Flowserve FlowAct IG 253 User manual

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Assembly Instructions
FlowAct IG
IG 253, IG 503, IG 701
Training Instructions, for internal use only !

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Contents
1 Contents 3
2 General 3
3 Assembling Instruction - FlowAct IG 253, 503, 701 - Spring to close - without Hand wheel 5 - 7
4 Assembling Instruction - FlowAct IG 253, 503, 701 - Spring to open - without Hand wheel 9 - 11
5 Technical Tables A1 to A3 - Torque requirements - Lubricants - Imperial and Metric Units 13
6 Technical Table A4 - Spring orientation 13
7 Technical Table A5 - Spring packages 14
8 Assembling Instruction - Valtek GS with FlowAct IG 253, 503, 701 - Spring to close - without Hand wheel 17 - 19
9 Assembling Instruction - Valtek GS with FlowAct IG 253, 503, 701 - Spring to open - without Hand wheel 21 - 23
10 Assembling Instruction - Valtek GS with FlowAct IG 253 - Spring to close - side Hand wheel 25 - 27
11 Assembling Instruction - Valtek GS with FlowAct IG 253 - Spring to open - side Hand wheel 29 - 31
12 Assembling Instruction - Valtek GS with FlowAct IG 503, 701 - Spring to close - side Hand wheel 33 - 36
13 Assembling Instruction - Valtek GS with FlowAct IG 503, 701 - Spring to open - side Hand wheel 37 - 40
14 Technical Tables VA1 to VA3 - Torque requirements - Lubricants - Imperial and Metric Units 41
15 Technical Table ST1 - Special Tools 42
16 Parts List 43
General
The following instruction are designed to assist in assembling as required on Flowserve FlowAct IG actuators.
This instruction does not include specific product design data. These are located at the corresponding data
sheet, calculation sheet, dimension sheet in the documentation. Procure the documents before you start
if this appears necessary. In Assembling Instructions can not be dealt with every conceivable situation
and installation options. It is expressly permitted only qualified stuff to work at FlowAct actuators who
are educated and trained at actuators and accessories. Review this bulletin prior to assemble the actuator.
Modifying this product, substituting non-factory parts other than outlined could drastically affect
performance and be hazardous to personnel and equipment. This manual should be used in conjunction
with applicable local and national laws.
WARNING
Failure to keep hands, hair, and clothing away from all moving parts when
operating the actuator can cause serious injury.
Apply appropriate personal protective equipment when working on the actuator to prevent hazards
arising from the operation. Protect yourself against scalds, cuts by protective clothing, gloves and
eye protection.
Actuators are provided for oil and grease-less service or oxygen service may only assembled in
clean rooms (ISO 14644 - ISO 8, US FED STD 209E - M 6.5, or equivalent) and in accordance with
the Flowserve Control Valves - Work Instruction T 007.

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Pneumatic multi spring actuator - FlowAct order code
FlowAct Order code
I G 503 B FY O Z B
Actuator design internal air supply I
Yoke design Multi-function yoke for GS only G
Actuator size 250 38.75 Stroke ( mm / inch ) 20 0.79 253
( cm2/ inch2) 500 77.50 20, 40 0.79, 1.57 503
700 108.50 20, 40, 60 0.79, 1.57, 2.36 701
Color white, powder coated B
Actuator size 253 503 701
Spring range 0,2 - 1,0 2.9 - 14.5 Actuator force ( N / lbs ) 500 112 1 000 225 1 400 315 AD
( bar / psi ) 0,5 - 1,9 7.3 - 27.6 1 250 281 2 500 562 3 500 787 BL
1,0 - 2,4 14.5 - 34.8 2 500 562 5 000 1 124 7 000 1 574 DY
1,5 - 2,7 1) 21.8 - 39.2 3 750 843 7 500 1 686 10 500 2 360 VC
1,5 - 3,8 21.8 - 55.1 3 750 843 7 500 1 686 10 500 2 360 VI
2,0 - 4,8 29.0 - 69.6 5 000 1 124 10 000 2 248 14 000 3 147 FY
2,3 - 3,4 2) 33.4 - 49.3 - - --16 100 3 619 TD
Handwheel without O
side-mounted S
Safety position at
air failure
spring to open A
spring to close Z
Stroke ( mm / inch ) 20 0.79 A
40 1.57 B
60 2.36 C
1) Stroke 20, 40 mm / 0.79, 1.57 inch only !
2) Stroke 20 mm / 0.79 inch only !

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FlowAct “IG”
Assembling instruction for
FlowAct order code: IGxxx BxxOZx
Actuator Type Multi spring 253, 503, 701
Hand wheel Without
Safety position Spring to close
Stroke 20, 40, 60
Step Image Instruction
1
202
253
254
275
273
• Place the bottom diaphragm casing (202) in the Special
Tool
The air connection should be on your side.
• InstalltheO-ring(275)andscraper-ring(273)intothe
guide bush (253).
• Firstlypress-inthepre-assembledguidebushintothe
diaphragm casing, secondly press-in the plain bearing
(254) into the guide bush.
2
211
255
225 272
227 228
348
349
Stem
Clamping
Tool
Positioning
Template
Marker
Window
• Fixtheactuatorstem(211)intotheSpecialTool.
• LubricatetheO-ring(272)withasuitablelubricant.
(See Page 13, Table A3)
• Lowerthe thrustwasher(255)
diaphragm (225)
O-ring (272)
diaphragm plate (227)
spacer bush (228)
lock washer (349)
onto the actuator stem.
• Lubricatethethreadofthestem(211)withasuitable
lubricant. (See Page 13, Table A3)
• Installandngertightenthespecialnut(348).
The diaphragm plate should be positioned to the
diaphragm with the aid of the Positioning Template.
• Turnclockwisethespecialnut(348)withtheSpecial
Tool using a suitable torque wrench. (See Page 13,
Table A1)
Mark the position with a felt-tip pen.

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Step Image Instruction
3
202
253
254
275
273
211
228
227
225
272
255
349
348
229
326
231
203
Drilling
and
marking
must
match !
• Lubricatetheactuatorstemwithasuitablelubricant.
(See Page 13, Table A3)
• Lower the pre-assembled diaphragm-stem unit into
the bottom diaphragm casing.
Be careful not to score the stem.
Positioning the diaphragm-stem unit such that the
air connection and the mark match.
• Installtheactuatorsprings(229).
The springs have to be aligned.
(See Page 13, Table 04)
• Installthespringadjustingplate(326).
Positioning the spring adjusting plate such that the
drilling, mark and air connection match.
• Installthedistanceplate(231).
• Installtheupperdiaphragmcasing(203).
Positioning the upper diaphragm casing such that
the drilling, mark and air connections match.
4
337
351
336
Preload
springs
with
Special Tool
• Lubricatethethreatsofthehexagonbolts(336)witha
suitable lubricant. (See Page 13, Table A3)
Improper handling of this procedure may result
in bodily injury !
• PreloadthespringswiththeSpecialTool.
In the field service can used 3 threaded rods in 8.8
quality (ISO 898-1) or higher as well as washers and
nuts alternatively. (Dimension M8 x 150 mm)
• InstallandngertightentheWashers(337),hexagon
bolts (336) and hexagon nuts (351).
• Tightenthenuts(351)intwosteps- 30%
 60%
- using a crosswise pattern. (See Page 13, Table A2)

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Step Image Instruction
5
351
335
209
• Lubricatethethreatsofthehexagonbolts(335)witha
suitable lubricant. (See Page 13, Table A3)
• Installandngertightenthehexagonbolts(335)and
hexagon nuts (351).
• Installandngertightenthehexagonbolts(335)and
ring nuts (209).
• Tightenthenuts(351)infoursteps- 30%
 60%
 100%
 andallaround100%
- using a crosswise pattern. (See Page 13, Table A2)
6
258
339
• Installtheventplug(258).
• Installtheplasticpipe(339).
7• Markandstorethepre-assembledactuatorbodyfor
further use.

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Space for personal notes

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FlowAct “IG”
Assembling instruction for
FlowAct order code: IGxxx BxxOAx
Actuator Type Multi spring 253, 503, 701
Hand wheel Without
Safety position Spring to open
Stroke 20, 40, 60
Step Image Instruction
1
202
253
254
275
273
• Place the bottom diaphragm casing (202) in the Special
Tool
The air connection should be on your side.
• InstalltheO-ring(275)andscraper-ring(273)intothe
guide bush (253).
• Firstlypress-inthepre-assembledguidebushintothe
diaphragm casing, secondly press-in the plain bearing
(254) into the guide bush.
2
348
349
255
272
225
227
228
211
Stem
Clamping
Tool
Positioning
Template
Marker
Window
• Fixtheactuatorstem(211)intotheSpecialTool.
• LubricatetheO-ring(272)withasuitablelubricant.
(See Page 13, Table A3)
• Lowerthe spacerbush(228)
diaphragm plate (227)
diaphragm (225)
O-ring (272)
thrust washer (255)
lock washer (349)
onto the actuator stem.
• Lubricatethethreadofthestem(211)withasuitable
lubricant. (See Page 13, Table A3)
• Installandngertightenthespecialnut(348).
The diaphragm plate should be positioned to the
diaphragm with the aid of the Positioning Template.
• Turnclockwisethespecialnut(348)withtheSpecial
Tool using a suitable torque wrench. (See Page 13,
Table A1)
Mark the position with a felt-tip pen.

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Step Image Instruction
3
202
253
254
275
273
211
228
227
225
272
255
349
348
326
229
203
Drilling
and
marking
must
match !
• Installthespringadjustingplate(326).
Positioning the spring adjusting plate such that the
drilling, mark and air connection match.
• Installtheactuatorsprings(229).
The springs have to be aligned.
(See Page 13, Table 04)
• Lubricatetheactuatorstemwithasuitablelubricant.
(See Page 13, Table A3)
• Lower the pre-assembled diaphragm-stem unit into
the bottom diaphragm casing.
Be careful not to score the stem.
Positioning the diaphragm-stem unit such that the
air connection and the mark match.
• Installtheupperdiaphragmcasing(203).
Positioning the upper diaphragm casing such that
the drilling, mark and air connections match.
4
337
351
336
Preload
springs
with
Special Tool
• Lubricatethethreatsofthehexagonbolts(336)witha
suitable lubricant. (See Page 13, Table A3)
Improper handling of this procedure may result
in bodily injury !
• PreloadthespringswiththeSpecialTool.
In the field service can used threaded rods in 8.8
quality (ISO 898-1) or higher as well as washers and
nuts alternatively. (Dimension M8 x 150 mm)
• Installandngertightenthewashers(337),hexagon
bolts (336) and hexagon nuts (351).
• Tightenthenuts(351)intwosteps- 30%
 60%
- using a crosswise pattern. (See Page 13, Table A2)

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Step Image Instruction
5
351
335
209
• Lubricatethethreatsofthehexagonbolts(335)witha
suitable lubricant. (See Page 13, Table A3)
• Installandngertightenthehexagonbolts(335)and
hexagon nuts (351).
• Installandngertightenthehexagonbolts(335)and
ring nuts (209).
• Tightenthenuts(351)infoursteps- 30%
 60%
 100%
 andallaround100%
- using a crosswise pattern. (See Page 13, Table A2)
6
339
258
• Installtheventplug(258).
• Installtheplasticpipe(339).
7• Markandstorethepre-assembledactuatorbodyfor
further use.

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Space for personal notes

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Table A1 - Imperial Units Torque Requirements for SPECIAL NUT (348) per actuator size
Unit IG 253 IG 503 IG 701
ft lb 33 ft lb 81 ft lb
Table A2 - Imperial Units Torque Requirements for CASING BOLTING (335 + 351 and 336 + 351, 209) per actuator size
Unit IG 253 IG 503 IG 701
ft lb 15 ft lb
Table A3 - Imperial Units Lubricants / release agents for the ACTUATOR in ambient temperature
Use for parts which are
not influenced by the
medium and the medium
temperature.
application
Standard use Oxygen use
- 40 °F to + 158 °F
(- 40 °C to + 70 °C)
- 40 °F to + 158 °F
(- 40 °C to + 70 °C)
for stem guiding, O-ring’s Dow Corning Molykote 55 O-Ring 1)
DuPont Krytox GPL 206 1)
for threads of the diaphragm casing bolting Fastorq A/G 1)
for the thread of the actuator lock nut
1) or equivalent
Table A1 - Metric Units Torque Requirements for SPECIAL NUT (348) per actuator size
Unit IG 253 IG 503 IG 701
Nm 45 Nm 110 Nm
Table A2 - Metric Units Torque Requirements for CASING BOLTING (335 + 351 and 336 + 351, 209) per actuator size
Unit IG 253 IG 503 IG 701
Nm 20 Nm
Table A3 - Metric Units Lubricants / release agents for the ACTUATOR in ambient temperature
Use for parts which are
not influenced by the
medium and the medium
temperature.
application
Standard use Oxygen use
- 40 °F to + 158 °F
(- 40 °C to + 70 °C)
- 40 °F to + 158 °F
(- 40 °C to + 70 °C)
for stem guiding, O-ring’s Klüber Unisilikon L250L 1)
Klüberalfa YV 93-1202 1)
for threads of the diaphragm casing bolting Klüberpaste 46 MR 401 1)
for the thread of the actuator lock nut
1) or equivalent
Table 04 Orientation instruction for ACTUATOR SPRINGS
Align this spring edge
to the actuator center !
• The surface respectively the edges of
the spring ends should be aligned to
the actuatos center.
If these will ignored the spring may
touch the actuators body and rub in
rare cases.

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Table 05 FlowAct IG - Spring packages
Spring range Actuator size / Stroke Spring
Spring arrangement
IG 253 IG 503 IG 701
Colour
Pcs.
Colour
Pcs.
psig bar 0.787 in. 0.787 1.574 0.787 1.574 2.362
20 mm 20 40 20 40 60
3 - 15 0,2 - 1,0 • • • -• • blue 3 - -
7 - 28 0,5 - 1,9 • • • -• • blue 6 - -
15 - 35 1,0 - 2,4 • • • -• • red 3 - -
22 - 39 1,5 - 2,7 • • • -• • silver 6 - -
22 - 55 1,5 - 3,8 • • • -• • blue 2 red 4
29 - 70 2,0 - 4,8 • • • -• • red 6 - -
33 - 49 2,3 - 3,4 - - - •- - blue 2 red 4

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FlowAct “IG”
Assembling instruction for
Valtek GS with FlowAct
Actuator Type Multi spring 253, 503, 701
Hand wheel Without
Safety position Spring to close
Stroke 20, 40, 60
Step Image Instruction
1
201
76
113
345
• Fix the valve on the assembly table.
• Lubricateallthreadswithasuitable,approved
lubricant. (See Page 41, Table VA3)
• Mounttheyoke(201),valvelocknut(76)ontothe
bonnet.
• Fingertightenandxthevalvelocknutclockwise.
(See Page 41, Table VA1)
The legs of the yoke should be parallel to the flow
direction.
• Mountthelocknut(113)andvalvecoupling(345)
onto the valve stem. (See Page 41, Table VA2)
The valve stem should placed one turn under the
upper edge of the valve coupling.
2
256
271
278
• Lubricate the O-rings (278, 271) with a suitable
lubricant. (See Page 41, Table VA3)
• Install the O-ring (278) onto the pre-assembled
actuator body.
• InstalltheO-ring(271)ontotheyoke.
• Lowertheactuatorbodyintotheyoke.
Be careful not to score the actuator stem
• Install, nger tighten and x the actuator lock nut
(256). (See Page 41, Table VA1)

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Step Image Instruction
3
249
344
Move the actuator
to the open position !
CRUSHING HAZARD ! Do not work between the
yoke legs while the valve is in operation.
• Connecttheactuatorwiththeairsupply(lessthan87
psig resp. 6 bar) and move it to the open position.
• Mountthelocknut(344)andactuatorcoupling(249)
onto the actuator stem.
4
Stroke
• Justifytheplugagainsttheseat.
• Adjustthedistancebetweenthevalvecoupling(345)
and the actuator coupling (249) with the aid of an
adapter in stroke height.
Size Stroke
1/2” - 2” 15 - 50 0.787 +0.02 in. 20 +0.5 mm
3” - 4” 65 - 100 1.574 +0.02 in. 40 +0.5 mm
6” 125 - 150 2.362 +0.03 in. 60 +0.8 mm
5
240
214
213
216
420
Put yourself to
the valves backside !
CRUSHING HAZARD ! Do not work between the
yoke legs while the valve is in operation.
• Disconnecttheairsupplysothatitmovetotheclose
position.
• Mountthecapscrews(240)
• Lock the lock nuts (113, 344). Secure the upper
coupling (249) against turn unwanted with a wrench.
(See Page 41, Table VA2)
• Installthestrokeindicator(216)withthecapscrews
(214) and fix it. (See Page 41, Table VA2)
• Installthestrokeindicatorscale(213)andxitwiththe
hex screw (420) (See Page 41, Table VA2). The stroke
indicator scale should be adjusted in conjunction with
the zero mark to the stroke indicator.
• Perform three full strokes and check if the stroke
indicator scale correspond with the end positions.

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Step Image Instruction
6
252
400
420
• Removeonehexagonbolt(336,351)andinstallthe
serial plate (252).
• Tightenthenut(336,351).(SeePage13,TableA2)
• De-grease the adhesive surface and stick on the
warning label (420) and the brand-name label (400)
7
• Thevalveisreadyforthemountingoftheaccessories.
• Referto therelevant manufacturer’s user instruction
for information regarding other ancillary equipment.

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FlowAct IG - FCD VLENAI00IGA4 03/15FlowAct IG - FCD VLENAI00IGA4 03/15
www.flowserve-villach.com
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