Flowserve UEX Limitorque User Manual

USER INSTRUCTIONS

Limitorque

Electronic Controls Module

FCD LMENIM1205-03-AQ – 05/15

®

UEX

Installation

Operation

Maintenance

Experience In Motion

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

Contents

1. Introduction 4

1.1 Purpose 4

1.2 User Safety 4

1.3 Product Description 5

2. Safety 6

2.1 Safety Precautions 6

2.2 Safety Practices 7

3. Limit Switch and Torque Switch Setting Procedures 8

3.1 Initial Actuator Preparation 8

3.2 Torque Switch 8

3.2.1 Setting Torque Switch 8

3.2.2 Balancing Torque Switch 9

3.3 Geared Limit Switch 10

3.3.1 Setting Limit Switch 10

3.3.2 Setting Procedure (Refer to Figure 3.2) 11

3.3.3 Combination of Contacts (Refer to Figure 3.2) 12

4. Removal of UEC-3 Electronic Controller 13

5. UEX Electronic Controller Installation 18

6. Standard Control Features 22

6.1 Basic Specifications 22

6.2 Local Control 23

6.3 Remote Control Modes of Operation 23

6.4 Emergency Shutdown (ESD) 24

6.5 Remote External Interlocks/Inhibits 25

6.6 Absolute Position Encoder 25

7. Protection Features 26

7.1 Autophase Protection and Correction 26

7.2 Jammed Valve Protection 26

7.3 Instantaneous Reversal Protection 26

7.4 Motor Thermal Protection 26

8. Optional Control Features 27

8.1 Modutronic 27

8.2 Analog Position Transmitter (APT) 28

8.3 Two-Speed Timer 28

8.4 Control Station (CSE) 28

9. Network Communications 29

9.1 Modbus™ 29

9.2 Master Station III 30

9.3 Foundation Fieldbus Communication 30

9.4 PROFIBUS DP V1 Communication 31

9.5 PROFIBUS PA Communication 31

9.6 DeviceNet 32

10. Monitoring and Diagnostic Features 33

10.1 Local Features 33

10.2 Diagnostics 34

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11. Remote Indication Features 36

11.1 Actuator Status Contacts (S1a, S1b, S2a, S2b) 36

11.2 Monitor Relay (RM) 37

11.3 Exact End Position Indication 37

12. Auxiliary Power Supply 38

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

13. Isolated Commons 38

14. Actuator Configuration 39

14.1 Local Configuration 39

14.2 Default Configuration 39

15. UEX Wiring Diagrams 41

16. Network Protocol Connections 47

16.1 Network Wiring – Modbus 47

16.2 Network Wiring – Foundation Fieldbus H1 49

16.3 Network Wiring – Profibus DP and PA 51

16.4 Network Wiring – DeviceNet 52

17. How to Order Parts 54

18. Regulatory Information 55

Figures and Tables

Figure 1.1 – UEX Local Control Panel 5
Figure 3.1 – Microswitch-Style Torque Switch and 600 Volt Torque Switch 9
Figure 3.2 – Limit Switch 11
Figure 3.3 – Setting the Open and Closed Contacts 12
Figure 4.1 – Removal of the UEC-3 Electronic Controller 14
Figure 4.2 – UEC-3, MPC, DDC Assembly 17
Figure 5.1 – Encoder / MDPI / Transformer Installation 19
Figure 5.2 – Power / Interface Board Assembly 19
Figure 5.3 – Main Board Set Installation 20
Figure 5.4 – CSE Jumper Assembly 20
Figure 5.5 – CSE Control Station 20
Figure 5.6 – Controls Compartment Assembly 21
Figure 6.1 – UEX Local Control Panel 22
Figure 6.2 – Absolute Position Encoder 25
Figure 10.1 – Normal and Diagnostic Displays 35
Figure 14.1 – Default Configuration Guidelines 40
Figure 14.2 – Configuring the UEX Controller 40
Figure 15.1 – Standard Wiring Diagram for UEX Controllers 42
Figure 15.2 – DDC Wiring Diagram for UEX Controllers 43
Figure 15.3 – MOD APT Wiring Diagram for UEX Controllers 44
Figure 15.4 – Optional Features Wiring Diagrams 45
Figure 15.5 – Modbus, Foundation Fieldbus, Profibus DP V1, and Profibus PA, 46

and DeviceNet Network Wiring Diagrams
Figure 16.1 – Typical Modbus Network Wiring Diagrams – Single Loop 48
Figure 16.2 – Typical Foundation Fieldbus System with a DCS Host (Daisy Chain Shown) 50
Figure 16.3 – Typical Profibus System with a DCS Host (Daisy Chain Shown) 52
Table 1.1 – Standard Application Voltages with +/- 10% Nominal Range 5
Table 2.1 – Required Rating for External Wiring 7
Table 3.1 – Maximum Number of Drive Sleeve Turns for Standard Four-Gear 10

and Optional Five-Gear Limit Switches
Table 3.2 – Limit Switch Parts 11
Table 5.1 – UEX Parts List 21
Table 16.1 – Specifications for the Profibus Cable 51
Table 16.2 – Maximum Segment Length 51
Table 16.3 – Belden Cable Specifications 53
Table 16.4 – Total Cable Length Between Repeaters or Nodes 53

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

Introduction

1.1 Purpose

This Installation and Maintenance Manual explains how to install, setup, and maintain the UEX controller
for the L120-10, L120-20, and L120-40 actuators. Information on installation, operation, control
features, and maintenance is provided.

Contact Flowserve Limitorque if assistance is needed or preferred for installation, upgrading, or training
in the operation of the UEX.

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 should be performed by a qualified tradesman
who is familiar with the operation and maintenance of electric actuators. Failure to observe these
precautions could result in serious bodily injury, damage to the equipment, voiding of the warranty, or
operational difficulty.

Safety notices are presented in this manual in three forms:

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.

NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and

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operation.

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

1.3 Product Description

The UEX is designed for use with the three-phase L120 electric actuators for weatherproof, explosion­proof, and submersible applications. The UEX is field-retrofittable to replace existing UEC-3 controllers.
With state-of-the-art controls based on MX control technology, the UEX offers an expanded feature set
compared to the UEC-3.

Please refer to LMENIM2306 for detailed menu configurations

Table 1.1 Standard Application Voltages with +/- 10% Nominal Range

Design Voltage Application Voltage

230 VAC, 60 Hz, 3 ph 208/220/230/240 VAC, 60 Hz, 3 ph

460 VAC, 60 Hz, 3 ph 380/400/415/440 VAC, 50 Hz, 3 ph

380/440/460/480 VAC, 60 Hz, 3 ph

525 VAC, 50 Hz, 3 ph 525 VAC, 50 Hz

575 VAC, 60 Hz, 3 ph 550/575/600 VAC, 60 Hz, 3 ph

Figure 1.1 – UEX Local Control Panel

Selector Switch Detail

(Knob removed for clarity)

A

A

Blue

Knob

Close

(No)

Lights (2)

Open
(Yes)

Red

Knob

CSE Control
Station

VIEW A-A

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

Safety

2.1 Safety Precautions

c WARNING: Read this Installation and Maintenance Manual carefully and completely before

attempting to install, operate, or troubleshoot the Limitorque L120 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 your
L120 actuator. Do not remove the actuator mounting bolts when the actuator is mounted on a rising
stem valve unless the valve is in the FULLY OPEN position and there is NO pressure in the line.

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.

c WARNING: Do not work on the actuator while it is mounted on a torque-seated valve.

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

2.2 Safety Practices

The following checks should be performed to maintain safe operation of the L120 actuator.

• Mount motors on a horizontal plane, if possible.

• Keep the switch compartment clean and dry.

• Keep the valve stem clean and lubricated.

• Set up periodic operating schedule for infrequently used valves.

• 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 2.1.

Table 2.1 – Required Rating for External Wiring

Up to: Use wire rated at least:

40°C 60°C

60°C 75°C

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

Limit Switch & Torque Switch
Setting Procedures

3.1 Initial Actuator Preparation

Replace all molded plastic conduit and top protectors (installed for shipping purposes only) with pipe
plugs when installation wiring is complete.

3.2 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.

3.2.1 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:

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.

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• Do not exceed the setting indicated by this plate without contacting the Limitorque service
department.

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

• Installing or adjusting the torque switch with the actuator in a loaded condition will result in a loss
of torque protection.

Item letters correspond to Figure 3.1.

1. Place the L120 actuator in manual mode.

2. Release the load on the wormshaft spring pack.

3. For open and close directions, loosen Screw (A) and move Pointer (B) to desired position. A higher
number indicates a high torque and/or thrust output.

4. Tighten Screw (A).

5. Operate the valve electrically to seat valve and to ensure tight shutoff.

6. Rebalance torque switch if required.

Figure 3.1 – Microswitch-Style Torque Switch and 600 Volt Torque Switch

B

Maximum Stop
Setting Plate

A

Maximum Stop
Setting Plate

B

A

OPEN

-10-20

Balancing
Screws

-10-20

CLOSE

Index Marks

B

A

Microswitch-Style Torque Switch

Mounting
Screw

Index Marks

600 Volt Torque Switch

3.2.2 Balancing Torque Switch

Item letters correspond to Figure 3.1.

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.

Balancing
Screws

Mounting
Screw

B

A

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

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.

3.3 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.

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3.3.1 Setting Limit Switch

Set the limit switch as follows. All item letters and piece numbers refer to Figure 3.2.

NOTE: See chart below for maximum number of drive sleeve turns for each unit size. The Intermediate
Shaft (B), shown in Figure 3.2, may take a considerable number of turns before rotor trip occurs.

Table 3.1 – Maximum Number of Drive Sleeve Turns for Standard Four-Gear and Optional Five-Gear
Limit Switches

Actuator Size Four-Gear Five-Gear

L120-10 630 6300

L120-20 740 7400

L120-40 640 6400

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 3.2 – Limit Switch

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

7

8

6

5

B

A

4

9

3

2

1

Table 3.2 – Limit Switch Parts

Piece Quantity Description

11 Gear Frame Assembly
22 Eight-Switch Contact Block Assy.
312Rotor Segment (short)
44 Rotor Shaft
54 Machine Screw
64 Flat Washer
74 Lock Washer
88 Hex Nut
94 Rotor Segments (long)

3.3.2 Setting Procedure (Refer to Figure 3.2)

1. Open the Controls Compartment Cover (refer to Figure 5.5).

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.

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

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.

Figure 3.3 – Setting the Open and Closed Contacts

Closed

position

Open

position

3.3.3 Combination of Contacts (Refer to Figure 3.2)

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.

NOTE: For mechanical operation and maintenance of the L120 actuators, please see section 5 and 6 of
LMENIM1201.

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Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

Removal of the UEC-3
Electronic Controller

NOTE: Confirm that the limit switches are set properly prior to disassembly and removal of the UEC-3
and related components. Confirming the settings will allow for installation of the UEX Electronic
Controller without requiring a reset of the limit switches.

1. Turn off the power to the actuator.

2. Open the Controls Compartment Cover.

3. Cut and remove all wire ties from wiring that is connected to the UEC-3 assembly (pc# C-201).

4. Disconnect the incoming power from the Interconnect Board.

5. Disconnect the Motor leads and Heater leads from the Interconnect Board.

6. Disconnect the Pushbutton Station ribbon cable from the Interconnect Board.

7. Disconnect the Analog-to-Digital Circuit Board (pc# C-223) ribbon cable from the Interconnect Board.

8. Disconnect the R/I circuit board (pc# C-210) ribbon cable

9. Uninstall the Potentiometer by removing the screws that fasten it to the MDPI assembly.

10. Uninstall the MDPI assembly by removing the screws that fasten it to the Geared Limit Switch
assembly.

11. Unplug the optional I/O Circuit Board (pc# C-223) from the SBC Board on the UEC-3 Assembly.

12. Label all customer wiring and disconnect from the Interconnect Boards.

13. Remove the four screws from the UEC-3 Assembly (pc# C-201) and carefully remove the Assembly
from the Controls Compartment.

14. Remove the Pushbutton Station with ribbon cable from the L120 gear housing conduit entry.

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Figure 4.1 - Removal of the UEC-3 Electronic Controller

DESCRIPTION

TMI INTERGAL ITEMS

SCREW, PAN HD. MACH.

LOCKWASHER,EXT. TOOTH

GROUND LUG

UNIVERSAL ELECTRONICS CONTROLLER

1

C185 1C186

1

C201

SCREW,PAN HD.MACH.

4

C202

LOCKWASHER

4

C203

FLAT WASHER

12

C203-1

TERMINAL STRIP (12 POINT)

TERMINAL STRIP INSULATOR

1 4 4

1

C204

C204-1

SCREW,PAN HD.MACH.

C205

HEATER ASSY

QTY.

1

1

PC.

NO.

C184

C23

LOCKWASHER,EXT.TOOTH

C206

SIGNAL CONVERTER

SCREW,PAN HD.MACH.

1 4 4

C210

C211

SCREW, PAN HD. MACH.

BRACKET, TERMINAL STRIP

LOCKWASHER,EXT.TOOTH

2

1

C217

C216

C212

LOCKWASHER,EXT. TOOTH

2

C218

BRACKET

1 2 2

C220

SCREW,PAN HD.MACH.

C221

LOCKWASHER,EXT.TOOTH

C222

INTERFACE P.C. BOARD

1 2 2

C223

SCREW, PAN HD. MACH.

C224

LOCKWASHER,EXT. TOOTH

C225

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

UEC

PIFF ASSY

1

311

C

186

C

185

(HEATER)

C

23

(GROUND LUG)

C

184

C

-1

204

C

C

206

204

C

205

C

218

C

C

216

217

12C1111C1010C99C

12C1111C1010C99C

INT.1

INT.1

12

12

INT.2

INT.2

16

16

16C1515C1414C1313C

16C1515C1414C1313C

(GEAR LIMIT SWITCH AND OTHER ITEMS REMOVED FOR CLARITY)

AA

(TORQUE SWITCH)

E

S

O

L

-10-20

INT 1

INT 2

C

14

75

100

50

OPEN

PERCENT

0

25

OPEN

CLOSE

4 GEAR

L120-10

UEC UEC

UNIVERSAL

ELECTRONICS

CONTROLLER

(UEC)

X3

C

T 2

C

A

A

202

203

C

203-1

C

201

Figure 4.1 – Removal of the UEC-3 Electronic Controller (continued)

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

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Figure 4.1 – Removal of the UEC-3 Electronic Controller (continued)

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

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Figure 4.2 – UEC-3, MPC, DDC Assembly

Limitorque UEX FCD LMENIM1205-03-AQ – 05/15

11

23

17

INSULATOR BEHIND PCB

B-E ELEC

34

25

31

4

ON BOM 4805-455

PLASTIC COVER

7

A

31

25

35

RIBBON FOR SW93

30

25

26

ON CLEAR

20

31

9

25

22

8

37

29

c

B

SUPPLY

MOTOR

HEATER

B

3

21

A

FUSE

FUSE

25

28

13

32

15

36

1918

35

2

FUSES

6

12

SECTION A-A

c

24

27

10

14

1

VIEW C-C

FUSE

16

37

1

SCREW, PAN HD

5

15

16

31

1348351362

1

SCREW, PT FLAT

SCREW, PT OVAL HD

BITBUS/MODBUS PROM

SCREW, PAN HD

SCREW, PAN HD

SCREW, PAN HD

SCREW, PAN HD

1DDC/4 UEC

LOCKWASHER (INT TOOTH)

SCREW, PAN HD

2271291303

5DDC/4 UEC

1261

LOCKWASHER (INT TOOTH)

HEX NUT 25HEX NUT

24

1

1

2

LOCKWASHER (EXT TOOTH)

TERMINAL COVER, UEC

CONTROL BOX, UEC

FRONT COVER, UEC

21

22

23

28

33

32

14

1

1

1

1

SBC W/ CIRCUIT TRACE

RAIL, DIN

STICKER, UEC-3 ALL

HARNESS, CONTACTOR

10

12

11

13

1

1

1

INTERCONNECT BD (DDC SHOWN)

HARNESS, STARTER

MOV SNUBBER, 12A/25A

7

8

9

1

1

1

HARNESS, RIBBON 50PIN

BRACKET, TRANSFORMER

DAUGHTER BOARD (DDC ONLY)

17

18

19

20

1

1

1

1

INSULATOR, SBC

SCREEN PLATE

LABEL, FRONT COVER

INSULATOR, ICB

3

5

6

1

141

1

GROUND WIRE, POWER

HARNESS, POWER

HARNESS, HEATER

HARNESS, ICB TO D. BOARD

ITEM

1

2

QT Y.

1

1

REVERSING CONTACTOR

POWER SUPPLY BOARD

33

DESCRIPTION

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