Assembly Procedure for SY…Retrofit SolutionPREFERREDDANGERACCEPTABLEHORIZONTAL909010Retrofit Requirement: The initial step is to determine if your application can accept a retrofit solution. As shown below (Fig. 1), the valve stem must not be located below the horizontal plane. If this condition exists, the SY actuator could not be used in this situation. A Belimo technical support person is available to help determine what solution best fits your application. A typical solution is shown in Fig. 2.Step 1) The valve must be stripped down to its basic form. Remove all other linkage components before starting the assembly sequence below. The linkage components have been designed to attach to the existing valve flange rather than to any existing hardware.Step 2) The valve has either flats, a key slot, holes or a mark indicating the position of the disc with respect to the shaft. Usually, the flats, keys, holes and marks are PARALLEL to the valve disc. The photo at left shows the flatted shaft in theCLOSED position.Assembly Procedure (Mechanical)BAFGCDEVALVE STEMTOP MOUNTINGHOLESEXISITING VALVE BODYStep 3)The valve MUST be in the OPEN position before starting the retrofit process. The photo at the left shows the shaft flats are PARALLEL to the piping, but the disc is PARALLEL to the flats, thereby indicating the valve disc is in the fully OPEN position. You MUST verify the disc is fully OPEN before proceeding. Step 4) Place the coupling (E) over the valve stem. It can be assembled in two different positions 180 degrees apart, but either position is OK. It would be helpful at this time to make a mark on the coupling and on the valve body so you can easily reference the position of the valve after the actuator is attached.Step 5) Install the actuator mounting bracket (A) onto the valve top works flange as shown. Step 6) Insert the four mounting bolts (B), lockwashers (C), and the hex nuts (D). Do NOT tighten at this time. Step 7) The SY actuator is shipped in the OPEN position. Make sure the actuator is in the OPEN position before attaching to the valve/coupling assembly. The SY actuator turns counter clockwise (CCW) to the OPEN position, when viewed from ABOVE the actuator. Step 8) Verify that the SY actuator is in the OPEN position also by looking at the bottom of the actuator. There is a dimple mark punched in the output shaft which will align with the "1" mark when the actuator is in the OPEN position.Step 9) Stand with the valve face (where the piping flange connects to the valve body) towards you. Hold the SY actuator with the handwheel on the RIGHT, and the EMT connectors to your LEFT. Align the square drive or keyway in the SY actuator with the square drive or keys in the coupling (C). The SY actuator will slide completely over the drive square and will rest ON the mounting bracket (A). Step 10) Attach the hand knob to the hand wheel as shown below (if not already completed). Step 11) Tighten the jam nut to prevent the hand knob from becoming loose. Step 12) Insert the four hex bolts (G) and lock washers (F) through the bracket and into the bottom of the SY actuator as shown. Do NOT tighten until all four sets have been installed. Slight twisting of the entire SY actuator will facilitate alignment of the bolts.Step 13) After all four have been inserted, tighten accordingly. Step 14) Now tighten the four bracket bolts (B, C, D) assembled previously in step 6 .Step 15) When mechanical assembly is complete, the SY actuator and valve body should be oriented as shown below. The actuator is in the OPEN position, and the valve disc is fully OPEN. All bolts are tight, and electrical checkout is now possible. Application Note:The hand wheel on the SY actuator is engaged at all times but does not rotate when the actuator is running. It is possible at anytime to turn the hand wheel by simply rotating it CW or CCW. The hand wheel does NOT need to be pulled or pushed into the actuator to make it operational. However, it should be noted that if a control signal and power is present at the actuator when the hand wheel is turned, the actuator will return to its controlled position. If it is desired to have the actuator maintain its position after turning the hand wheel, it will be necessary to remove power from the actuator, either at the source or by use of an optional SY-HOA local switch.BAFGCDEVALVE STEMTOP MOUNTINGHOLESEXISITING VALVE BODYStep 1) Remove the four hex bolts securing the cover to the base casting.Step 2) Remove cover from the SY actuator. A flat blade screwdriver inserted carefully into the provided slot (as shown) will facilitate removal of the cover.Step 3)Conduit entries into the SY actuator must be selected for their operating location (indoors protected, indoors wash down, outdoors, etc). Be sure to follow standard NEC guidelines when selecting conduit and connector types.Step 4)Follow the wire sizing chart in the Installation Operation Manual (IOM) (Belimo p/n 70103-00001D page 17) to make sure you use the correctly size wire when connecting the SY to your power source. Failure to follow the recommendations in the table could cause actuator failure or nuisance tripping. Step 5) Follow the wiring diagrams in the IOM pages 18 (single) & 23 (multiple) for proper power and control wiring to the SY actuator. Make note of the following:a. Do NOT connect multiple actuators in parallel without isolation relays.b. Be sure "Hot" is connected to terminal #7 to enable the heater circuit, and "Neutral" is connected to terminal #1.Step 6) Apply proper voltage to terminals 1 (Neutral) & 7 (Hot). Apply proper actuator voltage to terminals 1 (Neutral) & 4 (Hot) to drive the actuator CLOSED until the end-of-travel cam STOPS the actuator movement. 7. Visually check the position of the valve to make sure it reaches its full CLOSED position. Step 8) Apply proper voltage to terminals 1 (Neutral) & 7 (Hot). Apply proper actuator voltage to terminals 1 (Neutral) & 3(Hot) to drive the actuator OPEN until the end-of-travel cam STOPS the actuator movement. Step 9) Visually check the position of the valve disc to make sure it reaches its full OPEN position. Step 10) If the valve functions properly, mechanical assembly and electrical checkout are complete.Assembly Procedure (Electrical), On/Off ModelsFACTORY NOTE: The SY actuators have been calibrated at the factory before shipping to you for use in this retrofit kit. The SY actuator calibration will suffice 99% of the time for your application. Improper calibration to the actuator may void your warranty. If you have any questions, please contact a Belimo technical support representative at 800-543-9038 for assistance.Assembly Procedure (Electrical), Proportional ModelsStep 1) Remove the four hex bolts securing the cover to the base casting.Step 2) Remove cover from the SY actuator. A flat blade screwdriver inserted carefully into the provided slot (as shown) will facilitate removal of the cover.Step 3) Conduit entries into the SY actuator must be selected for their operating location (indoors protected, indoors wash down, outdoors, etc). Be sure to follow standard NEC guidelines when selecting conduit and connector types.Step 4) Follow the wire sizing chart in the Installation Operation manual (IOM) (Belimo p/n 70103-00001D page 17) to make sure you use the correct size wire when connecting the SY to your power source. Failure to follow the recommendations in the table could cause actuator failure or nuisance tripping. Step 5) Follow the wiring diagrams in the IOM pages 14 through 37 for proper power and control wiring to the SY actuator.Note: All SY1-P and SY2..12-SR/MFT actuators are factory pre-set with the proper customer requested control programming. Step 6) Connect the proper electrical power and control wiring per the wiring diagrams located on pages 14-37. Step 7) Check the operation of the actuator by commanding the control system to generate control signals matching the needs of the job to run the valve from fully CLOSED to fully OPEN, as well as a MID-POINT position. The indicator on the top of the SY actuator will be an indicator as to the position of the actuator, and therefore, the valve position. Step 8) If the valve functions properly, mechanical assembly and electrical checkout are complete.FACTORY NOTE: The SY actuators have been calibrated at the factory before shipping to you for use in this retrofit kit. The SY actuator calibration will suffice 99% of the time for your application. Improper calibration to the actuator may void your warranty. If you have any questions, please contact a Belimo technical support representative at 800-543-9038 for assistance.Assembly Sequence for Existing ValvesABCDEFGHIJKLMNOPTOP MOUNTING HOLESVALVE STEMEXISTING VALVE BODIESEXISTING TEEPlease refer to the above exploded view above when following the assembly procedure, to better identify which parts are being addressed in each step. Additionally, you need to determine the configuration of the valve you are trying to retrofit, using one of the three diagrams below:The valves should be stripped down to their basic form, as shown. Remove all other linkage components before starting the assembly sequence below. The linkage components have been designed to attach to the valve in this state, rather than to any existing hardware. Depending on the orientation of the tee assembly, if the valves are mounted on the TOP and BRANCH positions (tee mounted vertically), or on the LEFT and BRANCH positions (tee mounted horizontally) you will refer to configuration codes X10-X15. OpenDiscOpenDiscClosedSOpenCheck for rotation clearanceto brackets BEFORE attachingObserve direction of rotationon actuator(s) BEFORE mountingonto bracketry.actuator(s).Disc ClosedX20 - X25:Slave Valve is "S"Master Valve is "M"Slave Valve is Normally OpenSet Valve "M" Closed as shownSet Valve "S": Open as shownAttach Crank Arms as shownValves turn in directions shownMaster Valve is Normally ClosedX20 - X25MDiscClosedw/ "M" DiscArmCrankw/ "S" DiscCrank ArmClosedMX10 - X15:Master Valve is "M"Slave Valve is "S"Master Valve is Normally ClosedSlave Valve is Normally OpenSet Valve "M" Closed as shownSet Valve "S": Open as shownAttach Crank Arms as shownValves turn in directions shownCheck for rotation clearanceto brackets BEFORE attachingactuator(s).Observe direction of rotationon actuator(s) BEFORE mountingonto bracketry.Disc ClosedDiscOpenCrankArmw/ "M" DiscClosedOpenSDiscClosedDiscOpenCrank Armw/ "S" DiscClosedX10 - X15If the valves are mounted on the BOTTOM and BRANCH positions (tee mounted vertically), or on the RIGHT and BRANCH positions (tee mounted horizontally) you will refer to configuration codes X20-X25.Assembly Sequence for Existing ValvesStep 1) Assemblethe actuator mounting bracket(s) (A) to the top of the valve actuator mounting pad(s) using the supplied bolts (B),lock washers (C) and nuts (D). The bracket(s) need to be oriented so that they are parallel to the RUN of the tee, unless you have configuration codes X30-35, in which case the bracket(s) must be mounted parallel to the BRANCH of the tee. Step 2) Refer to the three configuration drawing types on pages 133 and 134 and position the valve discs as instructed. For example, if you have a Configuration Type A tee assembly, you will OPEN the master valve (A), and CLOSE the slave valve (B). During the assembly procedure, CLOSED and OPEN means 0 degrees and 90 degrees respectively. Failure to position the discs into their quadrants will result in improper operation and performance of the retrofit kit. Most manufacturers mark the TOP of the valve stem with a slot which indicates the disc angle.Step 3) Slide the drive pin assembly, consisting of the drive shaft(s)(E), the valve shaft couplings (F),the mating pins (G),and the setscrews (H), over the valve shafts. It may be necessary to back out the set screws (H) a few turns to make sure there is clearance in the coupling pockets (bottom of (F)for the valve shafts. Drive shafts (E) should be concentric and parallel with the valve shafts so there is no binding. Any angular alignment MUST be corrected before moving on to the next step.Note: Belimo recommends drilling a pilot hole into the shaft. This will ensure the set screw (H) sits flat. Failure to do this may result in the coupler (F) slipping over time.Step 4) Mark the top of each drive shaft (E)to indicate the disc position. Typically, this is done using a chisel to punch a line PARALLEL to the valve disc to make it easier to identify the disc position during the assembly process. OpenMaster Valve is Normally ClosedValves turn in directions shownAttach Crank Arms as shownSet Valve "S": Open as shownSet Valve "M" Closed as shownSlave Valve is Normally OpenMaster Valve is "M"Slave Valve is "S"X30 - X35:Disc Closedactuator(s).onto bracketry.on actuator(s) BEFORE mountingObserve direction of rotationto brackets BEFORE attachingCheck for rotation clearanceOpenCrank Armw/ "S" DiscClosedw/ "M" DiscOpenX30 - X35MArmCrankDiscOpenDisc ClosedClosedSDiscIf the valves are mounted on the TOP and BOTTOM positions (tee mounted vertically), or on the LEFT and RIGHT positions (tee mounted horizontally) you will refer to configuration codes X30-X35Step 6) Once the crank arms (K) are attached to the assembly, again refer to the drawings to make sure the entire assembly matches the corresponding configuration type.Step 7) The connecting rod (P) is supplied long enough to meet all configuration types, and will have to be modified in the field to properly fit your assembly. Connecting rod(P) is furnished with jamb nut (O),yoke (N), clevis pin (L) and cotter key (M) attached to one end, and the second yoke assembly attached to the opposite end. Remove the yoke assembly from the end without the jamb nut (O). Remove the cotter pins (M) and clevis pins (L) from both yokes (N). With the valve discs and crank arms (K) properly positioned, attach the end of the connecting rod (P) with the still attached yoke (N), to one of the crank arms (K), and reinstall clevis pin (L) to retain its position. Attach the free yoke (N) to the second crank arm (K) and again use the clevis pin (L) to retain its position. Point the connecting rod (P) towards the second yoke and align the yoke (N) with the connecting rod (P). You will now have an idea of where to CUT the connecting rod (P) for a proper fit. The correct length is attained when the ENDS of the connection rod (P) are even with the INSIDE ends of the threads on the yokes (N). Be sure to tighten the jamb nut (O)after the proper length has been attained. Reinstall the cotter pins(M) in both clevis pins (L) and bend to retain.Step 8) Assemble the actuator(s) to the linkage by sliding the actuator shaft clamp over the kit drive shaft(s)(E). The actuator anti-rotation pin(s) (I) should already be positioned in the correct hole for the actuator, but they can be moved to accommodate AM, GM or AF series actuators. Make sure the anti-rotation pin nut(s) (J) is tight. Make sure the bottom of the actuator(s) is PARALLEL to the mounting plate (A) when tightening the actuator clamp nuts. If this is not checked, it is possible that binding could cause erratic movement of the valve disc due to reduced torque transmission to the valve shaft(s). For AF series actuators, release the pre-load on the spring before tightening the clamp nuts, as the valve discs have already been positioned at their full travel stops in step 2 above.Step 9) Keep in mind that for dual actuator retrofits, the actuators turn in OPPOSITE directions. AF series actuators have to be mounted with opposite sides UP, and GM series actuators will need to have their 0/1 acting switches changed so one is opposite the other. Step 5) Refer to the three configuration drawing types and position the crank arms (K) as instructed. Slide the crank arms over valve couplings(F), and position just below the top edge of the couplings. Tighten set screws (H) to affix the crank arms (K) to the couplings(F).* On larger units it may be necessary to spot weld the crankarm to the coupler. Assembly Procedure for SY…Retrofit SolutionPREFERREDDANGERACCEPTABLEHORIZONTAL909010OMFLNAHJKBCDQRPEEXISITING TEEEXISITING SLAVE VALVEEXISITING MASTER VALVEBRACKET OPENINGWELDEDRetrofit Requirement: The initial step is to determine if your application can accept a retrofit solution. As shown below (Fig. 1), the valve stem must not be located below the horizontal plane. If this condition exists, the SY actuator could not be used in this situation. A Belimo technical support person is available to help determine what solution best fits your application. A typical solution is shown in Fig. 2.Depending on the orientation of the tee assembly, if the valves are mounted on the TOP and BRANCH positions (tee mounted vertically), or on the LEFT and BRANCH positions (tee mounted horizontally) you will refer to configuration codes X10-X15. Master Valve is Normally OpenValves turn in directions shownAttach Crank Arms as shownSlave Valve is Normally ClosedCheck for rotation clearanceto bracket BEFORE attachingObserve direction of rotationon actuator BEFORE mountingBracket Opening Directionw/ "S" DiscClosedCrank Armw/ "M" DiscCrankArmOpenMonto bracketry.SMaster Valve is "M"Slave Valve is "S"actuator.X20-X25:SY Orientation0X20 - X25Bracket Opening Directionw/ "S" Discw/ "M" DiscSClosedCrank ArmArmOpenCrankMon actuator BEFORE mountingto bracket BEFORE attachingSet Valve "M" Open as shownObserve direction of rotationCheck for rotation clearanceValves turn in directions shownAttach Crank Arms as shownSet Valve "S: Closed as shownactuator.onto bracketry.X10-X15:Slave Valve is "S"Master Valve is "M"SY Orientation0X10 - X15If the valves are mounted on the BOTTOM and BRANCH positions (tee mounted vertically), or on the RIGHT and BRANCH positions (tee mounted horizontally) you will refer to configuration codes X20-X25.Next >