Revolutionary

Electric Servo Actuators

for Process Control

Controlling Costs
Excess variability in a typical process
plant creates thousands of dollars of
lost profit due to excessive material
use, reprocessing costs, or wasted
product. Underperforming control
valves and dampers are one of the
main causes of this excess variability.
The performance of these key devices
is crucial to plant efficiency, but unless
your control valves have the ability to
consistently control the process in
perfect response to the closed loop
controller demand, youre losing money.
In order to get that optimum response,
dead time and other non-linearities
need to be eliminated or reduced.
Proper selection and sizing of your
valve is critical, but even more so is
the right selection of actuator for
your valve system.
Valve actuators are a major source of
control loop dead time which includes
friction and backlash. Dead time is
extremely destabilizing for a control
loop, causing limit cycles, overshoot
and slow response. Once a limit cycle
occurs, effective control is lost and
unwanted process variability is created.
The Exlar electric servo actuator
is a revolutionary design that virtually
eliminates dead time and promises
valve manufacturers, OEM's and end
users stable control response in all
conditions for all final control element
applications.

Exlar Replacements for

Pneumatic or Hydraulic
Actuators
Actuator non-linearities and dead
time are a function of many variables
including valve friction, load and control
loop activity. If friction is present with a
pneumatic actuator, the valve will move
too much to overcome it and the
process variable will go too far. Then,
the controller output will reverse
direction and the same thing will
happen again. This presents a problem
especially for small signal changes
(under 1%) which is typical for most
process loops.
The valve actuator also needs to be
stiff enough to resist movement when
the flowing load changes. Pneumatics
can have problems maintaining
stiffness, especially with load changes
like negative gradients.
Exlar actuators continuously hold the
position of the valve stem or shaft
allowing extremely fast response to
the smallest command signal
changes without overshoot even
when friction is present. This results in
improved loop performance and
reduced process variability.
Hydraulic actuators leak, and
introduce significant maintenance
problems. Exlar actuators are a direct
drop-in replacement for many
hydraulic actuators, especially
in the turbine control market.

Conventional
Electric Actuators vs Exlar
Traditional electric actuators use an
electric motor and some form of gear
reduction to move the valve. Typically
for on-off control, some of these
mechanical systems have been
modified for use in full modulating
control, with varying degrees of
success. Many of these electric
actuators can only modulate from
1200 to 3600 starts/hour and have a
minimum position change of 1%.

Exlar actuators incorporate a high

performance brushless servo motor
with a novel mechanism for converting
the motors rotary power and speed to
a highly accurate and reliable linear or
rotary motion. A high performance
closed loop controller yields both the
speed and precise control
unachievable by other electric
actuators. These electric servo
actuators were designed for use on
full modulating valves and dampers.

In addition, these electric actuators

operate slowly, meaning they are not
suitable for rapidly changing process
parameters such as pressure control or
loads that change quickly.

Exlar Actuator Advantages

Actuator
Technology

Response
Time

Resolution

Load Change
Stiffness

Maintenance
Cost

Initial Cost

Exlar

Very Fast

Very High

Very High

Low

Moderate

Pneumatic

Slow

Low

Low

Moderate

Low to
Moderate

Hydraulic

Fast

High

High

High

High

Conventional
Electric

Very Slow

High

Very High

Moderate

Moderate to
High

The Ultimate Electric Actuator Design

Exlar actuators have been used in the most
strenuous military and industrial applications for
years, but have been prohibitively expensive for
process applications until now. Our patented
linear actuator is based on a unique design
for integrating a robust and efficient
threaded roller mechanism into the

interior of a high power density, high

performance brushless servo motor. Combined
with a precise position feedback mechanism,
the result is an all-electric actuator which is
extremely compact, yet delivers superior,
consistent performance for your final
control element needs.

Built-in Positioner (Tritex)

The Tritex actuators from Exlar
include a built in positioner
with a 4-20 mA signal to tell
you the exact stroke position.

Built-in Feedback
Exlar actuators know their exact
position at all times due to the built in
feedback position sensors.

Extreme Accuracy
The Exlar actuators stroke the
valve based on exact position,
not air pressure. Accuracy and
repeatability are easily better
than 0.25%.of span.

Custom Valve Seat

Exlar actuators stroke the valve
based on position but can switch
to torque mode when seating the
valve. This allows a tight cut off.
It also helps with retrofitting valves
that may have some wear.
For new valves, it makes sure
damage isnt done due to
over-forcing the stroke.

100% Torque Available All the Time

Full torque means almost zero
deadband; and friction (stiction) in the
valve stem is no problem for the Exlar
actuator. Current is always available to
the actuator so it will hold its position
no matter what! This provides
excellent process loop control.

Fast Stroke Speeds

Most other electric actuators
are known for being slow a major
disadvantage. Exlar actuators can
close a valve in milliseconds if
needed.

High Stiffness
Similar to hydraulic actuators
without the cost or maintenance
issues. Exlar actuators are extremely
stiff, so dynamic flow problems
like negative gradients arent
a problem.

Proven Solutions
Exlar has delivered thousands of
electric servo actuator solutions around the
world. Process applications range from windbox
dampers to controlling fuel or steam valves on
turbine generators.

Windbox Damper Control

Steam Flow Control

In this GE turbine application, steam flow is controlled
by seven control valves mounted in the turbines steam
chest and operated via cams. The Exlar actuator
replaced a 10 inch single acting hydraulic cylinder
and featured a handwheel for manual operation.

In order to get the best possible damper

control, utility engineers replace existing
windbox dampers with Exlar electric servo
actuators. Each actuator, when supplied with
Exlars all-digital SV positioner, will respond to
command signal changes in less than 5 mSec.
The speed of the response combined with the
dynamic capability of the all-electric actuator
delivers accuracy and repeatability much
greater than pneumatic or induction motor
actuators.

Steam Turbine Control

Valve Control
Exlar provides an excellent solution for
standard control valve applications, including
linear globe valves, rotary ball valves, plug
valves and butterfly valves. Exlar actuators can
be mounted to any valve from any valve
manufacturer.

Many shell mounted control valves are

modulated by a rack and cam arrangement.
This valve operating method utilizes a common
hydraulic cylinder to lift a rack of four to nine
poppet valves in sequence. A fulcrum lever is
used to multiply actuator force. Exlar provided
a direct replacement of the hydraulic cylinder
with an electric servo actuator and positioner.
4

Tritex Linear Actuators

Our premier process control solution, the Tritex Series
linear actuators, integrate a motor, actuator and digital
positioner into one complete compact package. Rugged
and reliable, the Tritex is a high speed, high accuracy,
actuator that is suited for a wide range of demanding
process control applications.
Fully programmable to follow an analog signal representing
either position or force, the Tritex series is perfectly designed
for sliding stem valve applications with thrust needs up to
1250 lbs. Highly accurate position feedback allows the
Tritex to achieve combined repeatability
and hysteresis as low as 0.25%.
The Tritex Series linear actuators
offer extreme mechanical stiffness,
making the actuator's position output
resistant to non-linear or changing
load conditions such as negative
gradients. Exlars Tritex actuator
is a superior solution for all of your
critical valve control applications.

Product Features
Integrated servo motor,
actuator and positioner
24 to 48 VDC and
115 to 230 VAC power
Up to 3,699 lbf thrust
Strokes up to 18 inches

Tritex linear
actuators
are well suited
for dampers
and sliding
stem valves.

Optional Features

Custom valve mounts

Bellows
Manual operation
Class I Div 2 certification

Size

TLM20
TLM30
TLM/X90
TLM/X115

Frame Size
in (mm)

2.25 (57)
3.125 (79)
3.54 (90)
4.52 (115)

Stroke
in (mm)

3
3
3
3

to
to
to
to

18
18
18
12

(51
(51
(51
(51

to
to
to
to

Max. Output Force

lbf (N)

457)
457)
457)
304)

578 (2,571)
1,250 (5,560)
1,347 (5,992)
3,966 (17,642)

Max Speed
in/sec (mm/sec)

33
16
25
25

(.8k)
(.6k)
(.7k)
(.7k)

Tritex Rotary Actuators

The Tritex Series rotary actuators are ideal for operating
quarter-turn, full-turn or multi-turn valves or shaft driven dampers.
Its unique design integrates a high power density, electrically operated
brushless motor with a feedback mechanism, planetary gear reducer
and controller into one compact package. Tritex can be set up to
follow an analog signal representing torque, velocity, or position.
In shaft driven applications, Exlars Tritex rotary actuators
are directly coupled shaft-to-shaft. This eliminates the
ungainly mechanisms usually necessary to convert
the linear motion of pneumatic and hydraulic cylinders
to rotational motion. Gear ratios of 4:1 to 100:1 allow
the power of Tritex to be applied to a broad range
of applications.

Product Features
Integrated servo motor, planetary gearing
and positioner
24 to 48 VDC power
115 to 230 VAC power
Up to 4,000 lbf-in output torque

Optional Features
Custom valve mounts
Manual operation
Class I Div 2 certification

Size

RTM060
RTM090
RTM115

Direct shaft-to-shaft
couplings make the Tritex
rotary actuators perfect for
rotary valve applications.

Frame Size
in (mm)

2.36 (60)
3.54 (90)
4.52 (115)

Max Output Torque

lbf-in (Nm)

Max Speed
(RPM)

603 (68.1)
2,078 (234.8)
4,696 (531.0)

5,000
3,000
3,000

GS Series Linear Actuators

For applications that need higher forces or faster stoke times than available with the Tritex actuator,
the GS Series of actuators combined with the external SV Series Positioner is the perfect solution.

Product Features
Stroke times to 40 in/sec (1018 mm/sec)
Force rating range to 12,000 pounds/force (55,000 N)
Stroke length range up to18 inches (450 mm)

Options

Manual operation
UPS fail-safe
Custom valve mount
Class I Div 2 certification

Exlar
Model

GS20
GS30
GS40
GS50
GS60

Nominal
Frame Size

2
3
4
5
7

(50)
(75)
(100)
(130)
(180)

Max. Stroke
in (mm)

Max. Output Force

lbf (N)

Max Speed
in/sec (mm/sec)

12
18
18
14
10

578
1,347
3,966
8,544
12,389

33
25
37.5
40
40

(300)
(450)
(450)
(450)
(250)

(2,571)
(5,992)
(17,642)
(38,006)
(55,109)

(847)
(633)
(953)
(1,016)
(1,016)

SLG Series Rotary Actuators

For applications that need higher torque than available with the Tritex actuator,
the SLG Series of actuators combined with the external SV Series Positioner is the perfect solution.

Product Features
Integrated servo motor and planetary gear reducer
Higher stiffness than bolt-on gearhead and motor
60, 90 and 115 mm frame size
Up to 4696 lbf-in output torque
4:1, 5:1, 10:1, 16:1, 20:1, 25:1, 40:1, 50:1
and 100:1 reduction ratios
IP65 sealing

Options
Manual operation
UPS fail-safe
Valve mount
Exlar
Model
SLG60
SLG90
SLG115

Nominal
Frame Size
60mm
90mm
115mm
7

Max Output Torque

lb-in (Nm)

Max Speed
(RPM)

603 (68.1)
2,078 (234.8)
4,696 (530.4)

5,000
4,000
3,000

EL Series Explosion Proof Linear Actuator

EL Series linear actuators offer users all of the advantages of Exlars patented
inverted roller actuator GS design in a Class I div 1, Groups B,C or D
package.

Product Features

Explosion proof Class 1 div 1 Groups B,C and D

Stroke length range up to 6 inches
Resolver feedback
24 VDC to 460 VAC

Options
UPS fail-safe
Custom valve mounts

Exlar
Model

Nominal
Frame Size

Max. Stroke
in (mm)

Max. Output Force

lbf (N)

Max Speed
in/sec (mm/sec)

EL30

3 (75)

6 (150.0)

885 (39,362)

25 (635.0)

ER Series Explosion-Proof
Motors and Planetary Gearmotors
For hazardous duty environments, Exlars ER series servo motor rotary actuators
provide an excellent solution. The gearmotor comprises a brushless permanent
magnet motor optimized for use with an integral planetary gear set. Through the
uniform load sharing of several gears acting in concert, planetary gearheads
provide a very compact, reliable solution providing high torque, low backlash
and low maintenance for your rotary valve needs.

Product Features
Integrated servo motor and planetary gear reducer
Higher stiffness than bolt-on gearhead and motor
Explosion proof Class 1 div 1 Groups B,C and D
ATEX Zone 2 Category 3
115 mm frame size
Up to 4696 lbf-in output torque
4:1, 5:1, 10:1, 16:1, 20:1, 25:1, 40:1, 50:1 and
100:1 reduction ratios
24 VDC to 460 VAC

Options
UPS fail-safe
High temperature
Custom valve mount
Exlar
Model

Nominal
Frame Size

Max Output Torque

lb-in (Nm)

Max Speed
(RPM))

ER115

115mm

4,696 (530.4)

3000

FT Series Linear Actuators

The FT Series actuators are suited to operate large valves, dampers and
gates which require longer strokes and higher thrusts. They are an
excellent hydraulic actuator replacement. The FT Series product offering
consists of a roller screw thrust unit and a conventional NEMA or
metric frame motor sized to deliver the force and speed
needed to accomplish the application.

Product Features
Stroke lengths from 6 inches to 8 feet (150 mm to 2.5 m)
Force rating up to 40,000 lbs (177,929 N)
Speed range up to 60 in/sec (1,524 mm/sec)
Multiple motor mounting options
Long life and high load capacity
Shock resistance
IP65 ratings optional

Exlar
Model

Frame Size
in (mm)

Gear
Motor

Max Stroke
in (mm)

Max. output Force

lbf (N)

Max Speed
in/sec (mm/sec)

FT35
FT60
FT80

3.5 (89)
6.0 (152)
8.0 (203)

SLG60
SLG90
SLG115

48 (1,219)
96 (2,438)
96 (2,438)

2,000 (8,896)
10,000 (44,482)
20,000 (88,964)

60 (1,524)
39 (991)
35 (889)

Actuator Accessories and Options

Electrical
Fail-safe

Manual
Override

Additional Options

Bellows rod cover

Rod scrapers/seals
Adjustable position switches
Absolute feedback
Adjustable stroke limiter

Front and
Rear Clevis

SV Series Positioner
Exlars SV Series Positioner is for high force and speed
applications where an externally mounted positioner is required.
Designed specifically for use with Exlar GS and SLG actuators, the
SV Series Positioners operate using standard process control
communication standards. Position is controlled in proportion to an
analog input signal allowing a conventional 4-20 mA interface to
DCS or PLC systems. Alternatively the SV Series can interface digitally
via its RS485 port using ModBus protocol.

Product Features

Position control proportional to analog or digital commands

Analog or digital output proportional to actual position
24 Volt optically isolated digital inputs and outputs
ASCII or Modbus protocol serial communication
High accuracy valve seating algorithm

Current
Exlar
Model

RMS
Amps

SV2008
SV2015
SV2035
SV4020
SV4050

8
15
35
20
50

Peak
Amps

Voltage In
VDC

15
30
70
40
100

24
24
----

10

Voltage In
VAC
115-230 1 or 3 phase
115-230 1 or 3 phase
115-230 1 or 3 phase
380/460 3 phase only
380/460 3 phase only

Exlar Corporation - Headquartered in suburban Minneapolis,

Minnesota, serves a global customer base with an extensive
standard product line and complete engineering support for
custom actuator applications.
Exlar supports a large network of sales representatives in
North America. To find your local dealer, visit our website at
www.exlar.com or call our headquarters at 952-368-3434.
For assistance outside North America, please contact Exlar
direct or one of our worldwide partners listed below.

The Exlar Worldwide Partner Network

North America
Exlar Corporation
952-368-3434
www.exlar.com

Eastern Europe
TG Drives s.r.o.
420 545 234 935
[email protected]

Russia
Proautomatika, LLC
7 495 739 36 05
[email protected]

Australia/New Zealand
Applied Automation, Ltd.
61 7 3713 7000
[email protected]

Finland
SKS Control Oy
358 20 764 7524
[email protected]

South Korea
Macpion Corp., Ltd.
82 32 623 7830
[email protected]

Austria
KML Technologie
43 1 6415030 0
www.kml.at

France
Transtechnik SA
33 3805 50000
[email protected]

Singapore
I-Motion Pte. Ltd.
65-9046-2532
[email protected]

Belgium
ATB Automation nv/sa.
32 2 334 99 99
www.atb-automation.be

Germany
Exlar GmbH
49 6142 17590-0
[email protected]

Servo Drive Technology, Pte. Ltd.

65-9070-1308
[email protected]

Brazil
QG Industrial LTDA
11 4828 72 44
[email protected]

Holland
Mijnsbergen B.V.
31 297 28 58 21
www.mijnsbergen.nl

China
Beijing Reloh International Trade Co.
86-10-8957-8621
[email protected]

India
Servo Controls
91-831-2407501
www.servocontrolsindia.com

Step-Servo Co., Ltd.

86-28-8631-16677
[email protected]

Ireland
Pro2development, Ltd.
353 65 683 9369
[email protected]

JW Motion Controls (Shanghai) Ltd.

021-6999-0151
[email protected]
Columbia
Control de Movimiento Ltda
57 1 428 68 90
[email protected]
Czech Republic
TG Drives s.r.o.
420 545 234 935
[email protected]
Denmark
Delta Elektronik A/S
45 4371 8088
[email protected]

Israel
Suzin Transmission Systems
972-48724148
[email protected]
Italy
Servotechnica, srl
39 0362 492 1
www.servotecnica.it
Japan
JW Motion Controls Limited
045-312-9225
[email protected]

Spain
Mecanica Moderna S.A.
34 93 3000357
[email protected]
Sweden
Cabavo AB
46 8 559 15 330
[email protected]
Switzerland
Servotronic SA
41 22 794 93 26
www.servotronic.ch
Taiwan
Multitech Co., Ltd.
886 226956195
[email protected]
United Kingdom
Intelligent Motion Control, Ltd
44 1327 307600
www.inmoco.com
Venezuela
Digimex Sistemas C.A.
58 243 5511634
[email protected]

Luxembourg
ATB Automation
32 2 334 9999
www.atb-automation.be
Mexico
Urany S.A. de C.V.
442-220-90 89
[email protected]
Norway
Servi Motion Control AS
47 (64) 979714
[email protected]

Exlar Corporation
1470 Lake Drive West
Chanhassen, MN 55317
PH: 952-368-3434
FAX: 952-368-4877
w w w. ex l a r. c o m
5/2008 5K