Installation, Operation and Maintenance Manual
Series 2000LP
Low Pressure Pneumatic Actuator
Part Number: E7K-400-0413
Release: April 2013
When communicating with EIM for replacement parts or for technical questions, we MUST have
actuator nameplate information, including Job, Serial, and Model numbers. This allows us to check
records of EIM equipment furnished.
When ordering parts, specify repair part by EIM part number and description from drawings
furnished with actuator.
Installaton, Operation and Maintenance Manual
Part Number: E7K-400-0911, Rev. 0
Table of Contents
Section 1: Introduction ..................................................... 1
Section 2: Storage Instructions ......................................... 3
Section 3: Product Data .................................................... 4
Section 4: Lubrication and Maintenance ........................... 5
Section 5: Mounting Dimensions ...................................... 7
Section 6: Assembly to Valve ............................................ 8
6.1 Multi-Turn Valve Stem Nut Installation .......................................................... 8
6.2 Lockpin Installation ....................................................................................... 9
6.3 Thrust Spool Installation (Multi-Turn) ............................................................ 9
6.4 Spline Bushing (Quarter Turn) ....................................................................... 9
6.5 Quarter Turn Gearbox Stop Setting Procedure ............................................. 10
Table of Contents
April 2013
Section 7: Pneumatic Hookup ..........................................11
Section 8: Travel and Torque Limits ..................................13
8.1 General Information .................................................................................... 13
Section 9: Setting Travel Limit Valves ...............................15
Section 10: Setting Torque Limit Valves
10.1 Opening Torque .......................................................................................... 17
10.2 Closing Torque ............................................................................................ 18
Section 11: Optional Electric Limits ................................... 19
11.1 General Information .................................................................................... 19
11.2 Standard Wiring Diagram ............................................................................20
Section 12: Typical LP Control Package .............................. 21
Section 13: Typical Control Diagram .................................. 22
Table of Contents
I
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0911, Rev. 0
Section 14: Gast Pneumatic Motor .................................... 24
14.1 Installation .................................................................................................. 24
14.2 Lubrication .................................................................................................. 24
14.3 General Information .................................................................................... 24
14.4 Servicing ..................................................................................................... 25
Section 15: Troubleshooting ............................................. 26
Table of Contents
April 2013
II
Table of Contents
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 1: Introduction
This installation and operation manual explains how to install, operate, and maintain the
2000LP valve actuator.
Carefully follow the instructions in this manual and make sure you install the actuator correctly
and according to your requirements.
Safety notices in this manual detail precautions the user must take to reduce the risk of
personal injury and damage to the equipment. The user must read these instructions in their
entirety. Failure to observe these safety notices could result in serious bodily injury, damage to
the equipment, voiding of the warranty, or create operational difculty.
Safety notices are presented as follows:
WARNING:
Alerts user of potential danger; failure to follow the warning notice could result in serious
personal injury or death.
Section 1: Introduction and Safety Information
April 2013
CAUTION:
Identies precautions the user must take to avoid personal injury or equipment damage.
NOTE:
Highlights information critical to the user’s understanding of the 2000LP valve actuator
installation or operation.
WARNING:
Read this manual in its entirety before installing, operating, or performing
maintenance on the 2000LP actuator.
WARNING:
Use caution when working on, with, or around valves and actuators. High
pressures, forces, voltages and flammable media can be present.
WARNING:
Failure to follow instructions for proper electrical wiring, storage, setup, and
maintenance may cause serious injury, damage equipment, or void warranty.
Introduction and Safety Information
1
Section 1: Introduction and Safety Information
April 2013
WARNING:
If the actuator is being installed within a hazardous area, take into account that:
• Improper installation in hazardous areas can cause an explosion.
• Assembly, disassembly and maintenance are only allowed at the actuator
when, at the time of the activity, an explosive mixture is not present.
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
2
Introduction and Safety Information
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 2: Storage Instructions
If your actuator cannot be installed immediately, the following procedures are to be followed.
This will ensure optimum performance from your 2000LP actuator.
Failure to comply with recommended procedures could lead to actuator malfunction and will
void the warranty.
The 2000LP actuator is an inherently weatherproof unit when shipped from the factory,
providing that all compartment covers and entry plugs remain intact. The actuator should
be immediately stored in a clean, dry warehouse, free from vibration and rapid temperature
changes, until it can be installed and commissioned.
If the actuator must be stored outside, it should be stored off of the ground, at an elevation
sufcient to prevent it from being immersed in water or buried in snow, and covered to prevent
damage from site debris.
If not attached to a valve, the preferred orientation is with the motor and control compartment
horizontal.
Section 2: Storage Instructions
April 2013
If the actuator is mounted on a valve and the valve stem protrudes from the unit, a suitable
stem protector must be installed to prevent drive sleeve corrosion. Stem protectors may be
purchased from your local EIM distributor.
CAUTION:
Condensation or moisture that enters the actuator can damage internal components, which
may ultimately result in failures.
(1) Ensure integrity of gaskets and O-rings.
(2) Seal all conduit openings, whether used or not.
(3) Replace any plastic conduit plugs with pipe plugs appropriate for the application.
(4) Place a packet of dessicant in the control housing to absorb excessive moisture.
For storage procedures exceeding one year, contact your local EIM representative for
recommendations.
Contact information is located on the last page of this manual.
Storage Instructions
3
Section 3: Product Data
April 2013
Section 3: Product Data
The EIM 2000LP pneumatic actuator from Emerson is a multi-turn air driven actuator that
is perfect for applications using linear stem, rising stem or rotating stem valves. It can be
powered by air, nitrogen, or natural gas at pressures between 60 and 100 psi. Manual controls
and/or a number of remote pneumatic or electric control options can be provided as shown in
the table below.
Table 1. Standard Control Diagrams
Typ e Description Diagram
Manual
Pneumatic
Electric
No Controls PD-100
Local 2-Way PD-101
Fail Close PD-102
Fail Open PD-103
Double Acting PD-104
Fail Close PD-105
Fail Open PD-106
Double Acting PD-107
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
There is a ve digit alpha-numeric code used to describe basic actuator features for computer
assisted order entry. This number appears on the actuator nameplate afxed to the actuator
gear housing. The most signicant designators for a sample 2CLG-AF actuator are shown
below.
2 C L G - A F
Frame Size Motor Size Motor Gears Worm Gears Control System Special Services
1 = 1000 X = 6AM A = No controls
2 = 2000 Y = 8AM B = Local Manual
3 = 3000 Z = 16AM C = Remote
The 2000LP is based on the proven EIM Series 2000 platform and shares many of its distinctive
features and benets such as direct mounting and handwheel operation during power loss or
emergency situations.
The three most common frame sizes of EIM actuators, the 1000, 2000 and 3000, establish the
foundation for the 2000LP. Subsequently, most major 2000LP mechanical components are
interchangeable with standard EIM electric actuators, which facilitates the acquisition of spare
parts.
The control housing is also a shared EIM electric component, resulting in NEMA 4, 4X and IEC
IP66 product ratings for the 2000LP. Working temperature range is listed at -20 / +150°F (-29 /
+66°C).
4
Product Data
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 4: Lubrication and Maintenance
Section 4: Lubrication and Maintenance
An annual check of the following items should be made of your EIM 2000LP actuator.
1. Check for any external leaks and tighten ttings appropriately and/or replace failed
components.
2. Check for internal component leakage by testing for the presence of air exiting the
exhaust port(s) while the actuator is not moving.
3. Open the control housing to inspect and tighten any loose connections.
4. Visually inspect for any mechanical damage. Replace worn or damaged components.
5. Replace any seals that permit oil leakage or water ingress.
6. Lubrication consistency and quantity needs to be checked only after 3000 cycles
unless the actuator has been leaking oil or making excessive noise. Fill or replace with
recommended uid if required .
Lubrication – EIM actuator gear housings are factory lled with a high quality lubricant carefully
selected to ensure proper performance under specied operating conditions. Refer to EIM JOB
SPEC SHEET to identify the lubricant provided. Normal operation may not require lubricant
replacement.
April 2013
Lubricant level in the gear housing should be maintained at the following quantity. Do not
overfill.
• 1000 and 2000 Frame Sizes
(See “product data” section of this manual for determining frame size)
— Oil: 54 oz (1.54 Liters). Oil is recommended for all drive sleeve speeds over
51RPM.
— Grease: 3.5 lbs (1.58 Kg.). Grease is adequate for drive sleeve speeds under
51RPM.
• 3000 Frame Size
— Oil: 62 oz (1.83 Liters). Grease is not recommended for use in the 3000 Frame
Size
Lubrication and Maintenance
5
Section 4: Lubrication and Maintenance
April 2013
The following recommended lubricants are manufactured by Schaeffer Manufacturing
Company, but may be replaced with equivalent products manufactured by other reputable
companies. Lubricant selection must be made based upon ambient temperature and
application.
Table 2. Schaeffer Manufacturing Cpmpany Lubricants / Temperature for EIM
Products
Product Continuous Operating Range Part Number
#158 (ISO 68) Low Temp Oil -65 / +400°F (-54 / 204°C) 3000100228
#267 EIM Std. Oil -20 / +350°F (-29 / 177°C) 3000100227
#229 EIM Std. Grease -25 / +350°F (-32 / 177°C) 3000100222
#200 SUG (Special for EIM) -40 / +400°F (-40 / 204°C) 3000100212
#197 Low Temp, Grease -60 / +500°F (-51 / 260°C) 3000100219
#271 Food Grade -15 / +500°F (-26 / 260°C) 3000100216
#276 Food Grade Oil -15 / +300°F (-26 / 149°C) 3000100218
#286 High Temp *Na / +900°F (*Na / 482°C) 3000100220
#167 (Gear Oil) 75-140 Wt. -50 / +350°F (-45 / 177°C) 3000100230
#238 EP 1 Grease -10 / +350°F (-23 / 177°C) 3000100226
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
NOTE:
During operation of this actuator, gear housing temperature increase in combination with
variations of outdoor temperature may cause a small pressure build-up within the actuator gear
box. EIM furnishes Pressure Relief Vent Fitting Part No. 83385 to prevent excessive pressure
build-up. Pressure Relief Vent Fitting placement on the actuator can be determined after eld
location and position of the valve have been determined. Select the highest 1/2NPT vent
location of the actuator gear box; remove the ½ NPT plug and replace with Part No. 83385.
6
Lubrication and Maintenance
45°
45°
45°
45°
45°
45°
2.308”/2.305”
Pilot Dia.
(4) 3/8”-16 Holes
Tapped 0.8” (20) Deep
on 4.00” (102) B.C.
69.98mm/69.90mm
Pilot Dia.
(4) M10 Holes
Tapped 0.8” (20) Deep
on 4.00” (102) B.C.
3.745”/3.742”
Pilot Dia.
(4) 5/8”-11 Holes
Tapped 1.32” (33) Deep
on 5.50” (140) B.C.
99.98mm/99.90mm
Pilot Dia.
(4) M16 Holes
Tapped 1.32” (33) Deep
on 5.50” (140) B.C.
129.95mm/129.87mm
Pilot Dia.
(4) M20 Holes
Tapped 1.52” (38) Deep
on 6.50” (165) B.C.
4.994”/4.990”
Pilot Dia.
(4) 3/4”-10 Holes
Tapped 1.32” (33) Deep
on 6.50” (165) B.C.
FA10/F10
FA14/F14
FA16/F16
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 5: Mounting Dimensions
EIM Standard mounting is MSS SP-102 (FA) – Left column
ISO (F) Mounting can be supplied if requested – Right column
Section 5: Mounting Dimensions
April 2013
Mounting Dimensions
7
Section 6: Assembly to Valve
52
5556
54
April 2013
Installation, Operation and Maintenance Manual
Section 6: Assembly to Valve
6.1 Multi-Turn Valve Stem Nut Installation
Figure 1
Part Number: E7K-400-0913
1. Unscrew Locknut (55) holding Bronze Stem Nut (54) and remove Stem Nut and Key
(52).
2. Lubricate Stem and run Stem Nut (54) down stem to check acme thread t, then
remove Stem Nut and set aside.
3. Lower actuator over stem onto valve ange. After ensuring proper ange mating and
valve actuator orientation, insert Grade 5 mounting screws thru valve ange into
actuator. Screws must engage a minimum of one full screw diameter into bottom base
and be torqued to the following value:
• 3/8-16 = 50 lbf-ft (M10 = 68 Nm)
• 5/8-11 = 225 lbf-ft (M16 = 305 Nm)
• 3/4 -10 = 400 lbf-ft (M20 = 542 Nm)
NOTE:
If EIM supplied adaption, the mounting screws are included. If the adaption to the
valve was the responsibility of others, the mounting screws are not furnished by
EIM. Screws thru adapter MUST engage a minimum of one screw diameter into EIM
actuator base.
4. Screw Stem Nut (54) onto valve stem until it enters the Drive Sleeve. Align Nut Key (52)
with Drive Sleeve keyway and insert Stem Nut Key (52).
5. Turn handwheel in Open direction, pulling the Stem Nut into Drive Sleeve until it
bottoms out (valve will begin to open).
6. Place Locknut (55) over Valve Stem and screw into place rmly against top of Stem Nut
(54). Tighten Locknut by tapping ears with brass drift.
8
Locknut must be screwed very tightly against stem nut.
Assembly to Valve
CAUTION:
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 6: Assembly to Valve
6.2 Lockpin Installation
1. Using a number 30 (.1285) drill; drill a hole 3/4 inch deep into the Drive Sleeve
assembly threads for the Locknut Lockpin(56). Use groove in Stem Nut Locknut threads
as a guide.
2. Install Locknut Lockpin (56) into drilled hole to prevent the Stem Nut Locknut from
working loose and turning.
NOTE:
When installing, the Lock-nut Lockpin should extend 1/4 inch above the Drive Sleeve Assy to
allow for easy removal.
6.3 Thrust Spool Installation (Multi-Turn)
1. Locate Thrust Mounting bolts.
2. Remove the eight mounting bolts and separate the Spool from the actuator.
3. Position the Spool over the valve stem. Thread the Spool onto the valve stem until it
meets the valve plate.
4. Bolt and secure Spool onto valve.
5. Position actuator above Spool. Lower actuator onto Spool while manually rotating the
unit until ears on the stem nut and ears on main Drive Sleeve mesh.
6. Grease ange face before securing unit to Spool.
7. Re-install thrust plate mounting bolts. Tighten to proper torque.
April 2013
NOTE:
Reverse procedure if the stem nut needs to be replaced. Actuator does not need to be returned
to factory for this procedure.
6.4 Spline Bushing (Quarter-Turn)
EIM removable Spline Bushing allows easy adaption to valve shaft diameter and key. Actuator
may be rotated with respect to the valve shaft for unex-pected or awkward eld installations.
1. Move valve to full Open or Close.
2. Place Splined Bushing on valve shaft with key and tighten set screw.
3. Using the handwheel on actuator, move the Gear position indicator ar¬row to full Open
or full Close (duplicating the position in Step 1).
4. Position actuator so the Splined Bore is correctly aligned with the Splined Bushing on
stem shaft.
5. Lower the actuator onto the shaft until the ange faces properly mate. Se¬cure with
screws thru the adapter ange into the base of the actuator.
Assembly to Valve
9
Section 6: Assembly to Valve
8786
46
48
April 2013
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
6.5 Quarter Turn Gearbox Stop Setting Procedure
Built-in mechanical stops are provided in the gearbox to prevent operation beyond total valve
travel of 90° (± 6°).
End of travel stops are independently adjusted, locked in place and sealed.
Figure 2
Loosen both LOCKNUTS (46) and back out two STOPBOLTS (86 & 87) to allow valve to close and
open fully. Ensure Travel Limit Valves have been properly adjusted (see appropriate section of
this manual), and then proceed as follows:
1. Run actuator pneumatically to full closed position.
2. Screw CLOSE STOPBOLT (86) in until it seats, then back off 1/2 TURN. Install WASHER
(48) and tighten LOCKNUT (46).
3. Run actuator pneumatically to full open position.
4. Screw OPEN STOPBOLT (87) in until it seats, then back off 1/2 TURN. Install WASHER
(48) and tighten LOCKNUT (46).
CAUTION:
Do not set Actuator Travel Limit valves to drive into mechanical stops. Damage can occur if
actuator is allowed to repeatedly stall into end stops.
10
Assembly to Valve
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 7: Pneumatic Hookup
1. When mounting is complete, per previous instructions in Assembly to Valve, move the
valve position to mid-stroke with the actuator’s Handwheel. This will provide sufcient
time to stop actuator operation in case of incorrect pneumatic connection(s).
2. Identify a means of removing power from the actuator during hook up and check out.
3. Be sure no erroneous remote signal can be received that would cause the actuator to
energize.
4. Each pneumatic actuator is supplied with a directional valve that is sized to deliver an
air volume at the necessary required to achieve design performance for each actuator.
The following criteria should be used when selecting your air system. The air motor
size can be found on the unit ID (serial number) tag.
See Product Data Section of this manual to determine motor size.
Table 3. Motor Pressure Consumption
Section 7: Pneumatic Hookup
April 2013
Port Size (PSIG) (SCFM) SIZE
X 100 130 1/2" NPT
Y 100 180 1/2" NPT
Z 100 280 1" NPT
5. Consumption at a lower pressure is proportional to the data shown. Consideration
must be given to your piping system. At a normal 100 psi supply, schedule 40 piping,
or tubing with an equal internal diameter is recommended. A lter and lubricator
MUST have threaded connections equal to port sizes shown. Piping size should be
the same as that shown and connected to a larger header as close to the actuator as
possible.
Depending on the condition of the air supply, a lter may be required to maintain
ltration in a 40-50 micron range. Filter selection must meet this operating criteria.
6. Install an automatic lubricator in the air line leading to the motor. It should be
mounted in a horizontal pipe run as near as possible to the actuator.
NOTE:
Refer to “typical control diagrams” in this manual to determine proper piping location for
accessory connections.
NOTE:
Do not hang pipe loads on the actuator. Use external support or exible connections to the
actuator.
Pneumatic Hookup
The lubricator should be adjusted to feed one drop of oil for every 50-75 SCFM of air going to
the actuator. For example, an “X” motor running for one minute would require a minimum of
three drops of oil from the lubricator.
11
Section 7: Pneumatic Hookup
April 2013
Figure 3 TYPICAL FILTER, REGULATOR AND LUBRICATOR PACKAGE
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
7. A lubricant is required for all internal moving parts of the air motor and air control
valves. This is intended to reduce wear and prevent rust. Brand name oils are suitable
if they are mineral base, wax free & aniline point in the range of 200-220°F. Oils must
be thin enough to atomize in the lubricator. This should be in the range of Group D,
Turbine Light with a viscosity of 32 at 100°F. Listed below is a representative group of
suitable light oils that may be considered for use.
• Chevron - GTS OIl 32
• Exxon - Teresstic T32
• Mobil - Light
• Shell - Turbo 32
• Texaco - Capella 32 WF
NOTE:
Do not use penetrating oils or detergent type oils as they will damage seals and thicken in cold
weather.
NOTE:
Any temperature below 32°F may require the addition of small amounts of pure ethylene glycol
into the air system to prevent freezing. Do not concede the volume of oil normally used.
NOTE:
This product, as well as similar devices such as cylinders, solenoid valves, ESD valves, etc. emit
air to atmosphere in their normal operating mode. Confer with established codes and safety
regulations.
12
CAUTION:
Use of the product on any power medium other than compressed air or nitrogen may establish
a potential hazard.
Pneumatic Hookup
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 8: Travel and Torque Limits
Section 8: Travel and Torque Limits
8.1 General Information
All Series 2000LP pneumatic actuators are provided with 3-way pneumatic travel limit valves
(LVO and LVC). They are activated at each end of stroke to neutralize the control and stop the
actuator in the proper position.
See gure 4 for location in control housing.
Series 2000LP actuators are also provided with 3-way pneumatic torque limit valves (TVO and
TVC). They are activated when an over-torque condition is detected in either the opening or
closing direction and will neutralize the control in order to prevent valve damage. They may
also be set to provide the correct amount of torque for torque seated valves.
See gure 4 for location in control housing.
Figure 4
April 2013
LVC LVO
TSC TVC
NOTE:
All position and torque limit valves must be set according to the instructions on the following
pages of this manual after mounting the actuator to the valve.
The control assembly can also be tted with auxiliary pneumatic limit valves for remote
indication or other logic circuits as desired. These valves are mounted on top of the travel limit
valves (LVO - LVC) and are actuated by the same cams as the travel limit valves. Consequently
they cannot be adjusted to operate at any valve position other than full open and full closed
with the travel limits. These valves can be used as 3-way normally closed, 3- way normally open
or selector valves depending on port selection.
TSO
TVO
Travel and Torque Limits
13
Section 8: Travel and Torque Limits
April 2013
Pneumatic valve details:
• Maximum operating pressure rating - 125 psig
• Flow coefcient – 0.1 (20 CFM at 125 psig)
• Port size – 1/8 NPT
• With the roller actuator out (extended), the NO port is Open to Cylinder. This blocks
the NC port on the valve.
• When the roller actuator depressed, the NC port is open to Cylinder and the NO port is
blocked.
NOTE:
Optional electrical contacts are also available as needed. See pages 19 and 20 of this manual
for electrical limit switch information and wiring diagram. It must also be recognized that
auxiliary pneumatic limit valves and electrical limit switches cannot both be supplied on the
same unit.
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
14
Travel and Torque Limits
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 9: Setting Travel Limit Valves
Section 9: Setting Travel Limit Valves
Before setting limits it must be noted that actuators ordered specically for torque-seated valve
applications are assembled at the factory without tubing on the closing side limit valve. The
close side limit valve is physically installed but the tubing bypasses it and runs directly to the
torque limit.
1. Determine full-open valve position
Open the valve completely using the handwheel. Observe the rotational direction
of the adjusting shaft (1) during opening. When the valve is fully open, close several
turns (clockwise) to prevent overtravel.
2. Disengage drive pinion
Push the spring loaded shaft (2) down and rotate it 90° to the captured position. This
disengages the gear drive from the G/L pinion. The shaft (1) will now rotate freely.
3. Rotate adjustment shaft
Observe position of limit valve roller cam for one of two positions.
April 2013
• Position One - if the cam has not actuated the LVO valve, rotate the adjusting
shaft (1) in the same direction noted in step one until the rotating cam
actuates the limit valve.
• Position Two – if the cam has actuated the LVO valve, rotate the adjusting
shaft (1) in the opposite direction until the rotating cam actuates the limit
valve.
Note – Limit valves are actuated when the cam is pointing at the center of the limit
valve roller.
NOTE:
Many turns maybe required to set travel limits. It may be convenient to use a reversible
variable speed drill to rotate the adjusting shafts instead of a screwdriver.
4. Re-engage drive pinion
Rotate the spring-loaded shaft (2) 90°. The shaft will rise when locked in place.
5. Important
Lightly jiggle all adjusting shafts back and forth with a screwdriver to ensure correct
engagement: shafts should not turn when locked in place.
Setting Travel Limit Valves
15
Section 9: Setting Travel Limit Valves
3
1
3
April 2013
6. Determine full-close valve position
Close the valve completely using the handwheel. Observe rotational direction of
adjusting shaft (3) during closing. Once the valve is closed, open it several turns
(counterclockwise) to prevent overtravel.
Repeat steps 2 thru 5 for LVC limit valve.
Figure 5
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
16
Setting Travel Limit Valves
Installation, Operation and Maintenance Manual
Set Opening Value
Operating
Point
Part Number: E7K-400-0413
Section 10: Setting Torque Limit Valves
Section 10: Setting Torque Limit Valves
Torque limit valves prevent mechanical overload in the Closed (TVC) and Open (TVO) positions.
The torque limit valves are mounted in a stacked conguration. The top torque limit valve
(TVO) controls the actuator opening torque and the bottom limit valve (TVC) controls the
actuator closing torque.
Refer to the EIM Job Specication Sheet supplied with each actuator to review the customer-
provided valve torque requirement shown at the top of the sheet. The bottom of the
specication sheet shows numerous torque switch dial settings relative to output torque trip
point limits. All actuators are shipped from the factory at minimum torque dial setting unless
otherwise specied by customer.
NOTE:
Closing torque limits for torque-seated valve applications are factory set.
NOTE:
The customer supplied torque values on EIM Job Specication Sheets already includes a safety
factor.
April 2013
10.1 Opening Torque
Using the handwheel, open the valve completely while observing the Torque Dial rotation for a
reference operating point.
Figure 6
Refer to the EIM Job Specication Sheet for additional suggested setpoints. Determine
appropriate setpoint and press down on the TSO dial indicator approximately 1/16” with a at
blade screwdriver and position the arrow for the desired setting. Release to secure in place.
Partially open the valve and reseat with the Handwheel to ensure the set point is accurate.
Setting Torque Limit Valves
17
Section 10: Setting Torque Limit Valves
April 2013
10.2 Closing Torque
Using the handwheel, close the valve completely while observing the Torque Dial rotation for a
reference operating point.
Figure 7
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0913
Set Closing Value
Refer to the EIM Job Specication Sheet for additional suggested setpoints. Determine
appropriate setpoint and press down on the TSC dial indicator approximately 1/16” with a at
blade screwdriver and position the arrow for the desired setting. Release to secure in place.
Partially open the valve and reseat with the Handwheel to ensure the set point is accurate.
18
Setting Torque Limit Valves
Installation, Operation and Maintenance Manual
LSC
LSO
ETS 1
Part Number: E7K-400-0413
Section 11: Limit Switch and Wiring Information
Section 11: Optional Electric Limits
11.1 General Information
Two optional limit switches are available for Series 2000LP pneumatic actuators, one for open
position (LSO) and one for the close position (LSC) – see Figure 8.
The 12 point electrical terminal strip (ETS) for customer connection is mounted on the
backplate - see Figure 8.
Figure 8
April 2013
Limit Switch and Wiring Information
Limit switches LSO and LSC are mounted to a bracket located on top of the limit valves. They
are actuated by the same cam that actuates the limit valves and may be independently
adjusted by loosening the mounting screws (1) and repositioning the switch in the slotted
mounting bracket.
NOTE:
Electrical limit switches cannot be installed if auxiliary pneumatic limit valves are required.
19
Section 11: Limit Switch and Wiring Information
April 2013
Installation, Operation and Maintenance Manual
11.2 Standard Wiring Diagram
Limit switches are supplied with a potted exible connecting cable containing four wire leads;
one blue lead, one black lead, one brown lead and one gray lead. These leads are factory
prewired to the terminal strip (ETS) for each end of travel limit – see Figure 9.
NOTE:
When provided, solenoids will be wired to terminals 9, 10, 11 and 12, as shown in Figure 9.
Table 4. Rated Switching Capacity
AC DC
Resistive Inductive Resistive Inductive
400V 3A 2A
250V 5A 3A 0.4A 0.03A
30V 7A 5A 7A 5A
Part Number: E7K-400-0913
Figure 9
20
NOTE:
Limit switches are always wired to terminals #1 through #8 as shown, even when solenoids are
not provided.
Limit Switch and Wiring Information
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Section 12: Typical Control Package
Section 12: Typical LP Control Package
April 2013
Typical Control Package
21
Section 13: Manual Control Schematic
April 2013
Installation, Operation and Maintenance Manual
Section 13: Typical Control Diagram
Example One - Local Manual Control
Part Number: E7K-400-0913
22
Manual Control Schematic
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
Example Two - Double Acting Electric
Section 13: Manual Control Schematic
April 2013
Manual Control Schematic
23
Section 14: Gast Air Motor Information
April 2013
Installation, Operation and Maintenance Manual
Section 14: Gast Pneumatic Motor
The air motor supplied is a precision built rotary vane type. Internal components take up their
own wear & will last approximately 5 to 15 thousand hours of use. This depends on motor
speed, method of oiling, operating air pressure and plant preventative maintenance practices.
MOTOR SIZES
4AM 6AM 8AM 16AM
14.1 Installation
Install a moisture trap and lter in the air line ahead of the actuator’s air motor. For efciency
of output and speed control, use air lines the same size or in the next pipe size larger than the
intake port of the motor.
Part Number: E7K-400-0913
The motors are piped up to work equally well in both directions of operation. The control valve
makes reversing possible (refer to typical control diagram).
When coupling or connecting the motor to a driven member, avoid any end or side thrust on
the motor shaft. Do not hammer on the shaft itself.
14.2 Lubrication
Lubrication is necessary for all internal moving parts and rust prevention. An auto-matic air line
lubricator must be installed in the air line just ahead of the air motor. The lubricator should
be adjusted to feed one drop of oil for every 50 – 75 SCFM of air going through the motor. Oil
specications can be found in the Pneumatic Hookup section of this manual.
Excessive moisture in the air line can cause rust formation in the motor and might also cause ice
to form in the mufer due to expansion of air through the motor.
The moisture problem can be corrected by installing a moisture separator in the line & by
installing an aftercooler between the compressor and air receiver.
14.3 General Information
The air motor is designed to be driven by compressed air. Under no circumstances should it
be driven by uids, particles, solids or any substance mixed with air, particularly combustible
substances likely to cause an explosion.
24
WARNING:
Do not drive with ammable or explosive gases.
WARNING:
Do not allow corrosive gases or particulate material to enter the motor. Water vapor, oil-based
contaminants, or other liquids must be ltered out.
Gast Air Motor Information
Installation, Operation and Maintenance Manual
Part Number: E7K-400-0413
14.4 Servicing
If the motor is sluggish or inefcient, try ushing with an approved solvent:
• To ush, disconnect air line and mufer, add several teaspoons or spray solvent directly
into the motor.
• Rotate the shaft by hand in both directions for a few minutes, reconnect the air line
and slowly apply pressure until there is no trace of solvent in exhaust air.
• Flush unit in a well ventilated area.
• Re-lubricate the motor with a squirt of oil in the chamber.
Section 14: Gast Air Motor Information
April 2013
Table 5. Air Motor Consumption (SCFM)
Gast Air Motor Information
8AM SHOWN ABOVE
Motor 60 psi 80 psi 100 psi
4AM 40 50 62
6AM 70 90 110
8AM 95 120 145
16AM 135 175 220
25
Section 15: Troubleshooting
April 2013
Installation, Operation and Maintenance Manual
Section 15: Troubleshooting
SYMPTOM PROBABLE CAUSE CORRECTION
No power to actuator Check Air Supply
MOTOR WILL NOT RUN
HANDWHEEL HARD TO TURN
VALVE ONLY OPENS OR CLOSES
PARTIALLY WITH MOTOR
TORQUE VALUE IS CORRECTLY SET, BUT
ACTUATOR TORQUES OUT IN
MID-TRAVEL
HANDWHEEL WILL NOT OPERATE VALVE
MOTOR RUNS BUT WILL NOT OPERATE
THE VALVE
MOISTURE IN CONTROL ENCLOSURE
GREASE [OIL] IN CONTROL ENCLOSURE
Low Air Pressure – Filter is clogged in
power or control circuit or
Motor Vanes are Worn Check worn motor vanes
Valve stem improperly lubricated Lubricate with grease
Actuator lubrication has broken down
Valve Packing Gland too tight Loosen packing gland nuts
Drive Sleeve Bearing Failure Replace bearing
Jammed Valve Refer to Valve Maintenance
Torque Setting too Low Check setting & recalibrate
Limit Improperly Set Check actuation & reset
Damaged or bent valve stem Refer to Valve Maintenance
Valve Packing too Tight Refer to Valve Maintenance
Jammed Valve (obstruction in line) Refer to Valve Maintenance
Handwheel shaft bearing assembly
malfunction
Sheared gear key or stripped gearing Replace
P/S shifter in wrong position or malfunc-
tioning
Broken Handwheel shaft Repair or replace
Broken valve stem or stripped stem nut Replace as required
Motor Bearing assembly malfunction Repair/Replace
Sheared gear key [fastener, pin] Replace
Stripped gearing Replace
Broken valve stem or stripped stem nut Repair/Replace
Leakage through conduit entry Tighten all conduit plugs
Enclosure is not correctly sealed Inspect & replace o-ring
Pressure relief tting not installed Install pressure relief tting
Bad Torque Limit or Gear Limit assembly Replace assembly
Bad Torque Limit or Gear Limit seal Replace seal
Part Number: E7K-400-0913
Clean or replace lter
Clean out old grease and replace with
new
Repair or replace
Shift into proper position
Replace parts as required
26
Troubleshooting
Contact Us: Emerson Process Management, Valve Automation facilities at your nearest location:
NORTH & SOUTH AMERICA
13840 Pike Road
Missouri City, Texas 77489 USA
T +1 800 679 1561 (Toll Free USA)
T +1 281 499 1561
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Shanghai 201206
P.R.China
T +86 21 2892 9000
F +86 21 2892 9001
Please visit our web site for up to date product data.
www.EmersonProcess.com/EIM.
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