Bettis Q-Series Actuator Installation Operation & Maintenance Manual

Bettis Q-Series Actuator Installation Operation & Maintenance Manual
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
Bettis Q-Series Valve Actuator
APPROVED
www.Bettis.com
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
Page 2
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
Contents
A Before you start ................................ 4
A1
A2
Orientation (see fig. A1)............................. 4
Installation, operation and maintenance
reference documents................................. 4
A3 Operating medium..................................... 4
A4 Product integrity......................................... 4
A5 Hazardous areas....................................... 5
A6 Warning ; Moving parts.............................. 5
A7 Prevent moisture entering the actuator..... 5
A8 Warehouse storage................................... 5
A9 On site storage........................................... 5
A10 Lifting instructions...................................... 5
1Introduction........................................ 6
1.1 Orientation (see fig. 1.1)............................ 6
2Installation.......................................... 7
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Before you start.......................................... 7
Failure modes............................................ 7
Operating principle..................................... 8
Actuator assembly codes...................... 12
Valve Installation...................................... 14
Recommended tubing sizes.................... 15
Air consumption per stroke at
atmospheric pressure.............................. 15
3 Mechanical stroke adjustment....... 16
3.1 Adjusting the “Open” position.................. 16
3.2 Adjusting the “Closed” position................ 16
3.3 Adjusting the end position with no electrical
wiring connected...................................... 17
4 Removing and mounting of the
Bettis Q-Series Modules................. 18
4.1 Removing the Bettis Q-Series modules.. 18
4.2 Mechanical alignment and mounting
of the control module............................... 18
4.3 Tightning moments.................................. 18
4.4 Connecting air supply.............................. 18
5 Speed control option ...................... 19
5.1 Mounting Speed Control throttle(s):........ 19
2
Adjusting Speed Control throttle(s):........ 19
6 Manual Control option.................... 20
6.1 Mounting Manual Control........................ 20
6.2 Manual Control operation........................ 20
7 Trouble shooting Bettis Q-Series... 21
7.1 Mechanical problems............................... 21
7.2 Pneumatic problems................................ 21
7.3 Electrical problems................................... 22
8Maintenance..................................... 23
8.1General..................................................... 23
8.2 Single acting / Spring Return actuators.. 23
8.3 Bettis Q-Series recommended spare
parts.......................................................... 23
8.4 Position tracking device kits.................... 23
8.5 Conversion kits........................................ 23
8.6 High Temp and Low Temp Conversion
kits............................................................ 23
9Disassembly..................................... 24
9.1 Before starting ......................................... 24
9.2 Removing end caps all types QD and
QS 40 to QS 350..................................... 25
9.3 Removing end caps type QS 600
to 1600..................................................... 26
9.4 Removing limit stop bolts, pistons and
pinion assembly....................................... 27
10Reassembly...................................... 29
10.1 Reassembly guide band and pinion
assembly.................................................. 29
10.2 Reassemble the pistons.......................... 31
10.3 Reassembly end caps, all types QD and
QS 40 to QS 350..................................... 32
10.4 Reassembly end caps single acting
actuators QS 600 to QS 1600................. 33
10.5 Mounting and setting of limit stops.......... 34
10.6 Final assembly and airtightness test....... 35
11 Bettis Q-Series Parts....................... 36
11.1 Exploded view Bettis Q-Series
(base actuator)......................................... 36
11.2 Bill Of Material.......................................... 37
11.3 Exploded view Bettis Q-Series
(Control Module)...................................... 38
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Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
A
Before you start
• Bettis Q-Series actuators must be isolated
both pneumatically and electrically before (dis)
assembly.
• It is not permitted to connect a pressure vessel
with unreduced media to the Bettis Q-Series
pneumatic actuator.
• Bettis Q-Series actuators must not be connected
to an air supply greater than 8 bar g or 120 psig
• This manual does not provide instructions for
installations in hazardous areas.
• Installation, adjustment, putting into service, use,
assembly, disassembly and maintenance of the
pneumatic actuator must be done by qualified
personnel.
A1
Orientation (see fig. A1)
The Bettis Q-Series actuator is an integrated
concept for the automation of quarter turn valves,
dampers or other quarter turn applications. It can
consists of three basic parts:
1.Pneumatic actuator,
2.NAMUR Plate or
3.Control Module
1
A2
Before mounting, installing, commissioning or
(dis)assembling the actuator consult the following
documents:
- All chapters of this manual and
- Installation Guide of the supplied Control Module.
- For installation in hazardous area’s:
The applicable section of the Installation Guide,
as shipped with the Control Module.
- For Control Modules with bus communication
there may be an additional Reference Manual
with more detailed information.
(available from www.Bettis.com).
A3
Product integrity
• Assembly or disassembly is only allowed for
replacing seals and guide bands (soft parts).
3
2
Page 4
Operating medium
• Air or inert gasses:
- Filtered to 50 micron.
- Check the Installation Guide as shipped with the
module for the applicable air quality.
• Maximum pressure, 8 bar g / 120 psig
• Dew point 10 K below operating temperature.
• For subzero applications take appropriate
measures.
A4
Fig A1 Orientation
Installation, operation and
maintenance reference documents
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
A5
Hazardous areas
A8
Improper installation in a hazardous area can
cause an explosion.
• Assembly, disassembly and maintenance must be
done in safe area’s without a potential explosion
hazard.
• For information about installation in a hazardous
area, refer to the appropriate sections of the
Installation Guide, as shipped with the control
module.
A6
Warning ; Moving parts
Applying pressure to the actuator or
Applying a control signal to the Control
Module, may cause the actuator/valve
assembly to operate.
A7
Prevent moisture entering the
actuator
Condensation or moisture that enters the actuator or
the Control Module can damage these components
and can result in failures. Therefore:
• Try not to mount the actuator with the conduit
openings or the air entries, pointing upward.
• Ensure integrity of gaskets and o-rings.
• Install drip loops in conduit or cable.
• Seal all conduit openings whether used or not.
Warehouse storage
• Bettis Q-Series Actuators and Control Modules
should be stored in a clean, dry warehouse, free
from excessive vibration and rapid temperature
changes.
• Actuators should not be stored on any floor
surface.
A9
On site storage
• Bettis Q-Series Actuators and Control Modules
should be stored in a clean, dry warehouse, free
from excessive vibration and rapid temperature
changes.
• Ensure all actuator covers are in place and
securely fastened.
• Replace plastic conduit plugs with appropriate
pipe plugs.
Failure to follow proper storage guidelines will void
warranty.
A10 Lifting instructions
• Use lifting equipement as required by national or
local legislation.
Table A1 Weight of Actuators with
control modules
ACTUATOR
TYPE
OK
Fig A2 Install drip loops
Double
acting
Spring
Double
Return
in kg.
acting
Q40
3.9
4.5
Spring
Return
in Ib
8.6
9.9
Q65
4.5
5.7
9.9
12.6
Q100
5.2
6.7
11.5
14.8
Q150
6.9
9
15.2
19.8
Q200
7.9
11.2
17.4
24.7
Q350
12.5
19
27.6
41.9
Q600
21.5
29.7
47.4
65.5
Q950
28.5
40.7
62.8
89.7
Q1600
44.8
67.9
98.8
149.7
• It is strongly recommended to use lifting straps to
lift the actuator/valve assembly.
• If an actuator/valve assembly should be lifted, it
is strongly recommended to connect the lifting
straps in such way that the actuator and valve is
supported.
Page 5
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
1Introduction
1.1
Orientation (see fig. 1.1)
The Bettis Q-Series actuator is an integrated concept for the automation of quarter turn valves, dampers or other
quarter turn applications.
Factory setting:
Rotation 90°±0.5°
2
1
3
4
7
Insert according
ISO 5211 or DIN 3337
5
6
8
Optional insert shapes
Fig 1.1 Introduction
1.
2.
3.
4.
Pneumatic actuator
Visual Position Indication
Stroke adjustment bolts
Control Module
Page 6
5. Entries for optional manual control
6.Exhausts
7. Supply air entry
8. Entries for optional speed control
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
2Installation
2.1
Before you start
In case of an air or electrical failure, it is important to know the behavior of the actuator.
Before mounting the actuator on a valve consult the following paragraph’s.
2.2
Failure modes
2.2.1 Valve rotation
2.2.2 Position after a failure
Valves are normally manufactured so that:
- the valve is closed after a clock wise rotation
(viewed from above).
The position of the actuator after a failure depends
on the:
- Operating principles (see §2.3)
- Assembly code (see §2.4)
- Kind of failure
closed
Table 2.1 Position after a failure
Principle of
operation
Assembly
Kind of
code :
failure :
Position :
Pressure
not defined
Signal
Closed
Supply voltage
Closed
Pressure
not defined
Signal
Open
Supply voltage
Open
Pressure
Closed
Signal
Closed
actuator
Supply voltage
Closed
(Spring
Pressure
Open
Signal
Open
Supply voltage
Open
CW
Double
acting
actuator
CC
Fig. 2.2.1
- the valve is open after a counter clock wise
rotation (viewed from above).
Single
acting
Return)
open
CW
CC
Table 2.2 Position after a failure with a Double
acting module with Fail-In-LastPosition function
Principle of
operation
Fig. 2.2.2
Assembly
Kind of
code :
failure :
CW
Double
acting
actuator
CC
Position :
Pressure
not defined
Signal
not defined
Supply voltage
Closed
Pressure
not defined
Signal
not defined
Supply voltage
Open
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Installation Operation & Maintenance Manual
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April 2014
2.3
Operating principle
2.3.1 Double acting actuators
See paragraph 2.4 for more information about
actuator assembly codes
Important
The operating principle, as explained here, is
applicable for actuators with assembly code CW
(direct acting).
- The outward stroke will move the valve to the
“Open” position.
- The inward stroke will move the valve to the
“Closed” position.
* Electric control signals can be connected in the
Control Module (QC; see documentation supplied
with the Control Module). The Control Module is
equipped with a pilot valve which controls a 5/2
spool valve.
* Connect air supply to air inlet (Ps).
For assembly codes CC the operating principle is
reversed (reverse acting):
Outward stroke
A-port
Option:
Throttle 1
5/2 Spool valve
Option: LMC
1 Send control signal “Open” to the Control Module.
2 Pilot valve 1 will be activated and the 5/2 spool
valve will pressurize the central air chamber.
3 The piston will move outwards to the “Open”
position.
4 The Control Module indicates the “Open” position
and activates feedback signal “Open”.
B-port
Option:
Throttle 2
Rb
Ps
Ra
Pilot
valve 1
Fig. 2.3.1
Inward stroke
A-port
Option:
Throttle 1
5/2 Spool valve
Option: LMC
1 Send control signal “Close” to the Control Module.
2 Pilot valve 1 will be deactivated and the 5/2 spool
valve will pressurize the end cap air chambers.
3 The piston will move inwards to the “Closed”
position.
4 The Control Module indicates the “Closed”
position and activates feedback signal “Closed”.
B-port
Option:
Throttle 2
Rb
Ps
Ra
Pilot
valve 1
Fig. 2.3.2
Optional controls:
LMC
SC
Local Manual Control
Speed Control throttles
Important:
In case of an electric control signal failure, the
actuator will move to its “Closed” position.
Page 8
Installation Operation & Maintenance Manual
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April 2014
2.3.2 Double acting actuators with Fail In Last
Position function
Important
The operating principle, as explained here, is
applicable for actuators with assembly code CW
(direct acting).
- The outward stroke will move the valve to the
“Open” position.
- The inward stroke will move the valve to the
“Closed” position.
See paragraph 2.4 for more information about
actuator assembly codes
* Electric control signals can be connected in the
Control Module (QC; see documentation supplied
with the Control Module). The Control Module is
equipped with a pilot valve which controls a 5/2
spool valve.
* Connect air supply to air inlet (Ps).
For assembly codes CC the operating principle is
reversed (reverse acting):
Outward stroke
A-port
Option:
Throttle 1
1 Send control signal “Open” to the Control Module
to activate Pilot valve 1 and
de-activate Pilot valve 2.
2 The 5/2 spool valve will pressurize the central air
chamber.
3 The piston will move outwards to the “Open”
position.
4 The Control Module indicates the “Open” position
and activates feedback signal “Open”.
B-port
Option:
Throttle 2
5/2 Spool valve
Option:
LMC 2
Option: LMC 1
Ps
Rb
Ra
Pilot valve 1
Pilot valve 2
Fig. 2.3.3
Inward stroke
A-port
Option:
Throttle 1
1 Send control signal “Close” to the Control Module
to activate Pilot valve 2 and
de-activate Pilot valve 1.
2 The 5/2 spool valve will pressurize the end cap air
chambers.
3 The piston will move inwards to the “Closed”
position.
4 The Control Module indicates the “Closed”
position and activates feedback signal “Closed”.
B-port
Option:
Throttle 2
5/2 Spool valve
Option: LMC 1
Option: LMC 2
Ps
Rb
Ra
Pilot valve 1
Optional controls:
LMC
SC
Local Manual Control
Speed Control throttles
Pilot valve 2
Fig. 2.3.4
Page 9
Installation Operation & Maintenance Manual
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April 2014
2.3.2 Single acting (spring return) actuators
Important
The operating principle, as explained here, is
applicable for actuators with assembly code CW
(direct acting).
- The outward stroke will move the valve to the
“Open” position.
- The inward stroke will move the valve to the
“Closed” position.
See paragraph 2.4 for more information about
actuator assembly codes
* Electric control signals can be connected in
the Control Module (QC; see documentation
supplied with the Control Module). The Control
Module is equipped with a pilot valve controls a
3/2 spool valve.
* Connect air supply to air inlet (Ps).
For assembly code CC the operating principle is
reversed (reverse acting):
Outward stroke
A-port
1 Send control signal “Open” to the Control Module.
2 Pilot valve 1 will be activated and the 3/2 spool
valve will pressurize the central air chamber.
3 The piston will move outwards to the “Open”
position
4 The Control Module indicates the “Open” position
and activates feedback signal “Open”.
B-port
Option: Throttle 1
3/2 Spool valve
Option: LMC
Ps
Ra
Pilot
valve 1
Fig. 2.3.5
Inward stroke
A-port
1 Send control signal “Close” to the Control Module.
2 Pilot valve 1 will be deactivated and the 3/2 spool
valve will vent the central air chamber
3 The springs will move the pistons inwards to the
“Closed” position
4 The Control Module indicates the “Closed”
position and activates feedback signal “Closed”.
B-port
Option: Throttle 1
3/2 Spool valve
Option: LMC
Ps
Ra
Pilot
valve 1
Fig. 2.3.6
Page 10
Optional controls:
LMC
SC
Local Manual Control
Speed Control throttles
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
2.3.3 Position feedback
Bettis Q-Series patented, position sensing
system
1
3
The Bettis Q-Series actuator (1) has a patented,
contactless position sensing system. This system
consists of a position probe (2) which is rides on a
special curve (4) in the pinion bottom.
The curve is shaped in such a way that the position
probe moves linearly and proportionally to the
rotation of the actuator pinion.
2
The linear movement of the position probe is used,
inside the control module (3) to operated the limit
switches.
WARNING:
Do not put the Control module in direct contact
with magnetic material. This can cause damage or
malfunction of the position feedback.
Installation of the Bettis Q-Series modules
For installation instructions of the modules see
chapter 4.
4
Fig. 2.3.5
Installation Guides - Control modules
Each Control Module is shipped with an Installation
Guide, which contains more information on the
pneumatic and electrical installation and operation
of the Module. Additionally, these Installation Guides
can be downloaded from www.Bettis.com
Page 11
Installation Operation & Maintenance Manual
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April 2014
2.4
Actuator assembly codes
2.4.1 Double acting assembly codes
Standard assembly code:
Optional assembly code:
(= Counter Clock Wise Rotation)
CW
(= Clock Wise Rotation)
Visual indicator mounted:
Visual indicator mounted:
(= for In line position indication
I
(= for In line position indication
Pinion
B
A
2
2
B
2
2
2
1
B
A
A
Pistons
A
A
B
B
2
Optional assembly code:1
B
(= Clock Wise Rotation)
2
2
1
A
C
B
2
2
A
1
Visual indicator mounted:
2
(= for Cross line position indication)
2
1
2
A
A
A2
B
B
2
1
2
A= Pilot valve operated in Control Module B= Pilot valve not operated in Control Module 2
2
1
1
2
1
- Central air chamber (1) pressurized
- End cap air chambers (2) pressurized
All views are from above. Pistons are shown in inner position
2
2
2
1
2
1
1
B
Optional
assembly
code:
(= Counter Clock Wise Rotation)
B
2
2
2
2
CW
1
B
1
A
B
2
A
Visual indicator
mounted:
A
(= for Cross line position indication)
2
1
B
2
Page 12
A
B
2
1
I
A
Position
indicator
B
A
CC
2
CC
C
Installation Operation & Maintenance Manual
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April 2014
B
B
A
A
2.4.2 Single acting (Spring Return) assembly codes
2
2
Standard assembly code:
(=Clock Wise Rotation /
Spring to Close)
1
CW
Visual indicator mounted:
(= for In line position indication
Visual indicator mounted:
(= for In line position indication
I
Pinion
B
B
2
2
I
A
A
B
2
2
1
CC
B
Position
indicator
A
A
Optional assembly code:
(=Counter Clock Wise 1Rotation2/
Spring to Open)
2
2
1
2
B
21
1
2
A
B
A
Pistons
2
1
Optional assembly code:
(=Clock A
Wise Rotation /
Spring to Close)
B
Visual indicator
mounted:
(= for Cross line position indication
B
CW
A
C
B
2
A
2
2
1
1
CC
Visual indicator mounted:
(= for Cross line position indication
C
A
A= Pilot valve operated in Control Module B= Pilot valve
not operated in Control Module B
A
A
B
B
1
2
2
Optional assembly code:
(= Counter Clock Wise Rotation /
Spring to Open)
2
2
2
2
2
1
2
2
- Central air chamber (1) pressurized
- Spring stroke (2)
All views are from above. Pistons are shown in inner position
2
2
1
2
Page 13
Installation Operation & Maintenance Manual
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April 2014
2.5
Valve Installation
Warning!
Actuator must be isolated both pneumatically
and electrically before (dis)assembly. Before
mounting or (dis)assembling the actuator consult the
relevant sections of this manual.
Remove handle nut, handle, lock washer, etc. from
valve if required.
Caution!
- Before mounting the actuator on the valve
be sure that both the actuator and the
valve have the same position.
- When mounting do not hit with hammer on
pinion top.
2
1
Fig. 2.5.1
Fig. 2.5.4
OK
OK
Fig. 2.5.5
Fig. 2.5.2
Caution!
Be sure that the insert is mounted at 90° or
45°.
It is possible to mount the insert turned 22.5°. This
way the valve will not open or close the right way.
45°
90°
ISO 5211
Fig. 2.5.3
Page 14
DIN 3337
Important!
- When mounting the actuator across the
pipeline, the NAMUR slot at the pinion
top is turned 90° and does not reflect the
position of the valve blade.
- When mounting NAMUR (VDI/VDE3845)
switch boxes or positioners take care that
these devices can be and will be set to
reflect the actual limit positions.
Installation Operation & Maintenance Manual
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April 2014
2.6
Recommended tubing sizes
Actuator Model no.
Runs up to 1.2 mtr / 4 ft.
Runs over 1.2 mtr. / 4 ft.
Q-40, 65
6 mm / 1/4”
6 mm / 1/4”
Q-100, 150, 200, 350
6 mm / 1/4”
8 mm ~ 5/16”
600, 950, Q1600
8 mm / 1/4”
10 mm ~ 3/8”
2.7
Air consumption per stroke at atmospheric pressure
Model
Air chamber
- at 1 atm (litres)
Q40
Q65
Q100
Q150
Q200
Q350
Q600
Q950
Q1600
Central air chamber
0.16
0.33
0.35
0.84
0.8
1.8
2.9
4.7
7.3
End cap air chambers
0.22
0.36
0.49
0.78
1
1.9
3.1
4.9
8.0
Central air chamber
10
20
21
51
49
110
177
287
445
End cap air chambers
13
22
30
48
61
116
189
299
488
- at 1 atm (cu./in.)
Page 15
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3
Mechanical stroke adjustment
The factory setting of the stroke is 90° ±0.5°
Closed
15°
-3°
3.1
90°
Adjusting the “Open” position
1.Connect supply pressure and control wiring
according the instructions shipped with the
Control Module.
2.Remove the nut caps (A).
3.Loosen nuts (B). See table 3.1.
±0.5°
75°
Open
93°
Repeat next steps 4 to 8 until desired setting is
achieved:
Fig. 3.1
Code CW and Code CC
Closed
position
Open
position
Fig. 3.2
C
If required the stroke can be adjusted by means of
two stroke adjustment bolts.
B
A
4.Send the actuator/valve assembly to the “Open”
position (see instructions shipped with the Control
Module).
5.Check whether the position of the valve is correct.
The position indication knob (C) indicates the
valve position
If the position is not correct, proceed with the
following steps:
6.Send the actuator/valve assembly to the “Closed”
(opposite) position (see instructions shipped with
the Control Module).
7.Turn the limit stop bolts (see table 3.1):
Turning in reduces the stroke:
Turning out increase the stroke:
8.Send the actuator/valve assembly to the “Open”
position (see instructions shipped with the Control
Module).
9.Check whether the position of the valve is
correct..
When the “Open” position is correct proceed with
adjusting the “Closed” Position.
3.2
Adjusting the “Closed” position
1.Execute steps 4 to 8 of §3.1 but now for the
“Closed” position.
2.Mount the nut caps (A).
Fig. 3.3
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April 2014
3.3
OK
Adjusting the end position with no
electrical wiring connected.
If the Control Module is equipped with the optional
Pneumatic Manual Override (A), only supply
pressure needs to be connected to cycle the
actuator. For more information on how to use the
“Pneumatic Manual Override” see chapter 6.
OK
Remark:
In case of air leakage over the limit stop bolts,
turn the lock nut of the limit stop bolts tighter, until
leakage stops.
Fig. 3.1.2
Table 3.1 Angular Displacment & Tools
Actuator
Size
Tools
Angular
displacement
Nut
Bolt
Q40
3.0 °
W10 mm
SD1.2 mm
Q65
3.6 °
W13 mm
SD1.2 mm
Q100
2.7 °
W13 mm
SD1.2 mm
Q150
2.7 °
W17 mm
SD1.5 mm
Q200
2.3 °
W17 mm
SD1.5 mm
Q350
2.7 °
W19 mm
SD1.5 mm
Q600
2.7 °
W24 mm
W10 mm
Q950
2.5 °
W24 mm
W10 mm
Q1600
2.7 °
W30 mm
W10 mm
W = Wrench
SD = Screwdriver
Page 17
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April 2014
4
Removing and mounting of the Bettis Q-Series Modules
4.1
1
4
5
3
4
2
1 To prevent warping of the modules and damage to
the threads:
- First loosen the all screws 1/4 to 1/2 turns.
- The screws can now be removed completly.
2 Prevent damage to the position probe (5) to
guarantee accurate position feedback.
4.2
6
4x No. 2
3x No. 5
Fig. 4.1
Warning
Bettis Q-Series actuators must be isolated
both pneumatically and electrically before
(dis)assembly.
The Control Module (3) is mounted at the side of
the basic actuator housing (1). The actuator can be
equipped with a NAMUR plate (2) for direct solenoid
mounting.
Alignmentedge
IPT
probe
Mechanical alignment and
mounting of the control module
The control module is equipped with an alignmentedge on top of the module. This allows easy
alignment and mounting of the control module on to
the actuator housing.
Procedure: (see figure 4.2)
1.First take care that both mating faces from the
actuator and control module are clean and free of
dirt.
2.Check if the module has the required function.
3.Remove the transparent film from the control
module.
4.Ensure seals (4) are placed correctly.
5.Level the screws with the surface.
6.Place the alignment-edge (5) of the control
module at the top of the pneumatic interface.
7.Flip the module down taking care that the IPT
Probe (6)on the actuator fits in the mating hole on
the control module and loosely place the screws.
8.Tighten screws according force in sequence.
4.3
Alignmentedge
Removing the Bettis Q-Series
modules
Tightning moments
The Control Module should be fastened by using the
allen keys as indicated and applying the following
tightning moments:
- Phillips head size 2, 1.8 to 2.2 Nm
(16 - 19.5 In.lbs)
- Allen Key No 5:
6.1 to 6.6 Nm
(54 - 58.4 In.lbs)
4.4
Connecting air supply
To connect air supply see the Installation Guide
shipped with the control module.
Tip
Grease the O-rings and seals before
mounting. This makes them sticky and
prevents that these O-rings and seals fall
away during mounting.
Fig. 4.2
Page 18
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
5
Speed control option
Warning
Bettis Q-Series actuators must be isolated
both pneumatically and electrically before
any (dis)assembly is begun.
Speed Control option
O-ring seal
Speed control
Nut cover
The Bettis Q-Series can be supplied with a Speed
Control option. One throttle is required for Spring
Return actuators and up to two for Double Acting
actuators.
The speed control throttle controls the air flow in and
out of an air chamber and as such limits the speed
of the “Opening” and “Closing” stroke simultaneously
5.1
Double Acting:
Bottom and/or top entries.
Mounting Speed Control
throttle(s):
1 Remove the plug(s) at the side of the module and
turn in the throttle (1).
2 Spring Return actuators: Use the top entry only.
3 Double acting actuators: Use both bottom and top
entries.
- For standard actuators, the top entry will throttle
the closing stroke.
- For standard actuators, the bottom entry will
throttle the opening stroke.
- For reverse acting actuators, the opposite
strokes will be throttled.
2
Spring Return:
Top entry only.
2
1
Figure 5.1 Speed Control option
Adjusting Speed Control
throttle(s):
1 Remove the nut cap (2).
2 Clockwise rotation of the adjustment screw
reduces the speed.
3 Counter clockwise rotation of the adjustment
screw increases the speed.
4 Replace the nut cap.
Page 19
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
6
Manual Control option
Manual Control option
Warning
O-ring seal
Bettis Q-Series actuators must be isolated
both pneumatically and electrically before
(dis)assembly.
Manual control
Nut cover
Location for 2nd
Manual Control
For commissioning, emergency or maintenance
purposes, the Bettis Q-Series can be supplied with
one or two Manual Control options. These can
operate the pilot valve(s) inside the module and as
such operate the actuator, when there is air pressure
available, but no control signal or power supply.
6.1
Lock
45°
Unlock
On
Off
Fig. 6. 1 Local Manual Control option
Default location of
Manual Control
Mounting Manual Control
1 To add a Manual Control, remove the plug(s)
in front of the module and turn in the Manual
Control.
- For normal operation the module should be
fitted with one Manual Control.
- For Double Acting with a Fail-in-Last-Position
function, two Manual Control can be fitted.
6.2
Manual Control operation
1 The Manual Control has a “Push & Lock”
function:
- To operate the Manual Control, use a screw
driver, push to activate and release to deactivate the pilot valves.
- If required turn it 45°, to lock it in position and
keep the actuator in its operated state.
2 In case of a Fail in Last Position configuration with
two manual controls:
- The manual control on the right side (default
location) will pressurize the central air chamber
and cause the actuator to rotate counter
clock wise. For reverse acting Bettis Q-Series
actuators (Assembly code CC) the actuator will
rotate clock wise.
- The manual control on the left side (Location for
2nd Manual Control) will pressurize the end cap
air chambers and cause the actuator to rotate
clock wise. For reverse acting Bettis Q-Series
actuators (Assembly code CC) the actuator will
rotate counter clock wise.
- In order to operate one of the manual control,
be sure the opposite manual control is deactivated and unlocked.
3 It is possible to rotate the screw multiple cycles.
The unit will than toggle every 90° between
“locked” (1) and “unlocked” (0).
Page 20
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DOC.IOM.BQ.E Rev: 0
April 2014
7
Trouble shooting Bettis Q-Series
7.1
Mechanical problems
Problem
Possible error
Solution
Feedback position and actual
position are not the same.
Valve is in “Closed” position,
actuator is in “Open” position
and will not move anymore.
Actuator and valve are
mounted 90° rotated in
relation to each other.
Remove actuator from valve.
Check assembly code of
actuator. Put both valve and
actuator in “Closed” position.
Mount actuator on valve.
Limit stop screws are not set Readjust the limit stop screws
Valve does not reach the
completely “Closed” or “Open” correctly.
Insert is not mounted properly Mount the insert in the right
position.
position. Remark: Rotate
insert for one cam = 22.5°
Pressure to low
Apply pressure as per sizing
Sizing is wrong
Actuator rotates, valve does
not.
7.2
Check valve torque data with
actuator torque data
No coupling between actuator Install a coupling between
shaft and valve spindle.
actuator shaft and valve
spindle.
Where to find
Chapter 1 and 2 of
DOC.IOM.BQ.E
Chapter 3 of DOC.IOM.BQ.E
Chapter 2, §2.5 of
DOC.IOM.BQ. E
Data sheets DA =
BQ1.602.01.
SR = BQ1.602.02 or
BQ1.602.03
Chapter 2 of DOC.IOM.BQ.E
Pneumatic problems
Problem
Possible error
Solution
Where to find
Actuator does not react to
electrical control signal.
There is no supply pressure
at the actuator.
Supply pressure is connected
to one to the exhausts.
There is sufficient supply
air pressure but insufficient
supply air capacity.
Control Module is not
mounted properly.
Supply the right pressure to
the actuator.
Connect supply pressure to
port “Ps”.
Take care the supply
air tubing has the right
dimensions.
Mount the “Control Module”
in the right way to the
“Pneumatic Control Module”.
Turn the speed control more
open.
Select 1 size larger actuator
Unlock manual override on
the Control Module.
See supplied documentation
of the Control Module.
See supplied documentation
of the Control Module.
See chapter 2, §2.6 of
DOC.IOM.BQ.E
Actuator does not react good
to electrical control signal.
Speed control (if present)
blocks air flow.
Manual override (if present)
on the Control Module is
locke
Double acting actuator will
only move to “open” position.
Control module has wrong
pneumatic cartridge.
See chapter 4, of
DOC.IOM.BQ.E
See chapter 5 of
DOC.IOM.BQ.E
See chapter 6 of
DOC.IOM.BQ.E
Replace pneumatic cartridge See DOC.QC4.PNC.1
for version suitable for double
acting actuators.
Page 21
Installation Operation & Maintenance Manual
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April 2014
7.3
Electrical problems
Problem
Possible error
Solution
Where to find
Actuator does not react to
control signals
Control wiring, Power supply
wiring or feedback wiring are
not right connected.
The power supply voltage is
not the same as the voltage
of the applicable Control
Module.
Initialization was not
completed in the right way.
Connect all wiring in the right
way.
See documentation shipped
with the Control Module.
(DOC.IG.BQCxx)
See documentation shipped
with the Control Module.
(DOC.IG.BQCxx)
Actuator does not react
consistent.
Sizing is wrong
There are problems with
position feedback after
sending the actuator to
either the “Open” or “Closed”
position.
Page 22
The wiring of the feedback
signals may be switched.
Connect the right power
supply voltage.
Execute the initialization
procedure or set feedback
signal manuall
Re size the actuator to the
valve
Connect the feedback wiring
in the right way.
See documentation shipped
with the Control Module.
(DOC.IG.BQCxx)
Data sheets
DA = BQ1.602.01.
SR = BQ1.602.02 or
BQ1.602.03
See documentation shipped
with the Control Module.
(DOC.IG.BQCxx)
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
8Maintenance
CAUTION:
Actuator must be isolated both pneumatically and electrically before any (dis)assembly is begun. Before
mounting or (dis)assembling the actuator consult the relevant sections of this manual.
Important
Under the European Pressure Equipment Directive, conversion of actuators may only be performed by
companies or personnel, authorized by Emerson Process Management .
8.1General
All Bettis Q-Series actuators are supplied with sufficient lubrication for their normal working life. If required,
recommended lubrication for all standard actuators is a Castrol LMX, FINA Cera WR2 or equivalent. Periodic
checks should be performed to make certain that all fasteners remain tight.
Depending upon the conditions under which the actuator must work such as extended duty, or abnormal operating
conditions, periodic replacement of internal seals is recommended. Repair kits containing all necessary seals and
instructions can be obtained through authorized Bettis Q-Series distributors.
8.2
Single acting / Spring Return actuators
On spring return actuators, the springs can be replaced.
SPRINGS SHOULD ALWAYS BE REPLACED IN COMPLETE SETS.
Spring kits are available through authorized Bettis Q-Series distributors.
8.3
Bettis Q-Series recommended spare parts
All soft seals, bearings, and nonreusable parts are included in the Bettis Q-Series recommended spare parts kit.
The spare parts kit is identical for both the double acting and the spring return models. For the spring return models we recommend a set of spare springs for each different model in addition to the recommended spare parts kit.
Keep in mind that, when necessary, springs are to be replaced in complete sets. The following spare parts kits are
available:
1 Repair kit for Bettis Q-Series actuator and all modules, available per actuator size.
2 Module seals kit, suitable for all module variations.
8.4
Position tracking device kits
The position tracking device takes care of the mechanical part of the feedback signal. In case the position tracking
device malfunctions, spares are available. Position tracking device kits are available per actuators size and contain all necessary seals and lubricants. They can be obtained through authorized Bettis Q-Series distributors.
8.5
Conversion kits
When the action of an actuator needs to be changed from spring return to double acting or visa versa, conversion
kits can be utilized. Two kinds of conversion kits are available:
1 Single acting (spring return) Conversion kits, to make a spring return actuator.
2 Double acting Conversion kits, to make a double acting actuator.
8.6
High Temp and Low Temp Conversion kits
For the Bettis Q-Series actuators with the NAMUR plate, special conversion kits are available to make the Bettis
Q-Series suitable for High temperature or Low temperature applications.
There are no “High temp” or “Low temp” conversion kits available for Bettis Q-Series actuators with modules.
Page 23
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9Disassembly
9.1
Before starting
9.1.1
Caution! Never disassemble a valve that is
under pressure!
Caution! Ball valves and plug valves can
trap pressurized media in the cavity. Isolate
the piping system in which the actuator
valve assembly is mounted and relieve any
pressure on the valve.
1
2
9.1.1
9.1.1
No. 5
A
2
1
9.1.2
sw = 10mm
9.1.3
Page 24
/ 9.1.2
Prevent damage to the position probe (A) to
guarantee accurate position feedback.
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
9.2
Removing end caps all types QD and QS 40 to QS 350
9.2.1
1
Be careful not to damage the endcap (A) and B-port (B) O-rings.
QD
2
A
B
2
QS
A
B
9.2.1
9.2.2 / 9.2.3
Caution! If the actuator is a “spring return”
model, uniformly loosen all endcaps screws,
1/4 - 1/2 turns at a time, in sequence, to
relieve pre-load of the springs.
On all actuators with springs use caution
when removing endcaps.
9.2.2
9.2.3
Page 25
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9.3
Removing end caps type QS 600 to 1600
9.3.1
4
1
2
QS 600 / 950 / 1600
2
1
1
2
3
A
B
9.3.1
9.3.2
Page 26
Be careful not to damage the endcap (A) and B-port (B) O-rings.
Caution! If the actuator is a “spring return”
model, loosen endcap screws in sequence
as shown, 1/4 - 1/2 turns at a time, to relieve
pre-load of the springs.
On all actuators with springs use caution
when removing endcaps.
Installation Operation & Maintenance Manual
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April 2014
9.4
Removing limit stop bolts, pistons and pinion assembly.
9.4.1
Remove limit stop bolts.
9.4.1
2
1
9.4.2
Remove the two pistons by using an adaptor fitted in
a vice.
Place the actuator on top of the adaptor
(either the square end or the insert shape
end).
Turn the complete actuator and the pistons
will come out.
2
9.4.2
9.4.3
1
Before removing the pinion be sure the
position probe is removed (see chapter 1.1)
Remove spring clip from pinion top and
remove pinion.
For removing the circlip, circlip pliers are
required.
2
9.4.3
Page 27
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9.4.4
Remove spring clip form upper pinion part and
remove upper pinion part through bore of housing
1
9.4.5
3
For removing the circlip, circlip pliers are
required.
2
9.4.4
Removing the insert requires an extraction
tool. Please contact your local Bettis Q-Series
representative for more information about this
extraction tool.
9.4.5
Page 28
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DOC.IOM.BQ.E Rev: 0
April 2014
10Reassembly
10.1 Reassembly guide band and pinion assembly
Before reassembly check the requested
assembly code (see chapter 2.7).
CASTROL LMX or
FINA CERAN WR2
(or equal)
10.1.1
Apply grease to the parts as per table 10.1 and
figure 10.1.1
3
15
13
1
12
11
Part
Section of part
O-rings
Amount of grease
1
Light film
14
2
Piston bore
Light film
3
Top pinion bore
Light film
4
Bottom pinion bore
Light film
Fully greased
6
O-ring & guideband
groove
Outer side of legs
7
Gear teeth
Pistons
5
1
1
5
9
5
7
10
8
1
6
Completely
Housing
4
2
Table 10.1 Grease instructions
6
7
1
Pinion
Light film
Half the teeth depth
full with grease
8
Bottom O-ring groove
Fully greased
9
Top O-ring groove
10
Gear teeth
Light film
Half the teeth depth
full with grease
Upper pinion part
11
Outer diameter
Fully greased
12
Inner diameter
Light film
Housing guideband
14
13
Inner diameter
Light film
Piston Guidebands
10.1.1
14
Completely
Light film
Important:
Do not grease the middle part of the piston
bore (15) and the outer diameter of the
housing guideband .
Take care that half the gear depth is full with
grease.
Page 29
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10.1.2
1.
Mount the upper pinion part (A),
2.
Mount the stroke adjustment cam (B) and
housing guide band (C).
F
2
E
1
Keep the stroke adjustment cam in position
while mounting the pinion.
The two circlips have one side with bevelled
edges (E) which must go DOWN onto the
thrust washer, the square edge side (F) must
face UPWARDS.
C
A
1
2
B
10.1.2
1
2
3
Code CW
1
2
3
Code CC
10.1.3
Page 30
10.1.3
Mount the pinion.
For fastening the circlips, circlip pliers are
required.
Use limit stop screws (3) as a reference to
position limit stop cam (1) and pinion (2) as
shown. See indication dot in the Pinion top
slot. Views are from above.
The position of the pinion and the limit stop
cam, as shown, is the position where the
pistons are in the inward position (see next
paragraph).
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
10.2 Reassemble the pistons
CASTROL LMX or
FINA CERAN WR2
(or equal)
a=b
b
a
2
1
1
2
10.2.1 / 10.2.2
1 Check required assembly code.
2 Apply a light film of grease to the bore of the
housing.
3 Ensure that O-rings (1) and guide bands (2) are
kept in place during assembly.
4 Align the pinion so that the teeth on the pinion will
“pickup” the pistons rack teeth when turning the
top of the pinion:
- clockwise (CW) for assembly code CW or
- counter clockwise (CCW) for assembly code CC
Turn the pinion gently to guide the guide
band into the housing, taking care not to
damage the guide band.
= Code CW
10.2.1
CASTROL LMX or
FINA CERAN WR2
(or equal)
a=b
a
b
= Code CC
10.2.2
90°
ok !
ok !
c=d
c
d
10.2.3
Ensure that smooth movement and 90
degree operation can occur without moving
the pistons out of the actuator body.
Ensure that the slot on the pinion top is:
- exactly perpendicular (code CW) or
- in line (code CC) with the actuators centre
line.
If not, turn the pistons outward until they
disengage from the pinion. Shift one tooth of
the pinion, reassemble and check again.
10.2.3
Page 31
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10.3 Reassembly end caps, all types QD and QS 40 to QS 350
N-1
N-2
N-3
N-4
N-5
N-6
10.3.1
When replacing springs in a spring return actuator,
ensure that the springs are replaced in their identical
position in the spring pack from where they were
removed. Before assembling the springs and
endcaps, make sure that the pistons are inwards.
10.3.1
10.3.2
Put some grease on the endcap O-ring before
mounting.
CASTROL LMX or
FINA CERAN WR2
(or equal)
10.3.2
10.3.3
Ensure that endcap O-rings (1) and airport O-rings
(2) are in place on both sides.
1
Put some grease on the air port O-rings (2),
so they and stay in place while mounting.
2
10.3.3
Page 32
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April 2014
10.4 Reassembly end caps single acting actuators QS 600 to QS 1600
a
N-1
N-2
N-3
N-4
N-5
N-6
10.4.1
When replacing springs in a spring return actuator,
ensure that the springs are replaced in their identical
position in the endcap from where they were
removed.
Before assembling the springs and endcaps, make
sure that the pistons are inwards.
10.4.1
2
1
QS 600 / 950 / 1600
1
2
1
2
1
2
b
10.4.2
Ensure that endcap O-rings (a) and airport O-rings
(b) are in place on both sides.
Engage the bolts with the tapped holes in the
actuator body by forcing down slightly on the cap.
Tighten each bolt in small and equal turns.
Table 10.3 Tightening torque Bettis Q-Series
end-cap bolts
Actuator
Type
10.4.2
40
Cap
Bolt
Size
M5
Tightening Torque
Hexagon
Key size
4mm
Nm
max.
min.
1,7
1,3
in.lb
max.
min.
15
11
65
M6
5 mm
3,2
2,7
28
24
100
M6
5mm
3,2
2,7
28
24
200
M8
6mm
7,1
5,2
63
46
350
M10
8mm
14
11,2
124
99
600
M12
10mm
44,2
25
391
222
950
M12
10mm
44,2
25,1
391
222
1600
M14
12mm
70,6
39,6
624
350
Page 33
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10.5 Mounting and setting of limit stops
Setting of limit stops
Closed position
1 Move actuator to the “Closed” position(1.
2 Turn the “Closed” limit stop screw in until it blocks.
3 Move actuator to the “Open” position(1.
4 Turn the “Closed” limit stop screw in as shown in
table 2.5.2
Open position
1 Repeat the steps 1 to 4 as described for the
“Closed” position but now for the “Open” position.
(1
Apply pressure to port A or B
Remark
10.5.1
This procedure does not apply for setting the exact
end positions of a “Bettis Q-Series mounted on a
valve”.
To set the end positions of a Bettis Q-Series
mounted on a valve, do as described above, check
the valve position and adjust where necessary.
2
A
B
10.5.2
Table 3.1 Angular Displacment & Tools
Actuator
Size
Angular
displacement
Page 34
Nut
Bolt
Q40
3.0 °
W10 mm
SD1.2 mm
Q65
3.6 °
W13 mm
SD1.2 mm
Q100
2.7 °
W13 mm
SD1.2 mm
Q150
2.7 °
W17 mm
SD1.5 mm
Q200
2.3 °
W17 mm
SD1.5 mm
Q350
2.7 °
W19 mm
SD1.5 mm
Q600
2.7 °
W24 mm
W10 mm
Q950
2.5 °
W24 mm
W10 mm
Q1600
2.7 °
W30 mm
W10 mm
W = Wrench
10.5.3
Tools
SD = Screwdriver
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
10.6 Final assembly and airtightness test
10.6.1
Plug the IPT device hole (1) with a M12x1.5 plug.
Apply pressure (max. 8 barg / 116 PSI) to ports (2)
and (3). Use some soapsuds at the indicated points.
Applying pressure to the actuator will cause
the actuator/valve assembly to operate.
3
In case of leakage around :
1 The limit stop bolts (and/or the spring-packagebolt at spring return models):
- Turn the lock nut of the bolts tighter, until
leakage stops.
2 The endcaps :
- Disassemble the endcaps, replace O-rings and reassemble the endcaps.
3 The pinion top or bottom and A- or B-port:
- Disassemble the complete actuator, replace
O-rings and reassemble the actuator.
2
1
M12x1.5
10.6.1
CASTROL CLS
(or equal)
10.6.2
Take care that the position probe and the mounting
hole is clean. Apply Castrol CLS grease to the tip (1)
to ensure proper functioning.
1
sw = 10mm
10.6.2
Code CW
Code CC
10.6.3
Check the position of the inner part of the position
indication knob. When mounted to the pinion top, the
projection of the inner part will fit in the groove on
the pinion top.
To disassemble the inner part, press as shown.
For assembly of the Control
modules see Chapter 4
10.6.3
Page 35
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11 Bettis Q-Series Parts
11.1 Exploded view Bettis Q-Series (base actuator)
12
11
10
9
8
7
6
5
4
3
2
13
14
21
15
20
19
10
18
11
17
32
36
33
34
12
1
44
45
49
51
46
48
47
41
37
29
35
38
39
42
43
2
38
39
40
52
Page 36
15
13
50 20 19 18 17
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11.2 Bill Of Material
Pos.
Qty.
1
1
Description
Body
Note
Pos.
Qty.
32
3
Description
Note
Screw
2
2
Washer
1
33
1
NAMUR plate
3
1
Circlip
1
34
1
O-ring (NAMUR plate)
4
1
Circlip
1
35
1
O-ring (NAMUR plate)
2
5
1
Indicator insert
36
1
O-ring (pinion top)
1
6
1
Indicator knob
37
1
Pinion
7
1
Indicator arrow
38
2
Bearing ring
1
8
1
Screw
39
2
O-ring (pinion)
1
40
1
Insert
41
2
O-ring (B-port)
9
1
Guide band (housing)
10
2
Piston
1
11
2
O-ring (piston)
1
42
1
Limitstop cam
12
2
Guide band (piston)
1
43
1
Upper pinion part
13
8
End cap screws
44
2
Springpack bolt (QS)
14
2
End cap QD
45
2
Washer
46
2
Spring retainer
47
2
Outer spring
15
2
O-ring (End cap)
17
4
Nut cover
1
18
4
Nut
48
2
Middle spring
19
4
Washer limit stops
1
49
2
Inner spring
1
50
2
End cap QS
51
2
O-ring
52
1
Center plate
20
4
O-ring (limit stops)
21
2
Limit stop screw
29
1
O-ring (NAMUR plate IPT port)
2
2
1
3
Notes
1. Included in repair kits for the actuator
2. Included in seal kit for the modules and NAMUR plate.
3. Options
4. Some actuator size have a steel ball to close the B-port instead of O-ring B-port (41)
Page 37
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
11.3 Exploded view Bettis Q-Series (Control module)
6
4
5
3
2
7
1
12
11
10
22
23
9
8
13
17
16
15
Notes
1. Included in seal kit for the modules and NAMUR plate.
Pos.
qty
Description
1
1
Module Housing
2
1
Pilot valve Cartridge
3
1
Switch cartridge
4
1
Cover
5
1
Cover seal
6
1
Cover lock screw
7
1
Blind plug
8
1
Pneumatic compartment cover
9
1
Pneumatic compartment cover seal
10
1
Module to Actuator O-ring seal (1
11
1
Module to Actuator O-ring seal (1
12
3
Module fastening screws and washers
13
1
Pneumatic cartridge
14
1
Pneumatic cartridge seal
15
1
Shield switch adjustment screws
16
1
Manual control (option)
17
2
Manual control blind plug (default)
18
1/2
Silencer (1x SR, 2x DA)
19
0/1
Exhaust blind plug (0x DA, 1x SR)
20
2
Speed control blind plug
22
1
IPT device
23
1
O-ring seal IPT port (1
Page 38
14
18
19 20
Installation Operation & Maintenance Manual
DOC.IOM.BQ.E Rev: 0
April 2014
Page 39
World Area Configuration Centers (WACC) offer sales support,
service, inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
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www.emersonprocess.com/bettis
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T +31 74 256 1010
F +31 74 291 0938
All Rights Reserved.
We reserve the right to modify or improve the designs or
specifications of the products mentioned in this manual at any time
without notice. Emerson Process Management does not assume
responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use and maintenance of any
Emerson Process Management product remains solely with the
purchaser.
©2014 Emerson Electric Co.
For complete list of sales and manufacturing sites, please visit
www.emersonprocess.com/valveautomationlocations
Or contact us at [email protected]
w w w . Bettis. c o m
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