Flowserve MX-85 User Manual

F C D L M A I M 1 3 4 1 - 0 0

MX-85/140

Actuator

Maintenance and Spare Parts

Flow Control

Limitorque Actuation Systems

Contents

1 Introduction			1
1.1	Premise		1
1.2	Important Notes & Warning Statements		1
1.3	Procedure Emphasis		2
1.4	Reference Documents		2
2 Accutronix MX
	Actuator Subassembly		3
2.1	MX Actuator Subassembly Components		4
2.2	Product Information		4
	2.2.1	Product Description	4
	2.2.2	Storage	4
	2.2.3	Unit Weights	5
2.3	Product Identification		5
	2.3.1 Initial Inspection and Recording Suggestions		5
2.4	Maintenance		5
	2.4.1	Recommended Maintenance	5
	2.4.2	Unit Lubrication	6
	2.4.3	O-rings and Lubrication	7
2.5	Subassembly Removal and Remounting Procedures		7
2.6	How to Order Replacement Subassemblies		7
	2.6.1	Replacement Parts	7
	2.6.2	Return Procedure	7
3 Remove Actuator
	from Mounting Adapter		9
3.1	Actuator Removal with Type B1/B4/B4E Base (Torque)		9
	3.1.1 Removal (Type B1/B4/B4E Base)		9
	3.1.2 Remounting (Type B1/B4/B4E Base)		10
3.2	Actuator Removal with Type A1/A1E Base (Thrust)		11

3.2.1Removal (Type A1/A1E Base)—

	Actuator removal separate from thrust base	11
3.2.2	Remounting (Type A1/A1E Base)—
	Actuator remounting separate from thrust base	13
3.2.3	Removal (Type A1/A1E Base)—
	Actuator and thrust base as a unit	14

3.2.4Remounting (Type A1/A1E Base)—

Actuator and thrust base as a unit	15

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4 Mechanical Assemblies			17
4.1	Motor		17
	4.1.1	Removal	18
	4.1.2	Remounting	19
4.2	Declutch		21
	4.2.1	Removal	22
	4.2.2	Remounting	23
4.3	Side-Mounted Handwheel with Spur Gear Attachment		25
	4.3.1	Removal of Handwheel	26
	4.3.2	Removal	26
	4.3.3	Remounting	28
4.4	Thrust Base Type A1/A1E		31
	4.4.1	Removal	33
	4.4.2	Remounting	33
4.5	Baseplate Type B4		34
	4.5.1	Removal	35
	4.5.2	Remounting	36
4.6	Worm Shaft		36
	4.6.1	Removal	37
	4.6.2	Remounting	37
4.7	Drive Sleeve		39
	4.7.1	Removal	40
	4.7.2	Remounting	41
	4.7.3 Optional Drive Sleeve and Baseplate Removal		42
	4.7.4 Optional Drive Sleeve and Baseplate Remounting		44
4.8	Handwheel Worm Gear		46
	4.8.1	Removal	46
	4.8.2	Remounting	48
4.9	Clutch and Clutch Ring Components		50
	4.9.1	Removal	51
	4.9.2	Remounting	52

	5 Electronic Assemblies			55
5.1		Accutronix Control Panel (ACP)			55
	5.2	Installation and Removal of SMT Controls			56
		5.2.1	Installation		56
		5.2.2	Removal		59
		5.2.3	Fuse Replacement		60
		5.2.4 Control Module Return Options			60
	5.3	Adding Electronic Options to Your Accutronix MX Actuator			60
	5.4	Restoring Power to Actuator with New Control Module			61
	5.5	Terminal Block			62
		5.5.1	Removal		62
		5.5.2	Remounting		65
	5.6	Control Module—Contactor Assembly			67
		5.6.1	Removal		68
		5.6.2	Remounting		69
	5.7	Encoder			71
		5.7.1	Removal		72
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	5.7.2	Remounting	73
5.8	Encoder Drive Cartridge		74
	5.8.1	Removal	75
	5.8.2	Remounting	75
5.9	Motor Lead Harness		76
	5.9.1	Removal	76
	5.9.2	Remounting	77

6 Spare and
	Replacement Parts		79
6.1	Guidelines for Recommended Spare Parts		79
	6.1.1	Wear Components	79
	6.1.2 Bearings, O-rings and Seals		79
	6.1.3	Critical Components	80
6.2	Recommended Spare Parts for MX Actuators		80
	6.2.1	Commissioning and Startup	80
	6.2.2	Short-Term Duty	80
	6.2.3	Long-Term Duty	80
	6.2.4	Severe Duty	81
6.3	Other Concerns		81

7 Regulatory Information	83
7.1 Declaration of Conformity	83

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Figures

Figure 2.1 – Accutronix MX Actuator	3
Figure 2.2 – Accutronix MX Nameplate	5
Figure 2.3 – Oil Fill/Plug Locations	6
Figure 4.1 – Motor	17
Figure 4.2 – Declutch	21
Figure 4.3 – Side-Mounted Handwheel With SGA	25
Figure 4.4 – Type A1 Thrust Base – F25 Flange	31
Figure 4.5 – Type A1 Thrust Base (MX-85) - F16 Flange	32
Figure 4.6 – Type B4 Baseplate	34
Figure 4.7 – 10:1 and 13:1 ratio	39
Figure 4.8 – Handwheel Worm Gear Assembly	46
Figure 4.9 – Clutch and Clutch Ring Components	50
Figure 4.10 – Clutch Ring	52
Figure 5.1 – Accutronix Control Panel	55
Figure 5.2 – Location of Fuses and Voltage Jumper	60
Figure 5.3 – Restoring Power to Actuator
with New Control Module	61
Figure 5.4 – Terminal Block	62
Figure 5.5 – Control Module – Contactor Assembly	67
Figure 5.6 – Control Module – Contactor Assembly
Wiring Diagram	67
Figure 5.7 – Encoder	71
Figure 5.8 – Encoder Drive Cartridge	74
Figure 5.9 – Motor Lead Assembly	76

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Tables

Table 2.1 – MX Actuator Subassembly Components	4
Table 2.2 – Unit weights	5
Table 2.3 – MX-85 and 140 Oil Capacities
when using Oil Fill/Plug Ports	6
Table 4.1 – Motor Parts List	17
Table 4.2 – Declutch Parts List	21
Table 4.3 – Side-Mounted Handwheel Parts List	25
Table 4.4 – Type A1 Thrust Base Parts List	31
Table 4.5 – Type A1 Thrust Base Parts List (MX-85)	32
Table 4.6 – Type B4 Baseplate Parts List	34
Table 4.7 – Worm Shaft Parts List	36
Table 4.8 – Drive Sleeve Parts List	39
Table 4.9 – Handwheel Worm Gear Assembly Parts List	46
Table 4.10 – Clutch and Clutch Ring Components Parts List	50
Table 4.11 – Clutch Ring Assembly Parts List	52
Table 5.1 – Accutronix Control Panel Parts List	55
Table 5.2 – Terminal Block Parts List	62
Table 5.3 – Control Module—Contactor Assembly Parts List	67
Table 5.4 – Encoder Parts List	71
Table 5.5 – Encoder Drive Sleeve Speed (rpm)	72
Table 5.6 – Encoder Drive Cartridge Parts List	74
Table 5.7 – Encoder Drive Cartridge Drive Sleeve Speed	74

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1Introduction

1.1 Premise

The MX actuator components are separated into subassembly groupings. This manual covers the Removal and Remounting procedures for each subassembly group. Use these instructions when disassembly is required for servicing, maintenance, or parts replacement.

1.2 Important Notes and Warning Statements

Please read this Maintenance & Spare Parts Manual carefully and completely before attempting to store or perform maintenance on your Limitorque valve actuator. Further installation, setup, and operation instructions are available in the Installation & Operation manual (LMAIM1306) located in the actuator terminal compartment at shipment.

cWARNING: Be aware of electrical hazards within the actuator and high-pressure hazards of the attached valve or other actuated device when installing or performing maintenance on your MX actuator. Failure to observe these pre-cautions could result in serious bodily injury, damage to the equipment, or operational difficulty.

cWARNING: Do not manually operate actuator with devices other than installed handwheel and declutch lever. Using additive force devices (cheater bars, wheel wrenches, pipe wrenches, or other devices of this nature) on the actuator handwheel or declutch lever may cause serious per-son-al injury and/or damage to the actuator or valve.

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1.3 Procedure Emphasis

Please refer to the following methods used to emphasize text throughout this manual. Safety warnings, cautions, and notes present material that is important to user-safety. Be sure to read any safety notices you see as they could prevent equipment damage, personal injury, or even death to you or a co-worker.

Safety notices are presented in this manual in three forms:

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

aCAUTION: Directs the user’s attention to general precautions that, if not followed, could result in personal injury and/or equipment damage.

NOTE: Highlights information critical to the user’s understanding of the procedure.

1.4 Reference Documents

•Accutronix Protection, Control & Monitoring features of MX Electric Actuators (LMABR1300)

•Accutronix MX Control, Performance & Value in Multi-turn Electric Valve Actuators (LMABR1302)

•Accutronix MX Installation Manual (Bulletin LMAIM1306)

The latest revisions to these documents are available on-line from Limitorque’s web site, www.limitorque.com.

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2Accutronix MX Actuator Subassembly

Figure 2.1 – Accutronix MX Actuator

1 & 12

11

3

2

5

6

4

14

7

9

10

13

8

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2.1 MX Actuator Subassembly Components

Table 2.1 – MX Actuator Subassembly Components

No. Description

1 Top-mounted handwheel

2 Drive sleeve

3Worm shaft

4Motor

5Declutch Lever

6Encoder

7 Accutronix Control Panel (ACP)

8Control module

Optional bases

9Thrust Base type:

•A1 = Standard thrust base

•A1E = Extended-reach thrust base

Baseplate-type B4 with stem nut options type:

10• B4 = stem nut with variable bore and key

•B4E = extended-reach stem nut with variable bore and key

11Handwheel worm gear

12Side-mounted handwheel (not shown)

13Encoder drive cartridge

14Terminal block

2.2 Product Information

2.2.1 Product Description

Your MX actuator controls the opening and closing travel of valves and other actuated devices. OPEN and CLOSED limits are protected by an absolute encoder that provides optical sensing of valve position and measures valve position in both motor and handwheel operation. No battery or backup power supply is required. Output torque is derived from motor speed, temperature, and voltage. If the preset torque is exceeded, the motor shuts off. As a result of this reliable and advanced protection technology, all valve and other actuated devices are protected from potential damage from overload, improper seating, and foreign obstructions.

A range of control and network options is available and very simply added to the control capabilities already available on a standard actuator. Contact your local Limitorque distributor or Limitorque sales office for further information.

2.2.2 Storage

Storage Recommendations

Your MX actuator is double-sealed and weatherproof as shipped providing all compartment covers and cable entry plugs are left intact. Actuators should be stored in a clean, dry, protected warehouse until ready for wire-up. If actuators must be stored outdoors, they should be stored off the ground, high enough to prevent being immersed in water or buried in snow.

If your unit incorporates a rising stem application, it may be shipped with a plastic cap over the drive sleeve. If so, install a pipe plug or protective stem cover to protect the drive sleeve from possible corrosion.

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Preferred Storage Orientation

Your MX actuator should be stored with the motor and terminal compartment in the horizontal position to obtain optimum service life.

2.2.3 Unit Weights

Table 2.2 – Unit weights

Unit	lb.	kg
MX-85		117
	259
MX-140	300	136

NOTE: Weights include stem nut and lubricant.

2.3 Product Identification

2.3.1 Initial Inspection and Recording Suggestions

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

1.After removing the actuator from the shipping carton or skid, thoroughly examine it for any physical damage which may have occurred during shipment. If you note any damage, immediately report the damage to the transport company and call Limitorque for further assistance.

2.A nameplate with important information is attached to each actuator. Record the following information for use when you need to contact Limitorque with any questions about your actuator:

•Unit type/size

•Limitorque order number

•Serial number

Figure 2.2 – Accutronix MX Nameplate

Unit type/size

Limitorque order no.

Serial number

2.4 Maintenance

2.4.1 Recommended Maintenance

Under normal operating conditions, the MX is a maintenance-free actuator. Therefore, for normal applications, no formal actuator maintenance is required; although visual inspection for oil leakage and excessive noise is recommended every 1 million drive sleeve turns or every 3000 cycles. When conditions are severe, due to frequent operation or high

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temperatures, inspect the oil level and oil quality more often. Replace any seals that permit oil leakage or water ingress. When installing pipe plugs, use Teflon® tape or paste to achieve a proper seal.

2.4.2 Unit Lubrication

Check for proper oil level every 1 million drive sleeve turns (reference Installation and Operation Manual – Diagnostics Section to learn how to view drive sleeve turns data). Change oil every 6000 unit cycles or if water or other foreign material is found during oil inspection.

Oil Level Inspection and Fill Criteria

(Reference Lubrication Data table below for oil capacities when mounted in varying positions.)

•Actuator viewed in upright position (top-mounted handwheel up): Oil level should be approximately 1 inch (25.4 mm) below the outer surface of the housing at the oil fill port.

NOTE: Do not overfill with oil because oil will expand during actuator operation. Actuators are shipped with an oil volume suitable for any mounting position. When checking the factory-supplied oil level, excess oil may drain from the highest oil fill port due to the various mounting orientations of each application.

•Actuator viewed in side-mounted position (terminal compartment up): Oil level should be up to the bottom of the oil fill plug.

•Actuator viewed in all other positions than described previously should have the oil capacities maintained. Fill through the highest oil fill port until the oil is at a level that will contact the bottom of the pipe plug when installed in oil fill port.

Figure 2.3 – Oil Fill/Plug Locations

Lubrication Data

• Oil Specifications

MX actuators are oil-filled using Mobil SHC-632, which is a synthetic oil suitable for ambient temperatures of -22˚F to 250˚F (-30˚C to 120˚C). For extreme low temperature conditions, alternative lubricants are available – consult factory for further information.

Table 2.3 – MX-85 and 140 Oil Capacities when using Oil Fill/Plug Ports

Nominal Oil Capacities	oz.	liters
All Configurations		5.7
	192

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2.4.3 O-rings and Lubrication

O-rings and seals should be replaced anytime an actuator is disassembled. Lubricate with a substance that is compatible with Buna N seals.

2.5 Subassembly Removal and Remounting Procedures

This manual divides each MX actuator subassembly into a Removal and Remounting procedure. Use the following procedures to remove subassemblies for inspection, repair or replacement. Some subassemblies require prior subassembly removal before allowing the desired subassembly removal. Note the First Remove instructions at the beginning of each subassembly removal procedure. Remove these subassemblies first, then remove the desired subassembly according to the instructions. Once removed, evaluate subassembly components to determine requirement for a new subassembly. If a new subassembly is required, see Section 2.6, How to Order Replace-ment Subassemblies. Once components have been identified and replaced, remount following the appropriate Re-mount-ing procedures.

2.6 How to Order Replacement Subassemblies

2.6.1 Replacement Parts

Replacement parts are sold in modular subassemblies; therefore, when part replacement is required, order parts at the subassembly levels as shown in this manual. Parts may be ordered from your local Limitorque representative (see web site at www.limitorque.com) or direct from the factory:

Telephone: [phone]

Fax: [phone]

Please have the following information, found on the actuator nameplate, available to help us facilitate your order:

•Unit type/size

•Limitorque order number

•Serial number

2.6.2 Return Procedure

When parts are identified for warranty or other component replacement, a Return Material Authorization (RMA) must be obtained from Limitorque. All returned parts must be accompanied by documentation with the following information to obtain credit for returned goods:

•Return Material Authorization (RMA)

•Unit type/size

•Limitorque order number

•Serial number

Return parts to the address listed below:

Limitorque Actuation Systems

5114 Woodall Road

Lynchburg, VA 24502

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3Remove Actuator from Mounting Adapter

3.1 Actuator Removal with Type B1/B4/B4E Base (Torque)

3.1.1 Removal (Type B1/B4/B4E Base)

STEP 1	1

aWARNING: Hazardous Voltage! Turn off all power sources to actuator before removing actuator from mounting plate. Power sources may include main power or control power. If necessary, disconnect incoming power leads L1, L2, L3, and control wiring from the terminal block.

Remove the bolts that secure the actuator to the mounting adapter.

If type B1 or B4E base is used in addition to the standard type B4 baseplate, you may leave the B1 base attached to the mounting adapter and remove the actuator only. Or if required, you may remove the bolts that mount type B1 base to mounting adapter.

This will allow actuator removal along with optional

B1 base.

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STEP 2

aWARNING: Potential high pressure vessel! Before disassembling your actuator, ensure that the valve or other actuated device is isolated and is not under pressure.

Lift actuator from mounting adapter.

3.1.2 Remounting (Type B1/B4/B4E Base)

STEP 3

Ensure stem nut (#1-22) is secured inside actuator drive sleeve with retaining ring (#1-23). Lower actuator onto the mating component, making sure to align stem nut key and keyway with mating component.

Limitorque Actuation Systems

2

3

1-22

1-23

	STEP 4	4
	Ensure that the actuator and mounting adapter
	flange mating holes are aligned correctly.

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STEP 5

aWARNING: Hazardous Voltage! Turn off all power sources before rewiring incoming power leads L1, L2, L3, and control wiring in the terminal block.

Secure the actuator to the mounting adapter with mounting bolts.

Limitorque Actuation Systems

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STEP 6

Reconnect incoming power leads L1, L2, L3, and control wiring to the terminal block. Restore power source when ready for operation.

3.2 Actuator Removal with Type A1/A1E Base (Thrust)

NOTE: Two procedure options are available for removing the actuator and thrust base:

1.Remove actuator from thrust base, leaving thrust base mounted to mounting flange or removing thrust base separately.

2.Remove actuator and thrust base as a unit from mounting flange.

3.2.1Removal (Type A1/A1E Base)—Actuator removal separate from thrust base

	STEP 1	1
	a WARNING: Hazardous Voltage! Turn off all
	power sources to actuator before removing	10-10

	actuator from mounting plate. Power sources	10
	may include main power or control power.
	If necessary, disconnect incoming power
	leads L1, L2, L3, and control wiring from the
	terminal block.
	Remove the bolts (#10-10) that secure the actuator
	to the thrust base assembly (#10).

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STEP 2	2

aWARNING: Potential high-pressure vessel! Before disassembling your actuator, ensure that the valve or other actuated device is iso-

lated and is not under pressure.

10

Lift actuator from thrust base assembly (#10).

STEP 3	3

aWARNING: Potential for actuated device to change position! The thrust base will maintain position only if non-backdriving thread lead is used. Ensure proper thread lead is used in your application before allowing thrust base to be used for maintaining position when actuator is removed.

	Thrust base removal (if required)
	The valve position will be maintained if a locking
	thread lead is used on the valve stem. If thrust
	base removal is required, use the following
	removal procedure.
	Remove the bolts that secure the thrust base to the
	mounting adapter.
	STEP 4	4
	Rotate the thrust base (#10) until it feeds off the
	threaded stem.
		10

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3.2.2Remounting (Type A1/A1E Base)—Actuator remounting separate from thrust base

STEP 5

Thrust base remounting (if required)

Ensure the thrust base stem nut has the two lugs positioned upward to engage with the drive sleeve slots when actuator is reinstalled onto thrust base. Thread thrust base back onto mounting adapter.

STEP 6

Secure thrust base to mounting adapter with mounting bolts.

STEP 7

Actuator remounting

Lower the actuator onto the thrust base, making sure thrust nut lugs align and properly engage with drive sleeve slots.

5

6

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STEP 8

Install bolts (#10-10) to secure the actuator to the thrust base assembly (#10).

STEP 9

aWARNING: Hazardous Voltage! Turn off all power sources before rewiring incoming power leads L1, L2, L3, and control wiring in the terminal block.

Reconnect incoming power leads L1, L2, L3, and control wiring to the terminal block. Restore power source when ready for operation.

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3.2.3 Removal (Type A1/A1E Base)—Actuator and thrust base as a unit

STEP 1	1

aWARNING: Hazardous Voltage! Turn off all power sources to actuator before removing actuator from mounting plate. Power sources may include main power or control power. If necessary, disconnect incoming power leads L1, L2, L3, and control wiring from the terminal block.

Actuator + thrust base removal

Remove the bolts that secure the actuator and thrust base (#10) to the mounting adapter.

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STEP 2

aWARNING: Potential high-pressure vessel! Before disassembling your actuator, ensure that the valve or other actuated device is isolated and is not under pressure.

Declutch the actuator to manual mode.

STEP 3

Rotate the handwheel until the actuator lifts off the threaded stem.

2

3

3.2.4 Remounting (Type A1/A1E Base)—Actuator and thrust base as a unit

STEP 4	4

Actuator + thrust base remounting

Declutch the actuator to manual mode. Lift actuator up to the threaded stem and carefully align threads with thrust base threaded stem nut.

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STEP 5

Rotate the handwheel to lower the actuator along the threaded stem and onto the mounting adapter plate.

STEP 6

Install the mounting bolts to secure the actuator and thrust base (#10) to the mounting adapter.

STEP 7

aWARNING: Hazardous Voltage! Turn off all power sources before rewiring incoming power leads L1, L2, L3, and control wiring in the terminal block.

Reconnect incoming power leads L1, L2, L3, and control wiring to the terminal block. Restore power source when ready for operation.

5

6

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4Mechanical Assemblies

4.1 Motor

NOTE: Proper motor testing is required when replacing motor. Consult your Limitorque representative or the Limitorque factory to replace with correct motor.

Table 4.1 – Motor Parts List

Part Number		Description		Qty.
4-1		Motor Cover		1
4-2		Stator		1
4-3		Rotor Assembly		1
4-4		Bearing		1
4-8		Bearing Preload Spring		1
4-9		Setscrew		1

Figure 4.1 – Motor

		4-1
	A	4-2
	Assembly must have
	rotation of rotor as shown.
	Phase connections are:	4-3
	T1-Phase 'A'
	T2-Phase 'B'	4-8
	T3-Phase 'C'
	motor
	leads
	A	4-4
		View AA
	4-9
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4.1.1 Removal

STEP 1	1

cWARNING: Hazardous Voltage! Turn off all power sources to actuator before removing motor assembly. Power sources may include main power or control power.

1-14

Using an M8 hex key, remove the four M10 screws (#1-14) that mount the motor assembly to the actuator.

STEP 2	2
a CAUTION: The rotor is not connected to the	4-3
motor housing; when removing the motor,
ensure the rotor is carefully removed and not
dropped from the motor housing.
Withdraw the complete motor (subassembly	1-15

	#4), including the rotor (#4-3), until the wiring
	harness is accessible. Note the O-ring (#1-15) on
	the spigot/pilot of the motor assembly; replace at
	remounting.
	STEP 3	3
	Disconnect the motor power plug from the motor
	power socket connector.

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	4.1.2 Remounting
	STEP 4		4
	a WARNING: Hazardous Voltage! Turn off all
	power sources to actuator before removing		1-15
	motor assembly. Power sources may include
	main power or control power.

Lightly lubricate O-ring (#1-15) that is installed around the motor spigot/pilot (subassembly #4).

STEP 5	Motor Power Plug	5
Hold the motor assembly (housing/stator/rotor)
close to the actuator housing and reconnect the		Motor
motor power plug to the motor power socket		Power
connector.		Socket
		Connector

	STEP 6	6
	Coil the spiral-wrapped motor power wiring inside
	the motor cavity and around the motor bearing
	housing to ensure that it does not come into con-
	tact with the rotor shaft.
	The motor wiring will wrap around about 180°.

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STEP 7

Push the rotor shaft onto the protruding worm shaft, aligning the rotor shaft slots with the worm shaft pin. Slide the motor housing spigot/pilot into the actuator housing.

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STEP 8

Fit the four screws (#1-14) into the motor subassembly mounting holes and tighten.

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MX-85/140 Maintenance and Spare Parts

FCD LMAIM1341-00

Flow Control

Limitorque Actuation Systems

4.2 Declutch

Table 4.2 – Declutch Parts List

Part Number		Description		Qty.
5-1		Declutch Cover		1
5-2		Declutch Shaft		1
5-3		Declutch Cam		1
5-4		Declutch Spring		1
5-9		Retaining Ring		2
5-10		Socket Head Set Screw		1
5-11		O-ring		1
5-12		Socket Head Set Screw		2
5-13		Spiral Pin		1
5-15		O-ring		1
5-16		Pipe Plug		1

Figure 4.2 – Declutch

FCD LMAIM1341-00

MX-85/140 Maintenance and Spare Parts

21