DeZurik POWERRAC R3 User manual

DeZURIK R3 POWERRAC
TM
CYLINDER ACTUATOR
Instruction
D10359
August 2016

DeZURIK
R3 PowerRacTM Cylinder Actuator
D10359 © 2016 DeZURIK, Inc.
Instructions
These instructions provide information about the R3 PowerRac Cylinder Actuators. They are for use by
personnel who are responsible for installation, operation and maintenance of R3 PowerRac Cylinder
Actuators.
Safety Messages
All safety messages in the instructions are flagged with an exclamation symbol and the word Caution,
Warning or Danger. These messages indicate procedures that must be followed exactly to avoid
equipment damage, personal injury or death.
Safety label(s) on the product indicate hazards that can cause equipment damage, personal 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 R3 PowerRac Cylinder Actuator has been packaged to provide protection during shipment;
however, it 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
Recommended spare parts are listed on the assembly drawing. These parts should be stocked to
minimize downtime.
Order parts from your local DeZURIK sales representative, or directly from DeZURIK. When ordering
parts, please include the 7-digit part number and 4-digit revision number (example: 9999999R000)
located on the data plate 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.
DeZURIK Service
DeZURIK service personnel are available to install, 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
www.dezurik.com.

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R3 PowerRacTM Cylinder Actuator
August 2016 Page 3 D10359
Table of Contents
Description.................................................................................................................................4
Installation..................................................................................................................................4
Operation ...................................................................................................................................4
Lubrication..................................................................................................................................4
Open and Closed Position Stops ...............................................................................................4
Removing Actuator From Valve .................................................................................................7
Actuator Disassembly.................................................................................................................7
Actuator Reassembly.................................................................................................................8
Mounting Actuator on Valve.....................................................................................................10
Changing Mounting Position of Actuator on Valve...................................................................11
Lockable Model........................................................................................................................11
Unlocked Condition ..............................................................................................................12
Locked: Closed Position.......................................................................................................12
Locked: Open Position..........................................................................................................12
Troubleshooting .......................................................................................................................15

DeZURIK
R3 PowerRacTM Cylinder Actuator
D10359 Page 4 August 2016
Description
The R3 PowerRac Cylinder Actuator is a quarter-turn double-acting enclosed rack and gear cylinder
actuator. The actuator is used for on-off or modulating control of butterfly valves and other valves that
have a square or double-D shaft connection. A choice of an 8" (200 mm) or a 10" (250 mm) diameter
cylinder is offered. A lockable model is available as an option.
Installation
The actuator requires two pneumatic connections— one to each port on opposite ends of the cylinder.
Air to the connection closest to the actuator drives the actuator clockwise, towards the “shut” position
on the dial; air to the connection farthest from the actuator drives the actuator counterclockwise,
towards the “open” position on the dial. The 8" (200 mm) cylinder has ½" NPT connections, and the 10"
(250 mm) cylinder has ¾" NPT connections.
Operation
The R3 PowerRac Cylinder Actuator is powered pneumatically, and rotates 90° between the open and
closed positions. The cylinder is sized for 60 psi or 80 psi (415 kPa or 550 kPa), and is limited to 100
psi (690 kPa) maximum.
Lubrication
The R3 PowerRac Cylinder Actuator is lubricated at the factory, and does not require routine
maintenance lubrication. If the actuator is disassembled, lubrication is required as described in the
Actuator Reassembly section.
Open and Closed 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 and/or disassembled, the stops will require adjustment as described below. Refer to the Valve
Instructions for closed-position information, and adjust the stop screws after the actuator is mounted on
the valve.
The adjustable stop screws are secured with jam nuts, and are located in the extreme ends of the
actuator as shown in Figures 1 and 2. The closed position stop is located in the cylinder cap, and the
open position stop is located in the end cover. To adjust either stop screw, loosen the jam nut and turn
the screw counterclockwise to increase the stroke, or clockwise to decrease the stroke. After the stop is
adjusted to the desired position, hold the screw from turning, and tighten the jam nut.

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R3 PowerRacTM Cylinder Actuator
August 2016 Page 5 D10359
Figure 1 - Component Identification, Unassembled

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R3 PowerRacTM Cylinder Actuator
D10359 Page 6 August 2016
Figure 2 - Component Identification, Assembled

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R3 PowerRacTM Cylinder Actuator
August 2016 Page 7 D10359
Open and Closed Position Stops (Continued)
•With an 8" (200 mm) cylinder, tighten the closed position stop nut (3/4") to 140 ± 18 foot pounds
(190 ± 24 Nm); tighten the open position stop nut (7/8") to 230 ± 30 foot pounds (312 ± 41 Nm).
•With a 10" (250 mm) cylinder, tighten both stop nuts (7/8") to 230 ± 30 foot pounds (312 ± 41
Nm).
Removing Actuator From Valve
Refer to Figures 1 and 2 for component identification.
1. Shut down the flow in the pipeline.
Flow in the pipeline with the actuator removed 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 removing the actuator from the valve.
2. Disconnect and lock out the pneumatic power to the actuator to prevent accidental operation
of the actuator.
Moving parts from unexpected operation of a powered actuator can cause
personal injury or equipment damage. Disconnect and lock out power to the
actuator before servicing.
3. Disengage the actuator from the valve shaft by loosening the jam nut (B30) clockwise and
loosening the adjusting screw (B29) counterclockwise.
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 1 and 2 for component identification.
1. Remove the four pointer screws (B37) and washers (B38); remove the pointer (B9), together
with the other collet assembly components indicated in Figure 1.
2. Remove the four top cover screws (B15) and washers (B14), and remove the top cover (B11).
3. Remove the top cover gasket (B13) and the O-Ring (B10).
4. Remove the gear (B8).
5. Remove the four end cover screws (B19) and washers (B18), and remove the end cover
(B17) and gasket (B16).
6. Remove the rack screw (B7) and lockwasher (B6), and separate the rack (B5) from the piston
rod (B42).
7. Remove the rack bearing (B3).

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R3 PowerRacTM Cylinder Actuator
D10359 Page 8 August 2016
Actuator Disassembly (Continued)
1. Remove the tie rod nuts (B56) and washers (B55) from the tie rods (B54), and remove the
cylinder cap (B50).
2. Remove the piston rod (B42)— with piston (B46) and cylinder tube (B49)— from the cylinder
head on the housing (B1).
3. Remove the piston rod (B42) and piston (B46) from the cylinder Tube (B49).
4. Remove the piston nut (B47), the piston (B46), and the O-ring (B43) from the piston rod (B42).
5. Remove the piston seal (B44) and the O-ring (B45) from the piston (B46).
6. Remove the piston rod seal (B40) from the actuator housing (B1).
7. Remove the two cylinder tube O-rings (B48) from the cylinder head on the housing (B1) and
from the cylinder cap (B50).
8. Remove the tie rods (B54) from the actuator housing (B1).
Actuator Reassembly
Steps 1 through 7 apply to reassembly of the cylinder components. Clean and inspect all parts before
reassembly. Worn parts, especially sealing components such as O-rings and other seals should be
replaced. Lubricate the cylinder O-rings, other seals, and cylinder tube walls with a paint-like coating
using one of these lubricants:
- Dow Corning Molykote No. 44 (recommended)
- Shell Retinax AM (alternate)
- Shell Lithall MDS (alternate)
Refer to Figures 1 and 2 for component identification.
1. With the O-ring groove toward the piston rod, place the O-ring (B43), the piston (B46), and the
nut (B47) on the piston rod (B42). Tighten the nut to 120 ± 10 foot pounds (163 ± 14 Nm).
2. Place the O-ring (B45) in the smaller groove of the piston (B46). Place the piston seal (B44) in
the larger groove of the piston as far around the circumference as possible without stretching
the seal. Angle the remaining.
3. Place one cylinder tube O-ring (B48) in the groove in the cylinder head on the housing (B1),
and place the other O-ring in the groove in the cylinder cap (B50).
4. Place the 3-piece piston rod seal (B40) in the cylinder head of the housing (B1). Place the
rubber seal in position first, and then place a wiper ring in position on each side of the seal.
5. Place the cylinder tube (B49) over the piston (B46) at about a 45° angle. Carefully square
the piston into alignment with the cylinder tube, and push the cylinder tube and piston rod into
position on the cylinder head of the housing (B1). Use care to prevent damage to the seals.
Push the piston (B46) into the cylinder so that the piston is against the cylinder head.
6. Apply Loctite Primer N and Loctite Stud Lock to the shorter threads on each of the tie rods
(B54), and turn each stud as far as it will go into the housing (B1).
7. Align the holes in the cylinder cap (B50) with the tie rods (B54) and insert the cylinder cap into
the cylinder tube (B49). Place the tie rod nuts (B56) and washers (B55) on the tie rods.
Tighten the nuts to 16 ± 2 foot pounds (22 ± 3 Nm).

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R3 PowerRacTM Cylinder Actuator
August 2016 Page 9 D10359
Actuator Reassembly (Continued)
Steps 8 through 18 apply to reassembly of the housing components. Clean and inspect all parts before
reassembly. Worn parts, especially sealing components such as O-rings, other seals, and gaskets
should be replaced. Before housing reassembly, 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)
- Shell Alvania EP 1 (alternate)
- Texaco Multifak EP 1 (alternate)
to the following surfaces:
•The fabric side of the rack bearing (B3) and the mating side of the rack (B5)
•Both bearing hubs of the gear (B8)
•The top cover O-ring (B10) and the groove in the top cover (B11)
•Both sides of the four wedges, and the mating surfaces inside of the gear (B8)
•The teeth in the rack (B5) and in the gear (B8)
8. Place the rack bearing (B3) in position in the housing (B1). A dab of grease on the back side
of the rack bearing will help to hold it in place.
9. Note the witness mark on the tooth near one end of the rack (B5). Assemble the end of the
rack opposite the witness mark to the end of the piston rod (B42) with the rack screw (B7) and
lockwasher (B6). Do not tighten the screw until step 14 below.
10. With the four tapped holes facing upwards, place the gear (B8) into the housing bearing (B2)
so that the marked tooth on the rack (B5) meshes between the two marked teeth on the gear
as shown in Figure 3.
11. Place the O-ring (B10) in the groove of the top cover (B11).
12. Mount the top cover (B11) and gasket (B13) to the housing (B1) with the four screws (B15)
and washers (B14). Tighten the screws to 15 ± 2 foot pounds (20 ± 3 Nm).
13. Place the actuator in the open position— with the piston rod (B42) extended into the
housing— before the next step.
14. Tighten the rack screw (B7) to 216 foot pounds minimum, (293 Nm). If necessary, apply 80 psi
(550 kPa) air pressure to the cap end of the cylinder to prevent the piston rod from rotating.
15. Turn the jam nut (B22) and the lockwasher (B23) onto the stop screw (B21), and turn the stop
screw into the center hole in the end cover (B17) until the end of the stop screw protrudes
about 1/4" (6 mm) through the end cover. Turn the jam nut finger tight.
16. Mount the end cover (B17)— with the ‘T’ mark towards the top— and the gasket (B16) to the
housing (B1) with the four screws (B19) and washers (B18). Tighten the screws to 38 ± 5 foot
pounds (52 ± 7 Nm).
17. Turn the adjusting screw (B29) so that the four wedges (B34) are about 1/32" (0.8 mm) from
the bottom of the pointer (B9).
18. With the actuator in the open or closed position, place the collet assembly components into
the opening in the gear (B8), and align the pointer (B9) with the corresponding position on the
top cover (B11). Mount the pointer to the gear with the four screws (B37) and washers (B38).
Tighten the screws to 15 ± 2 foot pounds (20 ± 3 Nm).

DeZURIK
R3 PowerRacTM Cylinder Actuator
D10359 Page 10 August 2016
Figure 3 – Collet Assembly
Mounting Actuator on Valve
Refer to Figures 1 and 2 for component identification.
1. Select one of the available actuator-to-valve mounting positions shown on the Installation
Drawing. Match the open or closed position of the valve with the open or closed position of
the actuator. Also, note the position of the word “open” on the top cover (B11). The cover must
be positioned on the housing (B1) so that dial hash mark for “open” will be parallel with the
pipeline when the valve is installed. One or more of the following four steps may be required,
depending upon the positions of the valve, the actuator, the actuator cover, and the mounting
position selected.
a. Rotate the valve shaft, and/or
b. Stroke the actuator, and/or
c. Select a different actuator-to-valve mounting position, and/or
d. Remove and re-index the cover. If this step is necessary, remove the four cover screws
B15), rotate the cover, and replace the four cover screws (B15) and washers (B14).
Tighten the screws to 15 ± 2 foot pounds (20 ± 3 Nm).
2. If the actuator does not include the collet assembly (the components are identified in Figure 1,
grease the components as described in the Actuator Reassembly section and install the
assembly as explained in steps 17 and 18 in the same section.

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Mounting Actuator on Valve (Continued)
3. Certain high-temperature valves include and require a high-temperature gasket (B28). If the
valve includes a gasket, use the gasket included with the valve rather than the gasket
included with the actuator. Place the gasket between the actuator and the valve; engage the
actuator with the valve shaft in the desired mounting position as determined in step 1, and
slide the actuator onto the valve shaft.
4. Assemble the four actuator mounting screws (B26) with lockwashers (B27) up through the
mounting holes in the top of the valve (or the actuator adaptor on the valve), through the
gasket (B28), and into the threaded holes in the bottom of the actuator. Tighten the screws
finger tight— so that the valve and actuator mounting surfaces are in contact, but are free to
slide and self-center during the next step.
5. Tighten the adjusting screw (B9A) to 200 ± 30 foot pounds (271 ± 41 Nm).
6. Tighten the actuator mounting screws (B26) to 318 foot pounds minimum, (431 Nm).
7. Loosen the adjusting screw (B9A).
8. Re-tighten the mounting screws (B26) to 318 foot pounds minimum (431 Nm).
9. Tap the adjusting screw with a rubber mallet so that the gear (B8) bottoms out against the
lower housing bearing (B2).
10. Begin to tighten the adjusting screw (B9A); as the adjusting screw becomes snug, repeat step
9, and finish tightening to 200 ± 30 foot pounds (271 ± 41 Nm).
11. Tighten the jam nut (B30) counterclockwise to 200 ± 30 foot pounds (271 ± 41 Nm).
12. Adjust the open and closed position stops as explained in the Open and Closed Position
Stops section.
13. Operate the actuator and valve three full cycles to demonstrate that the unit operates
smoothly in both directions. Do not exceed 100 psi (690 kPa) in the cylinder.
Changing Mounting Position of Actuator on Valve
The actuator may be mounted on the valve in any one of the mounting positions shown on the
Installation Drawing. The mounting position may be changed as follows:
1. Remove the actuator from the valve as described in the Removing Actuator From Valve
section.
2. Replace the actuator on the valve as described in the Mounting Actuator On Valve section.
Lockable Model
The R3 PowerRac Cylinder Actuator is available as a lockable model that allows the actuator to be
locked in either the open or closed position. The lockable model is identified by PRL in the catalog
characteristic.
As shown in Figure 4, the lockable model includes two lock screws (B64) and two jam nuts (B65). In the
locked position, the screws engage with mating notches in the gear (B8). A lockout cover assembly
(B60) is also included.

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R3 PowerRacTM Cylinder Actuator
D10359 Page 12 August 2016
Lockable Model (Continued)
The two lock screws (B64) must be in either the unlocked or the locked position as
described in the following sections. The gear (B8) will be damaged if either of the stop
screws is placed in an intermediate position between the unlocked and locked positions.
Unlocked Condition
Under normal unlocked running conditions, both of the lock screws are backed out of the housing to
allow the gear to rotate freely in either direction. To be fully disengaged, the distance from the housing
to the end of each lock screw must be at least 3 1/8" (80 mm). To hold the lock screws in position, the
jam nuts are tightened to 140 ± 18 foot pounds (190 ± 24 Nm).
Locked: Closed Position
Follow the steps below to change the unit from the unlocked condition to the locked closed position.
Refer to Figure 3 for component identification. Before proceeding, the open and closed position stops
must be correctly adjusted as described in the Open and Closed Stops section.
1. Operate the actuator to the fully closed (clockwise) position.
Adjust only the left-side lock screw to lock the actuator in the closed position. Adjusting
the wrong screw does not lock the actuator, and can result in personal injury or
equipment damage.
2. Loosen the jam nut (B65) on the left side lock screw (B64), as viewed when facing the top of
the heads of the lock screws. Hold the lock screw from turning, and turn the jam nut several
turns counterclockwise, to the head of the lock screw.
3. Turn the left side lock screw clockwise several turns until resistance is felt from the lock screw
contacting the notch in the gear (B8). Tighten the lock screw to 5 to 10 foot pounds (7 to 14
Nm) to assure that the lock screw is contacting the gear.
4. Turn the left side jam nut clockwise against the actuator housing. While holding the lock
screw from turning, tighten the jam nut to 140 ± 18 foot pounds (190 ± 24 Nm).
5. Place and lock the lockout cover assembly (B60) on the head of the left side lock screw.
Locked: Open Position
Follow the steps below to change the unit from the unlocked condition to the locked open position.
Refer to Figure 4 for component identification. Before proceeding, the open and closed position stops
must be correctly adjusted as described in the Open and Closed Stops section.
1. Operate the actuator to the fully open (counterclockwise) position.

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R3 PowerRacTM Cylinder Actuator
August 2016 Page 13 D10359
Adjust only the right-side lock screw to lock the actuator in the open position. Adjusting
the wrong screw does not lock the actuator, and can result in personal injury or
equipment damage.
2. Loosen the jam nut (B65) on the right side lock screw (B64), as viewed when facing the top of
the heads of the lock screws. Hold the lock screw from turning, and turn the jam nut several
turns counterclockwise, to the head of the lock screw.
3. Turn the right side lock screw clockwise several turns until resistance is felt from the lock
screw contacting the notch in the gear (B8). Tighten the lock screw to 5 to 10 foot pounds (7
to 14 Nm) to assure that the lock screw is contacting the gear.
4. Turn the right side jam nut clockwise against the actuator housing. While holding the lock
screw from turning, tighten the jam nut to 140 ± 18 foot pounds (190 ± 24 Nm).
5. Place and lock the lockout cover assembly (B60) on the head of the right side lock screw.

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R3 PowerRacTM Cylinder Actuator
D10359 Page 14 August 2016
Figure 4 – Lockable Model, Component Identification

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R3 PowerRacTM Cylinder Actuator
August 2016 Page 15 D10359
Troubleshooting
Condition Possible Cause Corrective Action
Actuator closes to
wrong position Closed position stop is set incorrectly
Adjust closed position stop.
See
OPEN AND CLOSED STOPS.
Actuator opens to
wrong position Open position stop is set incorrectly Adjust open position stop. See OPEN AND CLOSED STOPS.
Actuator will not fully
operate valve
Cylinder pressure is low Increase cylinder pressure.
Do not exceed 100 psi (69
kPa).
Actuator is sized incorrectly
Use larger actuator
Piston seal in cylinder is leaking Replace piston seal(s). See
ACTUATOR DISASSEMBLY
AND REASSEMBLY.
Pipeline obstruction in valve is
preventing closure Remove obstruction
Lockable Model is locked. Place in unlocked condition.
See LOCKABLE MODEL.
Actuator rotates wrong
direction Air connections to cylinder are incorrect Reverse air connections to
cylinder