PPE, 4 – 20 inch Precision Electric Control Valves and Control Stations
Instruction
D11014
August 2018
Page 1: ...PPE 4 20 inch Precision Electric Control Valves and Control Stations Instruction D11014 August 2018 ...
Page 2: ...ifficult to see or read or if a label has been removed please contact DeZURIK for replacement label s Personnel involved in the installation or maintenance of valves should be constantly alert to potential emission of pipeline material and take appropriate safety precautions Always wear suitable protection when dealing with hazardous pipeline materials Handle valves which have been removed from se...
Page 3: ...hes when using a Resolver 24 Control Stations Wiring 26 Description of Features 31 Display Adjustment 33 Analog Station CPE103 CPE104 33 Time Durations station CPE101 CPE102 34 Schematic No 1 Time Duration Control Current models 35 Schematic No 2 Analog Control Current models 36 Schematic No 3 Time Duration Control Earlier models 37 Schematic No 4 Analog Control Earlier models 38 Schematic No 5 Ti...
Page 4: ...te with Dow Corning No DC 44 AC Power Requirement AC power required is 115 60 1 or 115 50 1 115 Volts 60 or 50 Hertz single phase Current consumption is less than 1 ampere fused at 2 amperes Valve speed of operation is 20 longer when using 50 Hertz power Alignment Tool Set DeZURIK offers an alignment tool set that is used to adjust limit switches and potentiometers and is also needed whenever the ...
Page 5: ...dental operation of the actuator 4 If the valve is in a position so the plug is horizontal open or close the valve so the plug is in the lowest position of rotation This will prevent the plug from swinging down by gravity during disassembly 5 Disconnect the Amphenol connector from the Control Module 6 Remove the four screws which fasten the Control Module to the adaptor at the bottom end of the va...
Page 6: ...til the motor plate has rotated about 10 degrees Thread two of the motor plate screws removed in step 17 back in to the reverse side of the adaptor These screws must be spaced on opposing sides so that when tightened they will push the motor plate off The circular spline and wave generator of the Harmonic Drive will come off with the motor plate 19 Remove the two screws used to push off the motor ...
Page 7: ... necessary to use spacers of different thickness 4 Set the bonnet on the valve body and fasten it in place with its screws Check to see that the plug turns freely but does not have end play If necessary change the spacers on the top plug journal to get free rotation while maintaining no end play Tighten the bonnet screws to their proper torque 5 Install the packing and gland as shown in Figure 2 I...
Page 8: ...m the side of the adaptor This provides contact to the surface of the flexspline b Install a precision dial indicator so that the detector rod passes through the inspection hole and measures the surface of the flexspline Turning the motor end shaft will cause the readings on the dial indicator to show two rises per motor output shaft rotation Two equal rises equal to within 0 002 inch 0 05 mm shou...
Page 9: ...closing direction until the stop lever touches the stop screw in the adaptor Manually turn the motor shaft until there is about inch clearance between the stop screw and the stop lever 19 At the bottom of the valve slide the lever with the pin in it onto the stem extension of the bottom plug journal The pin must face out away from the valve Locate the lever so that the centerline of its pin lines ...
Page 10: ...conduit and Amphenol connector 10 Remove the screws which fasten the motor plate to the adaptor 11 Remove the motor plate and motor by turning the motor shaft clockwise until the motor plate has rotated about 10 degrees Thread two of the motor plate screws removed in step 9 back in to the reverse side of the adaptor These screws must be spaced on opposing sides so that when tightened they will pus...
Page 11: ... Control Stations __________________________________________________________________________ _________________________________________________________________________________ August 2018 Page 11 D11014 Figure 3 Exploded View for New Style Harmonic Drive ...
Page 12: ...tical to the operation and service life of the unit Use extreme care when measuring drilling and pinning the hub to the motor shaft 4 Using the dimensions in Table C for your valve size and Figure 4 drill a 0 125 inch diameter hole through the new motor shaft Table C Hub Pinning Dimensions B Dimension Valve Size A A Original Model to 2 2009 New Hub inch mm Inches mm Hub 2nd Hub Inches mm 4 100 1 5...
Page 13: ...he flexspline to the circular spline It is a very tight fit If the parts do not mesh readily do not use force Manually turn the motor shaft one or two revolutions and try it again until the units engage 11 Check for correct flexspline circular spline alignment as follows a Remove the small pipe plug from the side of the adaptor This provides contact access to the flexspline surface b Install a pre...
Page 14: ... that the OPEN and CLOSED position switches be checked by electrically operating the valve to its fully open and closed position Note that the closed position switch stops the valve before the stop lever touches the mechanical stop If the switches do not trip as indicated they must be readjusted See the ADJUSTMENTS section of these instructions Limit Switch Potentiometer or Resolver Replacement re...
Page 15: ...Control Module 4 Remove the four screws which fasten the Control Module to the adaptor at the bottom of the valve and remove the Control Module Control Module Replacement installation Note All switches potentiometers and the resolver if so equipped have been set at the factory The location of the lever attached to the new Control Module shaft has been wired in place to retain these settings Be ver...
Page 16: ...e stop lever 4 Tighten the nut to lock the stop screw in place Adjustments Closed Position Switch No 1 Closed Limit No 3 Auxiliary 1 This valve operates with a powered actuator Disconnect and lock out the electrical power to prevent accidental operation of the actuator 2 Disconnect the Amphenol connector from the Control Module 3 Remove the four screws which fasten the Control Module to the adapto...
Page 17: ...d Limit and Auxiliary Closed Limit switch Switch numbers 2 4 are the Open Limit and Auxiliary Open Limit Switch Switch 1 is at the top opposite the shaft end When setting the switches use the designated steps first for Switch No 1 then repeat these steps for Switch No 3 Older valves equipped with two switches are designated as Switch No 1 Close and Switch No 2 Open 13 Connect an ohmmeter to termin...
Page 18: ...up and or adjusted is equipped with a Resolver a separate set of adjustment procedures need to be used to set the OPEN Limit Switch See Adjustment Resolver Open Position Switch for steps to set the switch under these circumstances 1 Adjust the Open Limit switch after the Closed Limit switch has been successfully adjusted 2 Rotate the Control Module lever so the removable pin in alignment tool G 21...
Page 19: ...lockwise revolution Tighten Lockscrew B 6 Repeat steps 3 through 5 to set Auxiliary Switch No 4 7 Remove the alignment tool from the Control Module shaft NOTE The location of the lever on the bottom of the Control Module has been set with the alignment tool Be very careful when handling the Control Module to prevent this lever from being moved in relation to the Control Module base 8 Mount the Con...
Page 20: ... gear to the potentiometer shaft and slide this gear from the potentiometer shaft 14 Manually turn the potentiometer shaft until there is 0 2 volts DC across the CCW and S terminals 15 Slide the anti backlash gear onto the potentiometer shaft until the first half of the gear meshed with the large drive gear 16 Wind the second half of the anti backlash gear tight and slide it in to mesh with the la...
Page 21: ...nner to allow access to both sides of the module 9 Attach the alignment tool and rotate the Control Module lever so the removable pin in the alignment tool fits into the hole in the longer arm of the tool and into the slot of the Control Module lever 10 Verify the total resistance of the potentiometer Connect an ohmmeter to terminals CW and CCW of the potentiometer and measure the resistance Recor...
Page 22: ...st line up with the hole in the bottom of the Control Module housing The slot in the lever must line up with the pin in the valve lever 20 Mount the cover to the Control Module 21 Reconnect the Amphenol connector to its receptacle on the Control Module 22 Reconnect electrical power to the valve Resolver Adjustment Using a 24VDC Power and Ammeter NOTE The resolver can be adjusted on the valve or by...
Page 23: ...ed shaft 17 Manually turn the resolver shaft until the signal at the ammeter is 4 25 mA 18 Slide the anti backlash gear onto the resolver shaft until the first half meshes with the drive gear 19 Wind the second half of the anti backlash gear tight and slide it into mesh with the larger drive gear Tighten the screw in the split clamp 20 Observe the mA reading at the ammeter To make final precise ad...
Page 24: ...ents of the reading loosen the two servo clamp screws slightly and rotate the resolver body until the reading is 4 25 mA Tighten the two servo clamp screws 36 Remove the screws which fasten the cover to the motor housing and remove the cover 37 Using the manual override knob on the top of the motor manually move the valve toward the open position while observing the reading from the ammeter connec...
Page 25: ...reached then turn Adjust Screw B counter clockwise revolution Tighten Lockscrew B 6 Repeat steps 3 through 5 to set Auxiliary Switch No 4 NOTE If the Control Module was removed from the valve for this adjustment go to step 14 to complete the adjustment operation 7 Shut off and disconnect the 24 VDC power supply from terminals C E in the valve junction box 8 Disconnect the ammeter from terminals E ...
Page 26: ...s run the wiring between the control station and valve potentiometer s in a separate conduit away from AC wiring such a motor power and switch wiring Leave enough wire length so the control station can be pulled out on its rack for servicing Connecting a Time Duration Control Station Part number stamped on control station case See Schematic No 1 for reference 1 This valve operates with a powered a...
Page 27: ...ring connect the position display in the control station to the terminals in the valve junction box according to Schematic No 1 4 Fasten the cover to the valve junction box 5 Unlock and reconnect the electrical power to the valve Connecting an Analog Control Station Part number stamped on front of case See Schematic No 2 for reference 1 This valve operates with a powered actuator Disconnect and lo...
Page 28: ...ctrical power to the valve Connecting a Time Duration Control Station Without part number stamped on station case See Schematic No 3 for reference 1 This valve operates with a powered actuator Disconnect and lock out the electrical power to prevent accidental operation of the actuator 2 Remove the junction box cover from the valve and check the locations of the jumper wires on the valve terminal s...
Page 29: ...No 4 If the valve has jumpers between 3 and 12 and 2 and 9 they must be changed so they are oriented as described in the paragraph immediately above If a wire is connected to valve terminal 16 leave it connected Change the RUN wire No 5 coming from the control station from valve terminal 2 to valve terminal 16 Check all wire connections from the control station to the valve using Schematic No 4 3 ...
Page 30: ... old control station without a part number stamped on the front was wired to this valve before change some of those connections as follows o Change the OPEN wire No 7 coming from the control station from the valve terminal 9 to valve terminal 7 o Change the CLOSE wire No 6 coming from the control station from valve terminal 12 to valve terminal 10 o Change the RUN wire No 5 coming from the control...
Page 31: ...th types of control stations are available in a vertical fully enclosed configuration or a horizontal rack mounted configuration See Figure 7 Control Stations Push Button Switches ON Power on off switch for valve and control station When control station is off valve can not be operated electrically MANUAL AUTO Selects MANUAL front panel switches or AUTOMATIC user s control signal inputs for exclus...
Page 32: ...Stations Indicator Lights RUN Lights while valve is being driven in either direction under manual or automatic control OPEN LIMIT Lights when valve has reached fully open position indicating that power has been disconnected from motor by the limit switch CLOSE LIMIT Lights when valve has reached the fully closed position indicating that power has been disconnected from motor by the limit switch Th...
Page 33: ...ation Models CPE 103 and CPE 104 With an Analog Control Station the valve is fully closed at a minimum signal and is fully open at the maximum signal Valve position is directly proportional to the input signal for intermediate positions DeZURIK Analog Control Stations are available with 1 5 mA 4 20 mA 10 50 mA or 1 5 volt signal ranges A servo amplifier in the Analog Control Station compares the a...
Page 34: ...ven 6 The DEADBAND for the valve control should be set to avoid hunting or overshoot Before beginning move the control signal to a point near mid scale example 12mA To make this adjustment turn the DEADBAND potentiometer fully counter clockwise and change the analog input signal by at least 5 percent If any hunting or overshoot occurs turn the DEADBAND potentiometer one revolution clockwise and re...
Page 35: ... 120 Volts AC Control Station fused at 2 Amps Control Station Terminal No 1 L1 Control Station Terminal No 2 L2 Control Station Terminal No 3 Ground Signal Connection 120 volts AC from user control system Control Station Terminal No 13 OPEN Control Station Terminal No 14 CLOSE Control Station Remote Status Indicator Relay Connection Control Station Terminals No 15 16 and 17 When Control Station is...
Page 36: ...s AC Control Station fused at 2 Amps Control Station Terminal No 1 L1 Control Station Terminal No 2 L2 Control Station Terminal No 3 Ground Valve Signal Connection 4 20 mA example from user s control system Control Station Terminal A Negative Control Station Terminal B Positive Control Station Remote Status Indicator Relay Connection Control Station Terminals No 15 16 and 17 When Control Station i...
Page 37: ...20 Volts AC Control Station fused at 2 Amps Control Station Terminal No 1 L1 Control Station Terminal No 2 L2 Control Station Terminal No 3 Ground Valve Signal Connection 120 volts AC from user control system Control Station Terminal No 13 OPEN Control Station Terminal No 14 CLOSE Control Station Remote Status Indicator Relay Connection Control Station Terminals No 15 16 and 17 When Control Statio...
Page 38: ...lts AC Control Station fused at 2 Amps Control Station Terminal No 1 L1 Control Station Terminal No 2 L2 Control Station Terminal No 3 Ground Valve Signal Connection 4 20 mA example from user s control system Control Station Terminal A Negative Control Station Terminal B Positive Control Station Remote Status Indicator Relay Connection Control Station Terminals No 15 16 and 17 When Control Station...
Page 39: ...rol Station Terminal No 2 L2 Control Station Terminal No 3 Ground Valve Signal Connection 120 volts AC from user control system Control Station Terminal No 13 OPEN Control Station Terminal No 14 CLOSE Resolver Signal Connection Power and mA Signal connections go directly to terminals in valve junction box as shown in Schematic No 5 and described on Page 28 in Connections Control Station Remote Sta...
Page 40: ..._______________________________________________________________________ _________________________________________________________________________________ D11014 Page 40 August 2018 Connecting a Time Duration Control Station and Resolver Schematic No 5 Control Station Valve ...
Page 41: ...ontrary contained in the purchase order or represented by any agent or employee of DeZURIK Inc in writing or otherwise notwithstanding including but not limited to implied warranties Metric fasteners should not be used with ASME Class 150 300 bolt holes and flange bolt patterns If you use metric fasteners with ASME Class 150 300 bolt holes and flange bolt patterns it may lead to product failure in...
