Flowserve RG Series Standard Actuator Jackscrew Override User Manual
User Instructions RG Series Standard Actuator - AXENIM0123-00 12/09
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RG Series Standard Actuator
Jackscrew Override
USER INSTRUCTIONS
Sandwich Gearbox Override
Hydraulic Override
FCD AXENIM0123-00 12/09
Installation
Operation
Maintenance
Experience In Motion
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User Instructions RG Series Standard Actuator - AXENIM0123-00 12/09
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INDEX
1 Using Flowserve valves, actuators and acces-
sories correctly
2 Jackscrew Override
2.2 Install jackscrew override onto heavy duty DA
actuator
2.3 install jackscrew override onto existing heavy
duty SR actuator
2.4 Operation –Jackscrew Override
2.5 Automatic Operation
3 Gear Override
3.2 Retrofit Gear Override onto Existing RG Actuator Installation
3.3 Mount a Preassembled Actuator
3.4 Operation
3.5 Restoring Automatic Operation
4 Hydraulic Override
4.2 Install hydraulic override onto existing heavy
duty Spring Return actuator
4.3 Operation –SR Override
4.4 Install hydraulic override on Standard DA
heavy duty actuator
4.5 Operation –DA Override
1 Using Flowserve Valves, Actuators and Acces-
sories Correctly
1.1 General usage
The following instructions are designed to assist in
unpacking, installing and performing maintenance
as required on FLOWSERVE products. Product users and maintenance personnel should thoroughly
review this bulletin prior to installing, operating or
performing any maintenance.
In most cases FLOWSERVE valves, actuators and
accessories are designed for specific applications
with regard to medium, pressure and temperature.
For this reason they should not be used in other applications without first contacting the manufacturer.
1.2 Terms concerning safety
The safety terms DANGER, WARNING, CAUTION
and NOTE are used in these instructions to highlight
particular dangers and/or to provide additional information on aspects that may not be readily apparent.
DANGER: indicates that death, severe personal injury
and/or substantial property damage will occur if proper
precautions are not taken.
WARNING: indicates that death, severe personal
injury and/or substantial property damage can occur
if proper precautions are not taken.
CAUTION: indicates that minor personal injury and/
or property damage can occur if proper precautions
are not taken.
NOTE: indicates and provides additional technical
information, which may not be very obvious even to
qualified personnel.
Compliance with other, not particularly emphasised
notes, with regard to transport, assembly, operation
and maintenance and with regard to technical documentation (e.g. in the operating instruction, product
documentation or on the product itself) is essential,
in order to avoid faults, which in themselves might
directly or indirectly cause severe personal injury or
property damage.
1.3 Protective clothing
FLOWSERVE products are often used in problematic
applications (e.g. extremely high pressures, dangerous, toxic or corrosive mediums). In particular valves
with bellows seals point to such applications. When
performing service, inspection or repair operations
always ensure, that the valve and actuator are depressurised and that the valve has been cleaned and is free
from harmful substances. In such cases pay particular
attention to personal protection (protective clothing,
gloves, glasses etc.).
1.4 Qualified personnel
Qualified personnel are people who, on account of their
training, experience and instruction and their knowledge of relevant standards, specifications, accident
prevention regulations and operating conditions, have
been authorised by those responsible for the safety of
the plant to perform the necessary work and who can
recognise and avoid possible dangers.
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User Instructions RG Series Standard Actuator - AXENIM0123-00 12/09
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1.5 Installation
DANGER: Before installation check the order-no.,
serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.
Do not insulate extensions that are provided for hot
or cold services.
Pipelines must be correctly aligned to ensure that the
valve is not fitted under tension.
Fire protection must be provided by the user.
1.6 Spare parts
Use on l y FLOWS E R V E origin a l spare parts.
FLOWSERVE cannot accept responsibility for any
damages that occur from using spare parts or fastening materials from other manufactures. If FLOWSERVE
products (especially sealing materials) have been on
store for longer periods check these for corrosion or
deterioration before using these products. Fire protection for FLOWSERVE products must be provided by
the end user.
1.7 Service / repair
To avoid possible injury to personnel or damage to
products, safety terms must be strictly adhered to.
Modifying this product, substituting nonfactory parts,
or using maintenance procedures other than outlined
in this instruction could drastically affect performance
and be hazardous to personnel and equipment, and
may void existing warranties. Between actuator
and valve there are moving parts. To avoid injury
FLOWSERVE provides pinch-point-protection in the
form of cover plates, especially where side-mounted
positioners are fitted. If these plates are removed
for inspection, service or repair special attention is
required. After completing work the cover plates must
be refitted.
1.8 Storage
In most cases FLOWSERVE products are manufactured
from stainless steel. Products not manufactured from
stainless steel are provided with an epoxy resin
coating. This means that FLOWSERVE products
are well protected from corrosion. Nevertheless
FLOWSERVE products must be stored adequately
in a clean, dry environment. Plastic caps are fitted
to protect the flange faces to prevent the ingress of
foreign materials. These caps should not be removed
until the valve is actually mounted into the system.
1.9 Valve and actuator variations
These instructions cannot claim to cover all details of
all possible product variations, nor can they provide
information for every possible example of installation,
operation or maintenance. This means that the
instructions normally include only the directions to
be followed by qualified personal where the product
is being used for is defined purpose. If there are any
uncertainties in this respect particularly in the event
of missing product-related information, clarification
must be obtained via the appropriate FLOWSERVE
sales office.
1.10 Unpacking
Each delivery includes a packing slip. When unpacking,
check all delivered valves and accessories using this
packing slip.
Report transport damage to the carrier immediately.
In case of discrepancies, contact your nearest
FLOWSERVE location.
Apart from the operating instructions and the
obligatory accident prevention directives valid in the
country of use, all recognised regulations for safety
and good engineering practices must be followed.
WARNING: Before produ c ts ar e re t urned to
FLOWSERVE for repair or service FLOWSERVE must
be provided with a certificate which confirms that
the product has been decontaminated and is clean.
FLOWSERVE will not accept deliveries if a certificate
has not been provided (a form can be obtained from
FLOWSERVE).
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2 Heavy Duty Jackscrew Overrides
User Instructions RG Series Standard Actuator - AXENIM0123-00 12/09
Jackscrew overrides on Automax heavy duty actuators provide economical, durable method for manually operating the
actuator. The jackscrews are either direct operating or bevel
gearbox driven, to reduce operation effort. The direct operation consists of a rotating screw, threading into the nut which
is fitted on the Torque module/ Spring module, and the hand
wheel directly turns the screw.
The bevel gearbox driven jackscrew, has an arrangement of
rotating nut and a rising screw. The higher thrust requirements for models bigger than 4000 Nm and for the stiffer
springs are met with this type of jackscrew design.
Jackscrews are available on models RG1 through RG5.
2.1 Installation
Automax standard jackscrew overrides are provided as a complete integral component of the heavy duty actuator. Override
units are shipped with the jackscrew assembly mounted to
the actuator and vent valves installed on the pressure module. No additional customer installation is required. Refer Automax Heavy Duty IOM (FCD AXENIM0121) for instructions
on installing Heavy Duty actuator into service.
2.2 Install jackscrew override onto heavy duty DA
actuator (see Fig.: 1)
2.2.4 Use the jackscrew mounting kit and the O-ring from
the DA cover.
2.2.5 Tighten the mounting stud nuts fully, with lock washers from the kit.
2.2.6 Fix the 3 way vent valves supplied in the kit, to both
ports of the pressure module and connect air supply
pressure lines to these valves.
2.2.7 Installation of pressure module side jackscrew requires replacement of std end plate of the pressure
module. Remove tie rod nuts and end plate, and fit in
the jackscrew assembly, supplied preassembled with
the suitable thrust base End Plate. Tighten the tie rod
nuts back on the pressure module. Fix the 3way valve
on the ports.
2.3 Install jackscrew override onto existing heavy
duty SR actuator (see Fig.: 2)
2.3.1 Disconnect air pressure and electrical power from actuator.
2.3.2 Remove the end cover plate on the Spring module, retaining the cover O-ring.
2.2.1 Disconnect air pressure and electrical power from actuator.
2.2.2 Remove the DA end cover plate.
2.2.3 Back off the jackscrew fully in the assembly and
mount the jackscrew assembly on the torque module
end flange, locating the spigot in the Torque module.
2.3.3 Tighten the mounting studs from the mounting kit with
thread lock compound into the spring module end
plate.
2.3.4 Back off the jackscrew fully in the assembly and mount
the jackscrew assembly on the spring module end
plate’s thrust base, locating the spigot in the spring
module end plate.
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Fig.: 1 Install Jackscrew Override (DA)
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