7 How to Order Parts 34
8 EC Declaration of Conformity 35
flowserve.com
3
1
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.
5
flowserve.com
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
6
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
flowserve.com
7
3
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
NCU10045112511074911954
BIC11552127581225513461
CLAMSHELL14064152691476715972
NCU14064158721536917178
BIC15570173781687618684
CLAMSHELL18082198901938821196
NCU190862169821296238108
BIC20593231105227103253115
CLAMSHELL230105256116252114278126
Drive 1 Weight (lb./kg)Drive 2 Weight (lb./kg)
Top HWSide HWTop HWSide HW
lb.kglb.kglb.kglb.kg
8
4
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.
9
flowserve.com
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°C60°C
60°C75°C
10
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
L120-104
L120-204
L120-404
4.3.2 Stem Acceptance
The maximum stem acceptance is provided in Table 4.3.
Table 4.3 – Maximum Stem Acceptance
Actuator size
L120-101.25321.0025¼x3/328x6
L120-202.25571.87547½x3/1614x9
L120-402.625662.12552½x3/1616x10
Mounting HolesTap size
QuantityMSSISO
3
⁄8-16x0.88M10x1.5x22.4
5
⁄8-11x1.25M16x2x32
5
⁄8-11x1.25M16x2x32
Drive 2Drive 1
TappedBoreKey
inchmminchmminchmm
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
11
flowserve.com
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
12
Actuator SizeFour-GearFive-Gear
L120-106306300
L120-207407400
L120-406406400
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.
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.
13
flowserve.com
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.
14
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
15
flowserve.com
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 QuantityDescription
61Housing Cover Shim
42-111O-Ring / Handwheel Mounting
441Quad Ring
451Pipe Plug
1501Bevel Housing
1511Bevel Housing Adapter
1521Bearing Cap
1531Bevel Gear
1541Bevel Pinion Shaft
157-14Hex Head Cap Screw
157-24Lockwasher
157-32Socket Head Cap Screw
157-41Roll Pin
157-52Socket Head Cap Screw
157-62Lockwasher
158-11Quad Ring
158-21O-Ring
158-31O-Ring
158-41Quad-Ring
1602Ball Bearing
1611Seal Insert
1641Spacer
1691Retaining Ring
1711Grease Fitting
1771Handwheel
1781Hex Head Cap Screw
1791Lockwasher
1801Key
1811Retaining Washer
182-11Handwheel Spinner
182-21Socket Head Cap Screw
182-31Hex 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
61 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
17
flowserve.com
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 QuantityDescription
61 Housing Cover Shim
42-111O-ring / Handwheel Mounting
441Quad Ring
451Pipe Plug
1501Bevel Housing Cover
1511Bevel Housing
1521Spur Gear Cover
1531Bevel Gear
1541Bevel Pinion
1551Input Pinion Shaft
1561Bevel Gear Adapter
157-14Hex Head Cap Screw
157-24Lockwasher
157-34Hex Head Cap Screw
157-44Lockwasher
157-58Socket Head Cap Screw
157-62Dowel Pin
157-71Socket Head Cap Screw
158-11Quad Ring
158-21O-ring
158-31Gasket
158-41Quad Ring
158-51O-ring
1591Spur Gear
1601Ball Bearing
1611Seal Insert
1631Ball Bearing
1642Ball Bearing
1671Key
1691Retaining Ring
1711Grease Fitting
1771Handwheel
1781Hex Head Cap Screw
1791Lockwasher
1801Key
1811Retaining Washer
182-11Handwheel Spinner
182-21Socket Head Cap Screw
182-31Hex Jam Nut
18
5
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.
19
flowserve.com
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 toUse wire rated at least
40°C60°C
60°C75°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.
20
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
418
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
AB
AB
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
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.
flowserve.com
25
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).
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).
flowserve.com
27
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.
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
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
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).
29
flowserve.com
Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18
Hex Head Cap Screw
1121Relief 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 QuantityDescription
1001Base Housing
1011Stem Nut
1021Seal Retainer
1032Needle Bearing
1042Thrust Washer
1052Thrust Washer
1061O-ring Seal
107 1 Quad Ring Seal
107A1Quad Ring Seal
1081Gasket
1091Grease Fitting
1104
1114Lock 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.
31
flowserve.com
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
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.
33
flowserve.com
7
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:
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.
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
flowserve.com
Loading...
+ hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.