keystone 777/778 electric actuator installation and maintenance ...€¦ · 4 n.f.b cs f ls1 ls2 12...

Keystone 777/778 electric actuatorInstallatIon and maIntenance InstructIons

Before installation or maintenance, these instructions must be fully read and understood

VCIoM-03138-en 16/04

IntroduCtIon

the Keystone F77x electric actuator range is available in 3 mounting options:• F777 – Keystone shaft and flange –

imperial threading• F777M – Keystone shaft and flange -

Metric threading• F778 – Keystone shaft / ISO flange –

Metric threading

the actuators offer a torque range of 35 to 4500 Nm. the product design is based on an epi-cyclic gearing, which provides a smooth running, dependable and robust drive system. all models have a visual position indicator and a manual override. the manual operation is continuously engaged, and requires no clutch mechanism. The models F77x-003 and F77x-005 have a manual override which requires a standard 8 mm wrench (not included). All other models are operated with a hand wheel.

the actuator is available in 12 V Dc, 24 V Dc, 24 V ac, 120 V ac single phase, 240 V ac single phase, and 400 V AC 3-phase versions. Please make sure that the correct voltage is ordered for your specific application.

Keystone F77x actuators are designed to be mounted to quarter turn valves either directly or using the correct mounting brackets/adapter kit.

the actuator drives the valve by means of a bored/double keyed female shaft output, or female double D conforming to the Keystone standard. a comprehensive range of adaptors is available for the various Keystone valves.

adjustable travel stops are provided for each end of travel to ensure that the actuator will open and close the valve precisely.

reCeIVIng/InspeCtIon

carefully inspect for any shipping damage. Damage to the shipping carton is usually a good indication for rough handling. report all damage immediately to the freight carrier and your emerson sales contact.

after unpacking the product and information packet, please take care to save the shipping carton and any packing material in case of product return or replacement. Verify that the item on the packing list or bill of lading is the same as your own documentation. If there is any discrepancy, please contact with the seller.

storage

if the actuator cannot be installed immediately, store it in a dry place, it must be protected from excess moisture, dust, and weather influences, until you are ready to connect the wiring.if the actuator has to be installed but cannot be wired immediately, please don’t remove the plastic transit cable entry plugs. When the actuator is ready to be wired, it is mandatory to replace the plastic transit plugs with water-proof plugs with suitable IP protection.

LubrICatIon

the gear train is permanently lubricated, and doesn’t require any further maintenance.

www.valves.emerson.com © 2017 Emerson. All rights reserved.

2


InstaLLatIon safety InstruCtIons:

1. Please make sure that the valve is fixed and that the actuator is firmly mounted onto the valve, ether direct or by using a mounting kit.

2. Check for correct voltage prior to wiring.3. Mount the wiring using the enclosed wiring

diagrams.4. use sealant to seal conduit connections to

prevent dust or water ingress.5. the electric actuator should be installed at

a maximum angle of 180 degrees. Do not install upside down or over 180 degrees.

6. Do not install this actuator in or near explosion hazardous areas.

7. actuators should be placed at a clean and dry place for storage, and protected with carton. large temperature changes and vibration should be avoided.

8. electronic components can be damaged by static electricity. Please avoid static electricity by touching any PcB components with metal tools or bare hands.

9. Please make sure to connect the ground wire to the PE connection inside the electric actuator.

WarnIng1Always turn off the power before servicing or any maintenance purposes.

WarnIng2When using a 3-phase on/off actuator please use the manual override to turn the actuator to 45 degrees open position before applying any power. If the direction of operation is the opposite direction than intended, please change any 2 wires labelled U, V, or W.

WarnIng3When applying power to the actuator with the cover removed, there is a risk of electrical shock or even death. For safety reasons the cover should always be mounted when power is applied to the actuator.

InstaLLatIon

1. Before mounting the actuator, please verify that the valve torque requirement is less than the output torque of the actuator.

2. check if the actuator output shaft and flange fits to the valve stem, and use appropriate mounting kit or adaptor to connect if it does not match.

3. Determine that actuator position (open or closed), matches with the valve position. use the manual override to change position if necessary.

4. Place actuator on top of the valve, and make sure it fits correctly. Tighten all screws and nuts.

7. Wire the actuator using the following wiring diagrams, or use the wiring diagram inside the cover.

8. For the 3-phase on/off actuator, please use the manual override to turn the actuator to 45 degrees open position before applying any power. If the direction of operation is the opposite direction than intended, please change any 2 wires labelled U, V, or W.

9. Mount the cover to the actuator and provide a control signal to the open command terminal.

10. Verify that the actuator opens the valve completely.

11. Switch power from open to close command terminal.

12. Verify that the actuator closes the valve completely.

note1: the actuator is calibrated for 90 degree operation in the factory. if adjustments for the full open or close position are required, please check the routine for adjusting the travel stops.

note2: For modulating applications, please check the configuration routine for the modulating module.

duty CyCLe

the duty cycle determines the starting frequency to which the actuator can be operated, and is defined with the formula:

Duty Cycle = Stroke Time / (Stroke time + rest time) × 100%

Based on this formula the rest time for an actuator with a 15 seconds stroke and 30% duty cycle is 35 seconds. this can be calculated by rewriting the formula into:

Rest Time = Stroke Time × (1- duty cycle) / duty cycle

example based on stroke time of 15 seconds:- 30% duty cycle: 15 × [ ( 1 – 30%) / 30% ] = 35.

The rest time will be 35 seconds.- 75% duty cycle: 15 × [ ( 1 – 75%) / 75% ] = 5.

The rest time will be 5 seconds.if the duty cycle is higher, the rest is shortened, and the starting frequency can be higher.

5. Check with the manual operator that the valve and actuator operate correctly in both open and close direction.

6. Check if the power is switched off and remove actuator cover. Please be aware that while the cover is lifted a vacuum is created. For your comfort there is a special pocket for a flathead screwdriver to support the lifting.

3


abbreviations used:MC1 and MC2 electromagnetic contactorNFB No fuse breakerC.S. Control switchc capacitorN Neutrall live WirePe Protective eartho.l. Over-load relayH HeaterLS Limit switchTS Torque switchSwitch(1) local/remote controlSwitch(2) Open/Stop/Close selectLS1 Limit switch for openLS2 Limit switch for closeLS3 Optional limit switchLS4 Optional limit switch

WIrIng dIagraMs

WIrIng dIagraM oVerVIeWVoltage

Model 12 V dC 24 V dC 12 V aC 24 V aC 120 V aC 240 V aCF77x-003 diagram 1 diagram 3 diagram 5F77x-005 F77x-008 F77x-013 F77x-014 F77x-035 F77x-036 diagram 2 diagram 4 diagram 6F77x-044 F77x-045 F77x-057 F77x-058 F77x-088 F77x-089 F77x-130 F77x-180 F77x-181 F77x-220 F77x-221 F77x-265 F77x-310 F77x-400

4

N.F.B

CS

F

LS1 LS2

12 V / 24 V Dc

leD 1

leD 2

H


WIrIng dIagraM 1 on/off aCtuator

12 V DC - F77x-003 to F77x-00524 V DC - F77x-003 to F77x-005

notes1. “+” connects to #7; “-“ connects to #12. “+” connects to #3 for “open”; “+“ connects to #4 for “close”3. Max. current for LS3 and LS4 is 3A

power supply12 V / 24 V Dc

LS3(option)

LS4(option)

Fully open lamp

Fully close lamp

For customer connecting reference

actuator

LS - Limit switchH - Heater (option)

Fully open

Fully close

a to B

a to e

5

N.F.B

CS

H

LS1

TS1

LS2

12 V / 24 V Dc

leD 1 leD 2

F


12 V DC - F77x-008 to F77x-05824 V DC - F77x-008 to F77x-310

notes1. “+” connects to #7; “-“ connects to #12. “+” connects to #3 for “open”; “+“ connects to #4 for “close”3. Max. current for LS3 and LS4 is 5A

power supply12 V / 24 V Dc

LS3(option)

LS4(option)TS2

(option)

Fully open lamp

Fully close lamp


actuator

H - Heater (option)LS - Limit switchTS - Torque switch (option)

Fully open

Fully close

a to c

D to F


(option)

6

N.F.B

CS

F

H

LS1 LS2

12 V / 24 V Dc

leD 1

leD 2


12 V AC - F77x-003 to F77x-00524 V AC - F77x-003 to F77x-005

notes1. “L” connects to #7; “N“ connects to #12. “L” connects to #3 for “open”; “L“ connects to #4 for “close”3. Max. current for LS3 and LS4 is 3A

power supply12 V / 24 V ac

LS3(option)

LS4(option)

Fully open lamp

Fully close lamp


actuator


Fully open

Fully close

a to B

a to e


7

N.F.B

CS

F

H

LS1 LS2

12 V / 24 V Dc

leD 1 leD 2

TS1





LS3(option)

LS4(option)

Fully open lamp

Fully close lamp


actuator


Fully open

Fully close

a to c

D to F


TS2(option)

(option)

8

o.l

N.F.B

CS

c

LS1 LS2

110 V / 220 V ac

H





LS3(option)

LS4(option)

Fully open lamp

Fully close lamp



Fully open

Fully close

a to B

a to e


actuator

9

N.F.B

CS

c

H

LS1 LS2

110 V / 220 V ac

o.l

TS1





LS3(option)

LS4(option)

Fully open lamp

Fully close lamp



Fully open

Fully close

a to c

D to F


actuator

TS2(option)(option)

10

tc4tc3tc2tc1

LS4LS3LS2LS1


LIMIt sWItCh and CaM settIng

The cams and switches are set to control the open and closed position of the valve. the position is set to stop the travel of the actuator when the travel cams activate the limit switch. Standard is two limit switches (LS1 and LS2), LS1 for open, LS2 for closed. LS1 and LS2 limit the maximum range by disabling the electric motor. LS3 and LS4 are optional, and they provide potential free contact to other equipment to confirm that the valve has reached the fully open or fully closed position.

The travel cams can be adjusted with a 2.5 mm allen key. the cams are preset at the factory for 0 and 90 degree operation. When additional adjustments are needed, follow steps described below:

note:If LS3 and LS4 are fitted, please set them to trip prior to LS1 and LS2 in order to avoid incorrect position feedback.

note:For modulating units please refer to the specific product literature.

to set the open position:a. Turn power off.b. use manual override to turn valve to the

fully open position.c. Remove cover and loosen the M5 set screw

on the TC1 with a 2.5 mm Allen Key.d. Rotate cam(TC1) counter clockwise to

contact with switch.e. Slowly rotate cam(TC1) clockwise until a

light click is heard.f. Securely tighten the M5 set screw and

apply power to check the travel position. If the position is not correct, please repeat steps a to f.

g. after the adjustment is completed, check again the M5 set screw is securely tightened.

to set the close position:a. Turn power off.b. use manual override to turn valve to the

fully-closed position.c. Loosen the M5 set screw on the TC2 with a

2.5 mm allen key.d. Rotate cam(TC2) clockwise to contact with

switch.e. Slowly rotate cam(TC2) counter clockwise

until a light click is heard.f. Securely tighten the set screw and apply

power to check the traveling position. If the position is not correct, please repeat steps a to f.


Shaft

Set screw M5

F77x-003 + F77x-005

11

tc4tc3tc2tc1

LS4LS3LS2LS1


Shaft

Set screw M5

F77x-008 to F77x-400

to set the open position:a. Turn power off and loosen both

mechanical stops.b. use manual override to turn valve to the

fully open position.c. Remove cover and loosen the M5 set screw

on the TC1 with a 2.5mm Allen key.d. Rotate cam (TC1) clockwise to contact

with switch.e. Slowly rotate cam (TC1) counter clockwise

until a light click is heard.f. Securely tighten the set screw and apply

power to check the travel position. If the position is not correct, please repeat steps a to f.


to set the close position:a. Turn power off.b. use manual override to turn valve to the

fully closed position.c. Loosen the M5 set screw on the TC2 with a

2.5mm allen key.d. Rotate cam (TC2) counter clockwise to

contact with switch.e. Slowly rotate cam (TC2) clockwise until a

light click is heard.f. Securely tighten the set screw and apply

power to check the travel position. If the position is not correct, please repeat steps a to f.


h. Tighten both mechanical stops and follow travel stop instructions.

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MeChanICaL traVeL stops

WarnIngMechanical travels stops should only be used during manual operation. If the travel limit switch is set incorrectly and the motorised actuator action is limited by the mechanical travel stop, the actuator life will be significantly reduced and will fail prematurely.

the mechanical stops are factory set, though in some cases adjustment may be required once the actuator is fitted to a valve and travel switches and cams have been adjusted.

note:For modulating units please refer to the specific product literature.

For on/off motorised end of travel adjustment please refer to “Limit switch and cam setting”.

for manual operation of on/off unitsa. Turn power off.b. Loosen locknut and unwind it a few turns.c. use manual override to turn the actuator to

desire limit position.d. Tighten the mechanical stop screw until it

reaches the shaft, and reverse one cycle.e. tighten locknut.f. Check that the electrical limit switches

are still engaged prior to reaching the mechanical travel stop.

open close

© 2017 Emerson. All rights reserved.

keystone 777/778 electric actuator installation and maintenance ...€¦ · 4 n.f.b cs f ls1 ls2 12...

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