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CEA Series Limitorque Automax
User Manual
28 pgs1.9 Mb0

Flowserve CEA Series Limitorque Automax User Manual

USER INSTRUCTIONS
Limitorque Automax CEA Series
FCD AXENIM2080-00-AQ – (01/15)
Installation
Operation
Maintenance
Experience In Motion
2
Contents
1. Important Notes 5
2. Actuator Quick Start Guide for C-PRO and C-MOD Versions 5
2.1 Wiring Diagrams 7,8
2.2 Menu Tree 9
3. Installation and Operation 11
3.1 Flowserve Automax Valve Products 11
3.2 Electrical Installation and Adjustment 12
4. Calibration and Commissioning 12
4.1 Travel Stop Adjustment 12
4.2 Gear Train 13
4.3 Rotation Speed Control 13
4.4 Variable Torque Output 13
4.5 Duty Cycle 13
4.6 Heater and Thermostat 13
4.7 HMI Display 14
4.8 Programmable Parameters 15
4.9 Alarm Output Setup 20
4.10 Position Indicator 21
5. Manual Override 22
6. Performance and Technical Data 23
7. Actuator Troubleshooting Guide (Electrical) 24
8. Parts List 25
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Using Flowserve Valves, Actuators and Accessories
General Usage
The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Flowserve products. Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating or performing any maintenance.
In most cases Flowserve valves, actuators and accessories are designed for specific applications with regard to pressure, temperature and media. For this reason they should not be used in other applications without first contacting the manufacturer.
Terms Concerning Safety
The safety terms WARNING, CAUTION and NOTE are used in these instructions to provide additional information on important aspects of the CEA.
WARNING: indicates that death, severe personal injury and/or
a
substantial property damage can occur if proper precautions are not taken.
CAUTION: indicates that minor personal injury and/or property
a
damage can occur if proper precautions are not taken.
Qualified Personnel
Qualified personnel are people who, on account of their training, experience and instruction, and their knowledge of relevant standards, specifications, accident prevention regulations and operating conditions, have been authorized by those responsible for the safety of the plant and its employees to perform the necessary work and who can recognize and avoid possible dangers.
Installation
WARNING: Before installation, check the order number, serial
a
number and/or the tag number to ensure the actuator is correct for the intended application.
Do not insulate extensions that are provided for hot or cold
services.
Fire protection must be provided by the user.
Spare Parts
Use only original Flowserve spare parts. Flowserve cannot accept responsibility for any damages that occur from using spare parts or fastening materials from other manufacturers. If Flowserve products, like sealing materials, have been in storage for longer periods, check these for corrosion or deterioration before using. Fire protection for Flowserve products must be provided by the user.
Service/Repair
NOTE: provides additional technical information, which may not
be obvious even to qualified personnel.
Compliance with all other notes regarding transport, assembly, operation, maintenance and technical documentation is essential in order to avoid conditions or occurrences that might directly or indirectly cause severe personal injury or property damage.
Protective Clothing
Flowserve products are often used in dangerous applications (e.g. extremely high pressures, or with flammable, combustible, toxic or corrosive media). In particular, valves with bellows seals point to such applications. When performing service, inspection or repair operations, always ensure that the valve is depressurized, the actuator is powered off and that the valve has been cleaned and is free from harmful sub­stances. In such cases pay particular attention to personal protection (protective clothing, gloves, glasses, etc.).
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To avoid injury to personnel and damage to products, users must strictly adhere to safety terms. Modifying this product, substituting non-OEM parts, or using maintenance procedures other than outlined in this instruction could affect performance and be hazardous to personnel and equipment, and may void existing warranties. Between the actuator and valve, there are moving parts. To avoid injury, Flowserve provides pinch-point-protection in the form of cover plates, especially where side-mounted positioners are fitted. If these plates are removed for inspection, service or repair, the cover plates must be refitted after the work is complete.
In addition to the operating instructions and the obligatory accident prevention directives valid in the country of use, all recognized regulations for safety and good engineering practices must be followed.
WARNING: Before products are returned to Flowserve for repair
a
or service, Flowserve must be provided with a certificate which confirms that the product has been decontaminated and is clean. Flowserve will not accept deliveries if a certificate has not been provided (a form can be obtained from Flowserve).
Storage
In many cases, Flowserve products are manufactured from stainless steel. Products not manufactured from stainless steel are provided with an epoxy resin coating. This means that Flowserve products are well protected from corrosion. Nevertheless, Flowserve products must be stored in a clean, dry environment.
Valve and Actuator Variations
These instructions cannot claim to cover all details of all possible product variations, nor can they provide information for every possible example of installation, operation or maintenance. This means that the instructions normally include only the directions to be followed by qualified personnel where the product is being used, for its defined purpose. If there are any uncertainties, particularly in the event of missing product-related information, clarification must be obtained via the appropriate Flowserve sales office.
Unpacking
Each delivery includes a packing slip. When unpacking, check the delivered actuator and accessories using this packing slip.
Report transport damage to the carrier immediately.
In case of discrepancies, contact your nearest Flowserve sales office.
ingress and harsh environments that may result in deterioration of internal components and void the unit’s warranty.
During final field installation, ensure that all cable entries are correctly sealed in accordance with National Standards or Regulatory Author­ities. All temporary transit plugs must be removed and any unused cable entries closed in an approved manner.
2. Actuator Quick Start Guide for C-PRO and C-MOD Versions
CEA model sizes 15/60/150 use ISO mounting F05/F07 with STAR drive interface as standard. The baseplate incorporates both mounting patterns with F07 required for size 150 torque output. A third mount­ing pattern with larger diameter is also provided for custom mounting installations.
1. Prior to assembly, check the mounting surfaces, the stem adaptor and the bracket to assure proper fit.
2. Manually open and close the valve to ensure smooth operation.
3. Be sure the valve and actuator rotate in the same direction and are in the same position (i.e. valve open, actuator open).
4. Secure the valve with the stem vertical.
1. Important Notes
• Please read this manual entirely before attempting to install or operate your CEA actuator. A full understanding of the installation and operation options will assist you in installing the actuator in the most effective manner. The CEA actuator is designed for long life even in harsh environments.
• All actuator enclosures are sealed by O-rings and cable entries are supplied with threaded plugs to protect the terminal compartment until the unit is wired. If the actuator cannot be installed imme­diately, it is recommended that it be stored in a clean, dry place, preferably in an area that is not subject to large fluctuations in temperature.
• Disconnect all incoming power before opening any cover on the actuator. The user/operator must ensure that safe working practic­es are employed at all times and are in accordance with local or national standards that are enforced at the particular site.
• To install and operate the actuator, only the terminal compartment cover needs to be removed. The actuator is factory calibrated according to nameplate information and is ready to install and operate upon receipt.
NOTE: If the controls cover is removed, electrical components
are exposed to the atmosphere. Avoid exposure to moisture
5. Bolt the bracket to the valve and place the stem adaptor on the valve stem.
6. Position the actuator over the valve and lower to engage the stem adaptor to the actuator output drive. Continue to lower until the actuator rests on the bracket mounting surface. In order to align the bolt holes, it may be necessary to turn or rotate the actuator a few degrees.
7. Bolt the actuator to the bracket.
8. Stroke the actuator several times to assure proper operation with no binding of the stem adaptor.
CAUTION: Fastener length must be less than mounting hole
a
depth for proper mounting and to avoid damage to mounting base.
CAUTION: Misalignment may reduce actuator cycle life and
a
cause premature failure.
Travel stops are provided with 90 tory set at 0 necessary to perform an AutoCalibration to recalibrate rotation limits. If travel stops are adjusted outward, it is recommended to perform an AutoCalibration to recalibrate rotation limits.
o
and 90
o
position. If travel stops are adjusted inward, it is
o
rotation angle models. They are fac-
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Normally there are no orientation restrictions for actuator mounting; consult factory with any questions. Typical installations include In­Line mounting with the handwheel in line with the piping and Cross­Line mounting with the handwheel cross line with the piping.
NOTE: Mechanical assistance may be required to remove and
tighten the threaded covers. A flat edge screwdriver 10 inches or longer may be of assistance.
NOTE: It is not necessary to remove the indicator dome on the
Controls Cover for removal.
Flat Edge Screwdriver (recommended)
Round Edge Screwdriver (not recommended)
Operation
C-PRO version
The C-PRO, ON/OFF voltage control actuator ships from the factory calibrated and ready to operate. It is not necessary to remove the Controls Cover if factory settings are suitable. Wire the actuator according to the wiring diagram located inside the Terminal Block cover.
Key default settings include:
• Factory calibrated for 0-90 degree operation
• CCW to Open, CW to Close
• Fastest operating speed (listed on nameplate)
• Maximum rated torque (listed on nameplate)
• L1 and L2 are for input voltage 120 or 240VAC (Consult Factory for other AC/DC voltages)
• Terminals 20, 21, 22 and 23
- Terminal 20 = voltage command common
- Terminal 21 = voltage command OPEN
- Terminal 22 = voltage command CLOSED
- Terminal 23 = voltage command MID
• Terminals 1 and 2 are Normally Open (NO) dry relay contacts for OUTPUT 1 (CCW)
X
After commissioning the actuator, the threaded cover(s) will need to be installed in reverse fashion. Rotate by hand until difficult to turn (about 90% complete). Use mechanical assistance until you feel the cover “bottom out.” For the controls cover to be properly sealed, the gap between the cover and the housing should be no more than 0.010 inch.
With the actuator in full CW position, the entire RED closed indicator should be shown in the viewing window of the dome. This is the factory default setting. User may change to CCW/Open position.
WARNING: All threaded covers must be installed with the above
a
criteria, otherwise NEMA/IP and Hazardous Area ratings could be compromised.
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• Terminals 3 and 4 are Normally Open (NO) dry relay contacts for OUTPUT 2 (CW)
• Terminals 5 and 6 are Normally Open (NO) dry relay contacts for OUTPUT 3 (Torque or MID)
• Terminals 7 and 8 are Normally Open (NO) dry relay contacts for OUTPUT 4 (Compartment Temp)
NOTE: L1 and L2 are to be powered at all times. Remote voltage
commands can be any voltage between 24VDC-240VDC or 24VAC to 240VAC: 4/5 wire power and control scheme.
For 3 wire power and control scheme, consult Flowserve.
C-MOD version
The C-MOD or Modulating control actuator ships from the factory calibrated and ready to operate. It is not necessary to remove the Con­trols Cover if factory settings are suitable. Wire the actuator according to the wiring diagram located inside the Terminal Block cover.
Key default settings include:
• Factory calibrated for 0-90 degree operation
• Direct Acting CCW to Open
• L1 and L2 are for input voltage 120 or 240VAC (Consult Factory for other AC/DC voltages)
• Terminals 11, 12, 13 and 14
- Terminal 11 = + 4-20mA current source (input)
- Terminal 12 = ( - ) 4-20mA current source (input)
- Terminal 13 = + Loop Powered 24VDC + 4-20mA current (output)
- Terminal 14 = ( - ) Loop Powered 24VDC + 4-20mA current (output)
• Terminals 1 and 2 are Normally Open (NO) dry relay contacts for OUTPUT 1 (CCW)
2.1 C-MOD Wiring
• Terminals 3 and 4 are Normally Open (NO) dry relay contacts for OUTPUT 2 (CW)
• Terminals 5 and 6 are Normally Open (NO) dry relay contacts for OUTPUT 3 (Torque or MID)
• Terminals 7 and 8 are Normally Open (NO) dry relay contacts for OUTPUT 4 (Compartment Temp)
NOTE: L1 and L2 are to be powered at all times
NOTE: 4-20mA output is to be loop powered with 24VDC.
Voltage range 13-24VDC.
NOTE 1: Contact rating = 16amp @ 250VAC, dry contact. All outputs
are programmable, remote voltage inputs are 12VDC to 240VAC for Open, Closed, Mid/Dribble terminals (20,21,22,23)
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2.80
71.02
3.17
80.50
10.13
257.19
.64
16.16
5.82
147.84
4.84
122.83
REVISION HISTORY
REV
EC/SO
DESCRIPTION
DATE
BY
APPV
0 5933
INITIAL RELEASE
8/15/13
BMN
MDR
1 5998
DIMENSION "W" FOR 0.875-1/4x3/16 BORE TORQUE NUT IN THE TABLE WAS CHANGED FROM 0.188 TO 0.250
12/3/2013
JDE
JDE
2 00001713
DRAWING RE-LINKED TO LATEST ASSEMBLY FILE CY102215A
6/17/2014
THIRU
JDE
3 00002000
ADDED LARGE BOLT CIRCLE DIMENSIONS
7/23/14
BMN
MDR
4 00002090
ADDED DUAL DIMENSIONS TO OVERALL DIMENSIONS
8/6/2014
JDE
DRM
D
C
B
6
5
4
3
2
1
E
F
C-PRO Wiring
ON/OFF with Isolated Voltage Command Control
C-PRO Wiring
ON/OFF with Non-Isolated Voltage Command Control
NOTE 1: Contact rating = 16amp @ 250VAC, dry contact. All
outputs are programmable, remote voltage inputs are 12VDC to 240VAC for Open, Closed, Mid/Dribble terminals (20,21,22,23).
NOTE 2: 208 - 240VAC, 3 phase (future)
Standard Baseplate Mounting
M8x1.25 - TAP
0.51 DEEP
(F07) M8X1 / (FA07) 5/16-18 UNC - TAP
(F05) M6X1 / (FA05) 1/4-20 UNC - TAP
0.67 DEEP
0.51 DEEP
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.974 .974
.702 .702
.974
.702
.702
.974
DOUBLE SQUARE TORQUE NUT
DESCRIPTION
0.669 0.669 0.787
0.551 0.551 0.630
1.890 TYP.
1.890 TYP.
+-.004
"A"
.000
+-.004
"A"
.000
DOUBLE SQUARE TORQUE NUT
"A" (SQUARE)
45°
DEPTH
R.08 MAX. TYP.
DESCRIPTION
0.875-1/4x1/4
0.875-1/4x3/16
"BORE"
BORE TORQUE NUT
"BORE"
0.879 0.991 0.250
0.879 0.960 0.250
+-.008
"T"
.000
+-.004
.000
BORE TORQUE NUT
"T"
"W"
DEPTH
"W"
+-.002
.000
1.63
1.63
45°
MOUNTING
BLANK TORQUE NUT
(F05/FA05 & F07/FA07)
2.2 Menu Tree
Full Menu show LCS Pos graph BakEMFFaul
Read Statistics Reset stats IRAM Fault
Diagnostic HWOv erTorq
Man/Auto AUT, OK=MAN MAN,OK=AUTO COP Fault
IGBT Short
Full Menu
Setup Full
linear*
Character equal %
quick open
custom
sqr root
# of points
Custom char custom curve
0% = 4.0mA*
Current range 100% = 20.0mA* free*
cutoff free* Cutoff Low L O = 1.0%
Set low limited cut off Cutoff High HI = 99.0%
Trvl ctrl Set high limited Limit Low LO = 0.0%
Values Limit High HI = 100.0%
Direct
Transmitter Direction Reverse Position
Pos/Set Setpoint
Setpoint %*, mA, degrees
Position %*, degrees Position
Language Torque Nm, Lb-in*, Lb-Ft Set & Pos*
Appearance Units Temp C, F*, K Set & Dev
Default Display Menu
Start Logo On*/OFF
Orientation Norma l*,Flipped
HW rev Message
SW rev Tag
Devicedata Capa bility Descriptor
HART/MBUS Date
Device ID ID = XXXXXX (= serial no)
Modbus adr ADDR = XXX
Assembly No.
Tuning Clos e Time MIN = 0.0s Universal Cmd Rev
Open Time MIN = 0. 0s Special Cmd Rev
Deadband D = 1.0% Burst
Expert
Control PID Parameters
Stroketime CCW = X.Xs
CW = Y.Ys
FACT SET (press OK for 3 se conds to set default settings)
Read
MAN/AUTO
Calibrate Duplicated - se e Basic Menu tree
Setup Pro
Status
Protection
Note: (*) indicate s factory default setting
Slow shaft detection percentage
Unit address
C-MOD Dedicated
Character
Custom char
Current range (sp lit range)
Trvl ctrl
Loss of setpoint signal position
Loss of setpoint signal time
Setpoint selector
Loss of position feedback action
C-PRO & C-MOD Menu Tree - SW120
Basic Menu* Standard* 1 (Pos*/Alarm) Show alarm
Calibrate Rotation Mid Pos 4 (Pos/Alarm*) Limit 2
Set Up Pro Torque Closed
Outputs ALARMS Torque AutoCal Compa temp Expert Cal Set Point Model Motor temp
Speed Direction Open Speed Curr Limit CCW/CW Close Speed
Transm Open
Turns 2 (Pos*/Alarm) Deviation Manual 3 (Pos/Alarm*) Limit 1
Status 0 0 Service N cycles Lo MotrVlt
Protection NO* Set & Dev # of reset IGBT Op en
Shift Basic Menu* comp temp Histogram Ha llldxLmp
IN Service* Pos Acc travel MotrTmpOOR
YES Enter Code Torque Run time Ha llldxCrt
Set & Pos* Mean dev MotrOvrTrq
motor temp Extreme Temp PMCB Reset
Full Menu
Shift Basic Menu
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