Flowserve 72 User Manual

Worcester Controls

Worcester Controls Series 72 actuators are electro-hydraulic quarterturn valve actuators. 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.

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. All units feature a normally open solenoid valve which returns the actuator to its initial position when power is lost to the actuator.

a WARNING: Series 72 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.

CAUTION: 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, radiation 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.

INSTALLATION

NOTE: The Series 72 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.

Actuators 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 72 actuator body, ONLY the proper length screws supplied with the mounting kit should be used. For small topmount 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. 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.

1. Valve Models Top-Mount 44 (

4"–2"), 45 (2

2"–4"), 51/52

(

2"–4"), 151/301 (3"–4"), Top Mount 59 (

4"–3"), WK70, WK74

and H71 (

2"–2"), 818/828 (2"–3"), 82/83 (

2"–3"), 94 (

2"–4"):

NOTE: For above listed valves, it is not necessary to remove any valve body bolts or remove valve from line in order to mount actuator.

a. 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.

WCAIM2049

(Part 18960)

Series 72 “Electri-SAFE” On/Off Operation Including CLC Option

Installation, Operation and Maintenance Instructions

2 Series 72 “Electric-SAFE” On/Off Operation Including CLC Option WCAIM2049

Flow Control Division

Worcester Controls

b. For

4"–2" 44,

2"–2" WK70 & WK74,

4"–1

2" 59 and

2"–1

2" H71 series top-mount style valves and

2"–2"

51/52 and

2"–1

2" 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 valves, and

valves 3" and larger with square stem, remove handle assembly, retaining nut, stop and stop screws. Replace with valve stem spacer or, if valve has graphite stem packing, with two Belleville washers, 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.

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"–4" 94 & 2"–3" E818/828 valves, remove handle assembly, stop, and spacer (if any). Do not remove gland plate or gland bolts.

For 2"–3" 818/828 valves, remove handle assembly, locking plates and hardware, and stop screw (if any). Do not remove stop plate.

c. Center coupling on valve stem.

d. Lower mounting bracket/actuator assembly over coupling

and onto valve, making sure that male actuator shaft engages slot in coupling.

e. Secure bracket to valve using cap screws and

lockwashers, or bolts and nuts provided in mounting kit. Tighten securely. For small top-mount style valves, bracket nameplate will be to side of valve.

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

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

Fail-Safe 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, invert actuator and cross-line mount actuator to pipe line.

For “FAIL-OPEN” in-line operation, 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.

For “FAIL-OPEN” cross-line operation, rotate the valve ball and stem 90°, so coupling lines up with actuator shaft. Mount actuator cross-line to pipe line.

g. Determine position indication. Buttons on position

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

1. Check which visual indication is required.

2. Check that indicator, when located on actuator shaft, will show correct indication.

3. To change indication, push out (remove) red and white buttons and reassemble in opposite positions.

4. Locate indicator on actuator shaft flats. Press firmly until location nibs snap into recess on actuator shaft.

ELECTRICAL INSTALLATION

AC Electrical Supply (on/off models with one integral solenoid):

With assembly complete to this point, it is convenient to make conduit connections and bring wiring through enclosure. It should be noted that the successful use of this device in hazardous atmospheres or other detrimental environments depends on proper conduit construction techniques.

The solenoid coil wattage and required amperage is as follows:

Voltage Holding Amps* Watts

120 VAC 50/60 HZ .2 10

240 VAC 50/60 HZ .1 10

*Inrush is 80% greater than Holding values on AC solenoids.

A. Remove limit switch cover and gasket.

B. Attach power supply wires to terminal strip locations 7 and 8 per

the wiring diagram shown below and also located on the inside of the limit switch cover.

NOTE: All wiring to terminal strip should be inserted only to midpoint of strip.

C. Attach the ground wire to the customer’s green grounding screw

located on the limit switch casting flange face.

WCAIM2049 Series 72 “Electric-SAFE” On/Off Operation Including CLC Option 3

DC Electrical Supply (on/off models with one integral solenoid):

The solenoid coil wattage and required amperage is as follows:

Voltage Holding Amps Watts

24 VDC .45 10

A. Remove limit switch cover and gasket.

B. Attach power supply wires to terminal strip locations 7 and 8 per

the wiring diagram shown on previous page and also located on the inside of the limit switch cover.

NOTE: All wiring to terminal strip should be inserted only to midpoint of strip.

C. Attach the ground wire to the customer’s green grounding screw

located on the limit switch casting flange face.

AC Electrical Supply (CLC models with two integral solenoids):

Control solenoid wattage for 120 VAC and 240 VAC is 6 watts.

The failsafe solenoid coil wattage and required amperage is as follows:

Voltage Holding Amps* Watts

120 VAC 50/60 Hz .2 10

240 VAC 50/60 Hz .1 10

*Inrush is 80% greater than Holding values on AC solenoids.

A. Remove limit switch cover and gasket.

B. Attach power supply wires to terminal strip locations 7 and 8 per

the wiring diagram shown below and also located on the inside of the limit switch cover.

NOTE: All wiring to terminal strip should be inserted only to midpoint of strip.

C. Attach the ground wire to the customer’s green grounding screw

located on the limit switch casting flange face.

Flow Control Division

Worcester Controls

DC Wiring

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