Flowserve L120-190 User Manual
USER INSTRUCTIONS
Limitorque L120-190 through L120-2000
FCD LMENIM1203-00 – 10/11
Installation
Operation
Maintenance
Experience In Motion
Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
2
Limitorque
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Contents
1 Introduction 5
1.1 Purpose 5
1.2 User Safety 5
2 Product Capabilities and Features 6
3 Initial Inspection and Storage Instructions 7
3.1 Product Identification 7
3.2 Inspection and Recording 8
3.3 Storage Procedures 8
3.3.1 Short-Term Storage (less than 1 year) 8
4 Actuator Weights 10
5 Installation Instructions 11
5.1 Safety Precautions 11
5.2 Safety Practices 12
5.3 Actuator Preparation 12
5.3.1 Mounting Base 13
5.3.2 Stem Acceptance 13
5.4 Double Torque Switch 13
5.4.1 Setting Torque Switch 14
5.4.2 Balancing Torque Switch 15
5.4.3 Torque Switch Terminal Connections 15
5.5 Geared Limit Switch – Rotor Type 16
5.5.1 Setting Limit Switch 16
5.5.2 Combination of Contacts 19
5.6 Position Indication 19
5.6.1 Local Position Indication 19
5.6.2 Remote Position Indication 20
5.6.3 Calibrating Position Transmitter PT20SD 20
6 Operation 21
6.1 Electrical Start-Up 21
6.1.1 Typical Wiring Diagram 22
6.2 Manual Operation 22
6.3 Motor Operation 23
6.4 Torque and Travel Limiting 23
7 Maintenance 24
7.1 Lubrication 24
7.1.1 Lubrication Inspection 24
7.1.2 Factory Lubricant 25
8 Disassembly and Reassembly 26
8.1 L120-190, -420, and -800 26
8.1.1 To Replace Stem Nut Only 26
8.1.2 L120-190, 420, 800 Disassembly 27
8.1.3 Reassembling Actuator Sizes L120-190, -420 and -800 28
8.1.4 Gaskets 29
8.2 L120-2000 38
8.2.1 Drive 2 Disassembly (Thrust Housing Only) 38
8.2.2 Drive 1 Disassembly (Torque Housing) 38
8.2.3 Drive 1 (Torque Housing) Reassembly 40
8.2.4 Drive 2 (Thrust Housing Only) Reassembly 42
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Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
9 Standard Wiring Diagrams 49
10 Troubleshooting 52
11 How to Order Parts 53
12 Regulatory Information 54
Figures
Figure 3.1 – L120-190 through 2000 8
Figure 5.1 – Double Torque Switch 13
Figure 5.2 – Setting Torque Switch 14
Figure 5.3 – Ring Tongue Terminal 15
Figure 5.4 – Geared Limit Switch 17
Figure 5.5 – Setting Geared Limit Switch 18
Figure 5.6 – Position Indicators 19
Figure 5.7 – Typical Connection for a 1000 ohm Potentiometer 20
Figure 8.1 – L120-190 and -420 Drive Sleeve Side View (Refer to Table 8.1 for parts list) 30
Figure 8.2 – L120-190 and -420 Worm Shaft Side View (Refer to Table 8.1 for parts list) 31
Figure 8.3 – L120-190 and -420 Top View (Refer to Table 8.1 for parts list) 32
Figure 8.4 – L120-800 Drive Sleeve Side View (Refer to Table 8.1 for parts list) 33
Figure 8.5 – L120-800 Worm Shaft Side View (Refer to Table 8.1 for parts list) 34
Figure 8.6 – L120-800 Top View (Refer to Table 8.1 for parts list) 35
Figure 8.7 – L120-2000 Drive Sleeve Side View (Torque Base) (Refer to Table 8.2 for parts list) 43
Figure 8.8 – L120-2000 Top View (Refer to Table 8.2 for parts list) 44
Figure 8.9 – L120-2000 Side View (Refer to Table 8.2 for parts list) 45
Figure 8.10 – L120-2000 Exploded View 46
Figure 9.1 – Wiring Diagram – No Controls 49
Figure 9.2 – Wiring Diagram – Integral Controls 50
Figure 9.3 – Wiring Diagram – NCU 51
Tables
Table 4.1 – Actuator Weights 10
Table 5.1 – Mounting Base Dimensions 13
Table 5.2 – Maximum Stem Acceptance 13
Table 5.3 – Terminal Dimensions By Cable Size 16
Table 5.4 – Maximum Drive Sleeve Turns 17
Table 7.1 – Lubricant Weights 25
Table 8.1 – L120-190, -420 and -800 typical parts list 36
Table 8.2 – L120-2000 typical parts list 47
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1
Limitorque
Introduction
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
1.1 Purpose
This Installation and Maintenance Manual explains how to install and maintain L120-190 through -2000
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. Failure to observe these precautions could result in
serious bodily injury, damage to the equipment, warranty void, 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.
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2
Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
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 and are available in weatherproof, explosionproof, and
submersible configurations.
The actuators are compatible with a wide range of control options from stand-alone actuators with local
control stations 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 actuators.
Torque overload protection is provided in both directions of travel.
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Limitorque
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Initial Inspection
and Storage Instructions
3
c WARNING: Read this Installation and Maintenance Manual carefully and completely before
attempting to store the actuator. Be aware of the electrical hazards.
3.1 Product Identification
The actuator nameplate is located on the back of the actuator opposite the limit switch controls
compartment. The nameplate contains the following information:
• Limitorque name
• Point of manufacture
• Actuator size
The motor nameplate is located on the motor. The nameplate contains the following information:
• ID number
• Run torque
• RPM
• Full load amps
• Insulation class
• Space heater size
• Service Factor
• Cycles
• Ambient temperature
• Start torque
• Order number
• Serial number
• Customer tagging
• Enclosure type
• Volts
• Locked rotor amps
• Duty
• Horsepower
• Phase
• Motor code
• Connection diagram
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Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Figure 3.1 – L120-190 through 2000
Motor
Declutch
Lever
Actuator Nameplate
(hidden)
Housing
Limit Switch
and Controls
Compartment
Handwheel
3.2 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.
3.3 Storage Procedures
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.
3.3.1 Short-Term Storage (less than 1 year)
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 tempera-
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ture 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.
Limitorque
1. Position the actuator in storage with motor and switch compartment horizontal.
2. Connect the space heaters (if supplied) or place desiccant in the switch compartment.
3. Connect space heaters if actuator is to be stored in a damp place.
4. Replace all plastic caps or plugs with pipe plugs and ensure that all covers are tight.
5. If the actuator is mounted on a valve and the stem protrudes from the actuator, a suitable stem
cover must be provided.
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
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Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Actuator Weights
The approximate L120 actuator weights are provided below:
Table 4.1 – Actuator Weights
Actuator Size Control Types
3
NCU
3
L120-190
L120-420
L120-800 NCU
L120-2000 NCU
Note 1: Torque Only
Note 2: Torque and Thrust
Note 3: NCU = No Controls Actuator
BIC = Basic Integral Controls
UEC = Universal Electronic Controller
BIC
UEC/Clamshell
3
NCU
3
BIC
UEC/Clamshell
3
3
Drive 1 Weight Side HW Drive 2 Weight Side HW
lb. kg lb. kg
520 192 520 192
3
3
586 217 586 217
586 217 586 217
1065 394 1065 394
1130 418 1130 418
1220 451 1220 451
1
1270
1
2500
471
925
1
1
1700
3300
2
2
629
1221
2
2
10
5
Limitorque
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Installation Instructions
5.1 Safety Precautions
c WARNING: Read this Installation and Maintenance Manual carefully and completely before
attempting to install, operate, or troubleshoot the Limitorque 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 the actuator. Do not remove the actuator mounting bolts from the valve or actuated device
unless the valve or device stem is secured or there is no pressure in the line.
c WARNING: For maintenance and/or disassembly of the actuator while installed on the valve,
ensure that the actuator is not under thrust or torque load. If the valve must be left in service,
the valve stem must be locked in such a way as to prevent any movement of the valve stem.
c WARNING: Do not attempt to remove the spring cartridge cap, housing cover, or stem nut
locknut from the actuator while the valve or actuated device is under load.
c WARNING: Do not manually operate the actuator with devices other than the installed hand-
wheel and declutch lever. Using force beyond the ratings of the actuator 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 and valve.
c WARNING: Do not exceed any design limitations or make modifications to this equipment
without first consulting Limitorque.
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Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
c WARNING: Actuators equipped with electrical devices (motors, controls) requiring field wiring
must be wired and checked for proper operation by a qualified tradesman.
c WARNING: Use of the product must be suspended any time it fails to operate properly.
a CAUTION: Do not use oversized motor overload heaters. Instead, look for the cause of the
overload.
a CAUTION: Do not operate the valve under motor operation without first setting or checking the
limit switch setting and motor direction.
a CAUTION: Do not force the declutch lever into the motor operation position. The lever returns to
this position automatically when the motor is energized.
a CAUTION: Do not depress the declutch lever during motor operation to stop valve travel.
a CAUTION: Do not use replacement parts that are not genuine Flowserve Limitorque parts, as
serious personal injury and/or damage to the actuator and valve may result.
a CAUTION: Do not lift actuator/gearbox or actuator/valve combinations with only the eye bolts in
the L120 actuator. These eye bolts are designed for lifting the L120 actuator only.
a CAUTION: Do not lift the actuator by handwheel.
5.2 Safety Practices
The following check points should be performed to maintain safe operation of the L120 actuator:
• Eye bolts are designed for lifting only the actuator and not associated gearboxes or valves.
• Mount motor on a horizontal plane, if possible. Preferably, keep the motor or limit switch compartment from hanging down. This prevents head of grease from being against motor or switch seals.
• Keep the switch compartment clean and dry.
• Keep the valve stem clean and lubricated.
• Set up periodic operating schedules for infrequently used valves.
• Verify that all actuator wiring is in accordance with the applicable wiring diagram.
• Carefully check for correct motor rotation direction. If the motor is driving the valve in the wrong
direction, interchange any two leads on the three-phase motor or switch the armature leads on DC
motors.
• Use a protective stem cover. Check valve stem travel and clearance before mounting covers on rising
stem valves.
• Verify that a locking nut tightly secures the stem nut and that the top thread of the lock nut is crimped
and staked in two places.
• For the DC motor, keep the armature clean and periodically check brushes for proper contact and wear.
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5.3 Actuator Preparation
NOTE: Replace all molded plastic conduit and top protectors (installed for shipping purposes only) with
pipe plugs when installation wiring is complete.
Limitorque
OPEN
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
5.3.1 Mounting Base
The mounting hole sizes and quantities are as detailed in Table 5.1, below:
Table 5.1 – Mounting Base Dimensions
Actuator Size
L120-190 8 ¾–10 x 1.13 M20 x 2.5 x 32 11.75 298 mm
L120-420 8
L120-800 (Torque Only) 8 ¾–10 x 1.63 N/A 17.0 N/A
L120-800 (Thrust Only) 8 1.25–7 x 2.0 N/A 16 N/A
Mounting Holes Tap Size
Quantity MSS MSS
7
⁄8–9 x 1.75 N/A 14.0 N/A
ISO
Bolt Circle
ISO
L120-2000 (Torque Only)
L120-2000 (Thrust Only) 12 1-½–6 x 3.0 N/A 18.0 N/A
16
1–8 x 2.0 N/A 23.5 N/A
5.3.2 Stem Acceptance
The maximum stem acceptance is provided in Table 5.2, below:
Table 5.2 – Maximum Stem Acceptance
Actuator size
L120-190 3.5 89 2.875 73 ¾ x ¼ 20 x 12
L120-420 5 127 4.25 108 1 x ¾ 28 x 16
L120-800 5 127 7 178 1 x ¾ 32 x 18
L120-2000 6.25 159 8.00 203 1¼ x
NOTE: For complete mounting dimensions, see sales brochure LMENBR1200.
Drive 2 Tapped Drive 1 Bore Drive 1 Key
inch mm inch mm inch mm
7
⁄8 40 x 22
5.4 Double Torque Switch
The torque switch is designed to protect the actuator in open and close directions.
Figure 5.1 – Double Torque Switch
NOTE: See Caution and Note on following page.
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Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
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 or 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 in
opposite direction ½ to 1 turn of the output drive sleeve.
NOTE: Torque switch contacts are rated 600 volts, in accordance with NEMA ICS-2.
5.4.1 Setting Torque Switch
The torque switch was set at the factory according to customer-supplied information regarding necessary torque or thrust output provided at the time of the order. However, if the torque switch is newly
installed or the setting needs to be adjusted, follow the procedure below:
a CAUTION: A maximum stop setting plate is provided on most actuators. Do not remove this
plate. Do not exceed the setting indicated by this plate without contacting Limitorque.
• Installing or adjusting the torque switch with the operator in a “loaded” condition will result in a
loss of torque protection.
Item letters correspond to Figure 5.2.
1. Place the L120 actuator in manual mode.
2. Release the load on the wormshaft spring pack. Put operator in manual mode and operate in
opposite direction until switch is in neutral position.
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 the valve and to ensure tight shutoff.
Figure 5.2 – Setting Torque Switch
Maximum Stop
Setting Plate
14
B
Torque Switch Dial
A
Limitorque
A
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
5.4.2 Balancing Torque Switch
Item letters correspond to Figure 5.2.
1. Place the actuator in manual mode.
2. Remove the load from the wormshaft spring pack.
NOTE: If the actuator has “torqued out,” release torque buildup by operating the actuator manually in
opposite direction ½ to 1 turn.
3. Note the open and close torque switch settings prior to re-installing the torque switch.
4. Loosen Screws (A) and position both Pointers (B) at the #1 setting; tighten Screws (A).
5. Mount the torque switch and tighten the mounting screws. Verify that both contact pointers are
touching the arms. The interface between the pointers and the arm is found beneath the torque
switch dial. If the pointers and the arms are not in contact, the clearance on the open and close
torque switches should be equal. If not equal, the torque switch needs to be balanced. (See Step 7.)
6. If the pointers and arms are in contact on both sides of the switch, manually rotate the torque
switch dial clockwise and counter-clockwise to determine if there is equal backlash in both directions of rotation. If there is not equal backlash in both directions, the torque switch needs to be
balanced. (See Step 7.)
7. Loosen both hex nuts.
8. Back out one setscrew and tighten the other setscrew until there is equal backlash in both directions
of rotation of the dial, or equal clearance between the pointers and arms.
9. Tighten the hex nuts and return the torque switch to its original settings.
a CAUTION: The balancing screws should not be touched except during the balancing procedure.
The switch is now balanced and ready for the pointers to be returned to their original settings.
5.4.3 Torque Switch Terminal Connections
Wiring connections to the L120 geared limit switch, torque switch, and marathon terminal strips are to
be made using ring-tongue terminals as shown below:
Figure 5.3 – Ring Tongue Terminal
C
B
See Table 5.3, next page
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Limitorque® L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Table 5.3 – Terminal Dimensions By Cable Size
AWG Screw Hole Insulation
22-16 #10 Vinyl 18RA-10 .97 .31 .27
18-14 #10 Vinyl 14RB-10 .97 .31 .27
12-10 #10 Vinyl 14RC-10 1.06 .31 .27
Terminals are to be crimped using Thomas & Betts crimping tool WT111M.
Thomas &
Betts P/N
A B C
5.5 Geared Limit Switch – Rotor Type
a CAUTION: The geared limit switch is not preset at the factory and must be adjusted after the
actuator has been mounted on associated equipment.
NOTE: Limit switch contacts are rated 600 volts, in accordance with NEMA ICS-2
• Disconnect all incoming power to the actuator prior to opening the limit switch compartment and
adjusting the switch.
• Consult the relevant wiring diagram for limit switch contact development. All L120 actuators are
supplied with 16-contact limit switches - four switches on each of the four rotors. Two rotors are
used for end-of-travel indication. The remaining two rotors may be adjusted for any intermediate
point-of-travel.
• Do not use abrasive cloth to clean the contacts on the limit switch.
• Do not attempt to repair gearing in the limit switch. Replace entire gear frame assembly if necessary.
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5.5.1 Setting Limit Switch
The maximum number of drive sleeve turns available is a funtion of actuator size, worm gear ratio,
and type of switch. See Table 5.4. The Intermediate Shaft shown in Figure 5.5 may take a considerable
number of turns before rotor trip occurs.
c WARNING: Potential Explosion Hazard. Do not use a variable speed electric drill for setting the
limit switch in an explosive environment.
a CAUTION: When setting the limit switch rotor segments (cams) using a variable speed electric
drill, do not run drill at speeds higher than 200 RPM. Operating the drill at high speeds can
damage the gearing within the limit switch.
Limitorque
®
L120-190 through L120-2000 FCD LMENIM1203-00 – 10/11
Table 5.4 – Maximum Drive Sleeve Turns
Limit Switch Gearing PIC Gearing
Actuator Size W.G. Ratio 4-Gear 5-Gear PIC or R/I (270) RVDT(90)
L120-190 13.3:1 3110 31100 13706 4569
33:1 1250 12500 5521 1837
60:1 690 6900 3037 1012
85:1 N/A N/A N/A N/A
L120-420 10.33:1 N/A N/A N/A N/A
16:1 3300 33000 11405 3797
41:1 1280 12800 4445 1481
57:1 910 9100 3195 1065
80:1 N/A N/A N/A N/A
L120-800 12.67:1 N/A N/A N/A N/A
19:1 2850 28500 9586 3195
49:1 1050 10500 3720 1240
58:1 N/A N/A N/A N/A
86:1 N/A N/A N/A N/A
L120-2000 43:1 1210 12100 4234 1413
71:1 740 7400 2566 855
Figure 5.4 – Geared Limit Switch
Set the limit switch as shown on the following page. All item letters and piece numbers refer to Figure 5.5.
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