Flowserve L120-85 User Manual

USER INSTRUCTIONS

Limitorque L120-85 Actuator

FCD LMENIM1202-00 – 11/05

Installation

Operation

Maintenance

Experience In Motion

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

L120-85 Actuator

Installation and Maintenance Manual

Printed in the United States of America.

Disclaimer

No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise without the written permission from Flowserve. While every precaution has been taken in the preparation of the book, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein.

This document is proprietary information of Flowserve furnished for customer use ONLY. No other uses are authorized without written permission of Flowserve.

Flowserve reserves the right to make changes, without notice, to this document and the products it describes. Flowserve shall not be liable for technical or editorial errors or omissions made herein; nor for incidental or consequential damages resulting from the furnishing, performance or use of this document.

This manual contains information that is correct to the best of Flowserve’s knowledge. It is intended to be a guide and should not be considered as a sole source of technical instruction, replacing good technical judgment, since all possible situations cannot be anticipated. If there is any doubt as to exact installation, conﬁguration, and/or use, please contact Flowserve at 1-800-225-6989.

The choice of system components is the responsibility of the buyer, and how they are used cannot be the liability of Flowserve Corporation. However, Flowserve’s sales team and application engineers are always available to assist you in making your decision.

Belden® is a registered trademark of Belden, a division of Cooper Industries, Inc.

Contents

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

1.1 Purpose 5

1.2 User Safety

2.1 Product Identiﬁcation

2.2 Product Description

2.3 Product Features

4.1 Safety 1

4.2 Initial Actuator Preparation 1

4.2.1 Inspection and Recording 1

4.2.2 Short-Term Storage (less than one year) 1

4.3 Actuator Mounting 1

4.3.1 Torque Only Applications (Drive 1) 1

4.3.2 Torque and Thrust Applications

4.3.3 Mounting Bolts 1

4.3.4 Stem Cover for Rising Stem Applications 1

4.4 Verifying Motor Rotation Direction 1

4.4.1 Initial Electrical Connections 1

4.4.2 Motor rotation (phasing) and OPEN/CLOSE pushbutton operation. 15

4.4.3 Three-Phase Motor 1

4.4.4 DC Motor 1

4.5 Limit Switch Settings 1

4.5.1 Basic Theory of Operation 1

4.5.2 Adjustment—General 1

4.5.3 Setting the OPEN Limit Switch 1

4.5.4 Setting the CLOSE Limit Switch 1

4.6 Torque Switch Setting and Wiring 1

4.6.1 Basic Theory of Operation 1

4.6.2 Setting the Torque Switch 1

4.6.3 Balancing the Torque Switch 1

(Drive 2) 12

4.6.4 Rewiring the Torque Switch

4.7 Position Indication 2

7 8 8 1

5.1 Description of Motor Operation 2

5.2 Description of Manual Operation 2

6.1 Lubrication 2

1 2 2

3 3

8.1 Handwheel Shaft Assembly and Shimming 3

8.2 Verifying Handwheel Operation 3

8.3 Thrust Base Assembly and Shimming 3

9.1 Typical Wiring Diagram 3

10.1 L120-85 Illustrated Parts Breakdown 4

10.2 L120-85 Parts List 4

5 6 7 7 8 9 9 9 9

for Non-Standard Drive Sleeve Rotation 20

4.7.1 Local Position Indication 2

4.7.2 Remote Position Indication 2

4.7.3 Setting the Potentiometer 2

6.1.1 Initial Inspection 2

6.1.2 Frequency 2

6.1.3 Routine Inspection 2

6.1.4 Factory Lubricants 2

6.1.5 Minimum Lubricant Qualities Required 2

Three-phase with Control Package 3

0 0 1 2 3 3 5 5 5 5 5 6 1 3 3 7 7 0 5

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Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Figures

Figure 1: Limitorque L120-85 Actuator 8 Figure 2: L120-85 Torque Drive Nut and Retaining Ring Details 1 Figure 3: Thrust Base removal from an L120-85 1 Figure 4: L120-85 Torque Drive Nut orientation (Drive 1) 1 Figure 5: L120-85 Thrust Base Assembly orientation (Drive 2) 1 Figure 6: Electrical Compartment and Conduit Pipe Plug openings 1 Figure 7: Grounding Lug location 1 Figure 8: Limit Switch Rotor development 1 Figure 9: L120-85 Limit Switch Components 1 Figure 10: Limit Switch OPEN/CLOSED Rotor Cam orientation 1 Figure 11: Torque Switch Components 1 Figure 12: Reversing Torque Switch wiring 2 Figure 13: Aligning MDPI Pointer for Fully CLOSED Position 2 Figure 14: Remote Position Indicator Calibration Conﬁguration 2 Figure 15: Potentiometer Calibration conﬁguration 2 Figure 16: Loosening Potentiometer Assembly 2 Figure 17: Removing Clutch Pinion Assembly 2 Figure 18: Key components affected by Handwheel shimming 3 Figure 19: Cut-away view of L120-85 actuator with Clutch Latch positioned on face of Clutch Bearing 3 Figure 20: Gap between Housing face and Handwheel Bushing shown as dimension “A” 3 Figure 21: Shimming parts and their order of assembly 3 Figure 22: Shim location for gap “B” dimension/ 3 Figure 23 Three-phase with Control Package 3 Figure 24: Electrical Compartment 4 Figure 25: Motor and Motor Drive Components 4 Figure 26: Handwheel Shaft and Associated Components 4 Figure 27: Drive Sleeve Group 4 Figure 28: Thrust Base Group 4

Tables

Table 1: L120-85 Approximate Weight Chart 9

Table 2: Torque Drive Nut: Maximum Allowable Bore and Key Sizes 1

Table 3: L120-85 Actuator/Mounting Base Tap Size 1

Table 4: Gap “A” shim thickness selection chart 3

Table 5: Gap “B” shim thickness selection chart 3

4 5 6 7 8 9 0 0 1 2 2 9 1

2 3 3 7 0 1 2 3 4

2 3 2 3

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Introduction

1.1 Purpose

This Installation and Maintenance Manual explains how to install and maintain the L120-85 actuator. Information is provided for installation, disassembly, reassembly, lubrication, and parts selection.

WARNING: Read this installation and maintenance man-

c

ual carefully and completely before storing, installing, operating or troubleshooting your Flowserve Limitroque actuator. Be aware of electrical hazards within the actuator and high-pressure hazards at the attached valve or other device when installing or performing maintenance on your L120-85 actuator.

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, voiding of the warranty, or operational difﬁculty.

Safety notices are presented in this manual in three forms:

WARNING: Refers to personal safety. Alerts the user to

c

potential danger. Failure to follow warning notices could result in personal injury or death.

CAUTION: Directs the user’s attention to general precautions

a

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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Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Product Capabilities and Features

2.1 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:

• Product name

• Point of Manufacture

• Unit Size

• Order Number

• Serial Number

• Customer Tagging

• Certiﬁcation Information

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

• Full Load Amps

• Insulation Class

• Horsepower

• Number of Phases

• Motor Code

• Connection Diagram

• Start Torque

• Enclosure Type

• Volts

• Locked Rotor Amps

• Duty Rating

• Service Factor

• ID Number

• Run Torque

• RPM

• Frequency

• Ambient Temperature

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Thrust

Base

Handwheel

Electrical

Compartment

Cover

Conduit Openings (plugged; two additional openings are supplied on the bottom of the Electrical Compartment)

Housing

Declutch

Lever

Motor

Position

Indication

Window

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Figure 1: Limitorque L120-85 Actuator

2.2 Product Description

Your L120-85 actuator controls the opening and closing travel of valves or other actuated devices. OPEN and CLOSED limits are protected by Limit Switches and output torque is measured and protected by the Torque Switches. As a result, all valves and other actuated devices are protected from potential damage from overload, improper seating and foreign obstructions.

Limitorque actuators may be mounted on any appropriately sized valve in almost any position or location.

Microprocessor-based controls and monitoring devices are also available for installation on your actuator. Contact your local Limitorque distributor or Limitorque sales ofﬁce for further information.

2.3 Product Features

• Up to 850 ft-lb/1156 Nm torque capacity.

• Up to 45,000 lb./20250 kg thrust capacity.

• Up to 3.25"/76 mm threaded stem capacity.

• Up to 2.75"/70 mm bore capacity.

• Torque Only (Drive 1) or Torque and Thrust (Drive 2) actuators, with removable ductile iron thrust base assembly.

• Torque unit can be removed from thrust base while valve position is maintained.

• Standard cast iron gear case.

• All power gearing supported on anti-friction bearings.

• All gearing is alloy, heat-treated steel or bronze.

• Speed range of 24-192 RPM (60 Hz), 20-160 RPM (50 Hz).

• Declutch force independent of load on valve stem.

• Self-locking gearing available.

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Unit Weight

The following table is an L120-85 representative weight chart. It provides the weight of several components that may be incorporated into a typical package. Use the chart as a guideline to estimate the weight of your particular actuator package.

Table 1: L120-85 Approximate Weight Chart

Components lb. kg

L120-85 with 40 ft-lb 1700 RPM Motor 253 558

18" Handwheel 7 15

Handwheel Adapter 5 11

Minimum Integral Control Package and Compartment

Thrust Base Assembly (Drive 2) 67 148

Total Weight 366 lb. 807 kg

34 75

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Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Initial Preparation and Installation

4.1 Safety

WARNING: Read this Installation and Maintenance

c

Manual carefully and completely before attempting to store, install, operate or troubleshoot your Limitorque valve actuator. Be aware of electrical hazards within the actuator and high pressure hazards of the attached valve or other actuated device when installing or performing maintenance on your L120-85 actuator.

4.2 Initial Actuator Preparation

4.2.1 Inspection and Recording

Upon receipt of the actuator, several steps should be initially followed to ensure condition of equipment and to establish proper record keeping.

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

2. A nameplate with important information is attached to each actuator. Record this information for future reference.

4.2.2 Short-Term Storage

(less than one year)

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

Store units in a clean, dry, protected warehouse away from excessive vibration and rapid temperature changes. If the units 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 compart ment horizontal.

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

3. Replace all plastic caps or plugs with taped or doped 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.

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#95 Torque Drive Nut

#98 Torque Nut Retaining Ring

#111 Lockwasher

#110 Socket Head Cap Screw

#100 Thrust Base Housing

#1 Housing

#101 Thrust Base Drive Sleeve

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

NOTE: If your unit incorporates a rising stem application, it may be shipped with a plastic cap over the Drive Sleeve Housing. If so, in order to store without possible corrosion occurring, install a pipe plug or protective stem cover to protect the Drive Sleeve Housing.

NOTE: Failure to comply with recommended storage procedures could cause the warranty to be voided. For long-term storage procedures, consult the Limitorque Customer Service Department.

4.3 Actuator Mounting

Your L120-85 is designed to perform actuation for torque only applications (drive 1) or for torque and thrust applications (drive

2). If you are using a torque only conﬁguration, before installing on the valve or other actuated device, you will need to verify that the Torque Drive Nut (piece 95) is properly bored and keyed to ﬁt your valve stem. If you are using a torque and thrust conﬁguration, you will need to verify that the Thrust Base Drive Sleeve (piece 101) is properly threaded to ﬁt your threaded valve stem. Use the following procedures to check for proper ﬁt of the Torque Drive Nut or the Thrust Base Drive Sleeve.

A) If Torque Drive Nut has been bored and keywayed by supplier,

verify dimensions of keyway for proper compatibility with the valve stem.

B) If Torque Drive Nut has not been bored and keywayed by sup

plier, it is provided solid (blank) to allow customer to custom bore and key up to the maximum permissible sizes as listed:

Table 2: Torque Drive Nut: Maximum Allowable Bore and Key Sizes

Key Type Maximum Bore in. (mm) Maximum Key in. (mm)

Rectangle 2.750 (69.85) .625 x .4375 (20 x 12)

Square 2.625 (66.67) .625 x .625 (20 x 20)

4.3.2 Torque and Thrust Applications (Drive 2) (Refer to Figure 28)

Remove Socket Head Cap Screw (piece 110) and Lockwasher (piece

111) that holds the Thrust Base Housing Assembly to the actuator

Housing (piece 1).

Figure 3: Thrust Base removal from an L120-85

4.3.1 Torque Only Applications (Drive 1) (Refer to Figure 27)

Remove the Torque Nut Retaining Ring (piece 98) and Torque Drive Nut (piece 95) from actuator.

Figure 2: L120-85 Torque Drive Nut and Retaining Ring Details

A) If the Thrust Base Drive Sleeve (piece 101) has been threaded by

supplier, verify thread compatibility with the threaded Valve Stem by screwing Drive Sleeve onto the valve stem.

B) If Thrust Base Drive Sleeve (piece 101) has not been threaded by

supplier, it is provided solid (blank) to allow customer to custom thread. Maximum threaded stem diameter is 3.25" (82.5 mm).

NOTE: If Thrust Base disassembly is required in order to thread blank Thrust Base Drive Sleeve, remove Quad Rings (piece 107) before removing Thrust Washer (piece 104) and Thrust Bearing

Drive 1 Actuator Mounting Base

Actuator Mounting Adapter

Valve Stem

#95 Torque Drive Nut

Key

Note: Key is shown for reference. It may be in one of several other orientations in reference to the actuator.

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

(piece 103). This will prevent damaging the Quad Rings (piece 107). For details refer to Section 10.1, Figure 28.

4.3.3 Mounting Bolts

Mount the L120-85 actuator on the Actuator Mounting Adapter (Drive 1) or on the Thrust Base Assembly (Drive 2). High-strength (minimum hex head SAE-Grade 5 or ISO Metric Class socket head cap screws) 8.8 hex head or socket head cap screws with lockwashers are recommended. The quantity and thread size of the actuator mounting taps are as follows:

Table 3: L120-85 Actuator/Mounting Base Tap Size

Unit Type Quantity Tap Size

Drive 1 and 2

English 4 ¾–10 Tap x 1.0 in. Deep*

Metric 4 M20 x 2.5 mm x 10 mm Deep*

*Complies with F16 IOS mounting ﬂange criteria

NOTE: Limitorque has supplied four taps for the L120-85 English and metric units. All four securing bolts are required to retain torque and/or thrust reaction on these units.

Installation Overview

1. Applications

A. Torque Only Applications (Drive 1)

Mount Torque Drive Nut (piece 95) in the actuator with the Torque Drive Nut axially aligned on the Drive Sleeve (piece

25) so that the bottom of the nut is positioned inside the actuator Mounting Base. Secure Torque Drive Nut inside Drive Sleeve (piece 25) with Retaining Ring (piece 98). Refer to Figure 27.

B. Torque and Thrust Applications (Drive 2)

Screw the Thrust Base Assembly onto the Threaded Valve Stem and secure the Thrust Base Assembly to the Actuator Mounting Base using Socket Head Cap Screws (piece 110) and Lockwashers (piece 111).

Figure 4: L120-85 Torque Drive Nut orientation (Drive 1)

4.3.4 Stem Cover for Rising Stem

a

Before putting your actuator into operational service, check the height of your valve stem at the full OPEN position and mount a suitable stem cover to protect the valve stems and to prevent water entry into the actuator.

Applications

CAUTION: Selection and installation of a stem cover which is too short will result in damage to the valve and/or actuator.

CAUTION: Be sure to complete each step of the installation overview before electrically operating your actuator. If your actuator is already mounted to a valve or other actuated device from the manufacturer, verify that the actuator is mounted according to the following overview. Failure to follow the installation procedures could result in personal injury or may allow the actuator to operate improperly and could cause damage to your equipment.

CAUTION: Ensure Retaining Ring (piece 98) is properly engaged in the Drive Sleeve (piece 25) to secure the Torque Drive Nut (piece 95) in place. If the Torque Drive Nut is not properly secured, it may fall from the bottom of the actuator when removed from customer mounting adapters.

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Drive 2 Actuator Mounting Base

Actuator Mounting Adapter

Threaded Valve Stem

#101 Thrust Base (Drive Sleeve)

Thrust Base Assembly

#110 Socket Head Cap Screws #111 Lockwashers

Conduit Pipe Plug Locations

Electrical Compartment

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Figure 5: L120-85 Thrust Base Assembly orientation (Drive 2)

4.4 Verifying Motor Rotation

Direction

4.4.1 Initial Electrical Connections

WARNING: Hazardous Voltage. No electrical power should

c

be connected until all wiring and Limit Switch adjustments have been completed. Once power is supplied to unit, exercise caution if cover is not installed.

1. Open the Electrical Compartment Cover (piece 200-1) and

remove the Conduit Pipe Plugs from the opening(s) most conveniently located for your power leads and other cabling.

Figure 6: Electrical Compartment and Conduit Pipe Plug openings

2. Adjust the Limit Switches, MDPI (Mechanical Dial Position Indicator) and Potentiometer following the procedures outlined in Sections 4.5 and 4.7.

3. Ensure Torque Switch is set properly for your application. In most cases, adjustments are not needed, but if changes are required, see Section 4.6, “Torque Switch Settings and Wiring”.

4. Connect wiring to Terminal Strips provided on the actuator. Refer to the wiring diagram supplied with your speciﬁc actuator. “Fork-type” terminal connections are recommended.

5. Be sure any unused conduit entrances are plugged with metal Conduit Pipe Plugs.

Notes:

a) Explosion-proof actuators require approved “sealing ﬁttings”

installed in accordance with the National Electric Code.

b) Submersible actuators require approved “sealing ﬁttings” in

order to prevent water entering the actuator.

6. Attach grounding wire to Grounding Lug (piece 14).

Grounding Lug

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-00 – 11/05

Figure 7: Grounding Lug location

7. Inspect actuator for proper lubrication. Refer to “Lubrication” Section 6.1 for lubrication instructions.

8. Verify that Motor rotation is operating in the proper direction; the Motor rotation will have a direct impact on the Limit Switch and Torque Switch functions. Follow the procedure “Verifying Motor Rotation Direction” in Sections 4.4.2, 4.4.3 and 4.4.4).

9. Close Electrical Compartment Cover (piece 200-1).

10. Unit is now ready for electrical operation. Continue to “Electrical Start-up Procedure” in Section 5.3.

4.4.2 Motor rotation (phasing) and OPEN/

CLOSE pushbutton operation.

It is very important to check for correct motor rotation to ensure that serious damage to your valve or other equipment does not occur. If the actuator motor rotates in the wrong direction, damage could occur by over-torquing equipment into a seated position.

Prior to being shipped from the factory, each actuator is inspected to verify proper operation of the Torque and position Limit Switch and to ensure that they function correctly (i.e. closes when the CLOSE pushbutton is depressed, opens with the OPEN pushbutton, etc.). These inspections are made with a properly phased power source connected as described in the actuator manual.

CAUTION: To ensure proper operation and to prevent your

a

actuator or other actuated equipment from damage, verify that your unit is properly connected to its power source.

NOTE: Your application may vary from the following standard wiring conﬁgurations for Three-phase, Single-phase and DC motors. Refer to your actuator wiring diagram for user-speciﬁc wiring conﬁguration.

4.4.3 Three-Phase Motor

1. Using the Handwheel, move the valve to a midtravel position (midtravel position allows electrical operation in the valve “safe” area and keeps the OPEN and CLOSED Limit Switches from tripping while testing motor direction).

2. Be prepared to immediately remove power should the actuator run the wrong way.

3. Test motor direction by momentarily pressing the OPEN push button:

A) If the actuator moves toward CLOSED, immediately turn all

power OFF and reverse the motor leads T1 and T3.

NOTE: Refer to your actuator wiring diagram for user-speciﬁc wiring conﬁguration.

B) If the actuator moves toward OPEN, the motor is wired

properly for the application.

4.4.4 DC Motor

1. Using the Handwheel, move the valve to a midtravel position (midtravel position allows electrical operation in the valve “safe” area and keeps the OPEN and CLOSED limit switches from tripping while testing motor direction).

2. Test motor direction by momentarily pressing the OPEN push button:

A) If the actuator moves toward CLOSED, immediately turn all

power OFF and reverse the motor leads A1 and A2.

NOTE: Refer to your actuator wiring diagram for user speciﬁc wiring conﬁguration.

B) If the actuator moves toward OPEN, the motor is wired

properly for the application.

4.5 Limit Switch Settings

The standard L120-85 Limit Switch has 16 contacts. The OPEN/ CLOSE Limit Switch (ﬁrst eight contacts) has two Rotor Sets, one for the OPEN position and one for the CLOSED position. Each Rotor Set has four electrical contacts which can be arranged in any combination of normally OPEN and normally CLOSED. The SPARE Limit Switch (second eight contacts) has two additional Rotor Sets with four contacts each that can be set to operate anywhere between the OPEN and CLOSE positions. These can be used to stop the valve in mid-travel or to interlock with other equipment such as pumps, fans, mixers, etc. Refer to Figure 8.

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