USER INSTRUCTIONS. Limitorque PT Series Worm Gear Operator. Installation Operation Maintenance. Experience In Motion

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1 USER INSTRUCTIONS Limitorque PT Series Worm Gear Operator FCD LMAIM /05 (Replaces ) Installation Operation Maintenance Experience In Motion

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3 Contents 1 Introduction 7 2 Inspection, Installation, and Mounting Procedures 9 3 Lubrication 13 4 Disassembly and Reassembly Instructions for the PT12 and PT Disassembly and Reassembly Instructions for PT18 through Disassembly and Reassembly Instructions for PT250 through PT Disassembly and Reassembly Instructions for PTC32 through PT150 Spur Gear Attachments (SGA) 35 8 Disassembly and Reassembly Instructions for PT250 through PT1000 Spur Gear Attachments (SGA) 37 9 How to Order Parts 43 3

4 PT Series An optimized worm gear drive specifically designed for motorized operation Figure 1 Typical PT Exploded View Tapered Roller Bearing Closed Endcap Piloted Cast Iron Base One-Piece Rolled Worm/Shaft Tapered Roller Bearing Enclosed Stops Open Endcap Jam Screw One-Piece Cast Iron Housing Stop Screw Stop Plate (Gasketed) Anatomy of the PT Series The PT has been optimized to provide user satisfaction using both common worm gear operator technology and state-of-the-art methodology. Designed using FEA optimization, the PT utilizes a one-piece rolled worm/shaft an economical yet highly efficient process. Care was taken to eliminate unnecessary parts and standardize on parts used across the nine torque ranges. Available with both ductile iron and bronze alloy worm gears (AWWA and modulating applications), the PT can be installed in the harshest of environments to -50 C where necessary. Whether purchased for manual applications or coupled with Limitorque electric actuators, the PT will provide years of trouble-free and reliable operation. 4

5 General Specifications Operator/SGA Ratio Efficiencies Output Torque Rating Input Torque for Output Torque Rating One-Time Input Torque (motorized) Start & Run ft-lb N m ft-lb N m ft-lb N m PTA/C , PTA/C ,600 2, PTA ,800 2, PTA ,200 4, PTA-32/S ,200 4, PTC ,200 4, PTC-32/S ,200 4, PTA ,000 10, PTA-65/S ,000 10, PTA-65/S ,000 10, PTC ,000 10, PTC-65/S ,000 10, PTC-65/S ,000 10, PTA ,000 16, ,530 2,075 PTA/C-120/S ,000 16, PTA/C-120/S ,000 16, PTA/C-120/S ,000 16, PTA ,000 20, ,130 1,530 2,075 PTA/C-150/S ,000 20, PTA/C-150/S ,000 20, PTA/C-150/S ,000 20, PTA ,000 48,816 1,563 2,118 2,604 3,531 PTA/C-250/S ,000 48, PTA/C-250/S18 1, ,000 48, PTA/C-500/S ,000 82,716 1,594 2,160 2,609 3,538 PTA/C-500/S ,000 82, ,094 1,320 1,789 PTA/C-500/S ,000 82, PTA/C-500/S20.9 1, ,000 82, PTA/C-1000/S , ,060 1,176 1,594 1,741 2,360 PTA/C-1000/S24 1, , ,

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7 1 Introduction 1.1 Purpose This installation and maintenance manual explains how to install and maintain the PT operator. Information on installation, disassembly, reassembly, lubrication, and spare parts is provided. 1.2 User Safety Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the equipment. The user must read and be familiar with these instructions before attempting installation, operation, or maintenance. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, voiding of the warranty, or operational difficulty. Safety notices are presented in this manual in three forms: c WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices could result in personal injury or death. a CAUTION: Directs the user s attention to general precautions that, if not followed, could result in personal injury and/or equipment damage. NOTE: Highlights information critical to the user s understanding of the operator s installation and operation. 7

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9 2 Inspection, Installation, and Mounting Procedures 2.1 Initial Inspection and Storage Instructions c WARNING: Read this installation and maintenance manual carefully and completely before attempting to store the operator. If an electric operator is attached to the PT manual operator, be aware of the electrical hazards. Consult the electric operator installation and maintenance manual for guidance. 2.2 Inspection and Recording Upon receipt of the operator, inspect the condition of the equipment, and record nameplate information. 1. Carefully remove operator from shipping carton or skid. Thoroughly examine the equipment for any physical damage that may have occurred during shipment. If damaged, immediately report the damage to the transport company. 2. A nameplate is attached to each operator with the following information: Operator size Operator ratio Flowserve Order Number Operator serial number Record this information for future reference, i.e., ordering parts, obtaining further information. 9

10 2.3 Storage Procedure NOTE: The following is the recommended storage procedure to retain maximum product integrity during storage. Failure to comply with recommended procedure will void the warranty. Storage (less than 1 year preferred) Store operators on wooden skids to protect the machined mounting flange. Place the wooden skids containing the operators in a clean, dry, protected warehouse. If the operators must be stored outside, they must be covered in polyethylene protection with silica gel crystals to absorb moisture. If an electric operator is attached to the PT, refer to the storage procedures in its respective manual for appropriate storage procedures. Rotate input shafts every three months to mix the lubricant. 2.4 General Mounting Instructions a CAUTION: To avoid the potential for disengaging the worm gear segment, ensure that the pointer cap pointer is oriented to the mid-point of the 90 valve travel. Full stroke rotation of the pointer should not move past the corresponding Open or Close ID marks on the housing cover. 1. Place valve in full closed position. 2. Remove pointer cap from PT operator. Refer to Section 5.1 for removal/replacement instructions for the pointer cap. 3. PT12/14/32/C32/120/150 Slide splined adapter on valve shaft and insert key, or utilize a setscrew to eliminate movement of splined adapter on the valve shaft. 4. Mount operator on valve and bolt securely. Confirm operator stop alignment before engaging splines. 5. PTA32/65 Remove the splined adapter from the PT and mount the PT to the valve. Align the valve shaft with the bore and key of the splined adapter. Using either the PT or electric actuator handwheel, rotate the PT drive sleeve to align the drive sleeve s splines with the splined adapter. Slide the splined adapter down onto the valve stem and into the drive sleeve of the PT. 6. PT250 through 1000 Torque nuts are bolted into place from the top of the PT. Remove the torque nut and align the valve drive stem with the bore and key of the torque nut. Slide the torque nut onto the valve stem. Using either the PT or electric actuator handwheel, rotate the PT drive sleeve to align the drive sleeve s threaded holes with the torque nut s through holes. Bolt the torque nut into position. Preload property class 8.8 fasteners, securing torque nut as follows at installation. (Preload is not set at factory.) 10 Unit Size ft-lb N m PT PT PT1000 1,200 1,620 Fasteners that are stainless steel or other than property class 8.8 require different preload torque than listed above. Consult factory.

11 7. Turn PT operator input shaft to full closed position. The stops are preset for 90 travel. Be certain of correct direction of rotation. 8. For standard stop setting instructions for the PT18 through 150, see Section 5.3, Adjustment, Removal and Replacement of Stops Screws. 9. For standard stop setting instructions for the PT250 through 1000, see Section 6.3, Adjustment, Removal and Replacement of Adjustable Stops. 11

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13 3 Lubrication The Limitorque PT operators are shipped with Conoco Dynalife-L-EP0, Lithium base grease in the operator. This lubricant is suitable for a temperature range of 0 F to 225 F (-18 C to 107 C). Alternative lubricants are: Triton ELL Lithium complex grease from -40 C to 88 C (-40 F to 191 F ) Troco EP-00 Calcium complex grease from -29 C to 121 C (-20 F to 250 F) (early shipments of PTs contain this grease) Mobil SHC632 synthetic oil from -30 C to 85 C (-22 F to 185 F) Standard options for arctic duty (-50 C/-58 F to 50 C) with Petro-Canada Traxon SYN75W90. The lubricant should be checked every 18 months for manual operators. a CAUTION: Do not add a different lubricant to a Limitorque operator unless it is of the same soap base as the existing lubricant or you have received the approval of the lubricant manufacturer. 13

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15 4 Disassembly and Reassembly Instructions for the PT12 and PT14 Item Component 1 Cover/input flange 17 2 Gearcase 4 3 Wormshaft oil seal 4 Quadrant Wormshaft 6 Wormshaft bearings Indicator cap 8 Nameplate 9 Cover screws 10 Stop screws Locknuts 12 Bearing thrust washers 13 Thrust bearings Indicator O-ring 15 Quadrant O-ring 8 16 Dowels 17 Locknut protection cap 18 Protection sleeve 19 Bearing 20 Key Circlip 22 Sealing ring Protection sleeve retainer Please contact Flowserve Limitorque factory at for assistance with the PT12 and

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17 5 Disassembly and Reassembly Instructions for PT18 through 150 Figure 5.1 PTA32 17

18 5.1 Removal and Replacement of Pointer Cap NOTE: Images in this section show a PTA18/32 unit but all are typical through the PT150. Remove/replace pointer cap and gasket by loosening the M4x10 hex head cap screws. Figure 5.2 Pointer cap removal Figure 5.3 Pointer cap, M4 screws and gasket 5.2 Removal and Replacement of Baseplate Remove/replace bottom mounting plate by loosening/tightening the M10x35 socket head cap screws. Figure 5.4 Bottom mounting plate shown 18

19 a. Rotate plate slightly to lift from unit. Use jack-bolt holes if necessary. Figure 5.5 Bottom plate removed b. When reinstalling the bottom plate, ensure both O-rings have been replaced. Lubricate the O-rings for easier installation. Figure 5.6 Bottom plate and O-rings c. Tighten the socket head cap screws to the recommended torques in Table 5.1. Figure 5.7 Torquing bolts that attach baseplate Table 5.1 Baseplate Torque Values Operator Size Bolt Size ft-lb N m PT18/32 M PTC32 M PTA32/65 M PTA/C120 M PTA/C150 M

20 5.3 Adjustment, Removal and Replacement of Stop Screws Remove/replace adjustable stops by removing the M4x10 hex head cap screws that retain the stop plate and stop plate gasket. Figure 5.8 Removal of stop plate screws a. Remove the jam screw. Jam screws locate and retain the stop screws once the worm quadrant positions have been set for the valve. Figure 5.9 Removal of jam screws b. Locate the worm quadrant positions by adjusting the stop screws such that the stop screw contacts the quadrant when the valve is at the end of travel. There is approximately ±5 of total travel adjustment to allow proper positioning of the worm quadrant. Figure 5.10 Stop screw 20

21 c. After adjustment of the stop screw, reinstall the jam screw until tight against the stop screw. Replace the stop plate gasket and stop plate by tightening the cap screws. Figure 5.11 Jam screw reinstalled and new stop plate gasket with stop plate ready to install 5.4 Removal and Replacement of Open End Cap Remove/replace the open end cap by loosening/tightening the M12x45 socket head cap screws as shown. When replacing, torque the screws to the values shown in Table 5.2. Figure 5.12 Removal of socket head cap screw from open end cap Table 5.2 Open/Blind Cap Screw Torque Values Operator Size Bolt Size ft-lb N m PT18/32 M PT65 M PTA/C120 M PTA/C150 M

22 a. When replacing open end cap, ensure the oil seal has been replaced and is properly lubricated. Figure 5.13 Lubrication of new oil seal in open end cap b. A series of gaskets are supplied in order to properly shim the open end cap. Start assembly with three (3) gaskets under the open-end cap and install onto the PT. Once installed, push/pull the worm along its axis. If there is any movement of the worm along its axis, remove the open end cap and remove one shim. Reinstall and check worm shaft movement again. No movement is allowed. Repeat if necessary. Figure 5.14 Open end cap gaskets (3) c. Install the tapered roller bearing cup into the open end cap as shown. Figure 5.15 Tapered roller bearing cup installed into open end cap 22

23 5.5 Removal and Replacement of Worm Shaft To facilitate this process, remove the baseplate and the open end cap, see Sections 4.3 and 4.4. a. Rotate the worm shaft until worm is disengaged from the worm gear. Figure 5.16 Worm shaft disengaged from worm gear. Note tapered roller bearing on worm shaft. 5.6 Removal and Replacement of Blind End Cap Remove/replace the blind end cap by loosening/tightening the socket head cap screws as shown. When replacing, torque screws to values in Table 5.2. Figure 5.17 Removal of screws that retain blind end cap a. Install one new gasket to the flange of the blind end cap. Figure 5.18 Blind end cap and gasket 23

24 b. Install the tapered roller bearing cup into the blind end cap as shown. Figure 5.19 Tapered roller bearing cup inserted into blind end cap 5.7 Removal and Replacement of Worm Gear/Drive Sleeve Remove worm gear/drive sleeve from PT housing. Figure 5.20 Removing worm gear/drive sleeve a. When replacing the worm gear/drive sleeve be sure to replace the O-ring, lubricate well and reinsert carefully. NOTE: In reassembling the operator, follow all of the above steps in the reverse order. Be sure to position the center of the worm gear at ~45 on the worm shaft before reinstalling the baseplate. Figure 5.21 Lubricating the worm gear/drive sleeve O-ring 24

25 6 Disassembly and Reassembly Instructions for PT250 through PT1000 NOTE: Pictures depict a PT250 actuator. The PT500 and PT1000 are similar except larger. In some cases, the number of fasteners is increased for PT500 and PT1000. Figure 6.1 PT250 with typical SGA attachment Figure 6.2 PT250 with typical SGA attachment (rear view) 25

26 6.1 Removal and Replacement of SGA unit Figure 6.3 PT250 SGA front plate a. Remove the six M16 hex head cap screws in the SGA front plate and remove the plate. Figure 6.4 SGA front plate removal (PT250 pictured) b. Carefully remove all traces of the cover gasket. Remove the ball bearing supporting the spur gear pinion and then remove the pinion, taking care not to damage the teeth. 26 Figure 6.5 PT250 spur gear pinion removal

27 c. Remove the idler shaft front bearing from the SGA cover plate. Figure 6.6 SGA front bearing removal d. Remove the ten M16 hex head cap screws in the SGA cover plate and remove. Figure 6.7 SGA front cover plate removed e. Remove the idler from the spur gear shaft. Figure 6.8 SGA removal 27

28 f. Remove the shaft. Figure 6.9 Shaft removal Figure :1 SGA idler shaft removal g. Remove the gasket from the SGA front cover surface. Figure 6.11 SGA front cover gasket removal h. Remove the front bearing from the PT250 input shaft. 28 Figure 6.12 SGA front bearing removal

29 i. Remove the SGA input gear from the PT250 input shaft. Figure 6.13 SGA input gear removal j. Remove the four hex head cap screws from the SGA housing and carefully remove the housing from the PT250. Figure 6.14 SGA housing from PT250 removed 29

30 6.2 Removal and Replacement of the Stem Nut a. Remove the eight hex head cap screws from the pointer cap and remove the cap. Figure 6.15 Pointer cap b. Attach two eye bolts to the stem nut and remove. Figure 6.16 Stem nut removal from drive sleeve 6.3 Removal and Replacement of the Worm Gear and Drive Sleeve a. Remove the four hex head cap screws from blind worm cap. Figure 6.17 Blind worm cap 30

31 b. Remove the blind worm cap from the PT250. Figure 6.18 Blind worm cap removal c. Remove the eight hex head cap screws from the mounting base. Insert two eye bolts into threaded holes and remove the mounting base. Figure 6.19 Mounting base removed from worm gear housing d. Before reinstalling the mounting base, ensure that the O-ring is securely positioned into the groove on the bottom of mounting base. Figure 6.20 Mounting base O-ring installation e. Remove the four hex head cap screws and remove the SGA adapter worm cap. Figure 6.21 SGA adapter worm cap removed 31

32 f. Remove the bearing and cone from the SGA adapter worm bore. Figure 6.22 SGA adapter worm bore bearing and cone removal g. Remove the bearing and cone from the blind worm bore. Figure 6.23 Blind worm bore bearing and cone removal h. Attach two eye bolts to worm gear/ drive sleeve and remove. Figure 6.24 Worm gear/drive sleeve removal i. Prior to reinstallation, ensure that the oil seal is installed in the SGA adapter housing and lubricated. Oil seal 32 Figure 6.25 SGA adapter housing oil seal

33 j. Remove the worm shaft from the housing. Figure 6.26 Worm shaft from housing removal k. Remove the hex nut from drive sleeve stops. Figure 6.27 Drive sleeve stop hex nut removal l. Remove the drive sleeve stop from the housing. Figure 6.28 Drive sleeve stop removal Reassembly is the reverse of disassembly. During reassembly, preload property class 8.8 fasteners to the following torques. See Section 2.4 for torque nut property class 8.8 fastener preload. Unit End Caps Baseplate SGA Cover and Adapter ft-lb N m ft-lb N m ft-lb N m PT PT PT For other than property class 8.8 fasteners, consult factory for preload values. 33

34 6.4 Worm Gear/Drive Sleeve Options Two versions of the worm gear/drive sleeve are available: ductile iron and bronze/ductile iron composite. Figure 6.29 Ductile iron (left) and bronze/ductile iron composite (right) 34

35 7 Disassembly and Reassembly Instructions for PTC32 through PT150 Spur Gear Attachments (SGA) Figure 7.1 SGA housing cover 35

36 a. Remove the six M16 hex head cap screws that secure the SGA housing cover and remove. Figure 7.2 SGA housing cover removal b. Carefully remove the intermediate gearset. Figure 7.3 Intermediate gearset removal c. Carefully remove the output gearset. Figure 7.4 Output gearset removal d. Prior to reassembly, lubricate the oil seal thorouhly. 36 Figure 7.5 Oil seal lubrication e. Reassembly is the reverse of disassembly.

37 8 Disassembly and Reassembly Instructions for PT250 through PT1000 Spur Gear Attachments (SGA) Figure 8.1 PT250 with typical SGA attachment Figure 8.2 PT250 SGA front plate 37

38 a. Remove the hex head cap screws in the SGA front plate and remove the plate. Figure 8.3 SGA front plate removal (PT250 pictured) b. Carefully remove all traces of the cover gasket. Remove the ball bearing supporting the spur gear pinion and then remove the pinion, taking care not to damage the teeth. Figure 8.4 PT250 spur gear pinion removal c. Remove the spur shaft front bearing from the SGA cover plate. Figure 8.5 SGA front bearing removal 38

39 d. Remove the hex head cap screws in the SGA cover plate and remove the plate. Figure 8.6 SGA front cover plate e. Remove the spur gear from the shaft. Figure 8.7 SGA removal f. Remove the shaft. Figure 8.8 SGA shaft removal Figure 8.9 SGA shaft removal 39

40 g. Remove the gasket from the SGA front cover surface. Figure 8.10 SGA front cover gasket removal h. Remove the front bearing from the input shaft. Figure 8.11 SGA front bearing removal i. Remove the SGA input gear from the input shaft. Figure 8.12 SGA input gear removed 40

41 j. Remove the hex head cap screws from the SGA housing and carefully remove the housing from the PT. Figure 8.13 SGA housing from PT250 removal k. Remove the hex head cap screws and remove the SGA adapter worm cap. Figure 8.14 SGA adapter worm cap removal l. Prior to reinstallation, ensure that the oil seal is installed in the SGA adapter housing and lubricated. Figure 8.15 SGA adapter housing oil seal Oil seal Reassembly is the reverse of disassembly. See Sections 2.4 and 6.3 for preload torques for property class 8.8 fasteners. 41

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43 9 How to Order Parts To order parts or obtain further information about your Limitorque PT valve operator, contact your local Flowserve Limitorque Actuation Systems distributor sales office, com, or: Flowserve Limitorque Actuation Systems 5114 Woodall Road Lynchburg, VA Telephone Fax All inquiries or orders must be accompanied by the following information, which is located on the nameplate: 1. Operator size and ratio 2. Order number 3. Serial number 43

44 United States Flowserve Corporation Flow Control Limitorque 5114 Woodall Road, P.O. Box Lynchburg, VA Phone: Facsimile: England Limitorque Abex Road Newbury Berkshire, RG14 5EY, England Phone: Facsimile: FCD LMAIM Printed in USA. 4/05 To find your local Flowserve representative: For more information about Flowserve Corporation, visit www. or call USA Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application. While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation. The Flowserve Limitorque Actuation Systems Lynchburg, Va. facility is ISO9001 certified. Japan Limitorque Nippon Gear Co., Ltd. Asahi-Seimei Bldg. 4th Floor Kita-Saiwai, Nishi-Ku Yokohama-Shi, ( ), Japan Phone: Facsimile: India Limitorque India, Ltd. 15/4, Mile Stone Mathura Road Faridabad , India Phone: Facsimile: Australia Flowserve Australia, Pty. Ltd. 14 Dalmore Drive Scoresby, Victoria 3179, Australia Phone: Facsimile: Singapore Limitorque Asia, Pte., Ltd. 12, Tuas Avenue 20 Singapore Phone: Facsimile:

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