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CEA Series Limitorque Automax
User Manual
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Flowserve CEA Series Limitorque Automax User Manual

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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
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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
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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
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depth for proper mounting and to avoid damage to mounting base.
CAUTION: Misalignment may reduce actuator cycle life and
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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
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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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Basic Menu
Calibrate Setup Pro Status Protection Shift Read Man/Auto
Calibrate
Rotation
Standard
90, 180, 270, 360, Multi
Turns set turns (1,6,10,12,17,20) Manual
subset of Standard Rotation,+/- 6 degrees of min/max rotation. (i.e. if 90 selected, select value (-)6 - (+) 96 (XX); 180 selected, select (-)6 - 186 (XXX)
Mid Positio (dribble Off/On)
subset of Standard Rotation,+/- 6 degrees of min/max rotation. (i.e. if 90 selected, select value 5 - 85 (XX); 180 selected, select 5 - 175
Outputs (XXX) Factory Default
1 (Pos/Alarm) 2 (Pos/Alarm) 3 (Pos/Alarm) 4 (Pos/Alarm) ALARMS
Show alarm Deviation Limit 1 Limit 2 Torque Compa temp Motor temp
AutoCal
start cal (press "OK"), note: must be Out of Service
Expert cal
Set Point (Setpoint LO, Setpoint HI) Transm (Transm low, Transm hi)
Set Up Pro
Torque Factory Default (Max per model size)
Model
Open torq Close torq 15, 60, 150, 250, 500
100%, 95%, 90%, …(10 selections 100% - 40%)
Speed Factory Default (fastest per model size)
Open speed
5,10,15, 20…180 (10 selections min to max)
Clos speed
5,10,15, 20…180 (10 selections min to max)
Direction
CCW or C (define the parameter) Factory Default
(CCW) Current Limit
1, 1.5, 2,2.5, … to max (selectable with 0.5 amp increments up to 10 amp) Factory Default (5 amp)
Status
0 0 service in service
Protection Shift
Basic Full menu
Pos Set & Pos Set & Dev Torque motor temp comp temp show LCS Statistics
Man/Auto
Auto Man Set
(press "OK", enter 4 digit code)
(No/Yes)Read Factory Default (Set & Pos)
N cycles (define parameter) Acc travel Mean dev (modulating only)
# of reset
Run time (power on time) Extreme Temp (hi, l Histogram Pos graph Reset stats Diagnostic
Pos - CCW Pos - CW Alarm - compartment temp Alarm - Torque
(No/ Yes)
ow)
3. Installation and Operation
Description
Flowserve CEA actuators are reversible electric rotary valve actuators. Standard units can provide up to 5000 in-lb of torque and use a Brushless DC (BLDC) motor and permanently lubricated gear trains. These actuators are equipped with integral thermal overload protection with automatic reset and electronically adjustable position and rotation limit switches. In the event of electrical power failure, all models feature manual override capabilities.
WARNING: SERIES CEA ACTUATORS ARE
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ELECTROMECHANICAL DEVICES SUBJECT TO NORMAL WEAR AND TEAR. ACTUATOR LIFE DEPENDS 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. AT ELEVATED TEMPERATURES THE DUTY CYCLE HAS TO BE DERATED, CONSULT FACTORY. FLOWSERVE ALSO RECOMMENDS THAT THE OPTIONAL AUXILIARY LIMIT SWITCHES BE USED FOR MONITORING AND/OR ELECTRICAL INTERLOCK.
CAUTION: If necessary, Flowserve recommends indoor, controlled
a
temperature storage of all products prior to installation. Do not store product in areas with 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. Do not store within 50 feet of any source of ozone.
CAUTION: FOR WIRING OF ACTUATOR, INCLUDING OPTIONS,
a
PLEASE REFER TO WIRING DIAGRAM(S) LOCATED INSIDE OF ACTUATOR TERMINAL BLOCK COVER. Wiring diagrams are also included in this manual on pages 6 and 7 for reference.
CAUTION: The gear train compartment is oil filled. High perfor-
a
mance Mobil 1 oil is used for standard temperature requirements. The compartment volume is 12oz. Oil replacement is not required under normal operating conditions.
3.1 Installation – Flowserve Automax Valve Products
1. Attach mounting bracket to actuator using the four (4) screws and lockwashers provided in the mounting kit, and tighten securely. For small size, top mount style valves, attach bracket so the bracket nameplate will be to the side of the valve.
2. Attach bracket/actuator assembly to valve as follows:
NOTE: If cross-line mounting of actuator is desired, note the following: Mount the actuator with conduit hole perpendicular to
the flow axis (center line) of the valve and reverse the open/close decals.
For diverter and three-way valves with V1 porting, and CPT valves, also see Electrical Installation and Adjustment Section for cam and limit switch adjustments to facilitate cross-line mounting operation.
CAUTION: Ball valves can trap pressurized media in the cavity.
a
If the valve is or has been in operation and it is necessary to re­move any valve body bolts, stem nuts, or the valve from the line, make sure there is NO pressure to or in the valve and operate the valve one full cycle before and after removal.
Valve Models Top Mount 44 (1/4”–2”), 45 (2.5”–6”), 51/52 (1/2”– 10”), 151/301 (3”–6”), Top Mount 59 (1/4”–4”), WK70/WK74 and H71 (1/2”–2”), 818/828 (2”–8”), 82/83 (1/2”–10”) and 94 (1/2”–6”):
NOTE: For above listed valves, it is not necessary to remove any valve body bolts or the valve from line in order to mount the actuator.
3. Close valve:
• For valves 1/4”–2”, the valve is closed when flats on valve stem are perpendicular to the line of flow.
• For valves 3” and larger, where the valve stem is square, the indicator line on top of stem will be perpendicular to the line of flow or check ball position for closure.
• If any valve information is marked on stop plate or handle, it will be necessary to transfer this information to the bracket nameplate.
For 1/4”–2” 44 and 1/2”–2” WK70/WK74, 1/4”–1 1/2” 59 and 1/2”–2” H71 Series top mount style valves and 1/2”–2” 51/52, 1/2”–1 1/2” 82/83 Series valves with high cycle stem packing as standard:
4. Remove handle nut, lockwasher, handle, separate stop plate (if any), retaining nut and stop pin(s).
5. Add the two additional Belleville washers with their larger diame­ter sides touching each other.
6. Add the self-locking nut to the stem and tighten while holding the stem flats with wrench.
7. Tighten until Belleville washers are flat, the nut will “bottom”, and then back nut off 1/3 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
a
must fully flatten Belleville washers before backing off the nut by one third of a turn.
For 2” 59, H71, 82/83, and 2.5” 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,
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with two Belleville washers (except 8”, 10” 82/83 and 10” 51/52) and replace retaining nut.
NOTE: Belleville washers are installed with larger diameters so they are touching each other. Using a wrench to prevent stem from turning, tighten retaining nut until the stem packing is fully compressed or until Bellevilles (if used) are fully flattened. Then, back off nut 1/6 turn. Excessive tightening causes higher torque and shorter seal life.
NOTE: 3” size and larger valves with V51 high cycle stem packing (no handle assembly) are ready to automate without modification.
For 1/2”–2” 94 valves, remove handle (if any). For 3”–6” 94 and 2”–8” E818/E828 valves, remove handle assembly, stop, and spacer (if any). Do NOT remove gland plate or gland bolts.
For 2”–8” 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).
1. Center coupling on valve stem.
2. Lower mounting bracket/actuator assembly over coupling and onto valve, making sure that male actuator shaft engages slot in coupling.
3. Secure bracket to valve using cap screws and lockwashers, or bolts and nuts provided in mounting kit. Tighten securely. For small size top mount style valves, bracket nameplate will be to side of valve.
4. Install set screws (if any) in the coupling and tighten securely.
tor housing. Connect power supply to actuator terminal strip as shown on electrical schematic diagram(s) located inside terminal block cover and also in this manual.
The actuator should be electrically grounded in accordance with standard procedures.
See table below for minimum fuse rating when overcurrent protection is used in motor power circuit.
Minimum Fuse Rating for Overcurrent Protection
Actuator Size Voltage Fuse Rating (A)
15/60/150 120 VAC 2A
15/60/150 240 VAC 1A
15/60 24 VDC 3A
150 24VDC 5A
NOTE: The table shows the minimum rating to prevent in-rush current from blowing the fuse.
4. Calibration and Commissioning
The CEA actuator ships from the factory calibrated for 0-90 degree rotation.
4.1 Travel Stop Adjustment
CAUTION: do not rotate travel stops counter clockwise (CCW)
a
beyond the inward/second “position orientation” groove as this will result in oil leakage. If accidentally rotated beyond this posi­tion and leakage is observed, adjust clockwise (CW) to reposition to the sealing zone between the two position grooves.
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3.2 Electrical Installation and Adjustment
NOTE: The CEA actuator has 3 threaded covers on the actuator housing: Controls cover, Terminal Block cover and Motor cover. Cover(s) use an O-Ring to provide environmental sealing and proper installation/assembly is required to prevent moisture ingress.
ATEX hazardous area installation
Each cover incorporates a locking bracket attached by a screw that must be loosened prior to cover(s) being removed.
Each cover is designed with 4 raised tabs and mechanical assistance is required to remove the cover. A common “tool belt” screwdriver, 10 inches or longer, is recommended for mechanical assistance. Place the tool between 2 adjacent tabs and rotate counter clockwise (CCW) to remove the cover. Once O-Ring compression is relaxed the cover will rotate freely by hand.
A. To gain access to terminal block, it is necessary to remove the
terminal block cover
B. Make conduit connection(s) to NPT/Metric fitting taps on actua-
CAUTION: it is not recommended to use the travel stops to
a
control normal rotation. Rotation limits should be electronically set using the HMI menu Calibrate/Rotation with travel stops set 1-2 degrees outside calibrated rotation
Mechanical travel stops are provided on 90 degree rotation units to provide over-travel protection. They are adjustable to provide +/- 6 degrees of adjustment. They are factory set 1-2 degrees outside the cal­ibrated rotation. Adjust CW to reduce travel and CCW to extend travel. One 360 degree rotation provides 3.2 degree position output change.
Each travel stop bolt has 2 position orientation grooves to identify the min and max rotation position. Adjustment must be maintained within these 2 grooves. CCW rotation beyond the inward groove will result in potential oil leakage.
To calibrate the unit after a travel stop adjustment, simply navigate using the arrow down key to the CALIBRATE menu and then to AUTO CALIBRATE and select OK. This will recalibrate the actuator to the new travel stop endpoints.
Please note that if any adjustments are made to the travel stops due to mount issues or special valve requirements then the unit will require a field AUTO CALIBRATION before it is placed IN SERVICE.
4.2 Gear Train
A precision cut bronze or ductile iron worm gear set delivers maxi­mum strength and durability. For optimum performance the gear set is permanently lubricated and submerged in oil in a sealed compart­ment.
High performance Petro Canada Syndro SHB-68 oil is used for stan­dard temperature requirements. The compartment volume is 12oz. Oil replacement is not required under normal operating conditions.
Options and Adjustments (Factory Installed)
Magnetic Rotary Positioner Sensor
Shaft position feedback is accomplished using a 12-bit magnetic rotary position sensor directly coupled to the output drive. Specifically designed for brushless DC (BLDC) motor control, this technology provides the highest accuracy and reliability.
Position and Alarm Outputs
4 outputs are provided as standard and pre-wired to the terminal block. Standard outputs are non-latching, dry contact,15A rated. Optional latching contacts are available; consult Flowserve.
Outputs may be configured for remote position indication and/or alarm feedback.
When alarms are activated, additional “action” may be programed:
> DO NOTHING (factory default)
> GO to OPEN
> GO to CLOSED
> MANUAL MODE
Also note that the relay stays energized during an alarm condition. It deenergizes when the value is outside of the MIN/MAX range entered.
Factory default settings:
Output 1: position CW
Output 2: position CCW
Output 3: Alarm High Torque
4.3 Rotation Speed Control
Selectable Rotation Times
Nominal
Model
150 1500(170) 10* 12 15 20 30 50 80 110 150 180
*Factory Default
Torque
in-lbs (Nm)
15 150(17) 5.0* 7.5 10 15 20 50 80 110 150 180
60 600(68) 5.0* 7.5 10 15 20 50 80 110 150 180
o
rotation time in seconds
90
Rotation speed is factory set to the fastest 90 degree rotation per the actuator model code specification (Example: M60 = 5 seconds). Both the CCW and CW rotation speed is independently adjustable with 10 pre-set selections that increase rotation speeds up to 180 seconds.
4.4 Variable Torque Output
Selectable Torque Output
Nominal
Model
150 1500 (170) 100* 95 90 85 80 75 70 60 55 40
*Factory Default
Torque
in-lbs (Nm)
15 150 (17) 100* 95 90 85 80 75 70 60 55 40
60 600 (68) 100* 95 90 85 80 75 70 60 55 40
Torque times percent equals maximum output torque
(valves listed below are percent (%)
Example Model 60: 600 in-lbs set at 100% = 600 in-lbs; set at 75% = 450 in-lbs.
Torque output is factory set to the maximum value per the actua­tor model code specification (example: M60 = 600 in.lbs.). Output torque is adjustable from 100% to 40% of rated value with 10 pre-set selections.
4.5 Duty Cycle
Model Open/Close Service Modulating Service
15 360/hr 1800 Starts/hr
60 360/hr 1800 Starts/hr
150 180/hr 1800 Starts/hr
Output 4: Alarm Compartment Temperature
The CEA actuator is rated for 1800 starts per hour, under full load conditions, within the normal operating temperature limits per specification listing.
4.6 Heater and Thermostat
Heaters are not required for operation to -40C and/or to control condensation. Condensation does not occur due to non-breathing enclosure and internal compartment temperature stabilization. The customer may order a factory-installed heater and thermostat if desired.
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ATTENTION: Actuator is factory calibrated for standard rotation, max speed, max torque and output settings per model code on nameplate. Unit ships with Output shaft in the CW position for mounting. Standard rotation is CCW to Open, CW to Close.
HMI Interface (see IOM for complete detail) The actuator is User configurable using the 5 push bottons and the display. Default display is position. Press the ESC button to display the Main Menu. Use the UP/DN push buttons to browse through the Main Menu and Sub-Menus.
OTHER FUNCTIONS: ESC- exit the menu or return to previous level
FUNC - Select a function and change parameters OK- To confirm a citical selection or change of parameters In Service - Normal status, actuator responds to remote
commands Out of Service - Actuator off-line, critical parameters may be changed Manual - Actuator rotation may be adjusted manually via push buttons Unprotcted - Parameters may be changed without passcode
MENUS: Basic Menu - Supports primary setup (read, man/auto, calibrate, setup, status, protection,
shift); Use status to change service and shift to advance to full menu Full Menu - Supports advanced configuration
Analog Output
Available option will provide analog 4-20mA continuous position feedback.
CAUTION: In cases where the conduit connected to the actuator
a
may be partially or completely run underground, or through which moisture may contact energized live parts, or where the actuator and/or conduit is exposed to temperature differences, the conduit should be sealed within 18” of the actuator in accordance with the National Electrical Code.
When electrical installation is complete, it is advisable to check the indexing of the actuator to ensure proper valve rotation.
Replace actuator cover(s).
NOTE: The CEA actuator has 3 threaded covers on the actuator housing: Controls cover, Terminal Block cover and Motor cover. Each cover is designed with 4 raised tabs and mechanical assis­tance is required to properly secure the cover. A common “tool belt” screwdriver, 10” or longer, is recommended for mechanical assistance. Rotate the cover by hand until difficult to rotate. Place the tool between 2 adjacent tabs and rotate clockwise (CW) to properly secure/install the cover (approximately 1.5 additional turns).
Cover is properly installed when no cover-to-housing gap is visible. Use a feeler gauge according to the listed procedure to confirm.
If using the ATEX locking tab, tighten screw to secure tab.
Feeler Gauge Procedure
Use a .010 inch feeler gauge inserted at the location of the nameplate just above the word MODEL, between the housing and controls cover. The feeler gauge should feel tight and be inserted approximately .060 inches
4.7 HMI Display
Menus and Push Buttons
The actuator is user configurable using the five pushbuttons and the LCD display, which are accessible when the top Controls Cover is removed. For normal functioning, the display shows the current value. Press the ESC button for two seconds to display the main menu.
Other Functions
ESC
Exit the menu without making any changes (as long as any changes have not been confirmed with OK).
FUNC
To select function and change parameters.
OK
To confirm selection or change of parameters.
MENU INDICATOR
Displays the position of the current menu row in the menu.
IN SERVICE
The actuator will respond to discrete input commands. This is the normal status when the actuator is working properly.
OUT OF SERVICE
The actuator will not respond to discrete input commands. Critical parameters can be changed.
MANUAL
The actuator can be adjusted manually using the pushbuttons. See section ”Man/Auto”, page 15.
UNPROTECTED
Most of the parameters can be changed when the actuator is in the ”Unprotected” position. However, critical parameters are locked when the actuator is in the ”In service” position.
Menus:
Use the Up/Dn buttons to browse through the main menu and the sub-menus.
14
OUT OF SERVICE
MANUAL
BASIC MENU MAN/AUTO
UNPROTECTED
ESC
OK
FUNC
Menu Indicator
There are indicators at both sides of the display window and they indicate as follows:
Flashing in position Out of service
FULL MENU MAN/AUTO
Flashing in position Manual
FULL MENU CALIBRATE
Displayed in position Unprotected
FULL MENU SHIFT MENU
Menu System
Basic Menu Full Menu
Calibrate Shift Menu
Setup Pro Setup Full
Status Tuning
Protection Fact Set
Shift Menu Read
Read Man/Auto
Man/Auto Calibrate
Setup Pro
Status
Protection
BASIC MENU READ
BASIC MENU MAN/AUTO
BASIC MENU CALIBRATE
BASIC MENU SETUP PRO
The indicators on the right-hand side show the position in the current menu.
Menus
To display the menus you can select:
- Basic menu, which means you can browse through seven different steps
- Full menu, which comprises ten steps. Use the Shift Menu to browse through the steps
Full Menu can be locked out using a passcode.
The main menus and sub-menus are shown on the following pages.
4.8 Programmable Parameters
Changing Parameter Values
Change by pressing until the desired figure is flashing.
Press to step to the desired figure. Confirm by pressing OK.
A change can be undone by pressing the ESC button, which returns you to the previous menu.
BASIC MENU STATUS
BASIC MENU PROTECTION
BASIC MENU SHIFT MENU
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The menu contents are shown in the figures on the right and the texts are described below:
BASIC MENU CALIBRATE
Calibrate/Rotation:
The Calibrate Menu is used to calibrate rotation variations, discrete outputs, Auto Calibration and Expert (advanced) Calibration. 4 con­figurable parameters are available: Standard, Turns, Manual and Mid Position.
1. Rotation/Standard: depending on product model, multiple rotation angles are available for selection. Option examples: 90, 180, 270, 360, Multi
2. Rotation/Turns: multiple 360o rotation turns are available for the multi-turn (MT) option only
3. Rotation/Manual: the user may manually select alternate positions for CCW/Open and CW/Closed rotation.
a. A known value may be entered (i.e. 0% = 10.0% or 100% = 70%) to change rotation position.
b. Use Set 0% or Set 100% and press the Up/Dn arrow to “step” position changes in 0.5% increments. Press “OK” button for 3 seconds to accept the new value. CAUTION: do not rotate outside the factory calibrated 0% and 100% positions without first adjusting the associated Travel Stop bolt CCW. This will prevent driving the output gear into the mechanical stop.
4. Rotation/Mid Position: Mid Position parameter is used for 3-position control (i.e. multi-port 3-way valves). To enable: go to Rotation/MIDPOS/dribble – select ON; next: mid = 050.0% (example); next: set midpos/press “OK” for 3 seconds.
Calibrate/Outputs:
The CEA provides 4 discrete programmable outputs. Each output may be configured for either Position Output or Alarm Output. Alarm outputs are further programmable to perform specific Valve Action when activated. See section 4.8 and 4.9 for more detail.
Calibrate/Expert Cal
This parameter provides advanced calibration for analog setpoint input and analog output.
1. Analog setpoint input may be configured for minimum signal input (i.e. LO = 4.0mA) and maximum signal input (i.e. HI =
20.0mA)
2. Analog output option should be calibrated to match the rotation minimum and maximum positions (i.e. Transm low/LO = 4.0ma; Transm hi/HI = 20.0mA)
BASIC MENU SETUP PRO
The Setup Pro menu is used to calibrate Torque, Speed, Direction and Current Limit.
1. Setup/Torque: Clockwise (CW) and counterclockwise (CCW) ro­tation torques may be independently configured using 10 preset values. Selectable values include: 100%, 95%, 90%... (10 se­lections 100% - 40%). Values are selected based on percentage of Rated Torque. For example: rated torque 600in-lbs.: 100% = 600in-lbs.; 50% = 300in-lbs.
2. Setup/Speed: Clockwise (CW) and counterclockwise (CCW) ro­tation speeds may be independently configured using 10 preset values. Selectable values are listed in “seconds” and include: 5,10,15,20…180 seconds.
3. Setup/Direction: 2 settings are available CCW and CW. CCW: When setpoint power is applied to TB point 21, the unit will ro­tate in the CCW direction. CW: when setpoint power is applied to TB point 21, the unit will rotate in the CW direction.
4. Setup/Current Limit: The user may select a maximum current load for the actuator not to exceed. This feature may support low power DC applications, torque seating and valve “jam” conditions. Available settings are 1amp up to 10amp in 0.5 amp increments.
16
Calibrate/AutoCal
AutoCal may be used to recalibrate the actuator at any time. This feature is most commonly used when rotation values are modified from factory default. When AutoCal is performed the unit will rotate to the mechanical stops or electronic limits and automatically update all 4 outputs for position and/or alarm.
BASIC MENU / STATUS
The Status Menu is used to select whether or not the actuator is in service.
o o service Not in service. Flashing indicator in upper left-hand corner of display.
in service Positioner in service. Critical parameters cannot be changed.
STATUS O O service
STATUS in service
When changing between In service and Out of Service, the OK button must be pressed for 3 seconds.
OK
OK
OK
OK
BASIC MENU SHIFT MENU
The Shift Menu is used to choose between the basic menu and the full menu.
The menu contents are shown in the figures on the right and the various texts are described below:
No Full menu selected.
Yes Basic menu selected.
Full menu no
Full menu yes
Full Menu can be locked with a passcode, see Setup menu.
OK
OK
OK
OK
BASIC MENU / PROTECTION
The Write Protect menu is used to protect all essential settings.
No Entered values are not write protected. ”Unprotected” is displayed in the lower left-hand corner.
Yes Entered values are write protected. Passcode needed for change to No (Applicable when a passcode has been set up in SETUP menu).
PROTECTION no
PROTECTION yes
When changing between Yes and No mode, the OK button must be pressed for 3 seconds.
OK
OK
OK
OK
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BASIC MENU READ
Values can be read using the Read Menu and some values can be reset.
Pos shows current position
Set & pos shows current setpoint and position
Set & dev shows current setpoint and deviation
Torque shows current load torque
Motor temp shows current motor temp
Compa temp shows current compartment temp
Statistics shows statistics and diagnostic data
Statistics
n cycles Shows number of movements
(turns)
Acc travel Shows accumulated
movement
mean dev Shows accumulated deviation in %
runtime Shows accumulated runtime
since last reset
Extr temp Shows extreme min and max
temperature
Histogram Shows position and time for
PV
Alarms Displays tripped alarms
READ pos
READ set&pos
READ set&dev
READ torque
READ motor temp
READ comp temp
READ statistics
Statistics n cycles
Statistics acc travel
Statistics mean dev
Statistics # of reset
Statistics run time
Statistics extreme temp
Statistics histogram
Statistics pos graph
Statistics reset stats
Statistics diagnostics
BASIC MENU MAN / AUTO
The Man/Auto menu is used to change between manual and automatic modes.
AUT, OK = MAN Positioner in automatic mode
MAN, OK = AUT Positioner in manual mode
In the MAN mode, the value of POS can be changed using the UP/ DN push buttons. The push-buttons increase/decrease the value in steps. The value can also be changed in the same way as for the other parameter values, as described on page 14.
AUT, OK=MAN POS= 12.3%
When changing between MAN and AUT mode, the OK button must be pressed for 3 seconds.
MAN, OK=AUT
OK
POS= 12.3%
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Basic Menu Outputs - Expanded View
Outputs
1(Pos/Alarm)
2(Pos/Alarm)
3(Pos/Alarm)
4(Pos/Alarm)
Postion
CW/CCW/MID
Alarm
Show Alarm
M, C, 1, 2, D, T
Deviation
ON/OFF
Distance
value=%
Time
value=seconds
Alarm out
on
off
Valve Action
no action
go to close
go to open
manual
Limit 1
ON/OFF
Min Position
value=%
Max Position
value=%
Hysteresis
value=%
Alarm out
on
off
Valve Action
no action
go to close
go to open
manual
Limit 2
ON/OFF
Min Position
value=%
Max Position
value=%
Hysteresis
value=%
Alarm out
on
off
Valve Action
no action
go to close
go to open
manual
Torque
ON/OFF
Min Torque
value=%
Max Torque
value=%
Hysteresis
value=%
Alarm out
on
off
Valve Action
no action
go to close
go to open
manual
Comp Temp
ON/OFF
Min Temp
degrees F
Max Temp
degrees F
Hysteresis
value=%
Alarm out
on
off
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Valve Action
no action
go to close
go to open
manual
Motor Temp
ON/OFF
Min Temp
degrees F
Max Temp
degrees F
Hysteresis
value=%
Alarm out
on
off
Valve Action
no action
go to close
go to open
manual
Status
Man/Auto
Auto (press up/down arrow for options, press enter to change selection)
Man Set (select value 0-100% (XXX.X) or press up/ down arrows to jog position CW/CCW)
Protection
Shift
Basic
Advanced
4.9 Alarm Output Setup
The actuator is equipped with (4) four configurable outputs. The alarm OUTPUT parameters are set in the ALARMS menu.
Alarm definitions are as follows:
M= Motor Temperature (Alm mtrtmp)
C= Compartment Temperature(cmptmp)
1=Alarm Limit 1 (Alm Lim 1)
2=Alarm Limit 2 (Alm Lim 2)
T-Torque (Alm Torque)
D=Deviation (Alm dev)
Each alarm can be viewed on the display and/or read by activating the selectable relay output. If the alarm is set to ON and an alarm condi­tion has occurred, the display will flash. The user can then navigate to the alarms menu to view the above defined alarm(s). NOTE: The alarm relay output will not be activated until the alarm is turned on in the alarms menu.
Basic Menu Calibrate/Outputs/Alarms/Compartment Temp
>>>> ON/OFF
Low temp
High temp
Hysteresis
Alarm out
Valve action
The above setting will indicate an alarm condition by flashing the display to indicate that one or more alarm conditions has occurred (M:C:1:2:T:D)
For example, to activate the relay output for compartment tempera­ture, navigate to the ALARMS menu as follows:
20
Basic Menu Calibrate/Outputs/Alarms/Compartment Temp
>>>> ON/OFF
Min temp
Max temp
Hysteresis
Alarm out
>>>> ON
OFF
For example, to set the compartment temperature relay output alarm to active when the temperature exceeds the MAX value of 125 degrees F or falls below the MIN value of -5 degrees F, perform the following:
Basic Menu Calibrate/Outputs/Alarms/Compartment Temp
>>>> ON/OFF
Min temp
>>>> -5
Max temp
>>>> 125
Hysteresis
Alarm out
>>>> ON
All (4) four relay outputs are configured in the same manner. Below is a list of the parameters.
Alm dev
Alm Lim 1
Alm Lim 2
Alm Torque
Alm mtrtmp
cmptmp
The default outputs are as follows:
4.10 Positioner Indicator
High visibility position indicator is standard with each actuator. Indicator rotation is accomplished using high performance neodym­ium magnets that eliminate cover shaft holes and potential path for moisture ingress.
Indicator is self-indexing and does not require removal to remove the top cover.
Dome Indicator Adjustment
The dome indicator will come preset from the factory. The indicator will display CLOSED in the clockwise (CW) position in the viewing window. The indicator dome may be rotated 90 the CW position.
The dome indicator also has adjustment slots to further align the OPEN and CLOSED display after the controls cover is completely tightened down. Loosen the 4 pan head screws that hold down the dome and rotate CW or CCW as needed. The screws holding down the dome should only be loosened (not removed) to ensure that the O-ring under the dome is not pinched when the screws are re-tightened.
o
to display OPEN in
OUTPUT 1= CCW (activates upon full CCW travel. NOTE: normally open dry contact closes)
OUTPUT 2=CW (activates upon full CW travel. NOTE: normally open dry contact closes)
OUTPUT 3 = TORQUE (activates when torque is below the low limit or above the high limit NOTE: normally open dry contact closes)
OUTPUT 4 = COMPARTMENT TEMPERATURE (activates when torque is below the low limit or above the high limit. NOTE: normally open dry contact closes)
Setting the dome indicator and internal magnet puck inside the controls cover
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Magnet Puck Adjustment
If for any reason the black plastic EMC/EMI controls cover is removed the indicator “puck” magnet will need to be timed such that the cor­rect indication will be shown on the dome window when the actuator controls cover is screwed down to the proper height.
Prior to adjustment the actuator must be in the Closed/CW position. Using a 3/32 hex head wrench, loosen the socket head cap screw and align the wrench with the controls cover set tab located on the housing. See Figure below.
22
5. Manual Override
Manual override is provided as standard with each actuator. The override requires minimum force to operate (less than 7lbs force) and is spring loaded, push to engage. When engaged the worm shaft is declutched from the motor drive to provide safe operation. The spring loaded design ensures the override will not accidentally be left in the By-Pass condition.
NOTE: If power is present and the handwheel is engaged and
rotated, the motor will power on but not impact rotation.
6. Performance and Technical Data
Performance Specifications
Output Torque
(Continuous
Start/Run
Torque)
Stall Torque (1.25X)
Cycle Time
(90°)
24VDC
120/240VAC
Version
Standard
On/Off
Modulating
Actuator
Platform
(PF)
Units Nm (in-lbs) Nm (in-lbs) Sec. RPM 24VDC 120/VAC 240VAC
PF1
PF2
Model
M15 17 (150) 21 (187) 5 3 0.8A 0.15A 0.08A
M60 68 (600) 85 (750 5 3 2.1A 1.0A 0.49A
M150 169 (1500) 211 (1875) 10 1.5 4.2A 1.4A 0.75A
M250 282 (2500) 422 (3125) 16 0.9 6.5A 1.6A 0.85A
M500 565 (5000) 706 (6250) 33 0.5 6.5A 1.6A 0.85A
Materials of Construction
Component Material
Housing and Cover Die cast aluminum
Aluminum surface treatment Non-chrome conversion coating
Worm Gear set Ductile iron (M15, M60), Bronze (M150, M250, M500)
Output Drive Ductile iron
Baseplate ISO 5211, F05/07, FA05/07
Paint
Polyester powder coat Salt Spray: ASTM B117, 1050 hrs.
Output
Speed
24VDC
120/240VAC
Full Load Amps
Technical Data
Voltage Rating 120/240 VAC/VDC; 12*/24 VDC; Single (and optional 3-phase)
Temperature -40C to +70C, low temp. option -48C
Environmental
Vibration Testing IEC60068-2-6 Appendix B
CE Declaration Low voltage, EMI/EMC approval
Weight M15/60: 24 lbs (10.9kgs) M150: 25.5 lbs (11.6kgs)
* For 12VDC, consult factory
Type 4, 4X,6, IP66/68 (3m for 48hrs) Class 1, Div 1,2, Gps B,C,D (CSA,FM) ATEX II 2G Ex d IIB +H2 T4: IECEx II 2G Ex d IIB +H2 T4
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7. Actuator Troubleshooting Guide (Electrical)
The actuator contains (5) five electrical devices, a 3 phase BLDC motor, Motor Controller, Main Control Board, Relay Board and a 12 bit Rotary Encoder Board. This is an electro-mechanical device and will, after many years of service, require inspection of mechanical compo­nents to ensure the root cause is not hidden there.
Symptom Resolution
Actuator is commanded to move but does not move.
NO Relay Output 1 or 2 (CW or CCW)
The actuator main position control is derived from the 12 bit magnetic rotary encoder. The actuator will be calibrated from the factory but if for any reason field service is performed on the actuator e.g. travel stop adjustment or board replacement, the actuator will require recalibration.
Before replacing any parts always check for loose field wiring at the terminal block. This usually solves most known issues with the actua­tor. If no loose wiring is found proceed below.
1. Use hand wheel to move actuator to check for binding in valve mounting.
2. Is there power to the actuator? Check voltage at terminals L1 and L2 must be between 90VAC and 240VAC
3. If a PRO unit check voltage between terminals 20 and 21 then check voltage between terminals 20 and 22 must be between 24vdc and 240VAC for AC models.
4. If unit is a MOD, remove the field wires from terminals 11&12. Apply 20 mA signal using a process output meter to terminals 11 &12 noting 11 is positive and 12 is negative. Apply a 4 mA signal, if still no actuator movement, replace main control board.
5. Check open and closed torque setting. Change to 100% and retry step 3 or step 4 depending on MOD or PRO unit.
6. Check the compartment temperature and motor temperature for excessive heat as motor controller or motor could have shut down due to excessive heat.
7. If unit still does not move when commanded then factory service will be required.
1. Check physical endpoint position using hand wheel.
2. Is there power to the actuator? Check voltage at terminals L1 and L2 must be between 90VAC and 240VAC for AC models
3. Remove field wiring from terminals 1 & 2 and measure continuity using a DMM. If output is activating resistance value will be zero. Check terminals 3 & 4 in a similar fashion for output 2.
4. Recalibrate unit and recheck. In Full CCW or Full CW output 1 or 2 should read ZERO continuity, if not ZERO replace relay board.
5. In the menu check for POS CCW and POS CW for output 1 and 2. If they are not POS CCW and POS CW change accordingly.
6. Beacon drive assembly has failed and will need to be replaced. (Factory service recommended)
24
No 4-20mA output at terminals 13 and 14.
Actuator is hunting (oscillating) back and forth
1. Confirm model code for this option
2. Is there 24vdc loop power on terminals 13 and 14? If so and there is still no output on terminals 13 and 14 replace Main Control Board (MCB)
1. For C-PRO unit check voltages between terminals 20 and 21 then check voltage between terminals 20 and 22. Is the supply voltage being com­manded ON and OFF from the source? If not replace PMCB.
2. For C-MOD unit check that deadband setting is not set below 0.1%
3. If unit is still oscillating replace encoder board and then recalibrate using autocal.
4. Beacon drive assembly has failed (factory service recommended)
8. Parts List
15-2
15-1
15-3
15-4
19
19
15-13
15-6
15-5
15-11
15-11
ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY.
15-1 DY102026A EMC Shield, Resin, CEA, 15, 60, 150 1 15-11 EY102004GV Pipe Plug (conduit) 3
15-2 EY102004BH EMI Screws M3x.5X10mm 4 15-13 EY102004M Locking Cover Screws 3
15-3 DY101938A Cover, Controls, CEA, 15, 60, 150 1 19 CY102219A Indicator Assembly Kit 1
15-4 EY102004DE Seal - Control Cover O-ring 1
15-5 DY101936A Cover, Motor, CEA, 15, 60, 150 1
15-6 EY102004DC Seal - Motor Cover O-ring 1
15-13
15-13
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15-5
15-6
15-1
15-2
15-13
19191919
26
15-8
15-7
ITEM NO. PART NUMBER DESCRIPTION QTY.
15-7 DY101937A Cover, Terminal, CEA, 15, 60, 150 1
15-8 EY102004DD Seal - Terminal Cover O-ring 1
15-9 DY102323A Nameplate, CEA, 15, 60, 150 1
15-10 EY102004G Nameplate screw 2
15-11 EY102004GV Pipe Plug (conduit) 3
15-12 HXU-3/4-NPT Pipe Plug (conduit - plastic) 1
15-14 DY102048A Torque Nut 05/07, CEA, 15, 60, 150 1
15-15 EY102004BA Screw - Torque Nut 2
19 CY102219A Indicator Assembly Kit 1
15-12
15-11
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FCD AXENIM2080-00-AQ Printed in USA. January 2015
To find your local Flowserve representative
or for more information about Flowserve Corporation, visit www.flowserve.com.
Flowserve Flow Control (UK)
Burrell Road Haywards Heath West Sussex United Kingdom RH16 1TL Phone: +44 1444 314400 Fax: +44 1444 314401
Flowserve Corporation
Flow Control Division 1978 Foreman Drive Cookeville, Tennessee 38501 USA Phone: +931 432 4021 Fax: +931 432 5518
Flowserve Pte Ltd
No. 12 Tuas Avenue 20 Singapore 638824 Phone: +65 6879 8900 Fax: +65 6862 4940
Flowserve Flow Control Benelux BV
Rechtzaad 17 4703 RC Roosendaal NB Netherlands Phone: +31 165 598 800 Fax: +31 165 555 670
Flowserve Australia Pty Ltd
Flow Control Division 14 Dalmore Drive Scoresby, Victoria 3179 Austrialia Phone: +61 3 9759 3300 Fax: +61 3 9759 3301
Flowserve Flow Control GmbH
Rufolf Plank Str. 2 D-76275 Ettlingen Germany Phone: +49 7243 103 0 Fax: +49 7243 103 222
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The pur­chaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.
© 2015 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.
Flowserve do Brasil Ltda
Rua Tocantins, 128 - Bairro Nova Gerti São Caetano do Sul, São Paulo 09580-130 Brazil Phone: +5511 4231 6300 Fax: +5511 4231 6329 - 423
Flowserve Corporation
Unit 01\02\06\07 9F China Fortune Tower No. 1568, Century Avenue, Pudong Shanghai China 200122 Phone: +86 21 38654800 Fax: +86 21 50811781
Flowserve Corporation
No. 35, Baiyu Road Suzhou Industrial Park Suzhou 215021, Jiangsu Province, PRC Phone: +86-512-6288-1688 Fax: +86-512-6288-8737
Flowserve China
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