IBP Series Modulating Electric Actuators

IBP Series Modulating Electric Actuators
Installation,
Maintenance and
Operating Manual
9 Brookside Industrial Estate, Sawtry,
Huntingdon, Cambridgeshire. PE28 5SB
Tel: +44 (0) 1487 833080
Fax: +44 (0) 1487 833081
Email: sales@valvecontrol.co.uk
IBP Series Modulating
Electric Actuators
With C, CL2 & CL3 Options
With “N” In The Model Number
Table of Contents
1
General ..................................................................................................................................... 2
IBP-Series Modulating Actuators ............................................................................................. 2
Power Board ........................................................................................................................ 2
LED Indicators ...................................................................................................................... 2
Operation ................................................................................................................................... 3
2.1.1
Control Board ....................................................................................................................... 3
2.1.2
Mode Selection ..................................................................................................................... 3
2.1.3
Features, Settings and Controls .............................................................................................. 3
2.2
Basic Set-Up - Modulating Operation........................................................................................ 4
2.2.1
Travel Limit Cam and Switch Operation .................................................................................... 4
2.3
Set Up for Operation ............................................................................................................. 5
2.3.1
Potentiometer Calibration ....................................................................................................... 6
2.3.2
Setting Zero and Span Positions .............................................................................................. 6
Battery Pack Information CL2 and CL3 ........................................................................................... 6
3.1
Battery Charging Circuit ......................................................................................................... 6
3.2
Battery Replacement ............................................................................................................. 7
IBP-Series Standard Options ......................................................................................................... 7
4.1
Option "H" - Tropical Heater and Thermostat ............................................................................ 7
4.2
Option "I" - ISO 5211 Output ................................................................................................. 7
4.3
Option "S2" - Two Auxiliary Limit Switches ............................................................................... 7
4.4
Option "T" - Heater and Thermostat......................................................................................... 8
4.5
Option “Y” - Keyed Output...................................................................................................... 8
4.6
OPTION "Z" - Handwheel Override ........................................................................................... 8
4.7 CSA Certification ...................................................................................................................... 8
4.8
Voltage ............................................................................................................................... 8
General Operating Information ...................................................................................................... 8
5.1
NEMA Ratings....................................................................................................................... 8
5.2
Duty Cycle and Motor Protection ............................................................................................. 8
5.3
Operating Temperature Limits ................................................................................................ 8
5.4
Actuator Mounting ................................................................................................................ 8
5.5
Lubrication........................................................................................................................... 9
5.6
Problem Prevention ............................................................................................................... 9
5.7
Warranty ............................................................................................................................. 9
5.8
Technical Assistance, Replacement Parts, Options and Repairs..................................................... 9
Specifications and Technical Information......................................................................................... 9
6.1
Analogue Control (Positioning) Control Board Option ................................................................ 11
6.2
Dimensions ........................................................................................................................ 12
6.3
Exploded View .................................................................................................................... 13
Enclosure ................................................................................................................................. 14
1.1
1.2
1.3
2
3
4
5
6
7
READ THESE INSTRUCTIONS FIRST!
This instruction manual contains important information regarding the installation, operation, and
troubleshooting of Valve Control Limited's IBP-Series Continuous Duty Modulating Electric Actuators with C, CL2
& CL3 Options. Please read these instructions carefully and save them for future reference.
Issue : 1 / March 2012
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Page 1 of 14
Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
1
1.1
General
1.3
IBP-Series Modulating Actuators
Visible on the P/N VT002360 Power Board, (see
Figure 1):
(with Optional Battery Back-up)
The modulating actuators are based on the IBP and
LIBP platform and provide an optional internal
battery pack to power the actuator in the event of a
loss of external power. IBP designates sizes from
150 to 600 in-lbs. LIBP designates sizes from 1000
to 3000 in*lbs. (see Figure 6)
The electronic package consists of three separate
boards; P/N VT002360 Power Board and the P/N
VT002980 Control Board, and either switching power
supply or a DC Isolator board.
1.2
Power Board
The P/N VT002360 Power Board provides terminals
for input and output wiring to the actuator as well as
plug-in connectors for IBP-Series options and
accessories.
IMPORTANT! Jumper must be set to "POSITIONER"
(45°) when positioning control board is installed.
Failure to do so could result in damage to the
positioner control board.
LED Indicators
DC POWER ON - This green LED indicator shows that
the user-supplied power is present.
Visible on the P/N VT002980 Control Board, (see
Figure 2):
INPUT POWER- A continuous green LED indicates
that external or battery power is present
STALL- A flashing red LED indicates a stall condition
exists and that the actuator has been prevented from
reaching the position commanded by the control
signal.
A STALL of more than several seconds will cause
power to be automatically removed from the motor
circuit, placing the actuator in a safe mode. A reverse
signal or a manual mode [CW] or [CCW] movement
is required to clear the stall condition.
A STALL condition can be initiated by a blockage in
the valve or damper, cam limit settings that are
inside of the electronically saved travel stop
positions, or some other increase in the torque load
on the actuator.
CLOCKWISE - A continuous yellow LED indicates
that the actuator is driving in the CW direction.
COUNTER-CLOCKWISE - A continuous yellow LED
indicates the actuator is driving in the CCW direction.
CHARGING - A continuous yellow LED indicates that
the battery is charging and is not fully charged.
CHARGED - A continuous green LED indicates that
the battery is fully charged. A flashing green LED
indicates the actuator is running on battery power.
RUN - A continuous green LED indicates that the
normal operating mode has been selected.
MAN - A continuous yellow LED indicates that
MANUAL mode has been selected. The actuator will
not respond to external control signals and the CW
and CCW push buttons are enabled for manually
driving the actuator in either direction. The manual
push buttons are also enabled in SPAN, ZERO and
CAL modes.
SPAN - A continuous yellow LED indicates that the
SPAN mode has been selected.
(See Section 2.3.3 - Setting Zero and Span Positions
for more on the SPAN setting)
ZERO - A continuous yellow LED indicates that the
ZERO mode has been selected.
(See Section 2.3.3 - Setting Zero and Span Positions
for more on the ZERO setting)
CAL - A continuous yellow LED indicates that the CAL
(calibration) mode has been selected.
(See Section 2.3.2 - Potentiometer Calibration for
more on the CAL setting)
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
2
Operation
2.1.1
Control Board
The P/N VT002980 Control Board connects to the
P/N VT002360 Power Board via two plug-in
connectors and a bracket and hardware that anchors
to the motor/gearbox.
The Control Board allows the actuator to modulate
(change position) in response to a change in an
analogue control signal. The P/N VT002980 accepts
either current, such as 4-20 mA, or voltage such as
0-10 VDC, or 2-10 VDC as the input control.
The control board also features antilog position
output, signal fail options, external power fail
options (with internal battery option installed),
adjustable input signal dead band, external power
"ON" indication, charge indication, stall protection,
manual push button control, simple travel limit setup, and auto calibration.
Connections for the optional Back-Up battery board
are located on P/N VT002980.
• Set Span mode permits the user to precisely
correlate the end of span travel stop with a
corresponding control signal value. Typically, the
Span position is the fully counter-clockwise
position and maximum control signal value, but
Span may be set at any position.
• Set Zero mode permits the user to precisely
correlate the opposite end of travel stop position
with a corresponding control signal value. The Zero
position is typically the fully clockwise position and
minimum control signal value, but Zero may be set
at any position.
• Cal mode allows the user to automatically calibrate
the position tracking potentiometer without the use
of an ohmmeter or other electronic instruments.
2.1.3
Features, Settings and Controls
• Enter is located directly below the mode selector
and permits the user to activate modes and
confirm settings by pressing the [ENTER] button.
• Input Signal The board can accept a current,
(mA) or voltage, (VDC) input control signal. The
Input Signal select switch must be correctly
positioned for the desired input control signal.
• Feedback Signal The board provides an
independent analogue Feedback Signal indicating
actuator output position. This signal can be
current, (mA) or voltage, (VDC).
The Feedback Signal select switch must be
correctly positioned for the desired feedback
signal; current, (mA) or voltage (VDC).
Feedback Signal is provided at terminals 12 (-) and
14 (+) on the P/N VT002360 Power Board. If the
feedback signal is not used, the switch may be set
in either position.
• Manual Control Selecting Manual (Man) Mode will
override the connected control signal and allow
driving the actuator to any position between Zero
and Span, using the [CW] and [CCW] push
buttons.
2.1.2
Mode Selection
The P/N VT002980 Control Board has five operating
modes which can be enabled by turning the yellow
mode selector knob.
LED indicators around the knob correspond to one of
the five modes;. Run, Manual (MAN), Set Span,
Set Zero and CAL (calibrate). When the Control
Board mode dial is set to any mode, the
corresponding LED turns on, indicating the mode is
selected.
• Run mode is the basic operating mode. The
actuator will respond to a command control signal
which is supplied to terminal 10 and terminal 11
on the P/N VT002360 Power Board.
• MAN (Manual) mode permits the user to override
the control signal and drive the actuator by using
the [CW] and [CCW] push buttons. In Manual
mode the actuator will not travel beyond the saved
settings for the Zero and Span stop positions.
Issue : 1 / March 2012
• Deadband Deadband is the window of control
signal change which the actuator will ignore. The
sensitivity of the actuator to respond to changes in
the control signal is adjustable.
Minimum deadband allows the actuator to respond
to small control signal changes.
Maximum deadband allows the actuator to ignore
small control signal changes (such as noise on the
control signal).
• Stall Indication The Control Board provides
protection and Stall LED Alarm in the event of a
condition such as a jammed valve or damper. In
the event of a stall, the control board will remove
power to the motor within 5 seconds.
The Stall LED continues to flash until a reverse
direction control signal or a manual mode [CW] or
[CCW] movement clears the stall condition.
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
Power/Signal Loss Settings
• Switch 1 P / B Single or Multi-Cycle - (Battery
Back-up Option) Upon loss of external power, this
selector switch provides options to drive the
actuator immediately to the "P" Power Loss
Position or to continue to cycle on "B" battery
power while control signal and adequate battery
power is available (approximately 10 full cycles).
When "B" is selected, the actuator will drive to and
remain at the "P" Power Loss Position when low
battery power level is detected.
• Switch 2 MIN / LAST "Signal Fail Position"
In the event that the control signal to the actuator
is lost and external power is still applied, the Fail
Position Selector Switch on the Control Board
provides options for the actuator to remain at its
LAST (current) position or to drive the actuator to
the minimum signal position.
Note: If you use a 0-10 VDC control signal, the
actuator will drive to the zero position regardless
of the switch setting.
• Switch 3 CW / CCW External Power Loss Setting
-(Battery Back-up Option) The CW/CCW Selector
• Switch in the field directs the actuator to drive to
the full CW or CCW position upon loss of power.
• "Sleep" and "Wake" (Battery Back-up Option)
When the battery drives the actuator to the Power
Loss Position, the P/N VT002980 board remains in
"Sleep" mode until external power returns to
terminals 1 & 2 on the P/N VTC002360 Power
Board.
To "Wake" the actuator, enabling the [CW] or
[CCW] push buttons, select position "B" on the P /
B selector switch and turn the mode selector dial
to MAN. Pushing the push button on the upper left
back side of the P/N VT002980 board will "Wake"
the electronics and the actuator can be manually
operated until low battery power level is detected.
To preserve battery power after manual
positioning is completed the actuator can be put
back into "Sleep" mode by returning the mode
selector knob to RUN.
2.2
2.2.1 Travel Limit Cam and Switch
Operation
With the P/N VT002980 Control Board installed, the
travel limit stops are set electronically as the Zero
and Span position. With the Battery Back-up Option
installed, the actuator will drive to the user-selected
Power Loss position upon loss of external power.
Two limit switches operated by the cams on the
output shaft are safety stops, only. They function to
prevent damage in the event of a failure of the
electronic limits.
Therefore: Each cam must be set to operate the
switch slightly outside of the electronic Zero and
Span position range. (Loosen set screw in cam; 1/16
hex wrench, provided)
Failure to set the cams properly may cause the
actuator to stall when it can not reach the
commanded, electronically set, end of travel position.
The bottom limit switch determines the clockwise
safety stop position. The next limit switch up from
the bottom determines the counter-clockwise safety
stop position.
If the auxiliary switch option is installed the
corresponding cams and switches will be the third
and fourth up from the bottom.
With the Battery Back-up Option installed, the
actuators are factory set to drive to the full clockwise
position upon loss of external power.
To change this "Power Loss" position to full counterclockwise, move the Switch 3 CW / CCW selector
switch to the CCW position.
CAUTION:
Dangerous Voltages Inside Actuator
Use extreme caution when working on the
actuator with the cover removed.
Basic Set-Up - Modulating Operation
For modulating operation, external power must be
applied to terminals 1 and 2, and a "control signal"
must be applied to terminals 10 and 11. (See Figure
3)
If a dry contact (volt free) or position indication is
required, auxiliary limit switches and cams may be
installed. Auxiliary limit switches plug into
connectors S2 and S3 on the back of the P/N
VT002360 Power Board.
Auxiliary switches may be set to operate in any
position and connection is made at terminals 3
through 8. (See Section 4), IBP-Series Standard
Options.
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Page 4 of 14
Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
2.3
1.
Remove actuator cover.
2.
Select Input Control Signal type - "mA" or "VDC"
(current or voltage), the actuator will accept 420 mA or 0-10 VDC. The unit will also accept a
split range signal, i.e. 4-12 mA, 12-20 mA or a
2-10 VDC signal. Slide the [INPUT SIGNAL]
switch up to select mA or down to select VDC.
3.
Select Output Feedback Signal type - "mA" or
"VDC" (current or voltage), the actuator will
provide a 4-20 mA or 0-10 VDC feedback signal.
Slide the [FEEDBACK SIGNAL] switch up to
select mA or down to select VDC.
4.
5.
Select Signal Loss Position - "MIN" or "LAST"
(Switch 2) - Slide the [MIN/LAST] to the right to
select LAST or to the left to select MIN.
Selecting MIN will drive the actuator to the
minimum input control signal position upon loss
of control signal.
If LAST is selected the actuator will remain in
place upon loss of input control signal.
If using 0 VDC as the minimum input control
signal, the actuator cannot differentiate between
a commanded minimum signal or a loss of
signal; therefore, MIN should be selected.
6.
Select Power Loss Position - "CW" or "CCW"
(Switch 3) - Slide the [CW/CCW] to the right to
select CCW or to the left to select CW.
Selecting CW will drive the actuator to the
clockwise position upon loss of input power.
Selecting CCW will drive the actuator to the
counter clockwise position upon loss of input
power.
Set Up for Operation
Select Power Loss Mode - "P" or "B" (Switch 1) Slide the [P/B] to the right to select B or to the
left to select P. Selecting P will drive the
actuator to the selected Power Loss position
upon loss of input power and the system will go
to "sleep" until input power is restored.
If B is selected the actuator will continue to
respond to changes in input control signal for up
to ten cycles; the battery monitoring circuit will
drive to the Power Loss position when it detects
that the battery should be charged.
Upon reaching the Power Loss position the
system will go to "sleep" until input power is
restored.
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
Set Span:
2.3.1
Potentiometer Calibration
Field installation of the Control Board option or
replacement of the position tracking potentiometer
requires calibration of the position tracking
potentiometer prior to setting positions and values
for Zero and Span. Control Board options installed at
the factory are fully calibrated at the factory and
should not require further calibration.
1.
Turn the Mode Selector Dial to [SPAN] and press
[ENTER] for 2 seconds. The Span LED will begin
to flash.
2.
Drive the actuator to desired maximum signal
position using the CW or CCW pushbutton. If the
"STALL" LED begins to flash; check to see if the
limit switch cam is preventing actuator from
reaching desired end-of-travel. If necessary back
the cam off so that it will trip the switch slightly
beyond the desired end-of-travel.
3.
Apply input control signal, (i.e. 20 mA).
4.
Press the [ENTER] button to save the Span
setting.
To confirm proper potentiometer calibration:
1.
Turn the Mode Selector Dial to [CAL] and press
[ENTER] for 2 seconds.
2.
Using the CW pushbutton, drive the actuator to
the full clockwise position. If the [CAL] LED is
flashing, potentiometer calibration is required;
proceed to step 3 below. If the [CAL] LED
remains on, calibration is not required; proceed
to Setting Zero and Span Positions section
below.
3.
Loosen the set screw in the larger Nylon gear
with a 1/16" hex wrench.
4.
Rotate the gear until the LED remains on
constantly; hold the gear in place and tighten
the set screw. Ensure that the LED remains on
after the set screw is tightened. Note: The LED
assists the user in locating the proper calibration
window; it will flash faster as you approach the
calibration window and slower as you move
away from it.
5.
Press the [ENTER] button to save the
potentiometer setting.
2.3.2
Setting Zero and Span Positions
Setting Zero and Span Positions - Once calibration
has been confirmed, set the desired end of travel
positions.
Make certain that the limit switch cams are set to
operate the switches beyond the desired range for
the Zero and Span positions. Zero and Span may be
set at any position between 0 degrees and 94
degrees of travel.
Verify Zero and Span Settings:
1.
Turn the Mode Selector Dial to [RUN].
2.
Apply various control signals to verify operation.
3.
Replace actuator cover.
At any point during Set-Up you may exit without
changing the stored data, by simply selecting a
different operational mode.
3
Battery Pack Information CL2
and CL3
The optional Battery Pack is capable of supplying
sufficient power to ensure operation of the actuator
during power outages.
The battery voltage of a fully charged battery should
read 13.6 volts as measured at the battery
connector, (with the battery disconnected).This
voltage will vary with temperature; see "Battery
Charging Circuit" below.
Replacement battery packs should be stored only
after a full charge and at less than SOT. Temperature
can affect battery shelf life. Generally lower
temperatures will increase shelf life while higher
temperatures will decrease shelf life.
Zero or Span may be either clockwise or counterclockwise and may be set to either a high value or
low value control signal.
When recharging battery packs, they should only be
recharged from the P/N VT002980 Control Board
charging circuit, which is calibrated to provide the
proper voltage and current for maximum battery
pack life.
The Control Board features full reverse acting set up,
requiring no wiring changes.
3.1
Set Zero:
1.
Turn the Mode Selector Dial to [ZERO] and press
[ENTER] for 2 seconds. The Zero LED will begin
to flash.
2.
Drive the actuator to desired minimum signal
position using the CW or CCW pushbutton. If the
"STALL" LED begins to flash; check to see if the
limit switch cam is preventing actuator from
reaching desired end-of-travel. If necessary
back the cam off so that it will trip the switch
slightly beyond the desired end-of-travel.
3.
Apply input control signal, (i.e. 4 mA).
4.
Press the [ENTER] button to save the Zero
setting.
Issue : 1 / March 2012
Battery Charging Circuit
The battery charging voltage has been designed for
optimum battery performance. When charging, the
yellow CHARGING LED will light. After reaching full
charge, the green CHARGED LED will light.
The voltage on the battery terminals, connector "J4"
will be between 10.5 and 12 volts, when external
power is off, and the battery is connected to the
2980 Control Board.
Fully charged, the battery voltage will reach
approximately 13.6 volts. This voltage is designed to
vary with temperature, and could be as high as 14.4
volts if in a very cold environment, or as low as 12.8
volts if in a very warm environment. This is normal
operation.
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
A battery case that is swollen or cracked must be
replaced. Please consult the factory for replacement.
If the battery does not reach full charge (the green
CHARGED LED remaining on and the yellow
CHARGING LED turning off) within 24hrs, consult the
factory.
3.2
Battery Replacement
The only suggested maintenance is to examine, and
if necessary, replace the batteries every two years.
Battery life can vary with temperature.
Cooler environments will generally prolong battery
life and under ideal conditions IBP batteries will last
in excess of five years.
To change the batteries, perform the following:
It installs with a plug-in connector and is
recommended in high-humidity applications. The
tropical heater option is also recommended
installations that experience wide temperature
swings in order to evaporate any condensation.
Thermostat is pre-set to active at or below 90°F and
deactivate at or above 110°F.The tropical heater
draws 15 watts @ 115 VAC, 12 VDC and 24V; 40
watts at 230 VAC.
This option can be installed in the field;
for 115 VAC applications, order kit P/N VT099035;
for 230 VAC applications, order kit P/N VT099036;
for 12 VDC applications, order kit P/N VT099037 and
for 24 V applications, order kit P/N VT099038.
(See Figure 4)
SMALL ENCLOSURE (150 - 600 in-lb)
1.
Remove power to the actuator.
2.
Disconnect battery connection at the daughter
board.
3.
Pry back the battery retaining tab on the battery
bracket.
4.
Remove the battery.
5.
Install new battery.
6.
Slide battery into bracket so that the retaining
tab secures the battery in place.
7.
Plug battery connector into the connector on the
back of the P/N VT002980 board, and re-apply
power.
LARGE ENCLOSURE (1000 - 3000 in-lb)
1.
Remove power to the actuator.
2.
Unplug the battery wire from the daughter
board.
3.
Remove battery hold-down bracket.
4.
Unplug the wires from the battery tabs.
5.
Remove and replace the battery. Re-install the
wires on the battery tabs, Black wire to Black
terminal and Red wire to Red terminal.
6.
Re-install the hold-down bracket.
7.
Plug the battery connector into the daughter
board, and re-apply power.
4
IBP-Series Standard Options
4.2
Option "I" - ISO 5211 Output
150 - 600 in-lb models are supplied with a 3/4"
female square output coupling; when the "I" option is
selected they are supplied with a 14 mm female
square.
1000 - 3000 in-lb models are supplied with a 1"
female square output coupling; when the "I" option is
selected, 1000 in-lb models are supplied with a 19
mm female square and 1500 - 3000 in-lb models are
supplied with a 22 mm female square.
This option is factory installed only.
All IBP-Series options are designed to be easily
installed in the field.
4.3
Option "S2" - Two Auxiliary Limit
Switches
Options for all standard IBP-Series actuators are
universal and completely interchangeable with each
enclosure size. For additional IBP-Series Options, see
(Table 3). Voltage is not field changeable.
The extra switches and stainless steel cams provide
dry contacts and are fully adjustable to trip at any
position. They are often used for position indication
or to interlock other devices (such as in sequencing
operations).
4.1
Option "H" - Tropical Heater and
Thermostat
The switches are single pole, double throw switches
rated for 1/2 HP, 15 amps @250 VAC. Auxiliary
switch kit P/N VT099900 is universal to all standard
IBP-Series actuators. (See Figure 5)
P/N VT099035, P/N VT099036, P/N VT099037, P/N
VT099038
The tropical heater and thermostat option is a selfadhesive, resistant heater strip which is applied to
primary gear-box.
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Page 7 of 14
Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
4.7
CSA Certification
CSA Certification is standard on all standard
ADC-Series actuators for applications in either
Hazardous (WX) or non-Hazardous (W) locations.
CSA certified actuators are identified by the CSA
logo on the product label.
4.8
Voltage
115 VAC, 230 VAC, 24 VAC, 12 VDC and 24 VDC.
IBP-Series actuators are rated for full torque at +/10% of the nominal voltage at 5OHz or 60 Hz. IBPSeries positioning actuators are rated continuous
duty. (Note: at 50Hz the cycle time will increase by
approximately 20%)
4.4
Option "T" - Heater and Thermostat
P/N VT099015, P/N VT099016, P/N VT099017, P/N
VT099018
The heater and thermostat option is a self-adhesive,
resistance heater strip which is applied to the
primary gearbox. It installs with a plug-in connector
and is required in installations where the ambient
temperatures drop below 32° F.
The heater option is also recommended in
installations that experience wide temperature
swings in order to evaporate any condensation. The
thermostat is pre-set to activate at or below 40T and
deactivate at or above 60°F. The heater draws 15
watt @115 VAC, 12 VDC and 24 V; 40 watts @ 230
VAC.
This option can be installed in the field;
for 115 VAC order kit P/N VT099015;
for 230 VAC applications, order kit P/N VT099016;
for 12 VDC applications, order kit P/N VT099017 and
24 V applications, order kit P/N VT099018.
(See Figure 4)
4.5
Option “Y” - Keyed Output
150 – 600 in-lb actuators are supplied with a 3/4"
female square output coupling; when the “Y” option
is selected they are supplied with a 15mm female
keyed output.
1000 – 3000 in-lb models are supplied with a
1" female square output coupling; when the “Y”
option is selected they are supplied with a 20mm
female keyed output.
This option is factory installed only.
4.6
OPTION "Z" - Handwheel Override
P/N VT009097, P/N VT009098
Standard IBP-Series actuators are supplied with a
plugged cover. Note that this not recommended for
IBP-Series actuators equipped the optional internal
battery back-up.
If the handwheel override option is selected at the
time of order a declucthable shaft and six-inch handwheel are provided for manual positioning.
This option can be replaced in the field; for 150 600 in-lb models, order kit P/N VT009097 and for
1000 - 3000 in-lb models, order kit P/N VT009098.
Issue : 1 / March 2012
5
General Operating Information
For enclosure specifications and dimensions, see
(Tables 1-4 and Figure 7)
5.1
NEMA Ratings
Valve Control Limited manufactures two styles of
enclosures: the "W" enclosure is weather tight and
designed to NEMA 4/4X standards the "WX"
enclosure is "explosion proof" and designed to NEMA
4/4X/7&9 (Class 1, Division 1, Groups C and D, and
Class 2, Division 1, Groups E,F and G) standards.
Use extreme care when removing the cover.
Scratches or nicks on the flanges may cause the
enclosure not to meet NEMA specifications.
5.2
Duty Cycle and Motor Protection
IBP-Series modulating actuators are equipped with a
brushless DC motor and can operate continuously;
they are rated for 100% duty cycle operation up to
104°F and for a maximum of 30 starts per minute.
Higher temperature applications decrease the
available duty cycle.
5.3
Operating Temperature Limits
IBP-Series actuators are designed to operate in
ambient environments between 32°F, (0°C) and
130°F, (55°C). If the ambient temperature may drop
below 32°F, (0°C), the heater and thermostat option
must be installed. The actuator is rated to operate at
-40°F, (-40°C) with the heater and thermostat option
installed. In outdoor applications where ambient
temperatures exceed 80°F, (27°C), actuators should
be shielded from direct sunlight.
In applications with high media temperatures,
insulating blankets, heat shields and / or extended
mounting shafts should be used to keep
temperatures within normal operating limits. Heaters
and thermostats are required for all outdoor
applications and may also be used to dry
condensation in high humidity environments.
5.4
Actuator Mounting
The actuator may be mounted in any position
including upside-down. It must be firmly secured to a
direct mount flange or sturdy mounting bracket. A
minimum of four bolts with lock washers should be
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
used to secure the actuator to the bracket.
Flexibility in the bracket is not allowed, and
backlash, or "play", in the coupling should be
minimized. The actuator output shaft must be in line
(centred) with the valve shaft to avoid side-loading
the shaft. See (Figure 6) for output drive dimensions
and mounting hardware specifications.
5.5
Lubrication
All rotating power train components are permanently
lubricated with multi-purpose Lithium grease suitable
for the operating temperature range of the actuator.
Additional lubrication is not required in normal
operation.
5.6
Problem Prevention
Most actuator problems result from improper
installation.
•
•
Incorrect Wiring and Set Up Make certain the
actuator is wired correctly and travel stops are
properly set before power is applied.
Potentiometer Calibration Confirm
potentiometer calibration setting during
installation. (See Section 2.3.1) for calibration
details.
• Coupling, Alignment, and Mounting Do not
add extra torque! Make certain that the mounting
arrangement is sturdy, centred, properly aligned,
and that all mounting hardware is secure and
properly tightened.
• Moisture Replace the cover tightly and make
certain conduit entry holes are sealed properly to
prevent moisture infiltration.
• Temperature Excessive temperatures affect duty
cycle, actuator performance and the condition of
the internal battery. IBP-Series actuators with
the"CL2"or "CL3"option installed are designed to
operate in environments below 130°F. In
applications with high media temperatures,
insulating blankets, heat shields, extended
mounting shafts or off-set mounting may be used
to maintain ambient temperatures at the actuator
within normal operating limits.
5.7
Warranty
All IBP-Series actuators are backed by a 1 year
warranty that covers materials and workmanship.
5.8
Technical Assistance, Replacement
Parts, Options and Repairs
All replacement parts, plug-in options, accessories,
and repair services for IBP-Series actuators are
available from Valve Control Limited.
6
Specifications and Technical Information
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
6.1
Analogue Control (Positioning) Control Board Option
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
6.2
Dimensions
Small: 12 - 50 lb-ft (16.3 - 68 Nm)
Large: 83 - 250 lb-ft (113 - 339 Nm)
Figure 6
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
6.3
Exploded View
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Installation, Maintenance and Operating Manual - IBP Series Electric Actuators
7
Enclosure
Enclosure "W" (weather tight) is designed to meet
specifications for NEMA 4/4X for weather tight and
dust tight, environments.
It is intended for non-hazardous locations in indoor
or outdoor use and provides a degree of protection
against corrosion, windblown dust and rain,
splashing water, hose-directed water, and damage
from external ice formation. It is not designed to be
submersible.
Enclosure "WX" (explosion proof & weather tight)
is designed to meet specifications for NEMA 7&9,
explosion proof environments as well as to meet
NEMA 4/4X specifications.
Explosion proof means that an internal explosion will
be contained, with no sparking that could ignite
external atmospheric gases.
The enclosure is rated for the following
environments:
• NEMA Class I, Division 1, Group C (Ethyl-ether
vapours, ethylene or cyclopropane)
• NEMA Class I, Division 1, Group D (Gasoline,
hexane, naphtha, benzene, butane, propane,
alcohol, acetone, benzol, lacquer, solvent, vapours
or natural gas)
Sample Model Code: IBPW150CL2IS2N24AC
Actuator Series
Enclosure Type
IBP
W
Torque
150
Board Option
CL2
Other Options I
(if applicable)
I
S2
Operating Voltage
N24AC
(For enclosure specifications and dimensions
see Table 2 and Figure 6).
Torque = Breakaway Torque Valve Control Limited
actuators are rated at breakaway torque; the amount
of torque the actuator will provide from a fully loaded
stop upon immediate power-up.
With running momentum and inertia, the amount of
torque supplied by the actuator at full speed (running
torque) or upon entering a stall condition (stall
torque) always exceeds the minimum rated
breakaway torque.
Since valves require most torque at breakaway, only
breakaway torque should be considered when sizing
actuators.
• NEMA Class II, Division 1, Group E (Metal dust,
including aluminium, magnesium, their commercial
alloys, and other metals of similarly hazardous
characteristics)
• NEMA Class II, Division 1, Group F (Carbon black,
coal or coke dust)
• NEMA Class II, Division 1, Group G (Flour, starch
or grain dust)
• NEMA Class III
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