Flowserve Automax SuperNova S050 - User Manual

SuperNova Series
S050 - S200
Rack & Pinion AUTOMAX Actuators
Page 1/4
B00043e4-rev2.doc
Installation, Operating & Maintenance Instructions
All actuators are factory lubricated for life, but still should
be protected from the elements and stored indoors until
ready for use. The ports of the actuator are plugged as
supplied from the factory. In case the actuators are stored
a long period before installation, it would be a good practice
to stroke the actuators before mounting. Prior to assembly,
check the mounting surfaces, the stem adaptor and the
bracket to assure proper fit.
Manually open and close the valve to insure freeness of
operation. Be sure the valve and actuator rotate in the
same direction and are in the same position. Secure the
valve with the stem vertical. Bolt the bracket to the valve
and place the stem adaptor on the valve stem. Position the
actuator over the valve and lower to engage the stem
adaptor to the actuator shaft.
Continue to lower until the actuator seats on the bracket
mounting surface. In order to align the bolt holes, it may be
necessary to turn or stroke the actuator a few degrees
and/or adjust the actuator travel stops. Bolt the actuator to
the bracket.
After consulting the valve manufacturer’s
recommendations, adjust the travel stop bolts of the
actuator for the proper open and closed valve positions.
Pneumatically stroke the actuator several times to assure
proper operation with no binding of the stem adaptor. If the
actuator is equipped with limit switches or other
accessories, adjust them at this time.
To prolong actuator life use only clean, dry plant air.
Lubricated air is not required, however it is recommended
particularly for high cycle applications. Do not use
lubricated air with positioners.
Actuator Endcap Screw
Socket Size
Adjustment Bolt
Socket Size
Spring Color
Code
S050 4 mm 3 mm White
S063 5 mm 4 mm Light green
S085 6 mm 5 mm Blue
S100 6 mm 6 mm Red
S115 6 mm 6 mm Yellow
S125 8 mm 6 mm Grey
S150 8 mm 8 mm Dark green
S175 10 mm 8 mm Purple
S200 12 mm 8 mm Orange
Travel Stop Adjustment (Patented)
Both Directions 5° Overtravel
12°Adjustment Each End
The SuperNova Series actuators have unique, patented
travel stop adjustments in both clockwise and
counterclockwise directions. The 10° total overtravel
provides adjustments from –5° to +7° at the “0°”
Counterclockwise position and from +83° to + 95° at the
“90°” Clockwise position.
All actuated valves require accurate travel-stop
adjustments at both ends of the stroke to obtain optimum
performance and valve seat life. The accumulation of
tolerances in the adaption of the actuators to valves is such
that there must be a range of adjustment for both ends of
the stroke to achieve the expected performance.
Ball and Plug Valves require precise adjustment at the
open (CCW) position to protect the seat from the flow
media and the closed (CW) position to assure absolute
shut-off
Butterfly Valves require precise adjustment at the closed
position to assure full shut-off, to prevent disc overtravel
and damage to the seat at the closed position.
Tandem Valves, where two valves are operated in tandem
through a single solenoid valve (eg. A 3-Way
configuration), absolutely require precise adjustment at
both ends of the stroke to assure the seating of both
valves.
Adjustment Bolt Location
Actuator Type Fail
position
Clockwise (CW)
closed
Counterclockwise
(CCW) open
Double Acting Left End Cap Right End Cap
Spring Return CW Left End Cap Right End Cap
Spring Return* CCW* Right End Cap Left End Cap
*The pistons are rotated 180° for CCW fail position

Summary

Installation, Operating & Maintenance Instructions

Travel Stop Adjustment

Details patented travel stop adjustments for optimal performance and valve seat life.

Operation

Double Acting Actuator Operation

Explains how air pressure to ports drives pistons for counterclockwise and clockwise pinion rotation.

Spring Return Actuator Operation

Details operation for spring return actuators, including fail-safe positions.

Changing Pinion Rotation Direction

Procedure to change actuator rotation direction from CW to CCW for spring return models.

Maintenance Instructions

Disassembly Procedures

Step-by-step guide for safely disassembling the actuator and its components.

Reassembly Procedures

Instructions for reassembling the actuator after maintenance or repair.

Changing Number of Springs

Guide to selecting and installing correct spring combinations for desired torque.

Parts and Materials

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The provided document describes the SuperNova Series S050 - S200 Rack & Pinion AUTOMAX Actuators, which are designed for controlling valves. These actuators are factory lubricated for life but require proper storage and pre-installation checks.

Function Description:

The SuperNova Series actuators utilize a rack and pinion mechanism to convert linear piston motion into rotary motion for valve operation. They can be configured as Double Acting, Spring Return Fail CW (Clockwise), or Spring Return Fail CCW (Counterclockwise).

• Double Acting:
  • Applying air pressure to Port 2 drives the pistons outward, causing the pinion to rotate counterclockwise. Air from the outside of the pistons exhausts through Port 1.
  • Applying air pressure to Port 1 drives the pistons inward, causing the pinion to rotate clockwise. Air from the inside of the pistons exhausts through Port 2.
• Spring Return (Fail CW):
  • Applying air pressure to Port 2 drives the pistons outward, compressing the springs and rotating the pinion counterclockwise. Air from the outside of the pistons exhausts through Port 1.
  • Exhausting air pressure from Port 2 allows the stored energy of the springs to drive the pistons inward, rotating the pinion clockwise. Air from the outside of the pistons vents through Port 1.
• Spring Return (Fail CCW):
  • Applying air pressure to Port 2 drives the pistons outward, compressing the springs and rotating the pinion clockwise. Air from the outside of the pistons exhausts through Port 1.
  • Exhausting air pressure from Port 2 allows the stored energy of the springs to drive the pistons inward, rotating the pinion counterclockwise. Air from the outside of the pistons vents through Port 1. This configuration requires rotating both pistons 180° around their axis during assembly.

Important Technical Specifications:

• Pressure Rating: 10 bar (150 psi) max.
• Travel Stop Adjustment (Patented): Unique, patented travel stop adjustments in both clockwise and counterclockwise directions.
  • Total overtravel: 10°.
  • Adjustment range: -5° to +7° at the 0° Counterclockwise position and +83° to +95° at the 90° Clockwise position.
  • Each end offers 12° of adjustment.
• Seals:
  • Standard (Nitrile): -30°C to +80°C (-20°F to +175°F).
  • High Temp (Viton): -30°C to +150°C (-22°F to +302°F).
  • Low Temp (Fluorosilicon): -50°C to +80°C (-58°F to +176°F).
• Materials:
  • Body: Hard Anodized Aluminium
  • Pistons: Die Cast Aluminium
  • Pinion: Nitride Coated Steel
  • Springs: Spring Steel Coated
  • Bearings: Hard Anodized Aluminium (top), PEEK (bottom)
  • Washers: Nylon, Stainless Steel
  • Snap Ring: Steel/Plated
  • O-rings: Nitrile Rubber (standard), Viton (high temp), Fluorosilicon (low temp)
  • Piston Guide/Band: Nylon and Molybdenum Disulfide

Usage Features:

• Installation:
  • Actuators are factory lubricated for life but should be protected from elements and stored indoors.
  • Ports are plugged as supplied.
  • Stroke actuators before mounting if stored for a long period.
  • Check mounting surfaces, stem adaptor, and bracket for proper fit.
  • Manually open and close the valve to ensure freeness of operation and correct rotation direction/position.
  • Secure the valve with the stem vertical.
  • Bolt the bracket to the valve, place the stem adaptor on the valve stem, then position the actuator over the valve to engage the stem adaptor and lower onto the bracket.
  • Align bolt holes by turning or stroking the actuator, or adjusting travel stops.
  • Bolt the actuator to the bracket.
• Travel Stop Adjustment: Crucial for optimum performance and valve seat life.
  • Ball and Plug Valves: Require precise adjustment at the open (CCW) position to protect the seat and at the closed (CW) position for absolute shut-off.
  • Butterfly Valves: Require precise adjustment at the closed position for full shut-off and to prevent disc overtravel.
  • Tandem Valves: Absolutely require precise adjustment at both ends of the stroke to ensure seating of both valves.
  • Adjustment bolts are located on the end caps: Left End Cap for CW closed (Double Acting & Spring Return CW) or CCW fail (Spring Return CCW), and Right End Cap for CCW open (Double Acting & Spring Return CW) or CW fail (Spring Return CCW).
• Air Supply: Use only clean, dry plant air. Lubricated air is not required but recommended for high cycle applications. Do not use lubricated air with positioners.

Maintenance Features:

• Disassembly Procedures:
  1. Disconnect air and electrical supplies.
  2. Remove accessories and dismount from valve.
  3. For Spring Return actuators, apply air pressure to Port 2 to release spring pressure from the Stop Bolt (9).
  4. Remove Stop Bolt Retaining Nut (14), Washer (15), and O-ring (16) on the left Endcap (19) and turn the Stop Bolt (9) clockwise until flush with the Endcap (19).
  5. Exhaust air from Port 2; the Stop Bolt (9) should turn freely. Continue turning clockwise until disengaged from the Endcap.
  6. For Spring Return actuators, completely remove two diagonal Endcap Screws (21) from one Endcap, then evenly remove the remaining two. Springs will push the Endcap out. Repeat for the opposite side. Remove springs (23, 24, 25).
  7. For Double Acting actuators, remove the 8 Endcap Screws (21). Endcaps (18, 19) will push from the Body (1).
  8. Rotate Pinion (3) counterclockwise (D & S-FCW) or clockwise (D & S-FCCW) to drive Pistons (2) off the rack. Pull Left Piston (2) from the body (1) by pulling on the Stop Bolt (9).
  9. Remove Right Piston (2a) by pushing out through inside of Body (1).
  10. Remove Snap Ring (5), Steel Pinion Washer (4a), and Pinion Washer (4).
  11. Tap Pinion (3) lightly with a plastic mallet to remove.
  12. Remove seals from pinion, endcaps, and piston. Remove seal from top pinion bearing if necessary.
  13. Top pinion bearing (26) is a light press fit; press out towards the bottom. Bottom pinion bearing (27) is split; spread apart to remove.
• Reassembly Procedures:
  1. Inspect parts for wear, replace worn parts and all O-rings.
  2. Clean components and lightly grease cylinder bore, pinion, and seals with a multi-purpose "polymer" fortified grease (e.g., DuBois Chemicals MPG-2).
  3. Reverse disassembly procedures.
  4. If top pinion bearing (26) was removed, press back into place, flush with the top of the body. Insert top pinion bearing seal (28) using a blunt screwdriver, taking care not to damage seals.
  5. Standard Pinion (3) orientation: top accessory drive slot at 90° to the Body (1) in the 0° position.
  6. When fitting Pistons (2 and 2a), ensure teeth engage Pinion (3) simultaneously by measuring in from each end. Piston orientation determines actuator operation.
  7. Test actuator for smooth operation and air leakage at service pressure before reinstalling.
• Changing Number of Springs:
  1. Follow Disassembly Procedures through step 6.
  2. Determine nested spring combination (inner, middle, outer) using catalog torque charts. Insert appropriate springs, ensuring proper seating against piston and endcap to prevent binding.
  3. Re-assemble the actuator.
  • Spring chart models 63-200 and 50 are provided, detailing spring configurations (inner, middle, outer) and corresponding standard air supply (e.g., 3 bar, 4 bar, 5 bar, 5.5 bar).
  • Springs are identified by color code dots: #1 (one dot), #2 (two dots), #3 (three dots).
  • S050 has a maximum of 2 springs per endcap.

Flowserve Automax SuperNova S050 Specifications