Flowserve Hydraulic Heavy Duty Actuators User Manual

Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr. Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501 www.flowserve.com Phone: 801 489 2233 Phone: 931 432 4021
Hydraulic Heavy Duty
Installation
1. All actuators are factory lubricated for life, but still should be protected from the elements and stored indoors until ready for use. The ports of the actuator are plugged as supplied from the factory. If actuators are stored for a long period of time prior to installation, the units should be stroked every 3 months to prevent the seals from taking a set.
2. Prior to assembly, manually open and close valve to insure freeness of operation. Be sure valve and Automax Actuator rotate in same direction and are in same position, i.e. valve closed, actuator closed.
3. Check mounting surfaces, stem adapter, and bracket to assure proper fit. Secure valve in closed position with stem vertical. Bolt bracket to valve and place stem adapter on valve stem. Position actuator over valve and lower to engage stem adapter to actuator shaft. Continue to lower until actuator seats on bracket mounting surface. To align bolt holes, it may be necessary to turn or stroke actuator a few degrees and/or adjust actuator travel stops. Bolt actuator to bracket.
4. After consulting valve manufacturer’s recommendations, adjust travel stop bolts of actuator for proper open and closed valve positions. Hydraulically stroke actuator several times to assure proper operation without binding of stem adapter. If actuator is equipped with an Ultraswitch or other accessories, adjust them at this time.
5. To prolong actuator life, use a petroleum based hydraulic oil, such as Mobil DTE 24. Consult factory for seal compatibility with other fluids. For normal temperature ranges (50°-110°F), use an oil with viscosity of 150 SSU at 100°F.
6. Oil should be filtered with a minimum of 40µ filter, depending on other system components and environment.
Travel Stop Adjustments
All actuated valving requires accurate travel-stop adjustments at both ends of stroke to obtain optimum performance and valve seat life. Accumulation of tolerances in adaption of actuators to valves is such that there must be a range of adjustments for both ends of stroke to achieve expected performance.
The Heavy Duty series actuators have travel stop adjustments in both clockwise and counterclockwise directions. The 12 degree overtravel feature provides adjustments from -6 to +96 degrees.
Field Conversion from FCW to FCCW
(For Spring Return Actuators)
1. Dismount actuator from valve.
2. Apply hydraulic pressure to actuator and loosen Stop Bolt Jam nut (17). Back off clockwise Stop Bolt (16) to remove spring preload.
3. Remove hydraulic pressure from actuator.
4. Support Spring Cartridge (11) and loosen all four Spring Cartridge Nuts (41) evenly until all nuts are loose. The spring cartridge does not have to be removed.
5. Remove Position Indicator (44) or any other accessories that may be on output shaft.
6. Remove Bearing Retainer Screws (14) from valve mounting side, and slide Retainer Plate (13) off shaft.
7. The Torque Shaft (20) may now be tapped out of Housing (1) using a soft faced hammer. Use care not to drop shaft or Bearing (12) when they come out.
8. Rotate Torque Shaft (20) end for end and reinstall into Yoke (4), using care to line up shaft with Bearing (12) on opposite end. Push shaft through until shaft bottoms out. Hand pressure only should be needed to reinstall shaft.
9. Reinstall Bearing (12) into housing, ensuring that it is flush with top of housing.
10. Reinstall Bearing Retainer Plate (13) and Screws (14) ensuring that Gasket (37) is in place.
11. Tighten Spring Cartridge Nuts (41) evenly until all four are evenly tightened. See bolt torque chart below.
12. Apply hydraulic pressure to actuator and reset Stop Bolt (16). Never adjust stop bolt against spring force.
13. Reinstall any accessories or position indicator onto Torque Shaft (20).
14. Check actuator for proper operation.
FCD AXAIM00010-00 (AUTO-10) 08/04
©
2004, Flowserve Corporation, Printed in USA
Page 1 of 4
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr. Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501 www.flowserve.com Phone: 801 489 2233 Phone: 931 432 4021
MAINTENANCE INSTRUCTIONS
Disassembly Procedures
1. Disconnect all hydraulic and electrical supplies from actuator.
2. Remove all accessories from actuator and dismount from valve.
Spring Group
Note: Personal Injury may result if Step 2 is
attempted before Step 1 is completed.
1. Apply hydraulic pressure to the cylinder to release spring pressure from Stop Bolt (16). Remove both Stop Bolts (16) and remove hydraulic pressure. This will relieve majority of spring load.
2. The Spring Cartridge (11) is welded as an integral component and cannot be disassembled. To remove from actuator remove Spring Cartridge Nuts (41) and Lockwashers (42). At this point all spring forces are contained within welded cartridge and spring may be removed from body.
Note:Support Spring Cartridge (11) during removal
so as not to damage Piston Rod (3).
Pressure Group
Note: Rod pusher pressure group will not have a
piston. Step 3 is not applicable.
1. Remove Tie Rod Nuts (28), Tie Rods (27), and Endcap (29).
2. Slide Cylinder (23) over and off Piston (24), being careful not to scratch or dent honed and chrome plated surface of cylinder (23).
3. Remove Piston Bolt (25), Piston Bolt Lockwasher (26), Piston (24), and Piston Face Seal (32).
4. Remove Adapter Bolts (43) and carefully slide the Adapter (22) over the Piston Rod (3).
Note: A double acting actuator will have a rod
pusher pressure group on the opposite side of the main pressure group (in place of spring cartridge). Follow disassembly procedure as above, skipping step 3.
Housing (Body Group)
1. Unscrew Inspection Cover Screw (9) with Lock­washers (10) and remove Cover (8) and Cover Gasket (35).
Note: Prior to disassembly of remainder of Body
Group visually check inspection opening to determine whether further disassembly is necessary. If Yoke (4), Yoke Pin (5), and Yoke Rollers (6) are in good condition, do not disassemble further.
2. To remove Piston Rod (3) and Piston Rod Bearing (2), center Yoke in mid- or 45 degree position.
R2 actuators: To remove the Yoke Pin Retainers (7),
use snap ring pliers with 90° tips. Access snap rings through inspection cover opening. Turn Piston Rod (3) to remove Yoke Pin Rollers (6) and Yoke Pin (5) through inspection cover opening.
R3 and R4 actuators: Remove both freeze plugs
located in Housing near Bearing Retainer (13). Through these openings, both Yoke Pin Retainer Rings (7) can be removed. Yoke Pin Rollers (6) can be slipped off Yoke Pin (5). Push Yoke Pin (5) through Piston Rod (3) and out opening in other side of Housing (1).
3. Unscrew Bearing Retainer Bolts (14) and remove Bearing Retainer (13), Retainer Gasket (37), and Torque Shaft Seal (38) from valve mounting side of actuator.
4. Remove Torque Shaft (20) by tapping with a soft­faced hammer. Use care not to drop shaft or Bearing (12) as they come out. After removal of Torque Shaft (20) repeat step 3 on accessory side.
Reassembly Procedures
1. Inspect all parts for wear and replace any worn parts as needed. Normally all seals and gaskets should be replaced when reassembling an actuator.
2. Clean and grease all components with a multipurpose “polymer” fortified grease such as DuBois Chemical MPG-2. (Different greases may be required for low or high temperatures; consult factory).
3. Reverse the disassembly procedures to reassemble. Use the proper torque from the torque chart on the Tie Rod Locknuts (28), the Adapter Bolts (43), the Spring Cartridge Nuts (41), and the Piston Bolt (25). These threads should be lubricated with Locktite Threadlocker 242 or equivalent prior to assembly.
4. See attached drawing which depicts all required spare parts.
5. Test the actuator for smooth operation and hydraulic leakage at service pressure before re-installing.
FCD AXAIM00010-00 (AUTO-10) 08/04
©
2004, Flowserve Corporation, Printed in USA
Page 2 of 4
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr. Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501 www.flowserve.com Phone: 801 489 2233 Phone: 931 432 4021
MODEL A DA SR05 SR07 SR10 SR12 SR15 SR17 SR20 SR22 SR25 C D E F DA
R2HR 19.50 19.50 29.00 30.00 30.00 32.00 38.00 38.00 38.00 40.00 41.00 5.00 0.00 1/4 7.19 5.00 R2HP 20.50 19.50 30.00 32.00 38.00 40.00 41.00 41.00 N/A N/A N/A 5.00 0.50 1/4 7.19 5.00 R3HR 21.00 21.00 34.00 34.00 36.00 39.00 38.00 42.00 41.00 43.00 44.00 5.50 0.00 3/8 8.19 6.75 R3HP 22.00 21.00 34.00 36.00 38.00 41.00 43.00 44.00 45.00 45.00 N/A 6.00 0.00 3/8 8.19 6.75
R3HM 23.00 21.00 36.00 38.00 41.00 44.00 45.00 45.00 N/A N/A N/A 6.50 0.00 3/8 8.19 6.75
R3HL 23.00 21.00 39.00 41.00 44.00 45.00 N/A N/A N/A N/A N/A 7.13 0.00 3/8 8.19 6.75 R4HR 28.50 28.50 N/A 50.00 56.00 59.00 55.00 55.00 56.00 56.00 58.00 6.50 1.00 3/8 10.56 7.19 R4HP 31.00 28.50 50.00 56.00 59.00 55.00 56.00 56.00 58.00 59.00 59.00 7.00 1.00 3/8 10.56 7.19
R4HM 31.00 28.50 56.00 55.00 56.00 57.00 59.00 59.00 N/A N/A N/A 7.50 1.00 3/8 10.56 7.19
R4HL 33.00 28.50 59.00 56.00 57.00 59.00 N/A N/A N/A N/A N/A 8.00 1.00 3/8 10.56 7.19
B
Notes:
1. Actuator is shown in full Clockwise position.
2.
Double Acting:
will result in CW rotation. Pressure at Port DA2 will result in CCW rotation.
Spring Return:
will result in CW rotation. Spring provides CW rotation upon loss of supply pressure.
Pressure at Port DA1
Pressure at Port DA2
MODEL SR05 SR07 SR10 SR12 SR15 SR17 SR20 SR22 SR25 H J K L Vol.
R2HR 9.13 9.13 9.13 9.13 9.13 9.13 9.13 9.13 9.13 3.00 3.25 2.78 5.75 11 R2HP 9.13 9.13 9.13 9.13 9.13 9.13 9.13 9.13 9.13 3.00 3.25 2.78 5.75 19 R3HR 13.25 13.25 13.25 13.25 13.25 13.25 13.25 13.25 13.25 3.00 4.13 4.44 6.81 30 R3HP 13.25 13.25 13.25 13.25 13.25 13.25 14.63 14.63 N/A 3.00 4.13 4.44 6.81 42 R3HM 13.25 13.25 13.25 13.25 14.63 14.63 N/A N/A N/A 3.00 4.13 4.44 6.81 58 R3HL 13.25 13.25 14.63 14.63 N/A N/A N/A N/A N/A 3.00 4.13 4.44 6.81 75 R4HR N/A 14.63 14.63 16.63 16.63 16.63 16.63 16.63 16.63 4.50 5.82 6.50 9.75 87 R4HP 14.63 14.63 16.63 16.63 16.63 16.63 16.63 16.63 N/A 4.50 5.82 6.50 9.75 113 R4HM 14.63 16.63 16.63 16.63 16.63 16.63 N/A N/A N/A 4.50 5.82 6.50 9.75 177 R4HL 16.63 16.63 16.63 16.63 N/A N/A N/A N/A N/A 4.50 5.82 6.50 9.75 255
Piston Bolt (25) (SAE Grade 8 Bolt)*
Actuator Size Bolt Size Torque Range
R2HP 3/4”-10 UNC 271-320 ft.lb. R3HP,R3HM,R3HL 1 1/4”-7 UNC 537-591 ft.lb. R4HP,R4HM,R4HL 1 1/4”-7 UNC 1014-1116 ft.lb.
*Not present in rod pusher actuators
Adaptor Bolt (43) (SAE Grade 5 Bolt)
Actuator Size Bolt Size Torque Range
R2HR,R2HP 5/8”-11 UNC 123-136 ft.lb. R3HR-R4HL 3/4”-10 UNC 217-240 ft.lb.
G
“Vol.” is Swept volume (in3)
BOLT TORQUE
Tie Rod (27) (A311 Stressproof Rod)
Actuator Size Bolt Size Torque Range
R2HR,R2HP 5/8”-11 UNC 117-130 ft.lb. R3HR-R4HL 3/4”-10 UNC 207-229 ft.lb.
Spring Cartridge Stud (ASTM A193 Grade B7)
Actuator Size Bolt Size Torque Range
R2HP 1/2”-13 UNC 64-71 ft.lb. R3HR-R3HL 3/4”-10 UNC 226-249 ft.lb. R4HR-R4HL 1”-8 UNC 546-603 ft.lb.
FCD AXAIM00010-00 (AUTO-10) 08/04
©
2004, Flowserve Corporation, Printed in USA
Page 3 of 4
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr. Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501 www.flowserve.com Phone: 801 489 2233 Phone: 931 432 4021
Parts and Materials
Note: Spring Cartridge is replaced by rod pusher pressure group on DA actuator.
Item Description Material Qty.
1 Housing Ductile Iron 1 2 Piston Rod Bearing Bronze 2 3 Piston Rod Steel/Chrome 1 4Yoke Ductile Iron 1 5Yoke Pin Steel 1 6Yoke Pin Roller Steel 2 7Yoke Pin Retaining Ring Steel 2 8 Inspection Cover Steel 1
9 Inspection Cover Screw Steel 6 10 Inspection Cover Lockwasher Steel 6 11 Spring Cartridge/Rod Cover Gp Steel 1 12 Torque Shaft Bearing Steel 2 13 Bearing Retainer Plate Steel 2 14 Bearing Retainer Screw Steel 8 15 Bearing Retainer Lockwasher Steel 8 16 Stop Bolt Steel 2 17 Stop Bolt Jam Nut Steel 2 18 Stop Bolt Washer Steel 2 19 Yoke Key Steel 1 20 Torque Shaft Steel 1
21* Piston Rod Seal Molythane 1
22 Adapter Steel 1 23 Cylinder Steel/Chrome 1
*Recommended Spare Parts **Not present in rod pusher pressure group
Item Description Material Qty.
24 Piston Steel 1** 25 Piston Bolt Steel 1** 26 Piston Bolt Lockwasher Steel 1** 27 Tie Rod Steel 4 28 Tie Rod Locknut Steel/Nylon 4
29 Endcap Steel 1 30* Pressure Cylinder Seal Nitrile 2 31* Piston Cylinder Seal Molythane 1** 32* Piston Face Seal Nitrile 1 33* Adapter Bolt Thread Seal Nitrile/Steel 4 34* Adapter Gasket-Pressure Side Fiber 1 35* Inspection Cover Gasket Fiber 1
36 Breather Plug Bronze 1 37* Bearing Retainer Gasket Fiber 2 38* Torque Shaft Seal Nitrile 2 39* S.C./Rod Cover Gp Gasket Fiber 1
40 Bolt (Rod Cover Gp) DA only Steel 4
41 S.C./Rod Cover Gp. Nut Steel 4
42 S.C./Rod Cover Gp. Lockwasher Steel 4
43 Adapter Bolt-Pressure Side Steel 4
44 Position Indicator Steel 1
45 Position Indicator Bolt Steel 2
46 Position Indicator Lockwasher Steel 2
Seal Kits
Buna/Molythane - R(Actuator Base Model No.)SKB Viton/Fluoromyte - R(Actuator Base Model No.)SKV ie: Buna Seal Kit for R3HRDA is R3HRSKB
Temperature Ratings
Standard- Buna/Molythane -25°F to 180°F High Temperature - Viton/Fluoromyte 0°F to 300°F
Note: These temperature ranges are for seals only. Hydraulic fluid temperature limitations may apply. Consult hydraulic fluid supplier.
FCD AXAIM00010-00 (AUTO-10) 08/04
©
2004, Flowserve Corporation, Printed in USA
Page 4 of 4
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