the internal
parts.

Low consumption of air

As compared to diaphragm actuators, cylinder design uses less supply of air.

Strokes are longer

In comparison to a inch (19mm) stroke on a comparable linear diaphragm actuator

Size 25 spring cylinder linear actuator has a 11/2 - inch (38mm) stroke. Stroke lengths
available up to 24 inches.

High-level positional
stiffness

Small air volume between the piston and the bottom of the cylinder provides
powerful pneumatic stiffness allowing high pressure, flow over the plug operation
without plug slamming.

* Limited operating pressure on some sizes because of valve sizes.

Linear Actuator
Actuator rigidity
Control valve operates with normally fluctuating flow. As this
might vary a force. It becomes necessary for the control valve
to remain in the same position as signaled by the controller.
To achieve required position, the valve depends on actuator
stiffness. Actuator stiffness is defined as an ability of an
actuator to withstand dynamic fluid forces acting on the valve
trim. For stiff and precise actuator operation, air pressure is
supplied to both sides of the piston, making the stiffness of
the Mascot spring cylinder greater than a valve with an
actuator having diaphragm.

The inherent property of this design is that as the volume

under the piston becomes smaller, the stiffness factor
becomes larger in a Mascot cylinder actuator. The equivalent
diaphragm actuator (46 square-inches) on the same valve
with a 3-15 psi (0-1 Bar) signal has a spring rate of only 920
lbs. per inch (161 kN/m) at mid-stroke. The spring rate for a
diaphragm actuator remains the same, regardless of
diaphragm position. When a valve with a diaphragm
actuator is operated close to the seat with flow over the plug,
sudden changes in the dynamic force can cause the valve to
slam shut. Because of this low-stiffness factor, diaphragm
operated valves are installed with the flow under the plug.

The stiffness, spring rate is equal to :

K=
Where:

As the valve plug approaches the seat, the stiffness of the

Mascot spring cylinder actuator actually increases. The
chances of the plug slamming into the seat are reduced. e.g.
A well designed actuator, with 100 Psi (6.9 bar) supply air
pressure and the plug 1 /8" (3 mm) away from a seat, the
piston is 3 /16" (5 mm) from the bottom of the cylinder. At
this point, the actuator generates a stiffness of 18,667 lbs.
per inch (3269 kN/m). See figure 3.

kPA2
v
K = spring rate
k = ratio of specific heat
P = supply pressure
A2 = piston area (in 2)
v = cylinder volume under piston

Thus, a spring cylinder actuated control valve may be

operated with the flow either over the plug or under the plug,
and still maintain the precise, throttling control required by
todays processes. This advantage allows the flow to assist
the actuator spring in obtaining the required failure position
and increases the ability of the valve for a tight shut off.

A 25 square-inch cylinder actuator at mid stroke (typical for a

2" valve) with a supply air pressure of 100 psi (6.9 Bar) and
a " (19mm) stroke will give the spring rate of 9333 lbs. per
inch at mid-stroke. See figure 2.

Figure 2: Cylinder Actuator at Mid-stroke

Figure 3: Cylinder Actuator with

High Stiffness/Spring Rate
4

Linear Actuator
Actuator performance
Thrust Producing Capability

Frequency Response

As compared to the diaphragm actuators, Mascot linear

spring cylinder actuators produce substantially higher thrust.
The cylinder operates with supply pressures up to 150 psi
(10.3 Bar). Throttling diaphragm actuators are limited to 4060 psi (2.8-4.1Bar), thereby reducing their thrust producing
capability. Higher actuator air supply, coupled with highpressure air on both sides of the actuator piston, provide
exceptional stiffness for precise throttling control. Mascot
cylinder actuator stiffness is sufficient to control high pressure
drops and allows the plug to throttle near the seat.

Extremely high frequency response is available with Mascot

cylinder actuator than comparable diaphragm actuator units.
Such response is achieved through a double-acting
configuration that uses pressure on both sides of the piston.

Size 25 Actuator, 9 psi 2 psi

0
3

Relative Response dB

Sensitivity and Speed

Degrees

Fast stroking speeds are produced because of higher air

volume handling capabilities of the positioner, coupled with
relatively low cylinder volumes. When approaching the final
plug position, high operating speed is achieved with virtually
no overshoot. Static sensitivity of the unit is excellent. e.g. As
little as 0.008 psi (0.0006 Bar) is required to move the stem
0.0005 inches (0.0127 mm) (the minimum detectable
movement in the tests conducted) on a size 25 actuator. To
reverse the stem motion, signal change of only 0.01 psi
(0.007 Bar) is needed. Presented in the table 1 are typical
stroking times. Increased stroking speeds are available with
Mascot flow booster valves.

12
0
30

Phase Angle

60
90
120
150
180
0.01

0.04

0.1

0.4

1.0

10

Frequency Hertz

Figure 4: Frequency Response

Hysteresis and Linearity
Ability to respond linearly to signal changes from the
controller and to provide uniform response unaffected by
decreasing or increasing pressures is an important
characteristic of any actuator. Tests prove the linearity of the
cylinder actuator to be within 1.0%. The same tests showed
that the difference in valve position for a given instrument
signal, regardless of the required direction of change in the
pistons position, was extremely small (refer to Table VII
Positioner Performance on page 11).

Table I: Typical Actuator Stroking Times

25
50
100
200
300

Time (Seconds)
For Maximum Stroke*
/4" Tubing
1.2
3.5
9.6
20.8
31.3

/8" Tubing
1.0
3.1
8.6
18.4
27.7

Stroke
(inches)
1.5
3
4
4
4

Size 25 Actuator, Signal 4.2 to 13.8 psig

Actuation pressure: 60 psi (4.1 Bar)

* Stroking time only (does not include time from receipt of
signal and beginning of stem motion).

13.8 psig

Input Signa
l

Actuator
Size

Signal

on
iti

lve

s
Po

Va

4.2 psig
0

0.0

0.50
Time (seconds)

Figure 5: Step Test

.72

1.00

Linear Actuator
Construction
Reversible Air Action

Sizes

Providing either air-to-open (air-to-retract) or air-to-close (airto-extend) action with easy reversal in the field is a function of
standard cylinder actuators. The spring is installed on the
upper side of the piston For air-to-close action, the spacer
and spring are installed on the underside of the piston with
the spring button stored on top of the piston.

Three standard sizes: 25, 50 and 100 square-inches

(nominal piston area) and five oversized actuator sizes: 200,
300, 400, 500 and 600 square-inch are available with
Spring cylinder linear actuators. A tandem of double piston
configuration is possible with 400 and 600 sizes.
Materials of construction
Corrosion resistant anodized aluminum is used in the cylinder
and piston. The tough ductile iron yoke withstands the impact.
Exposed actuator stem is made up of stainless steel, guided
by oilite bronze bushings. The yoke, cylinder, clamps and
other exposed parts can be supplied in stainless steel.
Clamps, bolts, nuts and yokes made in stainless steel are
available from regular stock.

Table II: Materials of Construction

O

Air-to-retract
(Air-to-open)

Part
Yoke
Yoke clamp
Yoke clamp bolts
Stem clamp*
Stem clamp nut and bolt
Cylinder retaining ring
Actuator stem
Stem spacer
Actuator stem
O-rings
Spring
Spring button
Adjusting screw
Piston
Cylinder

Air-to-extend
(Air-to-close)

Figure 6: Spring Cylinder Air Action

Material
Phosphated, painted ductile iron
Stainless steel
Zinc plated steel
Phosphated, painted ductile iron
Zinc plated steel
Zinc plated steel
416 stainless steel
Aluminum
lock nut Zinc plated steel
Buna-N
Alloy steel
Painted steel
Zinc plated steel
Anodized aluminum
Painted anodized aluminum

*Denotes stainless steel material on 25 and 50 sq.in.

Table IV:Mascot Cylinder Data

Cylinder
Size
25
50*
50
100*
100
200
300
400**
500
600**

Cylinder
Bore Dia.
(in.)
5.50
7.75
7.75
11.00
11.00
15.50
19.50
15.50
25.25
19.50

Upper
Cylinder
Area
(sq.in.)
23.76
47.17
47.17
95.03
95.03
188.7
298.6
371.5
500.7
590.2

Lower
Cylinder
Area
(sq.in.)
22.97
46.39
45.67
93.26
91.06
184.7
292.7
365.5
494.8
583.1

Stem
Diameter
(in.)
1.00
1.00
1.38
1.50
2.25
2.25
2.75
2.75
2.75
3.00

Stem
Area
(sq.in.)
0.79
0.79
1.50
1.77
3.98
3.98
5.94
5.94
5.94
7.07

Maximum
Volume

Table III: Actuator

Specifications

Over Piston

(cu.in.)
100
331
331
1031
1031
2087
3733
3033
5519
5661

*Used as oversized actuators in place of the next smaller actuator

**Tandem, doub le piston configur ation

Type
Sizes
Spring Designs
Action
Operating
pressure
Temperature
range

Cylinder with positive

spring action
25, 50, 100, 200, 300,
400, 500 and 600 sq. in.
Single (std.) and dual
Field reversible:
Air-to-open, Air-to-close
Up to150 psi (10.3 Bar)
-40O to 350O F*
(-40O to 177OC*)
O

* Ambient temperatures greater than 180 F

O
(82 C) require Viton O-rings. Ambient
O
O
temperatures below -40 F (-40 C) require
fluorosilicone O-rings.

Linear Actuator
Components of the actuator

Cylinder
Piston O-Ring
Piston

Figure 7: Piston Seal

A Buna-N O-ring seals the piston. The smooth finish of
cylinder bore ensures long service life. Dow corning 55M is
used to lubricate the cylinder walls. This lubricant does not
dissolve in water or oils that may be present in the air supply,
O
and is effective over a wide temperature range from -50 to
O
O
O
350 F (-46 to 177 C). Where ambient temperatures
are expected to exceed 120O F (49O C), a special Viton
O-ring can be supplied. Tests have demonstrated
service life in excess of five million strokes with zero or
negligible leakage. In continuous service for many years,
Piston O-rings used in these actuators have proven
successful.

Figure 9: Stem Clamp

A split steel clamp locks the actuator stem to the plug stem. A
split actuator stem permits this clamping action. Both stems
have standard wrench flats to simplify adjustment of plug
stem/actuator stem length. Feedback linkage attached to the
stem clamp is for transmitting the position of the actuator to
the positioner. In conjunction with the stroke plate, a pointer
is used fixed to one web of the yoke to indicate the actuator
stroke. The clamp and stem are prevented from rotating by
the other web.

Cylinder
Yoke O-Ring
Cylinder
Retaining
Ring
Yoke

Figure 8: Cylinder to Yoke Attachment

A solid square retaining ring attaches the cylinder to the yoke.
Removal is easy with the aid of two screw drivers. (Please refer
the Mascot Installation, Operation and Maintenance
Instructions for correct disassembly procedures). A static Or i n g
s e a l
is located at the cylinder bore and also at the actuator.

Figure 10: Lifting Ring

Size 25 and 50 actuators are furnished with a lifting
ring that is screwed into the adjusting screw to facilitate
handling of the actuator assembly. Size 100 and larger
actuators will accept a standard eyebolt.

Linear Actuator
Springs data
Table V: Cylinder Actuator Spring Data
Cylinder

Stroke
(inches)

Spring
Design

lb/in

(N/m)

/4
1
1 1 /2
3
/4
1
1 1 /2
1 1 /2
2
2 1 /2
3
1 1 /2
2
2 1 /2
3
2
2 1 /2
3
4
2
2 1 /2
3
4
2
2 1 /2
3
4

S TD
S TD
S TD
DUAL
DUAL
DUAL
S TD
S TD
STD
S TD
DUAL
DUAL
DUAL
DUAL
S TD
S TD
S TD
S TD
HE AV Y *
HE AV Y *
HE AV Y *
HE AV Y *
DUAL
DUAL
DUAL
DUAL

180
180
180
447
447
447
164
164
164
164
447
447
447
447
300
300
300
300
535
535
535
535
885
885
885
885

31523
31523
31523
78282
78282
78282
28721
28721
28721
28721
78282
78282
78282
78282
52538
52538
52538
52538
93693
93693
93693
93693
154987
154987
154987
154987

25

50

100

thru

600

Air-to-open
(Air-to-retract)
Spring Ext.
Spring Ret.
lbs
N
lbs
N

Rate

281
236
146
629
629
405
369
287
205
123
1194
970
747
523
1125
975
825
525
2098
1831
1563
1028
3471
3029
2586
1701

1250
1050
649
2798
2798
1802
1641
1277
912
547
5311
4315
3323
2326
5004
4337
3670
2335
9332
8145
6953
4573
15440
13474
11503
7566

416
416
416
964
1075
1075
615
615
615
615
1864
1864
1864
1864
1725
1725
1725
1725
3168
3168
3168
3168
5241
5241
5241
5241

1850
1850
1850
4288
4782
4782
2736
2736
2736
2736
8291
8291
8291
8291
7673
7673
7673
7673
14092
14092
14092
14092
23313
23313
23313
23313

Air-to-close
(Air-to-extend)
Spring Ret.
Spring Ext.
lbs
N
lbs
N
450
450
450

2002
2002
2002

315
270
180

1401
1201
801

656
656
656
656

2918
2918
2918
2918

410
328
246
164

1824
1459
1094
730

1725
1725
1725
1725

7673
7673
7673
7673

1125
975
825
525

5004
4337
3670
2335

* Heavy spring includes outer spring of dual spring set.

The unique four-way, double acting design in the Mascot

cylinder actuators does not require springs for positioning.
The spring serves only as a fail-safe device. It should be
noted that although valve flow direction usually assists the
actuator on loss of air, normally the spring is designed to
achieve the fail position independently. Proper sizing of the
cylinder
spring
requires an understanding of the specific spring force listed in
the table above.

Adjusting
Screw
Spring Button
Outer Spring
Inner Spring
Spring Guide

Dual Spring Actuator Construction

For heavy duty service in the air-o-retract (air-to-open)
configuration, Dual springs are available. Only five additional
parts: a new actuator stem, a spring button, the inner spring,
outer spring and a spring guide are needed for retrofitting a
standard cylinder actuator to dual springs. On the other
hand, valve equipped with dual spring actuators are not field
reversible and require a minimum of 60 psi (4.1 Bar) supply

Figure 11: Dual Spring Actuator

Linear Actuator
Valve Positioners

Corrosion-resistant
cover and base

Easy calibration

Withstands 150 psi

at all parts

Two -sided cam

for easy field
reversibility
Optional / NPT for
piped exhaust

Split ranges can be

easily adjusted
Electro-pneumatic (I/P) module

Figure 12: Valve Positioner Features

Pneumatic module

Interchangable

Easily Field Reversed A reversal of action in the field is

achieved by simply turning the cam over, reversing the
anti-backlash spring and changing the output tubing.

Valve positioners are primarily utilized by Mascot. A

pneumatic module for air control signals, or an electropneumatic (I/P) module for milliamp electrical control signals
is offered with Mascot valve positioner. Valve positioners are
single or double-acting, force-balanced instruments that
provide fast, sensitive and accurate positioning of cylinder
and diaphragm actuators. These positioners being compact,
field reversible, are designed for high performance and are
reliable because of the rugged built.

Insensitive to Mounting Position Positioners can

be mounted in any orientation.
Simple Calibration Easy calibration as there is minimal
interaction between zero and span. For protection and to
discourage tampering, positioner adjustments are totally
enclosed.

Features
P/P or I/P Signal Convertible Easy accomplishment of
field conversion from one control signal to another by
replacing one module with another

Split-Range Service Standard signal ranges are 4

- 20 mA for the electro-pneumatic (I/P) module and 315 psi (0-1 Bar) for the pneumatic (P/P) model. Optional
ranges are 10-50 mA and 6-30 psi (0.4-2.1 Bar),
respectively. All models can be calibrated for a 2 or 3way split range.

Corrosion Resistant Epoxy powder painted on cover and

base assembly and continuously purged from the inside with
instrument air making corrosion resistant internal section.
Internal working parts are constructed from 300 series
stainless steel, anodized aluminum or Buna-N.

Simplified Maintenance Ease in maintenance because

of positioners simplicity, modular design and a few parts.
Regulator not needed Designed to withstand 150 psi
(10.3 bar) at all parts, the valve positioners are insensitive to
supply pressure fluctuations.

Shock and Vibration Resistant the make and design of

valve positioners is such that they have high natural frequency
coupled with pneumatic damping. It is unaffected by
vibration, acceleration up to 2 Gs, and frequencies to 500
Hz.

Low Air Consumption Steady state air consumption is

.25 SCFM @ 60 psi (4.1 Bar) supply.
Changeable Flow Characteristics Easily changed
cam provides characterized flow feedback.

For Single or Double-acting Actuators The valve

positioner is versatile usable with either single or double
acting actuators.

High Air Flow Gain Model Standard on 200 square

inch actuators and above, optional on others.

Standard Mounting Valve positioners use the standard

mounting. By changing the cams and follower arms, the same
positioner can be used on both linear and rotary actuators.
This results in fewer required spare parts.

Output Gauge Helps Monitor Unit: Permits easy

verification of transducer and positioner calibration as it
indicates transducer output to the positioner.

Linear Actuator
Valve Positioner Operation
Figure 13 shows a valve positioner . The valve positioner is a
force-balanced instrument, with pneumatic module installed
on a double-acting actuator for air to open action.
Positioning is based on a balance of two forces; one
proportional to the instrument signal and the other
proportional to the stem position.

the instrument signal capsule and balance beam

downward. This motion of the balance beam also pulls
the pilot valve spool downward from its equilibrium
position. This opens the pilot valve ports, supplying
air to port 1 and exhausting air from port 2. This causes
the actuator piston upward.

A downward force is activated as the signal pressure acts

upon the diaphragms in the instrument signal capsule,
through the follower arm and cam, the motion of the actuator
stem is transmitted to the top end of the feedback spring
resulting in the varying of tension in feedback spring as stem
position changes.

Proportionally to the valve position, to counter the force

generated by the instrument signal capsule, the piston
continues to stroke upwards until force in the feedback spring
increases sufficiently. At this point the balance beam and
spool begin to return to equilibrium position. As the valve
spool ports start to close, the air flow rate to the actuator is
decreased.

The system will be in equilibrium and stem will be in the

position called for by the instrument signal when these
opposing forces balance exactly. The balance will move up or
down and by means of the spool valve, will change the
output pressures and flow rate if these opposing forces are
not in balance. This will lead to the piston to moving until the
tension on the feedback spring opposes exactly the instrument
signal pressure.

The feedback spring tension force will equal the force

generated in the instrument signal capsule after the piston has
reached the required position. The balance beam and
instrument signal capsule will remain in their
equilibrium positions with no air flowing to the actuator
until a change in the instrument signal is made.
A proportional downward movement of the actuator piston
and stem is affected by a decrease in the instrument signal
which reverses the described actions.

The detailed sequence of positioner operations are as

follows: An increase in the instrument signal forces

Figure 13: Positioner Schematic for Air-to-Open (Retract)

Output 2
Cylinder
Piston
Range Adjustment Gear

Output 1

MODULE

Signal

L-

Zero
Adjustment
Lock
Knob
Feedback Spring

Range Adjustment Lock Screw

Zero Adjustment Knob
Pivot
Follower Arm
Take-off Arm
Balance
Beam

3-15 psi
Instrument Signal Capsule
Pilot Valve Body Pilot Valve Spool

10

Linear Actuator
Valve Positioner Specifications
Table VI: Valve Positioner Specifications
Specification

Pneumatic Module

Input signal range:

3-15 psi (0-1 Bar), 2 or 3-way split range;

6-30 (0.4-2.1 Bar) psi, 2 or 3 and 4-way

Supply pressure

30 psi to 150 psi (2.1 to 10.3 Bar)

Ambient

Standard model: -20 to +185 F

temperature limits

(-30 to 85 C) Ext. temp. model:

-50 to +250 F (-46 to 121 C)

Connections

Supply, instrument and output: 1 /4 -inch

NPT; Gauges: 1/8 -inch NPT

Standard materials

Stainless steel, anodized aluminum,

nickel-plated steel, epoxy powder-painted
steel and Buna-N

Net weight

3 lbs. (1.4 kg)

Table VII: Valve Positioner Performance*

Valve Positioner Performance

Pneumatic Module

Independent Linearity Maximum deviation from a best fit straight line

1.0% F.S .

Hysteresis Maximum position error for the same value of input when
approached from opposite ends of the scale.

0.5% F.S .

Repeatability Maximum variation in position for the same value of input when
approached from the same direction.

0.2% F.S .

Response Level Maximum change in input required to cause a change in

valve stem position in one direction.

0.2% F.S .

Dead Band Maximum change in input required to cause a reversal in valve

stem movement.

0.3% F.S .

Resolution Smallest possible change in valve stem position.

.1% F.S .

Steady State Air Consumption @ 60 psi (4.1 Bar)

.25 SCFM

Supply Pressure Effect Position change for a 10 psi (0.7 Bar) supply pressure change.

.05 % F.S .

Open-loop Gain Ratio of cylinder pressure unbalance to instrument

pressure change with locked stem.

300:1
@60 psi

Maximum Flow Capacity @ 60 psi (4.1 Bar)

11 SCFM

Frequency Response
(With sinusoidal input of 5% F.S. centered about 50% F.S.)

Stroking Speed

-6 dB Frequency
Phase Angle at -6dB

.8 Hz
-71O

Closed to open Open to closed -

2.3 in/sec.
1.3 in/sec.

*Data is based on tests of the Valve positioner mounted on a double-acting cylinder actuator having a piston area of 25 square inches with
a valve stroke of 1.5 inches (38mm) and 60 psi (4.1 Bar) supply pressure. Instrument signal was 3-15 psi (0-1 Bar) with pneumatic module

11

Linear Actuator
Side-mounted continuously connected handwheels

Cylinder can be disassembled

White hand wheel securely holds
valve in position

Locking bar
Securely locks handwheel
setting

High load capacity

angular contact bearingsupport shaft with minimum
friction
OPEN

Efficient thread design

required less torque,
permits easier operation

Visible neutral position indicator

Size 25, 50 and 100*

Some applications only

Size 100 and 200

Mascots side-mounted handwheel is a continuously

connected, declutchable design which permits manual
operation of linear actuators. This is standard for valves upto
and including 4" strokes. It is especially convenient during
start-up, in emergencies, or due to air failure. Its efficient
design utilizes heavy-duty, anti-friction bearings that allow
high thrust with low torque on the handwheel. The sidemounted handwheel provides the mechanical advantage
needed for manual operation. Therefore, the handwheel
provides an effective means to overcome the fluid forces or
friction
within
the
valve
during manual operation.

2. Convenient access allows operator to turn the

handwheel easily in a more natural position.
3. Easy adaptation to a chain-driven mechanism is possible.
Due to the continuously-connected design, the
handwheel can act as a high or low-limit stop. By
effectively isolating the actuator stem from the actuator,
the
continuously-connected
handwheel
permits
positioner and actuator maintenance without interruption
of service.

Other advantages characterize side-mounted design:

The side-mounted handwheel features a highly visible,

neutral-position indicator and comes standard with a
locking bar.

1. The pneumatic spring cylinder can be disassembled

while the handwheel holds the valve in position on
fail-open valves. On fail-closed valves, the valve
must be closed.

A three-way bypass valve is installed in the positioner

supply line to shut off the air supply or neutralize the
pressure across the piston when operating the valve
manually.

12

Linear Actuator
Side-mounted continuously connected handwheels

Table VIII:
Standard Materials of Construction
Size 25, 50, 100 and 200
Part
Material
Yoke
Ductile iron
Actuator stem pin
Stainless steel (hardened)
Crank lever
4130 alloy steel (heat treated)
Crank pivot pin
416 stainless steel
Drive nut
Aluminum bronze*
Handwheel shaft
416 stainless steel*
(ACME screw)
Handwheel
Aluminum/Tubular Steel
Housing
Ductile iron
*Coated with electro film lubricant

Table IX: Side-mounted Continuously Connected Handwheel Specifications

Act.Size

Spud

HW Operator
Size

25
50
50
100(1)
100
200

2.00
2.00
2.62
2.62
2.88-4.75
2.88-4.75

25
25
50
50
100/200
100/200

HW
Diameter Turns per
in mm in mm
9
12
12
18
24
24

230
305
305
455
610
610

5.3
5.3
6.7
6.7
8.0
8.0

.21
.21
.26
.26
.31
.31

Force
Amplification
Factor
44:1
58:1
63:1
95:1
126:1
126:1

Maximum
Stroke
in
mm

Weight
lb
kg

1.5
3.0
3.0
4.0
4.0
4.0

39
85
96
198
290
395

38
76
76
102
102
102

18
39
44
90
132
179

Table X: Top-mounted Continuously Connected Handwheel Specifications

100
200

2.62-4.75
2.62-4.75

100/200
100/200

18
18

455 12
455 12

305
305

128:1
128:1

6.0/8.0 152/203
6.0/8.0 152/203

285
400

129
181

(1) 100 psi (6.89 Bar) maximum supply pressure when 50-inch HW Operator is used on a 100-inch actuator
.
Example: if you apply 50 lb (222 N) rim pull on the 12-inch (305-mm) handwheel of a 50-inch HW operator, then the operator output will be:
50 lb (222 N) rim pull x 63 = 3150 lb (14011 N) output thrust.

13

Linear Actuator
Top-mounted Handwheels
Two types are available: Continuously connected and pushonly. Top-mounted handwheels can be mounted on size 100
and large actuators.

Figure 16: Push-only Handwheel

Turning the handwheel clockwise drives the handwheel
stem down to extend the actuator stem. This handwheel
can be used to limit upward travel.

Figure 15:
Continously-Connected Handwheel
Being highly versatile, they can be used to retract or extend
the stem and act as either a high or low-limit stop. A
Simplicity of the design makes easy placing of wheel in the
neutral position for automatic operation.
A precision-made bevel gear sealed in a weather proof
housing is used in the handwheels to maximize performance.
High-thrust output can be achieved with low torque input on
the hand wheel. For specific applications, consult the factory.
In operation, the handwheel consult the factory on capacities
for specific applications.
In operation, the handwheel is turned counterclockwise to
move the handwheel screw against the stem locknut,
retracting the stem. Moving the handwheel clockwise turns the
handwheel screw down against the shoulder on the stem,
forcing the stem to extend. Returning the handwheel screw to
the neutral position (top of the screw even with a neutral line
as seen through the transparent cap liner) permits operation
of the actuator without interference from the handwheel.
Adjusting the handwheel screw to a position other than
neutral provides a limit stop to limit travel in either direction.

14

Figure 17: Actuator Limit Stops

Simple actuator stops are available to limit either opening
or closing of the valve. Handwheels are not provided,
and locknuts are included to maintain precise
setting of the selected limit stop position.

Linear Actuator
Lever & manual handwheel actuators

Figure 18: Lever Actuators

Sizes
Mascot cylinder-operated lever actuators can be used to
automatically position dampers, louvers, variable pitch fans,
and to make other mechanical adjustments to process
machinery. Lever actuator designs are available for various
sizes of 25, 50 and 100 cylinders

Cyl.Size

Table XI: Lever Actuator Force

25

50

100

Lever
Travel

in mm

80

4 102
5

127

Available Force (lb / N) at

Supply Pressure (Psig / Barg)

5.5

100

6.9

150 10.3

621

2762

776

3452 1164 5178

496

2206

621

2762

932 4146

6 152

414

1842

518

2304

776 3452

7 178

355

1579

444

1975

665 2958

8 203

311

1383

388

1726

582 2589

9 229

276

1228

345

1535

518 2304

10 254

248

1103

311

1383

466 2073

11 279

226

1005

282

1254

423 1882

12 305

207

921

259

1152

388 1726

6 152 1311

5832 1639

7291 2458 10934

7 178 1124

5000 1405

6250 2107 9372

8 203

4373 1229

5467 1844 8203

983

9 229

874

3888 1093

4862 1639 7291

10 254

787

3501

983

4373 1475 6561

11 279

715

3180

894

3977 1341 5965

12 305

656

2918

819

3643 1229 5467

12 305 1428

6352 1852

8238 2913 12958

16 406 1071

4764 1389

6179 2184 9715

20 508

857

3812 1111

4942 1747 7771

24 610

714

3176

4119 1457 6481

926

Figure 19: Manual Handwheels

Whenever a very high degree of performance in manual
operation is required, manual handwheels are available.
Handwheels are of rising stem design and are sized for easy
operation. The handwheel yoke is designed to be
interchangeable with cylinder or diaphragm actuators.

Table XII:
Manual Handwheel Specifications
Hand
Body Size
wheel (Class 150-600)
Size*
inches

25

50

/2 - 2

3-4
6 (Class 150)

100 6 (300 & 600)

thru 8

Handwheel
Diameter
inches (mm)

Thrust
@50 lb (222N)
Rim Pull

9 (STD)

230

2024

9003

12 (OPT)

305

2699 12008

12(STD)

305

2187

18 (OPT)

455

3280 14590

18 (STD)

455

2180

24 (OPT)

610

2907 12931

9728

9697

* Handwheel size is comparable to standard cylinder actuator

size.

15

Linear Actuator
Accessories
Accessories
PT is a position transmitter that exceeds the capabilities of
normal limit switches by providing a continuous, electrical
output signal in proportion to the position of a control valve.
PT operates with two wires on a 4 to 20 mA DC voltage,
ensuring infinite resolution for safe, dependable monitoring
of a control valves position within linearity 1 percent.
Mounted on the actuator, the infinite resolution potentiometer
is easily adjusted with zero and span settings for field
calibration. PT models may contain a potentiometer
and transmitter, two or four limit switches, weather and
explosion proof protection from external conditions is
provided by a rugged aluminum housing.
To electrically indicate open, closed, or intermediate
positions of the valve stroke, limit switches can be mounted
conveniently. Each switch is firmly mounted on the yoke, with
the switch arm contacting an ear on the
stem clamp to sense valve position. Single pole or
double pole, double-throw switches are available in
explosion-proof, hermetically sealed, or weatherproof
housings.

Figure 20: Position Transmitter

To provide fast stroking action with large input signal

changes, flow boosters are used on throttling, control valves.
At the same time the flow boosters allow normal positioner
air flow (and normal actuation) with small changes in the
positioner input signal. Boosters can decrease valve stroking
times by as much as 90 percent depending on actuator size,
packing set and the number used.
Three-way solenoids are used to interrupt an instrument
signal to a pneumatic positioner or to operate a spring
diaphragm valve.
Four-way solenoids are used on spring cylinder actuators
for on-off operation only, insuring fast, positive,
two-directional action. Available in a wide variety of
operation voltages for both AC and DC, solenoids are
standard equipment with a class F coil for continuous duty at
temperatures up to 155 degree F(68 degree C). For higher
temperature service, optional class H coils are available.

Figure 21: Limit Switches

We recommend air filters to the upstream of the positioner

which can handle 150 psi (10.3 bar) supply air pressure and
features high flow capacity. Easy access to the large drip well
permits inspection and replacement of the filter cartridge,
while the integral drain valve allows removal of trapped oil,
moisture and other foreign material. Regulators are usually
not required with Mascot actuators and positioners.

Figure 22: Flow Boosters

16

Linear Actuator
Cylinder Systems
Occasionally, few applications call for greater actuator spring
forces which standard or dual springs can provide. The air
spring is designed to solve many problems where building
special, extra-strong failure springs may be mechanically
difficult and economically not feasible.
Air springs, which provide a locked-up volume of air to drive
the actuator in the failure direction, are used primarily to
close valves upon air failure. A fail-closed Mascot valve is
customarily operated with the flow directed over the plug.
Thus, with the plug on the seat, the upstream pressure acts to
hold the valve closed. Air springs on Mascot valves work only
during the instant of air failure to drive the valve to the closed
position. Process line pressure will insure the valve stays
closed.

Figure 23:
Air Spring Using Cylinder Volume

Air Spring Using Cylinder Volume

Utilizing the stored volume within the cylinder for failure
protection, an air spring is a common fail-safe system. In this
case, the valve positioner is operated as a 3-way valve
positioner to supply air only to the underside of the piston. A
3-way switching valve senses air supply pressure. When
pressure drops to a predetermined value, the switching valve
locks the air on the upper side of the piston to drive the valve
closed. With full air supply pressure to the 3-way switching
valve, an airset regulates the proper amount of air
pressure to the upper side of the cylinder.
Air Spring with External Volume Tank
If the volume on the top of the cylinder is insufficient
to cause the valve to fully stroke upon air failure, an
external volume tank is used to supply the additional
volume required. This system requires a small lock-up
valve in the air supply to each side of the cylinder. The
lock-up valve serving the bottom of the piston operates
to exhaust that side upon failure. The lock-up valve on
the top side of the cylinder admits volume tank air to
the cylinder upon air failure. The volume tank can be
sized as required.

Figure 24:
Air Spring With External Volume Tank

Fail-in-place Lock-up System

The purpose of this system is to hold the actuator in
the last operating position upon air failure. A 3-way
switching valve is used to sense air supply. Upon failure
of the air supply, this valve operates to exhaust the
signal connections to two lock-up valves. These lockup
valves, in turn, hold the existing pressure on both
sides of the piston, thus locking it in place.

Figure 25: Fail-in-place Lock-up System

17

Linear Actuator
Overall dimensions

N
J

(Lifting ring available on sizes 25 and 50 only)

MATCH
LINE

MATCH
LINE

MATCH
LINE

MATCH
LINE

E0083

Standard Cylinder Actuator

With Top-mounted
Continuously Connected Handwheel

18

With Push-only
Handwheel

Linear Actuator
Overall dimensions

Table XIV: Side-mounted Handwheel Dimensions (Inches/mm)

Cylinder Body Size (inches)
Size
Class
Class
150-600
900-2500

Spud
Diameter

25

1/2 to2
1/2 to 2

1/2 to1
1/2 to 1

2.0
2.0

51
51

Acme Screw
Acme Screw

17.9
21.9

454
555

7.3
7.8

186
199

9.0
9.0

229
229

9.4
9.4

238
238

7.3
7.3

185
185

50

3 to4,
6(Class 150)

11/2 to 2

2.6

67

Acme Screw

25.6

650

7.3

184

12.0

305

12.7

322

10.3

262

3 to 4,
11/2 to2
6 (Class 150)
4,
6 (Class 150)
6 to 8,

2.6

67

Acme Screw

28.9

735

8.6

218

12.0

305

12.7

322

10.3

262

2.9

73

Bevel Gear

40.9

1038

9.9

252

18.0

457

15.3

388

13.8

352

10 to 12
(Class 150)
10 to14

3 and 4

3.4

86

Bevel Gear

41.8

1062

10.3 260

18.0

457

15.3

388

14.8

376

6and larger

100

200

Handwheel
Design

G*

4.0-4.8

102-121 Bevel Gear

41.8

1062

10.7 272

18.0

457

15.3

388

14.8

376

4,
6 (Class 150)
6 to 8,
10 to 12
3 and 4
(Class 150)

2.9

73

Bevel Gear

41.6

1057

9.9

252

18.0

457

15.3

388

13.8

352

3.4

86

Bevel Gear

42.6

1082

10.3 260

18.0

457

15.3

388

14.8

376

10 to 14

4.0-4.8

102-121 Bevel Gear

42.6

1082

10.7 272

18.0

457

15.3

388

14.8

376

6 and larger

(Lifting ring available on size 25 and 50 only)

G
OPEN

R
R
MATCH
LINE

With Size 100 and 200

MATCH
LINE

19

Linear Actuator
Overall dimensions

Table XV: Manual Handwheel Dimensions (inches/mm)

Handwheel
Type

Body Size (inches)

Class 150 to 600

Spud Size
(inches)

HA
HB

/2 to 2
3, 4,
6 (Class 150 )
4,
6 (Class 150 )

2.00
2.62/2.88

8.8
13.1
13.3

223
334
339

9.0
12.0
18.0

229
305
457

2.88

17.4
18.0

442
457

18.0
24.0

457
610

6 (Class 300, 600),

8, 10, 12 (Class 150)

3.38

17.5
18.1

445
461

18.0
24.0

457
610

HC
HD

MATCH
LINE

166 / 167, G I D C, Naroda, Ahmedabad : 382330. India

Phone : +91 79 22821619/22823369, Fax : +91 79 22822430
Email : [email protected] / web : www.mascotvalves.com