Flowserve ROTADISK RD User manual

Read and follow this operating manual before using a
ROTADISK Pneumatic Actuator.
ROTADISK Pneumatic Actuator
Type RD & RDF 2,5 –160
BA3002 EN
Translation of Original Operating Manual
Installation
Operation
Maintenance

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
Page 1of 79
Table of contents
1General Information....................................................................................................9
1.1 Aim of This Operating Manual...........................................................................................9
1.2 Exclusion of Liability .............................................................................................................9
1.3 Safety Information .............................................................................................................10
1.4 Units ......................................................................................................................................16
1.5 Graphic Conventions for Special Designations ...........................................................17
1.6 ROTADISK Pneumatic Actuator as a “Partially Completed Machine” ....................17
1.7 Nameplate: Identification of the ROTADISK Pneumatic Actuator ...........................17
2Safety Information .....................................................................................................18
2.1 Grouped Safety Messages...............................................................................................18
2.2 Responsibility of the Owner Company ..........................................................................21
2.3 Qualified Personnel ...........................................................................................................22
2.4 Personal Protective Equipment .......................................................................................23
2.5 Qualification of the Personnel .........................................................................................24
2.6 Target Groups.....................................................................................................................24
2.7 Product Warranty Information.........................................................................................26
2.8 Intended Use ......................................................................................................................26
2.9 Misuse...................................................................................................................................27
2.10 General Sources of Hazard/Residual Hazards..............................................................28
3Product Description...................................................................................................29
3.1 General Product Description...........................................................................................29
3.2 Variants................................................................................................................................31
3.3 Functional Description ......................................................................................................31
3.4 Scope of Delivery...............................................................................................................34
4Receipt of Goods ......................................................................................................35
4.1 Safety Information .............................................................................................................35
4.2 Examining Received Goods ............................................................................................35
4.3 Unpacking the ROTADISK Pneumatic Actuator ...........................................................36

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
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5Installation..................................................................................................................37
5.1 Safety Information .............................................................................................................37
5.2 Preparations for ROTADISK Pneumatic Actuator Installation .....................................37
5.3 Installing ROTADISK Pneumatic Actuator on the Valve ..............................................38
6Commissioning..........................................................................................................39
6.1 Safety Information .............................................................................................................39
6.2 Commissioning the ROTADISK Pneumatic Actuator....................................................40
7Maintenance .............................................................................................................41
7.1 Safety Information .............................................................................................................41
7.2 Required Spare Parts for Maintenance .........................................................................41
7.3 Maintenance Plan.............................................................................................................42
8Repair .........................................................................................................................43
8.1 Safety Information .............................................................................................................43
8.2 Required Spare Parts.........................................................................................................44
8.3 Repairing the ROTADISK Pneumatic Actuator..............................................................44
8.4 Troubleshooting Table.......................................................................................................62
8.5 Sending In the ROTADISK Pneumatic Actuator for Repair .........................................63
9Shutdown ...................................................................................................................65
9.1 Safety Information .............................................................................................................65
9.2 Shutting Down the ROTADISK Pneumatic Actuator.....................................................65
10 Storage .......................................................................................................................66
10.1 Safety Information .............................................................................................................66
10.2 Storing the ROTADISK Pneumatic Actuator...................................................................67
11 Packing ......................................................................................................................68
11.1 Safety Information .............................................................................................................68
11.2 Packing the ROTADISK Pneumatic Actuator ................................................................69
12 Transport.....................................................................................................................70
12.1 Safety Information .............................................................................................................70
12.2 Transporting the ROTADISK Pneumatic Actuator.........................................................71

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
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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....................................75

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
Page 4of 79
Overview of ROTADISK Pneumatic Actuator versions
Make
ROTADISK
Series/type
RD
Functional principle/
control type
double-action/pneumatic
Version
2.5
5
10
20
40
80
160
Weight in kg
0.85
1.4
3.46
5.78
13.2
25.6
46.9
Dimensions in mm
L
W
H*
134
65
82
180
78
91
260
90
117
310
108
133
394
138
177
495
168
213
608
204
278
Stroke in mm
25
32
42
53
66
84
104
Piston-Ø in mm
40
50
65
80
102
130
165
Filling volume per stroke
in l
0.07
0.14
0.28
0.56
1.12
2.2
4.5
*Height without position indicator

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
Page 5of 79
Make
ROTADISK
Series/type
RDF
Functional principle/control
type
single-action (spring-loaded return)/pneumatic
with failsafe function
Version
2.5
5
10
20
40
80
160
Available spring package
–1
–1.5
–2
–2.5
–3
–1
–1.3
–1.5
–1.8
–2
–2.5
–3
Weight in kg
1,15
1,48
4,43
7,93
15,5
31,1
64,2
Dimensions in mm
L
W
H*
187
65
82
260
78
91
340
90
117
440
108
133
485
138
177
630
168
213
835
204
278
Stroke in mm
25
32
42
53
66
84
104
Piston-Ø in mm
40
50
65
80
102
130
165
Filling volume per stroke
in l
0.07
0.14
0.28
0.56
1.12
2.2
4.5
*Height without position indicator

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
Page 6of 79
Make
ROTADISK Type RD & RDF
Materials
Body
aluminium alloy (anodised)
Lid
aluminium alloy (PU multilayer paint)
Piston
aluminium alloy
Transmission
shaft
stainless steel
Control media/
operating media
compressed air
(dry, filtered according to PNEUROP/ISO class 4 [50 µ])
neutral gases such as N2, und CO2
hydraulic oil (water on request)
Control pressure
3 to 8 bar (max. 8 bar)
Operating temperature
standard: –20 °C to +80 °C
temporary: –30 °C to +100 °C
special version low temperature: –40 °C to +60 °C
special version high temperature: –20 °C to +180 °C
Direction of rotation
clockwise rotation
anti-clockwise rotation (optional)
Lubrication
permanent lubrication SAPPHIRE Lo-Temp 2 made by ROCOL
Angle of rotation
90° ± 3° OPEN position,
(not in RD 2.5)
slewing actuator with
stroke limitation
(optional)
90° ± 3° OPEN position,
(not in RDF 2,5)
slewing actuator with
stroke limitation
(optional)
Spring load cycles
—
107 ≙10 000 000
Corrosion protection
anodised actuator body
PU-painted lid
Standardised interfaces
for add-ons
fittings
DIN/ISO 5211 and DIN 3337
signal devices
VDI/VDE 3845
positioners
solenoid valves
–Namur 1/4"

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
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Available spring packages with number of springs for ROTADISK Type RDF single-action
(spring-loaded return)
Spring package
Number of
large springs
Number of
small springs
Number of
special springs
(“medium”)
-1
0
2
0
-1.5
1
1
0
-2
2
0
0
-2.5
2
1
0
-3
2
2
0
-1.3
0
1
1
-1.8
0
0
2

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
Page 8of 79
Figure 1: Components of the ROTADISK Pneumatic Actuators RD & RDF
Item
Component
1
transmission shaft (signal device side)
2
threaded fastening holes for signal devices (M5 x 7)
3
solenoid valve panel
4
control air connection OPEN
5
control air connection CLOSED
6
connection to fittings according to DIN ISO 5211
7
transmission shaft (fittings side)
8
hexagon socket head screws for fastening the lid
9
lid
10
threaded pin/end stop for end position setting
(only in OPEN position is standard design, not in RD/F 2.5)
6
1
2
6
9
10
4
5
1
2
3
4
5
7
8
10
9
3
7
8

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
Page 9of 79
1General Information
1.1 Aim of This Operating Manual
This operating manual is intended to familiarise the reader with the ROTADISK Pneumatic
Actuator and its proper use. Use of the ROTADISK Pneumatic Actuator in compliance with
this operating manual is important to ensure its functionality and to avoid hazards.
This operating manual contains information for qualified personnel for using the ROTADISK
Pneumatic Actuator for its intended purpose.
Read this operating manual before using the ROTADISK Pneumatic Actuator in
any region world-wide and pay particular attention to the safety-relevant
warnings, information and notes.
Do not put the ROTADISK Pneumatic Actuator into operation until all the safe
conditions referred to in this operating manual are satisfied.
Failure to observe the information contained in this operating manual will be
considered as misuse of the product. Personal injury, product damages,
holdups in operation or product failure due to misuse of the product are not
covered by the Flowserve guarantee.
Observe all the relevant local health and work safety regulations at the place
of work –even when these are not explicitly referred to in this operating
manual.
Coordinate all repair work with the operating personnel and observe all safety
regulations of the industrial plant and applicable health and safety laws.
Inform Flowserve Flow Control GmbH if documents are missing or incomplete.
You will then receive replacements in electronic form.
Provide this operating manual at all workplaces near the production site.
1.2 Exclusion of Liability
The information in this operating manual can be considered as complete and reliable.
Despite all efforts of Flowserve Flow Control GmbH to supply comprehensible information
and instructions, good engineering and safety practice must be applied at all times. Please
consult a qualified engineer if in doubt.
Flowserve Flow Control GmbH manufacturers products according to applicable
international quality management standards which are audited by external quality
assurance organisations. Original spare parts and original accessories have been designed,
tested and incorporated into Flowserve products to ensure continuous product quality and
product performance in use. Since Flowserve Flow Control GmbH cannot test the spare
parts and accessories of other manufacturers, (incorrect) installation of these parts can
have a detrimental effect on the performance and safety properties of the product. 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. Moreover, any modifications to

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
Page 10 of 79
Flowserve products or the removal of original components can impair the safety of the
products in use.
1.3 Safety Information
This safety section contains detailed explanations of the different types of safety messages
that are used in this operating manual.
In accordance with ANSI standard Z535.6, safety information is classified in:
▪Supplemental Directives
▪Grouped Safety Messages
▪Section Safety Messages
▪Embedded Safety Messages
Supplemental Directives are complementary safety messages containing one or more
safety-relevant actions to ensure safe use of the ROTADISK Pneumatic Actuator.
Supplemental Directives are usually found at the beginning of a chapter in this operating
manual.
Grouped Safety Messages contain grouped general safety information to ensure safe use of
the ROTADISK Pneumatic Actuator. Grouped Safety Messages can be found in section
2.1 Grouped Safety Messages and in several safety sections of a chapter.
Section and Embedded Safety Messages warn against residual hazards which might
possibly occur during proper use and improper use (reasonably foreseeable misuse) of the
ROTADISK Pneumatic Actuator.
In addition, Section and Embedded Safety Messages offer safety information for avoiding
hazards resulting from various work situations and danger areas within the scope of the
product life cycle.
Section Safety Messages can be found in the safety section of a chapter.
Embedded Safety Messages can be found in front of a potentially very dangerous action.

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
Page 11 of 79
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
Description
DANGER
This signal word field indicates an immediate dangerous activity
which can result in death or severe injury. Observe all safety
messages with this signal word field to avoid the danger.
WARNING
This signal word field indicates a potentially dangerous activity
which can result in death or severe injury. Observe all safety
messages with this signal word field to avoid the danger.
CAUTION
This signal word field indicates a potentially dangerous activity
which can result in slight or minor injury. Observe all safety
messages with this signal word field to avoid the danger.
NOTICE
This signal word field indicates an activity which can lead to
material damage. Observe all safety messages with this signal
word field to avoid the danger.
Table 2: Additional symbols
Symbol/Warning Sign
Description
GENERAL DANGER
Indicates a danger which can lead to danger for the safety
of persons and/or material damage if not heeded.
DANGER FROM HEAVY OBJECTS
Indicates danger from a heavy object which can lead to
danger for the safety of persons and/or material damage if
not heeded.
DANGER FROM EXPLOSIVE MATERIAL
Indicates danger from explosive material which can lead to
danger for the safety of persons and/or material damage if
not heeded.

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
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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.
DANGER FROM SUSPENDED LOADS
Indicates danger from a suspended load which can lead to
danger for the safety of persons and/or material damage if
not heeded.
DANGER FROM TOXIC SUBSTANCES
Indicates danger from toxic substances which can lead to
danger for the safety of persons and/or material damage if
not heeded.
DANGER FROM HOT SURFACES
Indicates danger from a hot surface which can lead to
danger for the safety of persons and/or material damage if
not heeded.
DANGER FROM INFLAMMABLE MATERIALS
Indicates danger from inflammable materials which can
lead to danger for the safety of persons and/or material
damage if not heeded.
DANGER FROM MEDIA UNDER PRESSURE
Indicates danger from media under pressure which can
lead to danger for the safety of persons and/or material
damage if not heeded.
DANGER HIGH VOLTAGE
Indicates danger from high voltage which can lead to
danger for the safety of persons and/or material damage if
not heeded.
DANGER FROM AN EXPLOSIVE ATMOSPHERE
Indicates danger from an explosive atmosphere in
accordance with ATEX which can lead to danger for the
safety of persons and/or material damage if not heeded.
ENVIRONMENT HAZARD
Indicates an environment hazard from environmentally
harmful hazardous materials.

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
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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.
Indicates a potential danger of personal injury and/or
material damage. Please observe all the supplemental
directives with this warning sign.
Indicates particularly important information. Observe all
general information with this symbol.
1.
2.
3.
Introduces an action.

Indicates a prerequisite for an action referring to a
subsequent action.

Indicates a secondary action or an action within a safety
directive.
✓
Indicates the result of previous actions.
▪
Indicates a list entry.
1.3.2 Graphic Convention and Content Structure of the General Information
The following graphic conventions and content structure apply for general information:
General information

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
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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:
Provide this operating manual at all workplaces near the production site.

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
Page 15 of 79
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.
Example:
Danger of material damage due to inadequately qualified personnel!
Inadequate qualification of the personnel can lead to material damage on the ROTADISK
Pneumatic Actuator.
Make sure that only qualified personnel with suitable personal protective equipment
(PPE) and suitable tools are deployed.
See chapter 2 Safety Information.
Make sure that no unauthorised persons have access to the ROTADISK Pneumatic
Actuator.
Section Safety Messages
The following graphic convention and content structure apply for Section Safety Messages:
Warning sign
Signal word field
Type and source of danger!
Consequences of failure to heed.
Action for avoiding the hazard.
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
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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
tipping.
Danger of material damage due to inadequately secured loads during transport!
Inadequate securing of transported loads can lead to material damage.
Secure the ROTADISK Pneumatic Actuator against turning and tipping.
Embedded Safety Messages
The following graphic convention and content structure apply for Embedded Safety
Messages:
Signal word field
Type and source of danger!
Consequences of failure to heed.
Action for avoiding the hazard.
Example:
Danger of injury from falling loads!
Falling of suspended loads can lead to severe injury or death.
Never stand beneath suspended loads.
1.4 Units
The metric unit system (SI) is used in this operating manual.

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
1 General Information
Page 17 of 79
1.5 Graphic Conventions for Special Designations
The following graphic conventions apply for special designations:
▪For better legibility, some special English designations consisting of two or more parts are
written in italics.
▪For better legibility, object designations (for example, buttons, text fields, switches, levers,
knobs) of a product (machine or software) are written in CAPITALS.
1.6 ROTADISK Pneumatic Actuator as a “Partially Completed Machine”
The automatic ARGUS Ball Valve, i.e. an assembly comprising an ARGUS Ball Valve and
permanently fixed ROTADISK Pneumatic Actuator with the appropriate control components
for automatic switching can be considered as a “machine” in the sense of the European
Machinery Directive 2006/46/EC. The ROTADISK Pneumatic Actuator prepared for assembly
with the ARGUS Ball Valve is a “partially completed machine” in the sense of the Machinery
Directive.
This operating manual for the ROTADISK Pneumatic Actuators is part of the overall
documentation of the assembly (ARGUS Ball Valve and ROTADISK Pneumatic Actuator).
1.7 Nameplate: Identification of the ROTADISK Pneumatic Actuator
The nameplate that is affixed permanently to the ROTADISK Pneumatic Actuator contains
the most important information regarding the design and application of the 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.
1 Type designation
(e.g. RDF 10-3 | RDF = version | 10 = size [from 2.5 to 160] |
-3 = spring package [only for RDF actuators])
2 Maximum control pressure in bar
3 Commissioning number/order number
4 Identification number/serial number
5 Identification in which explosive areas (ex-zones) its use is permitted
1
2
3
4
5

ROTADISK Pneumatic Actuator RD & RDF
Operating Manual –BA3002 EN
2 Safety Information
Page 18 of 79
2Safety Information
2.1 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.
Make sure that only qualified personnel with suitable personal protective equipment
(PPE) and suitable tools are deployed.
See chapter 2 Safety Information.
Make sure that no unauthorised persons have access to the ROTADISK Pneumatic
Actuator.
Danger of material damage due to inadequately qualified personnel!
Inadequate qualification of the personnel can lead to material damage on the ROTADISK
Pneumatic Actuator.
Make sure that only qualified personnel with suitable personal protective equipment
(PPE) and suitable tools are deployed.
See chapter 2 Safety Information.
Make sure that no unauthorised persons have access to the ROTADISK Pneumatic
Actuator.