Operation Manual. Document No.: KE KITZ EKSR Series Spring Return Type Electric Actuators. For KITZ Ball Valves

Transcription

1 Document No.: KE Operation Manual KITZ EKSR Series Spring Return Type Electric Actuators For KITZ Ball Valves Thank you for choosing KITZ products. For safe and trouble-free function and performance of the product, make sure to read and understand all items in this manual before valve mounting and operation. Keep this manual in a convenient place for your valve operators easy access.

2 Document No.: KE This manual applies to the operation of the KITZ EKSR series spring return type electric actuators for KITZ ball valves. SAFETY PRECAUTIONS For the safe use of the product, please read all safety precautions in this manual before handling the product. The safety precautions in this manual are determined to ensure safe and proper use of the product and to prevent personal injury and property damage. This manual uses two terms, Warning and Caution, according to the hazard level, to clearly indicate the extent and severity of the risk. Both Warning and Caution indicate important safety instructions. Please be sure to follow them. Indicates an imminently hazardous situation that, if not avoided, may result in serious injury or death. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury and product damage. Indicates a prohibited action that must not be carried out. Indicates a mandatory action that must be carried out. NOTES TO USERS This manual is designed to show an appropriate usage of the products for transportation, storage, installation, operation and maintenance. Be sure to read through this manual before handling the product. This manual does not cover the whole scope of conceivable usage of the products for transportation, storage, installation, operation and maintenance. If technical assistance beyond the scope of this manual is required, contact KITZ Corporation or its distributors. The specifications have been determined with safety consideration. Do not use products beyond the specifications. The illustrations given in this manual do not show all the details. If more detailed information is required, refer to our relevant valve assembly drawings. *Any information provided in this operation manual is subject to change without prior notice.

3 Document No.: KE Contents 1. Technical Features Actuator Type and Size Actuator and Valve Type Appearance and Dimensions Actuator Specifications Wiring Diagram Installation Precautions for Handling and Storage Precautions for Installation Environment Precautions for Piping Precautions for Wiring Operation Manual Operation Electric Operation Precautions for Operation Maintenance and Inspection Dismounting and Reinstallation Troubleshooting Product Warranty... 20

4 Document No. : KE /20 1. Technical Feature 1) If the power supply is cut off while the valve is in the open position, the valve is switched to close by the force built up in the spring. (The valve is set to the fully closed position at the time of shipment from the factory.) * As a special specification, the valve can be remained in the open position when the power supply is cut off. 2) As approximately 5 seconds are required to fully close the valve (it varies depending on the fluid conditions), water hammer phenomenon can be prevented. 3) Only two cables for power supply are required for operation. 2. Actuator Type and Size EKSR Actuator size 2: Type 2 Power supply voltage 100: 100VAC 200: 200VAC Actuator series 3. Actuator and Valve Type EKSR 100 -TE 3/4 Valve size Valve type Power supply voltage 100: 100VAC 200: 200VAC Actuator series

5 Document No. : KE /20 4. Appearance and Dimensions Space required for removing the cover. Nominal size 1, 1/2 & 2 Fig. 4-1 Nominal Size d d 2 H H2 H6 L L1 S1 H3 1/2 10 Rc1/ /4 15 Rc3/ Rc ,1/4 25 Rc1,1/ ,1/2 32 Rc1,1/ Rc Table 4-1 Dimensions Unit: mm Electric Actuator H1 D1 E W H4 H5 H7 Type EKSR 100/200-2 * The dimensions include a TE type valve.

6 Document No. : KE /20 This product is not designed to be explosion-proof. Do not install the product in an explosive or corrosive environment. There is a danger of explosion. Do not carry out wiring work while the actuator is energized and do not remove the housing covers during wiring. There is a danger of electric shock. Do not disassemble the actuator from the valve while applying an electrical current. It may cause damage on the product and unexpected accidents. Do not put your fingers or tools into the valve ports while checking the valve opening or closing position, etc. Doing so may cause injury or product damage. Before dismounting the product, ensure to reduce the pressure inside the pipes and the valve to the atmospheric level and remove the remaining fluid. Otherwise, residual pressure and line fluid may blow out from the valve bore and cause unexpected accidents. Do not replace the actuator or the valve with another product. Replacement may result in malfunctions or seat leakage. This operation manual mainly covers the KITZ EKSR series spring return type electric actuators. As for valves, please refer to the valve specifications. Ensure to follow all the instructions given in this manual on piping installation, electric wiring, maintenance and inspection of the product. The failure to follow the instructions may result in accidents and product failures. When actuator-metal ball valve units are mounted on plastic piping systems, an excessive load is imposed on the pipes during manual operation and the pipes may be damaged.

7 Document No. : KE /20 5. Actuator Specifications Specifications Series EKSR100-2 EKSR200-2 Power supply voltage (50/60Hz) Single phase 100VAC±10% Single Phase 200VAC±10% Rated current 0.3A 0.15A Close Open operation Open Close operation Operation time Open Close Open-Close operation frequency Output torque for electric operation Spring return torque Insulation class Dielectric strength Insulation resistance Service environment Service temperature Mounting orientation Power cable Actuator material Cover Base Motor operation Spring force Approx. 15 seconds Approx. 5 seconds Max. 20 cycles/1 hour (At least 3 minutes of time interval is required for each operation cycle.) Operation durability: Approx. 100,000 cycles (It varies depending on the service environment) 19.6 N m or over 9.8 N m or over Class E 1500VAC /1 minute Min. 10MΩ (500VDC Mega) Indoors -10 to +50 (Humidity 5 to 70%R.H. No condensation or freezing) Vertical to horizontal (No downwards) Vinyl cabtire cable 2 cores, 0.75mm 2 Length: 30cm Plated steel plate (SECC) Surface coating finish Aluminum die-casting

8 Document No. : KE /20 6. Wiring Diagram * The diagram below shows a fully closed state. Fig. 6-1

9 Document No. : KE /20 7. Installation 7.1 Precautions for Handling and Storage Do not carry the product by holding the electric cables. Such handling may damage the product, leading to functional failure such as bad electric contact. (Fig. 7-1) Do not drop the product on the ground. Protect the product from excessive impact, shock or vibration to prevent malfunctions. (Fig. 7-2) Do not apply excessive load to the product during storage. Such storage may cause a functional failure. Fig. 7-1 Fig. 7-2 Do not store the product in a place where. the product is exposed to rainwater or a place of high humidity. Bad storage conditions may cause corrosion inside the actuator, leading to a functional failure. Do not disassemble this product. It may hinder the function of the product or damage the product. Take the product out of the package just before the installation. The product is kept in the package to prevent foreign particles from entering the inside. Keep the valve in the fully closed or open position during storage. Storing the valve in the partially open position for a long period of time may deform the ball seats, leading to internal leakage. (1) Store the product indoors avoiding direct sunlight and dusts. (2) Keep the product in the package until it is ready for installation on piping. (3) Keep the product in a place free from high humidity and corrosive gas when the product is stored for a long period of time.

10 Document No. : KE / Precautions for Installation This product is not designed to be explosion-proof. Do not install the product in an explosive or corrosive environment. There is a danger of explosion. Do not install the product where the product might be submerged. Do not install the product where vibration or other forces may hamper the function of the product. If such installation is unavoidable, provide an appropriate device to minimize the impact on the operation of the product. Provide appropriate protection, such as installation of a cover or a shelter, from the direct sunlight or water splash. Rise of the temperature of the product or intrusion of water may cause malfunctions. Take appropriate measures if salt damage, snow or freezing is a concern. Allow sufficient room for safe and easy operation and maintenance of the product. Where the product is exposed to radiant heat from other devices around it, take appropriate protective measures such as installation of a cover or a shield. Where the piping faces roads and is accessible by passersby, take appropriate protective measures, such as installation of a fence or an enclosure.

11 Document No. : KE / Precautions for Piping Do not excessively use sealing materials such as thread seal tape or sealing pastes. The excess of the materials may protrude from the piping threads and enter the inside of the valves to be mixed with the fluids. Such conditions may cause malfunctions and seat leakage. Leave the first one or two threads of pipe ends free from sealing materials. Fig.7-3 Do not use a pipe wrench to screw the valve or adjust the orientation of the installed valve. Such handling may cause damage the valve. (Fig.7-3) 1 2 Do not excessively screw the valve into the pipe. It will damage or deform the inside of the valve and cause a malfunction or external leakage. (Fig. 7-4) Do not hold the valve with a vice. It may damage or deform the inside of the valve and cause a malfunction or external leakage. (Fig. 7-5) During valve installation, do not apply any force to the direction (counterclockwise). It will loosen the body-cap connection and cause external leakage from the threaded portions. To prevent intrusion of water into the actuator, do not mount the product with the actuator facing downwards. When the product is installed, the actuator shall be oriented within 90 degrees from the upright position. (Fig. 7-6) Do not apply excessive load to the product nor step on it during installation. Such usage may cause leakage or malfunction. (Fig. 7-7) Make sure the pipe end does not damage the inside of the valve. Fig.7-4 Fig.7-5 Fig.7-6 Fig.7-7 Do not open nor close the valve for any reason during flushing. Foreign objects entering the pipe may damage the ball seats and cause internal leakage.

12 Document No. : KE /20 As shown in Fig.7-8, apply a wrench to the valve end on the piping side when mounting the valve. If the valve is screwed into the piping by applying a wrench on the opposite end, rotating force may deform the valve body, leading to damaging the valve. (Fig. 7-8) Fig. 7-8 Do not apply any excessive bending moment to the product. It may deform the valve body and cause a functional failure. When the weight of the product or valve operation causes excessive load to the piping, give the valve appropriate supports. (An extra care is required when the valve is mounted on plastic piping.) If sands, metallic particles and other foreign objects are likely to be contained in the line fluid, ensure to mount a filtering device such as a strainer on the upstream side of the piping. Foreign objects may get stuck around the ball seats and affect the valve function or cause internal leakage. (1) Before installation, check that the design specifications of the product satisfy all the service conditions. (2) Remove dusts, scales and other foreign objects from the valve end threads and the inside of the pipe. (3) Check the pipe thread type and size with a gauge. Make sure that the required number of the effective threads is provided. (4) Apply a wrench to the valve end on the piping side when mounting the valve. (5) To screw valves into the pipes, apply the tightening torques shown in Table 7-1. (6) To threaded ends, apply the sealing material that is suitable to the service fluid and temperature. (7) After piping work is completed, fully open the valve and perform flushing to remove foreign particles from the piping. Table 7-1 Tightening Torque (For bronze and brass valves) Valve Size 1/2 3/4 1 11/4 11/2 2 Tightening Torque N-m (Kgf-m) 20 to 29 (2 to 3) 39 to 49 (4 to 5) 49 to 59 (5 to 6) 59 to 69 (6 to 7) 69 to 78 (7 to 8) 78 to 88 (8 to 9)

13 Document No. : KE /20 Be careful not to catch your hand or fingers between the valve and the flanges during installation.. Be careful not to damage flange and seat surfaces during installation. Use appropriate support stands for correct alignment of the upstream and downstream pipes. Leakage from the packing area may occur if the gland bolts or nuts are loosened due to stress relaxation during transportation or storage. Retighten the gland bolts and nuts before operation. Use new gaskets when installing valves on the pipe. Evenly and alternately tighten the flange bolts as shown below to avoid uneven tightening. Fig. 7-9

14 Document No. : KE / Precautions for Wiring In order to eliminate the danger of electric shock, be sure to turn off the actuator before electric wiring. Do not work for electric wiring in the place subject to rainwater. There is a danger of electric shock. Do not unnecessarily pull out the connecting cables and wires. Doing so may disconnect the cables and cause an electric shock. Give slack to the cable between the actuator and the power supply when wiring. Fig Do not modify the product for any reason. Modification will cause functional failures. Do not separate or disassemble the actuator-valve unit. It may damage the product. The actuators are designed for 100VAC or 200VAC. Check that the power supply voltage on site matches the design specifications of the product. Perform wiring correctly to eliminate the danger of short circuit. Perform wiring according to the circuit diagram shown on the nameplate. Incorrect wiring may damage the electrical components. Securely seal the cord entrance of cord connectors and cord gland to prevent water intrusion in the actuator. Incomplete sealing may result in corrosion and malfunctions.

15 Document No. : KE /20 There is a small gap between the cable cover and the inner wires. If the cable connections and the wire ends are not properly waterproofed, water may intrude into the inside of the covered cables by capillary action, which causes internal corrosions, resulting in operational failure. The cable connections and the wire ends shall be completely waterproofed. (Fig.7-11) 1. Waterproof the insulated edges of unused wires and the crimped connections between wires and relay wires. 2. Waterproof the space between the wires and the cable cover. Closed end connector Gap filler Fully fill the gap with filler. Cable cover Plastic tape Actuator wires Cable cover To the control panel Gap filler 3. Bind the crimp wires outside the cable cover and firmly wrap plastic tape around them. Fig Wiring shall be performed by officially qualified personnel according to the relevant national standards, rules and/or regulations. 2. Refer to the wiring diagram provided on the actuator cover. 3. Use 0.75 mm 2 or above of cable for wiring extension.

16 Document No. : KE /20 8. Operation 8.1 Manual Operation Do not separate the actuator from the valve while the power is on. Doing so may damage the valve leading to an accident. Manual operation shall be conducted after the power is turned off. Otherwise, it may damage the actuator. Manual operation shall be conducted slowly. Excessive force or abrupt operation may damage the actuator. Step 1: Turn off the power supply. Step 2: Raise the connector A until the parallel portion of the connector B is exposed. Step 3: Turn the parallel portion of the connector B with an adjustable wrench. Actuator mounting side Connector A Bracket 1. Raise the connector A. 2. Apply the adjustable wrench to the parallel portion of the connector B and turn the shaft. Adjustable wrench Valve mounting side Connector B Parallel portion * The manual operation above is applicable to the following product types. EKSR100/200-TE EKSR100/200-TKLAE EKSR100/200-TKLASE

17 Document No. : KE / Electric Operation Never remove the actuator cover. Sudden ejection of parts due to the spring force may cause injury, or fingers may get caught without the cover. There is also a danger of electric shock. When this product is electrically operated, follow the procedure below. (1) Check that the power supply and the voltage correspond with the specifications of the actuator. (2) Check that the control circuits of the actuator are correctly wired according to the wiring diagram indicated on the actuator cover. (3) Electric operation [Opening operation] When power supply voltage is applied between the lead wires white and black of the actuator, the motor rotates to open the valve, and the spring in the actuator is wound up. When the valve reached the fully open position, the built-in limit switch shuts off the power supply to the motor and the electromagnetic brake is activated to keep the valve in the fully open position. Fig. 8-1

18 Document No. : KE /20 [Closing operation] When power supply voltage between the lead wires white and black of the actuator is shut off, the electromagnetic brake is deactivated and the output shaft operates to close the valve by the force stored in the spring. Fig. 8-2 (4) If abnormal heat or smoke is generated from the actuator or if meltdown of the fuse occurs, immediately turn off the power. Investigate the cause and take appropriate measures. 8.3 Precautions for Operation Do not operate the valve with the actuator at short intervals. At least 3minutes of time interval is required after one cycle of the valve opening and closing operation. The operation shall be limited to the maximum of 20 cycles per hour. Do not control the actuator with a solid-state relay (SSR). When the SSR is turned off, a leakage current may affect the function or service life of the actuator. If SSR must be used, ensure to test the actuator in advance to check the proper activation. Do not drive the actuator directly by the contact output of the sequence controller. If such activation is required, drive the actuator by means of a switching element such as a relay with adequate contact capacity. Do not close (or open) the valve while valve opening (or closing) operation is being performed. It will significantly shorten the operating life.

19 Document No. : KE /20 The EKSR series actuators are designed for general applications, and they may generate electromagnetic waves or noise when they are operated. For connection of this series of actuators with other devices, which can be disturbed by the electromagnetic waves and noise, make sure they will not affect the functions of the other devices before starting the operation. Ensure to provide a fuse or a short circuit breaker on the control panel to prepare for accidental short circuits. Prevention of extraordinary pressure rising When a floating-ball type ball valve is used for liquid service, rise of the line temperature or ambient temperature may often cause an extraordinary rise of the fluid pressure left within the body cavity and result in damage of the sealing areas or valve malfunction. This problem may be solved by the following preventive measures. Pressure equalization groove Body cavity Pressure equalization hole (pressure relief) Pressure equalization hole (pressure relief) Fully closed Flow direction Fully open Fig. 8-3 Fig. 8-4 For the valve in the fully closed position A pressure equalization hole through the upstream side (higher pressure side) of the ball can be provided (special specifications). Please specify the special specifications at the time of order. This provision will make the fluid flow uni-directional, so that care must be taken to decide mounting direction of the valve on piping. (Fig. 8-3) For the valve in the fully open position A pressure equalization hole is provided in the slot for the stem on the ball where the ball makes a contact with the stem as standard specifications. (Fig. 8-4) Extraordinary pressure rising could be also a problem for a valve mounted at the end of the piping for liquid service. No effective solution could be recommended for such a valve. The entire piping system needs appropriate design reconsideration in advance so that a pressure relief valve may be installed or the piping may not be ended with a valve.

20 Document No. : KE /20 9. Maintenance and Inspection Foreign objects stuck to valve seats may result in generation of abnormal noises. Ensure to remove them immediately to prevent damage of seats and valve malfunctions. Abnormal vibration on piping may also cause a failure of the product. Hold the piping with supports to prevent or minimize such vibrations. (1) The ball valves and actuators described in this manual are designed to run without replenishing lubricants. (2) Inspection of the product must be carried out periodically and as frequently as possible to prevent accidental mishaps. Required inspection items are as follows. 1) Check smooth operation of valves. 2) Check if there is any external leakage from valves and piping connections. 3) Check if there is any vibration of valves and piping during operation. 4) Check if there are any loosened pins, bolts and nuts. 9.1 Dismounting and Reinstallation Do not disassemble the actuator from the valve while applying an electrical current. It may cause damage on the product and unexpected accidents. Do not put your fingers or tools into the valve ports while checking the valve opening or closing position. Doing so may cause injury or product damage. Before dismounting the product, ensure to reduce the pressure inside the pipes and the valve to the atmospheric level and remove the remaining fluid. Otherwise, residual pressure and line fluid may blow out from the valve bore and cause unexpected accidents.

21 Document No. : KE /20 Do not replace the actuator or the valve with another product as they are correctly assembled and adjusted before shipment. Replacement may result in malfunctions or seat leakage. Maintenance work must be carried out in a dust-free and clean place to prevent intrusion of foreign objects into the inside of valves and actuators. During maintenance work, take care not to damage moving parts of the valve and prevent foreign objects from sticking to internal and external surfaces. (1) When removing the valve from the pipe, make sure that no fluid is remained in the pipeline and apply a wrench to the valve end on the piping side as shown in Fig Hold the pipe with a pipe wrench so that the pipe does not rotate. Hold the pipe with a pipe wrench so that the pipe does not rotate. Fig. 9-1 (2) For re-installation, please refer to the section 7 Installation.

22 ActuatorovalveactuActuationbnormaloatorperationDocument No. : KE / Troubleshooting The table below provides general guidance of remedial measures to solve technical problems. For further technical assistance, contact KITZ Corporation or your local KITZ agents. Control circuit failure Rated voltage is out of the specification range. If the product was used with over rated voltage, replace the product. Check the power supply to use the specified power voltage. Incorrect wiring Broken wires, loose connections or contact failures Replace the product if the problem is not solved. Check the circuit with this manual and then reconnect and retighten the cables or wires. Problems Causes Remedies Countermeasures NDamage of actuator parts Intrusion of water into the actuator Submergence of the actuator Improper orientation of the product installation Improper waterproofing of the cable connections or wire ends Abnormal pressure rise (in the valve cavity and pipeline) Deformation due to excessive threading of pipe ends Replace the product. Avoid installing the product at the place where danger of submerging is predictable. Correct the installing orientation of the product. Waterproof the cable connections and ends of wires with water-resistant tape to prevent capillary action, etc. Replace the product if pressure reduction cannot solve the problem. * Refer to Prevention of extraordinary pressure rising in 8.3 of this manual. Replace the product. Use proper tightening torques. Valve Excessively high valve operation torque Adhesion of sealing agent to the seating area, Inclusion of foreign particles into the ball seat area Replace the product. Apply appropriate amount of sealing agent. Replace the product. Install a strainer on the upstream side. Thoroughly flush the product before operation. Corrosion of the ball Replace the product. Reselect the appropriate valve material suitable for the service fluid. Galling of the stem shaft Replace the product. Reselect the appropriate valve material suitable for the High frequency of operation Use the product under the specified conditions. Replace the product if the problem is not solved. service fluid. A Take sufficient time intervals between operations. Out of service conditions Excessively high or low ambient temperature Use the product under the specified conditions. Replace the product if the problem is not solved. Make sure the product is used within the range of the specified ambient temperatures. *Investigate the causes of the failure and take preventive measures not to damage the actuator and the inside of the valve when replacing the products.

23 Document No. : KE / Product Warranty If a failure not due to the following matters occurs within 18 months after delivery or within 12 months after trial operation, whichever is shorter, we will repair or replace the product free of charge. (1) A case where the product is used outside the specification for the product concerned, and failures and damage which occur as a result of disregard of the precautions shown in this document defining the handling of this document. (2) Failures and damage which occur as a result of inappropriate use of the product, careless use, etc. (3) Failures and damage which occur as a result of acts of providence, such as fire, flood damage, earthquake and lightning strike. (4) Failures and damage which occur as a result of modification/addition carried out by persons other than those at KITZ Corporation and service establishments designated by KITZ Corporation. (5) Failures and damage which occur as a result of aged deterioration (rusting, color fading, chemical change, etc.) For information, repair of failures and damage due to the above matters, as well as replacement with consumables will be at the expense of customers.