ELS - Installation & Operation Manual

ELS - Installation & Operation Manual
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
ELS Electric Valve Actuator
ELS 18 & ELS 25
w w w. E l - O - M a t i c . c o m
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
1.0
Introduction
The ELS 18 and ELS 25 are small, economical, spurgear type valve actuators that are ideally suited to
automate small ball valves. Incorporating electrically
reversible, permanent split-capacitor AC single phase
motors, adjustable cam activated limit switches, and
tubular-screw style terminal strips for connection of
electrical supply and control wiring.
1.1
They are easy and straightforward to install, and
require no periodic maintenance. Panel mounted endof-stroke indicator lamps may be powered directly
from the actuator terminal strip without the need
switches in the actuator (lamps not supplied with
actuators).
Since a Valve actuator’s primary specification is
torque (the force it can deliver to turn the valve stem),
to successfully automate a valve, the valve’s torque
requirement must be known. This sounds simple until
an attempt is made to acquire this information. Selection of the valve must begin with a source that not
only can provide the desired mounting method and
process compatibility, but also reliable torque specifications for the specific process conditions under
which the valve will be operated. The actuator should
be selected to have a margin of reserve torque as
well, to ensure reliable operation within a range of
process and plant conditions.
The actuator housing is weatherproof and is finished
in a two-part polyurethane paint system to withstand
most common industrial environments. A threaded
conduit entry (M20x1.5 or 1/2” NPT) is provided in
the actuator base, permitting the cover to be removed
without disturbing the wiring connections.
Valve Selection
Ideally, valves intended for automation should be
selected early in the control system design process.
Valves intended for automation must be selected according to several criteria:
1.1.1
1.1.2
Torque:
Actuator Mounting Facility
Not all valves designs lend themselves to actuator
mounting requirements. Some type of bolting flange
around the stem (typical of butterfly valves) provides
a nice attachment point for an actuator. Ball valves
are not typically designed with such a flange, but if
the valve is selected to be of the pipe-flange mounting style (rather than threaded end, union, or sweattype) then the actuator bracket can be bolted trough
the pipe flanges.
Plug valves often look like good candidates for automation, but the flange around the stem can be misleading. It is typically provided to maintain tension on
the plug, and not for mounting of an actuator. Modifying this type of valve for actuator mounting can cause
problems in the areas of plug sealing (shut- off) and
torque. When in doubt, consult the valve manufacturer
on the compatibility of the valve with the requirements
of automation before buying the valve.
Fig. 1.0 ELS 18 and ELS 25 small, economical,
spur-gear type valve actuators
Page 2
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
2.0
Mounting to the valve
2.1
Shaft Coupling
The actuator is provided with a “double-D” male output shaft which will require an adapter to couple the
actuator to the valve stem.
2.4
Manual Operation
Suggested is to include wrench flats to the coupler to
allow manual operation.
The ELS, being a spur gear actuator, can be manually operated, in the event of a power failure, for
example, by turning the actuator output shaft with an
open-end wrench (hence; the reference to wrench
flats, above).
Valve coupling “blank adapters” are available, from
your EL-O-MATIC distributor, which have the correct
actuator-end treatment, with the valve end unfinished.
It is therefore recommended that the installation be
planned to allow access to the actuator shaft coupling
for this purpose.
2.2
Valve Bracket
The drilling patterns in the bottom of the actuator are
according ISO 5211. In most cases, a bracket must
be fabricated to mount the actuator to the valve.
2.3
The installation should also provide service access to
the actuator electrical compartment for ease of limit
switch setting and actuator wiring. The actuator can
be mounted in any position (right-side up, up-side
down, or sideways).
EL-O-MATIC Actuator Sizing And
Engineering software
The EL-O-MATIC Actuator Sizing And Engineering
software (available from www.el-o-matic.com) provides recommendations for:
*
Coupler material and diameter versus length,
should you wish to fabricate the coupling from
“scratch”.
*
Hot-Line Applications where heat is transfered
from a hot process pipe into the actuator. This will
deactivate the actuator when its internal temperature reaches approximately 135°C (275°F).
These recommendations minimize the heat
transfer from a process pipe, by simply extend the
bracket and coupling, to place the actuator further
from the valve and pipe.
*
Another method of reducing heat gain by the actuator, if space for an extended bracket is lacking,
is to interpose a sheet of light-gauge aluminium
or steel between the bracket and actuator, This
shield will be more effective if installed between
the valve and bracket, rather than between the
actuator and bracket. The side of the shield facing
the heat should ideally be reflective, and NOT
painted a dark color.
Fig. 2.0 Mounting to the valve
Page 3
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
3.0
Actuator Adjustments
3.1
Setting Limit Switches
EL’s limit switches are preset at the factory for a nominal 90° of rotation, however, it is recommended that
the limit switch settings be checked, and adjusted if
necessary, after the actuator is mounted to its valve.
WARNING:
* If the electric actuator is used in a manner
not specified by the manufacturer, the protection provided by the equipment may be
impaired.
* For electrical safety the marked protective
conductor terminal inside or outside the actuator housing shall be connected to earth.
* If required, mount earth wire (1) between
top (2) and bottom (3) ring of earth wire
connection.
2
CAUTION!
RISK OF ELECTRIC SHOCK
* Hazardous voltages are present in the actuator, and are exposed with actuator cover
removed.
* Installation, adjustment, putting into service, use, assembly, disassembly and maintenance of the electric actuator is strictly
reserved to qualified personnel.
Tools needed for this procedure:
-
2 mm hex (alien) wrench (limit-switch cams),
-
7 mm open-end wrench or “nut-driver” (ELS18
cover screws) or,
-
10 mm open-end wrench or “nut-driver” (ELS25
cover screws),
-
1/8” common screwdriver with insulated shank
(terminal-strip screws)
3.2
Procedure
1
1 Mount the actuator to the valve.
3
2 Remove actuator cover.
3 Guide the cable through the electrical entry.
Fig 3.1 earth wire connection
* To fulfill the electrical safety regulations
according IEC 61010-1, a switch or circuitbreaker shall be included in the building
installation. It is advised to indicate the
location of the circuit breaker by means
of a label on or nearby the installed ELS
actuator. The disconnection switch or
circuit-breaker shall disconnect all currentcarrying conductors.
- Use and mount a cable gland as required by
national or local legislation.
- When IP65/NEMA4X ingress protection is required, the electrical entries must be fitted with
glands rated IP65/NEMA4X or higher.
4 Make the electrical connections following the
wring diagram as shipped in the actuator electrical compartment (see also chapter 9 or 10).
5. Electrically operate the actuator/valve in the
clockwise (close) direction of rotation.
6. Check that the actuator stops rotating at the correct position relative to the valve seat.
6. Perform the same test for the counter clockwise
(open) direction of rotation.
If either the open or close stroke (or both) needs to
be adjusted, follow the steps outlined below:
Page 4
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
3.3
Clockwise (close) limit switch
adjustment
Important
1. Loosen set screws (11a) in cam (31a) for limit
switch #1 (10a)
*
Seal the gland threads where they enter the actuator with pipe dope or Teflon tape.
2. Use the 2mm Allen wrench, as a “handle”, to rotate the cam until curved portion is in contact with
the switch lever.
*
Tighten the gland nut to achieve a good seal to
the conduit. Re-check electrical operation before
replacing cover.
3 Rotate the cam clockwise until an audible “click”
is heard. The click Indicates that the switch has
,,tripped”, and is in the off state. Stop rotating the
cam as soon as the click is heard.
*
When mounting the cover, take care that the
cover seal is in place to comply to dust and water
tightness according to IP65 / NEMA4X.
*
Tighten the cover screws sufficiently to form a
good seal to the cover gasket.
*
To prevent cover distortion and consequent
water leaks, DO NOT OVERTIGHTEN COVER
SCREWS.
4 Tighten the set screws.
3.4
Counter clockwise (open) limit
switch adjustment.
For counter clockwise limit switch setting, perform the
same steps as for clockwise limit, except rotate cam
#2 (31b) counter clockwise until the click is heard.
Tighten cam set screws.
Re-check by operating the actuator again electrically
to be certain the settings are OK.
If the wiring connections were made in a temporary
manner for testing purposes, remake the connections
by routing the wiring through a proper conduit gland
in the actuator base.
7
8
12
11a
11b
31a
31b
10a
10b
15
16
13
Fig. 3.2 Limit switch setting
Page 5
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
4.0
Control Circuitry
Always refer to actuator wiring diagrams when designing actuator control systems or installing actuators
! WARNING !
DO NOT wire actuators in parallel!
Use a separate control switch or relay for each actuator. Paralleled actuators may run in opposite directions, and may stall and overheat.
“Neutrals” may be “daisy-chained” from one actuator
to another in installations where many actuators are
located in close Proximity.
4.1
Manual Remote Control
The simplest form of control circuit is the single-pole
double-throw panel switch. A momentary switch with
a centre-off position is recommended where the valve
must be “jogged” into position. It is only necessary to
run two wires from the switch to the actuator when
the neutral wire is daisy-chained from one actuator to
another.
Page 6
4.2
Signalling Options
The standard limit switches in ELS actuators will provide end-of-stroke lamp indication using panel lamps.
Two wires need to be brought from the actuator to the
lamp panel if the common neutral is available in the
panel. Otherwise, the neutral will have to be brought
from the actuator to the panel as well.
"XS" auxiliary switches
If isolated dry contacts are needed for signalling a
PLC or computer, order two auxiliary switches (model
,XS) which are cam-activated and can be set to trip
anywhere within the normal stroke of the actuator
(follow limit switch setting procedure above for adjustment method).
"POT" potentiometer
A gear-driven potentiometer (model POT, available in
1 kOhm and 10 kOhm resistance values, and in 90°
or 180° rotation) is available for installation in ELS
actuators to provide panel-meter position read-out for
re-setability of valve position (meter and power supply
not included with actuator).
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
5.0
Trouble Shooting
Although we would not expect you to experience any
problems with your EL-O-MATIC valve actuator we
have listed some checkpoints should your actuator
not function as desired.
5.1
Rotation
If limit switch fails to stop valve travel, check the following:
-
Direction of rotation of output shaft
-
Control wiring
-
Limit switch setting
5.2
5.4
-
No Valve Movement - Motor Runs
Drive sheared or not connected
5.5
No Valve Movement - Motor won’t
run
-
Valve plug/disk jammed or obstructed.
-
Valve requires torque higher than actuator rated
torque.
-
Valve packing gland too tight.
Motor Not Running
If unable to operate your EL-O-MATIC by motor:
- Check both power and control circuits for supply
and continuity.
-
Compare supply voltage with motor nameplate, if
OK, then check motor amperage load.
5.3
Overload
Motor overheating and/ or high motor amperage load
can indicate the following:
-
Excessive valve load.
-
Valve packing gland too tight.
-
Improperly lubricated valve.
-
Incorrect Motor capacitor.
-
Ambient temperature too high.
-
Valve cycling too often.
-
Incorrect voltage.
-
Incorrect wiring.
Page 7
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
6.0
Parts and Materials ELS-18
No. Qty. Description
1
2
3
4
6
7
8
9
10
11
12
13
15
16
Page 8
4
4
4
1
1
2
2
2
2
4
3
1
2
3
Screw
Lock Washer
Domed Cap Nut
Cover
Motor
Screw
Tooth Washer
Spacer
Micro Switch
Screw
Insulation Plate
Limit Switch Bracket
Screw
Lock Washer
Material
Steel
Steel
Nylon
Steel
Steel
Steel
Nylon
Steel
Steel
Steel
Steel
No. Qty. Description
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
1
1
2
1
1
1
1
1
2
1
1
1
1
2
1
Terminal Bracket
Terminal Block
Screw
Marking Tag
Capacitor
Cable Tie
Motor Support Plate
O-ring
Screw
Sticker Terminal No’s
Retaining Ring
Position Indicator Arrow
Gasket Cover
Limit Switch Cam
Blind stop
Material
Steel
Steel
Aluminium
Buna-N (Nitrile)
Steel
Steel
Aluminium
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
7.0
Parts and Materials ELS-25
No. Qty. Description
Material
No. Qty. Description
Material
1
2
3
4
6
7
8
10
11
12
13
15
16
17
18
Steel
Steel
Nylon
Steel
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Steel
4
4
4
1
1
2
4
2
4
3
1
3
3
1
1
Screw
Lock Washer
Domed Cap Nut
Cover
Motor
Screw
Lock Washer
Micro Switch
Screw
Insulation Plate
Limit Switch Bracket
Screw
Lock Washer
Terminal Bracket
Terminal Block
Steel
Steel
Steel
Steel
Steel
Steel
Steel
2
1
1
1
1
1
2
1
1
1
1
1
2
1
Screw
Marking Tag
Capacitor
Cable Tie
Motor Support Plate
O-ring
Screw
Sticker Terminal No’s
Retaining Ring
Position Indicator Arrow
Adapter O-ring
Gasket Cover
Limit Switch Cam
Blind stop
Aluminium
Buna-N (Nitrile)
Steel
Steel
Buna-N (Nitrile)
Aluminium
Page 9
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
1
G
BLACK
C
BLACK
M
MOTOR DC
H
FIELD WIRING
ACTUATOR WIRING
NO
INCOMING POWER VDC
16 Amp
0 OPEN
CLOSE
6
YELLOW
+
5
COM
NC
-
7
COM
NC
GREEN
OPEN
8
LIMIT SWITCH 2
OPEN
BLUE
CLOSE
NO
BLACK
RED
LIMIT SWITCH 1
CLOSE
WHITE
N
T
E
R
N
A
T
I
O
N
A
L
LIMIT SWITCHES SHOWN IN MID STROKE
I
IMPORTANT
Each actuator must be powered through its own
individual switch or relay contacts to avoid
cross feed between two or more actuators.
Page 10
Wiring diagram 990.40.020, ELS DC
8.0
Installation, Operation and Maintenance Manual
DOC.ELS.E Rev: A
January 2009
Wiring diagram 990.40.021, ELS 1-phase
1
2
C
RED
3
M
MOTOR 1
BLACK
4
S
9.0
FIELD WIRING
ACTUATOR WIRING
PURPLE
YELLOW
NEUTRAL
CLOSE
INCOMING POWER
6
OPEN
LIVE
0
7
COM
NC
GREEN
LIMIT SWITCH 2
OPEN
NO
WHITE
I
N
T
E
R
N
A
T
I
8
O
N
A
L
LIMIT SWITCHES SHOWN IN MID STROKE
BLUE
CLOSE
5
COM
NC
RED
LIMIT SWITCH 1
CLOSE
NO
BLACK
IMPORTANT
Each actuator must be powered through its own
individual switch or relay contacts to avoid
cross feed between two or more actuators.
Page 11
Contact Us:
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or visit our web site for up to date product data: www.El-O-matic.com
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All Rights Reserved.
We reserve the right to modify or improve the designs or specifications of the products mentioned in this manual at any time without notice. Emerson Process Management does not assume
responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management product remains solely
with the purchaser.
©2009 Emerson Electric Co.
w w w. E l - O - M a t i c . c o m
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