DeZurik POWERRAC R1 Bedienungsanleitung

DeZURIK, Inc. Sartell, Minnesota USA | Phone: 320-259-2000 | www.dezurik.com | info@dezurik.com

DEZURIK R1 POWERRAC®

SPRING-RETURN ACTUATOR

USED ON ½ - 3” PEC ECCENTRIC VALVES

Instruction

D10389

November 2020

DeZURIK

Instructions

These instructions are for use by personnel who are responsible for the installation, operation and

maintenance of DeZURIK valves, actuators or accessories.

Safety Messages

All safety messages in the instructions are identified by a general warning sign and the signal word CAUTION,

WARNING or DANGER. These messages indicate procedures to avoid injury or death.

Safety label(s) on the product indicate hazards that can cause injury or death. If a safety label becomes difficult

to see or read, or if a label has been removed, please contact DeZURIK for replacement label(s).

Personnel involved in the installation or maintenance of valves should be constantly alert to potential

emission of pipeline material and take appropriate safety precautions. Always wear suitable protection

when dealing with hazardous pipeline materials. Handle valves which have been removed from service

with suitable protection for any potential pipeline material in the valve.

Inspection

Your DeZURIK product has been packaged to provide protection during shipment; however, items can be

damaged in transport. Carefully inspect the unit for damage upon arrival and file a claim with the carrier if

damage is apparent.

Parts

Replaceable wear parts are listed on the assembly drawing. These parts can be stocked to minimize

downtime. Order parts from your local DeZURIK sales representative or directly from DeZURIK. When ordering

parts please provide the following information:

If the valve has a data plate: please include the 7-digit part number with either 4-digit revision number

(example: 9999999R000) or 8-digit serial number (example: S1900001) whichever is applicable. The

data plate will be attached to the valve assembly. Also, include the part name, the assembly drawing

number, the balloon number and the quantity stated on the assembly drawing.

If there isn't any data plate visible on the valve: please include valve model number, part name, and

item number from the assembly drawing. You may contact your local DeZURIK Representative to help

you identify your valve.

DeZURIK Service

DeZURIK service personnel are available to maintain and repair all DeZURIK products. DeZURIK also offers

customized training programs and consultation services. For more information, contact your local DeZURIK

sales representative or visit our website at DeZURIK.com.

DeZURIK

November 2020 Page 3 D10389

Table of Contents

Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Spring-to-Close - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Spring-to-Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Position Stops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Removing Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Actuator Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Spring-Return Cylinder Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Spring-Return Cylinder Reassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Actuator Reassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Mounting Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Changing Actuator from Spring-Return to Double-Acting - - - - - - - - - - - - - - - -

Reversing Spring Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Changing Mounting Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Lockable Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Unlocked Condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Locked Closed Condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Locked Open Condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

DeZURIK

D10389 Page 4 November 2020

Description

The R1 PowerRac® Spring-Return Actuator is a quarter-turn enclosed rack and gear cylinder actuator.

The R1 PowerRac® Spring-Return Actuator is used for on-off or modulating control on ½"–3" PEC

Eccentric Valves. The R number designates the 1" radius of the actuator gear. A choice of 4" and 6"

(100 mm and 150 mm) cylinder diameters is offered. The 4" cylinder is offered with one spring size

while the 6" cylinder has two spring sizes.

The actuator is available as a spring-to-open or spring-to-close actuator. The spring action may be

reversed by removing the spring-return cylinder assembly and mounting it on the opposite end of the

gear housing.

A lockable model of the PowerRac® Spring-Return Actuator is also available. See “Lockable Model”

section.

Figure 1—Available Configurations

DeZURIK

November 2020 Page 5 D10389

Installation

All cylinder port connections are 1/4" NPT. The spring-return actuator requires one pneumatic

connection as shown below.

Spring-to-Close

With a spring-to-close spring actuator, air to the connection drives the actuator counterclockwise,

towards the “open” position on the dial.

Figure 2—Spring-to-Close

Spring-to-Open

With a spring-to-open actuator, air to the connection drives the actuator clockwise, towards the “shut”

position on the dial.

Figure 3—Spring-to-Open

As the spring-return actuator is cycled, air is alternately exhausted and drawn in through a breather.

The breather is located at one end of the cylinder as shown in Figures 2 and 3. The breather must be

protected from water because water inside of the actuator will cause sticking and premature wear of the

internal components.

If the actuator is located outdoors or in an area that will be hosed down, the breather must be oriented

vertically. The “umbrella” top of the breather will then prevent water from being drawn in through the

breather. In locations that are submerged or subject to flooding, the breather must be removed and

remotely piped to a protected location.

DeZURIK

D10389 Page 6 November 2020

Operation

The R1 PowerRac® Spring-Return Actuator is powered pneumatically, and rotates 90° between the

open and closed positions, in the direction as described in the “Installation” section. The spring-return

cylinder is sized for a 60 psi (415 kPa) spring only, and is limited to 100 psi (690 kPa) maximum.

Lubrication

The actuator has been lubricated at the factory and requires no routine lubrication. If the actuator is

disassembled (see Figures 5 and 6 for actuator parts identification);

apply a paint-like coating using one of these lubricants:

- Dow Corning Molykote No. 44 (recommended)

- Shell Retinax AM (alternate)

- Shell Lithall MDS (alternate)

to the following surfaces:

Inside diameter of cylinder tube (S6)

Chamfer for cylinder tube on cylinder cap (S11) and cylinder head of housing (S1)

O-rings (S5, S8, and S14) and grooves

Seals (S3 and S9) and grooves

Thread seal (S16)

Inside diameter of bearing (S2) located in cylinder head housing.

Outside diameter of piston rod (S4).

apply a paint-like coating using one of these lubricants:

- Keystone Zeniplex-1 (recommended)

- Amoco Amolith Grease #1-EP (alternate)

- Amsoil GHD (alternate)

- Mobil Mobilux EP 1 (alternate)

- Petro-Canada Vultrex MPG EP 1 (alternate)

- Shell Alvania EP 1 (alternate)

- Texaco Multifak EP 1 (alternate)

to the following surfaces:

Flat side of rack bearing (B3), before assembly

Back side of rack (B5) that contacts rack bearing, before assembly

Both bearing hubs of gear (B8), before assembly

Top cover O-ring (B10) and groove in top cover (B11), before assembly

Teeth in rack (B5) and gear (B8) after assembly (so witness marks are visible during assembly).

DeZURIK

November 2020 Page 7 D10389

Position Stops

The adjustable open and closed position stops prevent the actuator from rotating beyond the open and

closed positions of the valve. If the actuator is factory-mounted on the valve, the stops are preset and

do not require further adjustment. If the actuator is not factory-mounted on the valve, or if the actuator

is removed or disassembled, the stops will require adjustment as described below. The adjustable

stops are screws, secured with jam nuts, and located in the extreme ends of the actuator as shown in

Figure 4.

With a spring-to-open actuator, the closed position stop is located in the cylinder cap and the open

position stop is located in the actuator end cover.

With a spring-to-close actuator, the open position stop is located in the cylinder cap and the closed

position stop is located in the actuator end cover.

Figure 4—Adjustable Stop Locations

To adjust either stop:

1. Adjust the stops after the actuator is mounted on the valve—refer to valve instructions for

closed-position information.

2. Loosen the jam nut, and turn the screw counterclockwise to increase the stroke, or clockwise to

decrease the stroke.

3. After the stop is adjusted to the desired position, hold the screw from turning, and tighten the

jam nut to the torque value shown in Table A.

Table A: Jam Nut Torques

Jam Nut

Foot Pounds

Newton Meters

1/2” Nut on 4” Cylinder Cap

38 ± 5

52 ± 7

5/8” Nut on 6” Cylinder Cap

77 ± 10

104 ± 14

5/8” Nut on End Cover

77 ± 10

104 ± 14

DeZURIK

D10389 Page 8 November 2020

Removing Actuator

Refer to Figures 5 and 6 for component identification.

Flow in the pipeline with the actuator power disconnected can allow the valve to slam

closed and cause personal injury and/or damage to the flow system. Shut down the

flow in the pipeline before disconnecting the actuator power.

1. Shut down the flow in the pipeline.

Moving parts from accidental operation of a powered actuator can cause personal injury

or equipment damage. Disconnect and lock out power to the actuator before servicing.

2. Disconnect and lockout the pneumatic power to the actuator to prevent accidental operation of

the actuator. Also disconnect and lockout any electrical power to the actuator accessories.

3. Remove the jam nut (B29), and remove the threaded pointer (B9) and spacer (B32) from the

stud [Stud Not Shown in Figure 5].

4. Remove the four mounting screws (B26) that fasten the actuator to the valve.

5. Remove the actuator from the valve by lifting the actuator from the valve shaft.

Actuator Disassembly

Refer to Figures 5 and 6 for component identification.

1. Remove the four top cover screws (B15) and remove the top cover (B11).

2. Remove the top cover gasket (B13) and the O-ring (B10).

3. Remove the gear (B8).

4. Remove the four cylinder assembly nuts (B20) and lockwashers (B19), and remove the cylinder

assembly (S00) and gasket (B16).

5. Remove the rack screw (B7) and lockwasher (B6), and separate the rack (B5) from the piston

rod (S4).

6. Remove the rack bearing (B3) from the pin (B4).

7. Remove the four end cover nuts (B20) and lockwashers (B19), and remove the end cover (B17)

and gasket (B16).

DeZURIK

November 2020 Page 9 D10389

Figure 5—Actuator Assembly, Less Cylinder

DeZURIK

D10389 Page 10 November 2020

Spring-Return Cylinder Disassembly

Refer to Figure 6 for component identification.

The spring assembly (S19) contains a compressed spring that can cause death or

personal injury if the cylinder tie rod nuts are removed while the spring force is on the

tie rod nuts.

DO NOT REMOVE THE CYLINDER TIE ROD NUTS UNLESS THE SPRING FORCE

DECREASES TO ZERO!

1. Loosen the tie rod nuts (S15) on the tie rods (S12).

Note: Force from the spring assembly will be felt during the first few turns of the nuts. As the

cylinder tie rod nuts are loosened, the force from the spring assembly must decrease to zero

before the nuts can be removed from the tie rods. The nuts and washers (S13) may be removed

safely after the force from the spring assembly decreases to zero. If the spring force does not

decrease to zero, re-tighten the nuts and contact the factory.

2. Remove the cylinder cap (S11).

3. Push the piston rod (S4) through the cylinder head (S1) so that the spring assembly (S19) is

accessible.

The spring assembly (S19) contains a compressed spring that can cause death or

personal injury if the assembly is taken apart.

DO NOT DISASSEMBLE THE SPRING ASSEMBLY!

4. Remove the spring assembly (S19) carefully from the cylinder tube (S6).

Note: Do not damage the cylinder wall with the spring assembly during this step. Do not

disassemble the spring assembly!

5. Remove the cylinder tube (S6), the piston (S7) and the piston rod (S4) from the cylinder head

(S1).

6. Remove the piston (S7) and the piston rod (S4) from the cylinder tube (S6).

7. Remove the piston nut (S10), the piston (S7) and the O-ring (S14) from the piston rod (S4).

8. Remove the piston seal (S9) and the O-ring (S8) from the piston (S7).

9. Remove the piston rod seal (S3) from the cylinder head (S1).

10. Remove the two cylinder tube O-rings (S5) from the cylinder head (S1) and from the cylinder

cap (S11).

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