Limitorque L120 - Instruction-And-Maintenance (l120) PDF
Limitorque L120 - Instruction-And-Maintenance (l120) PDF
Limitorque L120 - Instruction-And-Maintenance (l120) PDF
L-120 SERIES
INSTRUCTION AND MAINTENANCE MANUAL
Please before you attempt to install or operate your Limitorque Actuator be sure to read this booklet at
least once. Always keep it available for quick reference.
LIMITORQUE
TYPE L-120
Limitorque's L-120 series of actuators is the most advanced valve control on the market...
requirements. This booklet has been prepared to help you obtain the most benefit from the
equipment. It contains instructions on the installation and maintenance of the units, plus
helpful suggestions to enable you to become thoroughly familiar with the location and
Limitorque actuators control the opening and closing of the valve and limit the torque and
thrust applied to the valve stem. As a result, all valve operating components are protected
1
P R I N C I P L E S O F O P E R AT I O N
finite torque output. Movement of the worm operates the
Description of Motor Operation: torque switch which interrupts the power of the motor. The
Your Limitorque actuator is always for motor operation torque switch is adjustable and can be set to operate at pre-
whenever the motor is energized. determined torque levels.
The worm and worm shaft are supported in two rotating spring Geared Limited Switch : Inspect lubricant every 36 months.
packs. As torque is generated by the actuator, the worm
moves axially against one of the spring packs. Each pack is
pre-calibrated and hence, a finite compression represents a
2
6. Use protective stem cover, check valve stem travel and
INSTALLATION TIPS clearance before mounting covers on rising stem valves.
Caution : Do not attempt to store, install or operate your 7. Set up periodic operating schedule for infrequently used
Limitorque Valve Contol without reading the instructions and valves.
cautionary notes below. 8. Keep the valve stem clean and lubricated.
9. Reset the travel limit switches prior to motor operation if
Caution : Do not remove the unit mounting bolts when the unit the unit has been dismantled or removed from the valve.
is mounted on a rising stem valve unless the valve is in the fully
open position, or there is not, nor cannot be, any pressure in
Caution : Shut off incoming power before opening switch
the line.
compartment.
Note : Limit switches are not factory set by Limitorque. They
must be set when the unit is installed on the valve.
DO NOT :
1. Caution : Do not attempt to work on your Limitorque
actuator without first shutting off incoming power.
Short Term Storage 2. Do not attempt to work on your Limitorque actuator while
it is mounted on a torque seated valve.
(Less than one year) 3. Do not motor operate the valve without first setting or
checking the limit switch and motor rotation direction.
UNITS ARE NOT FULLY WEATHERPROOF UNTIL PROP- 4. DO NOT FORCE THE DECLUTCH LEVER INTO
ERLY INSTALLED ON THE VALVE OR PREPARED FOR MOTOR OPERATION LEVER WILL AUTOMATICALLY
STORAGE. RETURN TO MOTOR OPERATION WHEN MOTOR IS
ENERGIZED.
Units should be stored in a clean, dry, protected warehouse 5. DO NOT FORCE DECLUTCH LEVER INTO HAND
free from excessive vibration and rapid temperature changes. OPERATION. IF THE CLUTCH DOES NOT EASILY
If the units stored outside, they must be stored off the ground, ENGAGE, ROTATE HANDWHEEL SLOWLY WHILE
high enough to prevent their being immersed in water or OPERATING THE DECLUTCH LEVER.
buried by snow. 6. Do not use abrasive cloth to clean the contacts on the limit
and torque switches.
Connect the internal heaters (if supplied) or place dessicant in
7. Do not torque seat 90° operation valves nor run them
the switch compartment. Replace all plastic caps or plugs
against the stops as this may cause damage to the valves.
with pipe plugs and ensure that all covers are tight. If the unit is
8. Do not alternately start/stop the motor to open or close a
mounted on a valve and the stem protrudes from unit, a
valve which is too tight for normal operation.
suitable stem cover must be provided.
9. Do not reset torque switch to a setting higher than the
Unit should be stored with the motor and switch compartment recommended factory maximum.
horizontal. 10. Do not attempt to repair gearing in the limit switch.
Replace entire gear frame assembly if necessary.
FAILURE TO COMPLY WITH THESE RECOMMENDED
STORAGE PROCEDURES WILL VOID THE WARRANTY.
FOR LONGER TERM STORAGE PLEASE CONSULT
LIMITORQUE FOR PROCEDURES AND
RECOMMENDATIONS.
DO :
1. Mount motors on a horizontal plane, if possible.
2. Keep the switch compartment clean and dry.
3. Operate the unit by handwheel only, when initially setting
the limit switches.
4. Check all unit wiring to ensure that it coincides with the
applicable wiring diagram.
5. 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.
3
If the torque switch has been removed from the unit or if a new
TORQUE SWITCH torque switch is being installed, the torque switch must be
CAUTION : Disconnect all incoming power before opening rebalanced using the following procedure :
limit switch compartment or working on the torque switch. 1. Ensure that the unit is in manual mode and load is
removed from the wormshaft spring pack.
The torque switch is designed to protect the actuator in open 2. Prior to reinstalling the torque switch, note the open and
and close directions. The switch was set at the factory close torque switch settings.
according to information regarding necessary torque or thrust 3. Loosen screws (A) and position both pointers (B) at the
output that was provided at the time of order # 1 setting, tighten screw (A). In this position the index
marks should be aligned. Loosen balancing screws and
CAUTION : A maximum stop setting plate is provided on most
install the torque switch when properly installed, the base
units. Do not remove this plate. Do not exceed the setting
of the torque switch should be flush against the
indicated by this limiter plate without contacting Limitorque.
compartment and the hole for the mounting screw should
be aligned. Install the mounting screw.
Torque Switch Setting Procedure 4. Tighten the balancing screws. The switch is now
balanced and ready for the pointers to be returned to their
Before adjusting or installing a torque switch, place the L120
original settings.
unit in manual mode and release the load on the worm shaft
CAUTION : The balancing screws should not be touched
spring pack.
except during the balancing procedure.
CAUTION : Installing or adjusting the torque switch with the
operator in a loaded condition will result in a loss of torque
protection.
BALANCING PROCEDURE
(fig-1)
4
CAUTION: When setting the limit switch rotor segments
GEARED LIMIT SWITCH (cams) using a variable speed electric drill, do not run
CAUTION : The geared limit switch is not preset at the factory drill at speeds higher than 200 RPM. Operating the
and must be adjusted after the actuator has been mounted on drill at high speeds can damage the gearing within the
its associated equipment. limit switch.
Disconnect all incoming power to the unit prior to opening the 6. Push in setting rod (A) and turn one quarter turn. The rod
limit switch compartment and adjusting the switch. will latch in this depressed position.
CASE-I:- Trip contacts/end position contact is
Consult the relevant wiring diagram for limit switch contact closed (Generally required if UEC-3 family (fig-2)
development. All L120 units are supplied with 8 contact limit controller is supplied)
switches-4 switches on each of 2 rotors. Two rotors are used A If contact is Normally Open (NO):-
for end of travel indication. Rotate the intermediate gear shaft in same direction as
noted in Page No. 2 until it becomes normally close (NC)
B if contact is already Normally Close (NC):-
Limit Switch Setting Procedure rotate intermediate gear shaft in opposite direction as
noted in Point No. 2 until it change.
1. Open compartment cover (#200). 7. Before moving the value depress and turn the setting rod
2. Put the actuator into manual operation and use the (A) one quarter turn to the spring released position. Insert
handwheel to operate the valve in the "open" direction. a screwdriver into the intermediate shafts to ensure that
While operating the valve, note the direction of the they will not move.
intermediate shaft (B) corresponding to the rotor or rotors 8. Operate the valve by handwheel to the fully "close"
to be set. position, reverse direction by the turn of the handwheel to
3. When the valve is fully open, close it one turn of the allow for coast of moving parts.
handwheel to allow for coast of moving parts. CASE- II:- Trip contact/End position contact is opened
4. Check the contacts of gear limit switch. (Fig.) generally required if non control unit (NCU) Basic
Intepral Circuit (BIC) is supplied.
NOTE: The rotor segments can be separated and rotated (a) If contact is Normally Close :-
through90 degrees to give various combinations Rotate the intermediate gear shaft is same direction
of normally as noted in until if becomes Normally Open (NO).
open or normally closed contact for each rotor. (b) If contact is Normally Open:-
Rotate the intermediate gear shaft in opposite
5. Refer contact development wiring diagram and see the direction as noted in until if becomes normally close
contact required at trip position/end position-(NO/NC). (NC).
follow the Instruction as per requirement as shown given 9. Set the other rotors by following steps "1" through "7".
in case I or Case II
5
DRIVE SLEEVE & HOUSING
COVER ASSEMBLY
PARTS LITS
PC NO QTY. DESCRIPTION
16 1 BALL BEARING
17 1 BALL BEARING
18 1 DRIVE SLEEVE BEVEL GEAR
19 1 H.W.CLUTCH SLEEVE
20 1 WORM GEAR LUG RING
21 1 WORM GEAR
22 1 RETAINING RING
23 1 KEY
24 1 DECLUTCH SPRING
25 1 DRIVE SLEEVE
REMOTE INDICATION
26 1 HANDWHEEL ADAPTOR
27 1 HOUSING COVER (IF SUPPLIED)
28 1 RETAINING COVER 1 DISCONNECT ALL INCOMING POWER AND
29 1 HANDWHEEL REMOVE SWITCH COMPARTMENT COVER (#200).
33 1 HANDWHEEL COVER PLATE
Note : The remote position transmitter potentiometer is
34 1 H.W.COVER PLATE GASKET left disengaged to protect potentiometer from being
42 1 SEAL KIT damaged by accidental rotation of the handwheel prior
to installation and setting on the valve.
50 A/R HARDWARE
2. Engage manual operation and move the valve to fully
closed position. Note which direction the shaft and gear
would be driving the wiper arm on the transmitter.
3. Move the potentiometer wiper to the end of transmitter
corresponding to the closed position. Loosen hex nut on
the back of potentiometer and slide it in the direction of
LOCAL POSITION INDICATION idler pinion until the pinions are engaged. Retighten hex
nut on the back of the potentiometer.
The local dial position indicator is factory selected to show 4. With power off connect all wires as per wiring diagram.
valve position. The position indicator can only be adjusted 5. Turn power on the indicator should now read 0 or 4mA.
when mounted on the valve. Calibrate zero potentiometer until a 4mA. output signal
To set the local position indicator: is read as terminate
1. Disconnect all incoming power and removed switch 6. Move the valve to fully open position indicator will now
compartment cover. read 100% open or 20 mA. Calibrate span potentiometer
2. Place the valve in the fully “Close” position.
3. Loosen the round head machine screw which holds the
pointer in place, move the pointer to the “0” position, re-tighten
the screw.
6
7
PARTS LITS PARTS LITS
PC NO QTY. DESCRIPTION PC NO QTY. DESCRIPTION
1 1 HOUSING 36 1 KEY
2 1 MOTOR ADAPTOR 37 1 FLEX LOC NUT
3 1 ELECTRICAL COMPARTMENT 38 1 MOTOR PINION
4 1 SEAL RETAINER 39 1 KEY
5 1 WORM SHAFT END CAP 40 1 STOP NUT
6 1** HSG COVER SHIM SET 41 1* WASHER
7 1 DECLUTCH SHAFT ASSY 42 1 SEALS KIT
10 1 KEY 47 1 O-RING
30 1 NIPPLE FLANGE
* L 120-40 Only
31 4** MOTOR
** Not Shown
32 1 DOWELS
8
In order to replace the nut, proceed as follows :
THRUST BASE DISASSEMBLY
1. If thrust base option is present (#100), remove seal 1. Disconnect all incoming power to the unit.
retainer (#102) followed by stem nut (#101) and thrust 2. Remove actuator from valve
bearings (#s 103, 104 and 105). 3 Remove seal retainer (#102) followed by stem nut
2. Remove four bolts (#110) and lift thrust base from main bearings and seals
housing. 4. Check the fitment of the new stem nut on the valve stem -
Ensure that the nut travels freely without binding.
5. Reassemble the thrust base and remount the actuator on
the valve.
6. Remount actuator on thrust base.
7. CAUTION : The limit switches must be reset at this time.
Removing the actuator from the valve will have changed
the settings - refer to Geared Limit Switch Section of this
manual
8. Reconnect power and test for correct functioning.
PARTS LITS
PC NO QTY. DESCRIPTION
100 1 BASE HOUSING
101 1 STEM NUT
102 1 SEAL RETAINER
103 2 NEEDLE BEARING
104 2 THRUST WASHER
105 2 THRUST WASHER
106 1 O-RING SEAL TORQUE NUT DISASSEMBLY
107 2 QUAD RING SEAL
The L120 Series actuator can be supplied without the thrust
108 1 GASKET base option for applications requiring torque only. The torque
109 1 GREASE FITTING nut is driven by the drive sleeve lugs and held in place by the
torque bushing connector.
110 4 HEX HD CAP SCREW
111 4 LOCK WASHER Remove the internal circclips from torque nut (#190). now, it
can be removed from the bottom of the drive sleeve (#25).
9
DECLUTCH SHAFT ASSEMBLY
PC NO QTY. DESCRIPTION
7 1 DECLUTCH SHAFT ASSEMBLY.
7A 1 DECLUTCH SHAFT ASSEMBLY.
7-1 1 DECLUTCH ACTUATOR
7-2 & 7-3 2 DECLUTCH LATCH (LEFT & RIGHT)
8 1 DECLUTCH RETURN SPRING
9 1 DECLUTCH LEVER
10 1 KEY
11 1* DECLUTCH CAP
12 1 DELCUTCH INPUT PINION
42 SEAL
10
6. Check output rotation - if phase rotation is correct, the
ELECTRICAL START - UP valve should begin to open. If valve begins to close-stop
1. Check that the actuator has been correctly lubricated. immediately. Incorrect phase rotation will lead to serious
This is particularly important if the actuator has been in damage if the valve seats.
long-term storage. 7. Correct the phase rotation by switching any two of the
2. Ensure that the geared limit switch has been correctly set three power leads for three-phase power.
per instructions in this manual. (see Geared Limit Switch 8. The actuator should now operate correctly and will be
Section). stopped at the end of travel positions by torque or limit
3. It the valve stem (Rising stem applications) is not visible, switch functions. (Premature stopping may be caused by
remove the stem cover or handwheel cover plate so that incorrect limit switch of torque switch settings or line
stem will not damage the hand wheel adaptor housing obstructions in the valve). Replace stem cover or cover
(PC No. 27) Page No.-6. plate.
4. Engage manual operation and hand crank valve well
away from end of travel positions.
5. Turn on power supply and operate the actuator.
11
12
13
OPTIONAL SIDE MOUNTED HAND WHEEL
NOT APPLICABLE
14
LIMITORQUE INDIA LTD.
BHARAT
LIMITORQUE WORKS & MARKETING OFFICE
Plot No. 148, Sector-24, Faridabad - 121 005
Q
QUALITY
Phone: 0129-4047884, Fax: 0129-4042451 ASSURED
COMPANY
Website : www.limitorqueindia.com
CHENNAI 165, Broadway, 3rd Floor, Chennai - 600 018, Phone: 044-25227716, Fax: 044-25224616, E-mail: libacom@vsnl.com
DELHI: E-45/2, Phase-II, Okhla Industrial Area, New Delhi - 110 020, Phone : 011-26389567, 26384375, Fax: 011-26386790
MUMBAI 215, Neelam, 108, Dr. R. G. Thadani Marg, Off Worli Seaface Road, Worli, Mumbai - 400 018, Phone: 022-24935682, 30405682
Fax :022-24965943, E-mail: bso@limitorqueindia.com, libabom@vsnl.net
KOLKATA Chatterjee International Centre, Suit No. 6, 17th Floor, 33-A, Chowrihnghee Road, Kolkata - 700 071
Phone: 033-22260509, 22172253, Fax: 033-22268249
E-mail : kso@limitorqueindia.com, limitorque@sify.com, limitorque2008@gmail.com
PUNE 1/103, Gera Garden, Koregaon park road, Pune-411001, Tele Fax-020-26111472, E-mail : pune@limitorqueindia.ocm
TM
Bharat Limitorque