Flowserve R5 Actuator User Manual

Automax Valve Automation Systems
3-Position Control/Dribble Control
Installation, Operation and Maintenance Instructions
Flowserve Corporation 765 South 100 East 1978 Foreman Dr. Flow Control Division Provo, Utah 84606 Cookeville, TN 38501 www.flowserve.com Phone: 801 373 3028 Phone: 931 432 4021
SR Limit Switch Method
R5 Actuator
R5 Scotch-Yoke Actuator
The R5 scotch-yoke actuator is an extension to the R-series pneumatic scotch-yoke actuator. The R5 actuator will pro­duce up to 500,000 in.-lb. double acting torque and 225,000 in.-lb. spring end torque.
Installation to Valve
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 actuators should be stroked every 3 months to prevent the seals from taking set. See bulletin B00129 for long term storage instructions.
2. Prior to assembly, manually open and close valve to ensure freeness of operation. Be sure valve and Automax actuator rotate in the same direction and are i
n the same position (i.e., valve closed, actuator closed).
3. Check the mounting surfaces, the stem adaptor, and the bracket to assure proper fit. Secure the valve in the closed position with the stem vertical. Bolt the bracket to the valve and place the stem adaptor on the valve stem. Position the actuator over the valve and lower to engage the stem adaptor to the actuator output bore. Continue to lower until the actuator seats on the bracket mounting surface. In order to align the bolt holes, it may be necessary to turn or stroke the actuator a few degrees and/or adjust the actuator travel stops. Bolt the actuator to the bracket.
Travel Stop Adjustments
All actuated valves require accurate travel-stop adjustments at both ends of the stroke to obtain optimum performance and valve seat life. The accumulation of tolerances in the adaption of actuators to valves is such that there must be a range of adjustments for both ends of the stroke to achieve optimum performance.
The R5 actuator has travel stop adjustments in both the clock­wise and counter-clockwise directions. The 12 degree over­travel feature provides adjustments from -6 to +96 degrees.
Field Conversion from Fail CW to Fail CCW
(for Spring Return Actuators)
The R5 spring return actuator can be converted from fail CW to fail CCW easily. Simply turn actuator over and mount to valve. This is easily accomplished due to identical valve and accessory mounting pattern machined in the body and cover. Follow steps below:
1. Disconnect all air and electrical supplies from actuator.
2. Remove any accessories from top actuator mounting surface.
3. If actuator is mounted to valve dismount actuator from valve.
4. Remove valve mounting bracket from bottom actuator mounting surface.
4. Adjust the travel stop bolts of the actuator for the proper open and closed valve positions, per valve manufacturer’s recommendations. Pneumatically stroke the actuator several times to assure proper operation. The stem adaptor should not bind during operation. If the actuator is equipped with an UltraSwitch or other accessories, adjust them at this time.
5. To prolong actuator life use only clean, dry plant air. Lubricated air is not required, however it is recommended particularly for high cycle applications. Do not use lubricated air with positioners.
B00125-3 (AUTO-8) 3/02
©
2002, Flowserve Corporation, Printed in USA
5. Turn actuator over so that the body cover is now facing down.
6. Install actuator to valve as described above, using valve mounting pattern on body cover. (Be sure actuator and valve are in same position)
7. Reinstall any accessories that were removed from actuator.
8. Check actuator for proper operation.
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Automax Valve Automation Systems
3-Position Control/Dribble Control
Installation, Operation and Maintenance Instructions
SR Limit Switch Method
Maintenance Instructions
Disassembly Instructions
1. Disconnect all air 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 I is completed.
1. Apply air pressure to port DA2 to release spring pressure from the Stop Bolt (10). Remove both Stop Bolts (10) and release air pressure. This will relieve the majority of the spring preload.
2. The Spring Cartridge (47) is welded into an integral component and cannot be disassembled. To remove from actuator, remove Spring Cartridge Adapter Nuts (34) and Lockwashers (35). At this point, all spring forces are contained within the welded cartridge and the Spring Cartridge can be removed from the center body.
3. Before reassembling Spring Cartridge to body, make sure stud threads are clean of any dirt, shavings, or other debris. Clean threads with rag and solvent if required, and lubricate threads with an anti-sieze compound.
Note: Support the Spring Cartridge (47) during removal so as not to damage the Piston Rod (7).
Pressure Group
1. Check that all air is exhausted from the cylinder.
2. Remove the Tie Rod Nuts (37), Tie Rods (36), and the Endcap (30).
3. Slide the Cylinder (32) over and off the Piston (31), being careful not to scratch or dent the honed and chrome plated surface of the cylinder.
4. Remove the Piston Bolt (38) and Piston Bolt Lock­washer (39). Remove the Piston (31) and Piston Face Seal (44).
5. Remove the Adaptor Stud Nuts (34) and Lockwashers (35) and carefully slide the Adapter (29) over the Piston Rod (7).
Housing (Body Group)
NOTE: Spring Cartridge must be removed and air pressure must be removed from cylinders before the cover can be taken off the body.
1. Remove cylinder Piston Rod (7) and spring side Piston Rod (7) from Yoke Block (4).
2. Remove Body Cover Bolts (18) and Lockwasher (19). Remove cover by turning cover jackscrews (40) until cover is separated enough to pry apart.
3. Remove Yoke Pin Rollers (5), Yoke Pin (6), and Yoke Block (4).
4. Lift Yoke (3) out of body bore.
5. Remove Yoke Seals (23) and Yoke Bushing (21).
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. For low temperature units, use Lubriplate Low Temperature grease or equivalent.
3. Reverse the disassembly procedures to reassemble. Use the proper torque from the torque chart on the Tie Rod Locknuts (37), the Adapter Nuts (34), the Spring Cartridge Adapter Nuts (34), and the Piston Bolt (38). These threads should be lubricated with Locktite Threadlocker 242 or equivalent prior to assembly.
4. See parts and materials drawing which depicts all required spare parts.
Test the actuator for smooth operation and air leakage at service pressure before re-installing.
Bolt Torques
Bolt Size Torque Range
Piston Bolt (38) (SAEGr.8 Bolt)
1 1/4”-7 UNC 1014-1116 ft.lb.
Adapter Studs (34) (ASTM Al 93 Gr. B7)
7/8”-9 UNC 364-403 ft.lb.
Tie Rods (36) (ASTM A311 Stressproof)
7/8”-9 UNC 336-371 ft.lb. 1”-8 UNC 503-556 ft.lb. 1 1/4”-7 UNC 503-556 ft.lb.
Note:
14”-16” cylinders have 7/8”-9 Tie Rods 18”-22” cylinders have 1”-8 Tie Rods 24” cylinders have 1 1/4”-7 Tie Rods
How To Order:
R5 22 14 SR1 H V (1) (2) (3) (4) (5) (6)
B00125-3 (AUTO-8) 3/02
©
2002, Flowserve Corporation, Printed in USA
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Automax Valve Automation Systems
3-Position Control/Dribble Control
Installation, Operation and Maintenance Instructions
Flowserve Corporation 765 South 100 East 1978 Foreman Dr. Flow Control Division Provo, Utah 84606 Cookeville, TN 38501 www.flowserve.com Phone: 801 373 3028 Phone: 931 432 4021
SR Limit Switch Method
(1)R5 - R5 Model (2)Cylinder Size (3)Optional Dual Cylinder Size (blank if not present)
14 - 14” Cylinder 16 - 16” Cylinder 18 - 18” Cylinder 20 - 20” Cylinder 22 - 22” Cylinder 24 - 24” Cylinder
Note: larger cylinder is listed first, if present. See T orque
Charts for available combinations.
(4)Fail-Safe Option
DA - Double Acting SRxx Spring Return, where ‘xx’ denotes air pressure
at balanced torque
(5)Override Option
Blank - none H - Hydraulic Override
(6)Temperature Option
Blank - standard -20o to 180oF (nitrile seals)
(7) Trim Option
Blank - standard materials, polyurethane paint E - standard materials, white epoxy coating G - standard materials, gray epoxy coating M - marine trim
Example: R5 with dual 18” cylinders, double acting, with epoxy paint is R5I8I8DAE.
Seal Kits: Standard - R(Actuator Base Model)SKB High Temp - R(Actuator Base Model)SKV Low Temp - R(Actuator Base Model)SKL
Example: High Temp. viton seal kit for R522145R80 is
R52214SKV.
Actuator Weights and Volumes
Actuator Volume Weights (lb.)
Model (in R514 3,233 932 N/A N/A N/A N/A R51414 6,466 1,199 N/A N/A N/A N/A R516 4,222 1,066 N/A N/A N/A 2,040 R51614 7,455 1,333 N/A N/A N/A N/A R51616 8,444 1,467 N/A N/A N/A N/A R518 5,344 1,180 1,938 1,992 2,153 2,260 R51816 9,566 1,581 N/A N/A N/A N/A R51818 10,688 1,695 N/A N/A N/A N/A R520 6,597 1,297 2,035 2,253 2,378 2,559 R52020 13,194 1,929 N/A N/A N/A N/A R522 7,983 1,463 2,276 2,437 2,725 2,888 R52214 11,216 N/A 2,704 2,992 3,274 3,437 R524 9,500 1,730 2,686 2,811 3,155 3,274 R52416 13,722 N/A 3,212 3,556 3,838 N/A
V - high temperature 0o TO 300oF (viton) L - Low Temperature -55o to 180oF (nitrile)
3
) DA SR40 SR60 SR80 SR100
B00125-3 (AUTO-8) 3/02
©
2002, Flowserve Corporation, Printed in USA
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Automax Valve Automation Systems
3-Position Control/Dribble Control
Installation, Operation and Maintenance Instructions
SR Limit Switch Method
Parts and Materials
Item Description Qty Material
1 Body 1 Ductile Iron 2 Cover 1 Ductile Iron 3 Yoke 1 Ductile Iron 4 Yoke Roller 4 Alloy Steel 6 Yoke Pin 1 Carbon Steel 7 Piston Rod 1 Carbon Steel 8 Rod Bushing 1 Bronze
9 Rod Stud 1 Alloy Steel 10 Stop Bolt 2 Alloy Steel 11 Stop Bolt Locknut 2 Carbon Steel/Zn 12 Indicator Plate 1 Carbon Steel 13 Accessory Coupler 1 Carbon Steel 14 Roll Pin 3 Alloy Steel 15 Coupler Bolt 1 Carbon Steel 16 Indicator Plate Bolt 3 Carbon Steel 17 Lockwasher 3 Carbon Steel/Zn 18 Body Cover Bolt 12 Carbon Steel 19 Lockwasher 12 Carbon Steel/Zn 20 Pressure Relief Valve 1 Brass/Nitrile 21 Yoke Bushing 2 Steel/Teflon/Bronze
22* Cover Gasket 1 Gasket Material 23* Yoke Seal 2 Nitrile 24* Stop Bolt Thread Seal 2 Steel/N Nitrile 25* Indicator Plate Gasket 1 Gasket Material 26* Coupler Gasket 1 Gasket Material
27 Indicator 1 Carbon Steel
Item Description Qty Material
28 Indicator Bolt 1 Carbon Steel 29 Adapter 1 Carbon Steel 30 Endcap 1 Carbon Steel 31 Piston 1 Carbon Steel 32 Cylinder 1 Carbon Steel/Chrome 33 Adapter Stud 8 Carbon Steel 34 Adapter Nut 8 Carbon Steel 35 Lockwasher 8 Carbon Steel/Zn 36 Tie Rod 4 Carbon Steel 37 Tie Rod Nut 4 Carbon Steel 38 Piston Bolt 1 Carbon Steel 39 Lockwasher 1 Carbon Steel/Zn
40* Adapter Gasket 1 Gasket Material
41 Piston Rod Seal 1 Nitrile 42* Adapter Bolt Seal 8 Nitrile 43* Endcap Seal 2 Nitrile 44* Piston Bolt Seal 1 Nitrile 45* Piston Seal 1 Nitrile
46 Piston Wear Band 1 Teflon
47 Spring Cartridge 1 Carbon/Alloy Steel
*Recommended spare parts
B00125-3 (AUTO-8) 3/02
©
2002, Flowserve Corporation, Printed in USA
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