DWYER INSTRUMENTS, INC. Phone: 219/879-8000
Contents
1. Bulletin V 12 Series 3ABV Automated Ball Valves 3 Way Brass NPT Specifications Installation and Operating Instructions pC ETRCINMGEN rete Weds a te be 5 5D 6B 6H 65 7 GA 84 amp 40 40 40 40 45 46 45 4D 2644 264 264 3B 3B 4B 4 55 5 5 5 5 6B GB 6B 6B 1B 18 18 19 1g 2D 24 287 13 13 13 13 18 25 28 3 0 06 a 06 10 12 15 15 OE OS 1b 1S lel 1 26 26 PRR ATCOODREACING eS S OS 38 cya r a aT E an 48 50 594 6 zis 264 264 30 38 4B 4B Sis ep ae ee ee 18 1B 1p 1g 20 24 2g EEJ 18 18 18 25 28 3B 04 0 0 1M 12 15 15 O86 Hb 15 ig 1 28 2p DY be pe B mM 38 Cyr av i ae ae ie ae Cas ep ean be 29 3y 3y 4y 5D 18 13 04 Lodz Ox Y P N Q Y Q ia 2 el ee pty t wi wi mii a Arla am giolo gt m 5 Nle CURSE mlu ws Bl DI 18 BA 7d WININ SRB N ES we agua R Along gt H The Series 3ABV incorporates a standard port valve for great flow rates with mini SPECIFICATIONS Housing Material Aluminum with ther mal pressure drop Features include a blowout proof stem for added safety and rein Service Compatible liquids gases or mal bonding polyester powder finish forced TFE sea2. are correct 4 Mount actuator to valve Do not tighten nuts and bolts at this time 5 Remove actuator cover 6 Bring power to the actuator CAUTION Make sure power is OFF at the main box 7 Wire the actuator per the diagram attached to the inside of the cover Special actuators those with positioner boards etc will have diagrams enclosed inside the cover 8 Securely tighten bolts used to mount the actuator to a mounting bracket or directly to the valve mounting pad if it is 1505211 compliant 9 Cycle the unit several times and check the open and closed positions of the valve Cams are pre adjusted at the factory due to the variety of valve designs and types however slight adjustments might be required SEE II and Ill 10 Replace cover and tighten screws ll TO SET THE OPEN POSITION 1 Cycle the valve to the open position by applying power to terminals 1 and 2 The top cam and switch control this position In the open position the set screw in the top cam will be accessible 2 If the valve is not open completely A Slightly loosen the 8 32 x 1 4 set screw on the top cam B Rotate the cam clockwise CW by hand until the switch makes contact Contact is made when a slight click can be heard By making incremental CW movements of the top cam the valve can be positioned precisely in the desired position C When the top cam is set tighten the set screw securely 3 If the valve opens too far A Apply power to term
3. O ring 14 PTFE piston thrust block 4 PTFE pinion spacer ring 15 SS stop bolt retaining nut 5 NBR 70 top pinion O ring 16 SS stop bolt 6 PTFE cam spacer ring 17 External spring 7 SS indicator cam 18 Internal spring 8 Nylon position indicator 19 Die cast aluminum end cap left 9 SS pinion washer 20 Die cast aluminum end cap right 10 Pinion snap ring 21 NBR end cap seats 11 Die cast aluminum piston 22 SS end cap bolt spring return actuators only parts subject to wear Please contact the factory or your W E Anderson distribu tor for replacement kits Darina is a registered trademark of Shell Oil Company Copyright 2009 Dwyer Instruments Inc DWYER INSTRUMENTS INC P O BOX 373 MICHIGAN CITY INDIANA 46361 U S A Printed in U S A 8 09 Phone 219 879 8000 Fax 219 872 9057 MAINTENANCE The Series 3ABV Automated Balll Valves are not field serviceable and should be returned if repair is needed field repair should not be attempted and may void war ranty Be sure to include a brief description of the problem plus any relevant appli cation notes Contact customer service to receive a return goods authorization number before shipping FR RB 443400 50 Rev 1 www dwyer inst com e mail info dwyer inst com
4. am onto the flat section A slight click can be heard as the switch is no longer mak ing contact with the round part of the cam D Continue applying power to terminals 1 and 3 until valve is in the desired position IV MAINTENANCE Once the actuator has been properly installed it requires no maintenance The gear train has been permanently lubricated and in most cases will never be dis turbed In the event it becomes necessary to open the gear box for any reason however Darina 2 grease is recommended for re lubricating V DUTY CYCLE Most standard electric actuators are rated for 25 duty cycle at 100 ambient temperature at the rated torque VI THERMAL OVERLOAD All actuators are equipped with thermal overload protection to guard the motor against damage due to overheating Vil MECHANICAL OVERLOAD All actuators are deigned to withstand stall conditions It is not recommended to subject the unit to repeated stall conditions Vill SPARE PARTS When ordering parts please specify A Model B Serial C Part Description Recommended spare parts include A Standard actuator set of cams and switches B Actuators w positioner set of cams and switches 1K potentiometer valve posi tioner board IX NEMA 7 ELECTRIC ACTUATORS In general operation and maintenance of a NEMA 7 electric actuator is no differ ent that of a NEMA 4 actuator However some precautions must be followed 1 DO NOT under any circumstances remove the
5. cover of the actuator while in a hazardous location Removal of the cover while in a hazardous location could cause ignition of hazardous atmospheres 2 DO NOT under any circumstances use a NEMA 7 electric actuator in a haz ardous location that does not meet the specifications for which the actuator was designed 3 Always mount and cycle test the actuator on the valve in a non hazardous loca tion 4 When removing the cover care must be taken not to scratch scar of deform the flame path of the cover and base of the actuator since this will negate the NEMA rating of the enclosure 5 When replacing the cover on actuators rated for both NEMA 4 amp 7 take care that the gasket is in place to assure proper clearance after the cover is secured After the cover screws are tightened the clearance between the cover and the base should be checked A 002 thick by 1 2 wide feeler gauge is used for this it must not enter between the two mating faces more than 125 6 All electrical connections must be in accordance with the specifications for which the unit is being used 7 Should the unit ever require maintenance remove from the hazardous location before attempting to work on the unit If the actuator is in a critical application it is advisable to have a standby unit in stock XI TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Actuator does not Power is not on Turn on Power respond to control Actuator wired incorrectly eChec
6. es have been removed and that the actuator has been dismounted from the valve 1 Loosen the end cap fasteners 22 with a wrench size varies depending on actu ator model On the spring return actuator alternate 3 to 5 turns on each fastener until the springs are completely decompressed Use caution in removing the cap since the springs are under load until the fasteners are fully extended 2 Remove the pinion snap ring 10 with a lock ring tool The indicator 7 may now be removed 3 Turn the pinion shaft 2 CCW until the pistons are at the full end of travel Disengage the pistons 11 from the pinion NOTE Low pressure air 3 to 5 P S I MAXIMUM might be required to force the pistons completely from the body Note the position of the pistons before removing them from the actuator body The part numbers of the pistons are located on the side and should be right side up on an actuator with a standard orientation 4 Remove the pinion through the bottom of the actuator The actuator is now com pletely disassembled All replacement parts may now be put in W E Anderson recommends that all wear parts 3 4 5 6 12 13 14 be replaced before reassem bly REASSEMBLING STANDARD ACTUATORS IMPORTANT Be sure that the actuator surfaces are free of grit and scratch es before reassembling 1 Apply a light film of grease to all o rings and the pinion before replacing 2 Put the pinion 2 back through the actuator with the flats of the pinio
7. inals 1 and 3 This will begin to rotate valve CW When valve is full open and in the exact position desired remove power from actuator B Loosen the set screw in the top cam C Rotate the top cam counterclockwise CCW until the switch arm drops off the round portion of the cam onto the flat section A slight click can be heard as the switch changes state D Continue applying power to terminals 1 and 3 until valve is in the desired position lll TO SET THE CLOSED POSITION 1 Apply power to terminals 1 and 3 to move the valve toward the closed posi tion The bottom cam and switch control the closed position In the closed position the set screw in the bottom cam will be accessible 2 If the valve is not closed completely A Slightly loosen the 8 32 x 1 4 set screw on the bottom cam B Rotate the cam counter clockwise CCW by hand until the switch makes contact Contact is made when a slight click can be heard By making incremental CCW move ments of the bottom cam the valve can be positioned pre cisely in the desired position C When the top cam is set tighten the set screw securely 3 If the valve closes too far A Apply power to terminals 1 and 2 This will begin to rotate valve CCW When valve is fully closed and in the exact position desired remove power from actuator B Loosen the set screw in the top cam C Rotate the top cam clockwise CW until the switch arm drops off the round portion of the c
8. k wiring diagram signal re wire Incorrect voltage Bring correct supply to actuator Allow motor to cool resets automatically Remove actuator remount after 90 turn Thermal Overload Actuator and Valve in opposite positions when actuator installed Actuator will not Travel limit switch set open and or close incorrectly completely Valve torque too high Install correct unit Mechanical stops not Remove stops removed when installing actua tor eSet cams per instructions Valve oscillates Torque of valve too high Torque of valve too high Actuator without brake elnstall brake installed on butterfly valve eMotor brake misadjusted Adjust brake tighten screw Actuator motor runs eGear damaged sheared pin Contact factory but output shaft does not rotate Page 3 PNEUMATIC ACTUATOR PNEUMATIC ACTUATOR NOTE For optimal operation 3ABV actuators should be run with a supply of clean lubricated air SPRING RETURN ACTUATORS Air to PORT 2 the right hand port causes the actuator to turn CCW Loss of air to PORT 2 causes air to exhaust and the actuator turns CW This is the FAIL CLOSE operation DOUBLE ACTING ACTUATORS Air to PORT 2 the right hand port causes the actuator to turn CCW Air to PORT 1 the left hand port causes the actuator to turn CW DISASSEMBLING STANDARD ACTUATORS IMPORTANT Before beginning disassembly ensure that the air supply to the actuator has been disconnected all accessori
9. n shaft run ning parallel with the body 3 When reassembling the actuator make sure that the piston racks are square to the actuator body and returned to their original orientation NOTE The normal operation of all BV pneumatic actuators is FAIL CLOSED To change the orienta tion to FAIL OPEN rotate the racks 180 to create a reverse operation 4 When replacing springs in a spring return actuator ensure that the springs are replaced in their identical position in the end cap from which they were removed NOTE In some circumstances you might want to change the standard 80 pound spring set to fit your application and available air pressure Changing the spring sets on BV pneumatic actuators requires no special tools Please refer to the spring combination torque chart in our catalog for the inner and outer spring com binations that will allow you to operate with the spring set that you desire 4 Seal the end caps with a petroleum lubricant and bolt to actuator body 5 Check the seal of the actuator by covering seal areas pinion end caps with soapy water and using low pressure air to the actuator to ensure that no bubbles are produced Page 4 PNEUMATIC ACTUATOR PARTS LIST j 1 Id 1 4 onl i 1 4 bams 4 F i Y i ate k 5 e i A 1 zl a 1 Extruded aluminum housing 12 Piston O ring bushing 2 Nickel plated steel anti blowout pinion 13 PTFE antifriction ring 3 NBR 70 lower pinion
10. ts and seals for longer life and leak free operation The four seat design steam Temperature Limit 0 to 150 F allows for high cyclic capabilities and tight shut off in any position Perfect for mixing Body 3 way 18 to 65 C or diverting services in the food and chemical processing industries l Line Size 1 4 to 2 Conduit Connection 1 2 female NPT The 3ABV isan economical automated valve package with either an electric or pneu End Connections Eemale NPT Modulating Input 4 to 20 mA matic actuator Electrically actuated models are weatherproof NEMA 4 powered by standard 115 VAC supply and are available in either two position or proportional Pressure Limits 1 4 to 1 1 4 435 psi Standard Features Manual override control Two position actuators use the 115 VAC input to drive each of the valve ports 30 bar WOG 1 1 2 232 psi 16 bar and visual position indicator except open or closed while the modulating actuator accepts a 4 20 mA input for infinite WOG 2 145 psi 10 bar WOG 100 modulating units valve positioning Actuator features include thermal overload protection to withstand psi 6 9 bar SWP stall conditions visual position indication and a permanently lubricated gear train Wetted Materials Pneumatic DA and SR Series The pneumatic double acting actuator uses an air supply to drive each of the actua Body End Cap Stem Brass Type DA series is double acting and tor ports The actuator has t
11. wo supply ports with one driving the valve stem clock Ball Brass Chrome Plated SR series is spring return rack and pin wise the other for counterclockwise rotation Spring return pneumatic actuators use Seat Stem Seal TFE ion the air supply to drive the valve stem in one direction and internally loaded springs Temperature Limits 320 F 160 C Normal Supply Pressure 80 psi 5 5 return the valve to its original position Also available is the SV3 solenoid valve to on bar electrically switch the supply pressure between the air supply ports Actuators are Other pian arate Seal Body O Maximum Supply Pressure 120 psig constructed of anodized aluminum and are epoxy coated for years of corrosion free ring Stem O ring Fluoroelastomer 8 bar service Air Connections DA SR1 to 5 1 8 ACTUATORS female NPT all other sizes 1 4 female Electric NPT Power Requirements 120 VAC 50 60 Air Consumption per stroke DA1 Hz single phase Optional 220 VAC 24 2 32 cu in DAZ SR2 9 34 cu in VAC 12 VDC and 24 VDC DA3 SR3 17 21 cu in DA4 SR4 Power Consumption Locked Rotor 29 9 cu in SRS 39 54 cu in Current Two Position 14 to 3 4 Cycle Times per 90 DAT 03 sec 55A 1 to 2 75A Modulating 1 4 to DA2 04 sec DAS 08 sec DA4 12 3 4 55A 1 to 2 75A sec SR2 09 sec SR3 14 sec SR4 22 sec SR5 33 sec Housing Material Anodized aluminum body and epox
12. y coated aluminum end Caps Temperature Limit 4 to 180 F Duty Cycle Two Position 1 4 to 3 4 20 to 82 C 75 1 to 2 25 Modulating 75 Accessory Mounting NAMUR stan Enclosure Rating NEMA 4 Optional dard NEMA 7 Standard Features Visual position indicator Cycle Time per 90 Two Position 1 4 to 3 4 2 5 sec 1 to 2 5 sec Modulating 1 4 to 3 4 2 5 sec 1 to 2 5 sec DWYER INSTRUMENTS INC Phone 219 879 8000 www dwyer inst com P O BOX 373 MICHIGAN CITY INDIANA 46361 U S A Fax 219 872 9057 e mail info dwyer inst com Page 2 SERIES 3ABV AUTOMATED BALL VALVES 3 WAY BRASS Cv lin L Port T Port 43 76 44 58 3ABV1DA407 3ABV1SR507 3ABV1U1307 Complete model includes Port Configuration see chart below Port Flow Path Configuration Act Open Act Closed All Open A B T Port A C B C r 7 All Open L2 All Closed All Closed B C Example 3ABV1DA204 T2 ELECTRIC ACTUATOR I BASIC INSTALLATION 1 Operate valve manually and place in the open position NOTE ALL ELECTRIC ACTUATORS ARE SHIPPED IN THE OPEN POSITION 2 Remove any mechanical stops the valve might have DO NOT REMOVE ANY PARTS NECESSARY FOR THE PROPER OPERATION OF THE VALVE SUCH AS THE PACKING GLAND PACKING NUT ETC 3 Ensure that the actuator output shaft and valve stem are aligned properly If they are not operate the valve manually until they
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