Model DFR 047 Rotary Actuator - Dyna-Flo

Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
Figure 1 DFR 047
and 570 Control Valve
TABLE OF CONTENTS
General
2
Scope
2
Actuator Assembly
Bearing Tape Installation
15
Principles of Operation
2
Spring / Adjuster / Seat Assembly
15
Safety Caution
2
Diaphragm Plate Assembly
16
Specifications
3
Diaphragm Casing Assembly
16
Approximate Actuator Weights - Table 1
3
Lever Installation
16
Unpacking
4
Principles of Handwheel Operation
21
Installation
4
Handwheel Maintenance
21
15
Air Piping
4
Actuator Mounting
5
Actuator Cross Section - Figure 27
23
Spring Adjustment
7
Mounting Bolt Torques - Table 4
24
Initial Set
7
DFR Torque Specifications - Table 5
24
Stroke Range
8
Parts
25
Changing Actuator Style
8
Model Builder
28
Mounting Styles & Positions - Table 2
9
Mounting Orientations - Figure 9
10
Actuator Disassembly
11
Casing Disassembly
11
Spring / Adjuster / Seat Disassembly
12
Lever Removal
12
Bearing Tape Removal
14
O-Ring Replacement
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1
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
NOTICE
These instructions are meant to be used with the Dyna-Flo DFR Technical Sales Bulletin as they refer to
Figures and Tables therein. If you do not have the Technical Sales Bulletin, contact Dyna-Flo immediately,
or visit www.dynaflo.com.
Each control valve is factory checked. Check the calibration for the specific application, before a valve
or actuator is put into service.
It is the intention of this document to provide users with an accurate guide for safe installation and
maintenance of the DFR Actuator. Revisions and updates are available at above mentioned website.
GENERAL
The following instructions are to be thoroughly reviewed and understood prior to installing, operating or performing
maintenance on this equipment. Work on this equipment should be performed by experienced personnel. Throughout
the manual, safety and caution notes appear and must be strictly followed to prevent serious injury or equipment
malfunction.
SCOPE
The actuator configuration and construction materials were selected to meet particular pressure, temperature, operating medium,
and process fluid conditions. Some material combinations are limited in their pressure and temperature ranges. Do not apply any
other conditions to the actuator without first contacting your Dyna-Flo sales office.
This manual is written to be a practical and useful guide for maintaining the Dyna-Flo DFR Actuator.
PRINCIPLES OF OPERATION (For Top-Mounted Handwheels refer to Page 22)
The DFR actuator works by loading pressure on the top side of the diaphragm (Key 22), this loading pressure moves the actuator
stem (Key 7) downwards. As the loading pressure is decreased, the spring (Key 6) forces the actuator stem upwards.
The spring and diaphragm have been selected to meet a specific application requirement, and while in service the actuator should
produce full travel of the valve with the diaphragm pressure indicated on the nameplate (Key 36).
If there is no positioner being used with the control valve, a loading device (such as a 4-way switching valve) must be used. Loading
devices do not come equipped standard with the actuator. Refer to appropriate positioner instruction manual as required.
SAFETY CAUTION
Only well trained experienced technicians should perform these procedures. Use safe work practices and lock out
procedures when isolating valves and actuators. It is also important to wear the proper protective equipment when
performing any installation or maintenance activity. Use only parts and materials rated for the process being used,
operating conditions, and environmental conditions products will be used in.
To avoid personal injury or installation damage as a result of the sudden release of process pressure or damage to
equipment, do not install the actuator assembly where service conditions could exceed the limits stated in this manual,
sales bulletin or on the equipment nameplates. Use government codes, accepted industry standards and good piping
practices, and select proper pressure-relieving equipment for protection of your installation. Always be aware of
flammable process and instrument gas.
Always be aware of the hazards of actuators, especially spring-loaded actuators. Be sure that the actuator is
de-energized or in the failed position before performing any maintenance procedure.
These actuators have dangerous pinch points. Never put your hands inside the valve or actuator unless you are certain
that the valve or actuator will not suddenly move.
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
SPECIFICATIONS
Actuator Size
Active Diaphragm
Area in2 (cm2)
Maximum Casing
Pressure Psig (kPag)
047
48 (310)
65 (448)
Maximum Shaft Rotation
90 degrees.
Material Temperature Capabilities
Standard: -40 to 180 oF (-40 to 82 oC).
Shaft Connection Types
The standard shaft connection is a splined shaft suitable for a
Dyna-Flo 570 control valve.
Construction Materials
See Parts list for construction materials.
Contact your Dyna-Flo sales office for more information and
other options.
Valve Shaft Compatibility, inches (mm)
Size 047:
Standard Tubing Connection Size
All sizes, 1/4 inch NPT.
1/2 (12.7), 5/8 (15.9), 3/4 (19.1)
Options
• Manual override
• Reduced rotation output
• Increased tubing connection size
• Travel stops
Diaphragm Casing Volume
Refer to Table 7 of Sales Bulletin.
Actuator Dimensions
Refer to Figure 3 & 4 of Sales Bulletin.
Refer to Tables 2, 3, & 4 of Sales Bulletin.
Output Torque
Refer to Tables 5 & 6 of Sales Bulletin.
For more information and other options contact your Dyna-Flo
sales office.
Actuator Mounting Orientation Valve Applications
Refer to Figure 9.
Refer to Table 2.
Table 1
Approximate Actuator Weights - lb. (Kg)
Actuator Size
Standard Assembly
With Top Mounted Handwheel
047
46 (21)
57 (26)
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
UNPACKING VALVE FROM SHIPPING
CONTAINER
INSTALLATION
Special Tools Required:
• Read the General and Scope section of this manual (Page 2).
• Properly Rated Lifting Straps (2 – 4 Straps) See Table 1 for
actuator weights.
• Read Safety Caution (Page 2).
Before You Begin:
• Lifting Device (Example: Crane)
Check the packing list, verify that the list includes all the
materials in the shipping container before unpacking. Valve
information can be found on the nameplate (Key 36). Refer to
Figure 11 for nameplate location.
When lifting the valve from shipping container, place properly
rated lifting straps securely around the neck of the actuator,
refer to Figure 2 for strape placement. Straps should be placed
to avoid damage to tubing and other mounted accessories.
Lift the valve/actuator assembly using proper lifting techniques.
• Sudden movement of actuator can cause damage or injury.
It helps to have the actuator de-energized as long as the
valve installation will permit.
• Use safe work practices and lock out procedures before
placing valve in-line.
Actuators are typically shipped from factory as an assembly
already mounted to the valve. Follow the appropriate valve
installation instructions to install the actuator / valve assembly.
If the actuator was shipped separately, it will be necessary to
mount the actuator on the valve prior to installation, refer to
the Actuator Mounting section.
Operating medium must be controlled and directed, if a
positioner was not ordered or unavailable, use a loading
device such as a 4-way switching valve (not provided with the
actuator). For more information on positioner installation and
operation, refer to the appropriate positioner instruction
manual for your positioner type.
AIR PIPING
WARNING:
Property damage, environmental harm, and personal injury
can result from the use of supply gas other than clean,
non-corrosive, oil and moisture free air. Do not exceed the
supply pressure indicated on the nameplate (Key 36)
located on the actuator.
LIFTING STRAP
Before You Begin:
Note: Standard actuators accept 1/4” (6 mm) NPT connections.
Piping Installation Steps:
1
Use 3/8” (10 mm) outside diameter SST tubing
(or equivalent) for air lines. Keep length of tubing as short
as possible to prevent transmission lag in the control
signal.
2
Install the required line vents, valves, drains, seals, and
filters to the actuator.
Figure 2 Suggested Lifting Strap Placement
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
ACTUATOR MOUNTING
Before You Begin:
• Read the General and Scope section of this manual (Page 2).
• Read Safety Caution (Page 2).
• Use safe work practices and lock out procedures.
• Disconnect supply lines (air or gas), electric power, or control
signal to the actuator. Sudden movement of actuator can
cause damage or injury, make sure actuator will not operate.
20
1
10
• Vent any pneumatic actuator loading pressure.
27
• Relieve process pressure and drain the process fluid from up
and down stream of valve.
• Be aware of potentially hazardous process material that may
be present in-line and in-valve. Isolate the valve from
process pressure. Use a bypass or block valve if necessary,
or completely shut off the process. Relieve internal valve
pressure (refer to the appropriate valve instruction manual).
21
26
Lubricants Required:
14
• Permatex® Nickel Anti-Seize or equivalent (Key A)
• Fluid Film® (Key D)
11
1
Before mounting the actuator to a control valve, it is
recommended to perform the Spring Compression
Adjustment (Page 7). Spring Compression Adjustment
must be performed while the actuator is removed from the
valve.
ALIGN THE MARK
ON THE VALVE
SHAFT (KEY V)
WITH THE MARK
ON THE LEVER
(KEY 10).
2
If the valve has been removed from the pipeline, secure
the valve assembly in place on a flat work surface
that will support the weight of the combined valve and
actuator assembly.
3
Remove any positioners and/or instrumentation installed
on the actuator.
4
Remove the cover plate (Key 26) by removing the screws
(Key 27).
5
Using a 5/16” socket bit, loosen the cap screw (Key 11) on
the lever (Key 10).
6
Before placing the valve shaft (Key V) into the lever (Key
10), position the valve ball/disc as follows:
V
20
D
For push-down-to-close action (fail open):
Rotate the valve ball/disc into the fully open position.
For push-down-to-open action (fail closed):
Rotate the valve ball/disc into the fully closed position.
Figure 3 Actuator Mounting
Note: Refer to the appropriate valve instruction manual.
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
OPERATING PRESSURE
SUPPLY LINE WITH MAXIMUM
OPERATING
PRESSURE APPLIED
TO ACTUATOR
33
VALVE
BALL
NOT
100%
CLOSED
19
34
35
UP STOP
13
11
14
DOWN STOP
ADJUSTED DOWN
TO CLOSE VALVE
Figure 4 Actuator/Valve Body Bolting
ACTUATOR MOUNTING (Continued)
7
Apply Fluid Film® (Key D) to the teeth of the valve shaft
(Key V).
8
Slide the actuator onto the valve shaft as shown in Figure
3. Refer to Figures 9 for actuator mounting positions and
orientations. Align the mark on the valve shaft (Key V) with
the appropriate mark on the lever (Key 10).
VALVE
BALL
100%
CLOSED
Note: The actuator is typically installed in a vertical
orientation. Should the actuator be installed in a horizontal
position, then it may be necessary to have external support
for the actuator in this position.
9
Once the actuator is installed on the valve shaft in the
proper orientation, secure the actuator in place using the
mounting bolts (Key 33), lockwashers (Key 34), and hex
nuts (Key 35). Refer to Figure 4, and Table 3 for torque
values.
10 With a 5/16” socket bit, tighten the lever cap screw (Key
11) to secure the lever (Key 10) to the valve shaft (Key V).
DOWN STOP
PROPERLY ADJUSTED
Figure 5 Mounting Adjustment for Push-Down-To-Close
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KEY 19
INDICATES
VALVE IS CLOSED
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
ACTUATOR MOUNTING (Continued)
11 Adjust the up travel stop (Key 14, Figure 5) until the valve
ball/disc is in the desired position. Note: Refer to the
appropriate valve instruction manual for information on
valve travel and positions.
12 Slowly stroke the actuator until the maximum operating
pressure is reached as indicated on the nameplate (Key
36). Note: Use caution when stroking the actuator, avoid
dangerous pinch points and equipment damage by keeping
appendages and tools away from moving actuator parts.
13 With operating pressure applied to the actuator, adjust
the down travel stop (Key 14, Figure 5) until the travel
indicator (Key 19) shows the valve ball/disc to be in the
desired position. Refer to Figure 5 for a push-down-toclose valve configuration example.
When the actuator is connected to a valve with pressure
applied to that valve, a higher casing pressure will be required
to begin actuator travel.
The initial setting was selected to meet a specific set of service
condition requirements. Proper initial setting will ensure that
once the actuator and valve are in service, the valve will seat
properly and full travel will be achieved within the specified
diaphragm casing pressure range.
Note: If the actuator has been disassembled and reassembled,
or if service requirements have changed, it will be necessary to
perform the following steps for Initial Setting.
1
If the actuator is mounted to a valve, remove the screws
(Key 27) and cover plate (Key 26). With a 5/16” socket bit,
loosen the lever cap screw (Key 11) holding the valve shaft
(Key V) in the lever (Key 10). Remove the actuator from
the valve by removing the mounting bolts (Key 33), hex
nuts (Key 35), and washers (Key 34). Refer to Figure 4.
2
Disconnect any instrumentation attached to the actuator.
3
Remove the screws (Key 29) and the spring adjuster
cover (Key 28).
4
Apply operating pressure to the diaphragm casing, when
the spring is properly adjusted, the actuator stem (Key
7) will start to move when the Initial Set pressure
(indicated on the nameplate (Key 36) or in Table 5) is
reached. Make note whether the actuator stem started to
move before or after the Initial Set value.
5
Relieve actuator casing pressure.
14 Re-install the cover plate (Key 26) using the screws
(Key 27).
SPRING ADJUSTMENT
Before You Begin:
• Read the General and Scope section of this manual (Page 2).
• Read Safety Caution (Page 2).
• Use safe work practices and lock out procedures.
• Disconnect supply lines (air or gas), electric power, or control
signal to the actuator. Sudden movement of actuator can
cause damage or injury, make sure actuator will not operate.
• Vent any pneumatic actuator loading pressure.
• Relieve process pressure and drain the process fluid from up
and down stream of valve.
• Be aware of potentially hazardous process material that may
be present in-line and in-valve. Isolate the valve from
process pressure. Use a bypass or block valve if necessary,
or completely shut off the process. Relieve internal valve
pressure (refer to the appropriate valve instruction manual).
29
4
Special Tools Required:
• Flat-head screwdriver or flat-bladed tool.
• Regulated operating supply pressure and 1/4” NPT fittings.
INITIAL SET
28
Refer to the actuator nameplate (Key 36) for the Initial Set.
The initial setting is the casing pressure at which the diaphragm
(Key 22) begins to move the diaphragm plate (Key 8) and
actuator stem (Key 7) away from the up travel stop when
the actuator is not attached to the valve.
Figure 6 Spring Adjuster Cover Removal
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
To shift the casing pressure span upward – rotate the
spring adjuster to the left (clockwise when viewed from above).
CHANGING ACTUATOR STYLE
Refer to the Before You Begin section of the Actuator Mounting
instructions (Page 5).
TURNING THE SPRING
ADJUSTER (KEY 4)
CLOCKWISE (TO THE
LEFT) WILL INCREASE
THE INITIAL SETTING.
TURNING THE SPRING
ADJUSTER (KEY 4)
COUNTER-CLOCKWISE
(TO THE RIGHT) WILL
DECREASE THE INITIAL
SETTING.
Figure 7 Spring Adjustment
Mounting Styles B and C
Style B is right-hand mounted and Style C is left-hand
mounted, in all other ways Styles B and C are identical.
Refer to Figure 9.
Note: To convert a Style A or D into a Style B or C actuator,
the actuator must first be separated from the control valve.
Refer to Steps 1 and 2 of the Initial Set section (Page 7).
SPRING ADJUSTMENT (Continued)
INITIAL SET (Continued)
6
Mounting Styles A and D
Style A is right-hand mounted and Style D is left-hand
mounted, in all other ways Styles A and D are identical.
Refer to Figure 9.
Using a flat-head screwdriver or a flat-bladed tool,
adjust the spring adjuster (Key 4) accordingly:
Refer to Figure 8.
• To increase Initial Setting (increase spring compression)
– Turn the spring adjuster to the left (clockwise when
viewed from above).
1
Remove the machine screws (Key 18) and travel indicator
(Key 19).
2
Remove the machine screws (Key 18) and travel scale (Key
17).
3
Remove the cap screws (Key 21) and mounting yoke (Key
20).
4
Swap the position of the travel indicator (Key 19) and
mounting yoke (Key 20) as shown in Figure 8. Install
the travel scale on the opposite side of the actuator using
the machine screws (Key 18). Install the travel indicator
(Key 19) into the opposite side of the lever (Key 10) using
the machine screws (Key 18).
5
Place the mounting yoke (Key 20) in the desired
orientation (refer to Table 2 and Figure 9 for Mounting
Positions) on the opposite side of the actuator. Secure the
mounting yoke in place using the cap screws (Key 21),
tighten the cap screws to the torque specification listed in
Table 4.
6
Once an actuator has been converted to a different
mounting style, the actuator must be re-adjusted. Refer to
the Spring Adjustment section of this manual.
• To decrease Initial Setting (decrease spring compression)
– Turn the spring adjuster to the right (counterclockwise when viewed from above).
7
Repeat Steps 4 – 6 until the Initial Set pressure is reached.
8
Re-install the spring adjuster cover (Key 28) and screws
(Key 29). Proceed to Actuator Mounting section.
STROKE RANGE
Should the desired stroking range be unachievable during
normal operating conditions with the casing pressure used,
it may be possible to adjust the stroking range by making a
spring adjustment. A spring adjustment will shift the casing
pressure span and either increase or decrease the casing
pressure at which the actuator begins its stroke, this will affect
the pressure at which the actuator reaches full travel.
Refer to the Initial Set section and adjust the spring adjuster
(Key 4) as follows:
To shift the casing pressure span downward – rotate the
spring adjuster to the right (counter-clockwise when viewed
from above).
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
TO
STYLE A / D
STYLE B / C
21
20
17
19
18
18
21
1
18
10
10
20
Figure 8 Changing Actuator Style
Table 2
Model DFR Mounting Styles and Positions
Mounting
Action
Model 570 Valve
Model 660 Butterfly Valve
Style B
Right Hand
Fail Open
Style A
Right Hand
Fail Close
Style B
Style A
Left Hand
Fail Open
Style C
Style C
Left Hand
Fail Close
Style D
Style D
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
D
C
Left Hand Mount
B
A
Right Hand Mount
STYLE B
STYLE A
POSITION 1
POSITION 1
STYLE C
STYLE D
POSITION 1
POSITION 1
Flow
Flow
RIGHT-HAND MOUNTING
LEFT-HAND MOUNTING
Figure 9 Mounting Orientation and Valve Applications
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
ACTUATOR DISASSEMBLY
Before You Begin:
• Read the General and Scope section of this manual (Page 2).
• Read Safety Caution (Page 2).
• Use safe work practices and lock out procedures.
TURN THE UP TRAVEL STOP (KEY 14) CLOCKWISE UNTIL THE DIAPHRAGM (KEY 22) AND
DIAPHRAGM PLATE (KEY 8) NO LONGER MAKE
CONTACT WITH THE DIAPHRAGM CASE (KEY
23).
• Disconnect supply lines (air or gas), electric power, or control
signal to the actuator. Sudden movement of actuator can
cause damage or injury, make sure actuator will not operate.
8
• Vent any pneumatic actuator loading pressure.
• Relieve process pressure and drain the process fluid from up
and down stream of valve.
• Be aware of potentially hazardous process material that may
be present in-line and in-valve. Isolate the valve from
process pressure. Use a bypass or block valve if necessary,
or completely shut off the process. Relieve internal valve
pressure (refer to the appropriate valve instruction manual).
22
Special Tools Required:
• Soft tip felt marker.
• Flat-head screwdriver or flat-bladed tool.
CASING DISASSEMBLY
1
If the actuator has been removed from the valve and
pipeline, secure the actuator assembly in place on a flat
work surface that will support the weight.
2
Remove any positioners installed on the actuator.
3
Observe the position and movement of the travel indicator
(Key 19). Using a soft tip felt marker, mark the position of
the travel indicator on the travel scale (Key 17).
4
Note: There are two methods for removing spring tension
before disassembling the actuator casing. Method A can be
used for maintenance purposes to replace the diaphragm
(Key 22), Method B is quicker to use when completely
disassembling the actuator.
13
A
Remove all spring tension by first loosening the jam
nut (Key 13) on the up travel stop (refer to Figure 10),
and then adjusting the up travel stop clockwise (into
the housing) until the travel indicator (Key 19) begins
to move. Stop adjusting the up travel stop at this point
as the spring tension resting against the upper
diaphragm casing (Key 23) will have been removed.
14
THE TRAVEL INDICATOR (KEY 19)
WILL BEGIN TO MOVE WHEN THERE
IS NO LONGER ANY CONTACT
BETWEEN THE DIAPHRAGM CASE
AND THE DIAPHRAGM.
Figure 10 Method A - Spring Tension Removal
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
23
ACTUATOR DISASSEMBLY (Continued)
24
4
(Continued)
B
Remove the screws (Key 29) and spring adjuster
cover (Key 28). Using a flat-head screw driver or flatbladed tool, turn the spring adjuster (Key 4) to the
right (counter-clockwise when viewed from above)
until the spring seat (Key 5) makes contact with the
spring adjuster. Refer to Figures 6 and 7.
22
8
25
36
1
5
Remove the cap screws (Key 24) and hex nuts (Key 25)
from the diaphragm casing (Key 23).
6
Remove the upper diaphragm casing (Key 23) and
diaphragm (Key 22).
7
Inspect all parts for damage or wear, replace or repair
parts as necessary. All soft parts such as diaphragm should
be replaced.
SPRING / ADJUSTER / SEAT DISASSEMBLY
9
8
1
1
Using a 3/8” socket bit, remove the socket head cap
screw (Key 9) from the actuator stem (Key 7).
2
Remove the diaphragm plate (Key 8).
3
Remove the upper thrust washer (Key 3).
4
Remove the spring (Key 6).
5
Remove the spring seat (Key 5) and spring adjuster (Key
4).
6
Remove the lower thrust washer (Key 3).
7
Inspect all parts for damage or wear, replace or repair
parts as necessary.
LEVER REMOVAL
Note: For Styles B and C actuators, the actuator must be
removed from the control valve to be able to remove the
actuator stem (Key 7) by disconnecting it through the
housing cover (Key 15). Refer to the Spring Adjustment Initial Set Section, Steps 1 and 2 for actuator/valve
separation instructions.
1
Figure 11 Diaphragm Casing Disassembly
For Styles A and D actuator configurations:
A
Remove the machine screws (Key 18) and travel
indicator (Key 19).
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
3
STYLES A & D
6
1
16
17
4
18
5
11
3
19
1
7
18
10
20
13
15
2
14
STYLES B & C
Figure 12 Spring / Adjuster / Seat Disassembly
20
16
2
1
ACTUATOR DISASSEMBLY (Continued)
LEVER REMOVAL (Continued)
1
For Styles A and D actuator configurations (Continued):
B
Remove the machine screws (Key 18) and travel scale
(Key 17) if necessary.
C
Remove the cap screws (Key 16) and housing cover
assembly (Key 15).
For Styles B and C actuator configurations:
2
A
Remove the cap screws (Key 21) and mounting yoke
(Key 20).
B
Remove the cap screws (Key 16) and housing cover
assembly (Key 15).
21
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Figure 13 Housing Cover / Yoke Removal
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Remove the bolt (Key 12) from the lever/actuator stem
connection (Keys 10 and 7).
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13
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
10
2
ACTUATOR DISASSEMBLY (Continued)
LEVER REMOVAL (Continued)
3
Remove the actuator stem (Key 7).
4
Remove the lever (Key 10).
5
For Styles B and C actuator configurations, if not already
removed, remove the machine screws (Keys 18), travel
indicator (Key 19), and travel scale (Key 17).
6
Remove the travel stops (Keys 14 and 13) if necessary.
7
Inspect all parts for damage or wear, replace or repair
parts as necessary.
1
14
11
13
Figure 15 Lever Removal 2
BEARING TAPE REMOVAL
1
Inspect the bearing tape (Key 2) in the housing and
housing cover (Keys 1 and 15) for damage and wear. If the
bearing tape needs to be replaced, remove them using a
mechanic pick set or carefully with a flat-head screwdriver.
1
1
10
7
15
12
14
2
11
2
Figure 14 Lever Removal 1
Figure 16 Bearing Tape Removal
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14
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
ACTUATOR ASSEMBLY
Before You Begin:
• The Assembly section of this manual assumes that the
actuator has been completely disassembled prior to
assembly.
15
• Read the General and Scope section of this manual (Page 2).
• Read Safety Caution (Page 2).
• Use safe work practices and lock out procedures.
2
1
Special Tools Required:
• Flat-head screwdriver or flat-bladed tool.
• Regulated air supply (to stroke the actuator).
• Vise grips.
• Regulated operating supply pressure and 1/4” NPT fittings.
Lubricants Required:
• Permatex® Nickel Anti-Seize or equivalent (Key A)
• Lubriplate® No. 105 Grease or equivalent (Key C)
2
• Fluid Film® (Key D)
• Loctite® 242® (Key E)
• Mobil UnirexTM Lotemp Grease or Equivalent (Key F)
Figure 17 Bearing Tape Installation
Note: These assembly instructions assume that the control
valve is still installed in the pipeline. If the control valve has
been removed from the pipeline, make sure that the valve is
placed securely on a flat work surface or clamping device that
can support the combined weight of the control valve/actuator
assembly.
SPRING / ADJUSTER / SEAT ASSEMBLY
1
Apply Lubriplate® No. 105 Grease (Key C) to both sides of
the lower thrust washer (Key 3) and set it into the actuator
housing (Key 3) as shown in Figure 19.
2
Apply Permatex® Nickel Anti-Seize (Key A) to the threads
of the spring adjuster (Key 4).
3
Thread the spring seat (Key 5) completely onto the spring
adjuster (Key 4).
4
Apply Lubriplate® No. 105 Grease (Key C) to the bottom
surface of the spring adjuster (Key 4). Set the spring
adjuster/spring seat assembly (Keys 4 and 5) inside the
actuator housing (Key 1) so that it sits on top of the lower
thrust washer (Key 3).
5
Place the spring (Key 6) onto the spring seat (Key 5).
6
Apply Lubriplate® No. 105 Grease (Key C) to both sides of
the upper thrust washer (Key 3). Set the upper thrust
washer on top of the spring (Key 6).
BEARING TAPE INSTALLATION
1
If the bearing tape (Key 2) was removed from the housing
(Key 1) and/or the housing cover (Key 15), insert new
bearing tape. Refer to Figure 17.
2
Make sure that the cut ends of the bearing tape (Key 2)
do not overlap each other.
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
3
6
ACTUATOR ASSEMBLY (Continued)
C
DIAPHRAGM PLATE ASSEMBLY
Apply Permatex® Nickel Anti-Seize (Key A) to the threads
of the socket-head cap screw (Key 9).
2
Place the diaphragm plate (Key 8) onto the tapered end
of the actuator stem (Key 7). Thread the cap screw
(Key 9) through the diaphragm plate and into the
actuator stem, tighten the cap screw finger tight.
3
Place a wrench on the flats of the actuator stem (Key 7),
or place the actuator stem into a vice with jaw softeners.
Finish tightening the cap screw (Key 9) to the torque
specifications listed in Table 4.
4
Slide the diaphragm plate assembly (Keys 7, 8, and 9)
into the actuator housing (Key 1) so that the bottom of
the diaphragm plate (Key 8) rests on top of the upper
thrust washer (Key 3). Position the bearing of the actuator
stem (Key 7) so that it will fit properly into the lever (Key
10) once it is installed.
A
4
5
1
C
1
3
C
DIAPHRAGM CASING ASSEMBLY
Figure 19 Spring Barrel Assembly
9
Place the diaphragm (Key 22) over the diaphragm plate
(Key 8), align the holes in the diaphragm with the holes in
the actuator housing (Key 1).
2
Set the upper diaphragm casing (Key 23) on top of the
actuator housing (Key 1), align the holes. Note: If a TopMounted Handwheel is being used, it is advised that the
position of the stem (Key 103) be adjusted so that the
device will place no downward pressure on the actuator
spring (Key 6).
3
Install the cap screws (Key 24) through the diaphragm
casing (Keys 23 & 1).
4
Install the hex nuts (Key 25) and tighten them evenly in
an alternating crisscross pattern to the torque specification
listed in Table 4.
A
8
WRENCH ON
FLATS OF
ACTUATOR STEM
1
7
LEVER INSTALLATION
Figure 20 Diaphragm Plate Assembly
1
Refer to Figure 21 and slide the proper end of the lever
(Key 10) into the hole in the actuator housing (Key 1).
Refer to Figure 22.
2
Rotate and align the lever (Key 10) so that the connection
on the lever straddles the bearing of the actuator stem
(Key 7). Refer to Figure 22.
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
9
8
ACTUATOR ASSEMBLY (Continued)
LEVER INSTALLATION (Continued)
3
6
3
Apply operating pressure to the diaphragm casing until the
actuator stem (Key 7) begins to move. Continue to apply
operating pressure until the connection between the
actuator stem and the lever (Key 10) can be made.
4
Insert the end of the actuator stem into the lever and
thread the bolt (Key 12) through both. Tighten the cap
screw (Key 12) to the torque specification listed in Table 4.
5
Install the housing cover assembly (Keys 15 and 2) using
the cap screws (Key 16).
6
Relieve actuator casing pressure.
1
7
23
For Style A and D actuator configurations:
A
Install the travel scale (Key 17) onto the housing cover
(Key 15) using the machine screws (Key 18) as shown
in Figure 23.
B
Install the travel indicator (Key 19) onto the lever
(Key 10) using the machine screws (Key 18). Position
the travel indicator to point to the closest desired fail
position. Refer to Figure 23 and 24.
C
Determine desired mounting orientation (Figure 9).
Install the mounting yoke (Key 20) onto the actuator
housing (Key 1) using the cap screws (Key 21).
Tighten the cap screws to the torque specification
listed in Table 4. Refer to Figure 23.
22
8
For Style B and C actuator configurations:
A
Determine desired mounting orientation (Figure 9).
Install the mounting yoke (Key 20) onto the housing
cover (Key 15) using the cap screws (Key 21). Tighten
the cap screws to the torque specification listed in
Table 4. Refer to Figure 23.
B
Install the travel scale (Key 17) onto the actuator
housing (Key 15) using the machine screws (Key 18).
Refer to Figure 23.
C
Install the travel indicator (Key 19) onto the lever
(Key 10) using the machine screws (Key 18). Position
the travel indicator to point to the closest desired fail
position. Refer to Figure 23 and 24.
23
24
25
Figure 21 Diaphragm Plate Installation
8
Install the up and down travel stop (Keys 13 and 14) if not
already installed.
9
Adjust the up travel stop (Keys 13 and 14) untill the travel
indicator (Key 19) is pointing to the desired fail position
indicated on the travel scale (Key 17). Lock the up stop
(Key 14) in place using the jam nut (Key 13).
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
OPERATING PRESSURE SUPPLY LINE
APPLY ENOUGH PRESSURE TO
FACILITATE CONNECTION BETWEEN
THE LEVER (KEY 10) AND THE
ACTUATOR STEM (KEY 7).
1
7
10
1
7
WARNING!
DO NOT RELIEVE
OPERATING PRESSURE
UNTIL THE HOUSING
COVER (KEY 15) HAS
BEEN INSTALLED AND
CAN SUPPORT THE
OTHER END OF THE
LEVER (KEY 10).
10
11
1
12
7
10
11
Figure 22 Lever Installation
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18
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
STYLE A / D
STYLE B / C
23
23
29
29
16
1
28
1
28
15
21
19
18
18
26
27
27
15
10
13
26
17
10
16
20
13
14
DOWN STOP
14
DOWN STOP
Figure 23 Housing Cover / Mounting Yoke Installation
ACTUATOR ASSEMBLY (Continued)
12 Install the elbow vent (Key 32) if not already installed,
Refer to Figure 24.
LEVER INSTALLATION (Continued)
10 Apply operating pressure to the diaphragm casing until
the lever (Key 10) rotates the travel indicator (Key 19) to
the desired position on the travel scale (Key 17). Refer to
Figure 24. Warning: Do not stroke the actuator when the
lever (Key 10) is not supported at each end, make sure
that the housing cover (Key 15) is installed.
13 Proceed to the Spring Adjustment – Initial Set section of
this manual (Page 7). Once the spring adjustment has
been completed, install all the cover plates (Keys 26, 28, &
30). Refer to Figures 23 & 24.
11 Adjust the down travel stop (Keys 13 and 14) to make
contact with the lever (Key 10) and lock the down stop
(Key 13) in place using the jam nut (Key 13). Refer to
Figure 24.
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19
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
20
20
19
19
10
10
17
17
15
15
13
13
14
14
APPLY OPERATING PRESSURE TO THE DIAPHRAGM CASING
(KEY 23) UNTIL THE TRAVEL INDICATOR REACHES THE NEXT
OPERATING POSITION ON THE TRAVEL SCALE (KEY 17).
ADJUST THE DOWN STOP (KEY 14) TO TOUCH THE LEVER
(KEY 10) AND LOCK IT IN PLACE WITH THE JAM NUT (KEY 13).
ADJUST THE UP TRAVEL STOP (KEY 14) UNTIL
THE TRAVEL INDICATOR (KEY 19) POINTS TO THE
CLOSEST FAIL POSITION INDICATED ON THE TRAVEL
SCALE (KEY 17). LOCK THE UP STOP IN PLACE USING
THE JAM NUT (KEY 13).
Figure 24 Travel Stop Adjustment - Fail Open Style A/D Example
20
1
31
20
21
30
13
32
14
14
Figure 25 Positioner Plate and Vent Installation
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20
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
100
PRINCIPLES OF OPERATION AND
ADJUSTMENT – HANDWHEELS
101
TOP-MOUNTED HANDWHEELS
DFR Top-Mounted Handwheel assemblies are attached to a
modified upper diaphragm casing (Key 23A) using cap screws
(Key 109). To lock the handwheel in position, tighten the lock
nut (Key 104) into the body (Key 105) of the handwheel.
102
103
104
To compress the spring (Key 6) and move actuator stem
(Key 7) down:
Turning the handwheel (Key 102) clockwise into the upper
diaphragm casing (Key 23A) forces the pusher plate
(Key 112) onto the diaphragm (Key 22) and diaphragm
plate (Key 8) to compress the spring.
C
B
111
105
107
B
108
109
23A
To decompress the spring (Key 6) and allow actuator
stem (Key 7) to move up:
Turning the handwheel (Key 102) counterclockwise away
from the upper diaphragm casing (Key 23A) allows the
actuator spring to decompress which moves the diaphragm
plate (Key 8) and actuator stem (Key 7) upward.
112
Note: If the valve is push-down-to-close, full valve opening can
be restricted by adjusting the handwheel to the desired
position.
If the valve is push-down-to-open, full valve closing can be
restricted by adjusting the handwheel to the desired position.
110
Figure 26 DFR Top-Mounted Handwheel
MAINTENANCE - TOP-MOUNTED
HANDWHEELS O-RING REPLACEMENT
MAINTENANCE - TOP-MOUNTED
HANDWHEELS
Before You Begin:
Maintenance should be performed if actuator loading pressure
appears to be leaking from either the handwheel or travel stop.
It is possible that either of the o-rings (Keys 107 & 108) need
to be replaced.
Before disassembling the handwheel or travel stop to replace
o-rings, perform the following steps:
•
113
Lubricate the threads of the stem (Key 103) with white
petroleum grease, stroke the device a couple times after
application.
• Read the General and Scope section of this manual (Page 2).
• Read Safety Caution (Page 2).
• Use safe work practices and lock out procedures.
• Disconnect supply lines (air or gas), electric power, or control
signal to the actuator. Sudden movement of actuator can
cause damage or injury, make sure actuator will not operate.
• Vent any pneumatic actuator loading pressure.
• Relieve process pressure and drain the process fluid from up
and down stream of valve.
• Be aware of potentially hazardous process material that may
be present in-line and in-valve. Isolate the valve from
process pressure. Use a bypass or block valve if necessary,
or completely shut off the process. Relieve internal valve
pressure (refer to the appropriate valve instruction manual).
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21
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
MAINTENANCE - TOP-MOUNTED
HANDWHEELS O-RING REPLACEMENT
(Continued)
Special Tools Required:
• Flat-head screwdriver or flat-bladed tool.
Lubricants Required:
• Dow Corning Molykote® 111 or equivalent (Key B)
• Lubriplate® No. 105 Grease or equivalent (Key C)
1
Rotate the handwheel counterclockwise and remove any
spring tension applied by the handwheel.
2
Relieve any actuator spring (Key 6) compression by
turning the spring adjuster (Key 4) clockwise until it
stops turning. Refer to Step 4 of the Casing Disassembly
Section.
3
Refer to the Actuator Disassembly – Casing Disassembly
Steps 5 – 6 and remove the upper diaphragm casing (Key
23A).
4
Separate the handwheel assembly from the upper
diaphragm casing (Key 23A) by removing the cap screws
(Key 109).
5
Loosen the lock nut (Key 104).
6
Remove the hex nut (Key 100), flat washer (Key 101), and
handwheel (Key 102).
7
Rotate the stem (Key 103) clockwise out of the body (Key
105).
8
Remove and replace the o-rings (Keys 107 & 108).
Lubricate the new o-rings with Dow Corning Molykote® 111
(Key B).
9
Re-assemble the handwheel and diaphragm casing. Refer
to the Actuator Assembly section (Page 16).
10 Perform spring adjustment.
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
24
8
23
9
3
8
25
6
22
7
1
6
4
4
5
3
28
5
3
29
17
30
27
21
12
18
10
10
11
18
26
31
19
13
16
13
11
20
14
15
14
Figure 27 Actuator Cross Section
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23
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
Table 3
Torque Specifications for Valve Mounting Bolts (Key 33)
Mounting Bolts
Valve Shaft Diameter
1/2 Inch to 3/4 Inch
lbf-ft
N•m
65
88
Table 4
DFR Torque Specifications
Key
Bolt Size
9
Torque
lbf-ft
N•m
1/2”-20
40
54
11
3/8”-16
40
54
12
3/8”-16
40
54
13
7/16”-14
20
27
16
5/16”-18
30
41
21
5/16”-18
30
41
24
3/8”-24
20
27
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24
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
Parts
Key
1
Key
Description
Part Number
3
Housing Assembly, Cast Iron
DFR0470030D
Bearing Tape, CPTFE, 2 Required DFR0470021D
Thrust Washer, Nylon
2 Required
10B1526X01D
4
Spring Adjuster, Cast Iron
20B1509X01D
5
Spring Seat, Cast Iron
20B1507X01D
6
Spring
Refer to Table 5
7
Actuator Stem Assembly
DFR0470010D
8
Diaphragm Plate, Cast Iron
9
Socket Head Cap Screw, Diaphragm Plate
DFR047X001D
Steel
10
30B3576X01D
5/8 inch shaft
30B3575X01D
3/4 inch shaft
30B3572X01D
15
Steel
27
10B1516X01D
Screws, Front Cover Plate, Zinc Plated Steel
4 Required
28
SBRZ516.038
Cover Plate, Spring Adjuster,
Steel
29
10B1517X01D
Screws, Spring Adjuster Cover Plate, Zinc Plated Steel
2 Required
SBRZ516.038
30
Positioner Plate, Plastic
20B1515X01D
31
Screws, Positioner Plate, Zinc Plated Steel
33
4 Required
SBRZ516.038
Elbow Vent
Y602-12D
Mounting Bolt, Actuator / Valve, Zinc Plated Steel
Mounting bolts are included with the valve assembly.
34
Lockwasher, Actuator / Valve, Zinc Plated Steel
lockwashers are included with the valve assembly.
DFR0690021D
35
Hex Nut, Mounting Bolt, Zinc Plated Steel
Hex nuts are included with a 570 valve assembly.
Cap Screw, Lever/Actuator Stem
H5CZ38.112
36
Nameplate
NAMEXSRACTD
Jam Nut, Travel Stop, Zinc Plated Steel
2 Required
14
NHFZ38
Cover Plate, Front Cover plate,
Socket Head Cap Screw, Lever Clamp
Zinc Plated Steel
13
26
32
Steel
12
Nut, Diaphragm Casing, Zinc Plated Steel
1E76043299D
Lever, Cast Iron
1/2 inch shaft
11
25
Part Number
12 Required
Includes Bearing Tape (Key 2)
2
Description
DFR0690002D
Travel Stop, Zinc Plated Steel
2 Required
DFR0690016D
Housing Cover, Cast Iron
DFR0470020D
Includes Bearing Tape (Key 2)
16
17
18
19
20
21
Cap Screws, Housing Cover, Zinc Plated Steel
4 Required
H5CZ516.034
Travel Scale, SST
20B1518X01D
Machine Screws, Travel Scale & Travel Indicator
SST, 4 Required
1V74353522D
Travel Indicator, SST
28A4426X01D
Mounting Yoke, Steel
1/2 inch shaft
30B1514X01D
5/8 inch shaft
30B1514X01D
3/4 inch shaft
30B1513X01D
Cap Screws, Mounting Yoke, Zinc Plated Steel
4 Required
H5CZ516.034
Diaphragm, Nitrile
2E79190220D
23
Upper Diaphragm Casing, Steel
2J71382899D
24
Cap Screws, Diaphragm Casing, Zinc Plated Steel
22
12 Required
H5FZ38.114
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25
Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
PARTS - DFR Handwheel Parts List
KEY
PART DESCRIPTION
PART NUMBER
100
NYLOCK HEX NUT
DFO30109X1D
101
FLAT WASHER
DF060110X1D
102
HANDWHEEL
DFO40106X1D
103
STEM
DFR40102X1D
104
LOCK NUT
DFO60107X1D
105
BODY
DFR40201X1D
107
O-RING, STEM
1D23750699D
108
O-RING, BODY/CASING
1D26730699D
109
CAP SCREW, BODY/CASING (6 REQUIRED)
1A36842405D
110
PUSHER PLATE RETAINER
DFO60111X1D
111
SOCKET HEAD CAP SCREW, PUSHER PLATE RETAINER (3 REQUIRED)
DFO20114X1D
112
PUSHER PLATE
DFO60103X1D
113
SPRING PIN
DFO60115X1D
23A
UPPER DIAPHRAGM CASING
2E79222506D
Table 5
DFR Spring (Key 6) Information
Casing Pressure
Psig
Initial Spring Compression
Push-Down-To-Open
(Fail Closed)
kPag
0 - 18
0 - 124
0 - 33
0 - 228
Push-Down-To-Close
(Fail Open)
Part Number
Psig
kPag
Psig
kPag
4.9
34
3.0
21
10B1524X01D
4.9
34
4.9
34
10B1524X01D
6.3
43
3.0
21
10B1525X01D
Parts Ordering
Whenever corresponding with Dyna-Flo about a DFR actuator, refer to the nameplate (Key 36)
for the serial number of the unit. Please order by the complete part number (as given in the
following parts list) of each part required.
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Model DFR 047 Rotary Actuator
Operation, Parts, and Instruction Manual
This page left intentionally blank.
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27
Model DFR 047 Rotary Actuator
MODEL NUMBERING SYSTEM
S A M P L E PA R T N U M B E R : D F R - 0 4 7 - C - 0 6 S 1 - C - R A 1
ACTUATOR
047
SIZE 047
FAIL POSITION
C
FAIL CLOSED
O
FAIL OPEN
N
NOT APPLICABLE
-
DFPS-01 (STANDARD PAINT)
2
DFPS-02 (SEVERE SERVICE PAINT)
3
DFPS-03 (HI-TEMP PAINT)
04
1/2 INCH
06
3/4 INCH
S
SPLINED (STANDARD)
1
0 - 18
3
0 - 33
-
STANDARD
S
SST BOLTING
C
0-18 PSIG RANGE, 0-33 PSIG RANGE
H
0-33 PSIG RANGE
-
NONE (STANDARD)
T
TOP-MOUNTED HANDWHEEL
R
RIGHT HAND MOUNT
L
LEFT HAND MOUNT
A
STYLE A, B, C, D - REFER TO FIGURE 12
1
POSITION A, B, C, D - REFER TO FIGURE 12 (RIGHT HAND POSITION 1 IS STANDARD)
N
NOT APPLICABLE
047
C
PAINT
-
SHAFT CONNECTION SIZE
05
5/8 INCH
SHAFT CONNECTION TYPE
OPERATING PRESSURE RANGE (PSIG)
OPTIONS
SPRING RANGE (SEE TABLE 7)
HANDWHEELS / TRAVEL STOPS
06
S
1
C
-
MOUNTING
RA1
DFR -
-
-
-
-
Our Commitment to Quality
Dyna-Flo is committed to continuous improvement. While all efforts have been made to ensure the accuracy of the content in
this document, modifications or improvements to the information, specifications, and designs may occur at any time without
notice. This document was published for informational purposes only, and does not express or imply suitability, a warranty,
or guarantee regarding the products or services described herein or their use or applicability.
Neither Dyna-Flo Control Valve Services Ltd., nor any of their affiliated entities assumes responsibility for the selection, use
and maintenance of any product. Responsibility for selection, use and maintenance of any product remains with the purchaser
and end-user.
P-DFR2M0416A
Dyna-Flo Control Valve Services Ltd.
Phone: 780
•
469
•
4000
Toll Free: 1
•
866
•
396
•
2356
Fax: 780
•
469
•
4035
Website: www.dynaflo.com
28