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Troubleshooting

Limitorque L120-85 Installation, Operation and Maintenance FCD LMENIM1202-03-A4 – 06/15

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WARNING:

Be aware of electrical and high-pressure hazards when troubleshooting or performing maintenance

on your L120-85 actuator.

Symptom

Possible Cause

Corrective Action

Actuator will not operate electrically

1. No power to actuator

1a. Verify electrical supply is phased correctly and present at actuator.
1b. Verify electrical power leads are connected in accordance with the

applicable wiring diagram.

1c. Inspect for tripped circuit breaker, overload, open disconnect switch, or

blown fuse.

2. Loose or incorrect wiring

2. Check wiring for proper connections in accordance with the applicable

wiring diagram. Also check for loose connections.

3. Limit Switches not set or

incorrectly set

3. Check Limit Switch development for agreement with the applicable

wiring diagram. If not set properly, follow instructions for “Setting Limit

Switches”.

4. Foreign material on switch

contacts preventing good

electrical contact

4. Check continuity of switches with an ohmmeter.

Motor runs, but no output from

actuator

1. Actuator not coupled properly to

output

1. Inspect Torque Drive Nut and Valve Shaft to verify key is in place and

properly staked.

2. Torque Drive Nut disengaged

from Drive Sleeve

2. Verify Torque Drive Nut is properly installed in accordance with step 1 of

the Installation Overview.

3. Worm gear worn out

3. Remove Worm Shaft Assembly (following Disassembly Instructions).

Inspect worm gear for unusual wear. If excessive wear has occurred,

replace the Worm Shaft Assembly.

4. Damaged gearing

4. Disassemble actuator following the Disassembly Instructions and

inspect gearing for rough or damaged spots. Replace as required. Most

frequently, damaged spots are seen in motor gear set.

Actuator operation is noisy

1. Inadequate lubrication (poor

quality or not enough)

1. nspect quality and quantity of lubrication in accordance with the

Lubrication section. Add or replace lubricant as required.

2. Worn or damaged bearings

2. Disassemble actuator and replace worn bearings, seals and lubricant.

Содержание Limitorque L120-85

Страница 1: ...Experience In Motion USER INSTRUCTIONS Installation Operation Maintenance Limitorque L120 85 Actuator FCD LMENIM1202 03 A4 06 15 ...

Страница 2: ... Standard Drive Sleeve Rotation 21 4 5 Position Indication 21 4 5 1 Local Position Indication 21 4 5 2 Remote Position Indication 23 4 5 3 Setting the Potentiometer 24 5 Operation 26 5 1 Description of Motor Operation 26 5 2 Description of Manual Operation 26 5 3 Electrical Start up Procedure 27 6 Maintenance 28 6 1 Lubrication 28 6 1 1 Initial Inspection 28 6 1 2 Frequency 28 6 1 3 Routine Inspec...

Страница 3: ...on Configuration 24 Figure 15 Potentiometer Calibration configuration 24 Figure 16 Loosening Potentiometer Assembly 25 Figure 17 Removing Clutch Pinion Assembly 32 Figure 18 Key components affected by Handwheel shimming 34 Figure 19 Cut away view of L120 85 actuator with Clutch Latch positioned on face of Clutch Bearing 35 Figure 20 Gap between Housing face and Handwheel Bushing shown as dimension...

Страница 4: ...he 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...

Страница 5: ...therproof 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 compartmen...

Страница 6: ...omer Tagging Certification Information The motor nameplate is located on the motor The nameplate contains the following information ID Number Run Torque RPM Full Load Amps Insulation Class Horsepower Number of Phases Motor Code Connection Diagram Start Torque Enclosure Type Volts Locked Rotor Amps Duty Rating Service Factor Frequency Ambient Temperature Limitorque L120 85 Installation Operation an...

Страница 7: ...ppropriately sized valve in almost any position or location Microprocessor based controls and monitoring devices are also available for L120 actuators Contact your local Limitorque distributor or Limitorque sales office for further information 2 5 Product Features Up to 850 ft lb 1156 Nm torque capacity Up to 45 000 lb 20250 kg thrust capacity Up to 3 25 76 mm threaded stem capacity Up to 2 75 70 ...

Страница 8: ...your particular actuator package Table 1 L120 85 Approximate Weight Chart Components lb kg L120 85 with 40 ft lb 1700 RPM Motor Torque only 275 125 With Minimum Integral Control Package and Compartment 315 143 Thrust Base Assembly Drive 2 1 70 32 1 Add to weights shown above for basic actuator or basic actuator with integral control package Limitorque L120 85 Installation Operation and Maintenance...

Страница 9: ...mmended storage procedures could cause the warranty to be voided For long term storage procedures consult the Limitorque Customer Service Department 4 1 Actuator Mounting Your L120 85 is designed to perform actuation for torque only applications drive 1 or for torque and thrust applications drive 2 If you are using a torque only configuration before installing on the valve or other actu ated devic...

Страница 10: ...Nut has not been bored and keywayed by supplier it is provided solid blank to allow customer to custom bore and key up to the maximum permissible sizes as listed Table 2 Torque Drive Nut Maximum Allowable Bore and Key Sizes Key Type Maximum Bore in mm Maximum Key in mm Rectangle 2 750 69 85 625 x 4375 20 x 12 Square 2 625 66 67 625 x 625 20 x 20 4 1 2 Torque and Thrust Applications Drive 2 Refer t...

Страница 11: ...c actuators All four securing bolts are required to retain torque and or thrust reaction on these actuators 4 1 4 Stem Cover for Rising Stem Applications a CAUTION Selection and installation of a stem cover which is too short will result in damage to the valve and or actuator a CAUTION Be sure to complete each step of the installation overview before electrically operating your actuator If your ac...

Страница 12: ... Torque Drive Nut Key Note Key is shown for reference It may be in one of several other orientations in reference to the actuator Figure 5 L120 85 Thrust Base Assembly orientation Drive 2 Drive 2 Actuator Mounting Base Actuator Mounting Adapter Threaded Valve Stem 101 Thrust Base Drive Sleeve Thrust Base Assembly 110 Socket Head Cap Screws 111 Lockwashers 4 2 Verifying Motor Rotation Direction 4 2...

Страница 13: ... 3 Ensure Torque Switch is set properly for your application In most cases adjustments are not needed but if changes are required see Section 4 6 Torque Switch Settings and Wiring 4 Connect wiring to Terminal Strips provided on the actuator Refer to the wiring diagram supplied with your specific actuator Fork type terminal connections are recommended 5 Be sure any unused conduit entrances are plug...

Страница 14: ...ator or other actuated equipment from damage verify that your actuator is properly connected to its power source NOTE Your application may vary from the following standard wiring configurations for Three phase Single phase and DC motors Refer to your actuator wiring diagram for user specific wiring configuration 4 2 3 Three Phase Motor 1 Using the Handwheel move the valve to a midtravel position m...

Страница 15: ...tory and must be set after mounting on the valve or other associated equipment If your L120 85 actuator has been shipped already installed on your equipment your actuator should have the Limit Switch set for your application If your actuator is not already installed on your equipment or needs resetting use the following instructions to make the appropriate settings The following instructions for s...

Страница 16: ... as follows Contact 5 is the OPEN Torque Switch bypass After the valve has been tightly closed it may stick when it is first opened which would cause the Torque Switch Contacts to break To momentarily overcome this sticking the OPEN Torque Switch is bypassed This OPEN Torque Switch bypass is part of the closed valve position rotor so that as soon as the valve moves in the OPEN direction the bypass...

Страница 17: ...the Electrical Compartment Cover piece 200 1 3 Put the actuator into MANUAL operation by moving the Declutch Lever in the direction of the arrow on the lever until the Declutch Lever locks in place 4 Turn the Handwheel CCW to move the valve to the full OPEN position While turning the Handwheel note the direction of the Intermediate Shaft that corresponds to the Open Rotor Group See figure 9 NOTE M...

Страница 18: ...point and turn the Intermediate Open Shaft in a CCW direction until the Rotor Cam rotates 90 to make an OPEN contact OPEN limit trip point Rotor Cam in a vertical orientation to make an OPEN contact Once you have reached the full OPEN position point rotate the Intermediate Shaft slowly in the CW direction until the Rotor just trips again Figure 10 Limit Switch OPEN CLOSED Rotor Cam orientation OPE...

Страница 19: ...l CLOSED position point rotate the Intermediate Shaft slowly in the CW direction until the Rotor just trips again B If your Limit Switch Rotor Cams did trip before reaching the full CLOSE position point leave the valve at the full CLOSE position point and turn the Intermediate Close Shaft in a CW direction until the Close Limit Rotor Cam rotates 90 to make an OPEN contact CLOSE limit trip point Ro...

Страница 20: ...acement is required be sure to use an L120 85 Torque Switch rather than replacing with an L120 10 thru 40 Torque Switch The L120 85 Torque Switch Torque Arm is rotated 10 from the position of the Torque Arm on the L120 10 thru 40 Torque Switch the red dot on the Torque Switch Shaft indicates an L120 85 Torque Switch Figure 11 Torque Switch Components ID Limiter Plate not shown 300 4 Torque Switch ...

Страница 21: ... that your Torque Switch is wired appropriately for your application The Torque Switch will not protect your valve from over torque if you do not apply appropriate wiring for your application L120 85 actuators are typically supplied with a CCW Drive Sleeve rotation to open a valve The two Torque Switches are marked OPEN CCW and CLOSE CW based upon CCW Drive Sleeve rotation to open the valve The MD...

Страница 22: ...ter Indicator 4 5 1 Local Position Indication 1 Turn OFF all power to the actuator 2 Manually position the valve in the fully CLOSED position 3 Loosen the Round Head Machine Screw piece 523 on the MDPI Pointer piece 522 Figure 13 Aligning MDPI Pointer for Fully CLOSED Position 523 Round Head Machine Screw 522 MDPI Pointer MDPI Dial Plate 4 Move the MDPI Pointer to the CLOSED position NOTE If your ...

Страница 23: ... Nut at the base of the Potentiometer Bracket 7 Turn power to the actuator ON Your Test Meter should read 0 or almost 0 If not go back through the above steps 1 7 to get your Potentiometer calibrated to the proper end of travel 8 Now manually position the valve in the fully OPEN position 9 Move the Adjustable Resistor Slider toward the Power Connection end until the Test Meter reads 10 volts 10 Tu...

Страница 24: ...ing the Handwheel position the actuator to mid travel valve at the 50 position 3 Disconnect the Potentiometer Wiring Harness from the Interconnect Board or Terminal Strip 4 Using an ohmmeter verify that the potentiometer is in mid travel The resistance from each End Connection to the Center Connection should be half of the full resistance of the Potentiometer Example a 1000 ohm potentiometer shoul...

Страница 25: ...correct readings are obtained as described in step 3 8 Carefully reposition the Potentiometer Spur Gear to re engage with the gear train 9 Re tighten Hex Head Retaining Nut at the base of the Potentiometer Bracket 10 Recheck ohmmeter reading to assure Potentiometer adjustment was not changed when Potentiometer was tightened to Potentiometer Bracket If Potentiometer setting is not accurate repeat s...

Страница 26: ...Worm Gear piece 21 Lugs on the Worm Gear engage lugs on the outer diameter of the Drive Sleeve piece 25 Hammerblow or no lost motion is selected by the assembly arrangement of the Worm Gear and Drive Sleeve Lugs Lugs at the base of the Drive Sleeve can drive either a Torque Drive Nut similar to L120 10 through 40 or they can drive the lugs of the Thrust Stem Nut contained in the type Drive 2 Thrus...

Страница 27: ...ly important if the actuator has been in long term storage 2 Ensure that the Limit Switch and Torque Switch have been properly set 3 If the valve stem is not visible remove the Pipe Plug piece 45 to observe the output direction of the Drive Sleeve piece 25 4 Engage MANUAL operation and hand crank actuator well away from the OPEN or CLOSED end of travel 5 Turn power ON and push the OPEN button to e...

Страница 28: ...n inspection should be followed until operating experience indicates otherwise Gear Case Inspect lubrication every 18 months or 500 cycles whichever occurs first 6 1 3 Routine Inspection The three primary considerations in a lubrication inspection are 1 Quantity L120 85 operators are built to operate on the immersion principle The primary concern in the amount of lubricant is whether the worm is t...

Страница 29: ...effective The standard lubricants used by Limitorque have been proven extremely reliable over years of service We do not recommend a particular lubricant substitute for our standard lubricants but below is a list of minimum lubricant qualities required by Limitorque Should contain an EP additive Must be suitable for the temperature range intended Must be water and heat resistant and non separating...

Страница 30: ...ctuator mounted on the Thrust Base Before removing the actuator from the Thrust Base ensure that all actuated devices are secured to appropriate positions while actuator is removed from the Thrust Base 7 1 Removal From Valve 1 Rotate the Handwheel to the fully CLOSED position 2 Drive 1 applications Refer to illustrated parts breakdown a Loosen and remove customer installed Mounting Screws and Lock...

Страница 31: ...e Switch piece 300 3 Remove the Limit Switch piece 305 and Torque Switch piece 300 from the actuator with associated wiring intact 7 5 Remove Motor Assembly 1 Remove the M10 Hex Head Cap Screws and Lockwashers piece s 50 3 and 50 4 to remove the Motor piece 31 1 2 Slide the Motor piece 31 1 away from the actuator and pull the motor leads through the conduit hole 7 6 Remove Handwheel Loosen Set Scr...

Страница 32: ...ove Clutch Pinion Assembly 1 Use a socket wrench extension or another bar device to exert force against the face of the Clutch Pinion Assembly this will release some of the spring tension compressed behind the Clutch Pinion Assembly by the Declutch Compression Spring piece 30 With some of the tension released from the Clutch Pinion Assembly use retaining ring pliers to remove Retaining Ring piece ...

Страница 33: ...hrust base will use the same components note quantity and location of shims 2 After removing the Thrust Base Assembly from the actuator Housing and the Mounting Base remove the Socket Head Cap Screw piece 112 and Lockwasher piece 113 to remove the Thrust Base Housing piece 100 from Thrust Base Plate piece 102 See page 55 3 Remove the top Quad Ring piece 107 then remove the Thrust Bearing piece 103...

Страница 34: ...g Ring piece 4 3 Handwheel Spacer piece 4 2 Handwheel Shims piece s 6 1 and 6 2 Handwheel Bushing piece 4 1 O rings piece s 43 and 44 and second group of Handwheel Shims piece s 6 1 and 6 2 from the Handwheel Shaft Assembly Refer to the Illustrated Parts Breakdown for additional views Figure 18 Key components affected by Handwheel shimming Motor Cam not shown ClutchAssembly Clutch Pinion Assembly ...

Страница 35: ...itioned on the Clutch Bearing piece 19 2 as described in step 2 and the Handwheel Shaft Assembly is inserted into the actuator Housing as described in step 3 insert the Handwheel Shaft Washer piece 52 see Figure 22 into the actuator Housing 5 Once the Handwheel Shaft is installed and fully seated use a feeler gauge to measure the gap that is identified as Dimension A in Figure 20 Dimension A must ...

Страница 36: ...ased on step 6 on the Handwheel Shaft piece 2 The shims must rest on the major shaft diameter and be held in place by installing the Handwheel Bushing piece 4 1 with O rings piece 43 and 44 The shims that fill gap A must lie between the Handwheel Bushing piece 4 1 and the Handwheel Shaft Washer piece 52 Refer to figure 18 for assembly parts drawing 8 Install Handwheel Spacer piece 4 2 and Retainin...

Страница 37: ...ng 44 O Ring 43 O Ring 52 Handwheel Shaft Washer Table 5 Gap B shim thickness selection chart Shim Thickness for Gap B Shim Thickness Used at gap A Required for gap B 03 0 76 mm 15 3 81 mm 06 1 52 mm 12 3 05 mm 09 2 29 mm 09 2 29 mm 12 3 05 mm 06 1 52 mm 15 3 81 mm 03 0 76 mm 18 4 57 mm 0 0 mm 10 Install Gasket piece 42 4 and Handwheel End Cap piece 5 Secure these pieces with four Hex Head Cap Scr...

Страница 38: ...he Stem Nut as shown in the drawing 2 Install the two Quad Rings piece 107 in the seal grooves on the Stem Nut and lightly grease the seal and stem nut journal to aid in installation 3 Place the Stem Nut into the Thrust Base Housing piece 100 taking care not to damage the Quard Ring 4 Install O ring piece 106 on the Thrust Base Plate piece 102 and lightly grease the seal and journal to aid in inst...

Страница 39: ... Switches 4 Foreign material on switch contacts preventing good electrical contact 4 Check continuity of switches with an ohmmeter Motor runs but no output from actuator 1 Actuator not coupled properly to output 1 Inspect Torque Drive Nut and Valve Shaft to verify key is in place and properly staked 2 Torque Drive Nut disengaged from Drive Sleeve 2 Verify Torque Drive Nut is properly installed in ...

Страница 40: ...per lubrication of valve Consult Limitorque for review of application Motor overload tripping 1 Excessive current draw 1 Inspect valve for possible causes of high running load In particular check for excessive tightness of valve packing and for proper lubrication of valve Consult Limitorque for review of application 2 Incorrect overloads 2 Verify proper overloads selected for motor rating Excessiv...

Страница 41: ... L1F L2F L1F L2F REVERSING STARTER L2F L1F WHITE CLOSE ROTOR OPEN ROTOR 2 3 1 1 2 3 4 1 2 3 4 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 8C FOR TORQUE SEATING VALVES O OPEN CONTACT C CLOSE CONTACT OPENING COIL CLOSING COIL CPT CONTROL POWER TRANSFORMER MECHANICAL INTERLOC...

Страница 42: ...our local Limitorque distributor sales office or contact Flowserve Limitorque 5114 Woodall Road P O Box 11318 Lynchburg Virginia 24506 1318 Attn Service Manager Telephone 434 528 4400 Fax 434 845 9736 Before calling with inquiries on existing actuators be sure to have the following information from your actuator nameplate available 1 Actuator size and type 2 Serial number 3 Limitorque order number...

Страница 43: ...ion and Maintenance FCD LMENIM1202 03 A4 06 15 flowserve com 10 1 L120 85 Illustrated Parts Breakdown 300 27 13 Heater Bracket Kit 300 20 300 21 14 Grounding Lug Kit 200 1 200 2 200 3 47 305 305 47 305 48 1 300 Figure 24 Electrical Compartment ...

Страница 44: ...D LMENIM1202 03 A4 06 15 44 20 50 25 50 26 51 24 23 24 30 26 28 Clutch Pinion Assembly 18 41 Clutch Assembly 19 32 1 51 42 3 38 40 33 50 7 31 2 31 1 50 4 50 3 39 Motor Leads 32 2 19 2 19 3 19 1 18 2 18 1 18 3 not shown Figure 25 Motor and Motor Drive Components ...

Страница 45: ...wserve com 9 10 11 50 5 50 6 42 6 12 49 8 7 2 7 1 48 35 34 WormShaft Assembly 15 36 42 4 5 50 4 50 3 29 2A 29 2B 182 1 182 2 182 3 29 1C 29 2E 29 1A 29 1B 29 1D 29 2C 29 2D 37 2 1 Handwheel Shaft Assembly 52 6 1 44 4 1 4 2 4 3 2 3 2 3 3 3 1 Figure 26 Handwheel Shaft and Associated Components ...

Страница 46: ...Limitorque L120 85 Installation Operation and Maintenance FCD LMENIM1202 03 A4 06 15 46 50 24 42 2 50 2 27 50 1 95 98 22 42 5 16 21 25 42 1 17 50 24 1 45 50 16 Figure 27 Drive Sleeve Group ...

Страница 47: ...47 Limitorque L120 85 Installation Operation and Maintenance FCD LMENIM1202 03 A4 06 15 flowserve com 113 107 108 104 103 104 100 107 104 103 104 106 101 102 112 111 110 Figure 28 Thrust Base Group ...

Страница 48: ...y Disc Spring Mandrel 1 15 9 Worm Shaft Assy Bearing Adapter 1 15 10 Worm Shaft Assy Flange Nut 1 15 11 Worm Shaft Assy Key 1 15 12 Worm Shaft Assy Retaining Ring 1 16 Drive Sleeve Ball Bearing 1 17 Drive Sleeve Top Bearing 1 18 1 Clutch Pinion 1 18 2 Clutch Pinion Ball Bearing 1 Piece Description Quantity 18 3 Clutch Pinion Retaining Ring not shown 1 19 1 Clutch 1 19 2 Clutch Assy Ball Bearing 1 ...

Страница 49: ...asher 1 95 Torque Drive Nut 1 98 Torque Drive Nut Retaining Ring 1 100 Thrust Base Housing 1 101 Thrust Base Drive Sleeve 1 Worm Shaft Assembly Component Four used on Motor 31 1 Four used on Handwheel End Cap s Piece Description Quantity 102 Thrust Base Plate 1 103 Thrust Bearing 2 104 Thrust Washer 4 106 O ring 1 107 Quad Ring 2 108 Shim Set 1 109 Grease Fitting not shown 1 110 Socket Head Cap Sc...

Страница 50: ...11 EC Declaration of Conformity Limitorque L120 85 Installation Operation and Maintenance FCD LMENIM1202 03 A4 06 15 50 ...

Страница 51: ...51 Limitorque L120 85 Installation Operation and Maintenance FCD LMENIM1202 03 A4 06 15 flowserve com ...

Страница 52: ... 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 ...

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