Flowserve Limitorque L120 Series User manual

Experience In Motion

USER INSTRUCTIONS

Installation

Operation

Maintenance

Limitorque

®Actuation Systems L120 Series

For L120-10 through L120-40

FCD LMENIM1201-05-A4 – 03/18

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Contents

1 Introduction 4

1.1 Purpose 4

1.2 User Safety 4

2 Product Inspection - Storage - Identiﬁcation 5

2.1 Inspection and Recording 5

2.2 Short-Term Storage (less than 1 year) 5

2.3 Product Identiﬁcation 7

3 Actuator Weights 8

4 Installation Instructions 9

4.1 Safety Precautions 9

4.2 Safety Practices 10

4.3 Initial Actuator Preparation 10

4.3.1 Mounting Base 10

4.3.2 Stem Acceptance 10

4.4 Torque Switch 11

4.4.1 Setting Torque Switch 11

4.4.2 Balancing Torque Switch 12

4.5 Geared Limit Switch 12

4.5.1 Setting Limit Switch 12

4.5.2 Setting Procedure (Refer to Figure 4.2) 13

4.5.3 Combination of Contacts (Refer to Figure 4.2) 14

4.6 Position Indication 14

4.6.1 Local position indication 14

4.6.2 Remote Position Indication 15

4.7 Optional Side-Mounted Handwheel 16

5 Operation 19

5.1 Electrical Start-up 19

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

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5.2 Manual Operation 20

5.3 Motor Operation 25

5.4 Torque and Travel Limiting 25

6 Maintenance 26

6.1 Lubrication 26

6.1.1 Lubrication Inspection 26

6.1.2 Factory Lubricant 27

6.2 Minimum Lubricant Qualities Required 27

6.3 Disassembly and Reassembly 28

6.4 Disassembly of the L120-10, 20, and 40 28

6.5 Drive Sleeve and Housing Cover Disassembly 29

6.6 Torque Nut Disassembly (Drive 1 Option) 29

6.7 Thrust Base Disassembly (Drive 2 Option) 30

6.8 Stem Nut Replacement – Thrust Base Applications 30

6.9 Reassembly 31

6.9.1 Declutch Assembly (L120-10) 32

6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3) 32

6.9.3 Install the Motor (Refer to Figure 5.2) 33

6.9.4 Lubrication Procedure 33

6.9.5 Install Geared Limit Switch, Torque Switch and Finish Assembly 33

7 How to Order Parts 34

8 EC Declaration of Conformity 35

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

1 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 equip-

ment, voiding of the warranty, or operational difﬁculty.

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 actuator’s installation and

operation.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

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cWARNING: Read this Installation and Maintenance Manual carefully and completely before

attempting to install the actuator. Be aware of the electrical hazards.

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 tempera-

ture 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.

Product Inspection - Storage -

Identiﬁcation

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Figure 2.1 – L120-10 through 40

Motor

Limit Switch/

Controls

Compartment

Housing

Declutch

Lever

Handwheel

Actuator

Nameplate

(hidden)

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

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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

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

3 Actuator Weights

The approximate L120 actuator weights are provided below:

Table 3.1 – Actuator weights

Actuator

Size Control Types

Drive 1 Weight (lb./kg) Drive 2 Weight (lb./kg)

Top HW Side HW Top HW Side HW

lb. kg lb. kg lb. kg lb. kg

L120-10

NCU 100 45 112 51 107 49 119 54

BIC 115 52 127 58 122 55 134 61

CLAMSHELL 140 64 152 69 147 67 159 72

L120-20

NCU 140 64 158 72 153 69 171 78

BIC 155 70 173 78 168 76 186 84

CLAMSHELL 180 82 198 90 193 88 211 96

L120-40

NCU 190 86 216 98 212 96 238 108

BIC 205 93 231 105 227 103 253 115

CLAMSHELL 230 105 256 116 252 114 278 126

Note: Approximate weights are based on standard explosion-proof construction, with the largest

three-phase motor available for the model size.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

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4 Installation Instructions

4.1 Safety Precautions

cWARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to install,

operate, or troubleshoot the Limitorque actuator.

cWARNING: Be aware of electrical hazards. Turn off incoming power before working on the actuator and before

opening the switch compartment.

cWARNING: 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.

cWARNING: 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.

cWARNING: 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.

cWARNING: Do not exceed any design limitations or make modiﬁcations to this equipment without ﬁrst

consulting Limitorque.

cWARNING: Actuators equipped with electrical devices (motors, controls) requiring ﬁeld wiring must be wired

and checked for proper operation by a qualiﬁed tradesman.

cWARNING: Use of the product must be suspended any time it fails to operate properly

aCAUTION: Do not use oversized motor overload heaters. Instead, look for the cause of the overload.

aCAUTION: Do not operate the valve under motor operation without ﬁrst setting or checking the limit switch

setting and motor direction.

aCAUTION: Do not force the declutch lever into the motor operation position. The lever returns to this position

automatically when the motor is energized.

aCAUTION: Do not depress the declutch lever during motor operation to stop valve travel.

aCAUTION: 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.

aCAUTION: 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.

aCAUTION: Do not lift the actuator by the handwheel.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

4.2 Safety Practices

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

• Mount motors on a horizontal plane, if possible.

• Keep the controls compartment clean and dry.

• Keep the valve stem clean and lubricated.

• Set up periodic operating schedule for infrequently used valves.

• Carefully check for correct motor rotation direction. If the motor is driving the valve in the wrong

direction, interchange any two leads on three-phase motors or switch the armature leads on DC and

single-phase motors.

• Use a protective stem cover. Check valve stem travel and clearance before mounting covers on rising

stem valves.

• Verify all actuator wiring is in accordance with the applicable wiring diagram, national and local codes,

and Table 4.1.

Table 4.1 – Required Rating for External Wiring

Up to: Use wire rated at least:

40°C 60°C

60°C 75°C

4.3 Initial Actuator Preparation

Replace all molded plastic conduit and top protectors (installed for shipping purposes only) with pipe

plugs when installation wiring is complete.

4.3.1 Mounting Base

The mounting hole sizes and quantities are as detailed in Table 4.2.

Table 4.2 – Mounting Base Dimensions

Actuator Size Mounting Holes Tap size

Quantity MSS ISO

L120-10 43⁄8-16x0.88 M10x1.5x22.4

L120-20 45⁄8-11x1.25 M16x2x32

L120-40 45⁄8-11x1.25 M16x2x32

4.3.2 Stem Acceptance

The maximum stem acceptance is provided in Table 4.3.

Table 4.3 – Maximum Stem Acceptance

Actuator size

Drive 2 Drive 1

Tapped Bore Key

inch mm inch mm inch mm

L120-10 1.25 32 1.00 25 ¼x3/32 8x6

L120-20 2.25 57 1.875 47 ½x3/16 14x9

L120-40 2.625 66 2.125 52 ½x3/16 16x10

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