Dyna-Flo DFR 026 Operation, Parts, And Instruction Manual

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Page 1

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Figure 1 DFR 026

and 571 Control Valve

TABLE OF CONTENTS

General 2 Actuator Assembly 14 Scope 2 Bushing Installation 14 Principles of Operation 2 Mounting Yoke / Hub Assembly 14 Safety Caution 2 Spring / Adjuster / Seat Assembly 15 Speciﬁ cations 3 Diaphragm Rod / Plate Assembly 15 Approximate Actuator Weights - Table 1 3 Lever Assembly & Installation 16 Unpacking 4 Diaphragm Casing Assembly 17 Installation 4 Access Plate Installation 17

Air Piping 4 Principles of Handwheel Operation 18

Actuator Mounting 5 Handwheel Maintenance 18 Spring Adjustment 7 O-Ring Replacement 18

Initial Set 7 Actuator Cross Section - Figure 26 20 Stroke Range 8 Mounting Bolt Torques - Table 3 21

Changing Actuator Style 8 DFR Torque Speciﬁ cations - Table 4 21 Mounting Styles & Positions - Table 2 9 Parts 22 Mounting Orientations - Figure 10 10 Model Builder 24 Actuator Disassembly 11

Valve Removal 11 Casing Disassembly 11 Diaphragm Plate / Rod Remov al / Disassembly 12 Spring / Adjuster / Seat Disassembly 13 Mounting Yoke / Hub Removal 13 Bushing Inspection / Removal 14

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

NOTICE These instructions are meant to be used with the Dyna-Flo DFR Technical Sales Bulletin as they refer to

Figures and Tables therein. If you do not have the Technical Sales Bulletin, contact Dyna-Flo immediately, or visit www.dynaﬂ o.com.

Each control valve is factory checked. Check the calibration for the speciﬁ c application, before a valve or actuator is put into service.

It is the intention of this document to provide users with an accurate guide for safe installation and maintenance of the DFR Actuator. Revisions and updates are available at above mentioned website.

GENERAL

The following instructions are to be thoroughly reviewed and understood prior to installing, operating or performing maintenance on this equipment. Work on this equipment should be performed by experienced personnel. Throughout the manual, safety and caution notes appear and must be strictly followed to prevent serious injury or equipment malfunction.

SCOPE

The actuator conﬁ guration and construction materials were selected to meet particular pressure, temperature, operating medium, and process ﬂ uid conditions. Some material combinations are limited in their pressure and temperature ranges. Do not apply any other conditions to the actuator without ﬁ rst contacting your Dyna-Flo sales ofﬁ ce.

This manual is written to be a practical and useful guide for maintaining the Dyna-Flo DFR Actuator.

PRINCIPLES OF OPERATION (For Top-Mounted Handwheel refer to Page 18)

The DFR actuator works by loading pressure on the top side of the diaphragm (Key 23), this loading pressure moves the diaphragm rod (Key 16) downwards. As the loading pressure is decreased, the spring (Key 14) forces the diaphragm rod upwards.

The spring and diaphragm have been selected to meet a speciﬁ c application requirement, and while in service the actuator should produce full travel of the valve with the diaphragm pressure indicated on the nameplate (Key 33).

If there is no positioner being used with the control valve, a loading device (such as a 4-way switching valv e) must be used. L oading devices do not come equipped standard with the actuator. Refer to appropriate positioner instruction manual as required.

SAFETY CAUTION

Only well trained experienced technicians should perform these procedures. Use safe work practices and lock out procedures when isolating valves and actuators. It is also important to wear the proper protective equipment when performing any installation or maintenance activity. Use only parts and materials rated for the process being used, operating conditions, and environmental conditions products will be used in.

To avoid personal injury or installation damage as a result of the sudden release of process pressure or damage to equipment, do not install the actuator assembly where service conditions could exceed the limits stated in this manual, sales bulletin or on the equipment nameplates. Use government codes, accepted industry standards and good piping practices, and select proper pressure-relieving equipment for protection of your installation. Always be aware of ﬂ ammable process and instrument gas.

Always be aware of the hazards of actuators, especially spring-loaded actuators. Be sure that the actuator is de-energized or in the failed position before performing any maintenance procedure.

These actuators have dangerous pinch points. Never put your hands inside the valve or actuator unless you are certain that the valve or actuator will not suddenly move.

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

SPECIFICATIONS

Actuator Size

026 27 (174) 60 (414)

Material Temperature Capabilities

Standard: -40 to 180

Construction Materials

See Parts list for construction materials.

Contact your Dyna-Flo sales ofﬁ ce for more information and other options.

Valve Shaft Compatibility, inches (mm)

Size 026: 1/2 (12.7) & 5/8”x1/2”

Actuator Dimensions

Refer to Figures 3 & 4 of Sales Bulletin. Refer to Tables 2, 3, & 4 of Sales Bulletin.

Output Torque

Refer to Tables 5 & 6 of Sales Bulletin.

Active Diaphragm

Area in2 (cm2)

F (-40 to 82 oC).

Maximum Casing

Pressure Psig (kPa)

Standard Tubing Connection Size

1/4 inch NPT.

Maximum Shaft Rotation

90 degrees.

Shaft Connection Types

The standard shaft connection is a splined shaft suitable for a Dyna-Flo 570 control valve.

Options

• Manual override

• Reduced rotation output

• Increased tubing connection size

• Travel stops

Diaphragm Casing Volume

Refer to Table 7 of Sales Bulletin.

For more information and other options contact your Dyna-Flo

Actuator Mounting Orientation And Valve Applications

Refer to Figure 10. Refer to Table 2.

Approximate Actuator Weights - lb. (Kg)

Actuator Size

026 30 (14) 41 (19)

Standard Assembly With Top Mounted Handwheel

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sales ofﬁ ce.

P-DFR1M0918A

Table 1

Page 4

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

UNPACKING VALVE FROM SHIPPING CONTAINER

Special Tools Required:

• Properly Rated Lifting Straps (2 – 4 Straps) See Table 1 for actuator weights.

• Lifting Device (Example: Crane)

Check the packing list, verify that the list includes all the materials in the shipping container before unpacking. Valve information can be found on the nameplate (Key 33). Refer to Figure 3 for nameplate location.

When lifting the valve from shipping container, place properly rated lifting straps around the neck of the actuator (See Figure

2) to lift the valve/actuator assembly. Straps should be placed to avoid damage to tubing and other mounted accessories.

INSTALLATION

Before You Begin:

• Read the General and Scope section of this manual (Page 2).

• Read Safety Caution (Page 2).

• Sudden movement of actuator can cause damage or injury. It helps to have the actuator de-energized as long as the valve installation will permit.

• Use safe work practices and lock out procedures before placing valve in-line.

Actuators are typically shipped from factory as an assembly already mounted to the valve. Follow the appropriate valve installation instructions to install the actuator / valve assembly. If the actuator was shipped separately, it will be necessary to mount the actuator on the valve prior to installation, refer to the Actuator Mounting section.

Operating medium must be controlled and directed, if a positioner was not ordered or unavailable, use a loading device such as a 4-way switching valve (not provided with the actuator). For more information on positioner installation and operation, refer to the appropriate positioner instruction manual for your positioner type.

LIFTING STRAP

AIR PIPING

WARNING:

Property damage, environmental harm, and personal injury can result from the use of supply gas other than clean, non-corrosive, oil and moisture free air. Do not exceed the supply pressure indicated on the nameplate (Key 33) located on the actuator.

Before You Begin: Note: Standard actuators accept 1/4” (6 mm) NPT connections.

Piping Installation Steps: 1 Use 3/8” (10 mm) outside diameter SST tubing

(or equivalent) for air lines. Keep length of tubing as short as possible to prevent transmission lag in the control signal.

2 Install the required line vents, valves, drains, seals, and ﬁ lters to the actuator.

Figure 2 Actuator Lifting Suggestions

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

ACTUATOR MOUNTING

Before You Begin:

• Read the General and Scope section of this manual (Page 2).

• Read Safety Caution (Page 2).

• Use safe work practices and lock out procedures.

• Disconnect supply lines (air or gas), electric power, or control signal to the actuator. Sudden movement of actuator can cause damage or injury, make sure actuator will not operate.

• Vent any pneumatic actuator loading pressure.

• Relieve process pressure and drain the process ﬂ uid from up and down stream of valve.

• Be aware of potentially hazardous process material that may be present in-line and in-valve. Isolate the valve from process pressure. Use a bypass or block valve if necessary, or completely shut off the process. Relieve internal valve pressure (refer to the appropriate valve instruction manual).

Lubricants Required:

• Fluid Film® (Key D)

TURN THE HUB (KEY 5) TO ALIGN THE TRAVEL INDICATOR (KEY 6) WITH THE DESIRED ORIENTATION ON THE TRAVEL SCALE (KEY 8).

1 If the valve has been removed from the pipeline, secure the valve assembly in place on a ﬂ at work surface that will support the weight of the combined valve and actuator assembly.

2 Remove any positioners and/or instrumentation installed on the actuator.

3 Remove the access plate (Key 27) by removing the screws (Key 28).

4 Before placing the valve shaft (Key V) into the lever (Key

19), position the valve ball/disc as follows:

For push-down-to-close action (fail open):

Rotate the valve ball/disc into the fully open position.

For push-down-to-open action (fail closed):

Rotate the valve ball/disc into the fully closed position. Note: Refer to the appropriate valve instruction manual.

5 Loosen the lever clamp (Keys 19A & 19B). Refer to Figure 26.

6 Apply Fluid Film® (Key E) to the teeth of the valve shaft

(Key V).

7 Position the hub (Key 5) and travel indicator (Key 6) in the desired position. Note: It may be necessary to pull the valve shaft (Key V) back out of the hub after installation should the hub and travel indicator sit in an undesired position once the shaft is installed.

ALIGN THE MARK ON THE VALVE SHAFT (KEY V) WITH THE MARK ON THE LEVER (KEY 19).

THE POSITION OF THE VALVE BALL/DISC SHOULD MATCH THE POSITION OF THE TRAVEL INDICATOR (KEY 6).

Figure 3 Actuator Mounting

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

OPERATING PRESSURE SUPPLY LINE WITH MAXIMUM OPERATING PRESSURE APPLIED TO ACTUATOR.

UP STOP (KEYS 20 & 21)

VALVE BALL NOT 100% CLOSED.

3231

Figure 4 Actuator/Valve Body Bolting

ACTUATOR MOUNTING (Continued)

8 Slide the actuator onto the valve shaft as shown in Figure

3. Refer to Figures 10 for actuator mounting positions and orientations.

Note: The actuator is typically installed in a vertical orientation. Should the actuator be installed in a horizontal position, then it may be necessary to have external support for the actuator in this position.

9 Once the actuator is installed on the valve shaft in the proper orientation, secure the actuator in place using the mounting bolts (Key 30), lockwashers (Key 31), and hex nuts (Key 32). Refer to Figure 4, and Table 3 for torque values.

10 Center the lever (Key 19) and secure it by tightening the lever clamp cap screw (Key 19A) and jam nut (Key 19B).

11 Loosen the jam nut (Key 21) on the up travel stop. Adjust the up travel stop (Key 20) so that the valve ball/disc is in the fully open or closed position as required. Lock the travel stop in place by re-tightening the jam nut. Refer to Figure 6.

UP STOP

ADJUSTED

TO CLOSE

VALVE

VALVE BALL 100% CLOSED

TRAVEL INDICATOR (KEY 6)

SHOWS VALVE IS PROPERLY

CLOSED

Figure 5 Mounting Adjustment for Push-Down-To-Open

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

ACTUATOR MOUNTING (Continued)

12 Slowly stroke the actuator until the maximum operating

pressure is reached as indicated on the nameplate (Key

33). Note: Use caution when stroking the actuator, avoid dangerous pinch points and equipment damage by keeping appendages and tools away from moving actuator parts.

13 With the maximum operating pressure applied to the actuator, loosen the jam nut (Key 21) and adjust the down travel stop (Key 20, Figure 5) until the valve ball/disc is in the fully closed or open position as required. Lock the travel stop in place by re-tightening the jam nut.

14 Relieve the operating pressure from the actuator casing.

15 Perform the SPRING ADJUSTMENT - Initial Set.

TRAVEL

INDICATOR

(KEY 6)

SHOULD POINT

TO OPEN

• Vent any pneumatic actuator loading pressure.

• Relieve process pressure and drain the process ﬂ uid from up and down stream of valve.

Special Tools Required:

• Flat-head screwdriver or ﬂ at-bladed tool.

INITIAL SET

Refer to the actuator nameplate (Key 33) for the Initial Set. The initial setting is the casing pressure at which the diaphragm (Key 23) begins to move the diaphragm plate (Key 17) and diaphragm rod (Key 16) away from the up travel stop.

The initial setting was selected to meet a speciﬁ c set of service condition requirements. Proper initial setting will ensure that once the actuator and valve are in service, the valve will seat properly and full travel will be achieved within the speciﬁ ed diaphragm casing pressure range.

Note: If the actuator has been disassembled and reassembled, or if service requirements have changed, it will be necessary to perform the following steps for Initial Setting. Refer to the Actuator Mounting section (Page 5) before proceeding with the spring adjustment.

ADJUST DOWN STOP

(KEY 20 & 21)

Figure 6 Mounting Adjustment for Push-Down-To-Close

SPRING ADJUSTMENT

Before You Begin:

• Read the General and Scope section of this manual (Page 2).

• Read Safety Caution (Page 2).

• Use safe work practices and lock out procedures.

• Disconnect supply lines (air or gas), electric power, or control signal to the actuator. Sudden movement of actuator can cause damage or injury, make sure actuator will not operate.

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Figure 7 Access Plate Removal

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

TURNING THE SPRING ADJUSTER (KEY 12) CLOCKWISE (TO THE LEFT) WILL INCREASE THE INITIAL SETTING.

Figure 8 Spring Adjustment

SPRING ADJUSTMENT (Continued)

INITIAL SET (Continued) 1 When performing spring adjustment on the DFR 026, it will

be necessary to have a valve shaft (Key V) inserted into the actuator and to approximately pre-adjust the up travel stop to its desired position. Note: Travel error will occur if this step is not followed.

2 Disconnect any instrumentation attached to the actuator.

3 Remove the screws (Key 28) and the access plate (Key 27).

4 Apply operating pressure to the diaphragm casing, when

the spring is properly adjusted, the diaphragm rod (Key

16) will start to move when the Initial Set pressure (indicated on the nameplate (Key 33) or in Table 5) is reached. Make note whether the diaphragm rod started to move before or after the Initial Set value.

5 Relieve actuator casing pressure.

6 Using a ﬂ at-head screwdriver or a ﬂ at-bladed tool,

adjust the spring adjuster (Key 12) accordingly:

• To increase Initial Setting (increase spring compression) – Turn the spring adjuster to the left (clockwise when viewed from above).

• To decrease Initial Setting (decrease spring compression) – Turn the spring adjuster to the right (counter clockwise when viewed from above).

TURNING THE SPRING ADJUSTER (KEY 12) COUNTER-CLOCKWISE (TO THE RIGHT) WILL DECREASE THE INITIAL SETTING.

7 Repeat Steps 4 – 6 until the Initial Set pressure is reached.

8 Re-install the access plate (Key 27) and screws (Key 28).

9 Check the position of the travel indicator (Key 6), adjust if

necessary.

STROKE RANGE

Should the desired stroking range be unachievable during normal operating conditions with the casing pressure used, it may be possible to adjust the stroking range by making a spring adjustment. A spring adjustment will shift the casing pressure span and either increase or decrease the casing pressure at which the actuator begins its stroke, this will affect the pressure at which the actuator reaches full travel.

Refer to the Initial Set section and adjust the spring adjuster (Key 12) as follows:

To shift the casing pressure span downward – rotate the spring adjuster to the right (counter-clockwise when viewed from above).

To shift the casing pressure span upward – rotate the spring adjuster to the left (clockwise when viewed from above).

CHANGING ACTUATOR STYLE

Refer to the Before You Begin section of the Actuator Mounting instructions (Page 5).

Mounting Styles A and D Style A is right-hand mounted and Style D is left-hand

mounted, in all other ways Styles A and D are identical. Refer to Figure 10.

Mounting Styles B and C Style B is right-hand mounted and Style C is left-hand

mounted, in all other ways Styles B and C are identical. Refer to Figure 10.

Note: To convert a Style A or D into a Style B or C actuator, the actuator must ﬁ rst be separated from the control valve. Refer to Steps 1-4 of the Disassembly Section and 1-2 of Valve Removal Section (Page 11).

Refer to Figure 9.

1 Remove the machine screws (Key 10) and travel scale/hub assembly (Keys 5, 6, 7, 8, & 9).

2 Remove the cap screws (Key 4) and mounting yoke (Key

3).

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

CHANGING ACTUATOR STYLE (Continued)

3 Swap the position of the travel scale/hub assembly (Keys 5, 6, 7, 8, & 9) and mounting yoke (Key 3) as shown in

Figure 9. Install the travel scale/hub assembly on the opposite side of the actuator using the machine screws (Key 10).

4 Place the mounting yoke (Key 3) in the desired orientation (refer to Table 2 and Figure 10 for Mounting Positions) on the opposite side of the actuator. Secure the mounting yoke in place using the cap screws (Key 4), tighten the cap screws to the torque speciﬁ cation listed in Table 4.

5 Once an actuator has been converted to a different mounting style, the actuator must be re-adjusted. Refer to the Spring Adjustment section of this manual.

STYLE B / CSTYLE A / D

Model DFR Mounting Styles and Positions

Figure 9 Changing Actuator Style

Table 2

Mounting Action Model 570 Series Valves Model 660 Butterﬂ y Valve

Right Hand Fail Open Style A Style B Right Hand Fail Close Style B Style A

Left Hand Fail Open Style C Style C Left Hand Fail Close Style D Style D

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Page 10

Left Hand Mount

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Flow

STYLE A

POSITION 1

STYLE B

Right Hand Mount

STYLE D

POSITION 1 POSITION 1

STYLE C

POSITION 1

Flow

RIGHT-HAND MOUNTING LEFT-HAND MOUNTING

Figure 10 Mounting Orientation and Valve Applications

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

ACTUATOR DISASSEMBLY

Before You Begin:

• Read the General and Scope section of this manual (Page 2).

• Read Safety Caution (Page 2).

• Use safe work practices and lock out procedures.

• Disconnect supply lines (air or gas), electric power, or control signal to the actuator. Sudden movement of actuator can cause damage or injury, make sure actuator will not operate.

• Vent any pneumatic actuator loading pressure.

• Relieve process pressure and drain the process ﬂ uid from up and down stream of valve.

Figure 11 Valve Removal

Special Tools Required:

• Soft tip felt marker.

• Flat-head screwdriver or ﬂ at-bladed tool.

• Split-ring pliers.

1 If the actuator has been removed from the valve or the actuator/valve assembly has been removed from the pipeline, secure either assembly in place on a ﬂ at work surface that will support the weight.

2 Remove any instruments installed on the actuator.

3 Observe the position of the travel indicator (Key 6). Using

a soft tip felt marker, mark the position of the travel indicator on the travel scale (Key 8).

4 Relieve all operating pressure and/or rotate the handwheel counterclockwise to remove spring tension if a handwheel is installed. For Handwheel Maintenance refer to Page 18.

VALVE REMOVAL

For complete actuator disassembly, it will be necessary to separate the actuator from the control valve in order to remove the lever (Key 19). If maintenance is being performed on the diaphragm (Key 23) or handwheel, separating the actuator from the valve will not be necessary.

1 Remove the mounting hex nuts (Key 32), lockwashers (Key

31), and mounting bolts (Key 30).

2 Separate the actuator from the valve and slide the actuator off of the valve shaft (Key V).

CASING DISASSEMBLY 1 For maintenance purposes: To replace the diaphragm

(Key 23), it will not be necessary to remove spring tension when removing the upper casing (Key 24), the up travel stop will hold the spring in place. Proceed to Step 4.

For complete actuator disassembly: Proceed as follows.

2 Remove the screws (Key 28) and the access plate (Key

27). Refer to Figure 7.

3 Using a ﬂ at-head screw driver or ﬂ at-bladed tool, remove all spring tension by turning the spring adjuster (Key 12) counter-clockwise (to the right) as shown in Figure 8.

4 Remove the casing cap screws (Key 25) and hex nuts (Key 26).

5 Remove the upper casing (Key 24) and diaphragm (Key

23).

6 Inspect all parts for damage or wear, replace or repair parts as necessary. All soft parts such as diaphragm should be replaced.

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

5 Using a 5/16” socket bit, remove the socket head cap

screw (Key 18) from the diaphragm rod (Key 16) and separate the diaphragm plate (Key 17) from the diaphragm rod.

6 If necessary, unscrew the rod end bearing (Key 15) from the diaphragm rod (Key 16).

7 Inspect and repair or replace parts as necessary.

Figure 12 Diaphragm Casing Disassembly

ACTUATOR DISASSEMBLY (Continued)

DIAPHRAGM PLATE/ROD REMOVAL/DISASSEMBLY 1 Remove the cap screw (Key 22) from the diaphragm rod

(Key 16) and lever (Key 19).

2 Remove the lever (Key 19) from inside the actuator housing (Key 1).

3 Remove the diaphragm plate assembly (Keys 15, 16, 17, &

18) from the actuator housing (Key 1).

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Figure 13 Diaphragm Plate Assembly Removal

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Figure 14 Diaphragm/Rod Plate Disassembly

ACTUATOR DISASSEMBLY (Continued)

SPRING / ADJUSTER / SEAT DISASSEMBLY 1 Remove the spring (Key 14) from the actuator housing

(Key 1).

2 Remove the spring seat (Key 13) and spring adjuster (Key

12). Separate the spring seat from the spring adjuster if necessary.

3 Remove the thrust washer (Key 11).

Figure 15 Spring / Adjuster / Seat Removal

3 Using split-ring pliers, remove the retaining ring (Key 9)

from the hub (Key 5). Slide the travel scale (Key 8) off the hub.

4 Remove the machine screws (Key 7) from the hub (Key

5) and remove the travel indicator (Key 6).

4 Inspect all parts for damage or wear, replace or repair parts as necessary.

MOUNTING YOKE / HUB REMOVAL 1 Remove the cap screws (Key 4) and mounting yoke (Key

3).

2 Remove the machine screws (Key 10) and slide the hub/ travel scale assembly (Keys 5, 6, 7, 8, & 9) out of the actuator housing (Key 1).

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BUSHING INSPECTION / REMOVAL 1 Inspect the bushings (Key 2) in the actuator housing (Key

1).

2 If the bushings look worn or damaged and need to be replaced, carefully press the bushings out of the housing from the inside pushing out.

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

293

Figure 16 Mounting Yoke Removal

ACTUATOR ASSEMBLY

Before You Begin:

• The Assembly section of this manual assumes that the actuator has been completely disassembled prior to assembly.

• Read the General and Scope section of this manual (Page 2).

• Read Safety Caution (Page 2).

• Use safe work practices and lock out procedures.

Special Tools Required:

• Flat-head screwdriver or ﬂ at-bladed tool.

• Regulated air supply (to stroke the actuator).

• Vise grips.

• Split-ring pliers.

• 5/16” socket bit.

Lubricants Required:

• Permatex® Nickel Anti-Seize or equivalent (Key A)

• Lubriplate® No. 105 Grease or equivalent (Key C)

• Fluid Film® (Key D)

• Loctite® 242® (Key E)

Note: These assembly instructions assume that the control valve is still installed in the pipeline. If the control valve has been removed from the pipeline, make sure that the valve is placed securely on a ﬂ at work surface or clamping device that

9 10

can support the combined weight of the control valve/actuator assembly.

BUSHING INSTALLATION 1 If the bushings (Key 2) have been removed from the

housing (Key 1) insert new bushings. Bushings may need to be pressed into place.

MOUNTING YOKE / HUB ASSEMBLY

Figure 17 Hub Removal

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1 Refer to Figure 10 and Table 2, determine the desired mounting style and orientation. Install the mounting yoke (Key 3) onto the actuator housing (Key 1) with the cap screws (Key 4). Refer to Table 4 for cap screw torque values.

2 Install the travel indicator (Key 6) onto the hub (Key 5) using the machine screws (Key 7).

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

9 7

Figure 18 Hub Installation

ACTUATOR ASSEMBLY (Continued)

MOUNTING YOKE / HUB ASSEMBLY (Continued) 3 Slide the travel scale (Key 8) onto the hub (Key 5) and

secure it in place using the retaining ring (Key 9) and split-ring pliers.

4 Install the hub/travel scale assembly (Keys 5, 6, 7, 8, &

9) onto the actuator housing (Key 1) using the machine screws. Note: The hub and travel indicator can be rotated into the proper orientation at any time before the valve shaft is installed.

Figure 19 Spring / Adjuster / Seat Assembly

SPRING / ADJUSTER / SEAT ASSEMBLY 1 Lubricate the thrust washer (Key 11) with Lubriplate® No.

105 Grease (Key C) and install it into the actuator housing (Key 1).

2 Apply Permatex® Nickel Anti-Seize (Key A) to the threads of the spring adjuster (Key 12). Thread the spring seat (Key 13)all the way onto the spring adjuster.

3 Install the spring adjuster/spring seat assembly (Keys 12 &

13) over top of the thrust washer (Key 11) inside the actuator housing (Key 1).

4 Install the spring (Key 14) onto the spring seat (Key 13) inside the actuator housing (Key 1).

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DIAPHRAGM ROD/PLATE ASSEMBLY 1 If the rod end bearing (Key 15) was removed from the

diaphragm rod (Key 16), thread the diaphragm rod back into the rod end bearing.

2 Apply anti-seize compound (Key A) to the threads of the socket-head cap screw (Key 18).

3 Attach the diaphragm plate (Key 17) to the diaphragm rod (Key 16) using the socket-head cap screw (Key 18) and a 5/16” socket bit.

4 Torque the socket-head cap screw (Key 18) to the value listed in Table 4.

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Figure 21 Lever Assembly / Installation

Figure 20 Diaphragm Plate/Rod Assembly

ACTUATOR ASSEMBLY (Continued)

LEVER ASSEMBLY AND INSTALLATION 1 If the set screws (Key 20) and jam nuts (Key 21) were

removed from the lever (Key 19), re-install them as shown in Figure 21.

2 Place the lever assembly (Keys 19, 20, & 21) inside the actuator housing (Key 1) as shown in Figure 21.

3 Place the diaphragm plate assembly (Keys 15, 16, 17, &

18) into the actuator housing (Key 1). Be aware of the orientation of the rod end bearing (Key 15), the hole in the rod end bearing should be in alignment with the hole in the lever (Key 19). Refer to Figure 22.

4 Apply Loctite® 242® (Key E) to the threads of the cap screw (Key 22). Using the cap screw, connect the rod end bearing (Key 15) to the lever (Key 19). Torque the cap screw to the torque value listed in Table 4.

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Figure 22 Lever Installation

P-DFR1M0918A

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

ACTUATOR ASSEMBLY (Continued)

DIAPHRAGM CASING ASSEMBLY 1 Place the diaphragm (Key 23) over the diaphragm plate

(Key 17), align the holes in the diaphragm with the holes in the actuator housing (Key 1).

2 Set the upper diaphragm casing (Key 24) on top of the actuator housing (Key 1), align the holes. Note: If a Top-Mounted Handwheel is being used, it is advised that the position of the stem (Key 103) be adjusted so that the device will place no downward pressure on the actuator spring (Key 14).

3 Install the cap screws (Key 25) through the diaphragm casing (Keys 24).

4 Install the hex nuts (Key 26) and tighten them evenly in an alternating crisscross pattern to the torque speciﬁ cation listed in Table 4.

5 Mount the actuator to the valve before performing the SPRING ADJUSTMENT - Initial Set (Page 7).

ACCESS PLATE INSTALLATION

1 Install the access plate (Key 27) using the machine screws (Key 28).

28 27

Figure 23 Diaphragm Casing Assembly Figure 24 Access Plate Installation

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P-DFR1M0918A

Page 18

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

PRINCIPLES OF OPERATION AND ADJUSTMENT – HANDWHEEL

TOP-MOUNTED HANDWHEEL

DFR Top-Mounted Handwheel assemblies are attached to a modiﬁ ed upper diaphragm casing (Key 24A) using cap screws (Key 109). To lock the handwheel in position, tighten the lock nut (Key 104) into the body (Key 105) of the handwheel.

To compress the spring (Key 14) and move diaphragm rod (Key 16) down:

Turning the handwheel (Key 102) clockwise into the upper diaphragm casing (Key 24A) forces the pusher plate (Key 112) onto the diaphragm (Key 23) and diaphragm plate (Key 17) to compress the spring.

To decompress the spring (Key 14) and allow diaphragm rob (Key 16) to move up:

Turning the handwheel (Key 102) counterclockwise away from the upper diaphragm casing (Key 24A) allows the actuator spring to decompress which moves the diaphragm plate (Key 17) and diaphragm rod (Key 16) upward.

Note: If the valve is push-down-to-close, full valve opening can be restricted by adjusting the handwheel to the desired position.

102

111

109

104

107B

112

100

110113

105

101

103

108

24A

If the valve is push-down-to-open, full valve closing can be restricted by adjusting the handwheel to the desired position.

Figure 25 DFR Top-Mounted Handwheel

MAINTENANCE - TOP-MOUNTED

MAINTENANCE - TOP-MOUNTED HANDWHEELS

Maintenance should be performed if actuator loading pressure appears to be leaking from either the handwheel or travel stop. It is possible that either of the o-rings (Keys 107 & 108) need to be replaced.

Before disassembling the handwheel or travel stop to replace o-rings, perform the following steps:

• Lubricate the threads of the stem (Key 103) with white petroleum grease, stroke the device a couple times after application.

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HANDWHEELS O-RING REPLACEMENT

Before You Begin:

• Read the General and Scope section of this manual (Page 2).

• Read Safety Caution (Page 2).

• Use safe work practices and lock out procedures.

• Disconnect supply lines (air or gas), electric power, or control signal to the actuator. Sudden movement of actuator can cause damage or injury, make sure actuator will not operate.

• Vent any pneumatic actuator loading pressure.

• Relieve process pressure and drain the process ﬂ uid from up and down stream of valve.

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Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Special Tools Required:

• Flat-head screwdriver or ﬂ at-bladed tool.

Lubricants Required:

• Dow Corning Molykote® 111 or equivalent (Key B)

• Lubriplate® No. 105 Grease or equivalent (Key C)

1 Rotate the handwheel counterclockwise and remove any spring tension applied by the handwheel.

2 Relieve any actuator spring (Key 14) compression by turning the spring adjuster (Key 12) clockwise until it stops turning. Refer to Step 2 & 3 of the Casing Disassembly Section.

3 Refer to the Actuator Disassembly – Casing Disassembly Steps 1, 3 & 4 and remove the upper diaphragm casing (Key 24A).

4 Separate the handwheel assembly from the upper diaphragm casing (Key 24A) by removing the cap screws (Key 109).

5 Loosen the lock nut (Key 104).

6 Remove the hex nut (Key 100), ﬂ at washer (Key 101), and

handwheel (Key 102).

7 Rotate the stem (Key 103) clockwise out of the body (Key

105).

8 Remove and replace the o-rings (Keys 107 & 108). Lubricate the new o-rings with sDow Corning Molykote 111 (Key B).

9 Re-assemble the handwheel and diaphragm casing. Refer to the Actuator Assembly section (Page 11).

10 Perform spring adjustment.

Dyna-Flo Control Valve Services Ltd.

Phone: 780 • 469 • 4000 Toll Free: 1 • 866 • 396 • 2356 Fax: 780 • 469 • 4035 Website: www.dynaﬂ o.com

P-DFR1M0918A

Page 20

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

1817

Dyna-Flo Control Valve Services Ltd.

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19A

Figure 26 Actuator Cross Section

19A

19B

P-DFR1M0918A

19B

Page 21

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Torque Speciﬁ cations for Valve Mounting Bolts (Key 30)

Table 3

Valve Shaft Diameter

1/2 Inch &

5/8 Inch x 1/2 Inch

DFR Torque Speciﬁ cations

Mounting Bolts

lbf-ft N

65 88

•m

Table 4

Key Bolt Size

4 3/8”-16 25 34

18 5/16”-18 16 22

21 5/16”-18 20 27

22 5/16”-18 16 22

25 3/8”-24 20 27

lbf-ft N•m

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Torque

P-DFR1M0918A

Page 22

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

Parts

Key Description Part Number 1 Housing Assembly, Cast Iron

Includes Bushings (Key 2) 46A4670X01D

2 Bushing, Bronze, 2 Required DFR0260001D 3 Mounting Yoke, Steel

1/2 inch shaft 36A4658X01D

4 Cap Screw, Mounting Yoke

4 Required

5 Hub, Aluminum 26A4676X01D 6 Travel Indicator, SST 28A8529X01D 7 Machine Screw, Travel Indicator

SST, 4 Required 1V74353522D

8 Travel Scale, SST 28A8527X01D 9 Retaining Ring, Steel 1A90292899D 10 Machine Screw, Travel Scale Refer to Key 7 11 Thrust Washer, Steel 16A4681X01D 12 Spring Adjuster, Cast Iron 26A4665X01D 13 Spring Seat, Zinc Plated Steel 26A4664X01D 14 Spring Refer to Table 5 15

16 Diaphragm Rod Assembly, Zinc Plated Steel

17 Diaphragm Plate, Cast Iron 33B9686X01D 18 Socket Head Cap Screw, Diaphragm Plate

19 Lever, WCC 34B8600X01D 19A Cap Screw, Lev er, Zinc Plated Steel H5CZ516.100 19B Jam Nut, Lever, Zinc Plated Steel NHJCZ516 20 Set Screw, Travel Stop,

21 Jam Nut, Travel Stop

22 Cap Screw, Lever/Diaphragm Rod H5CZ516.034

23 Diaphragm, Nitrile 26A4668X01D 24 Upper Diaphragm Casing, Steel DF10408X01D 25 Cap Screw, Diaphragm Casing,

26 Hex Nut, Diaphragm Casing

27 Access Plate, Steel 26A4655X01D 28 Machine Screw, Access Plate

Rod End Bearing, Zinc Plated

Steel

Includes Rod End Bearing 26A4651X01D

Steel SCC516.100

18-8 Steel, 2 Required 16A4667X02D

Zinc Plated Steel, 2 Required NHJC516

Zinc Plated Steel

Zinc Plated Steel, 12 Required H5FZ38.114

Zinc Plated Steel, 12 Required NHFZ38

Zinc Plated Steel, 4 Required 1C12252898D

H5CZ38.100

Refer to Key 16

Key Description Part Number 29 Elbow Vent, Plastic Y602-12D

30 Mounting Bolt, Actuator / Valve, Zinc Plated Steel

Mounting bolts are included with the valve assembly.

31 Lockwasher, Actuator / Valve, Zinc Plated Steel

lockwashers are included with the valve assembly.

32 Hex Nut, Mounting Bolt, Zinc Plated Steel

Hex nuts are included with a 570 valve assembly.

33 Nameplate NAMEXSRACTD

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P-DFR1M0918A

Page 23

Model DFR 026 Rotary Actuator

Operation, Parts, and Instruction Manual

PARTS - DFR Handwheel Parts List

KEY PART DESCRIPTION PART NUMBER

100 NYLOCK HEX NUT DFO30109X1D 101 FLAT WASHER DF060110X1D 102 HANDWHEEL DFO40106X1D 103 STEM DFR40102X1D 104 LOCK NUT DFO60107X1D 105 BODY DFR40201X1D 107 O-RING, STEM 1D23750699D 108 O-RING, BODY/CASING 1D26730699D 109 CAP SCREW, BODY/CASING (6 REQUIRED) 1A36842405D 110 PUSHER PLATE RETAINER DFO60111X1D 111 SOCKET HEAD CAP SCREW, PUSHER PLATE RETAINER (3 REQUIRED) DFO20114X1D 112 PUSHER PLATE DFO60103X1D 113 SPRING PIN DFO60115X1D 24A UPPER DIAPHRAGM CASING DF10410X01D

DFR Spring (Key 6) Information

Casing Pressure Initial Spring Compression

Push-Down-To-Open

Psig Bar

0 - 18 0 - 1.2 3.9 27 3.0 21 16A4660X01D

0 - 33 0 - 2.3 6.8 47 3.0 21 16A4659X01D

(Fail Closed)

Psig kPa Psig kPa

Push-Down-To-Close

(Fail Open)

Part Number

Parts Ordering

Whenever corresponding with Dyna-Flo about a DFR actuator, refer to the nameplate (Key 33) for the serial number of the unit. Please order by the complete part number (as given in the following parts list) of each part required.

Table 5

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P-DFR1M0918A

Page 24

Model DFR 026 Rotary Actuator

MODEL NUMBERING SYSTEM

SAMPLE PART NUMBER: DFR-026-C-04S1-C-RA1

026 SIZE 026

C FAIL CLOSED O FAIL OPEN N NOT APPLICABLE

- DFPS-01 (STANDARD PAINT) 2 DFPS-02 (SEVERE SERVICE PAINT)

3 DFPS-03 (HI-TEMP PAINT)

SHAFT CONNECTION SIZE

04 1/2 INCH

SHAFT CONNECTION TYPE

S SPLINED (STANDARD)

OPERATING PRESSURE RANGE (PSIG)

1 0 - 18 3 0 - 33

- STANDARD S SST BOLTING

SPRING RANGE (SEE TABLE 7)

C 0-18 PSIG RANGE, 0-33 PSIG RANGE H 0-33 PSIG RANGE

HANDWHEELS / TRAVEL STOPS

- NONE (STANDARD) T TOP-MOUNTED HANDWHEEL

R RIGHT HAND MOUNT L LEFT HAND MOUNT A STYLE A, B, C, D - REFER TO FIGURE 10

1 POSITION A, B, C, D - REFER TO FIGURE 10 (RIGHT HAND POSITION 1 IS STANDARD)

N NOT APPLICABLE

ACTUATOR

FAIL POSITION

PAINT

OPTIONS

MOUNTING

026

RA1

DFR - - - - -

Our Commitment to Quality

Dyna-Flo is committed to continuous improvement. While all efforts have been made to ensure the accuracy of the content in this document, modiﬁ cations or improvements to the information, speciﬁ cations, and designs may occur at any time without notice. This document was published for informational purposes only, and does not express or imply suitability, a warranty, or guarantee regarding the products or services described herein or their use or applicability.

Neither Dyna-Flo Control Valve Services Ltd., nor any of their afﬁ liated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for selection, use and maintenance of any product remains with the purchaser and end-user.

Dyna-Flo Control Valve Services Ltd.

Phone: 780 • 469 • 4000 Toll Free: 1 • 866 • 396 • 2356 Fax: 780 • 469 • 4035 Website: www.dynaﬂ o.com

P-DFR1M0918A