Flowserve Limitorque L120 Series, Limitorque L120-10, Limitorque L120-40 User Instructions

USER INSTRUCTIONS
Limitorque
FCD LMENIM1201-05-A4 – 03/18
®
Actuation Systems L120 Series
Installation
Operation
Maintenance
Experience In Motion
Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Contents
1 Introduction 4
1.1 Purpose 4
1.2 User Safety 4
2 Product Inspection - Storage - Identification 5
2.1 Inspection and Recording 5
2.2 Short-Term Storage (less than 1 year) 5
2.3 Product Identification 7
3 Actuator Weights 8 4 Installation Instructions 9
4.1 Safety Precautions 9
4.2 Safety Practices 10
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
5.1 Electrical Start-up 19
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
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 LMENIM1201-05-A4 – 03/18
Introduction
Flowserve Limitorque actuators are available with a wide range of standard and optional features. Be aware of these features and their role in the setup and operation of the actuator.
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.
4
NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and operation.
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
Product Inspection - Storage -
2
c WARNING: Read this Installation and Maintenance Manual carefully and completely before
attempting to install the actuator. Be aware of the electrical hazards.
Identification
2.1 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.
2.2 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.
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Figure 2.1 – L120-10 through 40
Handwheel
Limit Switch/ Controls Compartment
Motor
Housing
Actuator Nameplate (hidden)
Declutch Lever
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
2.3 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 LMENIM1201-05-A4 – 03/18
Actuator Weights
The approximate L120 actuator weights are provided below:
Table 3.1 – Actuator weights
Actuator
L120-10
L120-20
L120-40
Note: Approximate weights are based on standard explosion-proof construction, with the largest three-phase motor available for the model size.
Control Types
Size
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
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
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 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. For maintenance and/or disassembly of the actuator while installed on the valve, or removal of the actuator from the valve or actuated device, ensure that the actuator is not under thrust or torque load. If the valve must be left in service and under load, 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 thrust base 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 handwheel 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.
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: Eye bolts may be used to lift the actuator for installation on the valve or actuated device. Do not lift
actuator/valve or actuator/gearbox combinations using eye bolts in the L120 actuator.
a CAUTION: Do not lift the actuator by the handwheel.
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
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 controls compartment clean and dry.
• Keep the valve stem clean and lubricated.
• Set up periodic operating schedule for infrequently used valves.
• 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
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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
4.3.2 Stem Acceptance
The maximum stem acceptance is provided in Table 4.3.
Table 4.3 – Maximum Stem Acceptance
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
Mounting Holes Tap size
Quantity MSS ISO
3
8-16x0.88 M10x1.5x22.4
5
8-11x1.25 M16x2x32
5
8-11x1.25 M16x2x32
Drive 2 Drive 1
Tapped Bore Key
inch mm inch mm inch mm
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
Balancing
300 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:
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.
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.
Figure 4.1 – Microswitch-Style Torque Switch and 300 Volt Torque Switch
B
Maximum Stop Setting Plate
Index Marks
A
Maximum Stop Setting Plate
OPEN
-10-20
-10-20
CLOSE
Mounting
B
Screw
A
Balancing Screws
Index Marks
B
A
A
B
Mounting Screw
Screws
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
4.4.2 Balancing Torque Switch
Item letters correspond to Figure 4.1.
1. Place the actuator in manual mode.
2. Remove the load from the wormshaft spring pack.
3. Note the open and close torque switch settings prior to reinstalling the torque switch.
4. Loosen Screws (A) and position both Pointers (B) at the #1 setting, tighten Screw (A). In this position the index marks should be aligned.
5. Loosen balancing screws and install the torque switch. The base of the torque switch should be flush against the compartment and the hole for the mounting screw should be aligned.
6. Install the mounting screw.
7. Tighten the balancing screws.
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.
4.5 Geared Limit Switch
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.
• 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 units 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.
4.5.1 Setting Limit Switch
Set the limit switch as follows. All item letters and piece numbers refer to Figure 4.2.
NOTE: See chart below for maximum number of drive sleeve turns for each unit size. The Intermediate Shaft (B), shown in Figure 4.2, may take a considerable number of turns before rotor trip occurs.
Table 4.4 – Maximum Number of Drive Sleeve Turns for Standard Four-Gear and Optional Five-Gear Limit Switches
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Actuator Size Four-Gear Five-Gear
L120-10 630 6300
L120-20 740 7400
L120-40 640 6400
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
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.
Figure 4.2 – Limit Switch
7
8
1
6
Piece Quantity Description
5
11 Gear Frame Assembly 22 Eight-Switch Contact Block Assy.
B
A
9
3 2
312Rotor Segment (short) 44 Rotor Shaft 54 Machine Screw 64 Flat Washer 74 Lock Washer
4
88 Hex Nut 94 Rotor Segments (long)
4.5.2 Setting Procedure (Refer to Figure 4.2)
1. Open the Compartment Cover (piece #200 of Figure 5.2).
2. Put the actuator into manual operation. Use the handwheel to operate the valve in the “open” direc­tion. While operating the valve, note the direction of the Intermediate Shaft (B) corresponding to the rotor or rotors to be set.
3. When the valve is fully open, close it one turn of the handwheel to allow for coast of moving parts or refer to the valve manufacturer setting requirements.
4. Push in the Setting Rod (A) and turn one-quarter turn. The rod will latch in this depressed position.
5. Refer to the applicable wiring diagram for contact development. The limit switch contact is closed when the rotor is engaged with the plunger. If the rotor to be set has not turned 90 degrees to operate the plunger, turn the intermediate shaft in the same direction as noted in Step 2 until the rotor clearly trips the switches. This rotor is now set correctly.
6. Before moving the valve, depress and turn the Setting Rod (A) one-quarter turn to the spring released position. Insert a screwdriver into the intermediate shafts to ensure that they will not move.
a CAUTION: Do not operate the valve when Setting Rod (A) is in a fully depressed position. Loss of
contact setting will occur and the setting rod will be damaged.
7. Operate the valve by handwheel to fully “close” position; reverse direction by one turn of the hand­wheel to allow for coast of moving parts or refer to the valve manufacturer setting requirements.
8. Set the other rotors by following Steps 4 through 6.
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Figure 4.3 – Setting the open and closed contacts
Closed
position
Open
position
4.5.3 Combination of Contacts (Refer to Figure 4.2)
The rotor segments can be separated and rotated through 90 degrees to give various combinations of normally open or normally closed contacts to each rotor.
1. Remove Nuts (piece 8) and Fillister Head Machine Screws (piece 5, for a total of two fasteners on each side of the switch).
2. Remove complete contact assembly from the back plate.
3. Rearrange cams on the camshaft to produce the required combination of contacts.
4. Replace contact assembly on back-plate (ensuring that the registers fit correctly) and secure with the machine screw and nuts.
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5. Set limits according to the procedure above.
4.6 Position Indication
4.6.1 Local position indication
The local dial position indicator is factory-selected to show valve position. The position indicator can only be adjusted when mounted on the valve.
To set the local position indicator:
1. Disconnect all incoming power and remove Switch Compartment Cover (piece 200 of Figure 5.2).
2. Place the valve in the fully “close” position.
3. Loosen the round head machine screw which holds the pointer in place, move the pointer to the “O”
position, and retighten the screw.
The indicator is now set.
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
Typical Connection for a 1000 ohm Potentiometer
NOTE: The end-of-travel rotors of the geared limit switch activate “Flip-flop” type indicators. This type of indicator will require no further setting after the geared limit switch has been adjusted.
4.6.2 Remote Position Indication
The L120 actuator with a position transmitter installed, transmits a 4-20 mA output signal to a remote position indicator. The transmitter responds to input of a 1K (ohms) potentiometer and can be powered by 18 VAC or 24 VDC.
NOTE: The pinion has been left disengaged to prevent damaging of rheostat prior to setting the valve. Set rheostat by turning pinion until the desired reading is obtained. Loosen the hex nut on the back of the rheostat and slide the rheostat in the direction of the idler pinion until pinions are engaged. Do not force engagement of the pinions. Retighten hex nut on back of the rheostat. Do not engage pinion until unit and valve have been set.
To Calibrate Position Transmitter
1. Position the actuator to mid-travel: valve at 50% position.
2. Disconnect the potentiometer wiring harness from the transmitter board and measure the resis­tance from each end connection to the center connection on the potentiometer.
3. Set the potentiometer to the correct resistance reading. Loosen the set screw that retains the spur gear on the potentiometer shaft and rotate the shaft until a reading of 500 ohms is achieved.
4. Tighten the set screw and reconnect the wiring harness.
5. Run the actuator fully CLOSED.
6. Calibrate ZERO position by adjusting the zero potentiometer until a 4 mA output signal is read at terminal +VE and -VE.
7. Run the actuator fully OPEN.
8. Calibrate SPAN position by adjusting the span potentiometer until a 20 mA output signal is read at terminals +VE and -VE.
9. Repeat steps 5 to 8 and fine-tune as necessary.
Figure 4.4 – 1000 ohm Potentiometer
Gearing
1000 ohms
Receiver
+
DC Power
­Supply
-
+
Customer Equipment
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
157-2
178 &
157-4
4.7 Optional Side-Mounted Handwheel
For actuator sizes L120-10, 20, and 40, the handwheel can be mounted on the side as shown in the following figures.
Figure 4.5 – L120-10 parts list, attachment ratio 4.2:1
157-3
&
157-6
157-5
158-1
158-3
160
171
182-2
182-1
182-3
161
179
181
177
180
154
169
152
Note: Apply Loctite 601/609
164
158-4
to ID of Bearing Cap
Piece Quantity Description
61Housing Cover Shim 42-11 1 O-Ring / Handwheel Mounting 44 1 Quad Ring 45 1 Pipe Plug 1501Bevel Housing 1511Bevel Housing Adapter 1521Bearing Cap 1531Bevel Gear 1541Bevel Pinion Shaft 157-1 4 Hex Head Cap Screw 157-2 4 Lockwasher 157-3 2 Socket Head Cap Screw 157-4 1 Roll Pin 157-5 2 Socket Head Cap Screw 157-6 2 Lockwasher 158-1 1 Quad Ring 158-2 1 O-Ring 158-3 1 O-Ring 158-4 1 Quad-Ring 160 2 Ball Bearing 161 1 Seal Insert 164 1 Spacer 169 1 Retaining Ring 171 1 Grease Fitting 177 1 Handwheel 178 1 Hex Head Cap Screw 179 1 Lockwasher 180 1 Key 181 1 Retaining Washer 182-1 1 Handwheel Spinner 182-2 1 Socket Head Cap Screw 182-3 1 Hex Jam Nut
16
45
157-1
&
150
158-2
151
153
44
6
42-11
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
6
44
Figure 4.6 – L120-20 with side-mounted handwheel and parts list, attachment ratio 5.7:1
179
182-2
182-1
182-3
&
178
181
180
177
157-5
157-3
157-4
157-1
&
157-2
&
158-1
154
158-3
171
157-6
161
152
169
160
Note: Apply Loctite 601/609
to ID of Bearing Cap
158-2
158-4
Piece Quantity Description
6 1 Housing Cover Shim 42-11 1 O-Ring / Handwheel Mounting 44 1 Quad Ring 45 1 Pipe Plug 150 1 Bevel Housing 151 1 Bevel Housing Adapter 152 1 Bearing Cap 153 1 Bevel Gear 154 1 Bevel Pinion Shaft 157-1 4 Hex Head Cap Screw 157-2 4 Lockwasher 157-3 4 Hex Head Cap Screw 157-4 4 Lockwasher 157-5 1 Roll Pin 157-6 2 Socket Head Cap Screw 158-1 1 Quad-Ring 158-2 1 O-Ring 158-3 1 O-Ring 158-4 1 Quad Ring 160 1 Ball Bearing 161 1 Seal Insert
169 1 Retaining Ring 171 1 Grease Fitting 177 1 Handwheel 178 1 Hex Head Cap Screw 179 1 Lockwasher 180 1 Key 181 1 Retaining Washer 182-1 1 Handwheel Spinner 182-2 1 Socket Head Cap Screw 182-3 1 Hex Jam Nut
45
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
179
Note: Apply Loctite 601/609 to ID of Bearing Cap
157-5
42-11
Figure 4.7 – L120-40 with side-mounted handwheel and parts list, attachment ratio 12:1
158-4
45
157-1
157-2
150
171
158-5
&
157-6
158-2
182-2
182-1
182-3
158-1
164
157-7
153
155
163
171
161
&
178
181
160
Section Through Pinion
154
152
158-3
151
44
156
6
180
169
177
167
Handwheel
157-3
&
157-4
159
164
Piece Quantity Description
61 Housing Cover Shim 42-11 1 O-ring / Handwheel Mounting 44 1 Quad Ring 45 1 Pipe Plug 150 1 Bevel Housing Cover 151 1 Bevel Housing 152 1 Spur Gear Cover 153 1 Bevel Gear 154 1 Bevel Pinion 155 1 Input Pinion Shaft 156 1 Bevel Gear Adapter 157-1 4 Hex Head Cap Screw 157-2 4 Lockwasher 157-3 4 Hex Head Cap Screw 157-4 4 Lockwasher 157-5 8 Socket Head Cap Screw 157-6 2 Dowel Pin 157-7 1 Socket Head Cap Screw 158-1 1 Quad Ring 158-2 1 O-ring 158-3 1 Gasket 158-4 1 Quad Ring 158-5 1 O-ring 159 1 Spur Gear 160 1 Ball Bearing 161 1 Seal Insert 163 1 Ball Bearing 164 2 Ball Bearing 167 1 Key 169 1 Retaining Ring 171 1 Grease Fitting 177 1 Handwheel 178 1 Hex Head Cap Screw 179 1 Lockwasher 180 1 Key 181 1 Retaining Washer 182-1 1 Handwheel Spinner 182-2 1 Socket Head Cap Screw 182-3 1 Hex Jam Nut
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
Operation
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.
a CAUTION: Do not motor-operate the valve without first setting or checking the limit switch setting
and motor direction.
• Do not force the declutch lever into hand operation. If the clutch does not easily engage, rotate handwheel slowly while operating the declutch lever.
• Do not alternately start/stop the motor to open or close a valve which is too tight for normal operation.
5.1 Electrical Start-up
1. Verify that the actuator has been correctly lubricated. This is particularly important if the actuator has been in long-term storage.
2. Verify that the geared limit switch has been correctly set (see Section 4.5.1, Setting Limit Switch).
3. If the valve stem is not visible, remove the stem cover or handwheel cover plate to observe output direction of the drive sleeve.
4. Engage manual operation and hand crank the valve well away from end of travel positions.
5. Turn on power supply and push button to “open.”
6. Check output rotation:
• If phase rotation is correct, the valve should begin to open.
• If valve begins to CLOSE, STOP immediately. Incorrect phase rotation will lead to serious damage
if the valve seats.
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
7. Correct the phase rotation one of two ways:
• Switch any two of the three power leads for three-phase power, or
• Reverse the armature leads for single-phase or DC power.
The actuator should operate correctly and will be stopped at the end of travel positions by torque or limit switch functions.
Table 5.1 – Required Rating for External Wiring
Up to Use wire rated at least
40°C 60°C
60°C 75°C
Figure 5.1 is a representation of a typical application and may not be applicable to your specific actuator. Please refer to the wiring diagram supplied with your actuator to confirm the actual equipment supplied.
5.2 Manual Operation
Piece numbers refer to Figure 5.2.
Counterclockwise rotation of the Declutch Lever (piece 9) causes the declutch actuator to lift the clutch sleeve out of engagement with the worm gear. Drive lugs on top of the clutch sleeve engage matching lugs in the Handwheel Adapter (piece 26) and then latches engage the clutch sleeve in this position. The actuator is now in the handwheel driving option. Energizing the motor at this point will cause the latches to drop out and the spring-loaded clutch sleeve reengages with the lugs on the worm gear. The actuator is once more in motor operation.
NOTE 1: The shift from manual operation to motor operation is automatic and does not require external positioning of the declutch shaft.
NOTE 2: If the declutch mechanism does not engage, rotate handwheel approximately 30-45° and attempt manual engagement. There is a chance that the lugs on the Clutch Sleeve (piece 19) and Handwheel Adapter (piece 26) are not correctly aligned.
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
SPARE
16
& (8C) FOR TORQUE-SEATING VALVES.
TH.OL-THERMAL OVERLOAD CONTACTS
Figure 5.1 (one of two) – L120-10 through 40 typical wiring diagram
10
GND
13
L1
12
L2
11
L3
ALTERNATE TRANSFORMER TYPES
500
A
480
B E
460
TAPS
D
415
E
380
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
GREEN/WHITE
1
600 575 550
7
(7)(7C)
3
(3)(3C)
21/22
STOP
PB2
FUSE
CD
SS
RED
GREEN
ELEC HTR
MTR HTR
REMOTE
BROWN
AB
115 V
RED
RES
RES
PURPLE
PB1
OPEN
PB3
CLOSE
18 V
YEL
YEL
WHITE
R
WHITE
G
WHITE
H2
BLUE
YELLOW
BLUE
O
YELLOW
C
BROWN
ORANGE
GRAY
PINK
32
230 V H1 AND H3 TO L1 H2 AND H4
­TO L2
-
H1
OFF
LOCAL
RED
RED
BROWN
RED
GRAY
E
18 V
BLU
WHITE
FUSE
CPT
BLU
19/20
BLUE
(4)
JUMPER SEE NOTE #5
(8)(8C)
1
2
3
4
5
6
GREEN/WHITE
GREEN/WHITE
4 18
BLUE
RED
(4C)
8
YELLOW
RED
OPEN
CLOSE
STOP
COMMO N
REMOTE IND
REMOTE IND
O
O
O
C
C
C
(5)
(18)
17
(17) (17C)
(1)
P2
5
(18C)
1
(5C)
(1C)
TH.OL
T1
T2
T3
P1
BLUE BLACK
YELLOW BLACK
(OPTIONAL)
BLACK
POT
MOTOR
BLUE
WHITE
C
YELLOW
WHITE
O
RED
BROWN
18
1716
P1
O
P1
C
Valve shown in full open position
ROTOR
1 2
OPEN
3 4
5 6
CLOSE
7 8
9 10
INT. 1
11 12
13 14
INT. 2
15
LIMIT SWITCH CONTACT DEVELOPMENT
VALVE POSITION
CONTACT
FULLY OPEN
A B
A B
FULLY
CLOSED
17
FUNCTION
BYPASS CIR
SPARE
IND LIGHT
OPEN LIMIT
BY-PASS CIR
SPARE
IND LIGHT
CLOSE LIMIT
SPARE SPARE SPARE SPARE SPARE SPARE SPARE
18
Notes
1.
2.
3. SEE CERTIFICATION SHEET FOR VOLTAGE SUPPLIED. TRANSFORMER UNUSED WIRES TO BE SEPARATELY COVERED WITH INSULATING HEAT SHRINK TUBING.
4. ROTORS INT.1 & INT.2 CAN BE SET AT VALVE POSITION FULL OPEN, FULL CLOSED OR ANY POSITION IN BETWEEN AS INDICATED BY POINTS A AND B.
5. ADD JUMPER ON LS#8 BETWEEN TERMINALS (8)
CLOSING TORQUE SWITCH INTERRUPTS CONTROL CIRCUIT IF MECHANICAL OVERLOAD OCCURS DURING CLOSING CYCLE
OPENING TORQUE SWITCH INTERRUPTS CONTROL CIRCUIT IF MECHANICAL OVERLOAD OCCURS DURING OPENING CYCLE
OPEN CONTACT CLOSE CONTACT
Legend O-OPEN CONTACT
C-CLOSE CONTACT
OPENING COI L
O
CLOSING COIL
C CPT-CONTROL POWER TRANSFORMER +-MECHANICAL INTERLOCK
RED INDICATING LIGHT
R
GREEN INDICATING LIGHT
G SS-SELECTOR SWITCH
(LOCAL-OFF-REMOTE ) PB1-OPEN PUSHBUTTON PB2-STOP PUSHBUTTON
PB3-CLOSE PUSHBUTTON ELEC HTR-COMPARTMENT HEATER MTR HTR-MOTOR HEATER POT-POTENTIOMETER (OPTIONAL, SEE CERTIFICATION SHEET IF SUPPLIED)
RES-LAMP RESISTORS˛
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Electrical Compartment
Figure 5.1 (two of two) – L120-10 through 40 typical wiring diagram
GRN/WHT
ELEC
HTR
BLK
FUSE
BLK
FOR SIGNAL CONVERTER USE WHEN SUPPLIED
WHT
BLK
WHT
BLK
LIMIT SWITCHES
INT.2 ROTOR INT.1 ROTOR
REMOTE OPEN
REMOTE CLOSE
REMOTE STOP
REMOTE COMMON
SELECTOR SWITCH IN REMOTE INDICATION
FOR SIGNAL
CONVERTER USE
(WHEN SUPPLIED)
INCOMING POWER GROUND
L3 INCOMING POWER
L2 INCOMING POWER
L1 INCOMING POWER
(13C)
(13)
(14C)
(14)
(15C)
(15)
(16C)
REVERSING STARTER
L1F
L2F
(NOTE#3)
PRIMARY
CPT
SECONDARY
18 V
YEL
YEL
2
1
BLU
BLU
BLK/WHT RED/WHT
1
2
3
4
5
6
7
8
9
10
11
12
13
10 VA
18 V
10 VA
BLU
BLU
BLU
YEL
BRN
ORG
GRY
PNK
BLK/WHT
RED/WHT
GRN/WHT
L3
L2
L1
115 V
75 VA
WHT
RED
1
2
1
2
(9C)
13
14
15
16
(16)
9
(9)
(10C)
10
(10)
(11C)
11
(11)
(12C)
12
(12)
SPARE
P1
O
YEL
BLU/BLK
BLU/RED
RED
BLK
YEL/RED
LIMIT SWITCHES
(5C)
(5)
(6C)
(6)
(7C)
(7)
(8C)
YEL
(8)
CLOSE ROTOR OPEN ROTO R
GRN/WHT
L1 T1
BLU/WHT
BLK
5
6
7
8
WHT
WHT
L2 T2
TORQUE SWITCH
BLK
BRN
RED
BLK
BLK
L2
L1
L3 T3
YEL/WHT
BLU
(2C)
FUSES
(1C)
1
(1)
2
(2)
(3C)
3
(3)
(4C)
4
(4)
(OPTIONAL)
14
15
16
17
18
19
20
21
22
CHASSIS
P1
C
PUR
(18C)
(17C)
POT
BLK
BRN
SPARE
SPARE
POT (CCW)
POT (SWEEPER)
POT (CW)
P2
H2
H1
GROUND
L2F
L1F
L3 T1
BLU
BLK
18
CLOSE
17
YEL/BLK
YEL/RED
GRN
BLK
BLU/RED
BLUE
RED
OPEN
(18)
(17)
L1 T3
L2 T2
PUR
YEL
BLU/RED
BLU/BLK
YEL/RED
YEL/BLK
MOTOR
T1
TH.OL
T2
MTR HTR
T3
P1
H1
H2
P2
MOTOR GROUND LUG
SW323 PUSHBUTTON STATION
WHT
BLK
BLU YEL
GRN
1
RED
2
WHT
3
LIGHTS
BLK
1
BLU
2
PUR
3
YEL
4
BUTTONS
BRN
1
GRY
2
PNK
3
ORG
4
AUX. TERM.
WIRE COLOR LEGEND
RED
R
PB1
OPEN
LOCAL
BRN
RES
RES
: BLU
BLUE
: YEL
YELLOW
: PUR
PURPLE
: BLK
BLACK
: ORG
ORANGE
: BRN
BROWN
: WHT
WHITE
: RED
RED
: GRN
GREEN
: PNK
PINK
: GRY
GRAY COLOR/STRIPED
STOP
BRN
PB2
RED
OFF
RED
WHT
REMOTE
BRN
GRY
PB3
CLOSE
GRN
G
ORG
PUR
PNK
22
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
24
Piece Quantity Description
Figure 5.2 (one of two) – L120-10 through 40 drive sleeve and housing cover parts breakdown
29
50
26
44
25
19
20
21
22
16
23
43
27
28
42/11
17
18
Piece Quantity Description
16 1 Ball Bearing 17 1 Ball Bearing 18 1 Drive Sleeve Bevel Gear 19 1 Handwheel Clutch Sleeve 20 1Worm Gear Lug Ring 21 1Worm Gear 22 1 Spirolox Retainer 23 1 Key 24 1 Declutch Spring 25 1 Drive Sleeve 26 1 Handwheel Adapter
27 1 Housing Cover 28 1 Retaining Ring 29 1 Handwheel 33 1* Handwheel Cover Plate 34 1* Handwheel Cover Plate Gasket 42/11 1 O-ring / Handwheel Mounting 43 1 Quad Ring 44 1 Quad Ring 50 A/R Hardware * Not shown
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
** Not Shown
Figure 5.2 (two of two) – L120-10 through 40 parts breakdown
50
39
31
42/7*
38
40
2
50
30
46
42/3
50
305
50
200
50
50
300
50
47
3
42/9
4
42/11
19
21
1
42/5
7
37
35
36
9
15
312
310
11
42/6
9
10
25
5
50
24
Piece Quantity Description
11 Housing 21 Motor Adapter 31 Electrical Compartment 41 Seal Retainer 51 Worm Shaft End Cap 6 1** HSG. Cover Shim Set 71 Declutch Shaft Assembly 91 Declutch Lever 10 1 Roll Pin 11 1 Declutch Cap 15 1Worm Shaft Assembly 19 1 Clutch Sleeve 21 1Worm Gear 25 1 Drive Sleeve 30 1 Nipple Flange 31 1 Motor 32 4** Dowels
35 1Worm Shaft Gear 36 1 Key 37 1 Flexloc Nut
Piece Quantity Description
38 1 Motor Pinion 39 1 Key 40 1 Stop Nut 41 1** Washer 42 1 Seals Kit
42/3 1 Gasket – Mtr Adapter 42/5 1 O-ring – Declutch Assembly 42/6 1 O-ring – Declutch Lever 42/7 1 O-ring Mtr
42/7* 1 Gasket Mtr
42/9 1 Seal – Drive Sleeve
42/11 1 O-Ring – Handwheel Mounting 46 1 O-ring / Motor Nipple 47 1 O-ring / Cover 50 1 Hardware Kit 200 1 Compartment Cover 300 1Torque Switch 305 1 Geared Limit Switch 310 1 Unit Nameplate 312 1 Rimpull Nameplate
* L120-40 Only
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
5.3 Motor Operation
The actuator is always available for motor operation whenever the motor is energized
a CAUTION: Do not force the declutch lever into motor operation. Lever will automatically return to
motor operation when the motor is energized.
Reset the travel limit switches prior to motor operation if the actuator has been dismantled or removed from the valve.
Piece numbers refer to Figure 5.2.
In motor operation, the Motor Gear Set (piece 35 and 38) drives the Wormshaft (piece 15) and Worm Gear (piece 21) which in turn rotates the Clutch Sleeve (piece 19) by means of driving the lugs. The clutch sleeve and worm gear may be assembled to produce either a “no lost motion” or “hammerblow” effect. The Drive Sleeve (piece 25) is keyed to the clutch sleeve and hence rotates, producing the required output rotary motion.
5.4 Torque and Travel Limiting
The geared limit switch is driven by a bevel gear connected to the upper drive lugs of the clutch sleeve. The limit switch is directly connected to the output of the actuator. Once properly set, the limit switch remains in step with the valve position regardless of electric or manual operation of the Limitorque actuator.
The worm and wormshaft are supported by two rotating spring packs. As torque is generated by the actuator, the worm moves axially against one of the spring packs. Each pack is precalibrated and hence a finite compression represents a finite torque output. Movement of the worm operates the torque switch, which interrupts the power to the motor. The torque switch is adjustable and can be set to operate at predetermined torque levels.
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6
Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Maintenance
6.1 Lubrication
The L120 series actuators have a sealed gear case, factory-lubricated with grease. The thrust base, when supplied, is factory-lubricated with the same grease as the gear case if the stem nut is factory­machined for the customer's driven shaft. If a blank stem nut is installed in the thrust base, a tag is provided on the actuator advising that the base is not lubricated. The gear case can be mounted in any position. However, mounting of the motor or the switch compartment in the down position is not recommended. These mounting positions may result in the motor or switch compartment being saturated with lubricant if the seal fails.
No seal can remain absolutely tight at all times. Therefore, it is not unusual to find a very small amount of weeping around shaft seals—especially during long periods of idleness such as storage. Using grease minimizes this condition as much as possible. If a small amount is weeping at start-up, remove it with a clean cloth. Once the equipment is operating on a regular basis, the weeping should stop.
6.1.1 Lubrication Inspection
Inspect Limitorque L120 series actuators for correct lubrication prior to operating - particularly following a long storage period.
Each application has its own effect on the actuator and the frequency of these inspections should be based on the application and the operating experience. The following lubrication inspection schedule is recommended until operating experience indicates otherwise.
26
For the Gear Case, inspect lubrication every 18 months or 500 cycles, whichever occurs first.
During an inspection consider the following:
• Quantity – Ensure there is enough lubricant so that the Worm and the Worm Gear are totally immersed in grease regardless of the position.
Note: The lubricant level can be verified by orienting the actuator with the control compartment facing
up. Remove the Geared Limit Switch. The level of lubricant should be within ½ inch of the bottom of the opening in the gear housing.
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
• Quality – Inspect lubricant for dirt, water or other foreign matter. If any one of these is found:
1. Flush the actuator with a commercial degreaser/cleaner that is not corrosive and does not affect the seal materials.
2. Repack the actuator with fresh lubricant allowing room for grease thermal expansion.
• Consistency – Ensure the lubricant is fluid approximating a standard NLGI-0 grade consistency or less.
6.1.2 Factory Lubricant
Gear Case: The L120 series actuator gear case is factory-lubricated with an EP-0 lithium grease, suitable for temperatures from -20°F (-29°C) to +250°F (+121°C).
Table 6.1 – Specified Approximate Lubricant Weights
Actuator Size lb. kg
L120-10 2.75 1.3
L120-20 4.25 1.9
L120-40 5.75 2.6
Geared Limit Switch: Permanently lubricated with Beacon 325. Limitorque does not recommend disas­sembly of the gearbox.
6.2 Minimum Lubricant Qualities Required
The standard lubricants used by Limitorque have been proven to be extremely reliable over years of service. Limitorque does not recommend a particular lubricant substitute for the standard lubricants; however, Limitorque does require the following lubricant qualities as a minimum.
a CAUTION: Do not mix lubricants of a different base chemical. Mixing lubricant bases may cause
lubricant properties to be ineffective.
The Lubricant must:
• contain an “EP” additive.
• be suitable for the temperature range intended.
• be water and heat-resistant and non-separating.
• not create more than 8% swell in Buna N or Viton.
• not contain any grit, abrasive, or fillers.
• comply with a slump-prefer NLGI-0 grade.
• not be corrosive to steel gears, ball, or roller bearings.
• have a dropping point above 316°F (158°C) for temperature ranges of -20°F (-29°C) to +250°F (+121°C).
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
6.3 Disassembly and Reassembly
a CAUTION: Turn off all power services before attempting to perform service on the actuator.
• Remove the actuator from the valve for complex work. Minor work, such as replacing geared limit switch, torque switch, or motor, may be readily performed while the actuator is still on the valve.
• Potential High-Pressure Vessel. Before removing or disassembling your actuator, ensure that the valve or other actuated device is isolated and is not under pressure.
NOTE: If the actuator is fitted with a Thrust Base (piece 100 of Figure 6.2), it is possible to remove the actuator housing while leaving the base on the valve to accept valve thrust. However, it is preferred that the valve be isolated from service and, if it is a rising stem, that the valve be fully open.
6.4 Disassembly of the L120-10, 20, and 40
Unless otherwise noted, piece numbers refer to the Illustrated Parts Breakdown of Figure 5.2.
1. Turn off power to the actuator.
2. Remove electrical Compartment Cover (piece 200).
3. Disconnect all electrical leads from the Torque Switch (piece 300) and Geared Limit Switch (piece 305). Ensure that all leads and terminals are clearly marked to facilitate reassembly.
4. Remove two screws holding limit switch and one holding torque switch. Remove both items.
5. Remove four bolts holding Motor (piece 31) and three bolts holding conduit Nipple Flange (piece 30). Remove motor, drawing motor leads through switch compartment.
6. Remove Motor Pinion (piece 38) by removing Stop Nut (piece 40).
7. Remove Worm Shaft Gear (piece 35), Flexloc Nut (piece 37), and Worm Shaft End Cap (piece 5) and draw complete wormshaft assembly from housing.
NOTE: The wormshaft has been assembled at the factory to obtain the correct preload on the spring packs. Do not attempt to disassemble further. If the worm shaft is worn or damaged, it is suggested that the complete wormshaft subassembly be replaced. The actuator must be in motor operation to remove the wormshaft assembly. When the wormshaft is partially out, the disc springs will hit the worm gear. Pull the declutch lever forward slightly without fully engaging the declutch mechanism and the wormshaft will come out.
8. Remove Declutch Cap (piece 11).
9. For unit size L120-10, completely withdraw the Declutch Assembly (piece 7 of Figure 6.3) from the housing. For unit sizes L120-20 and 40, remove Declutch Input Pinion (piece 12 of Figure 6.3) followed by the Declutch Assembly (piece 7 of Figure 6.3).
28
10. Remove Handwheel (piece 29) and Housing Cover (piece 27) and lift complete drive sleeve subas­sembly from housing.
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
6.5 Drive Sleeve and Housing Cover Disassembly
Piece numbers refer to Figure 5.2.
1. Remove Upper Ball Bearing (piece 17), Bevel Gear (piece 18), Declutch Spring (piece 24), Clutch Sleeve (piece 19), and Key (piece 23).
2. Remove Lower Ball Bearing (piece 16).
3. Spirolox Retainer (piece 22) may now be removed by inserting small flat blade screwdriver under the end of the ring and prying the first layer from the groove. Continue around the ring until it is free from the groove.
4. Remove the Worm Gear (piece 21) and the Lug Ring (piece 20).
5. Handwheel Adapter (piece 26) and Seal (piece 42) can be removed from Housing Cover (piece 27) by removing Retaining Ring (piece 28).
6.6 Torque Nut Disassembly (Drive 1 Option)
For applications requiring torque only, the L120 series actuator can be supplied without the thrust base option. The torque nut is driven by the drive sleeve lugs and held in place by the torque bushing connector.
Figure 6.1 – L120-10 through 40 standard and extended drive sleeve assembly
99
97
25
95
183
Standard
25
96
98
183
Piece Quantity Description
25 1 Drive Sleeve 95 1 Torque Nut 96 1 Torque Bushing Connector 97 1 Torque Bushing Washer 98 1 Retaining Ring 99 1 Elastic Stop Nut
95
183 1 Retaining Ring
Unless otherwise stated, piece numbers refer to Figure 6.1.
Standard Drive Sleeve
To remove the Torque Nut (piece 95), remove Retaining Ring (piece 183) and drop the torque nut out the bottom of the Drive Sleeve (piece 25 of Figure 5.2).
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Hex Head Cap Screw
112 1 Relief Fitting
two different part numbers for piece #107 and 107A.
Optional Drive Sleeve
1. Remove the Handwheel (piece 29 of Figure 5.2), Handwheel Cover Plate (piece 33 of Figure 5.2) and Gasket (piece 34) to provide access to the Elastic Stop Nut (piece 99).
2. Remove the Elastic Stop Nut (piece 99) from the Rod (piece 1). The Torque Nut (piece 95) can now be removed from the bottom of the Drive Sleeve (piece 25 of Figure 5.2).
3. The Torque Bushing Connector (piece 96) can be removed from the torque nut by removing the Retaining Ring (piece 98).
6.7 Thrust Base Disassembly (Drive 2 Option)
Piece numbers refer to Figure 6.2.
1. If the Thrust Base (piece 100) option is present, remove the Seal Retainer (piece 102) followed by Stem Nut (piece 101).
2. Remove the four Hex Head Cap Screws (piece 110) and the Lift Thrust Base from the housing.
107A
109, 112
Figure 6.2– L120-10 through 40 thrust base
103
105
105
107
NOTE: For the L120-10, use the same part number for piece #107 and 107A. For the L120-20 and L120-40, use
103
104
104
110, 111
106
100
101
102
6.8 Stem Nut Replacement –
108
Piece Quantity Description
100 1 Base Housing 101 1 Stem Nut 102 1 Seal Retainer 103 2 Needle Bearing 104 2 Thrust Washer 105 2 Thrust Washer 106 1 O-ring Seal 107 1 Quad Ring Seal 107A 1 Quad Ring Seal 108 1 Gasket 109 1 Grease Fitting 110 4
111 4 Lock Washer
30
This section is only applicable to thrust base applications. Occasionally the operator stem nut may need replacing if used in a threaded stem application on rising stem valves.
c WARNING: Possible Hazardous Voltage. Turn power OFF before disassembling or removing the
actuator from the mounting base. This will prevent accidental start-up during service to the unit.
c WARNING: Potential High-Pressure Vessel. Before removing or disassembling the actuator, ensure
that the valve or other actuated device is isolated and not under pressure.
Thrust Base Applications
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
a CAUTION: The L120-10 through 40 thrust base contains lubrication. Ensure that EP-00 is replaced
when reassembling thrust base.
NOTE: Installation and retention of O-rings and quad rings can be eased by applying a small quantity of EP grease to the ring during assembly.
To replace the stem nut:
1. Disconnect all incoming power to the actuator.
2. Remove actuator from the valve.
3. Remove Seal Retainer (piece 102 of Figure 6.2) followed by stem nut, bearings, and seals.
4. Check the fit of the new stem nut on the valve stem - ensure that the nut travels freely without binding.
5. Reassemble the thrust base and remount the actuator on the valve.
6. Remount the actuator on the thrust base.
7. Removing the actuator from the valve will change the limit switch settings. Reset the limit switch in accordance with Section 4.5.1, Setting Limit Switch.
8. Reconnect power.
9. Test for correct functioning.
6.9 Reassembly
Piece numbers refer to Figures 5.1, 5.2, 6.1, 6.2, and 6.3.
1. Install Lug Ring (piece 20) onto Drive Sleeve (piece 25) followed by the Worm Gear (piece 21). Ensure that the worm gear lugs engage with recesses on lug ring.
2. Install Spirolox Retainer (separate layers of retainer sufficiently to begin threading the retainer into the drive sleeve groove. Continue threading until the retainer is firmly located in the groove).
3. Install Key (piece 23) and Clutch Sleeve (piece 19).
4. Add the Declutch Spring (piece 24), Bevel Gear (piece 18), Upper Bearing (piece 17), and Lower Bearing (piece 16) to complete the assembly.
5. Replace the drive sleeve assembly into main housing, and secure with the Housing Cover (piece 27). Ensure that all the seals are in place.
6. Insert Wormshaft Assembly (piece 15) into the housing and locate the bearings in the housing journals. Replace the Wormshaft Cap (piece 5).
7. Install the Wormshaft Gear (piece 35) and Flex Loc Nut (piece 37).
NOTE: It is recommended that a new flex loc nut be used during reassembly.
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7
Declutch Stop
*L120-20/40 only
7-2
7-1
7-3
Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Figure 6.3 – L120-10 through 40 declutch assembly parts breakdown
7-1
7-2
8
42/5
&
7A
11
Declutch Stop
42
9
Declutch Actuator
LUG
Handwheel
Clutch Sleeve
10
L120-10
&
7-3
Piece Quantity Description
7* 1 Declutch Shaft Assembly L120-20/40 7A 1 Declutch Shaft Assembly 7-1 1 Declutch Actuator 7-2 & 7-3 1 Declutch Latch (left & right) 81 Declutch Return Spring 91 Declutch Lever 10 1 Roll Pin 11 1 Declutch Cap 12* 1 Declutch Input Pinion 42/5 1 O-ring – Declutch
8
42/5
L120-20/40
11
42
9
12
10
32
6.9.1 Declutch Assembly (L120-10)
8. Install Declutch Cap (piece 11) on the Declutch Shaft (piece 7A). Ensure that the return spring is located correctly in the endcap.
9. Replace Declutch Lever (piece 9) on the shaft with the lever against the stop.
10. While holding the cap steady, rotate the declutch shaft against the spring tension until the holes in the shaft and lever align.
11. Replace complete assembly in main housing. Ensure that the lug on the Declutch Actuator (piece 7-1) fits into the groove on the Handwheel Clutch Sleeve (piece 19 of Figure 5.2).
12. Secure the declutch cap.
NOTE: When the declutch lever is disengaged against the declutch stop (motor operation position), the Declutch Actuator (piece 7-1) should not be in contact with the groove on the Handwheel Clutch Sleeve (piece 19 of Figure 5.2).
6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3)
8. Install Declutch Cap (piece 11) on the Declutch Pinion Shaft (piece 12). Ensure that the return spring is located correctly in the slots.
Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
9. Replace Declutch Lever (piece 9) on the pinion and against the stop.
10. While holding the cap steady, rotate the Pinion Shaft (piece 12) against the spring tension until the holes in the shaft and lever align.
11. Insert Roll Pin (piece 10).
12. Slide Declutch Shaft (piece 7) into the housing, ensuring that the Declutch Shaft (piece 7) fits correctly into the groove in the Handwheel Clutch Sleeve (piece 19 of Figure 5.2).
13. Install the declutch cap assembly into the housing, finding the nearest tooth on the internal spur gear which will allow the cap to be secured without placing tension on the Declutch Actuator (piece 7-1) causing it to rub against the groove in the Handwheel Declutch Sleeve (piece 19 of Figure 5.2).
6.9.3 Install the Motor (Refer to Figure 5.2)
1. Install the Motor Pinion (piece 38) and Elastic Stop Nut (piece 40) onto the motor shaft.
NOTE: The elastic stop nut should not be reused. It is recommended that a new nut be used during reassembly.
2. Install conduit Nipple Flange (piece 30) and Seal (piece 42) onto the conduit nipple in the flange and secure the motor. Secure the nipple flange.
6.9.4 Lubrication Procedure
1. Set unit on mounting base.
2. Grease through the grease fitting located on the motor adapter, watch for grease entering the housing cavity.
3. Grease through the grease fitting in the housing cover until the adapter has been completely greased and grease can be seen entering the drive sleeve compartment.
4. Reposition the unit “nameplate down”.
5. Finish filling housing cavity through the gear limit switch opening to within ½” from the bottom of the gear limit switch opening.
6.9.5 Install Geared Limit Switch, Torque Switch
and Finish Assembly
1. Install torque and limit switch into the switch compartment housing.
NOTE: The limit switch must be reset before the actuator is placed back into service. The Torque Switch may need to be rebalanced. If required see Section 4.4.2, Balancing Torque Switch.
2. Connect all electrical leads in the switch compartment.
3. Replace the compartment cover, handwheel and thrust base, if applicable, to complete the assembly.
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
How to Order Parts
To order parts or obtain further information about your Limitorque L120 valve actuators, contact your local Flowserve Limitorque distributor sales office, or:
Flowserve Limitorque 5114 Woodall Road Lynchburg, VA 24502 Telephone (434) 528-4400 Fax (434) 845-9736
All inquiries or orders must be accompanied by the following information:
1. Actuator Size
2. Limitorque Order Number
3. Limitorque Serial Number
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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18
EC Declaration of Conformity
Application of Council Directives
2004/108/EC; EMC Directive
2006/42/EC; Machinery Directive
2003/10/EC; Airborne Noise Directive
Standards to which Conformity is Declared
Machinery; EN 60204-1
EMC; Emissions; EN 55022; 2006
Immunity; IEC 61000-4-6;2007, IEC 61000-4-8: 2001
ESD; IEC 61000-4-2: 2001
EFT Bursts; IEC 61000-4-4: 2004
Surge Immunity; IEC 61000-4-5: 2006
Airborne Noise; MIL-STD-740-1, Table 1, EN 60204
Manufacturer’s Name
Flowserve Limitorque
Manufacturer’s Address
5114 Woodall Rd Lynchburg, VA 24502 USA
Importer’s Name
Flowserve Limitorque
Importer’s Address
Flowserve Limitorque
Euro House
Abex Road
Newbury
Berkshire, RG14 5EY
United Kingdom
Type & Description of Equipment
Valve Actuators
Model Number
L120-10,20,40, 85
Note: Tested with Limitorque products only and with standards applicable at
time of tests.
I, the undersigned, hereby declare that the equipment specified above
conforms to the above Directives and Standards.
John Thilking
Senior Engineer – Certifications, ATEX/IEC-Ex Authorized Person
Flowserve Limitorque 5114 Woodall Road
Lynchburg, VA 24502 USA
Date; December 4, 2012
flowserve.com
35
Flowserve Corporation Flow Control
United States
Flowserve Limitorque 5114 Woodall Road P.O. Box 11318 Lynchburg, VA 24506-1318 Phone: 434-528-4400 Facsimile: 434-845-9736
Italy
Flowserve Limitorque Via Rio Vallone 17 20883 Mezzago (MB), Italy Phone: +39-039-62060-1 Facsimile: +39-039-62060-213
Japan
Limitorque – Nippon Gear Co., Ltd. NOF Bldg. 9th Floor 1-11-11, Kita-Saiwai, Nishi-Ku Yokohama (220-0004) Japan Phone: 81-45-326-2065 Facsimile: 81-45-320-5962
FCD LMENIM1201-05-A4 03/18 Printed in USA.
To find your local Flowserve representative
or for more information about Flowserve Corporation, visit www.flowserve.com.
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.
Singapore
Flowserve Limitorque 12, Tuas Avenue 20 Singapore 638824 Phone: 65-6868-4628 Facsimile: 65-6862-4940
China
Limitorque Beijing, Pte., Ltd. RM A1/A2 22/F, East Area, Hanwei Plaza No. 7 Guanghua Road, Chaoyang District Beijing 100004, Peoples Republic of China Phone: 86-10-5921-0606 Facsimile: 86-10-6561-2702
India
Flowserve Limitorque Office A, 7th Floor, Plot No. 32 A&B Ambit IT Park, Ambit IT Park Road Ambattur Industrial Estate, Chennai - 600058 Phone: 91-44-2432-8755 91-44-2432-4801 Facsimile: 91-44-2432-8754
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