Elkhart Brass 70133000 User Manual

70117000 & 70133000 Electric Valves

Industrial Electric Actuated Butterfly Valves

Installation, Operating, and Maintenance Instructions

98378000 REV. A

1302 WEST BEARDSLEY AVENUE  P.O. BOX 1127  ELKHART IN 46515  [phone]  FAX [phone]

© 2013 ELKHART BRASS MFG. CO., INC.

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Part 1

Keystone EPI2 Quarter-turn Electric Actuators

Instruction and Operation Manual

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INDEX

I. PRODUCT SAFETY 4

 System Information
 Manufacturer
 Intended Use
 Terms and Conditions
 Manufacturer’s Liability

II. OVERVIEW 6

 General
 Principle of Operation
 Electrical Operation
 Manual Operation
 Component Description

III. STORAGE AND PRE-INSTALLATION 8

 Checks to be Carried out when the Actuator is Received
 Storage Procedure

IV. INSTALLATION 10

 Checks to make Prior to Installation
 Environmental
 Coupling Block
 Installation of the Actuator onto a Valve
 Manual Operation
 Setting the Mechanical Stops
 Electrical Connections
 Removal of the Terminal Board Enclosure
 Field Wiring Terminations
 Cable/Conduit Entries
 Safety Instructions for Installation in Hazardous Area

V. LUBRICATION 19

 Lubrication Inspection

VI. ACTUATOR SETTING AND CONFIGURATION 19

 Removal of the Control Unit Cover
 Actuator Setup

VII. MAINTENANCE AND TROUBLESHOOTING 24

 Maintenance
 Troubleshooting

VIII. PARTS LISTS AND DRAWINGS 26

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I PRODUCT SAFETY

Important: Before installing and operating this equipment, read and study this manual
thoroughly. Proper installation is essential to safe operation. In addition, the following points should
be adhered to in order to ensure the safety of equipment and personnel:

WARNING: The actuator must be electrically isolated prior to performing any disassembly or
reassembly.

WARNING: The electronic parts of the actuator can be damaged by a discharge of static
electricity. Before you start, touch a grounded metal surface to discharge any static electricity.

WARNING: It is assumed that the installation, calibration, commissioning, maintenance, and
repair of the actuator is carried out by a qualified and experienced personnel.

WARNING: Repair work, other than operations outlined in this manual, is strictly reserved to
qualified Tyco Valves & Controls personnel or authorized by the Company itself.

SYSTEM INFORMATION

SERIAL NUMBER:______________________________
DETAILS:_________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

MANUFACTURER

Manufactured to comply with Machinery Directive 98/37: BIFFI ITALIA as specified on the motor label.

INTENDED USE

The Keystone EPI2 electric actuators covered in this manual are designed to automate quarter-turn industrial
valves (ball, butterfly, plug, and control valves) or dampers.

Tyco Valves and Controls is not liable for possible damage or physical injury resulting from the misuse or
improper installation, operation, adjustment, and maintenance of the actuator. Those risks lie entirely with the
user. Additional precautions may be required for certain applications.

As Tyco Valves and Controls has no direct control over particular applications, operation or maintenance
conditions, it is the operator’s responsibility to comply with all applicable safety rules.

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Please inform Tyco Valves and Controls immediately if an unsafe situation not covered by this IOM is
encountered. It is the sole responsibility of the operator to ensure that all local health and safety regulations are
adhered to.

The noise emitted by the Keystone EPI2 actuators during normal operation is less than 40 dB (A) with a peak
value equal to 85 dB (C). Standard references: ISO 11202 (1st edition, 1995-2-15).

TERMS AND CONDITIONS

Tyco Valves & Controls guarantees each single product to be free from defects and to conform to current
specifications. The warranty period is one year from the date of installation by the original user, or eighteen
months from the date of shipment to the original user, whichever occurs first. No warranty is given for products
which have been subject to improper storage, improper installation, misuse, corrosion, or that have been
modified or repaired by unauthorized personnel.

Repair work necessary to repair improper use will be charged at standard rates.

MANUFACTURER’S LIABILITY

Tyco Valves & Controls and Elkhart Brass assumes no liability for:

 Use of the actuator in direct contravention of local safety at work rules
 Incorrect installation, improper application or disregard of the instructions provided on the actuator

nameplate and in this manual.

 Modifications without the authorization of Tyco Valves & Controls
 Work performed on the actuator by unqualified personnel

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II OVERVIEW

GENERAL

The EPI2 is an electric quarter-turn actuator suitable to operate a valve or damper.

PRINCIPLE OF OPERATION

The electric motor drives an epicyclical gear train via a spur reduction. The epicyclical gear train has a single
compound planetary gear which meshes with two internally toothed gears, one being the fixed annulus and the
other being the output gear. The fixed annulus gear has external helical teeth meshing with a transversely
mounted worm gear, thus locking the annulus into a fixed position. The worm gear can drive the annulus;
eliminating the need for a declutch mechanism to enable manual operation.

Actuator position is controlled with a position sensor directly coupled to the actuator’s output drive.

ELECTRICAL OPERATION

Clockwise or counter-clockwise rotation may be selected during actuator setup.
An open or close electrical command will cause the actuator to move to the extreme end of travel or to a
partial position.

Control system details are shown in the specific wiring diagram.

MANUAL OPERATION

Manual operation can be utilized when there is no power to the actuator or during initial actuator setup and
calibration. The manual operating device is completely independent of the motor drive and can be operated at
any time (even during electrical operation) without endangering the actuator. The handwheel does not rotate
during electrical operation.

To close the valve, turn the handwheel clockwise.
To open the valve, turn the handwheel counter-clockwise.
If the handwheel is used during electrical operation an alarm is set and the actuator will stop.

Important: The standard direction of rotation for the handwheel is clockwise (CW) to close.

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COMPONENT DESCRIPTION

The actuator consists of five (5) main parts:

 Base Flange: Actuator to valve or damper interface
 Terminal Enclosure: Power and signal connections through four (4) available cable entries
 Mechanical Gearing: Internal epicyclical gear reduction
 Control Unit: Integral controls unit inclusive of electric motor, motor controls, electronic

power, and logic card

 Manual Override: Manual operation is used in the event of a loss of power or during setup

and calibration

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III STORAGE AND PRE-INSTALLATION

CHECKS TO BE CARRIED OUT WHEN THE ACTUATOR IS RECEIVED

Check that the information on the nameplate (Model, Serial Number, Nominal Torque, Nominal Voltage
range, Protection Degree, Operating Speed range, Protection Class, etc.) is correct for the application.

Check that the actuator was not damaged during shipment: in particular, inspect the local position indicator
area glass. If necessary, repair all damages to the exterior coating, etc.

STORAGE PROCEDURE
General – The base version actuator is weatherproof to NEMA 4, 4X, and IP 66/68. The actuators must be

properly installed or properly prepared for storage to maintain this rating.

The standard plastic plugs provided on cable entries are not weatherproof, and must be replaced prior to
installation or storage.

Storage for less than 1 year:

Indoor Storage:

- Ensure the actuators are kept in a dry place, stored on a wooden pallet (not directly on the floor

surface) and protected from dust.

- In very humid environments, a moisture absorbent desiccant packet should be used in the motor

enclosure. (Desiccant is not included in the actuator package).

Outdoor Storage:

- Ensure the actuators are protected from the direct exposure to the elements (use a canvas tarp or

similar)

- Store the actuators on a wooden pallet, or some raised platform, so the they are not in direct contact

with the ground, and protected from dust.

- For humid environments, a moisture absorbent desiccant packet should be used in the motor

enclosure. (Desiccant is not included in the actuator package)

- Remove the plastic conduit plugs from the conduit entries and replace with weatherproof plugs

appropriate for the environmental conditions.

Storage for more than 1 year:

Indoor Storage:

- All of the indoor storage instructions from the less than 1 year section above.

- Remove the plastic conduit plugs from the conduit entries and replace with weatherproof plugs

appropriate for the environmental conditions.

- Coupling parts (Mounting flange, etc.) must be coated with a protective oil or grease.

- If possible, blank off the flange with a protective disk.

Outdoor Storage:

- All of the outdoor storage instructions from the more than 1 year section above.

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- If the actuators are supplied with standard plastic plugs, replace them with weatherproof (metal)

plugs

- Coupling parts (Flange, etc.) must be coated with a protective oil or grease

- If possible, blank off the flange with a protective disk

- Inspect the condition of the terminal enclosure and the terminal board to ensure there has been no

ingress of foreign materials (dust or moisture)

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IV INSTALLATION

Valve Size

4”

8”

Actuator

EPI 2-E013

EPI 2-E025

Torque (in/lbs.)

1300

2500

Volts (AC)

120

240

120

240

Run Amps

1.10

0.70

1.60

0.95

Stall Amps

1.32

0.84

1.92

1.14

Weight (lbs.)

29

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CHECKS TO MAKE PRIOR TO INSTALLATION
To assemble the actuator onto the valve, proceed as follows:

- Check that the coupling dimensions of the valve flange and stem match the actuator’s coupling

dimensions.

- The electrical supply cables must be suitable for the power rating of the actuator (refer to the test

certificate delivered with the actuator, if available, or the actuator nameplate)

- Gather the necessary tools necessary to assemble the actuator to the valve and perform actuator setup.

- Lubricate the valve stem with oil or grease to facilitate assembly.

- Clean the valve flange. Remove anything that might prevent a perfect fit to the actuator flange,

especially all traces of grease or lubricant.

- Install the actuator onto the valve without forcing, using only the weight of the actuator. When the

actuator output shaft and the valve stem are connected, check that the holes of the valve flange match
the holes of the actuator mounting flange. If not, use the manual override to rotate the actuator until
the holes are aligned.

- Tighten the bolting evenly.

- If possible, operate the actuator with the handwheel to verify that it operates the valve smoothly.

If a long storage period has occurred, before installing the actuator:

- Check the status of the O-Ring seals.

- Check the installation of the plugs or cable connections on the cable entries.

- Check the integrity of enclosure covers.

SPECIFICATIONS

FM Approved: Class 1, Zone 1, AEx/Ex de IIB T5
Class II, Division 1, Groups E, F, & G
Class III, T4
NEMA 4, 4X, & 6 – IP66/68

Power Requirement: 120/240 VAC, 50/60 Hz., 1-Phase

Ambient operating temperature:

-40°C to +65°C (-40°F to +149°F) with 80% humidity

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COUPLING BLOCK
View of the base with one type of insert (only one insert is included with each actuator):

INSTALLAION OF THE ACTUATOR ONTO A VALVE

Move the valve to the full open position. Use the handwheel to move the actuator to the full open position
(verify with the local mechanical indicator) while checking that the rotation direction of actuator matches that
of the valve. The actuator should be mounted for counter-clockwise rotation to open and clockwise to close.

WARNING: Never lift the valve/actuator assembly without securing slings to both the valve and

the actuator.

The actuator can be installed onto the valve in two (2) different ways:

 Direct Mounting: Insert the valve shaft into the actuator bottom flange utilizing the proper

insert. Secure the actuator to the valve using the correct bolting.

 Bracket Mounting: Install the bracket and the adapter onto the valve then insert the valve shaft

into the actuator bottom flange, utilizing the correct insert. Secure the
actuator to the bracket using the correct bolting.

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MANUAL OPERATION

The actuator is supplied with a handwheel for manual override as standard, to operate the actuator in the event
of a loss of power, or during setup and calibration. The handwheel is always engaged. Then handwheel does
not rotate during electric operation. Turn the handwheel clockwise to close, and counter-clockwise to open.
Ensure proper direction of operation using the dial indicator on the actuator.

The reduction ratio of the handwheel is as follows:

 E006 and E013 - 73:1, handwheel turns to move 90 degrees - 18
 E025 and E051 - 91:1, handwheel turns to move 90 degrees - 23

WARNING: Do not use cheaters, valve wrenches, or similar tools on the handwheel. This can
cause personal injury and damage the equipment.

WARNING: Chain wheels cannot be used. This can cause personal injury and damage the
equipment.

Important: The standard handwheel operation is clockwise (CW) to open, and counter-clockwise
(CCW) to close.

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SETTING THE MECHANICAL STOPS
To set the actuator’s mechanical stops, proceed as follows:

- Loosen the locknuts on both stop screws.

- Rotate both stop screws counter-clockwise two (2) turns.

 Open Position: Move the actuator to the full open position. Rotate Stop Screw 1 one (1) turn

clockwise until it bottoms out, then rotate it counter-clockwise ½ turn.
Tighten the locknut by rotating it clockwise.

 Closed Position: Move the actuator to the full closed position. Rotate Stop Screw 2 one (1)

turn clockwise until it bottoms out, then rotate it counter-clockwise ½ turn.
Tighten the locknut by rotating it clockwise.

Using the handwheel, check that the travel of the actuator is correct. If the actuator stops before
reaching the end of travel (full open or full closed), proceed as follows:

- Rotate the Stop Screw counter-clockwise (CCW) while holding the locknut in position with a second

wrench. Manually move the actuator until the valve reaches the correct position. Re-tighten the
locknut.

If the actuator travels beyond the full range of valve travel (full open or full closed), proceed as follows:

- Rotate the Stop Screw clockwise (CW) while holding the locknut in position with a second wrench.

Manually move the actuator until the valve reaches the correct position. Re-tighten the locknut.