Series 39 Pneumatic Actuator

Series 39 Pneumatic Actuator
WCAIM2036
Worcester Controls
(Part 17430)
Series 39 Pneumatic Actuator
Installation, Operation and Maintenance Instructions
DESCRIPTION
Worcester Controls/McCANNA Series 39 actuators are pneumatic
quarter-turn valve actuators. The design utilizes a double-rack, singlepinion concept, with each rack integrally cast to a piston. On sizes
10-50, both pistons are supported and centered by large, stainless
steel guide rods. In double-acting units, both pistons are pressurized
on both strokes of the actuator.
Standard units feature an extended top shaft for manual override
capabilities and a completely modular design which allows simple
attachment of a variety of accessories. All units feature an integral
solenoid control block which properly directs supply air to the
actuator. On double-acting actuators, the solenoid control block
provides independently adjustable speed control for both opening and
closing strokes of the actuator. On spring-return actuators only the
spring stroke is adjustable.
a WARNING: SERIES 39 ACTUATORS ARE ELECTRO-MECHANICAL
DEVICES SUBJECT TO NORMAL WEAR AND TEAR. ACTUATOR LIFE
IS DEPENDENT UPON APPLICATION AND ENVIRONMENTAL
CONDITIONS. IF APPLIED IN HAZARDOUS SERVICES SUCH AS, BUT
NOT LIMITED TO, MEDIA TEMPERATURE EXTREMES, TOXINS,
FLAMMABLES, OR OTHER SERVICES WHERE IMPROPER OR
INCOMPLETE OPERATION COULD PRODUCE A SAFETY HAZARD, IT
IS INCUMBENT UPON THE SYSTEM DESIGNER AND THE USER TO
PROVIDE PROPER WARNING DEVICES SUCH AS TEMPERATURE
SENSORS, OXYGEN SENSORS AND FLOW SENSORS. FLOWSERVE
ALSO RECOMMENDS THAT THE OPTIONAL AUXILIARY LIMIT
SWITCHES BE USED FOR MONITORING AND/OR ELECTRICAL
INTERLOCK.
CAUTION: When actuator is installed in outdoor conditions, water
can enter the exhaust holes of the double-acting solenoid block,
and then freeze. Flowserve suggests a cover be used, or mount the
actuator such that the solenoid block is upside down. See
paragraph D.1.f.1.
Do not install 39S (spring-return) models with air connection in end
cap or with integral solenoid vertical, if water spray or rainfall can
occur in area. End cap or solenoid vent port will allow water to
accumulate in spring chambers.
Flowserve recommends that all products which must be stored
prior to installation be stored indoors, in an environment suitable
for human occupancy. Do not store product in areas where
exposure to relative humidity above 85%, acid or alkali fumes,
radiation above normal background, ultraviolet light, or
temperatures above 120°F or below 40°F may occur. Do not store
within 50 feet of any source of ozone.
IMPORTANT: INCLUDED IN ALL 39 ACTUATOR ACCESSORY AND
REPAIR KITS IS A REBUILD/ACCESSORY ADDITION LABEL, WHICH
IS TO BE MARKED WITH A PERMANENT MARKER AND THEN
APPLIED TO THE ACTUATOR AFTER AN ACCESSORY KIT HAS BEEN
INSTALLED OR AN ACTUATOR HAS BEEN REPAIRED.
INSTALLATION
NOTE: The Series 39 actuator is normally installed with its major axis
parallel to the pipe line (this is mandatory when mounting actuator to
90° V1 Diverter/Three-Way (D44 and T44) valves and CPT valves).
The actuator can be oriented above, beside or beneath the valve
without affecting its operation.
Sizes 10-35 Rev. R6 actuators may come with an ISO locating ring,
used for optional ISO mounting.
A. Determine mode of operation desired (normally open or normally
closed) of the valve.
B. Determine desired quadrant for bracket attachment and direction
of mounting of actuator (in-line or cross-line).
C. Attach mounting bracket to actuator using four (4) cap screws
and lockwashers provided in mounting kit. To avoid any damage
to the Series 39 actuator body, ONLY the proper length screws
Flow Control Division
Worcester Controls
supplied with the mounting kit should be used. For small size topmount style valves, attach bracket such that bracket nameplate
will be to side of valve.
packing is fully compressed or Bellevilles, if used, are
fully flattened, then back off nut 1/6 turn. Excessive
tightening causes higher torque and shorter seal life.
For mounting to 818/828 Series valves, insert ISO locating ring
into groove on bottom of actuator before attaching to bracket.
NOTE: Ring can be permanently held in groove by applying
Loctite to ring before inserting in groove.
NOTE: Large valves with V51 high-cycle stem packing
option installed, identified by two Belleville washers
installed and handle assembly, stop and stop screws
removed, and 818/828 series valves, do not require stem
area disassembly.
NOTE: Size 0539, if furnished with factory solenoid, shall be
“cross-line” mounted to ensure adequate clearance for air
connections.
For 2"–8" 818/828 valves, remove handle assembly,
locking plates and hardware, and stop screw (if any). Do
not remove stop plate (2"–6" sizes) or spacer (8" size).
D. Attach bracket/actuator assembly to valve as follows:
For 1/2"–2" 94 valves, remove handle (if any). Do not
remove gland plate or gland bolts.
CAUTION: Ball valves can trap pressurized media in the cavity. If it
is necessary to remove any valve body bolts, stem nuts, or remove
valve from the line, and if the valve is or has been in operation,
make sure there is NO pressure to or in the valve and operate valve
one full cycle.
For 3"–6" 94 and 2"–8" E818/828 valves, remove handle
assembly, stop, and spacer (if any). Do not remove gland
plate or gland bolts.
c. Center coupling on valve stem.
1. Valve models 45 (2 /2"–6"), 59 (2"–4"), 51/52 ( /2"–10"),
151/301 (3"–6"), 82/83 (1/2"–10"), 818/828 (2"–8"), 94 (1/2"–6"),
44 (1/4"–2"), 59 (1/4"–11/2"), WK70/WK74 and H71 (1/2"–2"):
1
1
NOTE: For above listed valves, it is not necessary to remove
any valve body bolts or remove valve from line in order to
mount actuator.
a. Rotate valve ball and stem to position necessary to
achieve desired operation. If any valve information is
marked on stop plate or handle, it will be necessary to
transfer this information to the bracket nameplate.
b. For 1/4"–2" 44, 1/2"–2" WK70/WK74, 1/4"–11/2" 59, and 1/2"–11/2"
H71 series top-mount style valves, and 1/2"–2" 51/52,
1
/2"–11/2" 82/83 series valves with high-cycle stem packing
as standard, remove handle nut, lockwasher, handle,
separate stop plate (if any), retaining nut and stop pin(s).
Add the two additional Belleville washers with their larger
diameter sides touching each other. Add the self-locking
nut to the stem and tighten while holding the stem flats
with wrench. Tighten until Belleville washers are flat —
the nut will “bottom” — and then back nut off 1/3 of a turn.
The two additional Belleville washers and the self-locking
nut are included in the mounting kit.
CAUTION: The self-locking stem nut requires a good
amount of effort to tighten, and must fully flatten
Belleville washers before backing off.
d. Lower mounting bracket/actuator assembly over coupling
and onto valve, making sure that male actuator shaft
engages slot in coupling.
e. Secure bracket to valve using cap screws and
lockwashers, or bolts and nuts provided in mounting kit.
Tighten securely. For small size top-mount style valves,
bracket nameplate will be to side of valve.
Install set screws (if any) in coupling and tighten
securely.
f.
Determine if mode of operation is as desired; if not:
1) Double-Acting Actuators – Mount the actuator 90°
from normal mounting (see paragraph D.1.f.3 for size
25 and larger actuators) OR if integral solenoid is
present, remove the solenoid block and gasket, invert
them (turn them upside-down) and remount them.
(This is an either/or situation. If you do both, the
direction of rotation of the actuator will not reverse.)
On 05–20 sizes, the actuator may also be inverted,
yielding the opposite mode.
2) Spring-Return Actuators – The normal method of
mounting is to have the actuator in line with the pipe
line and the valve and actuator in the “FAIL-CLOSED”
position.
For 2" 59, H71, 82/83, and 21/2" 45, 82/83 valves, and
valves 3" and larger with square stem, remove handle
assembly, retaining nut, stop and stop screws. Replace
with valve stem spacer or, if valve has graphite stem
packing, with two Belleville washers (except 8",10" 82/83
and 10" 51/52), and replace retaining nut. NOTE: Belleville
washers are installed with their larger diameter sides
touching each other. Do not use stem spacer when
Belleville washers are used. Using a wrench to prevent
stem from turning, tighten retaining nut until stem
2
Series 39 Pneumatic Actuator
For “FAIL-CLOSED” cross-line operation with 05–20
sizes, invert actuator and cross-line mount actuator to
pipe line.
For “FAIL-OPEN” in-line operation with 05–20 sizes,
invert actuator (NOTE: If in-line coupling is used,
actuator does not need to be inverted). Rotate the
valve ball and stem 90°, so coupling lines up with
actuator shaft. Mount actuator in-line with the pipe
line.
WCAIM2036
Flow Control Division
Worcester Controls
For “FAIL-OPEN” cross-line operation with 05–20
sizes, rotate the valve ball and stem 90°, so coupling
lines up with actuator shaft. Mount actuator crossline to pipe line.
For sizes 10–50, the ports are on the solenoid end
cap. The solenoid end cap is the one on the right end
of the actuator when looking at the nameplate. If the
air supply is connected to the left end cap, the unit
will not operate. For 05 size only, the ports are on the
solenoid block interface plate on back of actuator
when looking at the nameplate. For sizes 10-50
spring-return, the proper NPT port is to the rear of
actuator (away from the nameplate). For size 05
spring-return it is on the back and near center of
actuator.
3) On size 25 and larger double-acting and spring-return
actuators, the output shaft is square. This allows
selection of either mode of operation by indexing the
coupling (including valve ball and stem) 90° to the
actuator shaft, while keeping the actuator in an in-line
orientation. Cross-line mounting, if desired, requires a
special bracket, except for the 818/828 Series valves.
g. Determine position indication. Buttons on position
indicator are set up to show valve closed on in-line
mounting, i.e., pistons together on actuator. If different
indication is required:
b. With Integral Solenoid – Connect air supply line to the
NPT (1/8" on four-way double-acting blocks, 1/4" on threeway spring-return blocks) port on the solenoid block.
4. Recommended Tubing Sizes:
In order to provide sufficient flow of supply air to the
Series 39 actuator, the following tubing sizes are
recommended:
1) Check which visual indication is required.
2) Check that indicator, when located on actuator shaft,
will show correct indication.
3) To change indication, push out (remove) red and
white buttons and reassemble in opposite positions
(this step is only necessary on 10–20 sizes).
4) Locate indicator on actuator shaft flats. Press firmly
until location nibs snap into recess on actuator shaft.
Actuator Size
Runs Over
4 Ft. Long
05, 10, 15, 20, 25
1
/8"
1
30, 33, 35, 40, 42, 45
1
/4"
3
/4"
50
1
/4"
1
/8"
/2"
5. Air Consumption:
AIR SUPPLY AND
ELECTRICAL INSTALLATION
The following chart shows the amount of pressurized (80
psig) air consumed per stroke in cubic feet. To determine
the total amount of air consumed per complete cycle for
double-acting actuators, simply add the volumes for both
the opening and closing strokes together; for springreturn units, the total volume of air consumed is the
volume shown for the opening stroke.
A. 1. Air Supply:
The Series 39 Actuator is factory lubricated. For optimum
operation, the use of filtered and lubricated air is
recommended.
Stroke
2. Air Supply Pressure:
Actuator Size
Open
Close
0539
.01
.01
1039
.04
.05
1539
.08
.09
2039
.16
.17
2539
.28
.30
3039
.43
.47
3339
.65
1.10
3539
.90
1.27
Double-Acting (N Models) – Connect air supply lines
to both NPT (1/8" on sizes 05–20, 1/4" on sizes 25–50)
ports.
4039
1.26
1.43
4239
1.73
3.25
4539
3.1
4.6
Spring-Return (SN Models) – Connect air supply line
to the outboard NPT (1/8" on sizes 05–20, 1/4" on sizes
25–50) port.
5039
5.5
7.0
Standard double-acting actuators require 40–120 psig
supply air. Spring-return actuators require 80–120 psig
supply air. Spring-return actuators can also be set up to
operate on supply air pressures ranging from 40–80 psig
by using fewer springs. See “Rebuilding Instructions”,
Spring-Return Actuator, paragraph 1 on page 9 for proper
number and location of springs for reduced supply air
pressures.
3. Air Supply Connections:
a. No Integral Solenoid:
WCAIM2036
Runs Up To
4 Ft. Long
Series 39 Pneumatic Actuator
3
Flow Control Division
Worcester Controls
B. Electrical Supply (models with integral solenoid only):
B. Actuator With Factory-Supplied Solenoid
The solenoid coil wattage and required amperage are as follows:
General Purpose Solenoid
Holding
Amps
Inrush
Amps
Watts
24 VAC 50/60 Hz
.80
1.20
11
120 VAC 50/60 Hz
.15
.30
11
240 VAC 50/60 Hz
.08
.12
11
12 VDC
.70
—
11
24 VDC
.35
—
11
Voltage
Watertight and Hazardous Location Solenoids
Holding
Amps
Inrush
Amps
Watts
24 VAC 50/60 Hz
.71
1.13
11
120 VAC 50/60 Hz
.14
.23
10
240 VAC 50/60 Hz
.07
.11
10
12 VDC
.81
—
10
24 VDC
.41
—
10
Voltage
INSTALLATION OF ACCESSORIES
For details of installation of accessories refer to the installation
instructions contained in respective accessory kit.
OPERATION
A. Basic Actuator – (N Model)
The Series 39 actuator drive shaft rotates through a full 90°
segment with approximately 2° overtravel at each end of travel.
Rotation is accomplished by feeding supply air into the center
chamber, forcing the two opposing pistons apart, resulting in a
counter-clockwise rotation of the drive shaft to the “open”
position. For double-acting actuators, closure is obtained by
feeding supply air into the end cap chambers, which forces the
pistons together, resulting in a clockwise rotation of the drive
pinion. For spring-return actuators, closure is accomplished by
means of springs contained within the end caps which force the
pistons together when the supply air to the center chamber has
been interrupted.
If rotation opposite to that described above is required, refer to
the section on Installation for the proper procedure to reverse the
rotation.
Double-Acting – Air is supplied to the one NPT port on the bottom
of the block. When the solenoid is energized, the spring-loaded
plunger is withdrawn, allowing the supply air to shift the spool
within the block, which opens the supply path to the center
chamber of the actuator. Air from the end chambers of the
actuator is allowed to pass through the block and exhaust to
atmosphere.
When the solenoid is de-energized, the spring-loaded plunger
blocks the flow of air to the center chamber of the actuator. The
supply air now shifts the spool within the block to a position
which opens the supply path to the end chambers of the actuator.
Air from the center chamber of the actuator is allowed to pass
through the block and exhaust to atmosphere.
The double-acting solenoid assembly is electrically fail-safe. That
is, it will return to its de-energized position upon electrical failure
and cycle the actuator to the closed position provided the air
supply is not interrupted.
Double-acting solenoid assemblies have two independently
adjustable speed control screws which can be used to adjust the
speed of operation for the opening and/or closing stroke. If the
speed control screws are too tight, the unit will fail to operate.
NOTE: Speed control screws are shipped from the factory in the
full open position.
Spring-Return – Air is supplied to the one NPT port on the bottom
of the block. When the solenoid is energized, the spring-loaded
plunger is withdrawn, which opens the supply path to the center
chamber of the actuator. Air from the end chambers of the
actuator is allowed to pass directly through the block and exhaust
to atmosphere.
When the solenoid is de-energized, the spring-loaded plunger
blocks the flow of air to the center chamber of the actuator. The
springs in the end cap of the actuator, which were compressed on
the opening stroke, now relax, forcing the air contained in the
center chamber of the actuator to exhaust through its supply port
in the solenoid block. The exhaust air passes through the block
and the solenoid where it exhausts to atmosphere.
When using a spring-return solenoid assembly, only the speed of
the spring stroke is adjustable. This is accomplished by tightening
the set screw contained in the exhaust nut (shipped separately in
envelope) which mounts directly to the end of the solenoid.
C. Standard Stroke Times
Standard stroke times of the Series 39 actuator are shown in the
following table. Times shown are in seconds and represent
average times under 50% load conditions with an air supply
pressure of 80 psig. Times shown are per stroke for doubleacting actuators. For spring-return actuators, the opening stroke
times may be slightly longer; stroke times for the closing (spring)
stroke are dependent upon the number of springs used.
The figures shown below are meant as an indication of obtainable
speeds only. Faster or slower speeds are obtainable, if required,
by using additional control equipment.
4
Series 39 Pneumatic Actuator
WCAIM2036
Flow Control Division
Worcester Controls
Actuator Size
Stroke Time (sec.)
0539
1
1039
1
1539
1
2039
1
2539
2–3
3039
3–4
3339
4–5
3539
4–5
4039
5–6
4239
6–7
4539
10–12
5039
12–14
Depending upon the conditions under which the actuator must work,
such as extended duty, non-compatible operating media or abnormal
operating conditions, periodic replacement of internal seals is
recommended. Repair kits containing all necessary seals can be
obtained through any authorized Worcester/McCANNA distributor.
On spring-return actuators, the springs may need replacement after
extended duty since springs may fatigue and break. SPRINGS
SHOULD ALWAYS BE REPLACED IN COMPLETE SETS. Spring kits are
available through any authorized Worcester/McCANNA distributor.
SPARE PARTS
The following are recommended spare parts which should be kept on
hand for Series 39 pneumatic actuators:
Repair Kit(s) – Kits contain all necessary seals, bearings and
instructions.
Spring Kit(s) – For Spring-Return Actuators.
D. Manual Operation
In the event of air failure, the Series 39 actuator can be cycled
manually. This is accomplished by applying a wrench to the
exposed top shaft of the actuator and turning it in the desired
direction.
WARNING: Care must be taken to ensure that the actuator is not
operated automatically while manual operation is being
performed.
If a routine cycle check is to be performed on a double-acting
actuator equipped with the proper Worcester/McCANNA solenoid
control block, the actuator can be cycled manually by shifting the
spool valve within the block. This can be done by pushing the
piston nearest the outside surface of the control block towards
the center of the block with a pen or pencil. Care must be taken to
hold the spool valve in the desired position until the actuator has
cycled. Provided the air supply is still on, the actuator will cycle to
its original position as soon as the manually applied pressure on
the spool valve is released.
MAINTENANCE
CAUTION: The actuator must be isolated both pneumatically and
electrically before any maintenance activity is begun.
Periodic checks should be performed to make certain that all
fasteners remain tight. Care should be taken when tightening the end
cap retaining bolts since these fasteners are METRIC. All other
fasteners are UNIFIED IMPERIAL.
All actuators are supplied with sufficient lubrication for their normal
working life. If required, recommended lubrication for all standard
actuators is a #1 grease. Consult Flowserve for lubricants used for
high or low temperature applications.
TROUBLESHOOTING
BEFORE DISASSEMBLING ACTUATOR FOR ANY REASON, CONSULT
REBUILDING INSTRUCTIONS CONTAINED IN FOLLOWING SECTION.
I.
For solenoid controlled actuators (with Worcester/McCANNA
solenoid control block):
A. If actuator does not function, check to ascertain:
1. That valve is free to rotate. This can be done as described
above in Manual Operation.
2. That actuator is the correct size.
3. That speed control screws are loose (if screws are
tightened all the way, actuator will not operate).
4. That correct voltage is supplied to solenoid.
5. That sufficient air supply is available at inlet to control
block. Inlet pressure to control block should be at least
40 psig for double-acting, 80 psig for spring-return
(unless a reduced spring complement is installed (fewer
springs)). When checking supply pressure, place gage in
line at control block inlet and monitor gage for
unexpected pressure drops.
B. If proper voltage and air pressure have been verified and valve
is free, proceed as follows:
1. Turn on signal voltage. Check solenoid for clicking sound.
2. If no sound is detected, remove air pressure and turn off
signal voltage.
a. Carefully unscrew solenoid and solenoid stem from
block.
b. Reapply signal voltage and observe solenoid plunger.
If it does not retract, replace solenoid.
WCAIM2036
Series 39 Pneumatic Actuator
5
Flow Control Division
Worcester Controls
3. If solenoid functions, remove solenoid valve block and
place on bench. Connect to reduced air supply (50 psig)
and correct voltage. Switch signal voltage and check air
flow. Air should flow out only one output port when
solenoid is energized. The flow should occur only at the
other port when de-energized. (Slight back pressure may
be required to shift the valve spool. This may be
generated by obstructing the outlet ports.)
4. If control block and solenoid are operating correctly,
proceed to Section II below.
C. If the actuator functions but exhibits leakage, or power loss
accompanied by leakage, proceed as follows:
1. Check voltage. Voltage must be within 10% of the
specified voltage (low voltage will cause leakage out of
the back of the solenoid and burn out the coil).
2. Check air supply. Be certain that no sharp air pressure
drops occur as unit is cycled. Loss of air pressure can
cause incomplete shifting of the spool valves used in all
double-acting units, which results in bypass leakage and
substantial actuator torque losses.
3. If air supply and voltage are adequate, proceed as follows:
a. If leak is at solenoid exhaust port, replace the
solenoid.
b. If leak occurs at exhaust ports in the block itself, the
trouble will be in either the spool valves in the block,
or at one of the piston seals of the actuator. A leaking
piston seal will usually leak on either cycle.
On spring-return actuators, piston seal leakage will
show at the breather port of the end cap, or for 0539,
the solenoid block interface plate.
The recommended procedure in the cases above is to
replace the spool valve O-rings. If the leakage
persists, rebuild the actuator using a factory-supplied
repair kit.
II. For actuators without the Worcester/McCANNA solenoid control
block, or if block and solenoid are operating correctly, remove the
actuator from the valve, disassemble (per Rebuilding Instructions)
and check the following:
A. Make sure that all internal porting is free and clear of any
obstructions. End caps, guide rods and pistons are airtransporting components.
NOTE: The most common problem encountered on 39
actuators is the improper replacement of the piston guide rod
assembly with the hole in it, relative to the nameplate on the
body (see Step 6 on page 8).
B. Make certain that the actuator has lubrication, and that there
is no solidified grease between the pinion and the piston
racks.
6
1. If actuator has no lubrication, apply generous amount of a
#1 grease. If actuator is prepared for high or low
temperature operation, consult Flowserve for proper
lubricants.
2. If solidified grease between the pinion and the piston
racks is present, clean, dry, regrease and reassemble.
C. Verify that actuator pinion shaft and/or pistons are not bound.
If bound, reassemble per Rebuilding Instructions.
D. If unit exhibits excessive amounts of backlash, check teeth on
piston racks for wear. If worn, replace piston assemblies.
E. In spring-return actuators, check for misplaced or broken
springs. If springs are broken, check body bore for scoring.
1. If springs are broken, replace springs. SPRINGS SHOULD
ALWAYS BE REPLACED IN COMPLETE SETS.
2. If body bore is scored, replace it. Also, replace piston Orings (contained in repair kit).
F.
If actuator is free, valve is free and control block (if used) is
shifting air properly, reassemble the actuator and retest. If
unit still fails to operate, consult Flowserve.
REBUILDING INSTRUCTIONS
NOTE: For identification of all numbered parts discussed below,
consult exploded view of actuator.
After actuator has been repaired, mark rebuild label accordingly and
apply to actuator.
ACTUATOR DISASSEMBLY
1. Disconnect the air supply and electrical service to the actuator.
2. Remove the actuator and its mounting bracket from the valve. If
the actuator uses a positioner, loosen the set screws in the
coupling between the valve and actuator. (See Caution note
below.)
CAUTION: Ball valves can trap pressurized media in the cavity.
Isolate the piping system in which the actuator/valve assembly
is mounted and relieve any pressure on the valve. To remove
the actuator bracket from a three-piece non-top-mount style
“Miser” valve, the two top valve body bolts must be removed.
For all the valves listed in Installation Section D, the actuator
bracket can be removed without loosening or removing any
valve body bolts.
3. Remove the actuator bracket (and actuator positioner) from the
actuator to begin repair. (Note mounting of removed bracket and
positioner for easy reassembly.)
4. It is not necessary to remove solenoid control block (7A) or (7B)
(if so equipped) to rebuild actuator. However, if it becomes
necessary to remove the block, begin by removing the solenoid
block bolts (8E). Use care to retain the solenoid block gasket (9).
Series 39 Pneumatic Actuator
WCAIM2036
Flow Control Division
Worcester Controls
For 05 size only, also remove the solenoid block interface plate
(20) and the interface gasket (19) by removing the three screws
(21).
5. For sizes 10–50, each end cap (5A and 5B) is aligned onto the
body (1) over a “foolproof pin”. This ensures that the end caps
can only be assembled to their respective end of the actuator.
Remove all four metric screws (5C) from, and remove, both end
caps. For Rev. R1 and R3 through R6 actuators, remove the two
bearings (6A) and O-rings (15A and 15B) from each end cap.
Note that for Rev. R2 models with top-hat style (6C) bearings, the
bearings and particularly the retaining washers (16) in each end
cap should not be disturbed during O-ring seal replacement, as
they are not included in the rebuilding kit. For size 05, remove all
four metric screws (5C) from both end caps (5). Remove O-ring
(15A) from each end cap.
CAUTION: If the actuator is a spring-return model, first remove
two end cap screws diagonally opposite each other, then
lubricate the threads and under the head. Replace the screws
and repeat the procedure for the other two screws. Do this for
each end cap as this will aid reassembly. Now uniformly loosen
all four end cap screws on each end cap two to three turns at a
time, in sequence, to relieve preload of the springs. On larger
actuators with springs use caution when removing end caps.
End cap screws are long enough to allow springs to relieve
before disengaging.
After the screws are removed, gently pry off each end cap, being
careful not to damage the end cap O-Rings.
6. The two piston guide rod (4) assemblies can now be removed
from each end of the body and disassembled by removing the
piston set screws (12). Do not interchange piston guide rods (4)
and their respective piston (3). For sizes 10–20 Rev. R6, each
guide rod and piston may be press fitted together (do not use set
screws) and cannot be disassembled. (To assist reassembly, mark
the body with a line on the side from which the guide rod using
the thru-hole is removed). Remove all O-rings (15B and 15C) and
bearings (6B) from pistons (3). For size 05, the two pistons (3)
can now be removed from each end of the body. Remove O-rings
(15C) from pistons (3).
7. The shaft (2A) on Rev. R2 and sizes 05–20 Rev. R3 through R6
models can only be removed after the piston assemblies are taken
out. Remove the position indicator (17) (if any), the shaft clip
(15F) (not a reusable part!) (see Note below) and the stainless
steel washer from the top of shaft. Then remove the shaft through
the larger opening in the bottom of the body. The top bearing
(15G) and the O-ring (15D) can now be removed. Remove the
two stainless steel washers (10–35 sizes only) and thrust bearing
(10) from the top of the shaft, the O-ring (15E), and the bearing
(15H) (10–42 sizes only) from the bottom end. NOTE: For sizes
40 and 42 Rev. R3 through R6
models, only a single stainless
steel washer is used and thrust
bearing (10) is not used.
NOTE: Some actuators may be
using a spiral-ring type shaft clip
as shown at right.
WCAIM2036
To remove this clip, engage the lower end of the ring with a flat
blade screwdriver. Using another flat blade screwdriver push the
top end of the clip in the opposite direction. As the clip I.D.
expands, lift the clip from the shaft. The installation of a new clip
would be the above steps in reverse and ensuring that the edges
of the clip are properly seated in the shaft groove.
The Rev. R1 model, all sizes and the Rev. R3 through R6 models,
sizes 25 through 42, have an anti-ejection ring (15J). The antiejection ring on Rev. 1, sizes 45–50 consists of a flat washer with
a shaft clip. All others are a one-piece spiral wound ring. This ring
does not have to be removed and may or may not be included in
repair kits.
For Rev. R1 models, remove shaft clip (15F) (not a reusable part!)
(see Note above) and the stainless steel washer from the shaft.
Then remove the top shaft bearing (15G) and the bottom shaft
bearing (15H) by carefully prying them away from the body.
CAUTION: Both of these bearings may have a projecting “nib”
which locates the bearings to the actuator body. Be careful not
to break off these nibs inside the body when removing the top
and bottom bearings. Note: Top bearing is marked “Top”.
Bottom bearing has a larger ID than the top bearing.
Next, slide the shaft out through the bottom of the body and
remove the top O-Ring (15D) and the bottom O-Ring (15E) from
the body.
ACTUATOR REASSEMBLY
1. Be sure the actuator surfaces are clean and free of grit and
scratches. If the inside walls of the body are scored, or the guide
rod surfaces are scratched, the actuator will leak after rebuilding.
New parts should be obtained from the factory. Light tracking,
barely detectable to touch, is acceptable.
2. All rebuilding kit O-Rings and bearings may now be installed.
Lubricate the standard actuator thoroughly with a #1 grease.
Apply a light film of grease to all O-Rings.
3. If converting over to a “high-temperature” actuator, or rebuilding
an existing one, lubricate thoroughly with Dow Corning #7 or
other equivalent high temperature silicone or graphite base
grease.
4. Some Rev. R2 actuators, sizes 10–35, use flanged bearings in the
end caps. They resemble a “top hat” (6C), and are installed with
the brim of the hat facing out, and are retained by “star washers”
(16). These bearings and star washers should not be removed for
O-Ring seal replacement. On sizes 10 and 15 only, there is one
star washer, or retainer, per bearing. On sizes 20–35, there are
two star washers per bearing. They are installed one on top of the
other, with the “points” of the “star” overlapping each other (as
opposed to being on top of each other). All the washers must be
pressed in firmly and straight. The points of the star are bent
slightly. When installed, they bear back, away from the hole.
For sizes 10–50 Rev. R1 and 10–42 Rev. R3 through R6
actuators, replace the two split-ring style bearings (6A) and one
guide rod O-ring (15B) in each end cap.
Series 39 Pneumatic Actuator
7
Flow Control Division
Worcester Controls
Replace the split-ring style bearing (6B) and guide rod O-ring(s)
(15B) into I.D. groove(s) in each piston (3). Install O-Rings (15C)
onto pistons.
For size 05 actuators, install O-rings (15C) onto the pistons.
5. Replace O-ring (15E) and bearing (15H) (10–42 sizes only) on the
bottom of shaft. On the top of the shaft add the two stainless
steel washers (10–35 sizes only) with the thrust bearing (10)
between them. NOTE: For sizes 40 and 42 Rev. R3 through R6,
only a single stainless steel washer is used and thrust bearing
(10) is not used. Locate the top bearing (15G) and O-ring (15D)
into the body. NOTE: For sizes 10–35 Rev. R6 and size 05
actuators, top bearing (15G) is flat and the same as, and
interchangeable with, thrust bearing (10). Replace the shaft
through the larger opening in the bottom of the body.
For Rev. R3 through R6, sizes 25 through 42 actuators, replace
anti-ejection ring (15J) in its groove on the shaft (2B), if removed.
For Rev. R1 Models:
Locate the shaft O-Rings into the actuator body. O-ring (15D) is
the top O-ring while (15E) is the bottom O-Ring.
Replace the top bearing (15G) and bottom bearing (15H).
If the anti-ejection ring (15J) was removed, replace it in its groove
on the shaft (2B). Check that the ring is properly seated in its
groove.
Replace the shaft in the body through the larger opening in the
bottom of the actuator body.
6. For sizes 10–50, very carefully align the piston guide rod
assemblies inside the body. Keep the pistons square to the body.
(This is very important in the 30 39 actuator where steel set
screws can cause internal body damage if the piston assemblies
“cock” inside the actuator body.)
IMPORTANT: One piston guide rod assembly has a through hole
drilled in it. It can be easily located by looking down the ends of
both guide rods. This piston assembly must be reassembled, with
its respective guide rod, opposite the nameplate on the body, as it
was removed.
For size 05, align the pistons inside the body. Keep the pistons
square to the body.
7. Align the shaft so that the teeth on the shaft will “pick-up” the
piston assembly’s rack teeth when turning the top extension of
the shaft clockwise (CW). (See Figure 1.)
IMPORTANT: Proper 90° rotation can only be ensured if the shaft
teeth begin to mesh with the piston assembly’s teeth at the
“proper tooth” between these meshing gear pairs. (See Figure 1.)
8. To ensure proper meshing of teeth, move the shaft 15 to 20 degrees
counter-clockwise (CCW) from its normal position when the piston
assemblies are located at the body ends. (See Figure 2.) NOTE: The
“normal position” of the shaft on the 05–20 sizes is when the top
flats are parallel to the main axis of the actuator body. On the 25–
50 sizes the teeth of the shaft will be on the left side of the actuator
when viewed from the ends of actuator. (See Figure 1.)
9. With the piston assemblies in the body, gently push each piston
into the body. Turn the top shaft extension clockwise (CW). Do
not allow the pistons to “cock”.
At the proper point of engagement between the shaft and piston
assemblies, both piston assemblies will move toward the center
of the body when turning the top shaft extension of the actuator
clockwise (CW).
10. Once the shaft and pistons are properly engaged, ensure that
smooth movement and 90 degree operation can occur without
moving the pistons out of the actuator body. This is important!
11. Install O-Ring (15A) into and replace the actuator end caps, (5 or 5A
and 5B), noting that the “foolproof” pin between the body and end
cap mates properly (10–50 sizes only). For spring-return actuators,
see spring installation section on page 10 before installing end caps.
NOTES: When installing the end cap O-Rings, use a small amount
of a general purpose lubricant, such as petroleum jelly, to hold
them in place for ease of assembly and to avoid having them fall
and get pinched.
On Rev. R1 and earlier actuators, be sure O-Ring is installed in
groove on end cap.
12. Replace the stainless steel washer over the top shaft extension.
Figure 2
Figure 1
Alignment of Shaft at Reassembly
(Pistons at End of Body)
Double-Acting Actuator
NAMEPLATE
25–50 39 ACTUATOR
Pistons at End of Body
IMPORTANT: Note the relative location of the shaft teeth and the
piston assembly's rack teeth. The above figure is viewed when
looking at the top of the actuator.
8
05–20 39 ACTUATOR
IMPORTANT: Align gear teeth on the shaft per Figure 1.
Series 39 Pneumatic Actuator
WCAIM2036
Flow Control Division
Worcester Controls
13. VERY IMPORTANT: Install the NEW shaft clip (15F) into its mating
groove on the top shaft extension. (The removed shaft clip is not to
be reused.)
Place the numbered side up on the shaft clip and be certain the
clip is fully seated in its groove. See Note at bottom of page 7 for
installation of spiral-ring type shaft clip (which newer rebuilding
kits will contain).
14. If solenoid control block was removed:
For size 05 only, place interface gasket (19) onto solenoid block
interface plate (20) and attach securely to body with three screws
(21). Do not apply any grease to gasket.
Place gasket (9) on solenoid control block (7A) or (7B) (if used)
and attach block securely to end cap, or for size 05, the solenoid
block interface plate, to obtain a seal at gasket. NOTE: If fiber
gasket is used, work a generous amount of assembly grease or
petroleum jelly into the gasket prior to assembly (wipe off excess
grease). If a rubber gasket is used, do not apply any grease, it
must be installed dry.
15. Replace position indicator (17) (if any). See Section D.1.g for
proper installation and to determine position indication.
16. Mark Rebuild/Accessory Addition Label, if included in repair kit,
and apply to actuator.
1. When replacing springs in a spring-return actuator, ensure that
the springs are replaced in their identical position in the end cap
from where they were removed.
IMPORTANT: When less than the standard number of springs are
used in each end cap, these springs should be positioned
according to the air supply figures below.
Sizes 10–35 Rev. R2 through R6 and Sizes 40 and 42 Rev. R3 through R6
Remove center spring.
Remove center spring.
Use three on a diagonal.
Use two in opposite corners.
Sizes 10–50 Rev. R1 (Except Size 42)
70 psi - 22 springs - 11 per end cap.
60 psi - 18 springs - 9 per end cap.
50 psi - 16 springs - 8 per end cap.
40 psi - 12 springs - 6 per end cap.
4
5
6
7
()
Supply Pressure
40
50
60
70
80
Actuator Size
and Current Rev.
End of Spring Torque (In-Lbs)
10 R6
35
55
75
75
95
15 R6
74
105
145
145
185
20 R6
125
195
265
265
335
25 R6
210
330
450
450
575
30 R6
340
535
730
730
920
33 R6
680
1070
1460
1460
1850
35 R6
850
1330
1815
1815
2300
40 R1
1500
1950
2200
2750
3000
40 R6
1500
2240
2980
2980
3740
42 R6
2390
3800
4890
4890
6370
45 R1
4000
5500
6300
7800
8400
50 R1
6500
8500
9500
12200
13500
1
50
32
1
60
32
Ordering Code
Supply Pressure (psi)
05
SPRING-RETURN ACTUATOR
70 psi - 8 springs - 4 per end cap.
60 psi - 8 springs - 4 per end cap.
50 psi - 6 springs - 3 per end cap.
40 psi - 4 springs - 2 per end cap.
Ordering Code
Remove required number of
springs starting in the center.
Remaining springs should be
evenly spaced as possible.
The size 05 spring-return actuator operating at 80 psi has four
springs (two per end cap). For air supplies of 70, 60 or 50, remove
inner spring of each end cap.
The values listed below are for standard and less than the standard air
pressure as required per the ordering code.
1
70
32
()
80
41
3. When replacing the springs in a spring-return actuator, place the
springs in the end cap pocket after thoroughly lubricating each
spring. Be generous with lubricant!
4. With the springs pointing up and the end cap on a solid surface,
place the actuator body over the springs and the proper end cap.
(Each end cap can only be mounted to just one end of the
actuator body, as there is a “foolproof” pin in the end cap, which
aligns with a hole in the body.)
5. Force the body down and begin by engaging two end cap screws
(5C) by hand through the end cap. Take each end cap screw up in
SMALL and EQUAL turns. Once the end cap is temporarily
secured to the body, turn the actuator over to its normal position
and uniformly take up the four end cap screws. Uniformly load all
the springs to prevent any spring from buckling.
IMPORTANT: Locating nibs are permanently cast into the Rev. R1
(all sizes) and the Rev. R3 through R6 (sizes 25 through 42)
actuator piston face. The actuator springs must fit over these
locating nibs on the piston face. Care in following the above
instructions will ensure the proper alignment of the spring in the
actuator body — proper contact with the piston face and end cap.
6. In a similar manner, as written in the previous steps, replace the
springs in the other end of the actuator body.
NOTE: Maximum operating pressure does not change.
2. If a spring-return actuator is being repaired due to a failed spring,
REPLACE all the springs in this actuator, as well as any other
parts which may have been damaged.
WCAIM2036
Series 39 Pneumatic Actuator
9
Flow Control Division
Worcester Controls
05-39 Actuator
14A
5
(Spring-Return)
14A
18
17
14A
14B
5
(Spring-Return)
15F
S.S. Washer
5C
15G
5
(Double-Acting)
15A
15C
19
5
3
20
(Double-Acting)
Optional “Rebreather” Gasket
(Spring-return actuators only)
9
21
7B
1
3
15C
15D
10
15A
9
5C
8E
8B
2
8D
7A
8C
15E
8E
8A
ITEM
QTY
DESCRIPTION
1
2
3
5
5C
7A
7B
8A
8B
8C
8D
8E
9
10
11
14A
14B
1
1
2
2
8
1
1
1
1
1
1
2
1
1
1
2
2
Body
Shaft
Pistons
End Caps
End Cap Screws (Metric)
Solenoid Block (Double-Acting)
Solenoid Block (Spring-Return)
Solenoid
Solenoid O-Ring
Solenoid Plunger
Solenoid Spring
Solenoid Block Bolts
Solenoid Block Gasket
Thrust Bearing
Nameplate (Not Shown)
Inner Springs (See Table Page 9)
Outer Springs (See Table Page 9)
10
ITEM
QTY
15A
15C
15D
15E
15F
15G
17
18
19
20
21
2
2
1
1
1
1
1
1
1
1
3
DESCRIPTION
End Cap O-Rings
Piston O-Rings
Top Shaft O-Ring
Bottom Shaft O-Ring
Shaft Clip
Top Pinion Bearing
Position Indicator
Indicator Mounting Screw
Interface Gasket
Solenoid Block Interface Plate
Plate Mounting Screws (Metric)
To order proper parts, please specify the actuator size, model and
revision number. Use the standard nomenclature listed above.
The rebuilding kits include Items 15A, 15C through 15G, 10, 19 and
stainless steel washer. Color of some replacement parts, such as
bearings, may vary from the parts removed.
Series 39 Pneumatic Actuator
WCAIM2036
Flow Control Division
Worcester Controls
10-50 39 Actuator
The rebuilding kits include Items 15A
through 15H, 6A and 6B, 10, and
stainless steel washers. Color of some
replacement parts, such as bearings,
may vary from the parts removed. Item
15J may or may not be included in
repair kits.
Rebuilding kit labeled R6 is for Rev. R2
through R6 actuators.
ITEM
QTY
DESCRIPTION
1
2A
2B
3
4
5A
5B
5C
*6
6C
6A
6B
7A
7B
8A
8B
8C
8D
8E
9
10
11
12
13
1
1
1
2
2
1
1
8
4
4
2
1
1
1
1
1
1
2
1
1
1
2
2
Body
Shaft(10-2039)
Shaft (25-5039)
Pistons
Guide Rods
Solenoid Block (Inlet) End Cap
Limit Switch End Cap
End Cap Screws (Metric)
Bearings (Guide Rod)
End Cap Bearing (Top-Hat Style)
End Cap Bearing (Split-Ring Style)
Piston Bearing (Split-Ring Style)
Solenoid Block (Double-Acting)
Solenoid Block (Spring-Return)
Solenoid
Solenoid O-Ring
Solenoid Plunger
Solenoid Spring
Solenoid Block Bolts
Soleniod Block Gasket
Thrust bearing (R6 RK Only)
Nameplate
Piston Set Screws
Pipe Plugs
WCAIM2036
ITEM
14
15A
15B
15C
15D
15E
15F
15G
15H
15J
16
17
QTY
Varies
2
6 or 12
2
1
1
1
1
1
1
4 or 8
1
DESCRIPTION
Springs - See Table, Page 10
End Cap O-Rings
Guide Rod O-Rings (See Note Below)
Piston O-Rings
Top Shaft O-Ring
Bottom Shaft O-Ring
Shaft Clip
Top Pinion Bearing
Bottom Pinion Bearing
Anti-Ejection Ring (R1 and Sizes 25-42 R3-R6)
Bearing Retainer (R2 Only)
Position Indicator
NOTE: Size 15 Rev. R6 rebuilding kits include twelve Guide Rod
O-rings. The six larger diameter O-rings are for Rev. R3 through R6
actuators.
*End cap bearings (6C) illustrated are for Rev. R2 actuators only. All
other revision end caps use split-ring style (6A), same as piston
bearing (6B). Only split-ring style bearings are included in R6
rebuilding kits, and normally all styles of bearings do not need
replacement during a rebuild.
To order proper parts, please specify the actuator size, model and
revision number. Use the standard nomenclature listed above.
Series 39 Pneumatic Actuator
11
Flow Control Division
Worcester Controls
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function
safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial
service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore
assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation
Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of
satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve
is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning
these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.
For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.
FLOWSERVE CORPORATION
FLOW CONTROL DIVISION
1978 Foreman Drive
Cookeville, Tennessee 38501 USA
Phone: 931 432 4021
Facsimile: 931 432 3105
www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation.
WCAIM2036 10/03 Printed in USA
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