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Using Belimo Actuators To Retrofit Existing Valves and Dampers

Thursday, February 11, 2010

All webinar times are EST.

  • Which valves and dampers can be retrofit?
  • How to retrofit globe, butterfly and ball valves
  • How to convert pneumatic applications to electronic
  • How to select retrofit equipment
  • How to replace fire and smoke actuators

Damaged linkages and/or actuators resulting in non-functioning HVAC system applications, used to mean a loss of properly functioning systems leading to a degradation of energy efficiency, consumer comfort, time, and labor. Replacing a valve along with the actuator, or trying to determine how to fix an airside linkage, is not always a sensible solution. Taking a system off-line to replace various components is not only laborious, it’s expensive. Facilities can lose thousands of dollars a day during maintenance shut-down.

With retrofit solutions, this problem simply goes away. Valves and Damper applications can be quickly and conveniently restored without any interruption in service. In fact, entire systems can often be updated in a day. A poorly functioning or even non-functioning system can be transformed into a high functioning, more efficient system.

Belimo Retrofit Solutions Technical Documentation



Hello and welcome to the webinar. My name is David and I’m the marketing manager or Industrial Controls. We’ve been providing training classes on our 18 physical locations for the past 30 years. And now, since our customers are still widely distributed, we’ve extended the program to the internet. And today’s webinar is on using Belimo actuators to retrofit existing valves and dampers. We’re going to hear from two experts today. And after they finish, we’re going to take some time to answer your questions. During the presentation, feel free to answer your questions into the interface on the right-hand side of your screen. At the end, we’ll possibly open it up for voice questions depending on how much time we have left.


Wesley is a salesman at Industrial Controls in the New York City office. He’s worked with commercial controls for 17 years and he’s an instructor for local 638.


Rob has been conducting training classes for Belimo for 6 years. He has over 30 years experience troubleshooting and providing solutions for commercial applications.


So at this time, I’m going to pass the presentation to Rob.




Hello. Welcome, everyone. We have a half an hour to go through some quite a bit of material. So, I’m going to move it pretty quick but I’d like to just go in the intro. What we’re going to cover is basic retrofits and what do you need to know to provide a retrofit for your applications, dampers, and valves. We’re going to go over the different types of control signals. We’re going to touch on little wirings, something with wiring, and some tricks.


Retrofit catalogue you’ll see is going to be the main focus and I believe everyone is getting probably a copy of this who signed up and we’re going to go over the gap of motocross reference, we’re going to go through a globe valve cross and butterfly valves. And at the end, we’ll just show you some custom retrofits that Belimo will do and we’ll get started.


Obviously, these are the websites: www.industrialcontrolsonline.com and www.Belimo.com. You can use for reference. If you go into Industrial Controls, I believe you can link right into Belimo from their site.


So, we’re going to go quickly over to nomenclature for Belimo, some part numbers, and there’s a lot of people out there who may think that the first – I mean the second item is a spring return motor. The image says so, but in reality, it’s the LFT24-MFT US. And I’m just going to touch on some nomenclature now.


Belimo is a Swiss company, the America’s is located in Danbury, Connecticut. And the name was thought from the German Beraten, Liefern, and Montieren – meaning to Consult, Deliver and Mounting. And you ask why, it’s not a big deal, but what I’m trying to emphasize is that a lot of Swiss German is in our nomenclature status.


So, on all actuators, the second letter of the actuator with the designation of “F” is the term for Swiss German of Feder or spring. And SR, which everybody would assume as spring return and a lot of competitors use as a spring return designation, the Germans have it as Stetig Regler or Modulating. So that would be a modulating motor. So, those two things are pretty important when you’re going up and maybe trying to replace a Belimo. One may think it’s spring return, which it could be, but it also could be it’s modulating.


In the beginning chapters of PGPL, you’ll see that we have all the different torque ratings. So, the first designates the torque of the motor, second is the designation of spring return and non-spring return, and then we have some options that you’ll see fast running and no feedback, and obviously we need to know the power supply in which you need to drive the motor. The fifth designation is basically what kind of control we’ll use and we’ll cover that in a little while. And obviously, I’ll just rip through these and then at the end some have a -S which means a built-in auxiliary switch. Typically, this is at the first page of every section of our PGPL.


Right now, this is our line of spring return motors. We have the TF, our little tiny TF 18 in-lb, the LF, NF, and AF and then we have a full line of Fire & Smoke which I will just touch on later on because this is very important and a lot of people are interested now on how they repair their old fire & smoke dampers.


Beginning 2010, we’re introducing replacements for the AF and the NF. And the NF line is now available through Belimo and where the AF used to be – I mean the NF used to be 60 in/lb. You could see the NFB now is 90 in/lb. And there’s a lot more bells and whistles effect, we’ll not go through, but this one major advancement is this can be manual overridden with the manual crank for people who have been familiar with the AF. We also, as you can see, the AF Series is going to be basically coming in through throughout 2010. Right now, we have basically AFX Series with MFT, which if no one knows, I’ll explain about MFT later on. So, this is – the AF is available and it’s 180 in/lb. Being that we raised torques on these two actuators, you may be able to take care of some dual applications and just use one motor instead of two.


So in November, we started the NFB 90 in-lb, manual override and we’re going to come out with NEMA 4 models and you can order either/or. The indicator, as you can see on this valve application, is a lot larger so it’s easy to see, and basically when you whine the spring up, you can actually put it on hold with a little switch-down instead of clicking the on back. It’s kind of hard to do over here until I could actually show the crank on. And then in January, obviously we just kicked off the AF.


So, all the older models are available. The only other thing is if you have a dual application with old AF, you cannot interchange them. So, you’ll have to change both motors, or maybe you wouldn’t have to. Just to note that you may want to put down the guys who used AF and dual applications.


Okay. So, here’s the same nomenclature page for non-spring return. You could see we have a whole full line of these. And again, it’s the designation of the torque rating and then M is for motor which probably makes the most sense, H is for linear application and then we have 183 rotational. And we have also quick running, fast running and basic or customized. Customized is just if you want a special code links or change speed on a one-time application. Again, we have requirements for watt power using. There’ll be a lot of motors right now that you’ll be able to plug in from 120 to 240 and they’ll operate. And actually, on the AF side, we’ll have a UP, which is a spring return I was talking about. That will be have – UP would be universal power source. So, it will be the 2-position motor that you can replace from 24 V to 240 V, it wouldn’t matter. You just plug in the voltages and they’ll recognize it which is pretty cool. That’s probably available out in the summer.


Okay. And here, you have the control signals again, which we’ll go over and on the other end, we have terminal blocks for VAV type. This is mostly like OEM operations where you can have a cable or again the -S for switch.


This is our full line and non-spring return. We have a little CM which is introduced for residential and we’re doing some retrofits with them now. Our VAV motor, VLM, and then we have the NM through GM. These were all updated about 2 years ago. This is a new product. We updated all our talks and we also introduced the linear line and then the rotational line.


Coming in this year in this catalogue, we’re going to have housings, outdoor housings for the non-spring return motors. You can order them with heaters or without, the 4x enclosures. And then towards the middle of the year, we’ll also have enclosures for spring return with.




Okay. Let’s just talk fire & smoke motors. A lot of applications today, you may want to go from pneumatic to electronic. Can you place an electronic motor with a pneumatic motor? Yes, you can. And here are basically three lines. We have the FSLF, 350F at 15 seconds; the NF, 350F at 15 seconds; and then the AF. This FSLF probably is 85% of the time used in retrofits.


A couple of nomenclature items from UL. UL doesn’t really certify any replacement. It’s basically up to the AHA, the Authorized - I forgot the name of the acronym. I’ll get back to it. But for primarily, it’s either the building code or the fire marshal that will have final say. And basically, ordinary repairs on fire & smoke dampers need to be fixed.


So, you can change the Belimo motors. There are different forms you need to fill out. You can call your Industrial Controls rep and we can come in with Belimo. This is a whole days training in itself. But I just want to say that you can get into that business. If you have customers that have failing motors or they want to go pneumatic to electronic on the fire & smoke dampers, please give Industrial a call.


The other last thing I’ll just note on this are holding arms because when they drive open, their whole, and they’re always powered, we are into the lowest VA in the industry and as you can see, we have a VA holding on the FSLF at 3.5 and the next lowest was 8.


Let’s quickly go over control signals. Everyone knows we have all different types of control signals. These are the items that tell the motor what to do. So, we have on/off, open/close, we have 3-point, tri-state floating, proportional which is a 2-10 or a 0-10 signal with feedback. Then the other ones were proprietary applications that different manufacturers came up with, which is pulse width modulation, phase cut. These items are out there. Are they that popular? No, but they are around and we do have abilities to talk to those.


Multi-functional technology is a Belimo-exclusive. What it really allows you to do is be able to change any of the input signals to the signals I just spoke about. So, we have the ability to talk to anybody’s control system through multi-function technology.


Do you really need to use it all the time? No. We have the SRs which are 2-10 that everybody thinks spring return if you guys paid attention to the beginning of the training, but MFT allows you to do a lot of different things on an application.


So, basically, I just went through the slides. The other characteristics of MFT are we can actually change running, we can have selectable feedback. So, we can do volt VDC which you can actually put your option and where you can program 2-5 or however you want a volt’s input, we have pulse width modulation available, floating point, On/Off, and you can also change how you want the feedback scheduled back.


We also carry some specialized motors for exclusive Honeywell that uses 0-135 ohm signal and Barbara Colman had the old 6-9 V use and Staefa Control for phase cut.


So, how often, Wes, do you see this now? Is it still pretty common out there?




Well on this screen, specifically on the Barber Colman, I recall that when Belimo entered the valve retrofit market, that was the market that you targeted. There is Barber Colman motors out there and still out there and still sold new that we refer to as beer cans. They look like a large Foster’s beer can and they use that 6-9 V and there’s complaints in the field about the fact that they have hydraulic oil in them, they leak and this is a very good solution. So, this solution has been around on valves for at least probably 7 or so years or up.


On the one above, the Honeywell Series 90, you know, we see a lot of the mud motors, the old square box motors. So, keep in mind when you’re thinking about going through what might have otherwise been a $600 motor, you can enter the retrofit in the AF series for probably less than half that’s both on dampers and on valves.


So, Rob, really what drives this is what the signal is controlling it. So, in a retrofit situation, yes, if you’re going to stay series 90, then you need series 90. If you’re going to retrofit thermos, sometimes it makes more sense just to retrofit the thermostat with the motor and just go to a more modern 2-10 V DC.




Excellent. Okay. Here’s basically just the control signals and then we have the On/Off, they basically power up the spring return motor and break the old spring will close or open, however you set it up. And on the AMB side, the motor to the right, we have the black and red wire always powered and then the switch would be on the white wire and that’s why a lot of motors on the non-spring, you’ll see on/off or floating, which I’ll show you in the next screen. So just note that the white wire powered would always override the red wire. You have some signals or computer – I can't get the wire thing. The memory in the system now recognize that the white wire is powered, so it’s a nice way to check if your items power-drives one way without the other, and just put the white in with the red and if it drives the other way, you know that there’s something on the other side of the control signal. And here you have…




Rob, could you go back there a second. That’s – I checked on that myself, that’s a very odd wiring diagram, but what it allows you to do is if for some reason you want to – typically we’re going to do 2-position, you’re going to use the motor on the left, that’s the AF24.








But if for some reason, you had or even with the pricing issue, where you do not need spring return, but you have a thermostat that’s not a 3-point or floating thermostat, here you can use something like a T 87, that’s just 2 wires, and operate driving it open and driving it closed. What’s odd about this is as Bob pointed out, you can put power directly on 2 and 3 and the motor will drive in the opposite direction. The other point that I want to make on that one is that normally, Rob, on a 3-position motor is the motor is running the wrong way, you switch 2 of the wires and they could run the other way. Well, in the case of Belimo, there is just a little turn, directional, yes, you point into there and then in that same scheme it will just run the opposite direction. That’s all I want to say.




Cool. And here is the floating. Well, we just put it a single pole double-throw switch on that same motor and obviously we have our proportional 2-10 which allows you to have feedback and your control signal and obviously your power, which is the SR or stick at the regular modulating motor.


And here, on dual applications, for people who have been familiar with Belimo, right now on any dual application mount on either a damper or a globe valve for instance, what you want to do is set up a master slave. You don’t want to parallel old wires together. You want to take the 3 signals in to the master and take the feedback of that master and put it into the 3-wired slave. This way, this slave actuator will know that it’s driving off a master now. So, it eliminates some battling talk between the two motors on a common shaft and they’ll run consistently.




Rob, let me stay there for a second or two. So, what Rob just mentioned is that this is important where you have 2 actuators that are physically connected with one another. They’re on the same shaft of a damper, on the same shaft of a valve. That’s not to say like if you have an outdoor air damper and a return air damper. It isn't necessary to slave those two together because they’re not physically connected to one another.


Robert: Right.




So, it becomes less important on an again outdoor return now but it becomes critical when you have 2 motors that are again on the same shaft. Question, Rob, when you send something out from the factory a master slave, do you pre-wire those two together?


Robert: No, we do not. Its two separate models.


David: Alright. So, they would need to know how to wire that. Okay.




That’s correct. So, we’ll just go into the Retrofit Solutions Technical Documentation and we got 10 minutes to carry and go through a lot of stuff. But primarily, we have damper actuators and we have a cross-reference as you can see here, it goes to the different pages, and we look up the product numbers. These are just little examples. We have Honeywell, they’re 44 in/lb, and we can switch between the 35 or the 60 Belimo and so on and so forth. And there’s a non-spring crossover. These are just applications that you’d see we can go cross to the different manufacturers. Here’s a Siemens motor that we use the TF on and here’s our Siemens GCA121.1U. So basically, you would just go to the page, the Siemens, to Belimo, and you will see you have your Siemens number and then you have the Belimo replacements, and these particular columns, it will give you what the Belimo is set up.


Now, we have a GCA121.1U, it would be an AF24 US so on and so forth. Bu here, we got to be careful and this is where you need to check sometimes on some numbers. We have a GCA131.1P which is a floating type motor. Our suggestion is an AF24-MFT which is really the only thing we could use. As you can see, we stay here in the nomenclature that it looks like it’s a 2-10 motor which it can be but we need to program it to a floating motor.


So, this is very important, just when you do place the order to verify, like with Industrial, that we need – we have a GCA131.1P, so we’ve got to say, hey it’s a floating motor, so we’ll need to get that programmed. You want to answer that, Wes?




Yes. And across the board in the MFT series, even if you wanted a 2-10, you sort of need to state that upfront, so that we have 0-10, 2-10 floating in that MFT series. So, what I’m saying is when I place an order with Belimo, they’re looking for that program code whenever you see the MFT designation.




Alright. These are just some pictures we can do Trane retrofits. We use different types of brackets with the LF or AF. We’re just going through some pages and its all different types of items. But in the accessory page, just you can pull out a crank arm and what happens is just - to show where the designation is- it gives you the ZG-AF US would be okay for the AF and the NF. So, it’s just a quick little description.


And the ZG-AF108 and the ZG-LF112 are probably one of the more popular ones and I think they handle the majority of retrofits.


Wesley: Yeah, I would say that those two – now see that part number you have there, Rob – well see that doesn’t have a crank arm. Go back a second.


Robert: Okay.




And those are the part numbers or probably 99% of what you want to do when you’re not putting the Belimo dumper actuator onto the damper shift. So, these kits give you everything you need to get what you see in the picture there. That means you have a foot-mounted plate and also you convert what would have been the clamp into a crank arm. From there, to go to the damper, you’re going to need a ball joint on that crank arm, you’re going to need a push rod, at the other side, you’re going to need another ball joint and then if you’re going on the blade of the damper, you’ll need another crank arm, and/or if you’re going to the blade, you’ll need something to mount it on the blade with. But these 2 units, the ZG-AF108 and ZG-LF112, are probably 99% of what you use in kits to come up with the crank arm. That’s it.




Okay. There are some item pictures. Alright, let’s go to globe valve retrofits. We have globe valves of all different types out there and majority of them, we do have a good cross to them but if we don’t, we can work on doing a custom retrofit. On globe valves, we have two options. You can use the NV or the UGLK linkage, which is just the old regular Belimo on a linkage. And the UNV and the NV Series, the one thing, if you’re using spring return, you got to make sure that you get the right ones that fail in the UP position and the DOWN position. The only way to change UP to DOWN is you will need to change the actuator which becomes – you know, you have to return one in the water again and it’s a little difficult. So, you just got to make sure if you do like the NVF, it has very good close-off in a linear way and you just got to make sure you’ve ordered the correct fail-safe. UGLK is the nice thing about those – is if you ordered the wrong fail-safe, you can just turn the motor out, which is the nice thing.


And here are the different applications. We have multiple UNV kits and I’ll quickly go in through the components. We have the motor, we have this bracket, and the adaptors. Now, this bracket comes in different links. So, this is what changes the difference in stroke that’s required to open and close the valve. There’s the valve. This coupler, if you have to use this coupler, if you have one and existing the field, you should replace this coupler. I don’t have the product number right here but it’s important and it’s like a one-time use. And in the nomenclature, the retrofit catalogue, it tells you the exact how to assemble and shows you pictures.


So here, we’re going to go quite across, we got a V5011, 2-way, it’s somewhere between 1, like if I use the 1” for example, this would be a UNV-006. It’s a 1” and at 183 in-lb close-off, you could use an NVF Series, which is that linear series. If we go to a 1” in the non-spring return, you get 229 lb close-off with 250, we’ll have the NV or the NVG, which NV series is floating on/off, NVG is modulating.


So, when do we use the UGLK? 120 V is required because the NV is only coming 24 V. There’s a requirement that greater than ¾”. So, the NV is only limited to a ¾” stroke for the globe valve open or close. If you need the auxiliary switch, 0-135. And so, if you don’t know the spring position, this is a perfect one to order.


I also just showed up, we have NV kits for flange globe valves and the longest stroke that can be is no larger than a 1 ½”. So, if you have some of those big old-time globe valves that are larger than 1 ½” stroke, we do not retrofit those.




This is just a quick picture of a kit of UGL kit with the AF actuator – this is an NF, sorry. So, how do we pick a UGL kit? This particular example, we need a 1 ¼” valve, needing it 90 psi close-off spring return. So, based on those numbers, we go right to the actuator. And here we have to pick out a UGL kit. How do we do that? It’s a Siemens 6582A, somewhere between a half and 1 ¼”. They have two options here – the UGLK1350 or the UGALK1214. This (00.36) be the 1214 because it will give the close-off that you require to have on this application. The UGLK1350 uses an LF actuator and we’ll not close-off on that 90 psi. So, you would pick the UGLK1214, you go to 104 psi close-off and you’ll see, you see the NF series. So, depending on how you have the control in your power, then you pick the particular motor that you would need. So, the items would be order two items, the UGLK1214 linkage and then the actuator.


These are just the basic series that we have with UGLK retrofits and these are some of the NFT codes. You guys don’t need to memorize these. You just have to call, when you call Industrial, you give them the show signal that you need.


Okay. So say we can't identify the valve and the brands are gone and you can't see on it, we will have what we require as a custom retrofit. So, we have a form in the book that you’ll be required to fill out. This is actually changed in the books that you’re going to get. It’s a little easier to basically go through. But you fill out this form 90% of the time. And here’s another example of the diagrams, 90% of the time, we’ll be able to match up with the stock unit but if we do need to do some customization, we will do that in our machine shop at Belimo. So this is – you got to get Industrial involved and then get either us out or we can get this done on custom. So, we do do custom retrofits.


So quickly, butterfly valves, there’s time limited, same type of scenario. If you want to take a manual valve and make it automated or we can replace our competitor’s automated valves and we basically do the same type of thing. We have a centerline 2 ½” with 2 AF which is the maximum close-off with the AF. Or if it’s non-spring, it would be the GM or the dual GM, and we’ll basically be able to retrofit up to 24” butterfly valves and this is our industrial line, as you can see. This just shows a picture of the assemblies for the spring return and non-spring return, we do 3-ways, and this book not only shows you the assemblies, but it shows you pictures and it actually gives you instructions on assembly. These are our industrial motors, the NEMA 4 xs outside with heaters, 2 auxiliary switches and these are very common to the larger sizes.


Some custom retrofit examples. This is an example we used up in the Brown University where it’s a 3-motor (03.14) it’s like. That’s what we thought it was good for. When it is through MFT, we were able to program 104-degree drive. What happens is it was a pneumatic to electronic, and 90 degrees swing on the motor was not sufficient enough, so we were able to program this motor to give the extra degrees of drive and change this to a summer or winter switch.


These are just examples to show you that we’ll do custom stuff. So, if you’ve got something out there that’s kind of weird, we’ll get right into it. As you can see, it’s a globe valve, and globe valve we did a retrofit. And if the valve’s integrity is good, why change it? But most of the time, if the valve is older, you may want to have to think about changing the whole valves.


Here’s an example we just set up, it was a pneumatic application, and what we did was because of room constraints, we weren’t able to put that XY actuator right on the top of the valve as you can see here. So…


In Manhattan just recently. So, these are just examples to show you that Belimo will try to think outside the box to retrofit applications. Something coming out new, we are now going to come out probably in August with retrofits that will go on to Siemens 81 use I believe - Wes, I think that’s the actuator – and they’ll be able to screw around the retrofit to Siemens short stroke with no tools and these are just what – you could see this is the actual linkage and then a non-spring motor




You can type in to the interface and I will read those questions and if we can have enough, we’ll give the guys the opportunity to answer them. If you can raise your hand, but also using the interface, then I can pass the audio control over and you can ask your question that way.


Okay. We have Kyle who’s got a question. Let’s see if I can – Kyle, go ahead and ask your question. We have some audio issue there. Alright. I’m going to take a question that’s submitted by Tak, “Is there a way to retrofit ball valves?”




Yes, we just started retrofitting ball valves. We don’t have a lot of cross-reference on them but in the new catalogue, we do have basically the sheet that you need to fill out. So, any ball valve that can have a mounting on the top, driving 90 degrees, Belimo will look at and we’ve done quite a bit of industrial ball valve changes today.




Let me weigh in on out a second. I did a lot of inquiries regarding inexpensive ball valve with handles on them and I think watt in the old days had a sort of actuator that grabbed the handle like almost like a fork stuck down through the handle and was able to turn that. It’s a disaster. What you didn’t emphasize there, Bob, was we can retrofit something that was meant to have an actuator. So, it’s difficult to retrofit, sort of ball valves are only meant to be hand ball valves, cheap, inexpensive, so that it’s got a mounting pad, that’s a different story, that can be.


Robert: This is why I mentioned industrial type of valves, but that’s a good distinction. Thanks.




Okay. Michael is raising his hand. Michael, would you like me to ask your question? Okay and we have audio issue. But I do have a question on Tak, “Can we get some Belimo catalogues for us?” Actually, we’re going to send the Belimo retrofit catalogue out to everybody who registered for the webinar. You should probably have those within a week or so. We’re also posting on the internet. So, if you navigate to www.industrialcontrolsonline.com, you can go to our training link, and under the training link, you’re going to find this webinar. On that page, we’re going to have the PDF version of the catalogue.


Michael: That’s very useful to the rest of us.


Unknown: Let’s go over to – raise your hand.


David: Okay. I have another, Tak’s question, “How can I size an actuator motor to a damper?”


Robert: Okay, in the catalogue, it actually goes to a 10-step, in that retrofit book, 10-step process for you to properly size dampers. One of the biggest things today is if you have an old motor that say died, I’d say resize the damper, make sure that it actually works physically and then go from there. We do have extensive trainings again that we’ll go all with damper sizing. So, it’s in that retrofit book.


David: Okay. I don’t see any other questions coming through us. So, as we’re running out of time here, I just want to mention that we’re going to have few more webinars coming up. We’re planning something in March. It’s going to be about using non-obstructive airflow measuring stations. We don’t have a date for this yet but we’re going to have one posted on the website soon. So, you can look for that and we’re also going to send an email invitation out and one email address that we have here. If you missed any part of today’s presentation, we’re going to put a recorded version of it on the internet. We’re going to follow up with an email that’s going to link you to everything, that’s going to have our contact information if you have any questions that you’d like to give to our experts. And with that, I don’t have anything else and I’d like to thank you, guys, for the presentation and thank you, everybody for attending.


Robert: Thank you.


Wesley: Thank you.



Wesley Fagan is a salesman at Industrial Controls' New York City office. He has worked with commercial controls for 17 years and is an instructor for local 638.

Robert Siegel has been conducting training classes for Belimo for 6 years. He has over 30 years experience troubleshooting and providing solutions for commercial applications.

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