®

MaxFlo 3Excentric Rotary Plug Valve

2

MaxFlo 3 Control Valves

Figure 1: MaxFlo 3 Control Valve with Valtek High-Performance Diaphragm Actuator and Logix 500 Digital

Positioner

Figure 2: Safe, Reliable,Anti-Blowout Shaft System

Figure 4: Robust, ReliableFlanged End Plug Design

Figure 3: MaxFlo 3 Control Valve with Valtek High-Performance Spring Cylinder Rotary Actuator and Logix

Series 1000 Positioner

3

MaxFlo 3 Control ValvesIntroduction

Non-crossover shaftallows greater CV

Figure 5: MaxFlo 3 Rotary Eccentric Plug Control Valve, Body Subassembly

Extended bonnet asan integral part of theanti-blow-out system

Shaft with integral shoulder Solid end-post flange

High PerformanceThe MaxFlo3 control valve is a high-performance,eccentric rotary plug design, which is used in low-pressure, high C

V applications. The MaxFlo3 valve is

capable of operating temperatures between -100° to750° F/ -73° to 400° C.

The MaxFlo 3 eccentric plug offers rangeability up to160:1 – compared to 50:1 for typical globe valves and20:1 for most butterfly valves.

A heavy-duty, non-crossover shaft is out of the valve’sflow path. This superior design allows higher flowcapacity for a given valve size. It also eliminates shaftdamage from erosive process fluids. Many othermanufactures’ designs allow the shaft to crossover theflow path, resulting in lower flow capacity and shaftwear.

The MaxFlo3 control valve is available in 1- through12-inches in a flanged body style (ANSI Classes 150and 300 / PN 16 to 40). Multiple reduced trims for eachvalve size are available. These trim reductions allow awide range of C

V values in each valve size, providing

accurate, precise control across the capacity of thevalve with extremely fine resolution.

The positioners offered on the MaxFlo3 allow the controlvalve to respond to small signal changes withoutovershoot. The XL, XL90, Logix 500 and Logix 1000positioners can respond precisely to 0.1 percent signalchanges. This accuracy allows the MaxFlo3 controlvalve to precisely control the process fluid.

As the valve opens and the plug rotates smoothly out ofthe seat (Figure 6), the chances of water hammer aresignificantly reduced. And, since the plug and non-cross-over shaft do not obstruct the flow, the MaxFlo3 valveobtains a higher flow coefficient (CV) rating than othertraditional rotary valves. This is why Maxflo3 can obtaina rangability of 160:1. In addition, the MaxFlo3 designhas a zero breakout torque requirement, which allowssmaller actuators to be used — reducing costs and main-tenance time.

All these features make the MaxFlo3 control valve themost accurate, precise, eccentric rotary plug valve onthe market. High performance is the first key point inthe core design principles behind the MaxFlo3 controlvalve.

MaxFlo3 raises the bar to the highest standards of reliability

Thrustbearing

4

MaxFlo 3 Control Valves

Increased SafetyAn additional point in the core design principles behindthe MaxFlo3 control valve was increased safety.ANSI B16.34 section 6.5.1 states valves should bedesigned to prevent the stem from being removed whilethe valve is under pressure. Flowserve has taken thissafety issue one step further. The unique MaxFlo3 stem,with the integral thrust runner on the shaft, cannot beremoved unless the bonnet nuts are removed (See Fig-ure 5). Many other rotary control valves do not includeanti-blow out protection on shaft; designs offering anti-blow out protection lack the robust character MaxFlo3control valves provide (See Figure Nos. 2 and 5). Acci-dents, safety incidents and failures have been attrib-uted to other valves lacking the unique features of theMaxFlo 3 control valve.

The MaxFlo3 control valve’s durable flanged endpostdesign offers better guiding of the plug and eliminatesthe risk of parts becoming loose. The flanged end postis held in place by four bolts. It can’t come loose likeother manufacturers’ designs; thus eliminating any leakpath.

Long LifeLonger life is also a key principle behind the MaxFlo 3control valve. Its oversized shaft eliminates shaft failuresand provides a large shaft bearing surface, reducingbearing wear, improving reliability and increasing the

Introduction

life of the valve. The plug is produced from hardened1.4418 material to increase plug life, provide tightshutoff and increase reliability in a wide range of difficult-to-handle applications (including flashing, erosive, mildcavitation and steam services). The rugged plug designreduces valve failure caused by water hammer.

The non-crossover shaft allows for uninterrupted flow.When the valve is in the open position, the fluid flow isnot deflected into the seat or retainer, providing greaterreliability — even after years of service. The durableflanged endpost design provides a robust bearingsurface. Since the endpost is held in place by four bolts,it can’t come loose in service like other manufacturers’designs (see Figure 4).

The typical maintenance cycle for the MaxFlo3 valveexceeds five years and more than 20 years for totalvalve cycle expectancy. Most MaxFlo3 actuators havea cycle life exceeding one million cycles, making theMaxFlo 3 design one of the most reliable control valveson the market.

NACE certification is available with the MaxFlo3 design.Special Valtek packing sets, such as SureGuard™packing, are available to control fugitive emissions andto meet Environmental Protection Agency (EPA)requirements.

The MaxFlo3 double-offset eccentric plug rotates intothe seat at an angle that eliminates sliding over theseat surface (Figure 7). The design reduces seat wear,and thereby decreases maintenance requirements andcosts. At the same time, a tight ANSI Class VI shutoffis easily obtainable using the soft seat design.

Figure 6: MaxFlo 3 Plug – Open Figure 7: MaxFlo 3 Plug – Closing

5

MaxFlo 3 Control ValvesFeatures and Advantages

High PerformanceFeatures AdvantagesHigh flow coefficients Up to 70 percent more flow than other manufacturers’ rotary eccentric plug

designs (reduced trims also available).Non-crossover shaft Shaft is out of flow path for higher flow capacities and less erosion damage.

Valve may be used in paper pulp concentrations to 3 percentHigh rangeabillity For high rangeabillity up to 160:1. Rangeabillity due to non-crossover shaft

design. Allows accurate throttling ability over a very wide range.Accurate throttling Plug throttles without contacting seat.High-performance XL, XL90, Logix 500 and Logix 1000 positioners provide precise,positioners accurate process control by responding to signal changes of 0.1 percent

without overshoot.Bidirectional shutoff Allows valve to be mounted with shaft upstream or downstreamFlanged ANSI Classes 150-300 (PN 16-40)Reduced trims Available in 100, 75/70 and 40% (For other reductions, please contact your

Flowserve representativeOperating temperatures -73° C to 400° CSizes 1, 1.5, 2, 3, 4, 6, 8, 10, 12 (inches) DN25, 40, 50, 80,100, 150, 200, 250, 300Shutoff rating (ANSI) Metal seat: Class IV / Soft seat: Class VI

Increased Safety

Safe, anti-blowout shaft While conventional rotary control valves do not offer anti-blow out shafts, theunique MaxFlo 3 shaft design alleviates this problem. This feature also mini-mizes the risk of personal injury, fire and severe process leakage due to shaftblow out. During disassembly, removal of the valve shaft requires the removalof the bonnet nuts

Superior quality Standard shaft and trim materials allow higher pressure drops than othermanufacturers’ rotary eccentric plug designs, especially in NACE applications.Rugged and lightweight for easy handling and maintenance.

Reliable end post design The heavy-duty flanged end post construction ensures no parts of the valve canduty end post construction come loose and enter process line. Also, because ofthe robust flange, the gasket is uniformly compressed, thus eliminating leakagefrom the end post bore.

Fluid-assisted fail action Fluid assists the plug to fail-open or fail-closed upon air failure.

Long Life

Eccentric rotary plug No breakout torque.Plug lifts off seat immediately, reducing seat wear.

Non-selective plug Easier maintenance.and shaft Reduced cost – replace only the part needed, not entire assembly.NACE certification Allows valve’s use in petrochemical applications.Multiple packing options Configurations/materials available for most applications. Fugitive emission

options meet EPA requirements.Certifications NACE, Certified material test reportExternal Bonnet The external bonnet increases packing life and allows easier maintenance

6

MaxFlo 3 Control ValvesSpecifications

MaxFlo 3 Sizing Procedure and DataProcedures and data to size MaxFlo 3 valves – includingdetermining actuator size – are contained in thePerformance! valve sizing program.

Table I: Body Specifications

Sizes (inches) 1, 1.5, 2, 3, 4, 6,8,10,12 DN25, 4050, 80,100, 150, 200, 250, 300

End Connection Flanged

Body rating ANSI Class 150-300 / PN 16-40

Trim Area 100% (full), 75/70% reduction, 40%

Shutoff rating ANSI Class IV, ANSI Class VIwith soft seat

Operating -73° to 400° Ctemperature

Actuator Diaphragm: NR1, NR2, NR3Cylinder: 25, 50, 100, 200manual handwheel

Positioner Pneumatic: 0.2 - 1.0signals Electro-pneumatic:4-20 mA

Characteristics Linear

Body Carbon steel (A216 WCC)Stainless Steel (A351 CF8M)

Plug 1.4418, 316L w/Alloy 6 overlay

Shaft 1.4418, A453 Gr 660

End Post 1.4418, A453 Gr 660

Bearings 440C, UNSS31803 (Duplex 2205)

O-Rings Viton

Seat Retainer A351 CF8M; 8-inch and smallerA182 G F6 or 316L for 10/12-inchvalves.

Seat Ring 316L, 316L w/Alloy 6 overlay, 416 HT

Soft Seat PTFE

Packing PTFE V-ring, Graphite rib/braid,SureGuard, SafeGuard(XT and Firesafe)

Table II: Materials of Construction

* Actual data dependent on trim size and material, actuator size,and shaft orientation. Allowable drop should be determined afterdetailed sizing is complete in Performance valve sizing software.

(inches/mm)

Table III: Maximum Allowable ∆P*Valve Maximum AllowableSize Differential Pressure

psi bar

1-8/25-200 725 5010/250 450 3112/300 320 22

Table IV: Maximum Flow Capacity (CV)

Trim SizeBody 100 75/70 40Size Shaft Direction

(inches/ Up Down Up Down Up DownMetal Soft Metal Soft Metal Soft Metal Soft Metal Soft Metal Soft

1/25 21 12 18 10 15 8 13 7 8 6 7 611/ 2/40 50 42 47 39 35 35 33 33 20 20 19 19 2/50 78 69 80 71 43 43 52 52 24 24 32 323/80 214 214 241 241 167 167 182 182 95 95 104 1044/100 302 302 405 405 220 220 267 267 150 150 170 1706/150 730 730 955 955 567 567 669 669 324 324 382 3828/200 1130 1130 1700 1700 847 847 1275 1275

10/250 1785 1785 2505 2505 1339 1339 1879 187912/300 2560 2560 3600 3600 1920 1920 2700 2700

NotAvailable

mm)

7

MaxFlo 3 Control ValvesDiaphragm Actuators

Table VII: Diaphragm ActuatorSelection Guidelines

A diaphragm actuator should be applied when theprocess requires the following:

1. Single-acting action

2. Field-reversible design

3. Low supply pressure up to 4.0 bar

4. High controllability (ball bearing)

5. Handwheel (push-only)

6. Materials must include steel diaphragm casing,cast iron yoke

7. Reduced seat ring (rotation 60°)

Steel diaphragmhousing Actuator spring

for fail-safeoperation

Cast ironyoke/transfer case

Directlycoupledto valve shaft

High cyclediaphragm

Adjustablestroke stopprevents excessiverotation

Push-typehandwheel

Figure 8: Diaphragm Actuator

Diaphragm ActuatorThe diaphragm rotary actuator is a rugged single-acting ac-tuator designed to provide high performance, long life and re-liability. It operates with air supply pressures up to 4.0 bar andis field-reversible. High performance is assured with ball bear-ing internal action, which avoids thefriction associated with O-rings. The diaphragm actuator is very sensitive to small changesin air supply, which allows it to precisely move the valve plugwith out over shoot. This is also enhanced by thedirect cou-pling between the valve shaft and actuator stem. Long life isassured with the high-cyclediaphragm and a durable steel dia-phragm housing and cast iron yoke transfer case. Otherfeaturesinclude a convenient push-type jackscrew handwheel,an easily viewed external plug position indicator, and an ad-justable stroke stop that prevents excessive rotation.

* Some restriction may apply to certain applications

Table V: Diaphragm ActuatorSpecifications

Types Single-acting, high-performancediaphragm actuator

Sizes NR1, NR2, NR3 with 60° and 80°rotation

Action Air-to-open, air-to-close;fail-in-place

Supply 4 barg* (maximum)Pressure

Auxiliary Push-type handwheel

Analog XL90 pneumatic & NT 3000Positioners

Digital Logix 500 SeriesPositioners Logix 1000 Series

Table VI:Diaphragm Valve / Actuator Compatibility

ActuatorSize

Valve Size (inches / mm)1 1.5 2 3 4 6 8 10 12

25 40 50 80 100 150 200 250 300

NR 1NR 2NR 3

X X X

X X X XX X

8

MaxFlo 3 Control Valves

Types Double-acting cylinder with fail-safespring action

Sizes Cylinder sizes: 25, 50, 100, 200

Action Air-to-open, air-to-close;Fail-in-place

Supply Pressure 10 barg* (maximum)

Auxiliary Declutchable side-mounted;Handwheels manual gear-operated; handlever

Analog XL90 pneumatic and NT 3000Positioners XL pneumatic and NT 3000

Digital Logix 500 SeriesPositioner Logix 1000 Series

Spring Cylinder Rotary Actuators

Actuator spring forfail-safe operation

Adjustable strokestops preventexcessive rotationand reduceexcessive torqueon shaft

Rockingpistonprovidesdirectconnectionto shaft

Figure 9: Spring Cylinder Rotary Actuator

Table VIII: Spring CylinderRotary Actuator Specifications

* Some restriction may apply to certain applications

Spring Cylinder Rotary ActuatorThe Valtek spring cylinder rotary actuator combines high torqueand pneumatic stiffness with excellent throttling capabilities.These characteristics are designed into a lightweight, ruggedand compact assembly, making the Valtek rotary actuator anexcellent choice for quarter-turn applications. Valtek analogand digital positioners are available for throttling applications.The Valtek cylinder actuator and positioner are designed forsupply pressures up to 10 bar, making very high torques at-tainable. The actuator uses a rocking piston for direct conver-sion of linear motion to rotary motion. The rocking piston as-sembly combined with a splined shaft and lever eliminates lostmotion.

Splined lever/shaft

Table X: Spring Cylinder Rotary Actuator SelectionGuidelines

A cylinder actuator should be applied when theprocess requires the following:1. Double acting2. Field reversible3. Lightweight, compact design4. High stiffness (for throttling near seat)5. Actuation speed < 1 sec6. High supply pressure (above 4 bar and up to 10 bar)7. Interchangeability with Valtek rotary products (Valdisk,

Valdisk 150 and ShearStream)8. Aluminum cylinder/piston, cast iron yoke9. 90° shaft rotation

Table IX: Piston / CylinderValve / Actuator CompatibilitySpring Valve Size (inches / mm)Type

1 11/2 2 3 4 6 8 10 12

25 40 50 80 100 150 200 250 300

25 STD.

25 EXTD

50 STD.

50 EXTD

100 STD.

100 DUAL

200 STD.

200 DUAL

X X X X XX X X X X

X X X X XX X X X X

X X X XX X X XX X X XX X X X

ActuatorSize

(sq. inches)

9

MaxFlo 3 Control ValvesAnalog Positioners

Figure 10: XL90 positioner mountedon Diaphram Actuator

Figure 11: XL positioner mountedon Spring Cylinder Rotary Actuator

XL90 PositionerThe XL90 positioner is a high-performance analog po-sitioner designed specifically for rotary-type feedback.It can be used on applications with 60, 90 and up to 180degrees rotation. By using the same internal position-ing parts as its linear-motion counterpart (XL positioner),interchangeability between the XL and XL90 is signifi-cant, allowing for a lower spare part inventory. In addi-tion to its high-performance positioning functions, theXL90 uses internal position feedback potentiometers,as well as limit switches. The position indicator allowsfor easy viewing of valve/actuator position and the op-tional Ultra-dome™ provides increased visibility of po-sition. The UltraSwitch™ option provides explosion-proof or intrinsically safe switches and/or position feed-back. Mounting is accomplished using NAMUR, F05,Westlock or standard Valtek mounting. Available in ei-ther pneumatic or I/P models, the XL90 is the premierchoice for rotary positioning.

XL PositionerThe XL two-stage analog positioner offers fast and sen-sitive dynamic response characteristics to meet ex-tremely demanding control requirements. The positioneris available with either an electro-pneumatic (I/P) trans-ducer module for milliamp current control signals or apneumatic module for air control signals. Designed forhigh performance, this positioner is field-reversible andruggedly built for reliability in severe environments. It isfully capable of handling up to 150 psi / 10.3 bar withouta pressure regulator. Two and three-way split rangesare available without special feedback springs.

1 0

MaxFlo 3 Control ValvesDigital Positioners

Logix 1000 Series PositionersFor HART® and fieldbus applications, the Logix 1000 digitalpositioners offer unparalleled performance with a powerful 16-bit microprocessor and proprietary two-stage electronic relay(patent pending). For HART applications (Model 1200), theon-board Quick-Cal™ button allows the user to complete setupand calibration in less than 30 seconds without the use of hand-held devices or additional software. For fieldbus applications(Model 1400), the positioner offers an on-board Re-Cal™ but-ton that allows the user to complete setup and calibration inless than 30 seconds. Local status LEDs provide an insightinto valve status at a glance.

With the Logix 1200 positioner, data transfer with theSofttools™ software is substantially faster than other currentHART-compatible systems, resulting in a dramatic speed in-crease in configuration and diagnostic signature acquisition.When fieldbus communications are required, the Logix 1400positioner is designed and registered as a FOUNDATION™ fieldbusdevice, and contains AO and PID function blocks. In additionto high performance, both the Logix 1200 and 1400 positionersoffer in-process diagnostics for the valve as well as for theactuation system. They are designed to provide users with sig-nificant improvements in today’s plant operations whileoffering simple and economical migration to fieldbus standards.

Logix 500 PositionerThe Valtek Logix 500 series digital positioner is asingle-acting digital positioner that is quickly andeasily configured at the valve – which does not require a hand-held device or a host system. The Logix 500 digital positionercombines state-of-the-art piezo technology with inner-loop feed-back that provides high-performance control with minimal airconsumption. Highly visible LED status lights allow the userto diagnose the condition of the valve at a glance.

With its versatile mounting options, the Logix 500 positioneroffers a cost-effective retrofit solution for applications requir-ing communication (HART protocol) and diagnostics for dia-phragm-actuated valves from any manufacturer.

Figure 13: Logix 1000 positioner mounted on SpringCylinder Rotary Actuator

Figure 14: Logix 500 positionermounted on Diaphram Actuator

1 1

MaxFlo 3 Control ValvesDimensions / Weights

Table XII: Estimated Shipping Weight (kg / lbs.)

All dimensions are to be used for estimation only. Certified drawings will be supplied upon request. Face-to-face dimensions according toISA S75-04.

Table XI: MaxFlo 3, Flanged with NR Diaphragm Actuator (mm)

SizeInch mm A B C D E F G H J K L M N P R

1 25 102 51 70 56 411/2 40 114 57 92 70 208,7 42 192 245,5 276,2 36,5 140 201 125 113

2 50 124 62 94 743 80 165 82,5 145 984 100 194 97 150 1036 150 229 118 201 1618 200 243 136 212 178

10 250 297 158 259 20612 300 338 172 284 231

216,7 64 308 349,5 299,2 54.5 200 278 178,5 150

263,5 102 420 485,5 353 73 400 407,5 243,5 186

6

8

10

15

Size(mm / inch)

Weight(kg / lbs.)

25 / 1 40 / 1.5 50 / 2 80 / 3 100 / 4 150 / 6 200 / 8 250 / 10 300 / 12

38 / 18 22 / 45 25 / 55 56 / 123 70 / 154 160 / 352 195 / 429 245 / 539 300 / 660

1 2

MaxFlo 3 Control Valves

Table XIII: MaxFlo 3 Dimensions (mm)

Dimensions

CD

G

F

ECLEARANCEDISASSEMBLY

K

H

J

ACLEARANCEDISASSEMBLY

B max

All dimensions are to be used for estimation only. Certified drawings will be supplied upon request.Face-to-face dimensions according to ISA S75-04.* For standard Beta and XL positioners.

A B max C D E F G H J K*

1/25 25 11 102 56 272 510 152 332 142 28 165 165

1.5/40 25 16 114 71 295 535 152 332 142 28 165 165

2/50 25 16 124 74 297 535 152 332 142 28 165 165

2/50 50 16 124 74 297 535 203 457 170 51 231 188

3/80 25 23 165 99 348 635 152 332 142 28 165 165

3/80 50 23 165 99 348 635 203 457 170 51 231 188

4/100 25 23 194 104 353 661 152 332 142 28 165 165

4/100 50 23 194 104 353 661 203 457 170 51 231 188

6/150 50 26 229 160 468 680 203 457 170 51 231 188

6/150 100 38 229 160 468 722 279 574 231 61 318 216

8/200 50 26 243 190 479 685 203 457 170 51 231 188

8/200 100 38 243 190 479 733 279 574 231 61 318 216

10/250 50 26 297 226 548 751 203 457 170 51 231 188

10/250 100 38 297 226 548 802 279 576 231 61 318 216

12/300 100 38 338 267 573 827 279 576 231 61 318 216

Valve Actuator Shaftsize size size

in / mm

1 3

MaxFlo 3 Control ValvesDimensions / Weights

Table XIV: MaxFlo 3 – Handwheel andExtended, Heavy-duty Spring Dimensions (mm)

All dimensions are to be used for estimation only.Certified drawings will be supplied upon request.Face-to-face dimensions according to ISA S75-04.

Table XV:Estimated Shipping Weight (kg / lbs.)(with standard actuator and positioner)

Valve(mm / inch)

Poids(kg / lbs.)

25 / 1 40 / 1.5 50 / 2 80 / 3 100 / 4 150 / 6 200 / 8 250 / 10 300 / 12

25 / 56 29 / 64 34 / 75 45 / 99 57 / 126 107 / 236 133 / 294 181 / 398 270 / 595

E F M N P R

25 236 439 254 249 66 188

50 249 605 305 262 86 257

100 216 584 457 338 137 246

200 229 617 457 338 137 246

Actuator size(sq. inch)

1 4

MaxFlo 3 Control ValvesMounting Orientations

Right hand mounting (optional)

Air-to-OpenFail-Closed(Plug on Bottom)

Air-to-OpenFail-Closed

Air-to-CloseFail-Open

Left hand mounting (standard)

Air-to-CloseFail-Open(Plug on Bottom)

Air-to-CloseFail-Open

Right hand mounting (standard)

Air-to-CloseFail-Open(Plug on Bottom)

Air-to-OpenFail-Closed

Left hand mounting (optional)Air-to-OpenFail-Close(Plug on Bottom)

Diaphragm Actuator Orientation

Air-to-close Air-to-open

Figure 15: Diaphragm Actuator Orientations (for information only)

Shaft Upstream(according to flow direction)

Shaft Downstream(according to flow direction)

1 5

MaxFlo 3 Control Valves

Right hand mounting (optional)

Mounting Orientations

Air-to-OpenFail-Closed(Plug on Bottom)

Air-to-OpenFail-Closed

Air-to-CloseFail-Open

Left hand mounting (standard)

Air-to-CloseFail-Open Right hand mounting (standard)

Air-to-CloseFail-Open(Plug on Bottom)

Air-to-OpenFail-Closed

Left hand mounting (optional)

Air-to-CloseFail-Open(Plug on Bottom)

Air-to-OpenFail-Close(Plug on Bottom)

Actuator Orientation Handwheel Orientation

Figure 16: Orientations for Cylinder Actuator or Handwheel

Shaft Upstream(according to flow direction)

Shaft Downstream(according to flow direction)

1 6

MaxFlo 3 Control Valves

All data subject to change without notice©11.2002 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation

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