Limitorque LY Series Instruction Manual

Limitorque
050100
Limitorque® LY Series
Installation and Maintenance
for LY 1001, LY 2001 and LY 3001
LMAIM1501
(Replaces 150-12000)
November 2003
Limitorque Actuation Systems

ii LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
LY Series Installation and Maintenance for LY 1001 LY 2001 and LY 3001
©2003 Cop right Limitorque. All rights reserved.
Printed in the United States of America.
Disclaimer
No part of this book shall be reproduced, stored in a retrieval s stem, or transmitted b an means electronic, mechanical,
photocop ing, recording, or otherwise without the written permission of Limitorque. While ever precaution has been taken in the
preparation of this book, the publisher assumes no responsibilit for errors or omissions. Neither is an liabilit assumed for
damages resulting from the use of the information contained herein.
This document is the proprietar information of Limitorque furnished for customer use ONLY. No other uses are authorized without
written permission from Limitorque.
Limitorque reserves the right to make changes, without notice, to this document and the products it describes. Limitorque shall
not be liable for technical or editorial errors or omissions made herein, nor for incidental or consequential damages resulting from
the furnishing, performance, or use of this document.
The choice of s stem components is the responsibilit of the bu er, and how the are used cannot be the liabilit of Limitorque.
However, Limitorque’s sales team and application engineers are alwa s available to assist ou in making our decision.
This manual contains information that is correct to the best of Limitorque’s knowledge. It is intended to be a guide and should not
be considered as a sole source of technical instruction, replacing good technical judgment, since all possible situations cannot be
anticipated. If there is an doubt as to exact installation, configuration, and/or use, call Limitorque at [phone]. The latest
revisions to this document are available online at http://www.limitorque.com
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 iii
Table of Contents
1 Introduction 1-1
1.1 Purpose 1-1
1.2 User Safet 1-1
2 Product Capabilities and Features 2-1
3 Initial Inspection and Storage Instructions 3-1
3.1 Product Identification 3-1
3.2 Inspection and Recording 3-1
3.3 Storage Procedures 3-2
3.3.1 Short-Term Storage (less than 1 ear) 3-2
3.3.2 Long-Term Storage (1 to 5 ears) 3-2
4 Unit Weights 4-1
5 Installation Instructions 5-1
5.1 Safet Precautions 5-1
5.2 Initial Actuator Preparation 5-1
5.3 Installation Overview 5-2
5.4 Torque Switch Settings 5-6
5.5 Rewiring the Torque Switch for Non-Standard Drive Sleeve Rotation 5-6
5.6 Limit Switch and Mechanical Stop Settings 5-7
5.7 Setting the Limit Switches 5-7
5.7.1 Setting the CLOSED Limit Switch 5-7
5.7.2 Setting the OPEN Limit Switch 5-9
5.8 Mechanical Stops 5-10
5.8.1 Setting the CLOSED Mechanical Stop on the LY 1001 5-10
5.8.2 Setting the CLOSED Mechanical Stop on the LY 2001/3001 5-10
5.8.3 Setting the OPEN Mechanical Stop on the LY 1001 5-11
5.8.4 Setting the OPEN Mechanical Stop on the LY 2001/3001 5-11
5.9 Setting the MDPI (Mechanical Dial Position Indicator) 5-12
5.9.1 Setting the Potentiometer 5-13
6 Operation 6-1
6.1 T pical LY 1001 Operation 6-1
6.2 Verif Correct Motor Rotation (Phasing) and OPEN/CLOSE Pushbutton Operation6-1
6.2.1 Three-Phase Motor 6-1
6.2.2 Single-Phase Motor 6-5
6.2.3 DC Motor 6-8
6.3 Electrical Startup 6-8
6.4 Manual Operation 6-8
6.5 Motor Operation 6-9
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iv LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
7 Maintenance 7-1
7.1 Lubrication 7-1
7.1.1 Lubrication Inspection 7-1
7.1.2 Factor Lubricant 7-1
7.2 Minimum Lubricant Qualities Required 7-1
7.3 Disassembl and Reassembl 7-2
7.3.1 LY 1001 Disassembl 7-2
7.3.2 LY 1001 Reassembl 7-3
7.3.3 LY 2001/3001 Disassembl 7-5
7.3.4 LY 2001/3001 Reassembl 7-7
7.4 Troubleshooting 7-9
8 Parts Lists 8-1
9 How to Order Parts 9-1
10 Regulatory Information 10-1
Figures
Figure 2.1 – LY Actuator 2-1
Figure 3.1 – LY Nameplate 3-1
Figure 5.1 – Torque Nut and Retaining Drive Ring Removal from an LY 1001 5-1
Figure 5.2 – LY Ke wa Locations 5-2
Figure 5.3 – LY 1001, 2001, and 3001 Torque Drive Nut Orientation 5-3
Figure 5.4 – Removing Control Cover and Conduit Pipe Plugs 5-4
Figure 5.5 – Grounding Lug Location 5-5
Figure 5.6 – Reversing Torque Switch Wiring 5-7
Figure 5.7 – Limit Switch Setting Nut 5-8
Figure 5.8 – Setting CLOSE Limit Cam 5-9
Figure 5.9 – Setting OPEN Limit Cam 5-10
Figure 5.10 – Mechanical Stop Set Screw Adjusted to Torque Drive Nut
Contact Point on LY 1001 5-11
Figure 5.11 – Mechanical Stop Screw Adjustment on LY 2001 and 3001 5-12
Figure 5.12 – Aligning MDPI (Mechanical Dial Position Indicator) 5-13
Figure 5.13 – Potentiometer Calibration Components 5-14
Figure 6.1 – Standard Actuator/Three-Phase 6-2
Figure 6.2 – Three-Phase with Control Package 6-3
Figure 6.3 – Standard Actuator/Single-Phase 6-5
Figure 6.4 – Single-Phase with Control Package 6-6
Figure 6.5 – LY 1001 Cover and Associated Parts 6-7
Figure 6.6 – LY 1001 Top Plate and Associated Parts 6-9
Figure 6.7 – LY 1001 Housing and Associated Parts 6-10
Figure 6.8 – LY 2001/3001 Cover and Associated Parts 6-11
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 v
Figure 6.9 – LY 2001/3001 Top Plate and Associated Parts 6-12
Figure 6.10 – LY 2001/3001 Housing and Associated Parts 6-13
Figure 6.11 – LY 3001 Handwheel Assembl 6-14
Figure 6.12 – LY 1001 Declutch Return Spring Installation Position 7-4
Figure 6.13 – LY 2001/3001 Declutch Return Spring Installation Position 7-8
Tables
Table 4.1 – Unit Weights 4-1
Table 5.1 – Torque Drive Nut Custom Bore and Ke wa Sizes 5-2
Table 5.2 – LY Actuator/Mounting Base Tap Sizes 5-4
Table 5.3 – Control Cover and Conduit Pipe Plug Hardware 5-5
Table 5.4 – LY Control Cover and Integral Control Cover Bolt Sizes 5-5
Table 5.5 – Mechanical Stop Set Screws 5-10
Table 5.6 – Mechanical Stop and Locknut Screw Sizes 5-11
Table 8.1 – LY 1001 Parts List 8-1
Table 8.2 – LY 2001/3001 Parts List 8-2
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vi LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 1-1
1Introduction
1.1 Purpose
This Installation and Maintenance Manual explains how to install and maintain LY actuators. Information on
installation, disassembl , lubrication, and parts is provided.
1.2 User Safety
Safet notices in this manual detail precautions the user must take to reduce the risk of personal injur and damage
to the equipment. The user must read and be familiar with these instructions before attempting installation,
operation, or maintenance. Failure to observe these precautions could result in serious bodil injur , damage to the
equipment, void of warrant , or operational difficult .
Safet notices are presented in this manual in three forms:
aDANGER: Refers to personal safety. Alerts the user to danger or harm. The hazard or unsafe practice will
result in severe injury or death.
aWARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices
could result in personal injury or death.
CAUTION: Directs the user’s attention to general precautions that if not followed could result in personal injury
and/or equipment damage.
NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and operation.
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1-2 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 2-1
2Product Capabilities and Features
The LY actuator controls the opening and closing travel of the valve and limits torque through the torque switches provided. As a
result, all valve-operating parts are protected from overload, improper seating, and foreign obstructions.
LY actuators ma be mounted on an size valve in almost an position or location.
Microprocessor-based control and monitoring devices are available for installation on our actuator. Contact our local
Limitorque distributor or Limitorque sales office for further information.
Figure 2.1 – LY Actuator (LY 1001 shown)
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Limitorque
050 100
Housing
Position Indication Window
Control Cover
Conduit Adapter
Declutch Lever
Handwheel t picall
clockwise turn to CLOSE
and counterclockwise
turn to OPEN

2-2 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 3-1
3Initial Inspection and Storage Instructions
aWARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to store the
actuator. Be aware of electrical hazards within the actuator and high-pressure hazards of the attached valve or other actuated
device when installing or performing maintenance on your LY actuator.
3.1 Product Identification
The actuator unit nameplate is located on the side of the unit opposite the conduit entr . The nameplate contains
the following information:
• Limitorque name
• Point of Manufacture
• Unit Size
• Serial Number
• Order Number
• Electrical Power Suppl
• Operating Time (seconds)
• Motor Full Load Amperage
Figure 3.1 – LY Nameplate (Reference Drawing 61-682-0108)
3.2 Inspection and Recording
Upon receipt of the actuator, inspect the condition of the equipment and record nameplate information as follows:
1. Carefull remove actuator from shipping carton or skid. Thoroughl examine the equipment for an ph sical
damage that ma have occurred during shipment. If damaged, immediatel report the damage to the transport
compan .
2. Record the unit nameplate information for future reference, i.e., ordering parts, and obtaining further
information.
LIMIT ORQUE CORP.
LYNCHBURG, VA .
SIZE
SERIAL
ORDER
VOLT PHASE
OP . TIME FLA.
PA TENT PENDING
Unit T pe and Size
Serial Number
(unique for each actuator)
Order Number
Electrical Power Suppl
Motor Full
Load Amperage
Operating Time
(seconds)
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3-2 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
3.3 Storage Procedures
NOTE: The following are Flowserve’s recommended storage procedures to retain maximum product integrit during
short-term and long-term storage. Failure to compl with recommended procedures will void the warrant .
3.3.1 Short-Term Storage (less than 1 year)
Actuators should be stored in a clean, dr , protected warehouse, free from excessive vibration and rapid
temperature changes.
Preparation
1. Connect internal heaters, if supplied.
2. Replace all plastic caps or plugs with metal pipe plugs.
3. Ensure all covers are tight.
Outdoor Storage
If actuators must be stored outdoors, the must be stored off the ground, high enough to prevent being immersed
in water or buried in snow.
LY Storage Orientation
Store with the Control Compartment Cover (Limit Switch compartment) facing upward.
Do not store units on their side.
3.3.2 Long-Term Storage (1 to 5 years)
Actuators should be stored in a clean, dr , protected warehouse, free from excessive vibration and rapid tempera-
ture changes.
NOTE: During long-term storage, the maximum source of equipment deterioration anticipated is from possible
condensation within the actuator enclosure. This condensation ma occur with rapid temperature changes in the
storage environment. If reliable means are not available to prevent rapid temperature changes, a heat source should
be added in the electrical enclosure during storage. Consult the Limitorque Customer Service Department for
further information.
Preparation
1. Connect internal heaters, if supplied.
2. Replace all plastic caps or plugs with metal pipe plugs.
3. Ensure all covers are tight.
LY Storage Orientation
1. Store with the Control Compartment Cover (Limit Switch compartment) facing upward. Do not store units on
their side.
2. Store off the floor on suitable skids and cover with an unsealed dust cover leaving the bottom open and air
holes in the side.
Storage Inspection and Correction
1. Perform a semi-annual visual inspection. A minimum inspection should include checking the following:
• Packaging • Plugs
• Covers • Dr ness
• Cleanliness • Heat source (if used) for proper functioning
2. Record and correct deficiencies noted during inspection.
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 4-1
4Unit Weights
The approximate LY actuator weights are provided below.
Table 4.1 – Unit Weights
Unit Size Control lb. kg
LY 1001 NCU 40 20
BIC 75 34
UEC 90 41
LY 2001 NCU 100 45
BIC 110 50
UEC 144 65
LY 3001 NCU 105 48
BIC 130 59
UEC 149 68
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4-2 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 5-1
5Installation Instructions
5.1 Safety Precautions
aWARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to
install operate or troubleshoot the Limitorque LY actuator.
5.2 Initial Actuator Preparation
Piece numbers refer to Figure 5.1.
1. Remove the Retaining Drive Ring (piece #165 or #109) and Torque Nut (piece #32) from actuator.
Figure 5.1 – Torque Nut and Retaining Drive Ring Removal from an LY 1001
2. If Torque Nut has been bored and ke wa ed b Limitorque, verif dimensions and ke wa location for proper
compatibilit with the valve stem.
3. If Torque Nut has not been bored and ke wa ed b Limitorque, it is provided solid (blank) to allow customer
to custom ke and bore up to the maximum permissible sizes as listed in Table 5.1.
Limitorque
#32 Torque Nut
#165 (LY 1001)
#109 (LY 2001/3001)
Torque Nut Retaining Drive Ring
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5-2 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
Table 5.1 – Torque Drive Nut Custom Bore and Ke wa Sizes
Unit T pe Maximum Bore Maximum Ke wa
and Size inch (mm) inch (mm)
LY 1001 1¹₈ dia (28 dia) ¹₄ x ¹₈ (6 x 3)
LY 2001/3001 2³₈ dia (60 dia) ⁵₈ x ⁵₁₆ (15 x 7.5)
NOTE: Before ke wa ing, match the Torque Nut with the Valve Stem to ensure proper ke wa location. Use the
Ke wa Index Mark (LY 1001 onl ) for locating appropriate ke wa location.
Figure 5.2 – LY Ke wa Locations
5.3 Installation Overview
CAUTION: Be sure to complete each step of the installation overview before electrically operating your
actuator. If the actuator is already mounted to a valve from the manufacturer verify that the actuator is
mounted according to the following overview. Failure to follow the installation procedures could result in
personal injury and/or improper operation and could cause damage to the equipment.
1. Mount Torque Nut (piece #32) in the actuator as shown in Figure 5.3 with the following alignment:
A. For LY 1001 – Stop Lugs facing the Actuator Mounting Adapter with index lines positioned to face the
Mechanical Stop Screws.
B. For LY 2001/3001 – Torque Nut axiall aligned on the Drive Sleeve so that the bottom of the nut is
positioned inside the Actuator Mounting Base.
A
B
CD
LY 1001 Ke wa
Location Marks
D
A
B
CTorque Nut
Stop Lug
LY 2001/3001 Ke wa
Location Positions
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 5-3
Figure 5.3 – LY 1001, 2001, and 3001 Torque Drive Nut Orientation
Mechanical Stop
Setscrews
D
C
B
A
CCW to
Open
Actuator
Mounting
Base
#32 Torque
Nut
Torque Nut
Stop Lugs
Actuator
Mounting
Adapter
Valve
Stem
Stop Lug
index lines
facing
Mechanical
Stop Screws
Top view
Mechanical
Stops
Closed
Mechanical
Stop Screws
D
C
B
A
Stop Pins
located
within
actuator
housing on the
Drive Sleeve Gear
Closed Open
Actuator
Mounting
Base
#32 Torque
Nut
Actuator
Mounting
Adapter
Valve
Stem
Top view
of LY 2001/3001
Mechanical
Stops
CCW to
Open
Open
of LY 1001
LY 1001
LY 2001/3001
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5-4 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
2. Insert the Retaining Drive Ring (piece #165 for LY 1001, piece #109 for LY 2001/3001) on the Torque Nut
(piece #32) to hold the Torque Nut in place in the actuator.
3. Mount the LY actuator on the mounting flange of the valve or other actuated equipment. High-strength
(minimum SAE-Grade 5 120,000 psi tensile strength) hex head or socket head cap screws with lockwashers
are recommended. The actuator mounting tap quantities and thread sizes are detailed in Table 5.2.
Table 5.2 – LY Actuator/Mounting Base Tap Sizes
Unit T pe Tap Size
and Size Quantit English Metric
LY 1001 8 3/8-16 x M10 x 1.5 mm x
0.71 deep 25 mm deep
(Complies with F10 ISO
mounting flange criteria)
LY 2001/3001 8 5/8-11 x M16 x 2 mm x 35 mm
1.26 deep deep (Complies with
F14 ISO mounting
flange criteria)
NOTE: Flowserve has supplied eight taps for the LY 1001, LY 2001, and LY 3001 in English/Metric units to provide
flexibilit in mounting arrangements. A minimum of four securing bolts is required to properl secure and retain
torque reaction on these units.
aDANGER: HAZARDOUS VOLTAGE. No electrical power should be connected until all wiring and limit switch
adjustments have been completed. Once power is supplied to unit exercise caution if cover is not installed.
4. Remove the Control Cover (piece #3) and Conduit Pipe Plugs (piece #144).
Figure 5.4 – Removing Control Cover and Conduit Pipe Plugs
Limitorque
#3 Control Cover
#144 Conduit Pipe Plugs
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LMAIM1501 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 5-5
Table 5.3 – Control Cover and Conduit Pipe Plug Hardware
Unit T pe Control Cover Conduit Pipe Plug
Quantit Size Quantit Size
LY 1001 (WP & XP) 6 M8 x 40 mm 2 1” NPT Socket
Hex Head
LY 2001/3001 8 M12 x 50 mm (WP) 2 1” NPT Socket
M12 x 55 mm (XP) Hex Head
5. Adjust the Limit Switches, Mechanical Stops, and Position Indication Dial following the procedures detailed in
Section 5.6, Limit Switch and Mechanical Stop Settings.
6. Connect the wiring to the terminal strips provided on the actuator. Refer to the wiring diagram supplied with
the actuator. “Fork-t pe” terminal connections are recommended.
7. Insert a Conduit Pipe Plug in the unused conduit entrance if the wiring that enters the actuator uses onl one
conduit entrance.
NOTE:
A. Explosionproof actuators require approved “sealing fittings” installed in accordance with the National
Electric Code.
B. Submersible actuators require an approved “sealing fitting” in order to keep water from entering the
actuator.
8. Attach grounding wire to Grounding Lug (piece #141).
9. Verif motor rotation direction to ensure that the limit switch is wired properl for intended operation. (See
Section 6.2, Verif Correct Motor Rotation (Phasing) and OPEN/CLOSE Pushbutton Operation.)
Figure 5.5 – Grounding Lug Location
10. Reinstall Control Cover (piece #3).
NOTE: Submersible actuators require tightening the Control Cover Bolts and Integral Control Cover Bolts to a
specified torque in order to maintain submersibilit . (See Table 5.4 for specific torque settings.)
Table 5.4 – LY Control Cover and Integral Control Cover Bolt Sizes and Torques
Unit T pe Control Cover Integral Compartment
LY 1001 M8 - 10 to 15 ft-lb M10 - 15 to 20 ft-lb
LY 2001/3001 M12 - 20 to 25 ft-lb M10 - 15 to 20 ft-lb
Unit is now read for electrical operation.
#141 Grounding Lug
To earth ground
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5-6 LY Installation and Maintenance for LY 1001, LY 2001 and LY 3001 LMAIM1501
5.4 Torque Switch Settings
aDANGER: HAZARDOUS VOLTAGE. Turn power OFF before opening the Electrical Compartment Cover or
making any adjustments to the Torque Switch.
CAUTION: Installing or adjusting the Torque Switch with the actuator in a loaded condition will result in loss of
torque protection. Before adjusting or installing the Torque Switch place the actuator in MANUAL mode and
turn the Handwheel in the direction necessary to release the torque load on the Wormshaft Assembly.
NOTE: Removal or modification of the Torque Switch Limiter Plate will void the actuator warrant . Do not exceed
the torque setting indicated b the Torque Switch Limiter Plate without contacting the Limitorque Service
Department.
The LY unit is equipped with a do W to MEDIUM or HIGH b adjusting the Torque Switch Adjustment Screw unless
it is limited b the Limiter Plate. (See Figure 5.6 for Torque Switch Adjustment Screw location.)
5.5 Rewiring the Torque Switch for Non-Standard Drive Sleeve Rotation
CAUTION: Double-check the wiring diagram to verify that the Torque Switch is wired appropriately for the appli-
cation. The Torque Switch will not protect the valve from over-torque if the Torque Switch is not wired properly
for the application.
LY series actuators are t picall supplied with a CCW Drive Sleeve rotation to open a valve. The Torque Switch is
marked OPEN (CCW) and CLOSE (CW) based upon CW Drive Sleeve rotation to close the valve. The Mechanical
Dial Position Indicator (MDPI) is t picall mounted for CW rotation to indicate the CLOSED position. If opposite
Drive Sleeve rotation is required (CCW to close a valve), the following Torque Switch modifications are required.
1. Turn all power to the actuator OFF.
2. Reverse the ID Limiter Plate.
3. Interchange OPEN Torque Switch wires 18 and 18C with CLOSED wires 17 and 17C. (Refer to the wiring
diagram for other Torque Switch wiring configurations.)
Figure 5.6 – Reversing Torque Switch Wiring
4. Remove the MDPI Plate and flip over for indication of CCW rotation to the valve’s closed position. (See Figure
5.12 for MDPI Dial Plate.)
LY-1
H
M
L
HML
CLOSEOPEN
T pical CLOSE-circui t
microswitch (17 &17C)
T pical OPEN-circui t
microswitch (18 &18C)
ID-Limiter Plate
Torque Switch
Adjustment Screws
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