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2R2500 & 2R3500 Actuators

Installation & Maintenance Manual

2R-SERIES 2R2500 & 2R3500 DOUBLE ACTING & SPRING RETURN

SCOTCH YOKE ACTUATORS

BRIEF INTRODUCTION recommended. Oil mist lubrication requires a mineral oil type
TRIAC 2R2500 & 2R3500 scotch yoke actuators ISO VG32 Class 1 for usage in temperature range 15 to 158
have been designed and engineered to provide high cycle-life Deg. F. Oil mist lubricator must be set to the lowest setting.
to meet the demands of our customers. Equipped with dual Once begun, the oil mist lubrication cannot be discontinued.
travel stops and NAMUR accessory mounting. CAUTION
If the actuator is equipped with a pneumatic positioner or
!!!WARNING!!! pneumatic controller, oil mist lubricated air cannot be used
unless the instrument manufacturer indicates that the
FOR YOUR SAFETY, IT IS IMPORTANT THAT THE instrument is compatible with lubricated air.
FOLLOWING PRECAUTIONS BE TAKEN BEFORE ANY
DISASSEMBLY OF THE ACTUATOR OCCURS. Orientation of Pistons
1. Depressurize the lines and cylinder of the actuator Double Acting (DA)
before removing any components. The pistons of standard DA actuators are as shown below.
2. On spring return actuators be careful to loosen the This provides for the highest torque at the “closed” valve
end cap bolts evenly due to the preload on the position for valves that rotate clockwise to close. The pistons
springs. are then in their innermost position and the end of travel stop
can be fine adjusted + or – 5 degrees (SEE INSTRUCTIONS
on page 2).
Installation of Actuator
Triac actuators are adapted to the valve by means of an
intermediate bracket and coupler. The coupler adapts the star
output of the actuator to the valve shaft. Standard mounting
kits provided for mounting the actuator in the direction of the
pipe.
After mounting the actuator, it may be necessary to adjust the
travel stops for proper open or closed valve position.
Pneumatically stroke the actuator several times to assure
(DL/SAH)
proper operation with no binding of the coupler.
Spring Return (SR)
The pistons of standard SR actuators are mounted as shown
Air Supply
below. Although spring force is diminished, the geometry of
Pneumatic piping to the actuator and associated accessories
the mechanism provides a greater torque at the end of the
should follow the best practices for instrument pneumatic
spring stroke than at mid stroke. When the actuator is in the
piping systems, I.E. lines free of water, oil, pipe sealant or
“opened” valve position (springs fully compressed), the end of
other contaminants. The operating medium is to be filtered
travel stop can be fine adjusted + or – 5 degrees (SEE
dry air or inert gas which is filtered to 50 micron particles size
INSTRUCTIONS on page 2).
or less. It is extremely important that the actuator be powered
with the proper air pressure and air volume. Maximum
working pressure is 150 PSI.
The spring housing on spring return actuators, if not piped,
will breathe through the right hand port. It’s important that it
not be exposed to a corrosive atmosphere. Please contact A-T
Controls for possible solutions if this condition exists.

Lubrication
Triac actuators are factory lubricated for life and additional
(SAH)
lubrication is not normally required. However, for actuators
performing 100,000 cycles or more, an oil mist lubricator is

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2R2500 & 2R3500 Actuators
Installation & Maintenance Manual

Travel Adjustment 9. Take a punch rod and knock out the yoke pin. (Be careful
NOT to DAMAGE the yoke (5))
10. Remove snap ring (15), and washers (13) & (14) from the
!!!WARNING!!! top of the pinion.
11. Tap top of pinion lightly with a plastic mallet to remove
TO AVOID CATASTROPHIC FAILURE TO the pinion from the upper (31) and lower drive shaft
ACTUATOR, AIR MUST BE REMOVED FROM bushings.
ACTUATOR BEFORE ANY TRAVEL ADJUSTMENTS NOTE: Removal of the pinion and yoke (5) (steps 7-11) is
ARE MADE. not required for normal maintenance and is not
recommended.
The + or - 5 degree adjustment of the end of travel stop is
accomplished by loosening the lock nut on the center body Changing from “Fail Close” to “Fail Open” 2500
and turning the adjustment screw clockwise for reduced rotary 1. Disconnect electrical supplies and shut off pneumatic
motion and counterclockwise for increased motion. The spring supply and vent actuator.
force or pneumatic force must be relieved before adjusting the 2. Remove the eight end cap bolts (24). (14mm hex key
travel stops. IE The actuator must be rotated slightly off the wrench)
stop bolt before adjusting. It is very important that both travel 3. Remove both end caps (3).
stops are properly adjusted. 4. Loosen travel stop locknut (20).
5. Back out travel stops (21) about six turns so the Stop Cam
does not interfere with the travel stop bolts.
Disassembly Procedures 6. Mark the piston (6) and body (1) with a black marker to
designate placement on how the piston was removed.
!!!WARNING!!! 7. Rotate the pinion (4) until the piston is at the end of the
cylinder. (This can be done by turning the pinion with a
FOR YOUR SAFETY, IT IS IMPORTANT THAT THE wrench on the flats)
FOLLOWING PRECAUTIONS BE TAKEN BEFORE ANY 8. Remove the piston.
DISASSEMBLY OF THE ACTUATOR OCCURS. 9. Set actuator on its end so the short side of the body is
1. Depressurize the lines and cylinder of the actuator facing upward.
before removing any components. 10. Rotate the pinion until the flat side of the yoke pin (9) is
2. On spring return actuators be careful to loosen the facing upward. (There are two different sides to the yoke
end cap bolts evenly due to the preload on the pin, flat and a round side, grind off peen)
springs. 11. Take a punch rod and knock out the yoke pin. (Be careful
NOT to DAMAGE the yoke (5))
12. Once the yoke pin is removed, rotate the yoke 180
1. Disconnect electrical supplies and shut off pneumatic degrees without letting the pinion rotate.
supply and vent actuator. 13. Replace the yoke pin by putting the flat side in first and
2. WARNING: Do NOT touch the spring bolt (27) This hitting the pin on the rounded side and peen the flat side.
bolt is preset from the factory. Any adjustments could 14. Grease cylinder surface with multi-purpose grease.
result in injury or death. 15. Rotate the piston 180 degrees from the original position.
3. Remove end cap bolts (18) on DA, (24) on SR. 16. Ensure the piston roller bearing is properly seated in the
4. Remove end caps (2) on DA, (3) on SR from actuator. yoke for proper alignment.
5. Rotate pinion (4) until the pistons (6) are at the end of the 17. Rotate the pinion 90 degrees counter-clockwise to
cylinder. This can be done by turning the pinion with a confirm proper engagement.
wrench on the flats of the piston. 18. Set the travel stops.
6. Remove the piston(s) from the cylinder (1). See NOTE 19. Tighten travel stop locknut.
after step 11. 20. Replace the end caps (Align spring assembly so that one
7. Set actuator on its end so the short side of the body is of the four support points falls between the bosses on the
facing upward. piston and pins engage holes in the piston.
8. Rotate the pinion until the flat side of the yoke pin (9) is 21. Tighten bolts to 1,440 in-lbs (14mm hex key wrench)
facing upward. (There are two different sides to the yoke 22. Stroke actuator a couple of times to make sure the travel
pin, flat and a round side, grind off peen) stops are set correctly and for smooth operation.

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2R2500 & 2R3500 Actuators
Installation & Maintenance Manual

1. Inspect all parts for wear and replace any worn parts as
Changing from “Spring Closed” to “Spring Open” 3500 needed. Replace all O-rings.
1. Disconnect electrical supplies and shut off pneumatic
supply and vent actuator. SEAL KIT
2. Remove the eight end cap bolts (24). (14mm hex key TEMP RANGE -5°F TO 175°F 0°F TO 300°F -45°F TO 175°F
wrench) SIZE NITRILE BUNA VITON SILICONE
3. Remove both end caps (3). 2R2500 2BOK2500 V0K2500 LT0K2500
4. Loosen travel stop locknut (20). 2R3500 2BOK3500 V0K3500 LT0K3500
5. Back out travel stops (21) about six turns so the Stop Cam
does not interfere with the travel stop bolts.
6. Mark the piston (6) and body (1) with a black marker to REPAIR KIT
designate placement on how the pistons were removed. TEMP RANGE -5°F TO 175°F 0°F TO 300°F -45°F TO 175°F
7. Rotate the pinion (4) until the pistons are at the end of the
SIZE NITRILE BUNA VITON SILICONE
cylinder. (This can be done by turning the pinion with a
2R2500 2RKB2500 2RKV2500 2RKLT2500
wrench on the flats)
2R3500 2RKB3500 2RKV3500 2RKLT3500
8. Remove the pistons.
9. Grease cylinder surface with multi-purpose grease.
10. Rotate the pistons 180 degrees from the original position. 2. Clean all components and lightly grease cylinder bore,
11. Ensure the piston roller bearing is properly seated in the and seals with multi-purpose grease.
yoke (5) for proper alignment. 3. Install piston based on proper orientation.
12. Rotate the pinion 90 degrees Counter-clockwise to 4. Ensure that pistons are lined up so that roller bearing (8)
confirm proper engagement. engages scotch yoke correctly. Once pistons are in, rotate
13. Set the travel stops. shaft 90 Degrees clockwise to draw pistons in and
14. Replace the end caps (Align spring assembly so that one confirm proper engagement.
of the four support points falls between the bosses on the 5. SR - Align spring assembly so that one of four support
piston and pins engage holes in the piston.. points falls between the bosses on the piston and pins
15. Tighten bolts to 1,440 in-lbs (14mm hex key wrench) engage holes in the piston.
16. Stroke actuator a couple of times to make sure the travel 6. DA - Install end caps.
stops are set correctly and for smooth operation. 7. Install bolts (18).
8. Tighten locknut (24).
9. The travel adjustment can be accomplished by following
the procedure on page 1.
Reassembly Procedure

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 
2R2500 & 2R3500 Actuators
Installation & Maintenance Manual

OPERATION
(Viewed from top of actuator)

Double Acting Applying air pressure to port 2 drives the piston(s) inward,
Applying air pressure to port 1 drives the piston(s) outward, which turns the drive shaft clockwise as the air exhausts
which turns the drive shaft counterclockwise as the air volume through port 1.
on the outside of the piston(s) exhausts through port 2.

Spring Return (Fail CW)

Applying air pressure to port 1 drives the pistons outward, Exhausting the air pressure from port 1 allows stored energy
which compresses the spring and turns the drive shaft of the spring to drive pistons inward, tuning the drive shaft
counterclockwise as the air volume on the outside of the clockwise. Air volume on the outside of the pistons vents
piston(s) exhausts through port 2 through port 2.

Spring Return (Fail CCW)

Applying air pressure to port 1 drives the pistons outward,
which compresses the spring and turns the drive shaft
clockwise as the air volume on the outside of the pistons Exhausting the air pressure from port 1 allows stored energy
exhausts through port 2 of the spring to drive pistons inward, tuning the drive shaft
counterclockwise. Air volume on the outside of the pistons
vents through port 2.

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2R2500 & 2R3500 Actuators
Installation & Maintenance Manual

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2R2500 & 2R3500 Actuators
Installation & Maintenance Manual

Item Quantity Quantity Quantity Quantity

Description Material
No. 2500DA 2500SR 3500DA 3500SR
1 Actuator Body 1 1 1 1 Hard Anodized Extruded Aluminum
2 DA End cap 2 1 2 -- Epoxy Coated - Aluminum
3 SR End cap -- 1 -- 2 Epoxy Coated - Aluminum
4 Pinion 1 1 1 1 Nickel Plated Steel
5 Scotch Yoke 1 1 1 1 Hardened Steel
6 Piston 1 1 2 2 Aluminum
7 Pinion Pin 1 1 2 2 Hardened Steel
8 Roller Bearing 1 1 2 2 Hardened Steel
9 Yoke Pin 1 1 1 1 Hardened Steel
10 Center Bushings  2 2 2 2 Nylon
11 Lower Pinion O-Ring  1 1 1 1 Nitrile
12 Upper Pinion O-Ring  1 1 1 1 Nitrile
13 Support Bushing  1 1 1 1 RTFE
14 Support Washer  1 1 1 1 Plated Steel
15 Snap Ring  1 1 1 1 Plated Steel
16 Piston O-Ring  1 1 2 2 Nitrile
17 Piston Guide Band  1 1 2 2 Nylon
18 End Cap Bolt - DA 8 4 8 -- Stainless Steel
19 Travel Stop Washer 2 2 2 2 Stainless Steel
20 Travel Stop Locknut 2 2 2 2 Stainless Steel
21 Travel Stop Bolt 2 2 2 2 Stainless Steel
22 Travel Stop O-Ring 2 2 2 2 Nitrile
23 Travel Stop Cam 1 1 1 1 Hardened Steel
24 End cap Bolt - SR -- 4 -- 8 Stainless Steel
25 Pre-Tensioning Washer - SR -- 1 -- 2 Stainless Steel
26 Pre-Tensioning Locknut - SR -- 1 -- 2 Stainless Steel
27 Pre-Tensioning Screw - SR -- 1 -- 2 Stainless Steel
28 Pre-Tensioning O-Ring - SR -- 1 -- 2 Nitrile
29 End Cap O-Ring  2 2 2 2 Nitrile
30 Wear Band  1 1 2 2 PTFE
31 Top Pinion Bushing  1 1 1 1 Nylon
32 Spring Guide - SR -- 1 -- 2 Aluminum
33 Spring Internal - SR -- 1 -- 2 Spring Steel
34 Spring External - SR -- 1 -- 2 Spring Steel
 Recommended Spare Parts
 Parts Included in a Repair Kit
 Parts Included in a Seal Kit

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2R2500 & 2R3500 Actuators
Installation & Maintenance Manual

A-T Controls product, when properly selected, is designed to perform its intended function safely during its useful life. However, the purchaser or user of
A-T Controls products should be aware that A-T Controls products might be used in numerous applications under a wide variety of industrial service
conditions. Although A-T Controls can provide general guidelines, it cannot provide specific data and warnings for all possible applications. The
purchaser / user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of A-T
Controls products. The user should read and understand the installation operation maintenance (IOM) instructions included with the product, and train
its employees and contractors in the safe use of A-T Controls products in connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only. Because
A-T Controls is continually improving and upgrading its product design, the specifications, dimensions and information contained in this literature are
subject to change without notice. Should any question arise concerning these specifications, the purchaser/user should contact A-T Controls.

For product specifications go to http://download.a-tcontrols.com/

A-T Controls, Inc. • 9955 International Boulevard, Cincinnati, OH 45246 • Phone: (513) 530-5175 • Fax: (513) 247-5462 • www.a-tcontrols.com

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