Flow Line Controls Installation & Operations Manual SERIES 20/21 Pneumatic Actuators Flow Line Controls, Inc. P.O. Box 677 Schriever, LA 70395 Phone: 985-414-6003 Toll Free 1-800-815-9226 Fax 985-414-6072 www.flowlinecontrols.com Doc. No. FLCIOM21/21 2008 Flow Line
A-1 Introduction Flow Line Controls offers 18 different sizes of actuators which is one of the largest size offerings on the market today. Flow Line actuators are designed to operate at pressures of 30 PSIG to 125 PSIG utilizing air, hydraulic fluid, or water. All sizes are offered in Double Acting and Spring Return. Flow Line actuators are designed for use on Ball Valves, Butterfly Valves, Dampers, Plug Valves, and any other application requiring a device creating 0 to 90 degree rotational torque. A-2 Storage All Flow Line Controls actuators should be stored indoors and protected against humidity, dust, dirt, and other harmful elements. The actuator air ports are plugged from the factory before shipment and should stay so therefore preventing foreign matter from entering the actuator bore. A-3 Operating Characteristics for Double Acting Actuators Flow Line Controls actuators utilize a central pinion with 2 opposing pistons. Two air ports Port A (on the left side when looking at the air supply ports) and Port B (on the right side when looking at the air supply ports) supply the operating supply to the actuator. Port A enters directly into a central cavity in the actuator in-between the pistons. Port B is connected to the end caps by means of an internally drilled passage way. Air entering into Port A energizing the pistons is forcing them to move away from the pinion in a counter clockwise motion. Port B at this time is exhausting air. This movement has now caused the actuator to move to the open position. Air entering into Port B energizing the pistons is forcing them to move toward the pinion in a clockwise motion. Port A at this time is exhausting air. This movement has now caused the actuator to move to the closed position. A-4 Operating Characteristics for Spring Return Actuators Flow Line Controls actuators utilize a central pinion with 2 opposing pistons. Two air ports Port A (on the left side when looking at the air supply ports) and Port B (on the right side when looking at the air supply ports) supply the operating supply to the actuator. Port A enters directly into a central cavity in the actuator in-between the pistons. Port B is connected to the end caps by means of an internally drilled passage way. Springs are added on the outside of the pistons therefore negating the need for air to be supplied to Port B Air entering into Port A energizing the pistons is forcing them to move away from the pinion in a counter clockwise motion. Port B at this time is exhausting air. The springs are now being compressed. This movement has now caused the actuator to move to the open position. Air is now exhausted from Port A energizing the pistons with the stored energy from the compressed springs is forcing them to move toward the pinion in a clockwise motion. Port B at this time is allowing air to move into the actuator on the spring side of the pistons. This movement has now caused the actuator to move to the closed position.
A-5 Actuator Sizing It is important to note that there is certain information that is required prior to selecting the correct size of actuator. A5-1 Break Torque; The required amount of torque needed to initially open the valve. A5-2 Seating Torque; The required amount of torque needed to close the valve into the seat. A5-3 Running Torque; The amount of torque required to rotate the valve. A5-4 Air Supply; The amount of air being supplied to the actuator. A5-5 Double or Single Acting; Does the actuator operate (air to open / air to close) or does it operate (air to open / spring to close). A5-5 DA or RA Upon opening, the actuator moves counter clockwise direct acting), or upon opening, the actuator moves clockwise (reverse acting). The above required information is needed to correctly choose an actuator for the particular torque the actuator is required to overcome. A-6 Actuator Installation The Flow Line Controls Series 20 / 21 actuators are designed to be easily installed on various valves and other quarter turn applications. All sizes of actuators offered incorporate ISO mounting. Additional valve mounting patterns are available upon request. The use of fabricated brackets and couplers will be needed for mounting to valves that are not ISO. A6-1 Remove the actuator from packaging. Closely inspect for damage. A6-2 Supply air to the actuator to verify that the actuator functions properly. A6-3 Make sure that the valve shaft and mounting is clean and free of debris. A6-4 If an fabricated coupler is required, insert coupler into the actuator pinion to verify fit. A6-5 If an fabricated bracket is required, aligned bracket to bottom of actuator and check for proper bolt hole alignment. A6-6 After the inspection process, assemble the actuator and valve together. Tighten securely all fasteners before testing of the actuator / valve assembly. A6-7 Actuate pneumatically several times to ensure that the actuator / valve connection is not binding. If the assembly does not function properly, disassemble and check for the problem. If the problem persists, then contact your nearest Flow Line Controls representative.
A-7 Disassembly Procedure When disassembly of the actuator is need due to maintence, first and foremost all electrical and most importantly all air lines are to be disconnected from the actuator. Never disassemble an actuator that is under pressure. Serious injury or death could result. Never disassemble an actuator with springs under compression. Serious injury or death could result. A7-1 Remove the actuator the valve, this includes any and all mounting hardware That may have been used. A7-2 Remove Limit Switches, Solenoid Valves, and Positioners with their mounting from the actuator. A7-3 At this time double check that both air ports are fully vented. A7-4 If the actuator is a spring return unit, make sure that the actuator is in the failed position before proceeding. A7-5 Removing Position Indicator Cap 1) Remove screw from on top of indicator cap. 2) Lift position indicator cap off shaft, it may be necessary to pry with a Small screwdriver. A7-6 Removing Travel Position Stop Bolts 1) Remove both stop bolts together with stop nut and washer. 2) Remove stop bolt o-rings and discard if replacing all soft parts.
A7-7 End Cap Disassembly 1) Remove end cap screws in an opposing sequence. 2) When removing end cap screws on a spring return actuator additional caution must be used. When disassembling a spring return actuator the end caps should be loose after unscrewing the end cap bolts 4 to 5 turns. If there is still force on the end cap, this indicates that damage may have occurred to one or more spring cartridges. Further disassembly to the end caps is to cease immediately. The actuator should be sent to Flow Line Controls for further maintence. 3) Remove spring cartridges. 4) Remove and discard end cap o-rings if replacing all soft parts. A7-8 Piston Disassembly 1) Holding the actuator body stationary, rotate the drive shaft until the Pistons are released from the drive shaft. 2) Remove piston o-rings using a small screwdriver. 3) Remove both piston bearings in the same manor. 4) Discard o-rings and bearings if replacing all soft parts. A7-9 Pinion Disassembly 1) Remove the snap ring from the top of the pinion. Further remove the washer and thrust bearing. 2) Apply downward force to the top of the pinion moving it out of the body about one inch. Remove the travel stop cam from the pinion along with the internal thrust bearing. The pinion is now ready to be fully removed. 3) Remove the top and bottom o-rings along with the thrust bearings and discard if replacing all soft parts.
A7-10 At this point the actuator is now fully disassembled. Before reassembly all components that have not been discarded needs to be washed and cleaned and inspected for damage or wear before reassembly. A-8 Reassembly Procedure A8-1 Pinion Reassembly 1) Install top and bottom bearings and the top and bottom o-rings onto the pinion. 2) Grease the outside of the pinion, bearings, and o-rings. 3) Partially insert the pinion into the body. Install the travel stop cam, and internal thrust bearing.. Complete the reassembly of the pinion to the body by moving it upward until it stops. 4) Fit the external thrust bearing, washer, and install the snap ring locking the pinion to the body. A8-2 Piston Reassembly 1) Install the piston o-ring and both bearings. 2) Grease the outside of the piston, bearings, and o-ring. 3) Firmly fix the body in a horizontal position.
4) Press the two pistons simultaneously inside the body until they engage the pinion. 5) Ensure that when the two pistons are traveling inside the actuator they are evenly spaced and traveling together. A8-3 End Cap Reassembly 1) Lubricate the inside of the body. 2) For spring return actuators now is the time to install the spring cartridges. 3) Fit end cap o-ring onto the groove on each end cap and apply grease. 4) Fit the end caps onto the body verifying that the o-rings remain the grooves. 5) Install the end cap screws and tighten by applying even pressure on each screw. A8-4 Travel Bolt Reassembly 1) Insert on both the cap screw, the nut, the washer, and the o-ring. 2) Install into the body. 3) To set stroke adjustment for the closed position, first fully close the actuator. Screw into the body the cap screw until it stops against the internal travel stop. Tighten jam nut tight against the actuator body. 4) To set stroke adjustment for the open position, first fully open the actuator. Screw into the body the cap screw until it stops against the internal travel stop. Tighten jam nut tight against the actuator body.
A8-5 Position Indicator Cap Reassembly 1) Fit the position indicator cap onto the top of the shaft verifying that it it is in the correct position. 2) Reinstall the screw that retains the indicator.
A-9 Actuator Materials of Construction Part No. Qty. Description Material of Construction 01 1 Travel Stop Cam Carbon Steel 02 2 Travel Stop Screw 300 Stainless Steel 03 2 Washer (Stop Screw) 300 Stainless Steel 04 2 Nut (Stop Screw) 300 Stainless Steel 05 2 Bearing (Piston Back) Reinforced PTFE 06 1 Bearing (Pinion Top) Reinforced PTFE 07 1 Bearing (Pinion Bottom) Reinforced PTFE 08 2 Thrust Bearing (Pinion) Reinforced PTFE 09 2 Plug Carbon Steel 10 1 Thrust Washer (pinion) Reinforced PTFE 11 2 "O"Ring (Travel Stop) Nitril 12 2 Piston Guide Reinforced PTFE 13 8 Cap Screw (End Cap) 300 Stainless Steel 14 2 "O"Ring (End Cap) Nitril 15 2 Bearing ( Piston) Reinforced PTFE 16 2 "O"Ring (Piston) Nitril 17 2-12 Spring Cartridge Pre Compressed Spring Steel 18 1 Spring Clip (Pinion) 300 Stainless Steel 19 1 Position Indicator Polycarbonate 20 1 "O"Ring (Pinion Bottom) Nitril 21 1 "O"Ring (Pinion Top) Nitril 30 1 Right End Cap Cast Aluminum 31 1 Left End Cap Cast Aluminum 39 1 Cap Screw (Indicator) 300 Stainless Steel 40 2 Piston Cast Aluminum 41 1 Label Polycarbonate 42 2 End Cap Label Polycarbonate 43 1 Spacer Reinforced PTFE 50 1 Body Extruded Aluminum 60 1 Pinion ENP Carbon Steel