ERA12, 25, 50, 83, 125, 167, IMO-517 (7027) ISSUE 3/97 208 AND 250 ELECTRIC ACTUATORS INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS
2 Table of Contents 1 GENERAL........................................... 3 1.1 Introduction........................................... 3 1.2 Description........................................... 3 1.3 WARNING........................................... 3 1.4 CAUTION........................................... 3 1.5 General Technical Information.................................. 3 1.6 Operation........................................... 3 2 INSTALLATION....................................... 3 3 MANUAL OVERRIDE INSTRUCTIONS.......................... 4 4 CAM ADJUSTMENT INSTRUCTIONS........................... 4 4.1 General.............................................. 4 4.2 Valve Open Position: (Switch #2) (Upper Switch)........................ 4 4.3 Valve Closed Position: (Switch #1) (Lower Switch)....................... 4 5 OPTIONAL ACCESSORIES................................ 4 5.1 IMO s for Optional Accessories.................................. 4 6 OPERATING INSTRUCTIONS............................... 4 7 MAINTENANCE....................................... 5 7.1 General.............................................. 5 7.2 Replacement of a Motor Control Limit Switch.......................... 5 8 TROUBLE SHOOTING................................... 6 9 ASSEMBLY DRAWING/SPARE PARTS........................... 7 READ THESE INSTRUCTIONS FIRST! These instructions provide information about safe handling and operation of the actuator. If you require additional assistance, please contact your authorized Neles-Jamesbury distributor or representative. For address and phone number, call Neles-Jamesbury at (508) 852-0200. SAVE THESE INSTRUCTIONS! Subject to change without notice.
1 GENERAL 1.1 Introduction This instruction manual contains important information regarding the installation, operation and trouble shooting of Neles-Jamesbury s ERA Electric Actuator. Please read these instructions carefully and save them for future reference. 1.2 Description Neles-Jamesbury s ERA Series Electric Actuators are designed to provide reliable and efficient operation of 1/4 turn ball valves. The supported torque range for actuation is between 12 and 250 lb.-ft. The ERA Series is available in AC models with a 25% duty cycle and DC models with a 100% duty cycle. In addition, a variety of options and accessories are available. 2 INSTALLATION Mount these actuators by following actuator mounting instructions (AMI) contained in the linkage kit. To obtain copies of these, contact your nearest Neles-Jamesbury stocking distributor or representative or write: Neles-Jamesbury, Inc., Box 15004, 640 Lincoln St., Worcester, Massachusetts, 01615-0004 The AC terminal strip is shown in Figure 1. Power is connected to (1) common, (2) close and (3) open, using a two-way switch, (4) and (5) are wired to the normally open leg of the motor control limit switches as shown in Figure 2. 3 1.3 WARNING BEFORE REMOVING THE COVER, SHUT OFF ELECTRICAL POWER AND DISCONNECT ELECTRICAL CONNECTIONS. TO PREVENT IGNITION OF HAZARDOUS ATMOSPHERES, DISCONNECT SUPPLY CIRCUIT BEFORE OPENING UNIT. KEEP ASSEMBLY TIGHTLY CLOSED WHEN IN OPERATION. TO MAINTAIN THE HAZARDOUS LOCATION RATING OF THE ERD ACTUATOR, IT IS ESSENTIAL THAT THE MATING SURFACES OF FLANGES BE PROTECTED FROM NICKS AND SCRATCHES WHILE DISASSEMBLED. UPON REASSEMBLY, THERE MUST BE NO DIRT OR PARTICLES ON THE MATING SURFACES OR FLANGES. 1.4 CAUTION WHENEVER AN ACTUATOR IS REMOVED FROM THE VALVE AND THEN REMOUNTED, THE LIMIT SWITCH SETTINGS MUST BE CHECKED TO MAKE SURE THE VALVE IS MAKING THE PROPER TRAVEL. REFERENCE THIS IMO FOR CAM ADJUSTMENT INSTRUCTIONS. WHEN SERVICING A VALVE/ACTUATOR ASSEMBLY, THE BEST PRACTICE IS TO REMOVE THE ENTIRE ASSEMBLY FROM SERVICE. Figure 1 The DC terminal strip is shown in Figure 2. DC voltage actuators require a reversing of the power polarity. To drive the actuator CW (CLOSED), apply power so that Terminal 3 is positive and Terminal 1 is negative. To drive the actuator CCW (OPEN), apply power so that Terminal 1 is positive and Terminal 2 is negative. VAC 1.5 General Technical Information ERA Series AC voltage actuators use a split phase motor. All of the ERA series actuators have a manual override capability. It is important to verify that the actuator output torque is appropriate for the torque requirements of the valve and that the actuator duty cycle is appropriate for the intended application. 1.6 Operation A 25% duty cycle means that for every operating cycle that the actuator is ON (to open or close the valve), the actuator must be OFF for a time equal to three operating cycles. For example; if the operating cycle time is 5 seconds, for every operating cycle that the actuator is ON, it must be OFF for 15 seconds. Exceeding the actuators rated duty cycle may cause the thermal overload switch to temporarily shut off power to the motor. Continual overload may burn out the motor. VDC Operating temperature range is -40º F to 150º F, however, below +40º F the heater option is required. Figure 2
4 3 MANUAL OVERRIDE INSTRUCTIONS All of the ERA Series Electric Actuators have a manual override feature. To activate the override, depress the actuator override shaft, while depressed, rotate CW or CCW until the desired valve position has been reached. To re-engage the drive motor, release the override shaft. (If the override shaft fails to re-engage, rotate slightly in either direction.) Reference tag on cover for open and closed rotation, the output shaft may rotate in opposite direction of the override shaft. 4 CAM ADJUSTMENT INSTRUCTIONS 4.1 General There are NO TOOLS REQUIRED to adjust the cams. The cam is a friction fit to the shaft. Cams are adjusted by rotating the cam on the shaft by hand. To adjust for proper valve open and close positions, the cams for the motor control limit switches #1 and #2 must be moved as follows: A butterfly valve is fully open when the disc is perpendicular to the valve body flange. 4.3 Valve Closed Position: (Switch #1) (Lower Switch) If the valve needs to close more, (refer to the appropriate valve IMO for proper closed position) rotate the cam counterclockwise as viewed from the top of the motor. (See Figure 4) If less rotation is required, rotate the cam in the clockwise. Close Switch Package CW Open Switch Package CCW Figure 4 5 OPTIONAL ACCESSORIES 5.1 IMO s for Optional Accessories Please reference the following IMO s: IMO-521 For Potentiometer option. IMO-519 For Heater and Thermostat option. IMO-520 For Limit Switch option. IMO-522 For 4-20mA Feedback Option. 4.2 Valve Open Position: (Switch #2) (Upper Switch) Figure 3 If the valve needs to open more, rotate the cam clockwise as viewed from the top of the motor. (See Figure 3) If less valve rotation is required, then rotate the cam counterclockwise. For added ease in setting the cam there are three slots on the outside of each cam, these can be used to fine tune the final position of the cam lobe into the switch lever arm. The slots will accept the blade of a standard instrument type screw driver. The screw driver can be used as a lever arm to aid in moving the cam on the shaft. A ball valve is fully open when the hole in the ball is in the center of the valve body waterway. Any combination of options is possible. 6 OPERATING INSTRUCTIONS Normal operating voltages for electric actuators: 115 VAC, 230 VAC or as specified on the actuator. Refer to Product Bulletin A120-3 for torque output, duty cycle and operating speed. See wiring diagram for proper wiring. Operating temperature range is -40 F to +150 F, however, below +40 F the heater option is required.
5 MAINTENANCE General CAUTION Use the correct parts. Failure to do so could result in improper operation or personal injury. Contact your Neles- Jamesbury distributor for authentic Neles-Jamesbury replacement parts. 1. These actuators require no lubrication, and under normal operating conditions only periodic observation is needed to see that they are functioning properly. Maintenance or repair requirements other than those described herein, should be referred to Neles- Jamesbury for service. NOTE: ACactuators areequipped with thermal overload protection, if the actuator does not run, allow to cool before operating. 2. To remove the EU cover; remove the cover hold down screws. Extreme care must be taken to avoid any damage to mating faces of the cover flanges of EU actuators since scratches or nicks would violate hazardous location ratings. 3. To remove the capacitor, unplug the connector from the basic board and remove the capacitor from the wire tie. Remove two brake mounting screws. Disconnect cap leads from piggyback terminal (brake solenoid). 4. When reinstalling the cover, care must be taken not to allow the cover to cock in relation to the base. Care must be taken during reassembly that no particles or dirt are on the mating surfaces of flanges. Replace the cover and cover hold down screws. Tighten one screw partially, then another on the opposite side of the flange, repeating this procedure until all screws are partially tightened. Repeat this procedure to fully tighten screws. Replacement of a Motor Control Limit Switches To remove a limit switch package that is not working, pry the housing off of the mounting bracket or limit switch housing using a small instrument type screw driver. Slide the switch package up and off of the cam/gear shaft and discard. In most cases the switch package will be damaged during removal of the limit switch from the housing. A new housing is supplied with every limit switch. Each limit switch package is made up of: a limit switch housing, a cam, a prewired 5 AMP limit switch with a female connector. To install the switch package onto the top of an existing motor control limit switch, follow the steps as outlined below (See Figure 5): The standard convention for installing limit switches in Neles-Jamesbury products is the lower switch will control or indicate the close position, and the upper switch will control or indicate the open position. (1) Slide a fully assembled switch package over the cam/gear shaft and snap the locking legs into the holes on top of the switch housing or switch mounting bracket. The lower switch (the switch installed first) is used to control the CLOSE position of the actuator. (2) Repeat the procedure for the next switch. This switch would be used for control of the actuator OPEN position. (3) Attach the lead wire with the connector into the mating connector on the basic board. The connectors on the basic board are labeled OPEN and CLOSE. (4) Cam adjustments are made the same as in the Cam Adjustment section of this IMO. Switch Housing Cam/Gear Shaft Cam Locking Legs Switch Mounting Bracket Figure 5
6 8 TROUBLE SHOOTING Problem Try This 1. Motor will not run. 1. Check incoming voltage as it enters the terminal block #1 and #2 or #3 terminals. 2. Check that all plug-in connectors are tight. 3. Review the cam adjustment section to insure that the cams are set correctly. 4. Visually inspect basic board and capacitor for discoloration (burnt). (If present the board and/or capacitor must be replaced.) 5. Allow the motor to cool. 6. If these steps fail to correct or identify the problem, contact the Neles-Jamesbury Distributor or Representative in your area. 2. Motor runs, output drive will not turn. 1. Check that the manual override is fully engaged. Refer to IMO s listed below for OPTION Trouble Shooting: IMO-521 For Potentiometer option. IMO-519 For Heater and Thermostat option. IMO-520 For Limit Switch option. IMO-522 For 4-20mA Feedback Option.
7 9 ASSEMBLY DRAWING/SPARE PARTS ERA Spare Parts Item No. 1 2 3 4 5 6 7 8 Part Name Cover Assembly Cover Screws (8) O-ring Limit Switch Assembly Standard Basic Board Capacitor Assembly Override Shaft Brake Assembly
8 NOTES Jamesbury Inc. 640 Lincoln Street Box 15004 Worcester, Massachusetts 01615-0004 USA Tel: 508-852-0200 Fax: 508-852-8172 Internet: www.jamesbury.com Neles Controls Group A member of Rauma Corporation