Flowserve 10 ACCESS User Manual

DESCRIPTION

Worcester Controls/McCANNA ACCESS I and M Series 39 actuators are pneumatic quarter-turn valve actuators. The solenoid and limit switches for the ACCESS I are integral to the actuator end cap, while the ACCESS M is a separate factory-mounted enclosure containing the solenoid and limit switches. The design utilizes a double-rack, single-pinion concept, with each rack integrally cast to a piston. Both pistons are supported and centered by large, stainless steel guide rods. In double-acting units, both pistons are pressurized on both strokes of the actuator. Ambient temperature range of ACCESS unit is 0°F minimum to 160°F maximum.

Standard units feature an extended top shaft for manual override capabilities and a completely modular design which allows simple attachment of a variety of accessories. The units feature a control block (with spool valve) which properly directs supply air to the actuator. The control block provides independently adjustable speed control for both opening and closing strokes of the actuator on double-acting units, and for the closing stroke on spring-return units (standard mounting configuration). The units can also be supplied with an air connection block (in place of control block) for when there is no solenoid valve integral with unit.

a WARNING: SERIES 39 ACTUATORS ARE ELECTRO-MECHANICAL DEVICES SUBJECT TO NORMAL WEAR AND TEAR. ACTUATOR LIFE IS DEPENDENT UPON APPLICATION AND ENVIRONMENTAL CONDITIONS. IF APPLIED IN HAZARDOUS SERVICES, SUCH AS BUT NOT LIMITED TO MEDIA TEMPERATURE EXTREMES, TOXINS, FLAMMABLES, OR OTHER SERVICES WHERE IMPROPER OR INCOMPLETE OPERATION COULD PRODUCE A SAFETY HAZARD, IT IS INCUMBENT UPON THE SYSTEM DESIGNER AND THE USER TO PROVIDE PROPER WARNING DEVICES SUCH AS TEMPERATURE SENSORS, OXYGEN SENSORS AND FLOW SENSORS. FLOWSERVE ALSO RECOMMENDS THAT THE INTEGRAL LIMIT SWITCHES BE USED FOR MONITORING AND/OR ELECTRICAL INTERLOCK.

CAUTIONS: When actuator is installed in outdoor conditions, water can enter the exhaust hole(s) of the control block or air connection blocks, and then freeze. Flowserve suggests a cover be used, or mount the actuator such that the block exhaust hole(s) will not fill with water.

Flowserve recommends that all products which must be stored prior to installation be stored indoors, in an environment suitable for human occupancy. Do not store product in areas where exposure to relative humidity above 85%, acid or alkali fumes, radia tion above normal background, ultraviolet light, or temperatures above 120°F or below 40°F may occur. Do not store within 50 feet of any source of ozone.

IMPORTANT: INCLUDED IN ALL 39 ACTUATOR ACCESSORY AND REPAIR KITS IS A REBUILD/ACCESSORY ADDITION LABEL, WHICH IS TO BE MARKED WITH A PERMANENT MARKER AND THEN APPLIED TO THE ACTUATOR AFTER AN ACCESSORY KIT HAS BEEN INSTALLED OR AN ACTUATOR HAS BEEN REPAIRED.

All ACCESS M units have four threaded tamper proof plugs installed over the enclosure mounting machine screws. No attempt should be made to remove these plugs. If it becomes necessary to remove enclosure from actuator end cap, consult Flowserve.

INSTALLATION

NOTE: The Series 39 actuator is normally installed with its major axis parallel to the pipe line (this is mandatory when mounting actuator to 90° V1 diverter/three-way (D44 & T44) valves and CPT valves. The actuator can be oriented above, beside or beneath the valve without affecting its operation.

Sizes 10–35 Rev. R6 actuators may come with an ISO locating ring used for optional ISO mounting.

A. Determine mode of operation desired (normally open or normally

closed) of the valve.

B. Determine desired quadrant for bracket attachment and direction

of mounting of actuator (in-line or cross-line).

C. Attach mounting bracket to actuator using four (4) cap screws

and lockwashers provided in mounting kit. To avoid any damage to the Series 39 actuator body, ONLY the proper length screws supplied with the mounting kit should be used. For

4"– 2" top-

mount style valves, attach bracket such that bracket nameplate will be to side of valve.

For mounting to 818/828 Series valves insert ISO locating ring into groove on bottom of actuator before attaching to bracket.

FCD WCAIM2028-01

(Part 15908)

Worcester Controls 10, 15, 20 ACCESS I and 10-40 ACCESS M 39 Actuators Intrinsically Safe

Installation, Operation and Maintenance Instructions

2 10, 15, 20 ACCESS I and 10-40 Access M 39 Actuators Intrinsically Safe WCAIM2028

NOTE: Ring can be permanently held in groove by applying Loctite to ring before inserting in groove.

D. Attach bracket/actuator assembly to valve as follows:

CAUTION: Ball valves can trap pressurized media in the cavity. If it is necessary to remove any valve body bolts, stem nuts, or remove valve from the line, and if the valve is or has been in operation, make sure there is NO pressure to or in the valve and operate valve one full cycle. However, the valves listed below do not require the removal of any valve body bolts or removal of valve from line in order to mount actuator.

1. Rotate valve ball and stem to position necessary to achieve desired operation. If any valve information is marked on stop plate or handle, it will be necessary to transfer this information to the bracket nameplate

2. For

4"– 2" 44, and

2"– 2" WK70/WK74,

4"–1

2" 59 and

2"–1

H71 Series top-mount style valves and

2"– 2" 51/52,

2"–1

82/83 Series valves with high-cycle stem packing as standard, remove handle nut, lockwasher, handle, separate stop plate (if any), retaining nut and stop pin(s). Add the two additional Belleville washers with their larger diameter sides touching each other. Add the self-locking nut to the stem and tighten while holding the stem flats with wrench. Tighten until Belleville washers are flat, the nut will “bottom”, and then back nut off

3 of a turn. The two additional Belleville washers

and the self-locking nut are included in the mounting kit.

CAUTION: The self-locking stem nut is difficult to tighten, and must fully flatten Belleville washers before backing off.

For 2" 59, H71, 82/83, and 2

2" 45, 82/83 series valves, and

valves 3" and larger with square stem, remove handle assembly (if any), retaining nut, stop and stop screws. Replace with valve stem spacer or, if valve has graphite stem packing, with two Belleville washers (except 8", 10" 82/83 and 10" 51/52), and replace retaining nut.

NOTE: Belleville washers are installed with their larger diameter sides touching each other. Do not use stem spacer when Belleville washers are used. Using a wrench to prevent stem from turning, tighten retaining nut until stem packing is fully compressed or Bellevilles, if used, are fully flattened, then back off nut

6 turn. Excessive tightening causes higher

torque and shorter seal life.

NOTE: Large valves with V51 high-cycle stem packing option installed, identified by two Belleville washers installed and handle assembly, stop and stop screws removed, and 818/828 Series Valves do not require stem area disassembly.

For

2"– 2" 94 valves, remove handle (if any). Do not remove

gland plate or gland bolts.

For 3" and larger 94 and 2" and larger E818/828 valves, remove handle assembly, stop, and spacer (if any). Do not remove gland plate or gland bolts.

For 2" and larger 818/828 valves, remove handle assembly, locking plates and hardware, and stop screw (if any). Do NOT remove stop plate (2"– 6" sizes) or spacer (8" size).

3. Center coupling on valve stem.

4. Lower mounting bracket/actuator assembly over coupling and onto valve, making sure that male actuator shaft engages slot in coupling.

5. Secure bracket to valve using cap screws and lockwashers, or bolts and nuts provided in mounting kit. Tighten securely. For

2"– 2" top mount style valves, bracket nameplate will be to

side of valve.

Install set screws (if any) in the coupling and tighten securely.

6. Determine if mode of operation is as desired; if not:

a. Double-Acting Actuators

- Mount the actuator 90° from normal mounting (see last paragraph in D.6.b for size 25 and larger actuators). On 10–20 sizes, the actuator may also be inverted, yielding the opposite mode.

b. Spring-Return Actuators

- The normal method of mounting is to have the actuator in line with the pipe line and the valve and actuator in the FAIL-CLOSED position.

For FAIL-CLOSED cross-line operation with 10–20 sizes, invert actuator and cross-line mount actuator to pipe line.

For FAIL-OPEN in-line operation with 10–20 sizes, invert actuator. (NOTE: If in-line coupling is used, actuator does not need to be inverted). Rotate the valve ball and stem 90°, so coupling lines up with actuator shaft. Mount actuator in line with the pipe line. See Electrical Connection Section for proper wiring information.

For FAIL-OPEN cross-line operation with 10–20 sizes, rotate the valve ball and stem 90°, so coupling lines up with actuator shaft. Mount actuator cross line to pipe line. See Electrical Connection Section for proper wiring information.

On sizes 25 and larger double-acting and spring-return actuators the output shaft is square. This allows selection of either mode of operation by indexing the coupling (including valve ball and stem) 90° to the actuator shaft, while keeping the actuator in an in-line orientation. Crossline mounting, if desired, requires a special bracket, except for the 818/828 Series valves.

7. Determine position indication. Buttons on position indicator are set up to show valve closed on in-line mounting, i.e., pistons together in actuator. If different indication is required:

a) Check which visual indication is required.

b) Check that indicator, when located on actuator shaft, will

show correct indication.

c) To change indication, push out (remove) red and white

buttons and reassemble in opposite positions (this step is only necessary on 10–20 sizes).

d) Locate indicator on actuator shaft flats. Press firmly until

location nibs snap into recess on actuator shaft.

Flow Control

Worcester Controls

WCAIM2028 10, 15, 20 ACCESS I and 10-40 Access M 39 Actuators Intrinsically Safe 3

AIR SUPPLY AND ELECTRICAL INSTALLATION

A. 1. Air Supply:

The Series 39 Actuator is factory lubricated. For optimum operation, the use of filtered and lubricated air is recommended.

2. Air Supply Pressure: Intrinsically Safe versions of double-acting actuators require 40–100 psig supply air. Spring-return actuators require 80–100 psig supply air. Spring-return actuators can also be set up to operate on supply air pressures ranging from 40–80 psig by using fewer springs. See “Rebuilding Instructions”, Spring-Return Actuator, for proper number and location of springs for reduced supply air pressures.

3. Air Supply Connection: Connect air supply to

4" NPT connection on control block. For

units with no integral solenoid valve, air connection block has two

4" NPT connections for inlet air (only one used for

spring-return units).

4. Recommended Tubing Sizes: In order to provide sufficient flow of supply air to the Series 39 actuator, the following tubing sizes are recommended:

Actuator Size Runs Up To 4 ft. Long Runs Over 4 ft. Long

10, 15, 20, 25

30 and larger

5. Air Consumption: The following chart shows the amount of pressurized (80 psig) air consumed per stroke in cubic feet. To determine the total amount of air consumed per complete cycle for doubleacting actuators, simply add the volumes for both the opening and closing strokes together; for spring-return units, the total volume of air consumed is the volume shown for the opening stroke.

Actuator Size

Stroke 1039 1539 2039 2539 3039 3339 3539 4039

Open .04 .08 .16 .28 .43 .65 .90 1.26 Close .05 .09 .17 .30 .47 1.10 1.27 1.43

6. Electrical Supply: Make electrical connections in accordance with the wiring diagram on the inside of cover or appropriate wiring diagram in Section B.4.

7. Switch Ratings: 1 amp, 125 VAC

B. ELECTRICAL CONNECTION:

The intrinsically safe versions of the ACCESS I and ACCESS M will be intrinsically safe when connected through CSA Certified zener barriers rated 28 volts DC maximum, 300 ohms minimum (for SW-1 and SW-2 only; refer to paragraph 4 of this section for intrinsically safe wiring of solenoid), as shown in the wiring diagrams (Figure 2) below.

IMPORTANT: Shielded cable must be used for each intrinsically safe circuit (Switch circuits and solenoid circuit) and for zener barriers, the shield must be connected to a zener barrier ground.

1. The “standard” mounting configuration of the 39 actuator to the valve is in-line, fail-closed. In this configuration, SW-2, as described in the wiring diagram and part 3, will give indication when the actuator is in the closed position, or CW limit of rotation. SW-1 gives indication of the open position, or CCW limit of rotation (refer to the appropriate wiring diagram in figure 2).

NOTE: The CW or CCW rotation of the actuator shaft is determined when viewing the actuator from the nameplate side of the actuator while being able to read the nameplate from left to right.

2. Fail open configuration for sizes 10–20 may be obtained by either inverting the actuator, using in-line coupling, or mounting the actuator cross-line. For sizes 25 and larger the coupling (including valve ball and stem) must be indexed 90° to the actuator shaft. Refer to Installation Section D.6.b. In these cases, SW-1 and SW-2 indication will be reversed from the above but actuator rotation will vary, depending on which fail-open mounting is used, and wiring shall be done per the appropriate wiring diagram in figure 3.

Flow Control

Worcester Controls

Figure 1

Figure 2

4 10, 15, 20 ACCESS I and 10-40 Access M 39 Actuators Intrinsically Safe WCAIM2028

3. Switches have been factory adjusted, but should be rechecked after installation. Adjustment is as follows:

a) Switch adjustment for “standard” mounting:

With actuator mounted in “standard” mounting configuration (see Step 1) set actuator in full-closed position with the adjustment screw near its loose limit. Adjust closed position switch SW-2 (see Wiring Diagram) by tightening the adjustment screw until switch contacts click. Then tighten adjustment screw one additional turn. With air supply to actuator, energize solenoid, if applicable, cycle to the full-open position and adjust open position switch SW-1 in the same manner.

b) Switch adjustment for FAIL-OPEN mounting:

With actuator mounted in FAIL-OPEN mounting configuration (see Step 2) set actuator in full-open position with the adjustment screw near its loose limit. Adjust open position switch SW-2 (see Wiring Diagram) by tightening the adjustment screw until contacts click. Then tighten adjustment screw one additional turn. With air supply to actuator, energize solenoid, if applicable, cycle to the fullclosed position and adjust closed position switch SW-1 in the same manner as SW-2.

4. Wiring instructions for solenoid and/or limit switches: The Intrinsically Safe solenoid valve used in the ACCESS is designed to operate on power levels compatible with Intrinsic Safety requirements. They are Factory Mutual (FM) approved for Class I, II and III Groups A, B, C, D, E, F, and G applications. Entity Approval #OT4A6.AX (NFPA 493; July 19,

1990).

NOTE 1: For barrier interconnection, refer to maximum barrier output parameters as referenced on the specific barrier Installation drawing. Connect as follows:

a) V max > Voc of single or Vt of dual channel barrier.

b) I max > Isc of single or It of dual channel barrier

c) Ci + field wiring < Ca of single or dual channel barrier

d) Li + field wiring < La of single or dual channel barrier

For current and wattage values at various input voltages see table below.

Input Voltage Current Wattage

15.5 VDC 43 mA .7 24 VDC 68 mA 1.63 35 VDC 95 mA 3.3

Make electrical connections in accordance with the appropriate wiring diagram on inside of cover or the appropriate diagram in figure 3:

NOTE 2: Installation of Intrinsically Safe Systems is to be done in accordance with Canadian Electrical Code, Part 1 and National Electrical Code, Chapter 1.

DEFINITIONS:

Ca-Maximum Allowed Capacitance Li-Maximum Internal Inductance

Ci-Maximum Internal Capacitance Voc-Maximum Output Voltage

I max-Maximum Input Current V max-Maximum Input Voltage

Isc-Maximum Output Current Vt-Voltage Total

La-Maximum Allowed Inductance

Flow Control

Worcester Controls

Figure 3

FAIL-CLOSED

(Sizes 10–40 in-line operation)

(Sizes 10–20 in-line, inverted operation)

FAIL-OPEN

(Sizes 25–40 cross-line operation)

WCAIM2028 10, 15, 20 ACCESS I and 10-40 Access M 39 Actuators Intrinsically Safe 5

Flow Control

Worcester Controls

Figure 3 continued

FAIL-CLOSED

(Sizes 10–20 cross-line, inverted operation)

FAIL-CLOSED

(Sizes 10–40 in-line operation)

(Sizes 25–40 cross-line operation)

No solenoid

FAIL-OPEN

(Sizes 10–20 cross-line operation,

or with in-line coupling)

(Sizes 25–40 in-line operation)

FAIL-OPEN

(Sizes 10–20 in-line, inverted operation)

No solenoid

FAIL-CLOSED

(Sizes 10–20 cross-line,

inverted operation)

No solenoid

(Sizes 10–20 cross-line operation,

(Sizes 25–40 in-line operation)

SOLENOID/NO SWITCHES

FAIL-OPEN

or with in-line coupling)

No solenoid

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