EPI 2 -MAN-652. User s Manual. EPI 2 Quarter-turn Electric Actuators Instruction and operating manual

Transcription

1 EPI 2 -MAN-652 User s Manual 3 US Jan Revision 2 of N. A. Version T. K. / D. L. P. 3 US Dec Revision 1 of N. A. Version T. K. / D. L. P. 3 US Sept Create N. A. Version T. K. / D. L. P. 3 1/2/06 Revised A. Ghiadoni G. Alfieri 2 5/12/05 Revised A. Ghiadoni G. Alfieri 1 11/11/05 Revised A. Ghiadoni G. Alfieri 0 31/05/05 First Issue A. Ghiadoni G. Alfieri Rev. Date Description Prepared Approved Note: Biffi Italia has taken every care in collecting and verifying the documentation contained in this Instruction and Operating Manual. The information herein contained is reserved property of Biffi Italia. Copyright by BIFFI ITALIA. All rights reserved 1

2 INDEX 1. GENERAL SAFETY INSTRUCTIONS MANUFACTURER INTENDED USE TERMS AND CONDITIONS MANUFACTURER S LIABILITY GENERAL DESCRIPTION GENERAL PRINCIPLE OF OPERATION ELECTRICAL OPERATION MANUAL OPERATION COMPONENT DESCRIPTION OPTIONAL MODULES OPTIONS LABEL STORAGE AND PRE-INSTALLATION CHECKS TO BE CARRIED OUT WHEN THE ACTUATOR IS RECEIVED STORAGE PROCEDURE INSTALLATION CHECKS TO MAKE PRIOR TO INSTALLATION ENVIRONMENTAL COUPLING BLOCK INSTALLATION OF THE ACTUATOR ONTO A VALVE MANUAL OPERATION SETTING THE MECHANICAL STOPS ELECTRICAL CONNECTIONS REMOVAL OF THE TERMINAL BOARD ENCLOSURE FIELD WIRING TERMINATIONS BASE WIRING DIAGRAM CABLE / CONDUIT ENTRIES SAFETY INSTRUCTIONS FOR INSTALLATION IN HAZARDOUS AREA LUBRICATION LUBRICATION INSPECTION ACTUATOR SETTING AND CONFIGURATION REMOVAL OF THE CONTROL UNIT COVER ACTUATOR SETUP MAINTENANCE AND TROUBLE-SHOOTING MAINTENANCE TROUBLE-SHOOTING PARTS LISTS AND DRAWINGS PARTS LIST Copyright by BIFFI ITALIA. All rights reserved.

3 Copyright by BIFFI ITALIA. All rights reserved 3

4 1. GENERAL SAFETY INSTRUCTIONS Warning: The actuator must be electrically isolated prior to performing any disassembly or reassembly. Warning: The electronic parts of the actuator can be damaged by a discharge of static electricity. Before you start, touch a grounded metal surface to discharge any static electricity. Warning: It is assumed that the installation, calibration, commissioning, maintenance and repair of the actuator are carried out by qualified and experienced personnel. Warning: Repair work, other than operations outlined in this manual, is strictly reserved to qualified Tyco Valves & Controls personnel or authorized by the Company itself. 1.1 MANUFACTURER Manufactured to comply with Machinery Directive 98/37: BIFFI ITALIA as specified on the motor label. 1.2 INTENDED USE The Keystone EPI² electric actuators covered in this Instruction and Operating Manual are designed to automate quarter-turn industrial valves (i.e., ball, butterfly, plug and control valves) or dampers. Tyco Valves and Controls is not liable for possible damage or physical injury resulting from misuse or improper installation, operation, adjustment and maintenance of the actuator. Those risks lie entirely with the user. Additional precautions may be required for certain applications. As Tyco Valves and Controls has no direct control over particular applications, operation or maintenance conditions, it is the operator s responsibility to comply with all applicable safety rules. Please inform Tyco Valves and Controls immediately if an unsafe situation not covered by this IOM is encountered. It is the sole responsibility of the operator to ensure that all local health and safety regulations are adhered to. The noise emitted by Keystone EPI² actuators during normal operation is less than 40 db (A) with a peak value equal to 85 db (C). Standard references: ISO (1st edition, ). 1.3 TERMS AND CONDITIONS Tyco Valves & Controls guarantees each single product to be free from defects and to conform to current specifications. The warranty period is one year from the date of installation by the original user, or eighteen months from the date of shipment to the original user, whichever occurs first. No warranty is given for products which have been subject to improper storage, improper installation, misuse, corrosion, or that have been modified or repaired by unauthorized personnel. Repair work necessary to repair improper use will be charged at standard rates. 4 Copyright by BIFFI ITALIA. All rights reserved.

5 1.4 MANUFACTURER S LIABILITY Tyco Valves & Controls assumes no liability for: use of the actuator in direct contravention of local safety at work rules incorrect installation, improper application or disregard of the instructions provided on the actuator nameplate and in this manual modifications without the authorization of Tyco Valves & Controls work performed on the actuator by unqualified personnel 2. GENERAL DESCRIPTION 2.1 GENERAL The EPI2 is an electric quarter-turn actuator suitable to operate a valve or damper. 2.2 PRINCIPLE OF OPERATION The electric motor drives an epicyclical gear train via a spur reduction. The epicyclical gear train has a single compound planetary gear which meshes with two internally toothed gears, one being the fixed annulus and the other being the output gear. The fixed annulus gear has external helical teeth meshing with a transversely mounted worm gear, thus locking the annulus into a fixed position. The worm gear can drive the annulus; eliminating the need for a declutch mechanism to enable manual operation. Actuator position is controlled with a position sensor directly coupled to the actuator s output drive. 2.3 ELECTRICAL OPERATION - Clockwise or counter-clockwise rotation may be selected during actuator setup. - An open or close electrical command will cause the actuator to move to the extreme end of travel or to a partial position. Control system details are shown in the specific wiring diagram. 2.4 MANUAL OPERATION Manual operation can be utilized when there is no power to the actuator or during initial actuator setup and calibration. The manual operating device is completely independent of the motor drive and can be operated at any time (even during electrical operation) without endangering the actuator. The handwheel does not rotate during electrical operation. To close the valve, turn the handwheel clockwise. To open the valve, turn the handwheel counter-clockwise. If the handwheel is used during electrical operation an alarm is set and the actuator will stop. Important: The standard direction of rotation for the Handwheel is clockwise (CW) to close. Copyright by BIFFI ITALIA. All rights reserved 5

6 2.5 COMPONENT DESCRIPTION The actuator consists of five main parts: Base Flange: Terminal enclosure: Mechanical Gearing: Control Unit: Manual Override: actuator to valve or damper interface power and signal connections through four available cable entries internal epicyclical gear reduction integral controls unit inclusive of electric motor, motor controls, electronic power and logic card manual operation is used in the event of a loss of power or during setup and calibration 6 Copyright by BIFFI ITALIA. All rights reserved.

7 2.6 OPTIONAL MODULES EPI 2 actuators can be provided with several different optional modules, as listed in the table below. Please refer to this table for possible combinations of available modules. Notes: All modules except OM13 are available for both Universal Voltage and 3-Ph voltage versions. Bluetooth component is integrated into the OMx card: not available for field installation. Each Optional Module (OM) is provided with its own Instruction and Operating Manual (MAN652_OM1 through MAN652_OM13). Copyright by BIFFI ITALIA. All rights reserved 7

8 2.7 OPTIONS LABEL A label is always provided if the module is installed at the factory. The OM labeled is installed in this location Warning: Failure to following procedures will void the warranty. 3. STORAGE AND PRE-INSTALLATION 3.1 CHECKS TO BE CARRIED OUT WHEN THE ACTUATOR IS RECEIVED Check that the information on the nameplate (Model, Serial Number, Nominal Torque, Nominal Voltage range, Protection Degree, Operating Speed range, Protection Class, etc.) is correct for the application. Check that the actuator was not damaged during shipment: in particular, inspect the local position indicator area glass. If necessary, repair all damages to the exterior coating, etc. 3.2 STORAGE PROCEDURE General The base version actuator is weatherproof to NEMA 4, 4X and IP 66/68. The actuators must be properly installed or properly prepared for storage to maintain this rating. The standard plastic plugs provided on cable entries are not weatherproof, and must be replaced prior to installation or storage Storage for less than 1 year Indoor storage - Ensure the actuators are kept in a dry place, stored on a wooden pallet (not directly on the floor surface) and protected from dust. - In very humid environments, a moisture absorbent desiccant packet should be used in the motor enclosure. (Desiccant is not included in the actuator package) Outdoor storage - Ensure the actuators are protected from the direct exposure to the elements (use a canvas tarp or similar); - Store the actuators on a wooden pallet, or some raised platform, so that they are not in direct contact with the ground, and protected from dust. - For humid environments, a moisture absorbent desiccant packet should be used in the motor enclosure. (Desiccant is not included in the actuator package) - Remove the plastic conduit plugs from the conduit entries and replace with weatherproof plugs appropriate for the environmental conditions. 8 Copyright by BIFFI ITALIA. All rights reserved.

9 3.2.3 Storage for more than 1 year Indoor storage In addition to the instructions in section : - Remove the plastic conduit plugs from the conduit entries and replace with weatherproof plugs appropriate for the environmental conditions. - coupling parts (i.e. mounting flange, etc.) must be coated with a protective oil or grease - (if possible, blank off the flange with a protective disk) - If the actuator is provided with an alkaline battery, remove it and store it in a dry and clean place Outdoor storage In addition to the instructions in section : - if the actuators are supplied with standard plastic plugs, replace them with weatherproof (metal) plugs; - coupling parts (i.e. flange, etc.) must be coated with a protective oil or grease - (if possible, blank off the flange with a protective disk) - inspect the condition of the terminal enclosure and the terminal board to ensure there has been no ingress of foreign materials (dust or moisture) - If the actuator was provided with an alkaline battery, remove it and store it in a dry and clean place. 4. INSTALLATION 4.1 CHECKS TO MAKE PRIOR TO INSTALLATION To assemble the actuator onto the valve, proceed as follows: - Check that the coupling dimensions of the valve flange and stem match the actuator s coupling dimensions. - The electrical supply cables must be suitable for the power rating of the actuator (refer to the test certificate delivered with the actuator, if available, or the actuator nameplate) - Gather the necessary tools necessary to assemble the actuator to the valve and perform actuator setup - Lubricate the valve stem with oil or grease to facilitate assembly - Clean the valve flange. Remove anything that might prevent a perfect fit to the actuator flange, especially all traces of grease or lubricant. - Install the actuator onto the valve without forcing, using only the weight of the actuator. When the actuator output shaft and the valve stem are connected, check that the holes of the valve flange match the holes of the actuator mounting flange. If not, then use the manual over ride to rotate the actuator until the holes are aligned. - Tighten the bolting evenly. - If possible, operate the actuator with the handwheel to verify that it operates the valve smoothly If a long storage period has occurred, before installing the actuator: - check the status of the O-ring seals - check the installation of the plugs or cable connections on the cable entries - check the integrity of enclosure covers - install the alkaline battery (if required by the application) 4.2 ENVIRONMENTAL Standard actuators are suitable for the following environment temperatures: -40 C to +70 C (-40 F to +158 F) with 80% humidity Special versions are available for extreme environments: -40 C to +70 C (-40 F to +158 F) with 80% humidity -25 C to +70 C (-13 F to +158 F) with 100% humidity (tropicalization) Special versions for hazardous areas: -20 C to +65 C (-13 F to +149 F) with 80% humidity -20 C to +65 C (-13 F to +149 F) with 100% humidity (tropicalization) -40 C to +65 C (-40 F to +149 F) with 80% humidity Copyright by BIFFI ITALIA. All rights reserved 9

10 4.3 COUPLING BLOCK View of the base with one type of insert. Only one insert is included with each actuator. 4.4 INSTALLATION OF THE ACTUATOR ONTO A VALVE Move the valve to the full open position. Use the handwheel to move the actuator to the full open position (verify with the local mechanical indicator) while checking that the rotation direction of actuator matches that of the valve. The actuator should be mounted for counter-clockwise rotation to open and clockwise to close. Warning: Never lift the valve/actuator assembly without securing slings to both the valve and the actuator. The actuator can be installed onto the valve in two different ways: Direct Mounting: insert the valve shaft into the actuator bottom flange utilizing the proper insert. Secure the actuator to the valve using the correct bolting. Bracket mounting: install the bracket and the adapter onto the valve then insert the valve shaft into the actuator bottom flange, utilizing the correct insert. Secure the actuator to the bracket using the correct bolting. 10 Copyright by BIFFI ITALIA. All rights reserved.

11 4.5 MANUAL OPERATION The actuator is supplied with a handwheel for manual override as standard, to operate the actuator in the event of a loss of power or during setup and calibration. The handwheel is always engaged. The handwheel does not rotate during electric operation. Turn the handwheel clockwise to close and counter-clockwise to open. Ensure proper direction of operation using the dial indicator on the actuator. The reduction ratio of the handwheel is as follows: E006 and E013 73:1, handwheel turns to move 90 degrees - 18 E025 and E051 91:1, handwheel turns to move 90 degrees - 23 E091 93:1, handwheel turns to move 90 degrees - 24 E :1, handwheel turns to move 90 degrees 53 Warning: Do not use cheaters, valve wrenches or similar tools on the handwheel. This can cause personal injury and damage the equipment. Warning: Chain wheels cannot be used. This can cause personal injury and damage the equipment. Important: Standard handwheel operation is clockwise (CW) to open and counterclockwise (CCW) to close. Copyright by BIFFI ITALIA. All rights reserved 11

12 4.6 SETTING THE MECHANICAL STOPS To set the actuator s mechanical stops, proceed as follows: Loosen the locknuts on both stop screws. Rotate both stop screws counterclockwise 2 turns. See picture below. Open position: Closed position: Move the actuator to the full open position. Rotate Stop Screw #1 one turn clockwise until it bottoms out, then rotate it counterclockwise 1/2 turn. Tighten the locknut by rotating it clockwise. Move the actuator to the full closed position. Rotate Stop Screw 2 one clockwise until it bottoms out, then rotate it counterclockwise 1/2 turn. Tighten the lock nut by rotating it clockwise. Using the handwheel, check that the travel of the actuator is correct. If the actuator stops before reaching the end of travel (fully open or closed), proceed as follows: - Rotate the stop screw counterclockwise while holding the lock nut in position with a second wrench. Manually move the actuator until the valve reaches the correct position. Tighten the locknut. If the actuator travels beyond the full range of valve travel (fully open or closed), proceed as follows: - Rotate the stop screw clockwise while holding the lock nut in position with a second wrench. Manually move the actuator until the valve reaches the correct position. Tighten the locknut. 4.7 ELECTRICAL CONNECTIONS Before powering the actuator, ensure that the supply voltage details on the nameplate are correct for the installation. Access to terminals for electrical connections is through the terminal cover. Warning: After electrical installation, ensure that the removal of the cover assembly performed per all applicable safety and environmental rules. Warning: All accessories (cable glands in particular) must be certified per the requirements of the installation area and all relevant regulations. 12 Copyright by BIFFI ITALIA. All rights reserved.

13 Warning: Actuator setup must be done while the actuator is energized. All setup operations must be performed by qualified personnel. Important: As the installed conditions are unknown to Tyco Valves & Controls, responsibility for proper selection of protective devices must be the responsibility of others. 4.8 REMOVAL OF THE TERMINAL BOARD ENCLOSURE Using a 5 mm Allen wrench, loosen the four screws and remove the cover. The screws are captive. Warning: Ensure that the edges of the cover or enclosure are not damaged during removal. 4.9 FIELD WIRING TERMINATIONS Before applying voltage to the actuator, check that the electrical parameters (supply voltage and current) shown on the nameplate and on the attached wiring diagram are correct for the installation. Important: Cable or conduit connections must comply with all relevant safety and environmental regulations. Warning: Do not disconnect the grounding connection X while terminating the field ground connection. Copyright by BIFFI ITALIA. All rights reserved 13

14 Terminal enclosure Remove the plastic plugs from the cable entries. For all electrical connections, use components (cable glands, cables, hoses, conduits) that meet the requirements of the particular application and of all applicable Codes and Regulations. Screw the cable glands or conduit fittings tightly into the threaded entries. All connections must be properly secured to ensure proper weatherproof and explosion proof protection. Pull the cabling into the electrical enclosures through the cable glands (or conduits) and terminate to the terminal board per the applicable wiring diagram. Replace the plastic plugs of the unused cable entries with metal plugs. When all wiring terminations are complete, check that the controls and signals work properly. Two grounding studs, one internal and one external, are provided. It is recommended that a ground connection be used for every installation. Power supply cabling should be sized for the current produced by the actuator when running at its 100% rating. Refer to the appropriate amperage charts. 14 Copyright by BIFFI ITALIA. All rights reserved.

15 4.10 BASE WIRING DIAGRAM Output contact ratings: Remote control signals: up to 240 VAC - type: Push-to-Run up to 30 VDC - minimum pulse duration: 300ms 120 VDC 4.11 CABLE / CONDUIT ENTRIES The sealing of cabling and conduit entries should be done in accordance with National Standards or the Regulatory Authorities that have certified the actuators. This is particularly true for actuators that are certified for use in hazardous areas where the method of sealing must be to an approved standard, and cable glands, reducers, plugs and adapters must be approved and separately certified. Important: To prevent water ingress through the conduit, ensure the conduit fittings have the minimum protection degree required by the application. If rigid conduit is utilized, a flexible pipe connection between the conduit and terminal board should be utilized. To ensure proper weatherproof protection, screw the cable fittings tightly. Thread sealant must be used. Copyright by BIFFI ITALIA. All rights reserved 15

16 4.12 SAFETY INSTRUCTIONS FOR INSTALLATION IN HAZARDOUS AREA Instructions for Explosion proof Enclosures Important: The actuators must be installed and maintained per all applicable Rules covering electrical installation in hazardous areas (other than mines) classified as zone 1 and/or 2 (gas) and zone 21 and/or 22 (dust) During the disassembly and reassembly of the explosion proof enclosures (covers, cable glands, and joints) ensure that all enclosures are returned to their original condition to ensure their weatherproof or explosion proof integrity. Apply a film of recommend grease to all flange surfaces. Proceed as follows: Important: Do not damage the explosion proof mating surfaces of the housing of the electrical enclosure covers. Reinstall all retaining bolting, using a thread sealant and applying a film of copper or molybdenum-based grease. Replace any weatherproof seals that may have been removed (O-Ring for the covers). Important: Anytime covers are removed, check the condition of all sealing components. If damaged, replace with factory recommend replacement parts prior to reassembly Installation in Environments with Explosive Dust Important: The actuators must be installed and maintained per all applicable Rules covering electrical installation in hazardous areas (other than mines) classified as zone 1 and / or 2 (gas) and zone 21 and/or 22 (dust) Prior to assembly, all joint surfaces must be lubricated with a film of silicone oil or equivalent. All cable/conduit entries must have a minimum protection degree of NEMA 4 or IP 66/68 (EN 60529). Periodically remove any dust deposited on the cover. Use a damp cloth to remove the dust, thus avoiding the creation of a static discharge. 5. LUBRICATION 5.1 LUBRICATION INSPECTION The actuator is lubricated for life, therefore, under normal working conditions it is not necessary to replace or add lubricant. If maintenance is performed, the recommended lubricant is AEROSHELL GREASE 7 or equivalent, for ambient temperatures of -40 C to 70 C (-40 F to +158 F). 16 Copyright by BIFFI ITALIA. All rights reserved.

17 6. ACTUATOR SETTING AND CONFIGURATION Before connecting power to the actuator, ensure that the power supply to be connected matches the voltage indicated on the nameplate of the actuator. An incorrect power supply will cause permanent damage to the electrical components. All calibration and settings are performed utilizing the control panel inside the controls cover. To access the panel, remove the actuator cover, as follows: 6.1 REMOVAL OF THE CONTROL UNIT COVER Using a 5 mm Allen key, loosen the four bolts and remove the cover. Removal of the actuator cover. Warning: Do not damage any sealing components or the flanges of the cover or housing. 6.2 ACTUATOR SETUP Warning: Settings must be performed with power to the actuator energized. Ensure settings are carried out by qualified personnel Actuator default settings -Closed direction of travel, Position seating -Open direction of travel, Position seating -Stroke time: 15 seconds for models 006, 013, 025 and seconds for model seconds for model 171 -Closing torque set at 100% of rated torque -Opening torque set at 100% of rated torque -Reverse mode off. Copyright by BIFFI ITALIA. All rights reserved 17

18 EPI2 Default Configuration table Switches Function SW4 SW6 SW5 SW3 Default Values Enter pushbutton Setting Function Close limit Open limit Limit switch closing 2 1: position 0: torque 1 1 position Limit switch opening 3 1: position 0: torque 1 1 position Closing stroke time 4 0 to Opening stroke time 5 0 to Closing Torque 6 0 to Opening Torque 7 0 to Reverse mode (CCW) 8 0 = off 1 = on 1 1 OFF If the application requires different actuator settings, please proceed as described later in this chapter. Important: Setting modifications can be performed in any sequence. All parameters can be set independently. To restore the actuator s default settings, proceed as follows: Refer to the EPI2 Default Configuration Table above Enter setup mode: move switch SW3 to the ON position Starting with the first function Close Limit Rotate SW4 to the position indicated in the table - Rotate SW6 to the position indicated in the table Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Repeat this procedure for each following function in the table, then, Exit setup mode (move switch SW3 to position 1) 18 Copyright by BIFFI ITALIA. All rights reserved.

19 Modifications to the actuator s settings are done using the following components inside the actuators control enclosure: -Two rotary selector switches SW6 and SW4 -Enter push-button SW5 (confirmation push-button) -Dip-switch SW3 (enter setup mode) -Green LED, Power On indication (switched on when power supply is available). -Red LED for Enter confirmation (Blinks once to confirm the setting is accepted) Internal control panel and setting tools Close position limit setting (Position Seating) Enter setup mode: move switch SW3 to the ON position Move the actuator to the closed position using the handwheel Rotate switch SW4 to position 0 Rotate switch SW6 to position 0 Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Open position limit setting (Position Seating) Enter setup mode: move switch SW3 to the ON position Move the actuator to the open position using the handwheel Rotate switch SW4 to position 1; Rotate switch SW6 to position 0; Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Close position limit setting (Torque Seating) Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 2 Rotate switch SW6 to position 0 Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Electrically operate the actuator in the close direction until the actuator stops Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Copyright by BIFFI ITALIA. All rights reserved 19

20 6.2.5 Open position limit setting (Torque Seating) Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 3 Rotate switch SW6 to position 0 Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Electrically operate the actuator in the open direction until the actuator stops Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Stroke time setting closing direction of travel Important: Refer to Section ACTUATOR DEFAULT SETTINGS To modify the default setting, proceed as follows: Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 4 Rotate switch SW6 to: positions 0-9. Choose the required stroke time from the STROKE TIME SELECTION TABLE below. Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Stroke time selection table Note (1): times are +/- 10% tolerance for a 90 stroke. 20 Copyright by BIFFI ITALIA. All rights reserved.

21 6.2.7 Stroke time setting opening direction of travel Important: Refer to Section ACTUATOR DEFAULT SETTINGS To modify the default setting, proceed as follows: Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 5; Rotate switch SW6 to: positions 0-9. Choose the required stroke time from the STROKE TIME SELECTION TABLE above: Confirm by pushing ENTER pushbutton SW5 When pushing SW5, the red LED will blink once to confirm that the setting is accepted Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Output torque adjustment closing direction of travel Important: Refer to Section ACTUATOR DEFAULT SETTINGS To modify the default setting, proceed as follows: The settings are adjustable between 40% and 100% of the actuators rated torque output. Each adjustment step using SW6 is equal to approximately 6.67% of actuators rated torque. To adjust, proceed as follows: Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 6 Rotate switch SW6 to: positions 0-9 to select the torque output required Push ENTER pushbutton SW5 to confirm When pushing SW5, the red LED will blink once to confirm that the setting is accepted Exit setup mode (move switch SW3 to position 1) or proceed with the next step: Output torque adjustment opening direction of travel Important: Refer to Section ACTUATOR DEFAULT SETTINGS To modify the default setting, proceed as follows: The settings are adjustable between 40% and 100% of the actuators rated torque output. Each adjustment step using SW6 is equal to approximately 6.67% of actuators rated torque. To adjust, proceed as follows: Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 7 Rotate switch SW6 to: positions 0-9 to select the torque output required Push ENTER pushbutton SW5 to confirm When pushing SW5, the red LED will blink once to confirm that the setting is accepted Exit setup mode (move switch SW3 to position 1) or proceed to the next step: Copyright by BIFFI ITALIA. All rights reserved 21

22 Output rotation selection (CW or CCW) Enter setup mode: move switch SW3 to the ON position Rotate switch SW4 to position 8 Rotate switch SW6 to position 1 for counter-clockwise (CCW) operation; 0 counter-clockwise (CCW) OFF Push the ENTER pushbutton SW5 to confirm; When pushing SW5, the red LED will blink once to confirm that the setting is accepted Reverse mode (CCW) set is now completed Exit set up mode (move switch SW3 to position 1) or proceed to the next step: 7.3 Actuator setup using a PDA or PC and A Manager Software If the Bluetooth optional card is installed in the actuator, setup can be done with A Manager software installed on a PDA or PC. For instructions, refer to the Operating Manual provided with the A Manager software. Warning: Commands via Bluetooth over-ride all other commands to the actuator. Take care to prevent damage to the equipment or injuries to people working close to the valve. Biffi will not accept responsibility for damage or injuries caused by an improper use of your Bluetooth PDA. 7. MAINTENANCE AND TROUBLE-SHOOTING 7.1 MAINTENANCE Routine maintenance For normal operating conditions, routine maintenance is not required. It is recommended that a visual inspection for grease leakage or external damage is performed every two years. When conditions are severe (frequent operation or high temperatures), seal and lubricant replacement is recommended every two years. Important: Before beginning any maintenance operation, ensure all power sources to the actuator are de-energized. Recommended Inspections: - Ensure there is no grease leaking from the actuator housing. - Check external parts for possible damage. Replace any damaged or broken parts immediately. Refer to chapter 8 for a parts listing. - Repaint all areas where paint is damaged or missing. In chemically aggressive or saline environments, remove rust from surfaces and protect with a rust preventative. - Check that all nuts and bolts securing the actuator to the valve are tight. - For severe applications or if actuator operation is infrequent, perform maintenance checks more often Special maintenance For actuator disassembly, refer to the exploded view drawings and associated parts list contained in this manual. If parts are required, the serial number of the actuator along with the item number of the part will be required. 7.2 TROUBLE-SHOOTING If problems during setup or normal operation are encountered, proceed as follows: Basic Checks: - Ensure the power supply to the actuator matches the values shown on the nameplate of the actuator - Ensure there is power at the actuator terminal strip, Terminals 1, 2 and 3 - With power energized, the green LED will illuminate to indicate there is power available to the actuator - Dipswitch SW3: must be in the off position 22 Copyright by BIFFI ITALIA. All rights reserved.

23 7.2.1 Actuator does not work electrically - Ensure that the voltage at terminals L1 and L2 (and for 3 phase applications L3) is correct - De-energize the power to the actuator - Remove the cover assembly - Check the continuity of the wires between terminals L1, L2 (and for 3 phase applications L3) and the connector of the power card - If there is no continuity on the L1-L2-L3 cables, replace the terminal board; if there is continuity, check the fuse mounted on the power card - Replace if bad - If the fuse is ok, replace the power card DC output voltage not available at terminals 33 and 34 - De-energize the main power supply and disconnect all wires from terminals 33 and 34 - Energize the main power supply and check the voltage on terminals 33 and 34. The reading should be between 23 and 27 Vdc - If the voltage reading is correct, check the external wiring and the electrical load. It should not exceed 4W - If the voltage is not correct, replace the power card The actuator does not work using the remote controls Check that: - The wiring to terminals 32, 35 and 36 is correct - There is no short circuit between the wires - The electrical load does not exceed 4W - If an external source is used, the voltage must be Vac 50/60Hz or Vdc The motor is very hot and does not start - Wait until the motor cools down before trying to operate the actuator again - Check that the number of operations per hour and their duration is suitable for the actuator service (see the nameplate) - Check that the valve operating torque is within the range of the unit s designed operating torque The motor runs but the actuator does not move the valve - Verify that the drive insert correctly fits in the actuator base - Verify that the drive insert has enough engagement with the valve stem - Verify that the keyed connections for all keyways is correct - Use the actuator handwheel and ensure the valve will move. If not, proceed as follows: - Loosen the handwheel retaining screw - Remove the handwheel - Check the internal parts - Reassemble the handwheel to the actuator The valve does not seat correctly - For position seated applications, ensure the travel limits are set correctly - Confirm the torque required by the application and increase the actuator output torque setting if necessary - The internal trim of the valve may be damaged Copyright by BIFFI ITALIA. All rights reserved 23

24 7.2.7 Excessive torque for valve operation - Clean, lubricate and check the valve stem - Valve packing too tight - Check that the internal valve is well lubricated and not damaged The actuator does not stop in fully open or fully closed position - Ensure the travel limits have been set correctly for the full range of valve travel. - Make sure that the torque and travel limits are correctly set (see Chapter 7). 8. PARTS LISTS AND DRAWINGS Important: When ordering spare parts, please provide the actuator s serial number located on the name plate. Important: When ordering spare parts, please refer to the itemized parts list with the attached drawings. Important: Recommended spares for routine maintenance are noted with a bullet in the parts list. 24 Copyright by BIFFI ITALIA. All rights reserved.

25 8.1 PARTS LIST Model E006 General Assembly Parts List Item Description Qty 1 Cover assembly 1 2 Drive and control unit 1 3 Output drive assembly 1 4 Handwheel 1 5 Ground stud 1 6 Terminal block 1 7 Position label 1 8 Plug 1 9 Standard housing 1 10 Motor pinion 1 11 Wheel 1 12 Indicator 1 13 Eccentric 1 14 Plano-centric gear 2 15 Fixed annulus 1 16 Manual worm shaft 1 17 Spacer 1 18 Worm shaft flange 1 19 Indicator shaft 1 20 Base plate ISO5211/F05-f Cover gasket 1 22 Ring for alignment pins 1 23 Stopper 2 24 Ring 2 25 Sliding ring 1 26 Terminal block cover 1 27 HSHC screw UNI5931-M4x ESH screw UNI5931-M6x Lock screw M6x HSHC screw UNI5931-M6x HSHC screw UNI5931-M6x HSHC screw UNI5931-M8x Snap ring for shaft d O-ring DI =6.07/W= O-ring DI =18.77/W= O-ring DI =9.19/W= O-ring DI =52.07/W= Nut UNI5588-M Nut UNI5588-M Dowel pin UNI-EN22338 M4x8 type B 1 41 Ball bearing type Ball bearing type Ball bearing type HSSC screw UNI5933 M4x Lock washer UNI8842-J Ring RW7 UNI Seal washer Recommended Spare Parts Copyright by BIFFI ITALIA. All rights reserved 25

26 Model E006 Drive and Control Unit Parts List Item Description Qty 1 Sensor assembly 1 2 Motor support flange 1 3 Motor HS AG Spacer 4 5 Washer 4 6 Motor gasket 1 7 HSHC screw UNI5931- M4x HSHC screw UNI5931- M6x Screw pz type M3x10 UNI Control/drive card assembly 1 11 Power supply card 150W max 1 26 Copyright by BIFFI ITALIA. All rights reserved.

27 Model E013 General Assembly Parts List Item Description Qty 1 Cover assembly 1 2 Handwheel 1 3 Drive and control unit 1 4 Output drive assembly 1 5 Ground stud 1 6 Terminal block 1 7 Position label 1 8 Plug 1 9 Standard housing 1 10 Motor pinion 1 11 Wheel 1 12 Indicator 1 13 Eccentric 1 14 Plano-centric gear 2 15 Fixed annulus 1 16 Manual worm shaft 1 17 Spacer 1 18 Worm shaft flange 1 19 Indicator shaft 1 20 Cover gasket 1 21 Pin alignment ring 1 22 Stopper 2 23 Ring 2 24 Sliding ring 1 25 Base plate ISO 5211 /F07-F Terminal block cover 1 27 HSHC screw UNI5931- M4x ESH screw UNI M6x Anti loosening screw M6x HSHC screw UNI5931- M6x HSHC screw UNI5931- M6x HSHC screw UNI5931- M8x Snap ring for shaft d O-ring DI=6.07/W= O-ring DI=18.77/W= O-ring DI=9.19/W= O-ring DI=52.07/w= Nut UNI5588-M Nut UNI5588 M Dowel pin UNI-EN M4x8 type B 1 41 Ball bearng type Ball bearing type Ball bearing type HSSC screw UNI5933 M4x Anti-loosening washer UNI 8842-J Ring RW 7 UNI Seal washer Recommended Spare Parts Copyright by BIFFI ITALIA. All rights reserved 27

28 Model E013 Drive and Control Unit Parts List Item Description Qty 1 Sensor assembly 1 2 Motor support flange 1 3 Spacer 4 4 Washer 4 5 Motor Gasket 1 6 Motor HS AH HSHC screw UNI5931- M4x HSHC screw UNI5931- M6x Screw pz type M3x10 UNI Control/drive card assembly 1 11 Power supply card 150W max 1 28 Copyright by BIFFI ITALIA. All rights reserved.

29 Model E025 General Assembly Parts List Item Description Qty Recommended 1 Cover assembly 1 2 Drive and control assembly 1 3 Output drive assembly 1 4 Handwheel 1 5 Earth stud 1 6 Terminal block 1 7 Position label 1 8 Plug 1 9 Worm shaft flange 1 10 Housing 1 11 Motor pinion 1 12 Wheel 1 13 Indicator 1 14 Eccentric 1 15 Planocentric gear 2 16 Fixed annulus 1 17 Manual worm shaft 1 18 Spacer 1 19 Indicator shaft 1 20 Base plate ISO 5211 F07- F10-F Cover gasket 1 22 Ring for pins alignement 1 23 Stopper 2 24 Ring 1 25 Sliding ring 1 26 Terminal block cover 1 27 HSHC screw UNI5931- M10x HSHC screw UNI5931- M4x ESH screw UNI M6x Anti loosening screw M6x HSHC screw UNI M6x20 32 HSHC screw UNI5931- M6x Snap ring for shaft d O-ring DI=6.07/w= O-ring DI=18.77/w= O-ring DI=10.77/W= O-ring DI=69.52/W= Nut UNI5588-M Nut UNI5589-M Dowel pin UNI-En M4x8 type B 1 41 Ball bearing type Ball bearing type 6005-LT 2 43 Ball bearing type HSSC screw UNI M5x10 45 HSSC screw UNI5933 M4x Anti-loosening washer UNI 8842-J Ring RW 10 UNI Seal washer Copyright by BIFFI ITALIA. All rights reserved 29

30 Model E025 Drive and Control Unit Parts List Item Description Qty 1 Spacer 4 2 Washer 4 3 Motor Support Plate 1 4 Motor SK3899 Hn Motor Gasket 1 6 Sensor Assembly 1 7 HSHC screw UNI5931- M5x HSHC screw UNI5931- M6x Screw pz type M3x10 UNI Control/drive card assembly 1 11 Power supply card 500W max 1 30 Copyright by BIFFI ITALIA. All rights reserved.

31 Model E051 General Assembly Parts List Item Description Qty 1 Cover assembly 1 3 Handwheel 1 4 Drive and control assembly 1 5 Ground stud 1 6 Terminal block 1 7 Position label 1 8 Plug 1 9 Worm shaft flange 1 10 Housing 1 11 Motor pinion 1 12 Wheel 1 13 Indicator 1 14 Eccentric 1 15 Plano-centric gear 2 16 Fixed annulus 1 17 Manual worm shaft 1 18 Spacer 1 19 Indicator shaft 1 20 Cover gasket 1 21 Alignment Ring 1 22 Stopper 2 23 Ring 1 24 Sliding ring 1 25 Base plate ISO 5211 F10-f Terminal block cover 1 27 Output drive assembly 1 28 HSHC screw UNI5931- M10x HSHC screw UNI5931- M4x ESH screw UNI M6x Anti loosening screw M6x HSHC screw UNI5931- M6x HSHC screw UNI5931- M6x Snap ring for shaft d O-ring DI=6.07/W= O-ring DI=18.77/W= O-ring DI=10.77/W= O-ring DI=69.52/W= Nut UNI5588-M Nut UNI5589-M Dowel pin UNI-EN M4x8 type B 1 42 Ball bearing type Ball bearing type 6005-lt 2 44 Ball bearing type HSSC screw UNI5933 M5x HSSC screw UNI5933 M4x Anti-loosening washer UNI 8842-j Ring RW 10 UNI Seal washer Recommended Spare Parts Copyright by BIFFI ITALIA. All rights reserved 31

32 Model E051 Drive and Control Unit Parts List Item Description Qty. 1 Spacer 4 2 Washer 4 3 Motor Support Plate 1 4 Motor Gasket 1 5 Motor SK3909 HS AX Sensor Assembly 1 7 HSHC screw UNI5931- M5x HSHC screw UNI5931- M4x Screw pz type M3x10 UNI Control/drive card assembly 1 11 Power supply card 500W max 1 32 Copyright by BIFFI ITALIA. All rights reserved.

33 Model E091 General Assembly Parts List Pos Description Q.ty Recommended 1 Cover assembly 1 2 Earth stud 1 3 Output drive assembly 1 4 Handwheel assembly 1 5 Terminal block 1 6 Position label 1 7 Plug 1 8 Indicator 1 9 Cover gasket 1 10 Ring 1 11 Housing 1 12 Motor pinion 1 13 Wheel 1 14 Eccentric 1 15 Planocentric gear 2 16 Fixed annulus 1 17 Manual worm shaft 1 18 Spacer 1 19 Worm shaft flange 1 20 Indicator shaft 1 21 Base plate F10-F14 EN ISO Ring for pins alignment 1 23 Stopper 2 24 Bushing 1 25 Washer 1 26 Terminal block cover 1 27 Drive and control assembly 1 28 HSHC screw UNI M12x65 29 HSHC screw UNI5931- M4x ESH screw UNI M6x HSHC screw UNI5931- M6x HSHC screw UNI5931- M6x HSHC screw UNI5931- M8x O-ring DI=6.07/W= O-ring DI=25.12/W= O-ring DI=13.94/W= O-ring DI=82.22/W= Nut UNI 5588-M Nut UNI 5589-M Dowel pin UNI-EN M4x8 type B 1 41 Ball bearing type Ball bearing type HSSC screw UNI5933 M5x HSSC screw UNI5933 M4x HSSC screw UNI5933 M6x Anti-loosening washer UNI 8842-J Ring RW 14 UNI Seal washer Copyright by BIFFI ITALIA. All rights reserved 33

34 Model E091 Drive and Control Unit Parts List Item Description Qty. 1 Spacer 4 2 Washer 4 3 Motor Support Plate 1 4 Motor Gasket 1 5 Motor SK3909 HS AX Sensor Assembly 1 7 HSHC screw UNI5931- M5x HSHC screw UNI5931- M6x Screw pz type M3x10 UNI Control/drive card assembly 1 11 Power supply card 500W max 1 34 Copyright by BIFFI ITALIA. All rights reserved.

35 Model E171 General Assembly Parts List Copyright by BIFFI ITALIA. All rights reserved 35

36 Model E171 Drive and Control Unit Parts List 36 Copyright by BIFFI ITALIA. All rights reserved.

37 Installation, Operation, & Maintenance Manual Falcon Ridge Water Intake Upgrade Kelowna, BC Specification Section: Sluice Gates Golden Harvest Project Number: June, 2017 GOLDEN HARVEST, INC. PO BOX 287 BURLINGTON, WA PHONE: (360) FAX: (360) Rev: 04 Rev Date: 09/15/2016 Approved By: TB/RM

38 Table of Contents INTRODUCTION... 2 GENERAL OPERATOR SAFETY... 2 CATALOG DESCRIPTIONS... 3 MODEL GH-46 SLIDE GATES... 3 INSTALLATION... 4 RECEIVING SHIPMENT... 4 PRECISION NON-SHRINK GROUT REQUIREMENTS... 5 INSTALLATION OF ANCHOR BOLTS... 5 INSTALLATION OF WALL MOUNTED FRAMES... 9 INSTALLATION OF OPERATING APPURTENANCES OPERATION THEORY OF OPERATION OPERATION OVERVIEW ENVIRONMENTAL & EMERGENCY CONDITIONS OPERATOR SAFETY SPECIAL TOOLS GATE SHUT-DOWN - REMOVAL AND REPLACEMENT OF GATES PRE-COMMISSION & MAINTENANCE SLIDE GATE PRE-COMMISSION PLAN AND CHECKLIST ADJUSTMENT AND REPLACEMENT OF P-BULB SEALS EQUIPMENT MAINTENANCE LUBRICATION CHART SLIDE GATE TROUBLESHOOTING WARRANTY & SERVICE WARRANTY AUTHORIZED PARTS AND SERVICE SPARE PARTS LIST & REPLACEMENT DRAWINGS... A Page 1

39 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Introduction Introduction Golden Harvest, Inc. has developed Golden Gates, a complete line of aluminum and stainless steel gates made for worldwide distribution. These products, based on widespread experience in all types of environments, are the results of extensive research, field testing, and analysis. Golden Harvest, Inc.'s Golden Gates Installation, Operation, and Maintenance Manual was created for all personnel (engineers, contractors, operators, and installers) who will be involved in installing, operating, and maintaining this equipment. This manual contains Golden Harvest, Inc. s Golden Gates recommended procedures for handling, storage, installation, adjustment, and initial operation for the related equipment and operating mechanisms. Every precaution is taken at the factory to ensure that superior quality equipment is shipped. Therefore, we cannot be held accountable for damage caused by vandalism, negligence after shipping, or improper installation of the equipment. If appropriate care and accuracy are observed in the field when installing Golden Harvest, Inc. Golden Gates they will operate as designed at optimum efficiency. Should there be any questions please contact Golden Harvest, Inc. Field Service Department. GOLDEN HARVEST, INC. PO Box 287 Burlington, WA Telephone Fax All normal industrial safety practices and local and national codes must be adhered to, and common sense should be applied to all use of equipment. General Operator Safety Do not alter this equipment without gaining approval by Field Service Technician of Golden Harvest, Inc. Personnel should review and understand the complete Installation, Operation & Maintenance manual, the equipment, and drawings prior to handling, installation, operation and/or maintenance of this equipment. Personnel for rigging or chaining equipment for lifting should be fully trained in rigging procedures and should use chains, slings and hoists that have been fully inspected and test rated for the work being performed. Page 2

40 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Catalog Descriptions Catalog Descriptions Model GH-46 Slide Gates Submerged Service or Open Top Gates for Seating and Unseating Applications Flexible Design Customized to Fit Most Project Applications Fully-Adjustable Sealing System Meets AWWA C-561 Design and Leakage Standards Golden Harvest Inc. Fabricated Slide Gates are the industry standard for price and performance. UHMW seating faces in guide grooves and neoprene face seals provide for low leakage solutions at modest head levels. The resilient P-bulb seal design provides for a low leakage closure. Available in self-contained and non self-contained frame configurations. Standard mounting options include: flat-back for flush mounting to a wall face or wall thimble, embed mounting for new channel construction and in-channel mounting for existing channel retrofits. Golden Harvest, Inc. flat back designs are attached directly to the concrete wall without the need for any special block outs. A non-shrink grout pad is recommended so that the gate frame does not conform to possible imperfections in the concrete headwall during installation. Stainless steel and aluminum construction provides virtually limitless design flexibility. Slide Gate Models GH-46 Stainless Steel Submerged Service Page 3

41 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Installation Receiving Shipment All individually shipped parts, assemblies, and equipment are listed on a packing list. These should be inspected and counted immediately upon arrival. Should a deficiency occur, please notify Golden Harvest, Inc. immediately. We cannot be held responsible for any shortages reported more than 30 days after receipt of shipment. Special attention should be taken in counting and safely storing all bolts, nuts, and other small items which are often misplaced or lost at job sites. Unless your contract with Golden Harvest, Inc. states otherwise, all parts and equipment are shipped F.O.B. factory. Therefore, if any equipment or parts are damaged in transit, it is the purchaser's responsibility to file claims with the transportation company. For assistance in filing any claim and/or replacing equipment, please contact Golden Harvest, Inc. at Storage and Handling All Golden Harvest, Inc., Golden Gates' equipment and parts are durably constructed. However, there are precision machined seats and surfaces which require special attention when handling, storing, and installing. Although all equipment and parts are of sturdy design, it is possible to warp frames, heads, stems, and other parts and equipment. To avoid these problems we recommend the following: DO NOT DISASSEMBLE FOR STORAGE OR INSTALLATION: Cover and protect all equipment that will not be installed immediately; Avoid exposure of UV rays; Always brace and block equipment to avoid distortion and damage to sealing system; Warehouse equipment on a flat, clean, dry surface; Do not stack equipment without proper blocking, bracing and covering. Handle all equipment and parts like you would any other precision machinery. Page 4

42 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Precision Non-Shrink Grout Requirements NOTE: The recommended specifications are offered for reference only. Every application should be considered unique and a local grout supplier should be consulted prior to the non-shrink grout selection. The below specifications are applicable to most gates installed in the dry condition. 1. Grout shall not contain metallic aggregate, expansive cement, or gas generating additives such as aluminum powder. 2. Grout shall generate positive expansion. 3. Cured grout compressive strength shall be 7000 psi or better in 28 days. 4. Grout shall be capable of placement at a fluid capacity without segregation or the appearance of bleed water. 5. Grout shall provide a minimum 95% effective bearing area when mixed and applied. 6. Precision Non-Shrink Grout shall be installed per the manufactures instructions. Installation of Anchor Bolts Golden Harvest, Inc. furnishes type stainless steel anchor studs as required for the project. Adhesive is the responsibility of the contractor. Golden Harvest Inc.'s anchor bolt design calculations are based on the Hilti HIT-RE 500-SD adhesive anchoring system. Refer to drawing for recommended adhesive. Upper Gate Frame Anchor Bolts Anchor bolts are required to support the upper frame members. These anchor bolts are provided with double nuts so that upper gate frame members can be clamped in position. Anchor Bolt Torque Information NOTE: The below tables are offered as guides, anchor bolts should never be tightened to the point of frame distortion. TABLE 1: Mounting Bolts BOLT DIAMETER INCH (mm) 3/8 (10) 1/2 (13) 5/8 (16) 3/4 (19) 7/8 (22) 1 (25) TORQUE FT-LBS (N-m) 20 (27) 45 (60) 75 (100) 120 (163) 190 (257) 260 (353) TABLE 2: Mounting Bolts with Gasket BOLT DIAMETER INCH (mm) 3/8 (10) 1/2 (13) 5/8 (16) 3/4 (19) 7/8 (22) 1.0 (25) TORQUE FT-LBS (N-m) 15 (20) 35 (47) 70 (94) 90 (121) 125 (168) 150 (200) Page 5

43 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Hilti HIT-RE 500-SD Epoxy Adhesive Anchoring System Page 6

44 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Page 7

45 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Page 8

46 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Installation of Wall Mounted Frames NOTES: Be sure gate frames are installed plumb and straight. Failure to do so will impair smooth operation and cause excessive leakage. Make sure that any excess grout splatter that may get on the gate slide or invert member during the grouting process is washed or sanded off prior to exercising the gate. Failure to remove grout from slide before exercising will result in a damaged seal and gate leakage. When frame sections are bolted together at the bottom corners or areas that are intended to seal, application of industrial grade urethane sealant is required between flanged connections. INSTALLATION: 1. Secure all anchor bolts in the proper position on the concrete wall, using frame rail for template or in some cases (gate size or location) it might be easier to use a template patterned off the gate frame. For proper size, projection and anchor type see installation drawings. Epoxy type anchors are normally provided. For installing anchor bolts, see Installation of Anchor Bolts section. 2. Two nuts are provided per anchor bolt. Place one nut on bolt allowing for approximately 1.0" of grout between gate frame and concrete wall. 3. Place the gate frame into position on the anchor bolts. 4. Install second nut on each anchor bolt. Align the gate frame by adjusting the front and back nuts. Be sure that both frame rails are parallel and plumb, as an improperly aligned or warped gate frame will cause excessive leakage and impair smooth operation of the gate. 5. After the gate is set and before grout has been packed, check with feeler gauge that the seal makes contact with the gate head around entire parameter of head. For adjustment, see Adjustment and Replacement of P- Bulb Seals section. 6. Where possible, check the gate installation (prior to grouting in place) by opening the gate slide to its full up position. If excessive force is required while opening gate, this may indicate that the frame is not plumb. Also, using a thin wire, check the gate frame / seat area by stretching the wire along each side and most important across the horizontal top spigot. If there is a variation (1/32 or greater) in the seating face, excess leakage will result in those locations. Also, use the wire to stretch corner to corner of the opening. If the wires do not touch at the center, at minimum one corner has been pulled back from the plane. Make adjustments to double nuts as required. 7. After steps above are complete and gate frame is mounted plumb and straight and nuts are tightened (See Anchor Bolt Torque Information for torque reference), fill the void between gate frame and concrete wall with a precision non-shrink grout. Page 9

47 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Installation Installation of Operating Appurtenances Installation of Stem Refer to the installation drawings to select the proper stem length, section and diameter. IMPORTANT: If stems are in more than one piece, stems must be installed in their proper order from bottom to top. Refer to the installation drawings for proper stem section order. o When internally threaded couplers are supplied, each stem section and stem coupler are match marked to ensure correct installation. It is important to carefully check the alignment of the stem and lifting components. The maximum allowable deviation for misalignment is 1/8 (3mm) on the total length of the stem. INSTALLATION: 1. After gate and stem guides have been mounted, carefully lower the proper stem section through the stem guide(s) and into the stem pocket located on the gate head. 2. Secure the stem to the gate slide using the attached, pre-installed hardware. 3. Thoroughly clean the threaded portion of the stem and the nut in the lifting device. Keep these elements clean and lubricated to prevent damage or hard operation. 4. After assembling stem, be sure to screw bottom stop nut onto stem. Figure 1 Installation of Operator on Self Contained Gate Yoke 1. Carefully lower the lift unit over the upper threaded portion of stem engaging the threads of the lift unit and stem. 2. Turn the crank or handwheel to lower the lift onto the yoke, align operator mounting holes. Use bolts and nuts provided to secure lift to yoke. 3. Align center line of lift nut until it is parallel with the center line of the stem. Proper alignment is critical for smooth operation of stem. Page 10

48 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Operation Installation of Stop Nuts (Travel Limits) IMPORTANT: Over travel (open or close) of the gate slide will damage the horizontal top seal or potentially damage major components. Stop nuts are critical to preventing damage. Lower Stop Nut: NOTES: Lower stop nut must be installed prior to installing the operator. It is easiest to install lower stop nut when gate is in the closed position. INSTALLATION: 1. Verify gate travel. Measure down from bottom of operator plate gate travel distance. Install lower stop nut with upper edge at gate travel distance. Upper Stop Nut: After operator installation and gate is in the closed position adjust stop nut down on the top of the projecting stem until firm contact is made with the top of the lift nut. Tolerance = +/- 1/8 (3mm). Both Nuts: After the stop nut(s) are positioned correctly on the stem within specified tolerance then mark stem with set screw or pen, move stop nut off mark, file the mark flat, punch, and drill a 1/16 to 1/8" [1 3mm] deep dimple. Return stop nut to position and firmly tighten set screw on the dimple. Installation of Clear Plastic Stem Covers NOTES: Clear plastic stem covers have drilled vent holes on one end; make sure this end is up. Do not pack the stem cover tube with grease as this can lead to pressure build up in the gearbox. IMPORTANT: Stem covers must be stored supported along their full length in order to prevent distortion. INSTALLATION: 1. When clear plastic stem covers are used care must be taken not to scratch or break cover. Covers are marked to match gate. Check to make sure cover is approximately 6" longer than gate height. 2. A threaded PVC adaptor is provided. Polyurethane sealant should be used on threads, stem cover slip joint and cap. Screw adaptor into receiver on top of lift housing. Place a bead of sealant into the receiving end of the adaptor. Be sure stem cover is plum. Place a bead of sealant in the top cap and install on top end of stem cover. Attaching Mylar Indicators to Clear Plastic Stem Covers After lift and stem cover has been properly installed, the gate adjusted for proper seating, and the stop nuts are set and locked, the calibrated indicator must be installed. INSTALLATION: 1. Clean plastic stem cover. 2. Graduated, self-adhesive mylar tape is provided to indicate gate position. 3. Indicate/mark on plastic stem cover where top of stem comes when gate is in closed position. Cut mylar indicator strip with knife or scissors to the proper gate travel length. 4. Remove protective coating from mylar tape and smoothly apply to plastic stem cover. Page 11

49 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Operation Operation Theory of Operation Slide gates are used to either stop flow or allow flow in the desired direction by opening or closing the gate via the upward opening design. Operation Overview Manually operated slide gates are controlled by rotating a hand crank or handwheel counter clockwise to raise the gate head and clockwise to lower it. When fully closing the gate, avoid excessive pressure. Observe the position of the gate via the clear plastic graduated stem cover located on the operator. If the gate does not close completely without excessive force, stop operation and visually check gate for debris or other obstructions. See Pre-Commission & Maintenance section for further details. Under maximum head, the force required to rotate the handle should not exceed 40 lbs. If excessive force becomes necessary, gate operation should stop until the cause is determined. Never try to force the gate head in either direction, as this may cause damage to various gate components. Instead, visually inspect the gate head, the invert area, the operator, the guide rails, the p-seals and the stem to determine the source of the problem. Make certain the gate is not already in the fullopen position (stem stop nut against operator) when attempting to raise the gate head. Upon completion of gate operation, visually inspect the gate head to verify proper position. Make certain that the gate stem is not under excessive load. This may occur when excessive force has been applied to the operator upon gate closure. NOTE: Do not operate gate dry or without adequate lubrication on all seals. Environmental & Emergency Conditions Large or excessive debris in water can adversely affect gate operation. Freezing conditions can result in ice build-up, adversely affecting gate operation. Operator Safety Golden Harvest Inc. does not have specific instructions beyond basic plant safety practices for its products. Special Tools No special tools are required to install or maintain Golden Harvest gates. Page 12

50 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Operation Gate Shut-Down - Removal and Replacement of Gates Under normal operation and maintenance of these gates, removal of the gate head is neither required nor recommended. If removal of the gate head is necessary for any reason the following is required: 1. Remove the stem cover. See Stem Cover Installation instructions, removal steps are opposite of installation steps. 2. Remove the manual operator from the stem. See Operator Installation instructions, removal steps are opposite of installation steps. 3. Remove the stem from the gate head. See Stem Installation instructions, removal steps are opposite of installation steps. 4. Remove the stem guide and the yoke (bolted yoke only) for non-self-contained gates. For selfcontained gates, the gate and frame must be removed as a single unit. See Frame Removal step. 5. Attach a lifting strap to the gate head utilizing the stem pocket for slide gates. For stop logs, stop gates or bulkheads use lifting beam and/or picking points provided. 6. Secure the lifting strap to a crane or other lifting device. Frame Removal: 1. Remove grout from void between frame and wall. For Embedded Frames, attach lifting mechanism prior to removal of grout. 2. Re-install any removed frame portions and support frame with lifting mechanism. 3. Remove nuts from anchor bolts. 4. Move frame horizontally off anchor bolts. Lift out of position with lifting mechanism. It is best to remove the gate head with a balanced water head condition. Installation of the head is a reversal of the above sequence. Care must be exercised at all times to observe standard lifting safety practices. No special tools are required for removal of gates and frames. See drawings for dimensions. Page 13

51 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Pre-Commission & Maintenance Pre-Commission & Maintenance Slide Gate Pre-Commission Plan and Checklist After installing gate and before initial operation, please check the following: 1. Check guide frame for proper alignment. 2. Check to make sure stem guides and brackets are properly installed and securely fastened. 3. Clean and lubricate stem threads. 4. Clean the gate slide, guides, seals and invert of all foreign material. 5. If P-seals are used, clean contact area and adjust seal. 6. Adjust stop nut to within 1/8" of the top of lift nut and lock in place. 7. Install stem cover if required. 8. Lubricate gate sealing system. Vegetable oil is an acceptable break-in lubricant. IMPORTANT: Gate sealing system must be lubricated before initial use and after periods of time when gates are not submerged or wetted by service water (after shutdowns, dewatering, etc.). Operating gate without lubrication may damage seals. 9. The gate should be operated to the fully opened and fully closed position slowly to check for any misalignment or problems in operation. 10. If gate does not operate smoothly or shows excess leakage, see Slide Gate Troubleshooting for remedy. Page 14

52 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Pre-Commission & Maintenance Adjustment and Replacement of P-Bulb Seals Check the clearance between the seal and the head following installation with a.004 (0.10 mm) feeler gauge. Gauge should not pass at any point around the seal perimeter. Tools Required: - 10 [250mm] crescent wrench or 9/16 socket head - 3/4 [20mm] punch (for seal replacement only) SEAL SETTING ADJUSTMENT (COARSE): 1. Loosen seal retainer bolts. 2. Evenly force seal retainer bar and seal against gate slide to achieve approximately 1/16 seal compression. 3. Tighten seal retainer bolts evenly with approximately lbs (14-22 N-m) torque. SEAL ADJUSTMENT (FINE): 1. Identify area of concern with feeler gauge or visually. 2. Tighten retainer bolts by 3/4 to 1-1/2 turns to the formed leg of the retainer bar against the P-bulb seal; tightening the seal against the gate slide. 3. Use feeler gauge to check the adjusted area for correction. Do not over tighten retainer bolts (20 ft-lbs or 27 N-m Max). If leakage continues, refer to Coarse Adjustment. TO REPLACE P-SEALS: 1. Remove stainless steel hardware, retainer and P-bulb seal. 2. Place new P-bulb seal on spigot bolts. Verify that the pattern punched in the replacement seal will provide sufficient seal adjustment. If required, use punch to elongate holes. 3. Place stainless steel retainer bars over P-bulb seal and stud bolts. Hold retainer bar & P-bulb seal in place and loosely tighten each nut. Once seal and retainer have been loosely installed, follow instructions above for Setting and Adjusting the P-bulb seal. Figure 2 Page 15

53 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Pre-Commission & Maintenance Equipment Maintenance A brief visual inspection of the gate each time it is operated is a very important step in helping identify abnormalities or damage before it can become a major problem. All personnel should make an effort to develop a habit of visually inspecting the following major components regularly: The gate stem for any material build-up or damage. The gate head for damage, distortion, etc. The gate seals for damage. The UHMW guides should be checked for damage or excessive material build-up that may obstruct its movement. NOTE: If unusual force or erratic operation is detected during manual gate operation, discontinue and conduct an inspection as to the cause. If the gate does not easily move to the set stop limits (stop nuts) visually check gate for debris or obstruction. A documented maintenance program should be developed that includes the following items: At least once every 3 months exercise each gate completely through one cycle, carefully checking for any abnormalities. At least once every 6 months, apply grease to all fittings and manual operators. Also, clean gate stem and apply grease. To obtain maximum performance, Golden Harvest, Inc. recommends the following maintenance procedures. First inspection should occur after twenty (20) cycles or two weeks, whichever comes first: PART: RECOMMENDED MAINTENANCE: RECOMMENDED SCHEDUE: GATES: Clean and operate. QUARTERLY OPERATING STEMS: Clean and lubricate. NOTE: To ensure proper operation and life of operating stems and lift nuts, it is VERY IMPORTANT THAT OPERATING STEMS ARE CLEANED AND GREASED EVERY SIX MONTHS. To help keep stem and lift nuts clean, the use of stem covers are recommended. Refer to Lubrication Chart for recommended greases. BIANNUALLY NON-GEARED OPERATORS: Lubricate all fittings on manual operators with a small amount of heavy duty grease. Refer to Lubrication Chart for recommended greases. BIANNUALLY Page 16

54 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Pre-Commission & Maintenance Lubrication Chart PART: OPERATING STEMS: RECOMMENDED GREASES: Lubriplate #630-2* Shell Alvania 2-EP* Mobilox 2-EP* Valvoline Val-Lith 2-EP* Chevron Ultra Duty Grease EP-2* Unocal Unoba EP-2* FOOD GRADE: Mobilgrease FM221 & FM222 Loctite Food Grade Extreme Pressure BIANNUALLY RECOMMENDED SCHEDULE: To ensure proper function and life of operating stems and lift nuts, it is VERY IMPORTANT THAT OPERATING STEMS ARE CLEANED AND GREASED EVERY SIX MONTHS. To help keep stem and lift nuts clean, the use of stem covers are recommended. NON-GEARED OPERATORS: Mobilgrease Special* Lubriplate #630-AA* Chevron R.M.P. Heavy Duty Grease EPNLGI2* Unocal Megaplex XD-2* BIANNUALLY All fittings on manual operators should be lubricated with a small amount of heavy duty grease. *These greases are not considered food grade; if food grade grease is required use any high quality food grade grease intended for use in potable water. Page 17

55 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Pre-Commission & Maintenance Slide Gate Troubleshooting PROBLEM: REASON: SOLUTION: HARD TO OPERATE: LEAKAGE: SIDES: LEAKAGE: BOTTOM OF GATE: LEAKAGE: TOP OF GATE: BOWING STEM: Misaligned stem, stem guide, and/or hoist: Warped or distorted guides: Foreign material in guide grooves: Dry or dirty stem threads: Gates with dual stems: Head operating unevenly: Warped or distorted guides: Foreign material in guide grooves: Foreign material on or around seal: Over tightening operator in closed position: Loose stem guides: Stem guides not installed per installation drawings: Excessive operator output: 1. Realign stem, stem guide, and hoist. Check and adjust alignment. 1. Loosen anchor bolt nuts. 2. Shim gate to true plane. 3. Place non-shrink grout between guides and wall. Remove foreign material from guide grooves. Clean threads and grease with recommended lubricant. 1. Disconnect couplings on interconnecting shaft. 2. Rotate hoist until gate head is level. 3. Reconnect couplings. 1. Loosen anchor bolts nuts. 2. Shim gate to true plane. 3. Place non-shrink grout between guides and wall. Remove foreign material from guide grooves. Remove foreign material - Limit operator force to 40 lbs of pull. - Make sure stop nut is properly installed. Tighten stem guide anchor bolts and stem guide bushing bolts. Install stem guides per drawings. Limit input to crank or hand wheel to 40lbs. Page 18

56 INSTALLATION, OPERATIONS & MAINTENANCE MANUAL: Warranty & Service Warranty & Service Warranty LIMITED WARRANTY Golden Harvest, Inc. warranties its gates against defects in material and workmanship for one (1) full year. Warranty period begins at date of owner acceptance or six (6) months after receipt of shipment, whichever is first. The warranty can only be enforced by the original purchaser. During the warranty period, the gates will be repaired or replaced at GOLDEN HARVEST, INC. S option and at no cost to the purchaser. Measure of damage is the original purchase price of the defective material only. Any claim for defects in material and/or workmanship shall be in writing and within ten (10) days of the inspected defect. No charges for labor or expense required to remove or replace defective material or for any consequential damages will be allowed. Authorized Parts and Service For service, parts, and/or warranty repair, please contact: Golden Harvest, Inc. PO Box 287 Burlington, WA Phone: (360) Fax: (360) NOTE: Please reference the Golden Harvest Job # and shop drawing number in all correspondence regarding this project. Spare Parts List & Replacement All products supplied by Golden Harvest, Inc. are designed to last indefinitely if properly maintained and operated, therefore, no spare parts are recommended. Should it become necessary to replace a part, refer to the enclosed installation or detail drawings for the appropriate part name or number and size. Replacements may be ordered direct from the factory or through your local representative. Always be prepared to give the Golden Harvest Job Number and installation drawing number. Page 19

57

58 3-20 2FII & Groundhog Bonded Seat Butterfly Valve Operation and Maintenance Manual Job Name: Contractor: Date: Document #:3202FIIGD Revision Date: 7/13/10

59 3-20 2FII & Groundhog Bonded Seat Butterfly Valve SAFETY MESSAGES All safety messages in the instructions are flagged with an exclamation symbol and the word Warning. These messages indicate procedures that must be followed exactly to avoid equipment damage, physical injury, or death. Safety labels on the product indicate hazards that can cause equipment damage, physical injury, or death. Personnel involved in the installation or maintenance of valves should be constantly alert to potential emission of pipeline material and take appropriate safety precautions. Always wear suitable protection when dealing with hazardous pipeline materials. PARTS WARNING Order parts from your local Henry Pratt sales representative or directly from Henry Pratt Company. When ordering parts, please include the serial number located on the valve tag. WARRANTY ISSUE Seller warrants that, at its option, it will repair, replace, or refund the unit purchase price of any products which are non-conforming due to Seller s material or workmanship during the warranty period. The warranty period shall be twelve (12) months for parts and eighteen (18) months for all other goods after date of shipment. This shall be Buyer s sole remedy. In order to maintain this product warranty, Buyer must give written notice to Seller s Field Service Supervisor prior to any work being performed. IN CONSIDERATION OF THE FOREGOING, SELLER EXCLUDES ALL OTHER EXPRESS OR IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Seller does not warrant water operated metallic cylinders against damage caused by corrosion, electrolysis or mineral deposits. In no event shall warranty include valve removal or reinstallation. WARNING Read all applicable directions and instructions prior to any maintenance, troubleshooting or installation Document #: 3202FIIGD Revision Date: 7/13/10 2

60 3-20 2FII & Groundhog Bonded Seat Butterfly Valve Table of Contents FUNCTIONAL DESCRIPTION 4 INSTALLATION 5 OPERATION 8 MAINTENANCE 9 TROUBLESHOOTING 10 CONTACTING PRATT 11 PRODUCT DRAWINGS 12 Document #: 3202FIIGD Revision Date: 7/13/10 3

61 3-20 2FII & Groundhog Bonded Seat Butterfly Valve FUNCTIONAL DESCRIPTION Round butterfly valve discs rotate 1/4 turns to provide tight shutoff in air or water pipelines. The valves can be used to regulate flow rate by positioning the disc between 15 and 90 degrees open. Manually Operated Valve Manually operated butterfly valves are powered with gear actuators, which convert multiple handwheel, chainwheel or nut input turns into 1/4 turn valve operation. The travel of the valve disc is limited by physical stops in the actuator housing. WARNING Forcing the handwheel, chainwheel or nut against the stops will not provide tighter shutoff of the valve and may damage the actuator. Only actuator adjustments will affect valve shutoff. Motor Operated Valves Motor operated butterfly valves are powered with gear actuators, which convert multiple motor input turns into 1/4 turn valve operation. The travel of the valve disc is limited by limit switches in the motor housing and physical stops in the actuator housing. Valve shutoff is affected by limit switch and physical stop settings. WARNING Improperly set limit switches and/or physical stops may damage the motor and/or actuator. Cylinder Operated Valves Hydraulically operated butterfly valves are powered with a gear box and double acting cylinder. The linear stroke of the cylinder is converted to 1/4 turn operation by the gear box. Auxiliary controls are provided to direct hydraulic power to the cylinder and to control the operating speed of the cylinder. Document #: 3202FIIGD Revision Date: 7/13/10 4

62 3-20 2FII & Groundhog Bonded Seat Butterfly Valve INSTALLATION GENERAL Valves are a significant component of any piping system. Failure due to faulty installation, improper operation or maintenance in such systems could result in damage, down time and costly repairs. In buried underground installations, problems or malfunctions can result in extensive, costly unearthing operations to correct the problem. Many problems with valves can be traced to improper installation, operation, or maintenance procedures. UNLOADING Inspect valves on receipt for damage in shipment and conformance with quantity and description in the shipping notice and order. Carefully unload all valves to the ground without dropping using fork trucks or slings under skids. Do not lift valves with slings or chain around operating shaft, actuator, or through waterway. Instead, lift valves with eye bolts or rods through flange holes. STORAGE Whenever practical, store valves indoors. If not, protect valves and actuators from weather and accumulation of water, dirt, rocks and debris. When valves fitted with power actuators and controls are stored, energize electric actuator or otherwise protect electrical control equipment to prevent corrosion of electrical contacts due to condensation resulting from temperature variation. Do not expose rubber seats to sunlight or ozone for any extended period. Valves should be stored with the valve disc or closure member slightly open. INSPECTION PRIOR TO INSTALLATION Make sure flange faces and joint sealing surfaces, body seats and disc seats are clean. Check bolting attaching actuator to valve for loosening in transit and handling. If loose, tighten firmly. Open and close valve to make sure it operates properly and that stops or limit switches are correctly set so that the valve seats fully. Check that valve rotation direction is correct and close valve before installing. INSTALLATION The following items must be performed during installation to ensure proper function. Carefully place valves into position avoiding contact or impact with other equipment, vault walls or trench walls. Document #: 3202FIIGD Revision Date: 7/13/10 5

63 3-20 2FII & Groundhog Bonded Seat Butterfly Valve Valves are to be installed in accordance with the General Arrangement Drawings furnished for the order. Foreign material in a valve can damage the rubber seat when valves are operated. Be sure valve interiors and adjacent piping are clear of foreign material prior to mating valve to pipe joint. Prepare pipe ends and install valves in accordance with the pipe manufacturer s instructions for the joint used. Do not deflect pipe/valve joint. Do not use valve and jack to pull pipe into alignment. In plant piping, install so as to minimize bending of valve connection with pipe loading. In case of wafer type butterfly valves, concentrically center the valve disc between the mating flanges. Make sure valve disc, when opened, will not contact pipe port. This is especially necessary on pipe with linings and when wafer valves are used. Check manufacturer for minimum pipe I.D. required for clearance. WARNING It is recommended that valves be installed into piping system in accordance with AWWA M-11 in order to prevent any undue piping stress, deflection or bending that may affect the performance of the valve. WARNING Valve disc without actuator may open or close at any time and cause injury to persons or damage to valve and other property. The shaft/disc clamping device when furnished is intended for temporary use during shipping, handling and valve installation only. Do not subject valve to flow conditions before actuator is mounted and tested for performance and clamping device is removed. Buried valves installed with valve boxes must be so installed that the valve box does not transmit shock or stress to the valve actuator as a result of shifting soil or traffic load. When valves are installed in vaults, the vault design must provide space for purposes of repair. The valve opening nut should be accessible from the top opening of the vault with a tee wrench. MECHANICAL JOINT INSTALLATION The successful operation of the mechanical joint requires that the plain end be centrally located in the bell and that adequate anchorage be provided where abrupt changes in direction and dead ends occur. The rubber gasket will seal more effectively if the surfaces with which it comes in contact are thoroughly cleaned (for example, with a wire brush) just prior to assembly in order to remove all loose rust or foreign material. Document #: 3202FIIGD Revision Date: 7/13/10 6

64 3-20 2FII & Groundhog Bonded Seat Butterfly Valve Lubrication and additional cleaning should be performed by brushing both the gasket and the plain end with soapy water or pipe lubricant just prior to slipping the gasket into the plain end and assembling the joint. TESTING When rubber seated valves are used to isolate sections of line for test, it is important to realize that these valves are designed or factory adjusted to hold rated pressure only. Test pressure may cause leakage past the rubber seat or damage to the valve. In order to prevent time lost in searching for leaks, it is recommended that excavations for buried valves not be back-filled until after hydrostatic pressure tests have been made. Seat leakage can occur due to foreign material in the line. If this occurs, open valve 5 10 degrees to get high velocity flushing action. Close and repeat several times to clear seats for tight shutoff. Seat leakage can occur due to rotational shift in position of the disc with relation to the body seat. Readjust closing stop in accordance with manufacturer s instructions. RECORDS Upon completion of installation, valve location, size, make, type, date of installation, number of turns to open, direction of opening and any other information deemed pertinent should be entered on the owner s permanent records. Document #: 3202FIIGD Revision Date: 7/13/10 7

65 3-20 2FII & Groundhog Bonded Seat Butterfly Valve OPERATION Do not permit use and operation of any valve at pressure above the rated pressure of the valve. Do not exceed 300 ft-lb input torque on actuators with wrench nuts, 200 lb. rim pull input torque for handwheels or chainwheels. If portable auxiliary actuators are used, size the actuator or use a torque limiting device to prevent application of torque exceeding 300 ft-lbs. If an oversize actuator with no means of limiting torque is used, stop the actuator before valve is fully opened or closed against stops and complete the operation manually. Be sure to check actuator directional switch against direction indicated on wrench nut, handwheel or records before applying opening and closing torque. If a valve is stuck in some intermediate position between open and closed, check first for jamming in the actuator. If nothing is found, the interference is inside the valve. In this case, do not attempt to force the disc open or closed since excessive torque in this position can severely damage internal parts. Contact the Pratt Service Department. MANUAL ACTUATOR FUNCTION AND USE: The manually operated butterfly valves are operated by rotating the handwheel, chainwheel, or nut. The actuator is equipped with gearing to convert the many turns into 1/4 turn operation. Inside actuator stops that limit the travel of the valve are pre-set at the factory. Forcing the handwheel, chainwheel, or nut will not cause the valve to shut off any tighter and may cause damage to the gearing. CYLINDER ACTUATOR FUNCTION AND USE: The cylinder operated butterfly valves are operated automatically by directing hydraulic pressure to either side of the power cylinder. Solenoid valves are used to direct the fluid to the cylinder ports based on electrical power signals. In cylinder actuators, the travel stops are in the cylinder so that full hydraulic pressure can be held on the cylinder at either end of travel. MOTOR ACTUATOR FUNCTION AND USE: The motor actuator is designed to open and close the valve through its one quarter turn of rotation. It contains gearing so that hundreds of turns of the motor or handwheel will slowly move the valve from open to close position or vice versa. Electrical controls are included in the motor actuator for local electrical control. The output motion of the actuator is limited to about 100 degrees of output rotation by mechanical stops in the gearing. These are factory set and should not need adjustment. The actual positioning of the valve disc will be done by limit switches in the motor actuator. The switches are also set at the factory but adjustment is sometimes required if the motor unit is installed on a separate mounting base or floorstand. Detailed procedures are given in the motor manual if adjustment is needed for the mechanical stops or the limit switches. The wiring and power requirements are given on wiring diagrams included in this instruction manual. Document #: 3202FIIGD Revision Date: 7/13/10 8

66 3-20 2FII & Groundhog Bonded Seat Butterfly Valve MAINTENANCE Maintenance of rubber-seated valves by owner is generally limited to actuators and shaft seals. In some instances, valve design permits field adjustment or replacement of rubber seats when leakage occurs. Unless the owner has skilled personnel and proper equipment, any major rework will require removal of the valve from the line. Depending on condition, valve may require return to the manufacturer. ANNUAL MAINTENANCE 1. Cycle valve to verify operation and no interference in line. 2. Close valve and check for leakage. If leakage is detected, check actuator stops to verify that disc is fully closed. If leakage persists, remove valve to inspect seat. A damaged seat requires valve to be returned to the factory for repair Check flange connections for leakage. Tighten bolts accordingly. Check top trunnion area for shaft leakage. If leakage is detected, replace valve packing. NOTE: 10 and larger valves have top and bottom packing. WARNING Removal of actuator from valve shaft will cause disc to rotate, striking persons or objects in the disc path, causing injury to persons and damage to valve. Block or lock disc before removing actuator. Typical maintenance would be shaft packing replacement and actuator adjustment. Seal leakage, broken parts and difficult operation should be discussed with Pratt s Service Department before valve repairs are attempted. Pratt Service Engineers are available to perform or supervise valve repairs in the field. Stop line flow and isolate from line pressure prior to performing any corrective maintenance. After completing repair, cycle valve through one complete operating cycle and after line pressure has been restored, inspect for leakage. Document #: 3202FIIGD Revision Date: 7/13/10 9

67 3-20 2FII & Groundhog Bonded Seat Butterfly Valve Troubleshooting Guide Problem Causes Remedies Leakage between valve and actuator Packing Leak First, cycle the valve several times. This should adjust the packing. If this fails, clean packing bore and replace packing. Bottom trunnion leaks Packing or gasket leak Replace bottom shaft packing, o-ring or gasket. Valve leaks when closed Disc not fully closed or past fully closed Adjust actuator closed position stop. Disc edge wear or damage Clean and/or repair disc edge. Rubber seat wear or damage Replace valve seat (Bonded seat vavles 20 or below must be returned to factory for repair). Chainwheel jams Poorly fitting chain Replace with correct chain. Valve hard to operate Foreign material in valve Remove obstructions Automatic valve does not actuate Corroded actuator parts Loose actuator No power source Improper Signal Burned out or impaired component Clean and grease actuator Apply Loctite or Omnifit locking compound and tighten bolts. Check incoming power source and replace fuses or rest pressure. Check actuating signal sequence. Check and repair or replace solenoids, motors and relay devices. Document #: 3202FIIGD Revision Date: 7/13/10 10

68 3-20 2FII & Groundhog Bonded Seat Butterfly Valve HOW TO CONTACT PRATT HOW TO ORDER PARTS: To order parts, contact our Parts Department: Write: - Henry Pratt Company 401 South Highland Avenue Aurora, IL Attn: Parts Manager Call - (630) Fax - (630) Please include valve serial number and description of part requested. HOW TO OBTAIN SERVICE: To obtain further information or secure field service, contact our Field Service Department: Write: - Henry Pratt Company 401 South Highland Avenue Aurora, IL Attn: Field Service Manager Call - (630) Fax - (630) Please include the following with your inquiry for service: Henry Pratt Order Number: Henry Pratt Item Number: Valve Serial Number: Type of Service Requested Document #: 3202FIIGD Revision Date: 7/13/10 11

69 3-20 2FII & Groundhog Bonded Seat Butterfly Valve Document #: 3202FIIGD Revision Date: 7/13/10 12