Flowserve L120 User Manual

USER INSTRUCTIONS

Limitorque

For L120-10 through L120-40

FCD LMENIM1201-04-AQ – 05/15

Actuation Systems L120 Series

Installation

Operation

Maintenance

Experience In Motion

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Contents

1 Introduction 4

1.1 Purpose 4

1.2 User Safety 4

2 Product Capabilities and Features 5

2.1 Initial Inspection and Storage Instructions 5

2.1.1 Inspection and Recording 6

2.1.2 Short-Term Storage (less than 1 year) 6

2.2 Product Identiﬁcation 7

3 Actuator Weights 8 4 Installation Instructions 9

4.1 Safety Precautions 9

4.2 Safety Practices 9

4.3 Initial Actuator Preparation 10

4.3.1 Mounting Base 10

4.3.2 Stem Acceptance 10

4.4 Torque Switch 11

4.4.1 Setting Torque Switch 11

4.4.2 Balancing Torque Switch 12

4.5 Geared Limit Switch 12

4.5.1 Setting Limit Switch 12

4.5.2 Setting Procedure (Refer to Figure 4.2) 13

4.5.3 Combination of Contacts (Refer to Figure 4.2) 14

4.6 Position Indication 14

4.6.1 Local position indication 14

4.6.2 Remote Position Indication 15

4.7 Optional Side-Mounted Handwheel 16

5 Operation 19

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

5.1 Electrical Start-up 19

5.2 Manual Operation 20

5.3 Motor Operation 25

5.4 Torque and Travel Limiting 25

6 Maintenance 26

6.1 Lubrication 26

6.1.1 Lubrication Inspection 26

6.1.2 Factory Lubricant 27

6.2 Minimum Lubricant Qualities Required 27

6.3 Disassembly and Reassembly 28

6.4 Disassembly of the L120-10, 20, and 40 28

6.5 Drive Sleeve and Housing Cover Disassembly 29

6.6 Torque Nut Disassembly (Drive 1 Option) 29

6.7 Thrust Base Disassembly (Drive 2 Option) 30

6.8 Stem Nut Replacement – Thrust Base Applications 30

6.9 Reassembly 31

6.9.1 Declutch Assembly (L120-10) 32

6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3) 32

6.9.3 Install the Motor (Refer to Figure 5.2) 33

6.9.4 Lubrication Procedure 33

6.9.5 Install Geared Limit Switch, Torque Switch and Finish Assembly 33

7 How to Order Parts 34 8 EC Declaration of Conformity 35

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Introduction

1.1 Purpose

This Installation and Maintenance Manual explains how to install and maintain the L120-10, L120-20, and L120-40 actuators. Information on installation, disassembly, reassembly, lubrication, and parts is provided.

1.2 User Safety

Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the equipment. The user must read and be familiar with these instructions before attempting installation, operation, or maintenance. Work to be performed on the actuator should be carried out by a qualiﬁed tradesman familiar with the operation and maintenance of electric actuators. Failure to observe these precautions could result in serious bodily injury or death, damage to the equipment, voiding of the warranty, or operational difﬁculty.

Safety notices are presented in this manual in three forms:

c WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning

notices could result in personal injury or death.

a CAUTION: Directs the user’s attention to general precautions that, if not followed, could result in

personal injury and/or equipment damage.

NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and operation.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Product Capabilities and Features

L120 Series actuators operate without modiﬁcation in any rising or non-rising stem application for linear action valves.

The actuators meet rigid safety requirements. The actuators are available in weatherproof, explosionproof, and submersible conﬁgurations.

The actuators are compatible with a wide range of control options from stand-alone units with local pushbutton to open standards-based DDC-100 networks with up to 250 actuators.

The actuators are designed with integral control packages including plug-in interconnect boards that increase control functionality for stand-alone or networked units.

Durable torque overload is provided in both directions of travel.

2.1 Initial Inspection and Storage Instructions

c WARNING: Read this Installation and Maintenance Manual carefully and completely before

attempting to store the actuator. Be aware of the electrical hazards.

2.1.1 Inspection and Recording

Upon receipt of the actuator, inspect the condition of the equipment and record nameplate information:

1. Carefully remove actuator from shipping carton or skid. Thoroughly examine the equipment for any physical damage that may have occurred during shipment. If damaged, immediately report the damage to the transport company.

2. Record the actuator nameplate information for future reference; i.e. ordering parts, obtaining further information.

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Handwheel

2.1.2 Short Term Storage Procedures (less than 1 year)

NOTE: The following are our recommended storage procedures to retain maximum product integrity during short-term storage. Failure to comply with recommended procedures will void the warranty. For longer-term storage, contact Limitorque for procedures and recommendations.

Actuators are not weatherproof until properly installed on the valve or prepared for storage.

Store actuators in a clean, dry, protected warehouse away from excessive vibration and rapid temperature changes. If the actuators must be stored outside, they must be stored off the ground, high enough to prevent them from being immersed in water or buried by snow.

1. Position the actuator in storage with motor and switch compartment horizontal.

2. Connect the internal heaters (if supplied) or place desiccant in the switch compartment.

3. Replace all plastic caps or plugs with pipe plugs and ensure that all covers are tight.

4. If the actuator is mounted on a valve and the stem protrudes from the unit, a suitable stem cover must be provided.

Limit Switch/ Controls Compartment

Figure 2.1 – L120-10 through 40

Motor

Housing

Actuator Nameplate (hidden)

Declutch Lever

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

2.2 Product Identiﬁcation

The actuator unit nameplate is located on the back of the unit, opposite the limit switch compartment. The nameplate contains the following information:

• Limitorque name

• Point of Manufacture

• Unit Size

• Order Number

• Serial Number

• Customer Tagging

• CE Stamp

The motor nameplate is located on the motor. The nameplate contains the following information:

• ID Number

• Start Torque

• Run Torque

• Enclosure Type

• RPM

• Volts

• Full Load Amps

• Locked Rotor Amps

• Insulation Class

• Duty

• Horsepower

• Service Factor

• Phase

• Cycles

• Motor Code

• Ambient Temperature

• Connection Diagram

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Actuator Weights

The approximate L120 actuator weights are provided below:

Table 3.1 – Actuator weights

Actuator

Size

L120-10

L120-20

L120-40

Control Types

NCU 100 45 112 51 107 49 119 54

BIC 115 52 127 58 122 55 134 61

CLAMSHELL 140 64 152 69 147 67 159 72

NCU 140 64 158 72 153 69 171 78

BIC 155 70 173 78 168 76 186 84

CLAMSHELL 180 82 198 90 193 88 211 96

NCU 190 86 216 98 212 96 238 108

BIC 205 93 231 105 227 103 253 115

CLAMSHELL 230 105 256 116 252 114 278 126

Drive 1 Weight (lb./kg) Drive 2 Weight (lb./kg)

Top HW Side HW Top HW Side HW

lb. kg lb. kg lb. kg lb. kg

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Installation Instructions

4.1 Safety Precautions

c WARNING: Read this Installation and Maintenance Manual carefully and completely before

attempting to install, operate, or troubleshoot the Limitorque L120 actuator.

c WARNING: Be aware of electrical hazards. Turn off incoming power before working on the actuator

and before opening the switch compartment.

c WARNING: Potential HIGH-PRESSURE vessel – Be aware of high-pressure hazards associated with

the attached valve or other actuated device when installing or performing maintenance on your L120 actuator. Do not remove the actuator mounting bolts when the actuator is mounted on a rising stem valve unless the valve is in the FULLY OPEN position and there is NO pressure in the line.

c WARNING: Do not manually operate the actuator with devices other than installed Handwheel and

Declutch Lever. Using force beyond the ratings of the unit and/or using additive force devices such as cheater bars, wheel wrenches, pipe wrenches, or other devices on the actuator Handwheel or Declutch Lever may cause serious personal injury and/or damage to the actuator or valve.

c WARNING: Do not work on the actuator while it is mounted on a torque-seated valve.

4.2 Safety Practices

The following checks should be performed to maintain safe operation of the L120 actuator.

• Mount motors on a horizontal plane, if possible.

• Keep the switch compartment clean and dry.

• Keep the valve stem clean and lubricated.

• Set up periodic operating schedule for infrequently used valves.

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

• Carefully check for correct motor rotation direction. If the motor is driving the valve in the wrong

direction, interchange any two leads on three-phase motors or switch the armature leads on DC and single-phase motors.

• Use a protective stem cover. Check valve stem travel and clearance before mounting covers on rising

stem valves.

• Verify all actuator wiring is in accordance with the applicable wiring diagram, national and local codes,

and Table 4.1.

Table 4.1 – Required Rating for External Wiring

Up to: Use wire rated at least:

40°C 60°C

60°C 75°C

4.3 Initial Actuator Preparation

Replace all molded plastic conduit and top protectors (installed for shipping purposes only) with pipe plugs when installation wiring is complete.

4.3.1 Mounting Base

The mounting hole sizes and quantities are as detailed in Table 4.2.

Table 4.2 – Mounting Base Dimensions

Actuator Size

L120-10 4

L120-20 4

L120-40 4

Mounting Holes Tap size

Quantity MSS ISO

⁄8-16x0.88 M10x1.5x22.4

⁄8-11x1.25 M16x2x32

4.3.2 Stem Acceptance

The maximum stem acceptance is provided in Table 4.3.

Table 4.3 – Maximum Stem Acceptance

Drive 2 Drive 1

Actuator size

L120-10 1.25 32 1.00 25 ¼x3/32 8x6

L120-20 2.25 57 1.875 47 ½x3/16 14x9

L120-40 2.625 66 2.125 52 ½x3/16 16x10

Tapped Bore Key

inch mm inch mm inch mm

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-AQ – 05/15

Balancing

600 Volt Torque Switch

Microswitch-Style Torque Switch

4.4 Torque Switch

The torque switch is designed to protect the actuator in open and close directions.

a CAUTION: Disconnect all incoming power before opening limit switch compartment or working on

the torque switch.

• Do not use abrasive cloth to clean the contacts on the torque switch.

• Do not torque seat 90° operation valves nor run them against the stops. This may cause damage to the valve.

NOTE: If the actuator has “torqued out,” release torque buildup by operating the actuator manually.

4.4.1 Setting Torque Switch

The torque switch was set at the factory according to customer-supplied information regarding necessary torque or thrust output that was provided at the time of the order. However, if the setting needs to be adjusted, perform the following procedure:

a CAUTION: A torque switch limiter plate is provided on most actuators.

• Removal or modiﬁcation of the torque switch limiter plate will void the actuator warranty.

• Do not exceed the setting indicated by this plate without contacting the Limitorque service department.

• Installing or adjusting the torque switch with the actuator in a loaded condition will result in a loss of torque protection.

Item letters correspond to Figure 4.1.

1. Place the L120 actuator in manual mode.

2. Release the load on the wormshaft spring pack.

3. For open and close directions, loosen Screw (A) and move Pointer (B) to desired position. A higher number indicates a high torque and/or thrust output.

4. Tighten Screw (A).

5. Operate the valve electrically to seat valve and to ensure tight shutoff.

6. Rebalance torque switch if required.

Figure 4.1 – Microswitch-Style Torque Switch and 600 Volt Torque Switch

Maximum Stop Setting Plate

Index Marks

Maximum Stop Setting Plate

OPEN

-10-20

Mounting

Screw

Balancing Screws

Index Marks

Mounting Screw

Screws

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