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: [phone] Phone: [phone]

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.

Page 1 of 4

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: [phone] Phone: [phone]

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

Page 2 of 4