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ROTADISK Pneumatic Actuator Installation Operation Type RD & RDF 2,5 – 160 Maintenance BA3002 EN Translation of Original Operating Manual Read and follow this operating manual before using a ROTADISK Pneumatic Actuator.
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Copyright note All rights reserved. No parts of this operating manual may be reproduced, stored in a data system or transferred in any way or form without the prior consent of the Flowserve Corporation. Document version Rev.: -, 30. Jul. 2021...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Table of contents General Information ....................9 Aim of This Operating Manual ................... 9 Exclusion of Liability ......................9 Safety Information ......................10 Units ............................16 Graphic Conventions for Special Designations ............17 ROTADISK Pneumatic Actuator as a “Partially Completed Machine”...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Installation ........................37 Safety Information ......................37 Preparations for ROTADISK Pneumatic Actuator Installation ........37 Installing ROTADISK Pneumatic Actuator on the Valve ..........38 Commissioning ......................39 Safety Information ......................39 Commissioning the ROTADISK Pneumatic Actuator ............
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 13 Disposal and Recycling .................... 72 13.1 Safety Information ......................72 13.2 Disposing of and Recycling the ROTADISK Pneumatic Actuator ......72 Appendix A: Manufacturer’s Declaration ..............73 Appendix B: Declaration of Incorporation ..............74 Appendix C: Torques of the ROTADISK Pneumatic Actuators ........
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Overview of ROTADISK Pneumatic Actuator versions Make ROTADISK Series/type Functional principle/ double-action/pneumatic control type Version Weight in kg 0.85 3.46 5.78 13.2 25.6 46.9 Dimensions in mm Stroke in mm Piston-Ø...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Make ROTADISK Series/type Functional principle/control single-action (spring-loaded return)/pneumatic type with failsafe function Version –1 –1 –1.3 –1.5 –1.5 Available spring package –2 –1.8 –2.5 –2 –3 –2.5 –3 Weight in kg 1,15 1,48 4,43...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Make ROTADISK Type RD & RDF Body aluminium alloy (anodised) aluminium alloy (PU multilayer paint) Materials Piston aluminium alloy Transmission stainless steel shaft compressed air (dry, filtered according to PNEUROP/ISO class 4 [50 µ]) Control media/ operating media neutral gases such as N2, und CO2...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Available spring packages with number of springs for ROTADISK Type RDF single-action (spring-loaded return) Number of Number of Number of special springs Spring package large springs small springs (“medium”) -1.5 -2.5 -1.3...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN Figure 1: Components of the ROTADISK Pneumatic Actuators RD & RDF Item Component transmission shaft (signal device side) threaded fastening holes for signal devices (M5 x 7) solenoid valve panel control air connection OPEN control air connection CLOSED connection to fittings according to DIN ISO 5211...
The wrong choice or incorrect installation or failure to use approved Flowserve spare parts and accessories will be considered as misuse of the product. Damage or failure due to product misuse is not covered by the Flowserve guarantee.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information Flowserve products or the removal of original components can impair the safety of the products in use. Safety Information This safety section contains detailed explanations of the different types of safety messages that are used in this operating manual.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information 1.3.1 Safety Symbols and Description This operating manual contains specific safety messages with signal word fields which, if unheeded, could constitute a hazard. The specific signal word fields are: Table 1: Explanation of the signal word fields Signal word field...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information Symbol/Warning Sign Description DANGER FROM MOVING PARTS Indicates danger from moving parts which can lead to danger for the safety of persons and/or material damage if not heeded.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information Symbol/Warning Sign Description HEALTH HAZARD Indicates a health hazard from irritant hazardous substances. HEALTH HAZARD Indicates a health hazard from inflammable hazardous materials. HEALTH HAZARD Indicates a health hazard from explosive hazardous materials.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information Example: This operating manual contains further information about the use of the ROTADISK Pneumatic Actuator. 1.3.3 Graphic Convention and Content Structure of Safety Directives Supplemental Directives The following graphic convention and content structure apply for Supplemental Directives: Action Example:...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information Grouped Safety Messages The following graphic convention and content structure apply for Grouped Safety Messages: Signal word field Type and source of danger! Consequences of failure to heed. Action for avoiding the hazard.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 1 General Information Example: Danger of injury due to inadequately secured loads during transport! Inadequate securing of transported loads can lead to severe injuries. Secure the ROTADISK Pneumatic Actuator against turning and ...
ROTADISK Pneumatic Actuators. If the nameplate is missing or illegible, do not put the ROTADISK Pneumatic Actuator into operation and contact the Quick Response Center (QRC) of Flowserve Flow Control GmbH for support. Type designation (e.g.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information Safety Information Grouped Safety Messages The following sections contain Grouped Safety Messages for the qualification of personnel and for the important life cycle phases of the ROTADISK Pneumatic Actuator. 2.1.1 Qualification of Personnel Danger of injury due to inadequately qualified personnel! Inadequate qualification of the personnel can lead to severe injury.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information 2.1.2 Life Cycle Phases of the ROTADISK Pneumatic Actuator Installation Danger of injury and material damage due to improper installation work! Improper installation work can lead to severe injury and material damage. Make sure that only qualified personnel with suitable personal protective equipment ...
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Do not carry out repair work on the ROTADISK Pneumatic Actuator during operation or when it is under pressure. If repair work must be carried out, contact Flowserve Flow Control GmbH Service Teams or the Flowserve Quick Response Centers for support.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information Packing Danger of injury and material damage due to improper packing work! Improper packing work can lead to severe injuries and material damage. Make sure that only qualified personnel with suitable personal protective equipment ...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information ▪ The operating conditions and limits of the ROTADISK Pneumatic Actuator shall be continuously monitored and all risks ensuing from operation of the ROTADISK Pneumatic Actuator shall be eliminated. ▪...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information Personal Protective Equipment It is the owner company’s responsibility to provide the operating personnel with high-quality personal protective equipment (PPE). This personal protective equipment must also be suitable for work on the ROTADISK Pneumatic Actuator within the scope of the life cycle.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information Qualification of the Personnel The personnel of the owner company who are entrusted to work on the ROTADISK Pneumatic Actuator must have suitable knowledge and skills as well as satisfying the following prerequisites: ▪...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information 2.6.4 Work Activities of the Target Groups The table below lists the work activities assigned to the target groups. In order to avoid personal injury and/or material damage, make sure that only target groups with suitable qualifications are allowed to perform the work listed in Table 4: Target groups with assigned work activities.
ROTADISK Pneumatic Actuator. ▪ The ROTADISK Pneumatic Actuator is used with spare parts and/or accessories from third suppliers which do not originate from Flowserve Flow Control GmbH. ▪ The ROTADISK Pneumatic Actuator is operated with unauthorised modifications.
If there are any doubts regarding the suitability of the ROTADISK Pneumatic Actuator for the respective intended use, contact the Quick Response Center (QRC) of Flowserve Flow Control GmbH and state the serial number or article number of the ROTADISK Pneumatic Actuator that is specified on the nameplate.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 2 Safety Information General Sources of Hazard/Residual Hazards 2.10 This section describes general sources of hazard/residual hazards that exist during intended and improper use (reasonably foreseeable misuse). Figure 2: General sources of hazard/residual hazards of the ROTADISK Pneumatic Actuator Danger of injury from a heavy ROTADISK Pneumatic Actuator! A heavy ROTADISK Pneumatic Actuator (≥...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 3 Product Description Product Description General Product Description The ROTADISK Pneumatic Actuators serve for valve automation. They are available in two types: ▪ RD (double-action) ▪ RDF (single-action or spring-loaded return) ROTADISK Pneumatic Actuators are based on a pneumatic twin piston drive according to the Scotch-Yoke principle which are designed primarily for switching check valves and ball valves.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 3 Product Description transmission shaft position: transmission shaft position: OPEN OPEN interior pressurised interior pressurised exterior vented alternative left-hand rotation (CCW) or spring opening, Design Normally Open (NO) or Fail Open (FO) Basic position OPEN RDF single-action (spring...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 3 Product Description also possible that the ROTADISK Pneumatic Actuator moves into the OPEN position by means of the springs (spring opening or Fail Open) in the event of a compressed air drop. The slewing angle of the ROTADISK Pneumatic Actuators can be adjusted by ±3°...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 3 Product Description 3.3.1 Double-action Function (ROTADISK Pneumatic Actuator Type RD) The following functional description refers to a ROTADISK Pneumatic Actuator in standard design ( see section 3.1). The interior of the ROTADISK Pneumatic Actuators is pressurised through connection “P1” between the two pistons.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 3 Product Description 3.3.2 Single-action Function (ROTADISK Pneumatic Actuator Type RDF) The following functional description refers to a ROTADISK Pneumatic Actuator in standard design ( see section 3.1). The interior is pressurised through connection “P1” between the two pistons. The pistons move apart and press the springs together.
Documents demanded by law or by the customer Check whether the delivery complies with the specifications on the delivery note upon receipt of the goods. Report any deviations immediately to the carrier and Flowserve Flow Control GmbH. Page 34 of 79...
Report any defects and/or material damages immediately to the carrier and Flowserve Flow Control GmbH. Flowserve Flow Control GmbH must receive all claims in writing within one month of receipt of the ROTADISK Pneumatic Actuator. Please note that Flowserve Flow Control GmbH will be unable to accept later claims.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 4 Receipt of Goods Unpacking the ROTADISK Pneumatic Actuator Open the box or wooden crate. Loosen and remove the entire packing and load securing material (for example, wedges). Lift the ROTADISK Pneumatic Actuator out of the box and/or wooden crate ( see chapter 12 Transport).
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 5 Installation Installation Safety Information To avoid personal injury and/or material damage, make sure that installation work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools. See chapter 2 Safety Information.
Important for the correct switching of the valve by the ROTADISK Pneumatic Actuator is that the valve and the pneumatic actors have an identical basic setting. Contact the Quick Response Center (QRC) of Flowserve Flow Control GmbH for installation support.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 6 Commissioning Commissioning Safety Information To avoid personal injury and/or material damage, make sure that commissioning, flushing and pressure testing work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 6 Commissioning Commissioning the ROTADISK Pneumatic Actuator Observe the specifications in the manufacturer documentation (e.g. ball valve operating manual) of the automatic valve components for commissioning work. Check the pipework and all control lines for leakages. Connect the power supply to the pneumatic actuator control components.
GmbH offers repair sets or spare parts kits for every ROTADISK Pneumatic Actuator. In order for Flowserve Flow Control GmbH to be able to offer suitable repair sets and spare parts kits for the ROTADISK Pneumatic Actuator, the ROTADISK Pneumatic Actuator must be clearly identified.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 7 Maintenance Maintenance Plan The recommended inspections/maintenance work can be carried out in the installed state. As a rule, it applies that the normal industrial plant operation must not be interrupted.
Contact service teams of Flowserve Flow Control GmbH or the Flowserve Quick Response Centers if repair work needs to be carried out. Danger of injury due to high spring tension! A lid under spring tension can cause severe injury or even death if you remove it without an assembly device with press.
Suitable spare parts are required for this repair work. Flowserve Flow Control GmbH offers spare parts kits for every ROTADISK Pneumatic Actuator. In order for Flowserve Flow Control GmbH to be able to offer suitable spare parts kits for the ROTADISK Pneumatic Actuator, the ROTADISK Pneumatic Actuator must be clearly identified.
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Do not loosen/unscrew lid screws without an assembly device with press. Contact Flowserve Flow Control GmbH if no assembly device with press is available. Make different marks on the edges of both lids [2] on the top of the body.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Loosen the lid screws [1] diagonally opposed on the lid [2]. Take the spring package out of the side of the body. Repeat the previous steps for the other side of the body. Unscrew the locking pin (threaded pin) [5] from the drive shaft.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Pull the shim bushing [8] out of the body [10]. [10] Knock the drive shaft [4] out of the body [10] with a rubber hammer. [10] Remove the bearing bushes [15] and the Q/O-rings [12][14] from the body [10]. Press out the piston pair [9] with a soft tool until it is flush with the body [10].
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Do not use a solvent to clean the piston pair [10]. [11] [10] Grease the cleaned parts with low-temperature grease. Flowserve Flow Control GmbH recommends the low-temperature grease SAPPHIRE Lo-Temp 2 made by ROCOL. Pull the new O-rings [12] onto both pistons [9]. [12] Assemble the two pistons [9] with the double swing arm [11] in a piston pair [9].
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[13] Grease the bearing opening [13] on the top body flange side. Flowserve Flow Control GmbH recommends the low-temperature grease SAPPHIRE Lo-Temp 2 made by ROCOL. Fit a new greased Q-ring [14] on the top body flange side and a new bearing bush [15] into the bearing opening [13].
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Press the greased drive shaft [4] carefully into the body [10] from the bottom. Make sure that the groove in the drive shaft [4] has the original position (transverse or parallel to the longitudinal axis).
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Place the washer [7] over the drive shaft [4]. Fit the shaft locking ring [6]. Make sure that the sharp side is facing upwards. Mount both lids [2] with spring package on the body [10]. Use an assembly device with press and the lid screws [1] for mounting.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Screw the locking pin (threaded pin) [5] into the drive shaft [4]. Place the black support ring [17] onto the shim bushing [8]. [17] Fit the position indicator [16]. [16] Check the ROTADISK Pneumatic Actuator for correct direction of rotation and leaks.
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair 8.3.2 Replacing Seals on the ROTADISK Pneumatic Actuator (RD 2,5–160) The ROTADISK Pneumatic Actuator is ▪ taken out of operation (no compressed air supply is connected). ▪...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Mark the position of the drive shaft groove on the body [10]. Standard design Alternative design (inverse direction of rotation) Unscrew the locking pin (threaded pin) [5] from the drive shaft. Remove the black support ring [17].
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Remove the shaft locking ring [6] and the washer [7]. Pull the shim bushing [8] out of the body [10]. [10] Knock the drive shaft [4] out of the body [10] with a rubber hammer. [10] Remove the bearing bushes [15] and the Q/O-rings [12][14] from the body [10].
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Do not use a solvent to clean the piston pair [10]. [11] [10] Grease the cleaned parts with low-temperature grease. Flowserve Flow Control GmbH recommends the low-temperature grease SAPPHIRE Lo-Temp 2 made by ROCOL. Pull new O-rings [12] onto the two pistons [9]. [12] Assemble the two pistons [9] with the double swing arm [11] in a piston pair [9].
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Centre the pistons [9] or double swing arm [11] in the middle under the shaft bearing. Grease the bearing opening on the bottom body flange side [13]. Flowserve Flow Control GmbH recommends the low-temperature grease SAPPHIRE Lo-Temp 2 made by ROCOL. [13] Fit a new Q-ring [14] on the bottom body flange side and a new bearing bush [15] into the bearing opening [13].
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Fit a new greased Q-ring [14] on the top body flange side and a new bearing bush [15] into the bearing opening [13]. [14] [13] [15] Press the greased drive shaft [4] carefully into the body [10] from the bottom. Make sure that the groove in the drive shaft [4] has the original position (transverse or parallel to the longitudinal axis).
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Insert the shim bushing [8] into the bearing opening. Place the washer [7] over the drive shaft [4]. Fit the shaft locking ring [6]. Make sure that the sharp side is facing upwards. Page 59 of 79...
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Mount both lids [2] on the body [10]. Use an assembly device with press and the lid screws [1] for mounting. Also check whether the marks ( see step 1) on the lid [2] and body [10] match. [10] Screw the locking pin (threaded pin) [5] into the drive shaft [4].
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ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 8 Repair Fit the position indicator [16]. [16] [17] Check the ROTADISK Pneumatic Actuator for correct direction of rotation and leaks. ✓ Replacement of the seals is completed. Page 61 of 79...
It is generally an advantage to contact the service teams of Flowserve Flow Control GmbH or the Flowserve Quick Response Centers to get specific support.
Please make sure that the ROTADISK Pneumatic Actuator is free from hazardous fluid residues and other substances as well as cleaned and preserved before it is sent in to Flowserve Flow Control GmbH. Flowserve Flow Control GmbH will only open and repair the ROTADISK Pneumatic Actuator if a decontamination certificate and the safety data sheet of the ROTADISK Pneumatic Actuator are enclosed.
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The decontamination certificate and the safety data sheet certify that the ROTADISK Pneumatic Actuator presents no risk for persons and the environment. Flowserve Flow Control GmbH will only accept the returned goods if a completely filled in and signed decontamination certificate and safety data sheet are enclosed with them.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 9 Shutdown Shutdown Safety Information To avoid personal injury and/or material damage, make sure that shutdown work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools. See chapter 2 Safety Information.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 10 Storage Storage Safety Information 10.1 To avoid personal injury and/or material damage, make sure that storage work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools. See chapter 2 Safety Information.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 10 Storage Storing the ROTADISK Pneumatic Actuator 10.2 The following prerequisites are satisfied: The ROTADISK Pneumatic Actuator ▪ is not connected to and has been dismantled from the valve (e.g. ball valve). ▪...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 11 Packing Packing Safety Information 11.1 To avoid personal injury and/or material damage, make sure that packing work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools. See chapter 2 Safety Information.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 11 Packing Packing the ROTADISK Pneumatic Actuator 11.2 The following prerequisites are satisfied: The ROTADISK Pneumatic Actuator ▪ is not connected to and has been dismantled from the valve (e.g. ball valve). ▪...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 12 Transport Transport Safety Information 12.1 To avoid personal injury and/or material damage, make sure that transport work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools. See chapter 2 Safety Information.
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 12 Transport Transporting the ROTADISK Pneumatic Actuator 12.2 The following prerequisites are satisfied: The ROTADISK Pneumatic Actuator ▪ is not connected to and has been dismantled from the valve (e.g. ball valve). ▪...
ROTADISK Pneumatic Actuator RD & RDF Operating Manual – BA3002 EN 13 Disposal and Recycling Disposal and Recycling Safety Information 13.1 To avoid personal injury and/or material damage, make sure that disposal and recycling work is performed only by qualified personnel with suitable personal protective equipment (PPE) and suitable tools.
ROTADISK Pneumatic Actuator RD & RDF User Instructions – BA3002 EN Appendix B: Declaration of Incorporation Appendix B: Declaration of Incorporation Page 74 of 79...
ROTADISK Pneumatic Actuator RD & RDF User Instructions – BA3002 EN Appendix C: Torques of the ROTADISK Pneumatic Actuators Appendix C: Torques of the ROTADISK Pneumatic Actuators Series/Type Control pressure (bar) 17,5 22,5 1120 1280 1120 1280 1440 1600 1920 2240 2560 Series/...
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ROTADISK Pneumatic Actuator RD & RDF User Instructions – BA3002 EN Appendix C: Torques of the ROTADISK Pneumatic Actuators Series/ Control pressure (bar) Spring Type RDF at 0° – – – – 10-1 at 90° – – – – at 0° –...
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ROTADISK Pneumatic Actuator RD & RDF User Instructions – BA3002 EN Appendix C: Torques of the ROTADISK Pneumatic Actuators Series/ Control pressure (bar) Spring Type RDF at 0° – – – – 80-1.5 at 90° – – – – at 0° –...
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When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions.
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