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Document No：KE-4032-02
KITZ ESR Series Spring Return Type Electric Actuators
Operation Manual
for KITZ Compact Ball Valves
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For safe and trouble-free use of the product, ensure to carefully
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Summary of Contents for Kitz ESR Series
- Page 1 Operation Manual KITZ ESR Series Spring Return Type Electric Actuators for KITZ Compact Ball Valves ...
- Page 2 Document No：KE-4032-02 SAFETY CAUTIONS This manual calls users careful attention to the dangers and hazards that may be caused to personnel or properties during handling, storage, installation, operation or maintenance of the product. Such dangers and hazards are specifically highlighted in the operation manual with either one of the following marks. A warning indicates a potentially hazardous condition that may result in serious injury or death of personnel, if such a warning is ignored. A caution indicates a potentially hazardous condition that may result in minor injury to personnel or damage to properties, if such a caution is ignored. ＊ Refer to the following for the classification of severity of damages. Serious injury: Loss of sight, injury, burn (high and low temperature), electric shock, fracture of bones, intoxication, etc. that have aftereffects. And those requiring hospitalization and/or long-term hospital visit for treatment Minor injury: Injuries not requiring hospitalization and/or long-term hospital visit Physical damage: Enlargement loss, etc. related to houses, household articles, live stocks, and pets Moreover, the types of precautions we ask you to observe are classified and explained by the following graphics. (The followings show examples of graphic.) This type of graphic indicates cautions to call users attention to be careful. This type of graphic indicates prohibition of actions. ...
- Page 3 Document No：KE-4032-02 NOTES TO USERS ◆ This manual provides users with the instructions on correct use of KITZ ESR Series electric actuators. Ensure to carefully read all the items of this manual before handling, storage, installation, operation and maintenance of the product. ◆ This manual covers the normal use of the product as a general guide to users, but does not necessarily cover all possible conditions or situations that may be caused to users while using the product. If technical assistance beyond the scope of this manual is required, users are recommended to contact KITZ Corporation or the distributors in their locations. ◆ Numerical limits and procedures of operation, maintenance and inspection provided in this manual are specified in consideration of safe and trouble-free operation of the product. It is forbidden to use the product in any condition that may exceed such numerical limits or conflict with such procedures. ◆ Drawings, tables, photographs and illustrations of the product in this manual provide users with only the basic information. Ask KITZ Corporation or the distributors for detailed assembly drawings of the products, if needed. ◆ Any information provided in this manual is subject to from-time-to-time change without notice for error rectification, product discontinuation, design modification, or any other causes that KITZ Corporation considers necessary. ...
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Page 4: Table Of Contents
Document No：KE-4032-02 Contents Page 1. Design and Functions ･･････････････････････････････････････ 1 1-1. Technical Features ･･･････････････････････････････････ 1 1-2. Product Coding ･･････････････････････････････････････ 1 1-3. Appearance Diagrams and Dimensions ･････････････････ 2 1-4. Actuator-valve Assembly ･････････････････････････････... -
Page 5: Design And Functions
100: Power supply: AC100V 200: Power supply: AC200V Actuator type: KITZ ESR Series ... -
Page 6: Appearance Diagrams And Dimensions
Document No：KE-4032-02 Page：2/19 1-3. Appearance Diagrams and Dimensions [ESR100-1, ESR200-1] Motor Rubber bush Cover Gear Box Cord Gear Manual lever Base plate Housing Coil spring Shaft Fig. 1 1-4. Actuator-valve Assembly Actuator (ESR) Cord ... - Page 7 Also do not install it in any corrosive environment which will affect the service life. Do not carry out wiring works on actuators being energized, and do not remove covers of their housings during wiring, to eliminate the danger of an electric shock. Do not disassemble energized actuators from valves. It will damage valves or actuators and cause problems. Do not put your fingers or foreign objects such as tools into ports of valves being fully opened or closed. It may cause injuries or equipment damages. Before dismantling actuated valves from piping, ensure to equalize the piping pressure with the ambient pressure and thoroughly release line fluid from the piping. Otherwise, residual pressure and line fluid will dangerously extrude from valve bores. Factory-assembled actuated valves are adequately adjusted for satisfactory function and performance. Do not disassemble them for any reason, unless approved in advance by KITZ Corporation, as it may cause valve malfunction, valve seat leakage and other technical problems. This manual covers the procedures to properly handle KITZ compact ball valves driven by KITZ ESR Series actuators. For the product specifications of ball valves and so on that mount this product, refer to individual specifications. Ensure to follow all instructions given in this manual on piping installation, electric wiring, maintenance and inspection of actuated valves, to eliminate concerns of accidental mishaps and product failures. Mounting actuated metal valves on plastic piping may cause an excessive load during manual operation, and damage the piping. Care must be taken to eliminate such a concern ...
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Page 8: Design Specifications
Document No：KE-4032-02 Page：4/19 1-5. Design Specifications 1-5-1. Design Specifications Type-size ESR100-1 ESR200-1 Specifications Power supply (single phase) AC100V AC200V 50/60 Hz * Rated current 200mA 100mA Approx. 90° (50/60Hz) 10 sec. operation time Spring return 20 sec. Duty factor Continuous Insulation class Class E Insulation strength 1 min./AC1500V or 1 sec./AC1800V Insulation resistance Minimum 100MΩ (DC 500V) Service environment Indoor type * Ambient temperature -10℃ 〜 +50℃ Mounting orientation Vertical to horizontal (no downwards) Power cable / cable connection Vinyl cabtyre cord 0.75 mm2, length 3000 mm Lubrication Grease Black housing with light blue cover ... - Page 9 Document No：KE-4032-02 Page：5/19 1-5-3. Actuator Operation Principle of ESR ● Opening operation (fully closed → fully open) ① If you turn on the motor power supply, the motor rotates and the motor force is transmitted to the output shaft via the reduction gear and the valve rotates in the opening direction. ② It opens the valve while lifting the spring attached to the output shaft. ③ When the Actuator shaft opens in the direction by 90°, it gets into contact with the stopper inside the actuator and stops at the full-open position. At this point, the motor stops and maintains the spring s reaction force. Close Toggle switch Open Motor 100/200 V 50/60Hz Product provision range Fig. 4 ...
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Page 10: Handling And Storage
Document No：KE-4032-02 Page：6/19 2. Handling and Storage 2-1. Cautions for Handling and Storage Handle actuated valves by holding valve bodies. Holding instrumentation cables will cause electric wiring failures and other troubles (Fig.6). Do not fall the product on the ground. Protect the product from excessive impact shock or vibration to eliminate concerns of malfunction (Fig.7). Overloading the product must be prevented. Do not place any heavy object on the product. Do not step on the product. Fig. 6 Fig. 7 Do not store the product in the place subject to rain or high humidity. Poor storage environment will cause product malfunction, such as corrosion inside the product. Do not disassemble the product to avoid malfunction or damage of the product. The product is carefully packed to protect actuators and valves from intrusion of dusts and other foreign objects. Do not unpack the product until you are ready for installation on piping. ... -
Page 11: Piping Installation
Document No：KE-4032-02 Page：7/19 3. Piping Installation 3-1. Recommended Service Environments The product is not designed for explosion-proof. Do not install it in any explosive environment to prevent accidental mishaps. Also do not install it in any corrosive environment which will affect the service life. This product is indoor type. Do not install the product outdoor, in location subject to water splash or high humidity. Do not install the product where rainwater may gather high enough to submerge the product installed on piping. Do not install the product where the vibration generated by nearby facilities might affect the function of the product. Otherwise, take appropriate protective measures to insulate the vibration Do not install the product where it is directly exposed to the sunlight. Otherwise, take appropriate protective measures such as installation of a cover or a shelter. Raising the temperature of the product may cause malfunction and affect service life of the product Protect the product appropriately in environments where salty water, snow or freeze may affect functions of the product. Keep a sufficient room around the installed product to ease dismantling, disassembly, manual operation, maintenance and re-installation of the product. Where the product is exposed to radiant heat, take appropriate protective measures such as installation of a cover or a shelter. ... -
Page 12: Cautions For Piping Installation
Document No：KE-4032-02 Page：8/19 3-2. Cautions for Piping Installation Do not apply too much sealing materials for piping. An excessive application may cause intrusion of sealing materials into the valve interior and cause malfunction or internal leakage of line fluid. The first one or two threads of piping ends are better to be left free from sealing materials Do not apply an excessive load by hand to adjust mounting orientation of an actuated valve, or do not tighten a valve with a wrench, to eliminate a risk of damaging the valve (Fig.8). Fig. 8 Do not excessively thread a valve into a pipe. It will damage or distort the valve interior and cause malfunction of the valve or external fluid leakage.（Fig. 9, Table 1 in Page 13）. Do not hold a valve with a vice to eliminate a concern of deformation or damage of the valve, No bumping of a pipe end against the which may cause valve malfunction or external valve interior：No scratching fluid leakage (Fig.10). Fig. 9 Do not apply an external force to a valve counterclockwise during mounting on piping. It may loosen the body-cap joint of the valve and cause external fluid leakage. Fig. 10 ... - Page 13 Document No：KE-4032-02 Page：9/19 Mount an actuated valve with a wrench firmly held around the valve end, which is jointed with a pipe. Holding the wrench around another valve end, which is open to the atmosphere, may cause a too excessive load to the Fig. 13 valve body (Fig.13). Do not apply any excessive bending moment to an actuated valve, to avoid valve body deformation and valve functional failure. Provide an appropriate support to an actuated valve, if the weight of the valve and operation cycles may cause an excessive load to the piping. Where metal valves are mounted on plastic piping, care must be particularly taken to securely support the both ends of the valve. If sands, metallic particles and other foreign objects are contained in the line fluid, ensure to mount a filtering device such as a strainer on the upstream side piping. These foreign objects may get stuck around valve seats and affect valve function or cause internal fluid leakage. ① Prior to piping installation, check that the design specifications of an actuated valve all satisfy service conditions. ② Also remove dusts, scales and other foreign residues from valve end threads and piping internals ③ Check the kind and the standard of valve threads with a gauge and confirm that the required number of effective threads are provided. ④ For threading a valve into piping, use a wrench held around the valve end, which is jointed with a pipe. ⑤ Thread a valve with a tightening torque recommended in Table 1. ⑥ ...
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Page 14: Cautions For Electric Wiring
Document No：KE-4032-02 Page：10/19 3-3. Cautions for Electric Wiring Ensure to switch off an actuator before electric wiring, to eliminate the danger of an electric shock Do not work for electric wiring in rainwater, to avoid the danger of an electric shock. Do not unnecessarily pull out connecting cables and wires, as they may get disconnected and cause an electric shock. Cabling an actuator to the power source with some slack is recommended (Fig.14). Fig.14 Do not modify an actuator for any reason, to avoid concerns of functional failures. Do not separate an actuator-valve assembly or disassemble an actuator, to avoid damage of the actuator. An actuator is designed for either AC100V or AC200V. Check that the power source voltage on site matches to the design specification of an actuator. Ensure to make correct wiring to eliminate the danger of an earth leakage or a short circuit. Work for electric wiring according to the indication attached to an actuator. Incorrect wiring may damage instrumentation devices. ... - Page 15 Document No：KE-4032-02 Page：11/19 There is a small gap between an electric cable and inner wires. If waterproofing of cable connections and exposed cable ends is not adequately done, capillary phenomenon may cause water intrusion into the interior of an actuator, resulting in corrosion of parts and components. To prevent malfunction of an actuator, ensure to adequately waterproof all cable connections and exposed cable ends (Fig.15). ② Waterproofing clearance between ① Waterproofing for edges of unused cables and cable sheath. electric cables, and for joint of cable wires with relay cables. to the Gap filler control Actuator cable panel Closed end Tightly filled with no gap connector Gap filler Cable ...
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Page 16: Operation
Document No：KE-4032-02 Page：12/19 4. Operation 4-1. Manual Operation Do not disassemble energized actuators from valves. It will damage valves or actuators and cause problems. Ensure to turn off an actuator for manual operation not to damage the actuator. Manual operation must be done slowly to prevent an actuator from damage or malfunction. [ESR100-1, ESR200-1] ① The valve operation range is 100% (fully open) at manual operation. ② Since it is equipped with the lock groove, it is possible to hold the valve in the fully opened status by the manual operation. ③ When shifting from manual to electric operation, make sure to check that the manual lever is released from the lock groove. Lock groove Closed position Opened position ... -
Page 17: Electric Operation
Document No：KE-4032-02 Page：13/19 4-2. Electric Operation Perform the electric operation with the following procedure. ① Checking power supply voltage Check that the power source voltage conforms with the design specification of an actuator. ② Checking wiring connection Check that control circuits of an actuator are correctly wired, according to the wiring diagram indicated on an actuator housing and the color codes of wires ③ Turning on the power supply Turn on an actuator to detect if anything abnormal might happen. If anything abnormal such as smoke emission or failure of control circuit fuse happens, immediately turn off the actuator, detect the cause and take an appropriate corrective measure to solve the problem. ④ Electric operation Turn on the power supply and confirm that valve opens. Similarly, turn off the power supply in the fully open status and confirm that the valve closes. ⑤ Others In case of motor overheating, smoke emission or fuse failure, turn off an actuator, ● detect the cause of failure and apply an appropriate corrective measure to solve the problem. ... -
Page 18: Operational Precautions
Document No：KE-4032-02 Page：14/19 4-3. Operational Precautions Do not drive an actuator to continually open and close a valve. Pause for at least ten second between opening and closing operations (Fig. 17). open close Pause for 10 seconds or longer Fig. 17 Do not control an actuator with a Solid-State Relay (SSR). When the actuator is turned off, a leakage current may affect its function or affect its service life. If SSR must be used for any particular reason, ensure to test the actuator to check its proper activation prior to operation. Do not drive an actuator directly by contact output of a sequence controller. If such an activation is inevitable for any particular reason, drive the actuator by means of a switching element like a relay provided with an adequate contact capacity. Do not perform the closing (opening) operation while the valve is in the middle of opening (closing). It will shorten the life significantly. This series of actuators is designed for technically non-critical applications, and electromagnetic waves and noises may affect its operation. For connection of this series of actuators with other equipment, which may cause electromagnetic waves and noises, ensure to check its proper operation before application. ... - Page 19 Document No：KE-4032-02 Page：15/19 Ensure to provide a fuse or a short circuit breaker on the control panel to prepare for accidental short circuits. Protective measures for extraordinary pressure rises When a floating-ball type ball valve is used for highly volatile liquid service, rise of line temperature or ambient temperature may often cause an extraordinary rise of the pressure of the fluid left within a body cavity and result in seat damage or valve malfunction. This problem may be solved by the following preventive measures: Pressure Pressure Body equalization groove equalization hole cavity Pressure Fully closed Fully open equalization hole Fluid flow direction Fig. 18 ...
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Page 20: Maintenance/Inspection
Document No：KE-4032-02 Page：16/19 5. Maintenance/Inspection Unusual noise may be generated if foreign objects are caught in the valve seat. Promptly remove foreign objects in the seat. If such objects are left as is, the seat may be damaged or malfunction. Leaving unusual piping vibration as is causes malfunction. If unusual vibration is detected, fix the piping with support or similar to prevent vibration. ① Ball valves and actuators introduced in this manual are all designed lubrication-free. ② Inspections of all actuated valves must be carried out periodically, and as frequently as possible to prevent accidental mishaps. Here are the items of inspections required as a minimum: １） Check trouble-free opening and closing of valves. ２） Detect any external fluid leakage from valves and piping connections. ３） Check vibration of valves and piping during operation. ４） Inspect loosened bolts and nuts 5-1. Dismantling and Reinstallation Do not disassemble an energized actuator from a valve, to eliminate concerns of valve damages and accidental mishaps. Do not put your fingers or foreign objects such as tools into ports of valves being fully opened or closed. It may cause injuries or equipment damages. Before dismantling an actuated valve, ensure to equalize the pressure of the piping and the valve interior with the ambient pressure. Otherwise, residual pressure and line fluid may dangerously extrude from the valve bore and cause accidental mishaps. ... - Page 21 Document No：KE-4032-02 Page：17/19 Factory-assembled actuated valves are all adequately adjusted for satisfactory function and performance. Do not disassemble them for any reason, unless approved in advance by KITZ Corporation, as it may cause valve malfunction, valve seat leakage and other technical problems. Maintenance works for dismantled valves must be carried out in dust-free, clean places to prevent intrusion of foreign objects into the interiors of valves and actuators. During maintenance works and dismantling from or reinstallation on piping, take care not to damage sliding parts of actuated valves such as shafts and stems, and prevent foreign objects from sticking to internal and external surfaces. ① To remove the valve from a piping, check that no fluid remains within the piping and use a valve spanner hook closer to the piping to be removed and remove the valve as shown in Fig. 20. Hold here with a Hold here with a monkey wrench to monkey wrench to avoid pipe avoid pipe Fig. 20 ...
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Page 22: Trouble Shooting
Document No：KE-4032-02 Page：18/19 5-2. Trouble Shooting The following table provides the general guidance of remedial and preventive measures to settle technical problems which may occur on site during operation of actuated ball valves. For further technical assistance, contact KITZ Corporation or your local KITZ distributors or agents. Categories Causes of failures Remedial measures Preventive measures of failures ・Discrepant power ・Replacing actuators, ・Correct power supply Control supply if subjected to circuit voltage higher than failure design specification ・Discrepant control ・ Replacing ・Checking correct circuitry circuitry actuators, if with operation manual ・Inadequate contact corrective measures ・Correct and secured between terminals could not solve the terminal connections ... -
Page 23: Others
If the actuator or inside the valve is damaged by problems indicated by *, the product must be replaced. Take sufficient actions to prevent recurrence at the replacement. ・The allowable voltage fluctuation range shall be ± 10 % . ・This product shall not be used outdoors or in the area subject to water splash or high humidity. ・This product shall be used only for ON-OFF (fully open ⇔ fully closed) control. ・Do not electrically open the valve when it is being closed by a spring return type actuator. ・The valve cannot be opened when the power is shut down. ・The product life will be shortened when the valve is frequently opened and closed (20 times/hour) for air-conditioning equipment (e.g. fan coil unit). ・This product cannot be used to always keep the valve in the fully open position. Please use for temperature control of air-conditioners. ・When the valve is continuously used in the fully open position over 24 hours, use of a three-wire system actuator which turns off the power with a limit switch is recommended. 6. Others 6-1. Product Warranty Failed or damaged products shall be repaired or replaced at no cost to users, if the failure or damage occurred within 12 months after pilot operation, but not exceeding 18 months after shipment from KITZ factories, while the following conditions are satisfied: (1) The product has been correctly handled, stored, installed, operated and maintained according to this manual within the scope of design specifications and service conditions of the product. (2) Failure or damage of the product has not been caused as a result of the user s incorrect operation or lack of care. (3) The product has not been damaged due to an act of God or a natural disaster. (4) The product has not been modified by any party other than KITZ Corporation or its authorized modification shops. (5) The product function and performance has not been deteriorated by aging. Note that repairing of defects/damages caused by problems above and replacement of consumables are performed for pay. ...
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