Flowserve L120 User Manual

USER INSTRUCTIONS

Limitorque® Actuation Systems L120 Series	Installation
For L120-10 through L120-40	Operation
FCD LMENIM1201-04-AQ – 05/15	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

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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:

cc WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices could result in personal injury or death.

aa 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

2 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

cc 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

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.

Figure 2.1 – L120-10 through 40

Handwhee

Motor

Actuator Nameplate (hidden)

Declutch

Lever

Limit Switch/	Housing
Controls
Compartment

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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

3 Actuator Weights

The approximate L120 actuator weights are provided below:

Table 3.1 – Actuator weights

Actuator				Drive 1 Weight (lb./kg)								Drive 2 Weight (lb./kg)
	Control Types		Top HW				Side HW				Top HW				Side HW
Size
			lb.		kg		lb.		kg		lb.		kg		lb.		kg
	NCU		100		45		112		51		107		49		119		54
L120-10	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
L120-20	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
L120-40	BIC		205		93		231		105		227		103		253		115
	CLAMSHELL		230		105		256		116		252		114		278		126

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

4 Installation Instructions

4.1 Safety Precautions

cc WARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to install, operate, or troubleshoot the Limitorque L120 actuator.

cc WARNING: Be aware of electrical hazards. Turn off incoming power before working on the actuator and before opening the switch compartment.

cc 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.

cc 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.

cc 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.	9
	•	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	Mounting Holes		Tap size
	Quantity	MSS		ISO
L120-10		3⁄8-16x0.88		M10x1.5x22.4
	4
L120-20	4	5⁄8-11x1.25		M16x2x32
L120-40	4	5⁄8-11x1.25		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		Tapped			Bore					Key
	inch		mm		inch		mm		inch		mm
L120-10			32		1.00		25		1/4x3/32		8x6
	1.25
L120-20	2.25		57		1.875		47		1/2x3/16		14x9
L120-40	2.625		66		2.125		52		1/2x3/16		16x10

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

4.4 Torque Switch

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

aa 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:

aa 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

	B	A
Maximum Stop
Setting Plate
			10	-	20	OPEN
		-
		20
		-
		10
				CLOSE
				-
Index Marks						Mounting
	B					Screw
		A

Microswitch-Style Torque Switch

B
Maximum Stop	A
Setting Plate
Balancing	Balancing
Screws	Screws
	Mounting
Index Marks	Screw
A	B

600 Volt Torque Switch

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