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Series 70

Bray SERIES 70 Installation, Operation And Maintenance Manual

SERIES 70
ELECTRIC ACTUATOR
Installation, Operation and Maintenance Manual
THE HIGH PERFORMANCE COMPANYBRAY.COM
1
Series 70 Electric Actuator
FOR MORE INFORMATION ON THIS PRODUCT AND OTHER BRAY PRODUCTS
PLEASE VISIT OUR WEBSITE – bray.com
Table of Contents
Safety Instructions - Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hazard-Free Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Part Numbering System Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electrical Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
S70 On/Off Actuator with Interposing Relay Board (I.R.B.) . . . . . . . . . . . . . . . . . . . .4
Servo NXT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Mounting the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Wiring the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Setting Travel Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Setting Mechanical Travel Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Field or Factory Installable Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Auxiliary Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Local Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Control Station Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Backup Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Indication of Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Spinner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Receptacles (Quick Connectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
External Signal Feedback Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Basic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Actuator Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Series 70 – Size 003, 006 – Electric Actuator Exploded View . . . . . . . . . . . . . . . . . . . . 20
Series 70 – Size 008, 012, 020 – Electric Actuator Exploded View . . . . . . . . . . . . . . . . . .22
Series 70 – Size 030, 050, 065 – Electric Actuator Exploded View . . . . . . . . . . . . . . . . . .24
Series 70 – Size 130, 180 – Electric Actuator Exploded View . . . . . . . . . . . . . . . . . . . . 26
Series 70 – Size 130, 180 – 3:1 Gear Box Exploded View . . . . . . . . . . . . . . . . . . . . . . 28
2
Series 70 Electric Actuator
Hazard-Free Use
This device left the factory in proper condition to be safely installed and operated in a hazard-free manner. The notes and warnings in this document must be observed by the user to ensure hazard-free operation of this device.
All necessary precautions need to be taken to prevent damage due to rough handling, impact, or improper storage. Do not use abrasive compounds to clean the device, or scrape its surfaces with any objects.
Configuration and setup procedures for this device are described in this manual. Proper configuration and setup are required for the safe operation of this device.
The control system in which this device is installed must have proper safeguards to prevent injury to personnel, or damage to equipment, should a failure of system components occur.
The device generates large mechanical force during normal operation.
Qualified Personnel
The actuator must only be installed, commissioned, operated and repaired by qualified personnel.
Installation, commissioning, operation and mainte­nance must be performed under strict observation of all applicable codes, standards and safety regulations.
As per this document, a qualified person is one who is trained in:
• The operation and maintenance of electric equipment and systems in accordance with established safety practices.
• Procedures to energize, de-energize, ground, tag and lock electrical circuits and equipment in accordance with established safety practices.
• The proper use and care of personal protective equipment (PPE) in accordance with established safety practices.
• First aid.
• In cases where the device is installed in a potentially explosive (hazardous) location – is trained in the operation, commissioning, operation and maintenance of equipment in hazardous locations.
Reference is specifically made here to observe all applicable safety regulations for actuators installed in potentially explosive (hazardous) locations.
Safety Instructions - Definition of Terms
READ AND FOLLOW THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTICE
indicates a potential situation which, if not avoided, may result in an undesirable result or state, including property damage.
3
Series 70 Electric Actuator
Introduction
The Bray Series 70 is a quarter turn electric actuator with manual override for use on any quarter turn valve requiring up to 18000 in-lb [2034 Nm] of torque. Operating speeds vary between 15 to 110 seconds.
Principle of Operation
The Series 70 actuator is divided into two internal sections, the power center below the switch plate, and the control center above the switch plate. Below the switch plate, the gear motor, with its spur gear train, drives a non-backdriveable worm gear output. The override mechanism for manual operation is also housed here. Above the switch plate is where user required readily accessible components are placed. The indicator shaft assembly, limit switches, terminal strips, torque switches, heater, and electronic controllers are all placed here for easy access.
External to the unit are adjustable mechanical travel stops, a large and easy to read indicator, the unique manual override handwheel, and dual conduit entry ports. The external coating is a high-quality polyester powder coat which has exceptional UV protection and chemical resistance.
Electrical Operation
The gear motors used in the Bray Series 70 are of either permanent split capacitor (PSC) design (single phase AC power) or permanent magnet (PM) design
(DC power). Travel limit switches are mechanical form (SPDT) with contacts rated at 10 Amp (0.8 PF), 1/2 HP 125/250 VAC.
In cases where the torque capacity of the unit is exceeded to the point where the motor stalls, a thermal protector switch, built into the PSC motor windings, will automatically disconnect the motor power and prevent overheating. Once the motor cools sufficiently, the thermal protector switch will reset automatically.
Optional torque switches are available in all units to prevent the possibility of stalling the motor, thus reducing the possibility of an inoperable thermal cool down period. Torque switches, installed by Bray, are factory adjusted to the output torque rating of the unit using electronic torque testing equipment.
Mechanical Operation
Mechanically, the ratio of the gear motor determines the speed of the unit. The gear motor utilizes high efficiency spur gears with various ratios for the different speeds. Initial gear reduction through the spur gears is then transferred to the worm shaft. The final gear reduction and output is through a non-backdriveable worm gear set. Positioning is determined by an indicator/cam shaft, which is linked to the output shaft. In the declutchable condition, the manual override drives the worm shaft when engaged.
Part Numbering System Reference Chart
SerieS Torque Code Speed produCT STyle VolTage Trim
70 AAA X 113 Y Z TTT
aCTuaTor
S
ize
parT Number
Torque
In.Lbs
TorqueNmSpeed, ¼ TurN
Seconds
Supply
Z Voltage
S70-003
70-003X-113YZ-TTT 300 34 30/15 0/2/4
S70-006
70-006X-113YZ-TTT 600 68 30 0/2/3/4
S70-008
70-008X-113YZ-TTT 800 90 30/15/6 0/2/4
S70-012
70-012X-113YZ-TTT 1200 136 30/15/6 0/2/4
S70-020
70-020X-113YZ-TTT 2000 226 30/15 0/2/3/4
S70-030
70-030X-113YZ-TTT 3000 339 30/18 0/2/4
S70-050
70-050X-113YZ-TTT 5000 565 30/18 0/2/3/4
S70-065
70-065X-113YZ-TTT 6500 734 30 0/4
S70-130
70-13WX-113YZ-TTT 13000 1469 110 0/4
S70-180
70-18WX-113YZ-TTT 18000 2034 110 0/4
Use this chart as a guide to interpret the S70 electric actuator part number. Note: Not all combinations are possible.
TTT - DESIGNATES THE PRODUCT TRIM
536 Standard Bray Red
5F5 Bray Seacorr Coating
YZ - STYLE / VOLTAGE:
Imp. Metric
DA NA 120VAC Interposing Relay Board
DB NB 220VAC Interposing Relay Board
DC NC 24VAC On/Off with Controller
DD ND 24VDC On/Off with Controller
AA MA 120VAC Modulating with Servo Pro
AB MB 220VAC Modulating with Servo Pro
AC MC 24VAC Modulating with Servo Pro
AD MD 24VDC Modulating with Servo Pro
G0 R0 120VAC Modulating with Servo NXT
G2 R2 24VDC Modulating with Servo NXT
G3 R3 24VAC Modulating with Servo NXT
G4 R4 220VAC Modulating with Servo NXT
NOTE: 220VAC units are 230VAC compatible
W - DESIGNATES THE OUTPUT BORE DIAMETER
0
2.5 Inches
[63.5 mm]
1
1.97 Inches [50 mm]
X - DESIGNATES THE SPEED
X: 0 1 2 6
Sec: 60 30 15/18 110
Y - DESIGNATES STYLE
Imp. Metric
G R Servo NXT
D N I.R.B. On/Off
A M Servo Pro
Z - DESIGNATES THE VOLTAGE
Z:
0 2 3 4
A D C B
Voltage:
120VAC
24VDC
24VAC
220VAC
Units of measure designation = Imperial [Metric]
4
Series 70 Electric Actuator
Actuation
Manual Operation
The manual override operates similar to a watch adjusting knob. To engage the manual override, simply pull the handwheel to its outermost position. A yellow stripe is revealed to visually indicate manual override engagement as shown in Figure 1. The two handwheel positions, engaged and disengaged, are held in place with the use of spring plungers. The handwheel remains in position until physically moved.
Yellow Stripe
Figure 1 - Handwheel is engaged, revealing the yellow stripe.
Once the manual override is engaged, rotating the handwheel in the clockwise direction will rotate the output shaft in the clockwise (close) direction and vice-versa.
To disengage the manual override, the handwheel needs to be pushed towards the actuator until the ‘yellow stripe’ is hidden.
A label on the handwheel hub warns users not to exceed a specific ‘rim pull’ force, for each size of actuator.
If the ‘rim pull’ force is exceeded, the roll pin securing the handwheel onto the manual override shaft is designed to shear, thus preventing serious internal gearing damage.
Remote Operation
1. Verify that the main electric power supplied to the actuator is in compliance with the specifications on the actuator label.
2. Engaging the handwheel before or during the application of a supply voltage will prevent the actuator motor from operating.
3. If torque switches are installed in the actuator, an over-torque condition will prevent the actuator motor from operating in the direction of fault.
S70 On/Off Actuator with Interposing Relay Board (I.R.B.)
The back feeding of one actuator by another one wired in parallel is eliminated by using the I.R.B. If actuator is running Open and customer switches “instantaneously” to run Closed, the Open relay will take time to ‘drop-out’ and the Close relay will take time to ‘pull-in’ this time lapse is ~ 40ms. The time delay provided by the I.R.B. will protect the switches and gears from the controller’s instantaneous command signal reversal. Current draws and field wirings are not affected by adding I.R.B.
S70 120VAC I.R.B., auxiliary switch, heater, and torque switch option are UL certified units
NOTE: The host controller should use a one second time delay for command signal reversal.
Apply voltage to only one direction terminal at a time.
Figure 2 - S70 with I.R.B.
5
Series 70 Electric Actuator
Servo NXT
To control the actuator remotely from a process controller in a modulating application, user must apply the proper supply voltage and the configured control signal to the Servo NXT electronics package. The control signal may be applied locally from a hand-held signal generator or remotely from a process controller.
For more information, please refer to the S70 Servo NXT Manual. This manual is available on the company website (bray.com).
Figure 4 - S70 with Servo NXT
FIELD WIRING ACTUATOR
SINGLE PHASE POWER SUPPLY
GROUND
N
L
OPEN
BLUE
CLOSE
OPEN
CLOSE
(SEE NOTE 5)
FOR HEATER OPTION ONLY
RED
YELLOW OR
BLACK
O
C
N
MOTOR
YELLOW YELLOW
RED
RED
RED
RED
BLUE
OVERRIDE SW
CLOSE
OPEN
RED
HEATER (OPTIONAL)
BLUE
BLUE
BLUE
BLUE
GREEN
CAM
RED
CAM
N.C.
COM
N.O.
N.C.
COM
N.O.
OPEN
CLOSE
COM
COM
N.C.
N.O.
N.C.
N.O.
CL
OP
N
MC
MO
INTERPOSING RELAY
1
2
3
4
5
6
7
8
9
Actuator shown in closed position
Figure 3 - Sample field wiring diagram for Series 70 actuator with I.R.B. Actuator specific wiring diagram located inside actuator cover.
Figure 5 - Sample field wiring diagram for Series 70 actuator with Servo NXT. Actuator specific wiring diagram located inside actuator cover.
FEEDBACK
POTENTIOMETER
WHITE
ORANGE
GREY
YELLOW
YELLOW
OVERRIDE SW
N.C. N.O.
N.C.
N.C.
N.O.
N.O.
N.C. N.O.
COM
COM
COM
COM
BLUE
BLUE
RED
RED
OPEN
CLOSE
GREEN
CAM
RED
CAM
COM
INPUT+
INPUT–
OUTPUT+
OUTPUT–
NEUTRAL
LIVE
NEUTRAL
CLOSE
LIVE
NEUTRAL
OPEN
WIPER
POWER
COM
CLOSE
COM
COM1
COM2
CLOSE
OPEN
COM1
COM2
CLOSE
OPEN
HW
OPEN
LIMIT SW
MOTOR
COMMAND
INPUT
POWER HEATER
HAND
WHEEL
CTRL BOX
FB POT
TORQUE SW
RED
YELLOW
OR BLACK
BLUE
HEATER
(OPTIONAL)
MOTOR
O
N
C
FIELD WIRING ACTUATOR
SHIELDED CABLE
OUTGOING FEEDBACK SIGNAL (SHIELDED)
INCOMING COMMAND SIGNAL
(SEE NOTES 5–7)
(SEE NOTES 6–8)
LOAD DEVICE
NOT TO EXCEED
400 OHMS
(4–20mA CONFIGURATION)
SINGLE PHASE
POWER SUPPLY
NEUTRAL
LIVE
GROUND
POSITION FEEDBACK
DEVICE
6
Series 70 Electric Actuator
Storage
Actuators are not weatherproof unless they are properly installed on the valve or prepared for storage. Bray cannot accept responsibility for deterioration caused on-site.
• Store units on a shelf or wooden pallet in order to protect against floor dampness.
• Cover the units to protect against dust and dirt.
• To prevent condensation from forming inside these units, maintain a near constant external temperature and store in a well-ventilated, clean, dry room away from vibration.
• For units with an internal heater, power should be supplied to the heater via conduit entry with an appropriate sealing gland.
Commissioning
Mounting the Actuator
All Bray Series 70 electric actuators are suitable for direct mounting on Bray butterfly valves. With proper mounting hardware, the S70 actuator can be installed onto other quarter-turn valves or devices.
NOTICE
The standard mounting position for the actuator orients the unit with its handwheel in a vertical plane and parallel to the pipeline.
If the actuator is mounted on a vertical pipe, it is recommended that the unit be positioned with the conduit entries on the bottom to prevent condensation from entering the actuator through its conduits.
In all cases, the conduit should be positioned to prevent drainage into the actuator and the handwheel should not be facing down.
Follow the steps below to mount the actuator onto the valve.
1. Manually operate the actuator until the output shaft of the actuator is in line with the valve stem. If possible, select an intermediate position for both the valve and actuator.
2. If required, place the proper adapter onto the valve stem. It is recommended that a small amount of ‘anti-seize’ lubricant be applied to the adapter to ease assembly.
3. Mount the actuator onto the valve stem.
4. Install the furnished mounting studs by threading studs all the way into the actuator base. It may be necessary to manually operate the actuator to align the valve and actuator bolt patterns.
5. Fasten the mounting studs in place with furnished hex nuts and lock washers
7
Series 70 Electric Actuator
Wiring the Actuator
Turn off all power and lockout/tag out service panel before installing or modifying any electrical wiring.
1. Take the actuator cover off. The cover should be kept on hand for reference.
2. Wire the actuator as per the wiring diagram attached to the inside of the actuator cover.
NOTICE
Power and control wiring should use separate conduit entries.
NOTICE
A minimum of 18 AWG wire is recommended for all field wiring.
Terminals directly mounted on the actuator switch plate accept wire sizes ranging from 14 to 22 AWG.
Terminals of internally mounted electronics modules accept wire sizes ranging from 14 to 24 AWG.
NOTICE
The conduit connections must be properly sealed to maintain the weatherproof integrity of the actuator enclosure.
Setting Travel Limit Switches
NOTICE
If the unit came assembled to a valve, the switches have been factory-set and DO NOT need adjustment.
Bray uses its patented cam design along with two SPDT mechanical switches to set the ‘Open’ and ‘Closed’ position of the valve. The green cam actuates the ‘open’ switch when the actuator reaches the ‘open’ position. Similarly, the red cam actuates the ‘closed’ switch when the actuator reaches the ‘closed’ position.
Standard factory setting of the travel limit switches allows 90° travel between open and close positions. Cams for each switch are adjustable for applications where less than 90-degree travel is desired between the open and closed positions.
Cam Locking Screw
Figure 6. Two SPDT Travel Limit Switches
Follow the steps below to adjust the travel limit cams. NOTE: For Actuator Size 130, 180, ignore steps 1 and 10.
1. Remove the indicator rotor by pulling away from the indicator shaft as shown in Figure 7.
Figure 7. Indicator rotor pulled up from the indicator shaft.
2. Manually operate the actuator clockwise until the valve reaches the desired ‘closed’ position.
3. Loosen the cam locking screw shown in Figure 6.
8
Series 70 Electric Actuator
NOTICE
Cam locking screw must be slackened before cam adjustments and re-tightened after cam adjustments.
Figure 8. Top view of the indicator shaft.
NOTE: It is possible that the rotation of one cam will move the other cam. If this occurs, hold the other knobs or cams during adjustment.
4. Rotate the red cam adjustment knob by hand or with a flat head screwdriver until the red cam lobe just activates (depresses) the ‘closed’ switch from a clockwise direction.
NOTE: If fixed auxiliary switches are installed, the auxiliary cam will activate prior to the main cam.
5. Tighten the cam locking screw.
6. Manually operate the actuator counterclockwise until the valve reaches the desired ‘open’ position.
7. Loosen the cam locking screw.
8. Rotate the green cam adjustment knob until the green cam lobe activates (depresses) the ‘open’ switch from a counterclockwise direction.
9. Tighten the cam locking screw.
10. Place the indicator rotor back on the indicator shaft.
Setting Mechanical Travel Stops
NOTICE
If the unit came assembled to a valve, the stops have been factory-set and DO NOT need adjustment.
Mechanical travel stops are designed to prevent over travel while manually operating the actuator. They are not designed to stop the electric motor.
Mechanical travel stops are located outside of the actuator base for easy readjustment. Stainless steel lock nuts with O-ring seals hold the travel stops securely in place. Travel stop spacers are used to ensure that travel stop bolts are not engaged to where they could limit 0° to 90° electrical operation.
NOTE: Actuator Size 130, 180 does not use travel stop spacers.
Open Travel
Stop
Closed
Travel
Stop
Figure 9. Mechanical Travel Stops (CW Close).
Follow the steps below to set the mechanical travels stops.
1. Manually drive the actuator to the ‘closed’ position.
2. Once the actuator is in the ‘closed’ position, rotate the handwheel clockwise:
• ½ turn for Actuator Size 003, 006.
• 1 turn for Actuator Size 008, 012, 020.
• ½ turn for Actuator Size 030, 050, 065.
• 2 turns for Actuator Size 130, 180.
3. Adjust the ‘closed’ travel stop bolt until the travel stop spacer is fully engaged or the travel stop bolt contacts the output segment gear.
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