Norbro 40R 90 Degree Actuator User Instructions
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
NORBRO Series 40R Pneumatic Actuator
FCD NBENIM0002-03-A4 07/15
USER INSTRUCTIONS
Installation
Operation
Maintenance
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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Contents
Page
1Safety
2
2 Health and Safety
2
3Description
3
4 Actuator markings
4
5Installation
4
6 Fitting indicators
6
7 Air supply and installation
6
8 Air Consumption
7
9 Installation of accessories
7
10Operation
7
10.1 Basic Actuator7
10.2 Actuator With Solenoid8
10.3 Standard Stroke Times8
10.4 Manual Operation8
11Maintenance
8
12 Spare Parts
9
13Troubleshooting
9
14 Rebuilding instructions
10
14.1 Actuator disassembly
10
14.2 Actuator reassembly
11
15 Spring-return actuator12
16 Size 05 Exploded view/parts/materials
14
17 Size 10-50 Exploded view/parts/materials 15
1
SAFETY SYMBOLS
2
HEALTH AND 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.
When installing or maintaining actuators:
2.1 Conduct a risk assessment and eliminate or reduce
hazards to an acceptable level.
2.2
Work in accordance with Safe Systems of Work.
2.3
Observe all site Health and Safety Rules in particular
Permit to Work and Hot Work procedures.
2.4
Wear all necessary Personal Protective Equipment.
2.5
Never remove or maintain an actuator or joint unless
the supply has been fully de-pressurised, drained and
where necessary, purged of toxic / explosive / flammable
media. Always operate the actuator to ensure that no
trapped pressure exists.
2.6
Never handle actuators that have been used on harmful
substances unless they have been completely decontaminated and certified safe to handle.
2.7
Never use an actuator on a duty, which exceeds its
prescribed operating parameters. Refer to Flowserve
Flow Control Technical Sales for further information.
2.8
Never modify or alter actuators unless the manufacturer
has been consulted and/or recommends such changes.
DANGER: indicates that death, severe personal i­njury
and / or substantial property damage will occur if proper
precautions are not taken.
STOP!
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 mistakes, which, in themselves, might directly or
indirectly cause severe personal injury or property damage.
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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2.9
Due to the large physical size and weight of some sizes
of this product, always use correct lifting methods and
equipment when installing, removing and maintaining
the product, and that it is correctly supported in its final
operating location.
2.10
Due to the variety of duties on which this product can be
employed, it is the end users responsibility to ensure the
compatibility of the product with the specific application
(i.e. air supply, torque, corrosion, which may effect it's
suitability).
2.11
Before equipment is installed in areas which may be
subject to seismic activity or extreme climatic conditions
consult Flowserve Flow Control Technical Sales.
2.12
If the processes or environments that the products are
used in are likely to cause temperatures (high or low)
that may cause injury to personnel if touched, then
adequate insulation/protection must be fitted.
2.13
If the equipment is to be used on unstable gas duty,
ensure that the operational parameters as indicated on
the product label cannot be exceeded.
2.14
This equipment should be protected by other devices to
prevent over-pressurisation. (i.e. caused by external fire
etc).
2.15
STOP!
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.
Do not install spring-return models with air connection
in end cap or with integral solenoid vertical, without
proper precautions to eliminate the ingress of water
spray or rainfall. Exposed 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
50 °C or below 4 °C may occur. Do not store within 50
feet of any source of ozone.
2.17 This equipment is not a safety device and must be
controlled / guarded by other devices.
2.18
Do not rub actuator with a dry cloth as this can cause a
build up of static charge. Only clean with a damp cloth.
3DESCRIPTION
WARNING: Series 40R 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.
This equipment must be installed in a system that is
designed to prevent excessive forces acting on the
mounting kit, switch box/positioner, connections etc.
2.16 Care must be taken when removing the actuator or
accessing the valve that the actuator does not unexpectedly operate due to the stored failsafe spring torque,
causing personal injury.
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 allow the direct mounting a solenoid
control block which properly directs supply air to the
actuator.
NORBRO Series 40R actuators are pneumatic quarter-turn valve actuators. The design utilizes a double-rack,
single pinion 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 that are also
used to control the rotation of actuator via externally
mounted stroke adjustment screws. In double-acting
units, both pistons are pressurized on both strokes of
the actuator.
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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ACTUATOR MARKINGS
Each actuator has the following identification information on
the product label attached to the side of the body:
Product Series
CE Mark
Atex Directive
94/9/EC
II2GDcX
PNEUMATIC ACTUATOR
IMPORTANT: Dismantle only in accordance with Installation,
Operation & Maintenance notes. Refer to notes to ensure proper
use of actuator. Maximum Working Pressure see below.
PRODUCT CODE
YEAR
WORKS ORDER
BAR
Flowserve Flow Control (UK) Ltd.
Tel: +44(0)1444 314400 Fax: +44(0)1444 314401
Website: www.flowserve.com
UK & Foreign Patents
ATEX Directive: If the product label carries the ATEX Directive
number '94/9/EC' followed by the Explosion Protection Symbol
and codes identifying the equipment group and category, the
zone suitability and protection type beside the CE mark, the
product complies with the ATEX Directive and The Equipment
and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 1996.
{
Explosion Protection Symbol,
Equipment Group & Category,
Zone Suitability and Protection Type
Maximum Working Pressure
Works Order Number
Year of Manufacture
Flowserve Flow Control (UK) Ltd
Product Code
5INSTALLATION
NOTE: The Series 40R actuator is normally installed
with its major axis parallel to the pipe line. The actuator can be oriented above, beside or beneath the valve
without affecting its operation.
Sizes 10-35 actuators may come with an ISO locating
ring, used for optional ISO mounting.
'II' = Equipment Group.
Size 40-50 actuators have an integral ISO location ring.
'2' = Equipment Category.
5.1
Determine mode of operation desired (normally open
or normally closed) of the valve.
5.2
Determine desired quadrant for bracket attachment and
direction of mounting of actuator (in-line or cross-line).
5.3
Attach mounting bracket to actuator using four (4)
cap screws and lock washers provided in mounting
kit. To avoid any damage to the Series 40R actuator
body, ONLY the proper length screws supplied with the
mounting kit should be used.
5.4
If an ISO locating ring is used, insert ISO locating ring
into groove on bottom of actuator before attaching to
bracket. Ring can be permanently held in groove by
applying Loctite® 638 to ring before inserting in groove.
NOTE: Size 40R, if furnished with factory solenoid, shall
be “cross-line” mounted (i.e. at 90 degrees to the pipe
run) to ensure adequate clearance for air connections.
Definition of product label marking above:
'G' = Gas Zone suitability (Zones 1 & 2).
'D' = Dust Zone suitability (Zones 21 & 22).
'c' = type of protection i.e. constructional safety (prEN 13463-5).
'X' = Special temperature reference (Surface Temperature: As
per BS EN 13463-1:2001 paragraph 14.2g, the temperature
class or maximum surface temperature cannot be marked on
the product as it is dependent on the operating conditions).
The operational temperature range is as follows:
(S) = Standard -20 °C to +100 °C.
(L) = Low Temperature variant -40 °C to +85 °C.
(H) = High Temperature variant -20 °C to +150 °C.
NOTE: Under constant use the surface temperature of
expose parts may rise by a maximum 20 °C above the
operating media temperature.
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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5.5
Prepare valve for actuation:
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.
NOTE: It is not normally necessary to remove any valve
body bolts or remove valve from line in order to mount
actuator.
Position of pinion
flats and groove
(60º approx.)
Inlet support rod
(with cross hole)
Label
5.5.1 Rotate valve ball and stem to position necessary to
achieve desired operation.
5.6 Blank support rod
(without cross hole)
Foolproof pin
location holes
Bores containing
bearings only
Attach bracket/actuator assembly to valve as follows:
5.6.1 Center coupling on valve stem.
5.6.3 Secure bracket to valve using cap screws and lockwashers, or bolts and nuts provided in mounting kit.
Tighten securely.
5.6.4 Install set screws (if any) in coupling and tighten
securely.
5.6.5
Determine if mode of operation (air to open or close/fail
open or closed) is as desired; if not:
Air to Open or Close - On all sizes of 40R doubleacting and spring-return actuators, the female drive
shaft is either a NORBRO square or a star drive
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.
Fail Open or Fail Close - 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”
(Clockwise to close) position. “FAIL-OPEN” can be
achieved using the method above but the actuator will
then work as Clockwise to open).
Inlet
End Cap
Inlet port
Limit Stop
End Cap
#
5.6.2 Lower mounting bracket/actuator assembly over
coupling and onto valve, making sure that female star
drive or NORBRO square actuator shaft engages in the
correct orientation with the coupling.
Foolproof pin
Label
Bores containing Foolproof pin
bearings and
0-rings
Actuator
Size
05
10
15
20
25
30
33
35
40
42
45
50
Pinion Offset
Angle #
0°
10°
2°
2°
2°
2°
2°
2°
0°
0°
0°
12°
For “FAIL-OPEN” but with Clockwise to close operation, the pistons in the actuator will need to be removed
and reassembled from the opposite ends of the
actuator (keeping the guide rods the same sides
relative to the body). This will result in a slight offset
of pinion position on some sizes. See following:
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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FITTING INDICATORS
7
AIR SUPPLY AND INSTALLATION
Actuator sizes 10, 15, 20
7.1
Air Supply:
The Series 40R actuator is factory lubricated. For
optimum operation, the use of filtered and lubricated
air is recommended.
7.2
Air Supply Pressure:
Standard double-acting actuators require 2–8 bar
supply air. Spring-return actuators require 2.5–7 bar
supply air. Spring-return actuators can also be set
up to operate on supply air pressures ranging from
2.5–5.5 bar by using fewer springs. See “Rebuilding
Instructions”, Spring-Return Actuator, paragraph 1 on
page 13 for proper number and location of springs for
reduced supply air pressures.
White Plugs
Plugs
White
RedPlugs
Plugs
Red
White Plugs
Plugs
White
Red Plugs
Plugs
Red
Fig.: 1Fig.: 2
As supplied
Alternative Indicating Position
NOTE: Indicator is set up to show pistons together on
actuator, i.e. valve closed when in-line mounting - See Fig. 1.
6.1
Check which visual indication is required.
6.2
Check that indicator when located on pinion will show
correct indication.
6.3
To change indication, push out red and white buttons
and reassemble in alternative position.
6.4
Locate indicator on pinion flats. Press firmly until location nibs fit into recess on pinion.
Actuator sizes 25, 30, 33, 35, 40, 42, 45, 50
WARNING: Air pressure greater than the maximum on the
STOP!
label must not be applied.
7.3
Air Supply Connections:
Double-Acting – Connect air supply lines to both BSPP
(1/8” on size 05/10: ¼” on sizes 15–50) ports.
Spring-Return Models – Connect air supply line to the
outboard BSPP (1/8” on size 05/10: ¼” on sizes 15–50)
port.
For sizes 10–50, the ports are on the solenoid end cap.
The solenoid end cap is the one on the left end of the
actuator when looking at the nameplate. For 05 size
only, the ports are on the solenoid block interface plate
on back of actuator when looking at the nameplate. For
size 05 spring-return it is on the back and near center
of actuator.
7.4
Recommended Tubing Sizes:
In order to provide sufficient flow of supply air to the
Series 40R actuator, the following tubing sizes are
recommended:
White Plugs
Plugs
White
Actuator Size
6.5
Check which visual indication is required.
6.6
Locate indicator on pinion flats. Press firmly until location nibs fit into recess on pinion.
6
Runs Up To
1.5 m Long
Runs Over
1.5 m Long
05, 10, 15, 20, 25
1 8
/
¼
30, 33, 35, 40, 42, 45
¼
3 8
50
¼
½
/
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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8
AIR CONSUMPTION
The following chart shows the amount of pressurized
(5 bar) air consumed per stroke in litres. 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
spring return units, the total volume of air consumed is
the volume shown for the opening stroke.
Actuator Size
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.
The accurate rotation of the actuator pinion is controlled
through the adjustment of two hexagon headed bolts
on the end cap. Each bolt will control either the open
or closing stroke (based on how the actuator has been
orientated on the valve). The adjustment of each bolt
is shown on the end cap. Actuators are factory set
to provide a 90˚ operation. If adjustment needs to be
made the lock nut will need to be backed off, the adjustment screw rotated to provide correct positioning and
the lock nut retightened. For size 10 to 35 turn screw
clockwise to decrease rotation and counterclockwise to
increase rotation. For size 40 to 50 the reverse applies.
It is critical to retighten to ensure an effective seal of the
washer.
Care should be taken to secure travel stop setting when
tightening lock nut.
Air consumption litres
Opening Stroke
Closing Stroke
05
0.05
0.05
10
0.17
0.22
15
0.35
0.39
20
0.69
0.74
25
1.22
1.31
30
1.86
2.05
33
3.39
4.79
35
3.93
5.54
40
7.73
8.19
42
12.0
13.89
45
13.51
20.0
50
23.87
30.5
9
INSTALLATION OF ACCESSORIES
For details of installation of accessories refer to the
installation instructions contained in respective accessory kit.
10OPERATION
10.1
Basic Actuator
The Series 40R actuator drive shaft rotates through
a full 90° segment with approximately 3° overtravel
at each end of travel (limit stop version). 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
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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10.2
Actuator With Solenoid
Actuator Size
Stroke Time (sec.)
Double-Acting – Air is supplied to the one BSPP 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.
05
1
10
1
15
1
20
1
25
2–3
30
3–4
33
4–5
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.
35
4–5
40
5–6
42
6–7
45
10–12
50
12–14
The double-acting solenoid assembly is electrically failsafe. 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.
Spring-Return – Air is supplied to the one BSPP 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.
10.4.
Manual Operation
In the event of air failure, the Series 40R 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.
STOP!
11MAINTENANCE
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.
Actuator
size
Fastener size
Torque
05
M5
4Nm
10
M6
9Nm
10.3
Standard Stroke Times
15
M6
9Nm
Standard stroke times of the Series 40R 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 5 bar. Times
shown are per stroke for double acting 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.
20
M8
19Nm
25
M8
19Nm
30
M10
35Nm
33
M10
35Nm
35
M12
49Nm
40
M12
49Nm
42
M16
98Nm
45
M16
98Nm
45
M20
216Nm
8
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.
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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All actuators are supplied with sufficient lubrication for
their normal working life. If required, recommended
lubrication for all standard actuators is a Rocol Sapphire
Lo-Temp 2 grease. Consult Flowserve for lubricants
used for high or low temperature applications.
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 Flowserve 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.
12 SPARE PARTS
The following are recommended spare parts which
should be kept on hand for Series 40R pneumatic actuators:
Repair Kit(s) – Kits contain all necessary seals, bearings and instructions.
13TROUBLESHOOTING
STOP!
WARNING: BEFORE DISASSEMBLING ACTUATOR
FOR ANY REASON, CONSULT REBUILDING INSTRUCTIONS CONTAINED IN FOLLOWING SECTION.
For solenoid controlled actuators:
13.1
If actuator does not function, check to ascertain:
13.1.1 That valve is free to rotate.
13.1.2 That actuator is the correct size.
13.1 3 Any speed control screws are loose (if screws are tightened all the way, actuator will not operate).
13.2.2 If no sound is detected, remove air pressure and turn
off signal voltage.
• Carefully unscrew solenoid and solenoid stem from
block.
• Reapply signal voltage and observe solenoid plunger.
If it does not retract, replace solenoid.
13.2.3 If solenoid functions, remove solenoid valve block and
place on bench. Connect to reduced air supply (4 bar)
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.)
13.2.4 If control block and solenoid are operating correctly,
proceed to Section 13.3.2 below.
13.3
13.3 .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).
13.3.2 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.
13.4 If air supply and voltage are adequate, proceed as
follows:
13.4.1 If leak is at solenoid exhaust port, replace the solenoid.
13.4.2 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 05 size,
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.
13.5
For actuators without the 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:
13.1.4 That correct voltage is supplied to solenoid.
13.1.5 That sufficient air supply is available at inlet to control
block. Inlet pressure to control block should be at
least 2.5 bar for double-acting, 5 bar for spring-return
(unless a reduced spring complement is installed
(fewer springs)). When checking supply pressure,
place gauge in line at control block inlet and monitor
gauge for unexpected pressure drops.
13.2
If proper voltage and air pressure have been verified
and valve is free, proceed as follows:
13.2.1 Turn on signal voltage. Check solenoid for clicking
sound.
If the actuator functions but exhibits leakage, or power
loss accompanied by leakage, proceed as follows:
13.5.1 Make sure that all internal porting is free and clear of
any obstructions. End caps, guide rods and pistons are
air transporting components.
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Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
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NOTE: The most common problem encountered on 40R
actuators is the improper replacement of the piston
guide rod assembly with the hole in it, relative to the
nameplate on the body (see section 14.2.7 on page 12).
13.5.2 Make certain that the actuator has lubrication, and that
there is no solidified grease between the pinion and the
piston racks:
• If actuator has no lubrication, apply generous amount
of grease. If actuator is prepared for high or low
temperature operation, consult Flowserve for proper
lubricants.
• If solidified grease between the pinion and the piston
racks is present, clean, dry, re-grease and reassemble.
13.5.3 Verify that actuator pinion shaft and/or pistons are not
bound. If bound, reassemble per Rebuilding Instructions.
13.5.4 If unit exhibits excessive amounts of backlash, check
teeth on piston racks for wear. If worn, replace piston
assemblies.
13.5.5 In spring-return actuators, check for misplaced or
broken springs. If springs are broken, check body bore
for scoring:
• If springs are broken, replace springs. SPRINGS
SHOULD ALWAYS BE REPLACED IN COMPLETE SETS.
• If body bore is scored, replace it. Also, replace piston
O rings (contained in repair kit).
13.5.6 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.
14 REBUILDING INSTRUCTIONS
piece non-top-mount style valve, the two top valve
body bolts must be removed.
14.1.3 Remove the actuator bracket (and actuator positioner)
from the actuator to begin repair. (Note mounting of
removed bracket and positioner for easy reassembly.)
14.1.4 It is not necessary to remove solenoid control block (if
so equipped) to rebuild actuator. However, if it becomes
necessary to remove the block, begin by removing the
solenoid block bolts. Use care to retain the solenoid
block gasket.
For 05 size only, also remove the solenoid block
interface plate (20) and the interface gasket (19) by
removing the three screws (21).
For sizes 10 to 35 it is not necessary to remove the limit
stop bolts from the end cap.
CAUTION: For sizes 40 to 50 the limit stop bolts will
need to be removed to facilitate disassembly. On these
sizes remove the air inlet end cap. Then remove the limit
stop lock nuts and unscrew the limit stop bolts through
the guide rods. This should be done in conjunction with
the instructions below.
14.1.5 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, remove the two
bearings (6) and O-rings (15A and 15B) from each end
cap. Note that for models with top-hat style 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.
NOTE: For identification of all numbered parts discussed
below, consult exploded view of actuator (see pages
14/15)
WARNING: Spring return actuators contain energized
STOP!
springs. The following section must be followed to
ensure safe disassembly of the actuator.
After actuator has been repaired, mark rebuild label
accordingly and apply to actuator.
14.1
Actuator disassembly
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.
14.1.1 Disconnect the air supply and electrical service to the
actuator.
14.1.2 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.)
10
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-
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
14.1.6 The two piston guide rod (4) assemblies can now be
removed from each end of the body. Do not disassemble the piston from the guide rod. (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).
14.1.7 The shaft (2A) 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: On later 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.
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.
Sizes 25 through 42, have an anti-ejection ring (15J).
The anti-ejection ring does not have to be removed and
may or may not be included in repair kits.
14.2
Actuator reassembly
14.2.3 If converting over to a “high-temperature” actuator, or
rebuilding an existing one, lubricate thoroughly with
high temperature silicone or graphite based grease.
NOTE: Some older style actuators, sizes 10–35, use
flanged bearings in the end caps. They resemble a “top
hat”, and are installed with the brim of the hat facing
out, and are retained by “star washers”. These bearings
and star washers should not be removed for O-Ring
seal replacement.
For sizes 10–50 replace the two split-ring style bearings
(6) and one guide rod O-ring (15B) in each end cap.
Replace the split-ring style bearing (6) 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.
14.2.4 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: On later
models 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. Insert the shaft
through the larger opening in the bottom of the body.
14.2.5 Replace the stainless steel washer over the top shaft
extension.
14.2.1 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.
14.2.2 All rebuilding kit O-Rings and bearings may now be
installed. Lubricate the standard actuator thoroughly
with grease. Apply a light film of grease to all O-Rings.
11
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
14.2.6 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,
40R 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.
14.2.9 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”.
14.2.10Once 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!
°
Nameplate
Figure 1
Pistons at End of Body
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).
CAUTION: For sizes 40 to 50 limit stop variant, the limit
stop end cap must be assembled first. Once assembled, feed the limit stop bolts through the guide rods
and screw into the end cap. Add the sealing washer,
backing washer and lock nut and then attach the air
inlet end cap. This should be done in conjunction with
the instructions below.
14.2.11 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).
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.
For size 05, align the pistons inside the body. Keep the
pistons square to the body.
NOTE: For spring return actuators, see spring installation section on page 13 before installing end caps.
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).
NOTE: 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 drop down and get pinched.
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 10 for installation of spiral-ring type
shaft clip (which newer rebuilding kits will contain).
On Rev. R2 and earlier actuators, be sure O-Ring is
installed in groove on end cap.
14.2.7 Align the shaft so that the teeth on the shaft will “pickup” 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).
14.2.8 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).
12
14.2.12 Replace position indicator (17). See Section 6.
15 SPRING-RETURN ACTUATOR
15.1
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.
The values listed below are for standard and less than
the standard air pressure as required per the ordering
code.
NOTE: Maximum operating pressure does not change.
15.2
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.
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
15˚ - 20˚
15˚ - 20˚
Size 05 - 20
Size 25 - 50
Series 40R Sizes 10 - 42
4.5 bar - 8 springs - 4 per end cap.
Remove center spring.
4.0 bar - 8 springs - 4 per end cap.
Remove center spring.
3.5 bar - 6 springs - 3 per end cap.
Use three on a diagonal.
3.0 bar - 4 springs - 2 per end cap.
Use two in opposite corners.
Series 40 Sizes 45 - 50
4.5 bar - 20 springs - 10 per end cap.
Figure 2
Alignment of Shaft at Reassembly
IMPORTANT: Align gear teeth on the shaft as per Figure 1.
15.3
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!
15.4
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).
15.5
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 cast into the piston face
on sizes 25 to 50. 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.
15.6
In a similar manner, as written in the previous steps,
replace the springs in the other end of the actuator
body.
NOTE: On sizes 40 to 50 limit stop, only encapsulated
springs (pre-compressed) can be used with this design.
Remove required number of
4.0 bar - 20 springs - 10 per end cap. springs starting in the center.
3.5 bar - 16 springs - 8 per end cap. Remaining springs should be
evenly spaced as possible.
3.0 bar - 12 springs - 6 per end cap.
The size 05 spring-return actuator operating at 5.5 bar has four
springs (two per end cap). For air supplies of 4.5, 4.0 or 3.0, remove
inner spring of each end cap.
13
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
16 Size 05 Exploded view/parts/materials
14A
14A
5
(Spring return)
18
17
5
(Spring return)
14A
14B
15F
S. S. Washer
5C
15G
5
19
5
(Double acting)
3
15A
15C
1
3
20
21
15C
15A
15D
10
5C
8B
2
7A
15E
Item
1
2
3
4
5
5A
5B
5C
10
11
12
13
Qty.
1
1
2
2
2
1
1
8
1
1
2
2
Description
Body
Shaft
Pistons
Guide Rods
End Caps
Solenoid Block (Inlet) End Cap
Limit Switch End Cap
End Cap Screws (Metric)
Thrust Bearing
Nameplate (Not Shown)
Piston Set Screws
Pipe Plugs
(Double acting)
Item
14A
14B
15A
15C
15D
15F
15G
17
18
19
20
21
8E
Qty.
2
2
2
2
1
1
1
1
1
1
1
3
8E
8D
18C
Description
Inner Springs (See Table Page 13)
Outer Springs (See Table Page 13)
End Cap O-Rings
Piston O-Rings
Top 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.
14
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
17 Size 10-50 Exploded view/parts/materials
The rebuilding kit includes items
15A through 15H, 6, 9, 10, and
stainless steel washers. The color
of some replacement parts, such as
bearings, may vary from the parts
removed.
REVISION D
9
4
11
4
9
9
Old style
New style
21
21
Item
1
2A
2B
3
4
5A
5B
5C
6
9
10
11
12
14
Qty.
1
1
1
2
2
1
1
8
6
1
9
1
2
10
Description
Body
Shaft, Size 10 to 20
Shaft, Size 25 to 50
Pistons
Guide Rods
Inlet End Cap
Limit Stop End Cap
End Cap Screws (Metric)
End Cap/Piston Bearing
Thrust Washer, Stainless Steel
Thrust bearing
Nameplate
Piston Set Screws
Spring
Item
15A
15B
15C
15D
15E
15F
15G
15H
15J
17
18
19
20
21
Qty.
2
6
2
1
1
1
1
1
1
1
2
2
2
2
Description
End Cap O-Rings
Guide Rod O-Rings
Piston O-Rings
Top Shaft O-Ring
Bottom Shaft O-Ring
Spiral Retaining Ring
Top Pinion Bearing
Bottom Pinion Bearing
Anti-Ejection Ring
Position Indicator
Limit Stop screws
Limit Stop Nuts
Backing Washers (sizes 25 to 50 only)
Sealing Washers
NOTE: To order proper parts, please specify the actuator size, model and revision number. Use the standard nomenclature listed above.
15
Series 40R Pneumatic Actuator - NBENIM0002-03-A4 07/15
®
Flowserve Flow Control (UK)
Burrell Road
Haywards Heath
West Sussex United Kingdom RH16 1TL
Phone: +44 1444 314400
Fax: +44 1444 314401
FCD NBENIM0002-03-A4 07/15
To find your local Flowserve representative:
For more information about Flowserve Corporation.
visit www.flowserve.com
© 2015 Flowserve Corporation. Flowserve a trademark of Flowserve Corporation
Due to continuous development of our product range. we reserve the
right to alter the dimensions and information contained in this leaflet as
required. Information given in this leaflet is made in good faith and based
upon specific testing but does not, however, constitute a guarantee.
16
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