GUIDELINES FOR MOUNTING & SETTING ELECTRIC ACTUATOR ON VALVE

KIRLOSKAR BROTHERS LIMITED MANUFACTURING UNIT, KONDHAPURI (PUNE)

GUIDELINES FOR MOUNTING & SETTING ELECTRIC ACTUATOR ON VALVE

KIRLOSKAR BROTHERS LIMITED

MANUFACTURING UNIT, KONDHAPURI (PUNE)

MOUNTING & SETTING ELECTRIC ACTUATOR ON VALVE Note: Before wiring and limit switch setting, please study the Instruction Manual(s) supplied by the Electric Actuator manufacturer. Initial trials of the Electric Actuators are taken at our factory, with their mounting on with the valves. For safe transport of the Electric Actuators, we dispatch the Electric Actuators alongwith the valves, but in separate case(s). Therefore, assembly of the Electric Actuators with the valves, followed by its due setting is necessary at site. Setting of the Electric Actuator includes electrical wiring & limit switch setting. 1. Actuator Mounting & Setting 1.1 Mount the electric actuator on Valve Stool / Gearbox actuator adapters flange (as appropriate) and fasten the actuator with fasteners provided.

1.1.1 Mounting of the actuator having E-base (Bore with Key-way) a. Ensure key is fitted on valve keyed spindle / gear box pinion shaft. b. Engage the Valve Spindle keyed end (in case of direct mounted actuators without intermediate gear box on valve) / Gear Box pinion shaft in the drive sleeve of the electric actuator. c. Match the tapped holes on actuator base with Stool provided on valve / actuator adapter flange on the gear box. d. Fasten the actuator base & the stool on valve / actuator adapter flange with the fasteners provided. 1.1.2 Direct Mounting of the actuator having A-base (Thrust type base with threaded sleeve, on Rising Spindle type Sluice / Gate Valve) When the Electric Actuator is to be directly mounted on the Rising Spindle type Sluice Valve / Gate Valve, follow the steps as below: a. Engage the Manual Operation lever of electric actuator. b. Bring the actuator base having internal threads in drive sleeve, near to the valve spindle threads, and take guide of valve spindle threads into the internal threads provided in actuator drive sleeve. Hold the actuator for its balancing and rotate the actuator hand wheel in 'ANTI CLOCKWISE' direction, so that the valve spindle goes on engaging into the actuator drive sleeve and the actuator moves towards the mounting flange provided on the valve. Continue this till the base of actuator matches the actuator mounting flange provided on the valve. b. Match the tapped holes on the actuator base with the holes provided on the stool / actuator adapter flange provided on the gear box and fasten the same with the fasteners provided.

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c. 1.2 1.3

Continue to rotate actuator hand wheel in ANTICLOCKWISE direction, so that valve spindle rises and open the valve.

Rotate the actuator hand wheel to partly open the valve, so that its disc / wedge / gate reaches intermediate position. Carry out electric terminal wiring of the actuator, as per the information / instructions given in the individual Electric Actuator manual, by the Actuator manufacturer. Ensure that the proper earthing is made for the actuator body. Read the actuator & its motor name plate details carefully. Supply the rated power to the actuator to receiving terminals of the actuator.

1.4 1.5 1.6 1.7

Checking correctness of phase of power supply: Operate the switch 'OPEN' and the valve should start Opening. (In Electric mode of operation, the 'Manual' operation lever in the actuator automatically disengages.) In case after switching on the OPEN' button, if the valve starts Closing, switch-off the incoming power supply immediately. Interchange two of three phases of the incoming power supply. Again switch on the 'OPEN' button, and ensure that the valve starts Opening. This test is to set correct Direction of Rotation of the actuator, to Open / Close the valve w.r.t. the sequence of the supplied power phases. Note: During this test, DO NOT fully open or fully close the valve with electric actuator.

1.8

Setting of Actuator Travel Limit Switches in 'OPEN' and 'CLOSE' positions: Note: This is very important setting for the Actuator Operated Valves and the setting must be done very carefully and correctly for avoiding any trouble / damages of valve / actuator. 1.8.1 Once again switch on 'OPEN' button of the actuator. Cut-off the power supply as the valve disc / wedge / gate is near to OPEN position. Engage the Manual Operation Lever in the actuator and fully Open the valve using the hand wheel provided on the actuator. Set the 'OPEN' travel limit switch in the actuator at the valve 'Open' position. 1.8.2 Press the 'CLOSE' button on the actuator. The Manual operation lever will again disengage, and valve will start Closing. When the valve disc / wedge / gate nears the 'Close' position, switch off the actuator. Close the valve fully using the hand wheel provided on the actuator, after engaging the Manual Operation lever. Set the 'CLOSE' travel limit switch in the actuator at the valve 'CLOSE' position.

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This completes the Travel Limit Switch setting of the actuators. 1.9 It is strongly recommended that electric operated valve should be opened or closed with use of Open or Close Travel Limit Switches only. Torque Limit switches provided in the actuators are to be used as stand by in case the valve requires excessive torque at open / close / intermediate position. In such case, the torque limit switches will stop the valve.

2.

OPERATION OF THE VALVE WITH ELECTRIC ACTUATOR 2.1 When the actuator is supplied with correct sequence of phases of the power, the valve will Open / Close corresponding to the appropriate switch operation. The travel limit switches in the actuator will stop the motor at the end of the valve travel. In case the movement of valve disc / wedge / gate is mechanically obstructed by any other reason, the torque limit switch will operate and stop the valve to safeguard the motor and driving mechanism against damage. The valve can also be operated 'Manually' by engaging the manual operation lever provided in the actuator. As soon as the actuator is operated electrically, the hand wheel will get automatically disengaged. In case the motor operation stops due to operation of torque switch or during the manual operation the hand wheel stops before the indicator shows that the disc / wedge / gate has reached its full extent of travel; do not use extension levers on the hand wheel. In such case,inspect the valve and gearbox internally to remove such obstructionor identify & remove cause of stoppage of travel. Normally the electric actuators supplied for the valves are meant for short time on-off duty. Actuator motor is rated for 15 minutes operation time maximum and 60 starts per hour. In case the requirement of customer is special than this, and intimated to KBL in purchase order specifications, we can arrange for special motor alongwith the actuator.

2.2 2.3

2.4

2.5

2.6

In case if you need additional information or help, please contact: Customer Service & Support Sector Kirloskar Brothers Limited Chintan, Mukund Nagar, Pune 411 037, (India) Phone: +91 20 2444 0770 Fax: +91 20 24270879 E-mail: kblin@kbl.co.in

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